INTERNSHIP

REPORT
2018

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Submitted to:
H.R Department
Department of Internship:
Industrial Engineering Department
Submitted by:
Saeed Ullah
University ID:
16-IE-02
Internship Session:
07th August, 2018 – 04th September, 2018
University:
University of Engineering & Technology, Taxila
Organization:
Kohinoor Textile Mills Limited, Rawalpindi

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Report of Approval
This is to be certify that I Saeed Ullah have completed 4-weeks internship program at Kohinoor
Textile Mills Limited, Peshawar Road, Rawalpindi. Internship report has been checked and
approved by the concerned HOD / Supervisor & HRO / AM HR.

Signature of HRO / AM HR Signature of HOD / Supervisor

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Acknowledgement
The time I spent in KTML as an intern from 07th August to 04th September 2018 was a memorable
one for me as it was rich in experience sharing and helped me to discover our potential.
This report would not have been possible without the contribution and collaboration of others. My
sincere gratitude:

 To Almighty Allah who granted me health and long life, without which I could not have
finished this internship report;
 To the Executive HR of KTML, Mr. Imran Nazir for endorsing my application for
internship;
 To The Head of Department of Industrial Engineering Department Engr. Adeel & also to
the Engr. Kousar Abbas for their technical support and constant supervision which
contributed immensely to my personal development. I also thank them for their guidance
which was a remarkable force that enabled me to successfully complete the internship
program;
 To the rest of the KTML staff for their support and guidance which helped me to overcome
the challenges I faced during the past 4 weeks in KTML.

To all of you, I extend my deepest gratitude.

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Executive Summary
Kohinoor Textile Mills Limited, being one of the many subsidiaries of the Sehgol Group of
companies, is a well reputed Textile industry. I got this opportunity to get training from the industry
as internees to fulfill my requirement of BSc program on department of Industrial Engineering
from the University of Engineering and Technology (UET), Taxila. The duration of the program
was 4 weeks.
The visit was an attempt to get knowledge that how various principles of Industrial Engineering
could be applied to industries. I got to work with full support of the Industrial wing of Kohinoor
Textile Mills.
The Industrial department is mainly in charge of the stitching department and its linked processes;
recruiting of tailors/supervisors, production officers, production supervisor, overseeing training
programs/initiatives of new Taylors, rate fixation, how to control insubordinations and other such
management-related activities.
The first part of the report deals with the layout of the stitching department. Packing of the products
is also discussed in the latter part.
The remaining report discusses the articles that are being manufactured in this industry, time and
motion study and other activities of the Made-ups department.
Kohinoor specializes in bedding, tablecloths, napkins, curtains and various such household textile
items. Thus my focus has been on these articles and the breakdown of their operations.
Understanding of the stitching machines, article operations, rate fixation, cutting of articles and
cutting machines, and division of work occupied most part of our training.
I also assisted the industrial department in Time and Motion Study which remained my core area
of interest and study during my four-week long internship program.
The successful program at the Mills not only helped me fulfill my course requirement but every
hour spent in the industry also gave a valuable experience to me that cannot be put to words.
Nevertheless, my personal views about the industry, my value addition to the department are also
given in the report in the form of SWOT analysis of the industry.
Before drawing the conclusion to this report, it would be worth mentioning that the report was
prepared using the best of knowledge (although insufficient) within a short interval of time. Any
discrepancies may thus be forsaken.

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Table of Contents

REPORT OF APPROVAL ................................................................................................................. 3

ACKNOWLEDGEMENT ................................................................................................................... 4
EXECUTIVE SUMMARY ................................................................................................................. 5
OVERVIEW OF THE ORGANIZATION .............................................................................................. 8
ORGANIZATIONAL STRUCTURE .................................................................................................... 8
Introduction ........................................................................................................................................... 8
Type of Production ............................................................................................................................... 9
PLAN OF INTERNSHIP PROGRAM ................................................................................................. 11
TRAINING PROGRAM .................................................................................................................. 11
Industrial Engineering ......................................................................................................................... 12
Layout ................................................................................................................................................. 12
Types of Machines in IE Dept. ........................................................................................................... 13
Faults & Defects of Stitching .............................................................................................................. 15
Environment ........................................................................................................................................ 15
Functions of Operations ...................................................................................................................... 16
Time & Motion Study Technique ....................................................................................................... 17
Basic Time .......................................................................................................................................... 18
Standard Minute Value (SMV) ........................................................................................................... 18
Target .................................................................................................................................................. 19
Efficiency ............................................................................................................................................ 19
Line Balancing .................................................................................................................................... 20
Operation Breakdown of Observed Articles ....................................................................................... 21
SWOT ANALYSIS ...................................................................................................................... 25
Strengths ............................................................................................................................................. 25
Weaknesses ......................................................................................................................................... 25
Opportunities....................................................................................................................................... 26
Threats................................................................................................................................................. 26
CONCLUSION .............................................................................................................................. 26
RECOMMENDATIONS .................................................................................................................. 26
REFERENCES .............................................................................................................................. 27

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Table of Figures
Figure 1. General Layout of Unit .................................................................................................................. 9

Figure 2. Layout GF1.................................................................................................................................. 12

Figure 3. Layout GF2 & GF3 ..................................................................................................................... 13

Figure 4. Lock Stitched ............................................................................................................................... 14

Figure 5. Over Lock M/C............................................................................................................................ 14

Figure 6. Observed Articles ........................................................................................................................ 17

Figure 7. Line Balancing............................................................................................................................. 20

Figure 8. Example of Line Balancing ......................................................................................................... 21

Figure 9 .Time & Motion Study of Shower Curtain ................................................................................... 21

Figure 10. Time & Motion Study of Pillow Case ....................................................................................... 23

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Overview of the Organization
From its incorporation in 1987 as a small weaving mill, over the last 30 years Kohinoor Mills has
evolved into one of Pakistan’s largest vertically integrated textile operations with approximately
1700 employees and an annual turnover of PKR 10.6 Billion. Spread on a 100-acre state of the art
facility near Lahore, they supply over 90 million meters of world-class grey, white and dyed fabrics
to leading fashion brands in 20 countries around the globe.

The company is involved in three major businesses; Dyeing & Finishing, Weaving, and Energy.
The company’s board and management’s aim is to create superior value for Kohinoor’s customers
and shareholders and suppliers without compromising its commitment to the safety, environment
and health of the communities in which it operates.
Organizational Structure
Introduction
The Industrial Engineering Department holds its own importance at KTML because of its well
skilled & experienced large work-force. Actually, Indirectly IED is source of earning for hundreds
of employers working there. IED also has a Training Center which gives training to many students
of different universities & to the new employers (tailors) so that they can get experience of working
environment. In Made ups department different articles operations are performed in different
tracks. Made ups department is divided into 3 units named as
a) Stitching 1
b) Stitching 2
c) Stitching 3

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Different types of machines are available for stitching i.e. Single Needle LOCK STITCH M/Cs,
Over-Lock M/Cs, Double Needle LOCK STITCH M/Cs, Bratta M/Cs etc.
All units are further divided into two sections (Section A & Section B) & further into tracks.

UNIT

SECTION A SECTION B

T1 T2 T3 T4 T1 T2 T3 T4
Figure 1. General Layout of Unit

Hundreds of workers are working hard in this department for full filling or making product 100%
according to the customers’ demand.
Apart from stitching, in this department packing area is also specified for packing of different
articles.
Type of Production
In stitching department, different article (e.g. Pillow Case, Napkins, Bed Sheets, fitted sheets,
bed spread, table cloth, place mate, Sheet set, Quilt cover, window panel etc.) are made /
produce by using different machines of stitching. There are different articles operations which
are performed on machines which are enlisted below:

 Hemming (Top, Side & Bottom)

 Hemming + label attachment
 Reinforcement
 Safety Over Lock (2 thread)
 Front / Reverse Attachment & shoulder making
 Overlock with safety (5 threads)
 Mock
 Cord Making
 Corner Making

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For example, if a KTML customer (INDIGO) orders for producing 500 Napkins pcs, following
will be the article operation sequence:
First of all, cutting department will cut the fabric piece (using HOUSER / Gerber M/C) to the given
dimension (22” * 22”). That’ll be forwarded to the stitching dept. for following operations.

Mitered Corner making of 2”

1” Hem all 4 side+ Label

attachment

Clipping

Stitching
Audit

OK

Packing

Packing Audit

OK NO

Shipment

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Plan of Internship Program
a) Branch office:
IED main purpose is to employs certain techniques (such as floor layouts, time standards,
wage rates, incentive payment plans, Loss time analysis, Sampling Technique) to control
the quantity and quality of goods and services produced”(Maximum output with
Minimum available resources). Engr. Adeel Shakeel Ahmad is the Head of Department.
b) Internship started:
07th August, 2018
Internship ended:
04th September, 2018
c) Department:
Industrial Engineering Department
Duration:
4 WEEKS

Training Program
This section described learning which I have learned under Industrial Engineering department
during my internship time period.
Overview
Week # 01
 General Overview of Organization
 Layout of Made Ups Department
 Introduction to different types of stitching Machines present in Made ups department
(Stitching Units)
 Task: Observed & studied the number of M/Cs present in different sections, tracks & lines
of all three stitching units.
Week # 02
 Observed the articles operations that were performed in different tracks of stitching unit 1
 Observed the cut sizes of different articles.
 Task: Studied & Understood 10 different Articles E.g. Pillow Case, Napkins, Bed Sheets,
fitted sheets, bed spread, table cloth, place mate, Sheet set, Quilt cover etc. & their
operations of Stitching Unit 1, 2 & 3.
 Time & Motion study
 Task: Time and Motion Study of the Articles of Stitching unit 1
Week # 03
 Task: Time and Motion Study of the Articles of Stitching unit 2 & 3
 Piece Rate (Rating factor)
 Target per hour, Target per day
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Week # 04
 Time & Motion study of Bed Spread (CM # 348) from unit 1 & 2.
 Line Balancing
 Task: Calculation of line balancing of 10 articles from unit 1.
 Efficiency
 Task: Calculation of efficiency of different articles from unit 1, 2 & 3.

Industrial Engineering
“Maximum output with Minimum available resources”
“Discipline of utilizing and coordinating humans, machines, and materials to attain a desired
output rate with the optimum utilization of energy, knowledge, money, and time. It employs certain
techniques (such as floor layouts, personnel organization, time standards, wage rates, incentive
payment plans) to control the quantity and quality of goods and services produced”

Layout
General Floor 1

Figure 2. Layout GF1

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General Floor 2 & General Floor 3

Figure 3. Layout GF2 & GF3

Cut Sizes of observed Articles

Napkins: (22 * 22) in
Exclusive Pillow case: (56 * 95) cm
Exclusive Bed sheet: (305 * 325) cm
Table cloth: (63.5 * 123.5) in
Indigo Shower curtains: (74.5 * 78) in
Indigo Fitted sheet: (40 * 77) in
Quilt Cover: (222 * 230) cm
Indigo Bed sheet: (83 * 100) in
Indigo Pillow case: (20 * 33) in

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Types of Machines in IE Dept.

Lock Stitch Machine

A lockstitch is the most common mechanical stitch made by a sewing machine. The single
lockstitch uses two threads, an upper and a lower. Lockstitch is so named because the two threads,
upper and lower, "lock" (entwine) together in the hole in the fabric which they pass through. The
upper thread runs from a spool kept on a spindle on top of or next to the machine, through a tension
mechanism, through the take-up arm, and finally through the hole in the needle. Meanwhile the
lower thread is wound onto a bobbin, which is inserted into a case in the lower section of the
machine below the material.

Figure 4. Lock Stitched

Double Needle Lockstitch Machine

It’s a high speed lockstitch sewing machine. Its having twin-needle bar structure, the machine is
very convenient to make comer seam as well. It feeds in phase needle bar and feed dog for
wonderful and nice stitch. These high speed lockstitch sewing machines are ideal for Jeans, Jeans
Overcoat including decorating and corner seam.

Over Lock Machine

An overlock is a kind of stitch that sews over the edge of one or two pieces of cloth for
edging, hemming, or seaming. Usually an overlock sewing machine will cut the edges of the cloth
as they are fed through (such machines being called "sergers" in North America), though some
are made without cutters. The inclusion of automated cutters allows overlock machines to create
finished seams easily and quickly.

Figure 5. Over Lock M/C

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Faults & Defects of Stitching
Mainly there are three types:
1) Defects due to problem of stitch formation.
2) Defects due to fabric distortion.
3) Defects due to fabric damage along seam line.
Major Faults of Stitching are:
 Skip Stitch
 Graining
 Uneven label attachment
 Wrinkle
 Uneven Hem
 Lubing
 Reinforcement issue
 Open seam

Environment
Environment has a great impact on the working of employees. I observed some elements of
environmental conditions in industrial department, these are:

 Learning environment

 Cooperative staff

 Proper arrangements for safety

 Very neat and clean department

Every one follows the rules and regulation set by the HR department
Operations in Units
Path followed for completion of any Article (Department wise):
Order >> Sample Room >> Cutting Department >> Stitching Department >> Packing Area >>
Shipment

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 Loadin line Stitch- Packing Shipmen Order
Stitch Inspecti Press ing Packing Packing
g on Audit t Recieved
Audit

Functions of Operations
Loading:
To facilitate workers for
 less time consumption
 Ease of access
 Easy Manual handling

Stitching:
To stitch fabric for
 Durability
 Domestic Use
 Decoration

Unloading:
 To facilitate fabric for ironing

Pressing:
 To give smooth & finished touch of fabric

Packing:
 Bulk Packing without stiffener (e.g. Exclusive bed sheets)
 Barrel Packing without stiffener (e.g. Pillow case)
 Packing using Stiffener (e.g. Shower curtains)
 Packing with hanger (e.g. table cloth)
 Ribbon packing
Shipment:
 Shipment is sent to the customers after packing

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Types of Articles Manufacturing (Observed)

Quilt Cover with Comforter Bed Sheet with Pillows

Curtains Napkins

Figure 6. Observed Articles

Time & Motion Study Technique

“Motion and time study is the analysis of the methods
of the materials, of the tools and equipment used, or
to be used in the performance of a piece of work.”

Founder of Time & Motion study:

 Frederick W. Taylor and his followers developed and refined the Time Study

 Frank B. Gilbreth and his wife Lillian developed and refined the Motion Study

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Time Study Equipment:

Stopwatch

 Mechanical stopwatches

 Electronic stopwatches

Basic Terminologies in Time Study

Basic Time
• Elements
a. No. of readings
b. Calculation of average
𝑺𝒖𝒎 𝒐𝒇 𝒂𝒍𝒍 𝒓𝒆𝒂𝒅𝒊𝒏𝒈𝒔 𝒏𝒐𝒕𝒆𝒅
Average =
𝑵𝒐 𝒐𝒇 𝒓𝒆𝒂𝒅𝒊𝒏𝒈𝒔
c. Personal Ratings (PR)
A tailor can be rated between 60% - 130%
d. Calculation of basic time in seconds
TSec = Average × PR
e. Basic time in mins
𝐓𝐬𝐞𝐜
TMin =
𝟔𝟎
Standard Minute Value (SMV)
SMV =TSMV = TMin + Allowance
.: Allowance = TMin × (⁒ Allowance)
Where ⁒ Allowance = personal time, fatigue, delays & machine allowance
o If the work cycle includes machine-paced elements, then standard time may include a
machine allowance applied to the machine time
⁒ Allowance = P & F+ A Machine
Allowance factors:
Work-related interruptions
 Machine breakdowns
 Waiting for materials or parts
 Receiving instructions from foreman
 Talking to co-workers about work-related matters
 Rest breaks for fatigue

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  Breaking of needle/bobbin thread

Non-work-related interruptions
 Personal needs (e.g., rest room breaks)

 Talking to co-workers about matters unrelated to work

 Personal telephone call

Target
• Tailor target Per hour
60 Mins
= ----------------
SMV
• Tailor target Per day
Shift Mins
= ----------------
SMV
 Target per track (per hour /per day)
Shift Mins
= ---------------- × No of M/Cs
SMV

Shift Mins = per day (480 mins)

Efficiency

Shift Mins == per day (480 mins)

Earn Mins = Produced pieces × SMV

⁒ Efficiency = Earn mins

------------------------ ×100
Available mins

Available Mins. = Shift Mins × Number of Machines

Standard Number of M/Cs per track = 16

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 Allowances (P & F + M/C) for Over Lock M/Cs = 16%

Allowances (P & F + M/C) for Lock Stitch M/Cs = 17%

Allowances (P & F + M/C) for Double Needle & Bratta M/Cs = 22%

Note: efficiency can be calculated for per worker, per track, per section & per unit.

Line Balancing
A production strategy that involves setting an intended rate of production for required materials to
be fabricated within a particular time frame. In addition, effective line balancing requires assuring
that every line segment's production quota can be met within the time frame using the available
production capacity.
Example:

Figure 7. Line Balancing

Line balancing = Operational SMV × No of Machine

Total SMV

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Benefits of Line Balancing:

Figure 8. Example of Line Balancing

Operation Breakdown of Observed Articles

Shower Curtains
 Top Hem + tape + label attachment
 2 side Hem
 Bottom Hem

Figure 9 .Time & Motion Study of Shower Curtain

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Track TGT per hr.
Mins
= ---------------- × 16
SMV
= 60 / 2.1696 * 16 = 442
Track TGT per day
shift Mins
= ---------------- × 16
SMV
=480 / 2.1696 * 16 = 3540
Line balancing of track
Line balancing = Operational SMV × No of Machine
Total SMV
 Top Hem + tape + label attachment = 1.6945 / 2.1696 * 16
=10
 2 side Hem = 0.4547 / 2.1696 * 16
=3
 Bottom Hem = 0.3674 / 2.1696 * 16 =3

% Efficiency per track =?

Shift Mins == per day (480 mins)

Earn Mins = Produced pieces × SMV = 2900*2.1696 = 6205

⁒ Efficiency Earn mins

= ------------------------ ×100
Available mins

Available Mins. = Shift Mins × Number of Machines = 60*480=7680

Standard Number of M/Cs per track = 16

𝟔𝟐𝟎𝟓
= × 10 = 80% of track
𝟕𝟔𝟖𝟎

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Pillow Case
 1cm Hem on Flap + label attachment
 Flap attached with front side
 1cm Hem on the top of reverse side
 Front / Reverse attachment
 3 thread Over lock

Figure 10. Time & Motion Study of Pillow Case

Track TGT per hr. = 60 / 3.9755 * 16 = 241

Track TGT per day = 480 / 3.9755 * 16 = 1931
Line Balancing of track
Line balancing = Operational SMV × No of Machine
Total SMV
 1cm Hem on Flap + label attachment = 0.81432 / 3.9755 * 16
=3.2 ~ 3
 Flap attached with front side = 1.33767 / 3.9755 * 16
=5.3 ~ 3
 1cm Hem on the top of reverse side = 0.91988 / 3.9755 * 16
=3.7 ~ 4

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  Front / Reverse attachment = 0.64650 / 3.9755 * 16
=2.6 ~ 3
 3 thread Over lock = 0.89320 / 3.9755 * 16
=3.5 ~ 3
⁒ Efficiency per track ⁇

Shift Mins == per day (480 mins)

Earn Mins = Produced pieces × SMV = 1450 × 3.9755 = 5800

⁒ Efficiency per track?

Earn mins
= ------------------------ ×100
Available mins

Available Mins. = Shift Mins × Number of Machines = 60*480=7680

Standard Number of M/Cs per track = 16

Earn mins = produced pieces × SMV

= 1450 × 3.9755= 5800 mins

⁒ Efficiency = × 100

= 76% of track

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SWOT Analysis
SWOT

S= Strength W= Weaknesses O= Opportunities T= Threats

Strengths
 Man power (Experienced & Skilled Labor)
 High Professional quality check management that have check on Tailors every time to
makes articles quality better than others.
 Line Supervisors are always being there to check the articles after each operation have
been performed so that if any problem, should be sought out immediately.
 They have very strong quality check system. One article is checked many a times till it
goes for packing. After there is still last final Audit to ensure that every think is fine. If any
problem found, then whole lot will be cancelled.
 Imported stitching machines (especially JUKI imported from Japan)
 Trustable safety arrangements (especially in emergency e.g. fire alarm, fire extinguisher,
emergency door etc.)
 Managed the supply chain well (from loading of cutting material to the shipment of
product in the containers)
 Good lighting system that helps Taylor to work without any interruption
 Backup for load-shedding is always there in the form of backup Generators so there is no
chance of work to be stopped.
 Hundreds of workers are working there at a time which provide a great platform of
earning for them to fulfill their daily needs which removes an inferiority of unemployment
inside them.
 Very strict security system.
 Maintenance of department & machines always been there.
 Each unit of made ups department have track system there which maintains the production
flow of articles operations between Taylors.
 Employees get their salaries in time.
Weaknesses
 No incentives or bonuses or medical allowances to the beginners (new employers).
 No awards for the best Taylor of the month / year.
 Non-Corporative culture.
 Less chances of promotions for employees.

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  Although they maintain the cleanness in the department but still due weak ventilation
system, workers are having breathing problems.

Opportunities
 The demand of its products is high in international market
 We can reduce the cost by proper utilization of resources.
 Production flow can be maintained by flowing only one article at a time in one track.
 There is also an opportunity lying in Gov. policy because it has direct effect on production
rates of article operations.
 When there is big order, then there is an opportunity for workers for more earning.
 Technology changes (new developments).
Threats
Technological changes (negative aspect).
Impending Gov. policy regulation (increment in tax).
If quality standard is not maintained properly in the future, then it will be bigger threat
for them as they will lose their customers.
Conclusion
From my experience of four weeks in this organization I have learnt many things. The most
important is that practical professional life is very hectic, competitive and tough. The best thing,
which I was able to find out, is that the stronger the culture of the organization better will be the
productivity. In textile sector the thing of immense importance is how well the organizational
personnel communicate with each other. There is no room for personal grudges because each and
every one depends on each other if any one screw up the whole organization suffers. The overall
analysis is indicating that the company's progress has mainly attained through dedication of
employees. The effectiveness of its management, their willingness to take advantage of
opportunities and face challenges of changing economic picture, this all contributes to the very
much improved and sound position of company. This is really appreciable for the devotion and
hard work of all the employees of the company.

Recommendations
Educated staff & workers should be preferred.
The training of staff and workers is required to improve and modernize the techniques
Although quality check is very fine yet there is room for further improvement.
There is also a problem of work overload for the employees and it should be control
properly so that the employees are motivated.
Improvement of the cleanliness and hygiene of the departments as a whole so that visitors
leave with a good impression.
Piece rate system should replace by company salary system for senior workers because of
their experience and their skills, they deserve more than any.
There should be proper planning for fabric induction in tracks. There should be one article
in operation to avoid any production flow problem.

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 Upper management should create friendly working environment.
Awards should be given to the best Tailor.
References
 www.kmlg.com/pk

 www.google.com

 "https://en.wikipedia.org/w/index.php?title=Lockstitch&oldid=823694939"

 "https://en.wikipedia.org/w/index.php?title=Time_and_motion_study&oldid=851543292

 "https://en.wikipedia.org/w/index.php?title=Overlock&oldid=835976922"

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