M52GED ENVIRONMENTAL ENERGY MANAGEMENT

ENVIRONMENTAL MANAGEMENT FACULTY OF BUSSINESS, ENVIRONMENT AND SOCIETY

M52GED ENVIRONMENTAL ENERGY MANAGEMENT
STUDENT NAME- Mr. SHAIK ABDUL WAHAB Student ID- 3928736 Module Head- Mr. I Duckers COVENTRY UNIVERSITY, 2011-12 Submission date- 1ST December 2011

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....... 6 A............................................................................................................................................................................... I Duckers .......................................................................................................................................................................... 8 MAN POWER REQUIREMENT AND ANNUAL LABOUR COST ....................................................... 1 ENVIRONMENTAL ENERGY MANAGEMENT ................................1ST December 2011 ........................................................................................................................................................................................... 8 Fabric Painting (Only for special orders) ................................................... 1 COVENTRY UNIVERSITY.......... 1 SuperNova Fashion Limited ........................................................................................................................................................................................................................................................................................................M52GED ENVIRONMENTAL ENERGY MANAGEMENT Contents M52GED........................................ D................................... 8 MACHINERY .............................. 4 COMPANY PROFILE............................................................................................. 6 MANUFACTURING ................... 7 Pre sewing functions ........................................................................................................................................... B......................................................................................................................... 1 Module Head.... Industrial Sewing ....................................................... 7 Significant aspects of sewing ......................... 8 ENVIRONMENTAL ISSUES ............................................................................ 6 Sewing ... 7 Fabric Edges to be sewn ................................................................................................................................................................................................................................................................................................................. 14 REFERENCES .............................................................................. E..................................... 3 PRODUCTS ..................................... 14 2|Page ......................................................................................................................................................................................................................................................................................................................................... 7 Planning of sewing process ............................................. 1 Submission date.........Mr......................................................... 8 Printing Process ........................................................... 2011-12 ..................................................................................... 3 Manufacturers and Exporters of Quality Clothing Worldwide .................................................... 9 NEW PROPOSITIONS............................................................................................................................... 5 RAW MATERIALS ....................................................................... 10 CONCLUSION .................... C........ 3 INTRODUCTION .... 9 LEGISLATION .................................................................................................................................................................. 7 Identification of seam lines .............................................................................................................................................................................................................................................................................................................................................................

Transparency. SA 8000. after his retirement from appex management now the next generation take the seat of the concern. WHY US? We have marked a distinguished position for ourselves in this competitive market by providing finest quality products as per the latest fashion trends.Competitiveness. cut and designs inputs.The samples are made to clients specifications and our innovative creation based on fashion trend in the global market. Price Negotiation . OUR SERVICES Sampling Development and R&D .Choosing the vendors according to the product specification and order placement accordingly. Vendor selection / Order placement . Our products are widely recognized for its quality.M52GED ENVIRONMENTAL ENERGY MANAGEMENT SuperNova Fashion Limited Manufacturers and Exporters of Quality Clothing Worldwide INTRODUCTION SuperNova Fashion was constituted by Mr. products * Skin friendly products Okeo Tex certified vendors * Organic certified vendors GOTS. 3|Page . since there we have grown from a small company to one of the best company in India. We are ahead of our competitors due to following features: * Quality standards * Competitive prices * Innovation * On time delivery * Expert product solutions * Highly skilled professionals * Stock holding and management upon request * Short time deliveries * Handling minimum quantities * Vertical manufacturers * Eco friendly suppliers. OE100 * Complaint factories WRAP. Eashwaran (founder and adviser) who has sound background and 20 years of experience in Textiles and was formed in the year 1999. processes.

Planning and organizing the buyers visit to any our factories. industrial problems. Flatback rib. Corduroy Knitted fabrics . Velour. Over t-shirts. Scarf. Terry. Poloshirt. Shorts. Shoulder cover Kids wear . Tank top. Dresses. Bath robes. Jumpsuits. Curtains. Pyjama sets. Bikini wear. Zipper/Button polo. Night wears.M52GED ENVIRONMENTAL ENERGY MANAGEMENT Order follow up . Jump suits. Suitings. Dobbies. Romper. Logistics and Shipment follow up . dresses. socio-political activities. PRODUCTS Mens wear . Buyers will be taken to vendors and their factories in order to make personal assessment about the vendor. Pull on/Constructed waistband Shorts and pants. double Jersey. Double layer Shorts. Shorts & Pants. Basic T-shirts. Personalized Follow Up . Bath robes. Trousers.Shirts.Shirts. Pull on pants. Pillow covers. Jump suits. Market information and Fashion trend . Drill. Flunnel. Table cloths. Fleece. Pique. Mock neck. T-shirt. Voile. 4|Page . Body-suit. Crop tops. Pants. Bed covers.. Double rib Derby rib. Yarn dyed check & Stripes. Crew neck.Single jersey. Satin.Periodical market information such as competitor activities. Intimates Infant wear .Frequent visiting across the globe to have a personal encounter with the Company's long list of clients ensures instantaneous updating of fashion. Jeans.Ensuring correct shipping documents and prior approval from the clients before and post shipment ensuring trouble free delivery.Shirts.Romper. Capri.Napkins. Boxer shorts. Sweatshirts. Vests. Denim. Intimates. Skirts. Trousers. Right from laboratory test with international accredited lab and quality control at various stages from fabric to Final Random Inspection. Track suits Womens wear . Intimates. will be informed to the clients. Tank top. Capri. Skirts. Waffle. T-shirts. Towels. Interlock.Periodic production status. Pull on pant. Jackets (Quilted/Lined). Shorts. Placemats FABRICS Woven fabrics . T-shirt. Track suits. Scarf Mock neck. Capri. developments and consolidation clubbed with expansion. Honeycombed. Pinafore gowns. Bias jumper. Canvas. Jeans. Boxer shorts. vests. Buyer & Seller meet . Vest Jackets. Bed sheets.Poplin. Airtex. currency fluctuations etc. trends. Jacquards. Quilted skirts. Intimates Home Textiles . Single rib. Pointel.

Sections B contains of a canteen. highly-skilled. Linen. salesmen. cashiers. With over 10 years of experience in the competitive textile industry. contracted) OWNERSHIP & CAPITAL Year Established: TRADE & MARKET Main Markets: 1. storekeepers and so on. Organic Cotton.M52GED ENVIRONMENTAL ENERGY MANAGEMENT Polar fleece. Rayon Polyamide. North America 2. consumes more amount of energy compared to the other three sectors. Section C contains office rooms and medical amenities. export and Wholesale Mens Wear. Hemp. The company factory is located in the outskirts of Tirupur (TeOnline). Women’s wear. COMPANY PROFILE BASIC INFORMATION Company Name: Business Type: Product/Service (We Sell): Product/Service (We Buy): Number of Employees: SuperNova Fashion Ltd Manufacture. all with lycra & without lycra and combination blends of all above. Auto & Engineered Stripes Contents .Cotton.Eastern Europe 1999 5|Page . India Our unit is divided into 4 sections. SuperNova Fashion Ltd will always try to pursue good workmanship. Bamboo. finishing and packaging process. Jaquards. Viscose. Modal. drivers. Mentioned below in detail 103 People (Permanent and temporary. our proficiency as an apparel manufacturer allows us to provide our customers with clothing that is the absolute top class in quality and durability. The company employs a 100 odd people from all races on various categories such as skilled. All the infrastructures in the respective sectors have fire exists in case of mishap. Polyester. Herringbone. Kid’s wear etc. Flat knit. Feeder strippers. Sections A consists of machineries required for the production. Our certain range of clothes is hand-made by our finest tailors for a personal touch. rest rooms for both male and female and a small lounge for relaxation and recreation. Section D consists of a midsized go down for the purpose of storage for raw materials and the finished products along with the waste yarn that are to be recycled and is a part of an old warehouse.

2 million 3 million 12 Tonnes Table 1. S. We procure mostly polyester and cotton yarn. fabrics. handling and transportation). The cut pieces of a garment are mostly tacked. No 1 Types of Raw materials Yarn  Cotton  Polyester  Nylon Buttons  Round  Trouser  Jeans  Special Units Quantity 2 Tonnes Tonnes Tonnes Pcs 75 54 14 16million 4.Raw Materials MANUFACTURING Sewing The basic process of sewing involves fastening of leather.Southern Europe Total Annual Sales Volume: Export Percentage: FACTORY INFORMATION Contract Manufacturing: OEM Service Offered. threads. 6|Page . zippers and buttons from India and Bangladesh.Africa 4. Design Service Offered.100% RAW MATERIALS We import high quality yarn. Sewing is one of the important processes in apparel making. Industrial sewing machines do most of industrial sewing.Northern Europe 6.South America 5. In all we have 12 registered vendors for raw materials. furs with the help of needle and threads. labour charges.5 million 3 million 500. Buyer Label Offered INR 400 Million to INR 600 Million 91% .M52GED ENVIRONMENTAL ENERGY MANAGEMENT 3. The price of the raw materials would be estimated upon the type of order we get. If it is a large order. the raw materials we purchase is about 15 Million Rupees (inclusive of taxes.000 average Or as per order 3 4 Zippers  Trousers  Jeans Threads-all colours Pcs 2.

Industrial Sewing Looks to be a simple process. A. Fabric Edges to be sewn Two basic types of stitches. etc.one is that are for joining two parts of cloth together and the other one is done for decorative purposes. Planning of sewing process Sequence of seams to be stitched is checked before you start sewing. there are certain other tasks that have to be taken care of which can be termed as fabric handling functions ply separation. Identification of seam lines Sewing process is performed on seam lines situated inside the fabric edges. Sometimes.M52GED ENVIRONMENTAL ENERGY MANAGEMENT or stitched temporarily at the initial stage. both types of stitching have to be done for eg. Quality sewing also depends on the sound technical knowledge that goes into designing pattern and making. Flat sheets of fabric having holes and slits into it can curve and fold in threedimensional shapes in very complex ways that require a high level of skill and experience to manipulate into a smooth. a pocket has to be joined on three sides with the apparel as well as it may be given some decorative stitches too. B. the single ply is transferred over the receiving end of a conveyor for further processing. Like mentioned above. D. placing the fabric on working table. some stitches have to be necessarily done before or after another stitch. an edge of the separated fabric is presented between the jaws of a gripping device. A proximity switch checks the space between the gripper jaws. wrinkle-free design. seam line is parallel to the outer edge and the distance between the two has to be determined as it is different for different parts of the cloth. Seam allowance is the area between the edge of the fabric and the line of stitching. the decorative stitches must be done first followed by the joining stitches E. stacks of fabric plies are sequentially positioned with the help of some feeding apparatus in an unloading position. what stitches will follow one another. C. While ply separation. In the process. guiding the fabric towards sewing needle and tension control of fabric during the sewing process. At what points and which type of stitching has to be done. the seam line is found by transferring the outer lines inside the fabrics and the intersection of these lines makes the vertices of the seam line. The complex parts of the machine then pierces thread through the layers of the cloth. Hence. The topmost ply in such a stack is individually and sequentially separated from the stack. Which part will be joined first.sewing functions Before the actual task of sewing begins. are decided. Pre. When this spacing confirms that only one fabric ply is in place between the jaws.all such information is stored digitally on automated devices through CAD and properly sewn. some mm inside the fabric's outer line. industrial sewing is quite complex involving many preparations and mathematical calculations for the correct seam quality. However. For the straight lines. It is usually 7|Page . interlocking the thread.

naphthol and disperse colours which have good fastness properties. t-shirts and jackets.foot displacement and compressing force Needle penetration force measurement Fabric Painting (Only for special orders) Different fabrics such as apparel fabrics or home furnishing fabrics can be crafted beautifully using fabric painting.5 cm or more for standard home dressmaking. MACHINERY S. Significant aspects of sewing There are certain aspects that have to be carefully considered while the sewing process as they are very crucial for high quality sewing. Pigments are among the fastest known colours and are effective for light to medium shades. Industry seam allowances vary but they are usually 0. reactive. If used for applying dark colours. Cheap prints are made from basic colours mixed with tartar emetic and tannic acid but they are not acceptable in today’s market.M52GED ENVIRONMENTAL ENERGY MANAGEMENT 1.    Thread tension and consumption Presser. which are not truly dyes. they may crock or rub off.6 cm. This technique can also be used for decorating denim jeans. skirts. are also used extensively for printing.NO 1 2 3 4 5 6 7 8 9 LIST OF MACHINARY Sewing Machine Embroidery machine Cutting machine for garments Industrial Sewing machine Household sewing machine Ironing machine Steam Press Hemming Machines Denim Sewing Machines QTY 20 1 1 1 10 10 5 2 3 MAN POWER REQUIREMENT AND ANNUAL LABOUR COST 8|Page .5 cm away from the edge of the fabric. Printing Process The Dyes used for printing mostly include vat. Seam allowance is usually 2. These colours are fixed to the fibre through resins that are very resistant to laundering or dry-cleaning. shirts. The pigments.

Dyes and paints. 1 1 1 1 2 1 3 3 3 25 55 2 1 3 1 Annual Salary (INR) 350.500 350.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Plant Manager Production and Technical manager Finance and administrative manager Commercial manager Chemist Executive secretary Production supervisors Mechanic Electrician Skilled operators Unskilled workers Accountant Purchaser Sales man Cashier Req.View to minimise working more shifts during daytime.000 200.000 200.Vapours of paint and dyes · Energy consumption.000 Table 2-Manpower Required Any additional worker employed at per day basis.500 245. The Safety Representatives and Safety Committees Regulations 1977 9|Page . · Wastewater. · Solid and liquid waste. · Emissions to air.M52GED ENVIRONMENTAL ENERGY MANAGEMENT S.waste extra cloth sold as cleaning LEGISLATION   The Health and Safety at Work Part 8.000 500 per day 180. ENVIRONMENTAL ISSUES Environmental issues during the operational phase of textile manufacturing primarily include the following: · Hazardous materials management.000 180.500 200.000 200.Chemical water but drained properly.000 200 per day 200 per day 180.000 150. No.000 200.

Investigating potential hazards. 10 | P a g e . YEAR 2006 Economic/Environmental Strategy Driving force Climatic change and the increase in utilisation cost Improved energy efficiency will achieve the target of reducing Group energy consumption by 19% from that of the 2006 calendar year by 2011. safety and welfare. It is good practice to investigate all accidents that occur in the workplace. cases of diseases or ill health and dangerous occurrences.M52GED ENVIRONMENTAL ENERGY MANAGEMENT    The Management of Health & Safety Regulations 1992 amended 1999 The Health & Safety (Consultation with Employees) Regulations (HSCEC) 1996 The Information and Consultation with Employees Regulations 2004. Yearly Future plans accomplishments Accomplishment of 46% reduction in energy consumption with mitigation of utility price increase and daytime machinery operation. (house) Contract Law     Employer will ensure the employees’ health. Investigating reportable accidents. NEW PROPOSITIONS The propositions made from 2006-2011 to mitigate the amount spent. environmental issues. Solar panels installation could be possible. Besides this there is the common laws and regulations. Inspecting the workplace.

odour. noise with upgraded treatment processes. Table 3-New Propositions-2006 YEAR 2007 Taking into account the environmental drivers such as climatic changes and utility costs we aim to start using renewable sources of energy. mitigating. Land fill availability and costs This can be achieved by avoiding waste creation and there by employing the beneficial technique of reuse. The sale of by-products has also replaced landfill. Shaving reduced and alternate application of waste recovery in case of more waste and thereby increasing profit by 6%. Noise and air emission The odours from the site should not impact the boundaries beyond the site. Both the compliance and feasibility trials are successfully completed. Upgraded odour control and wet scrubbing plant with bio filters. This will tremendously reduce gas purchase and also lessen waste disposal. YEAR 2008 Economic/ Environmental Strategies Yearly accomplishments Future plans 11 | P a g e . Sound proofing sewing unit. The risk assessment is planned with the detailed design of the application process and the methods on how to achieve it with minimum cost. Site now accredited to ISO 9001:2005 with mature management Reduction of complaints is achieved by proper techniques of abatement. Composting or beneficial application account for 80% of biodegradable waste. Achieve EMAS accreditation within 2 years. Another method is to not keep excess stock. This is achieved by generating thermal energy from the waste. emission.M52GED ENVIRONMENTAL ENERGY MANAGEMENT Management and corporate social responsibility auditing ISO 9001:2005 accreditation of site.

application of variable speed drives. Seek business case for EMAS accreditation. boiler decentralisation and radiant heating applications. Storage systems Proper storage of fuels. variable speed drive installations. application of variable speed drives. Table 4-New Propositions-2008 YEAR 2009 Economic or Environmental Driving force Climatic change and the increase in utilisation cost Strategized objective Yearly achievements Futuristic action or anticipated deviation Continued efficiency gains especially heat recovery systems. boiler decentralisation and Improved energy efficiency will achieve the target of reducing Group energy consumption by 10% in the year 2008. This ensures a proper management system and low vulnerability towards laws and also improves the aesthetics of the site windows.M52GED ENVIRONMENTAL ENERGY MANAGEMENT Driving force Climatic change and the increase in utilisation cost Improved energy efficiency will achieve the target of reducing Group energy consumption by 10%. Raw materials used for production are stored efficiently under cool dry containers. Auditing management and corporate social responsibility ISO 14001:2007 accreditation of site. Reduce risk to forthcoming environmental liability legislation. waste and raw materials pre production and post production. reduced water temperatures. Continued efficiency gains especially heat recovery systems. All sites are now accredited to ISO14001:2007 with optimise management system. Reduced Carbon Dioxide Emissions and improved efficiency through application of radiant heating. variable speed 12 | P a g e . Reduced Carbon Dioxide Emissions and improved efficiency through application of radiant heating. The products produced are packed and sealed and finally stored onsite for transport two times a week.

best quality yarn manufacturers across the world especially in India. radiant heating applications. As well as significant area gains. SuperNova Fashion Ltd Yield Improvement Programmes offer a low risk strategy to improve profitability in a very short time frame. SuperNova Fashion Ltd area yield improvement programmes improve company performance by maximising the quality. Registered and compliant to Packaging Obligations. Table 5. concentrating on using raw materials economically. Minimise landfill. depending on the type of clothes produced and the degree of comprehensive perception and control of existing products and process. low energy consumption. along with the strategies. YEAR 2011 The money saved from the profit. Sewing operation facilities need to remain focused on maximising company performance. The programmes are carried out systematically in collaboration with the operational team. employing beneficial reuse and recycling. maintaining quality standards. 13 | P a g e .M52GED ENVIRONMENTAL ENERGY MANAGEMENT drive installations. Sale of all recyclables remains a target Land fill availability and costs Avoid landfill by avoiding waste creation. Thermal Energy Plant with direct waste heat recovery.New Propositions-2009 YEAR 2010 Concentration on yield improvement. View to keep the value of the business high. The effluent and the contaminated water are directed into the water treatment system thereby cleaning the discharge making it contaminant free and reusing that for industry purposes. A key element of the success rate is training labour. Area gains of 4% to 8% or more are achievable. The reduction of shavings by precision splitting and sale of trimmings. Accreditation of clean water act and clean air act of 2010 and also ISO 14001:2010 adhering to the legislation is prioritized and all employees of all positions are knowledgeable of the laws and regulations of the company along with its policies and work towards a better futures. low waste strategy year by year from 2006 to 2010 is used to increase the buying of raw materials in order to supply too many other customers in 2010 and also to build up an efficient pre treatment facility for water discharge. the programmes also contribute to easier production management and enhanced competitive advantage. maintaining and improving output rates.

hse.htm TeOnline.d. Retrieved from http://www. (n. We also have a new 5 year plan in place and if we act accordingly we hope to maximise our profits by 8-18%. (n.). p.d.gov. The company has prioritized the effective strategies such as the reduction energy over consumption.html 14 | P a g e . Retrieved from http://www. REFERENCES house. Retrieved from http://www.com/knowledge-centre/textileprocesses. H.edym. (n.d. water treatment facilities to mitigate environmental problems and also has invested a lot in saving energy keeping in mind the depletion of natural resources. E.teonline.com/en/ Safety. a.).uk/textiles/audit/part8.M52GED ENVIRONMENTAL ENERGY MANAGEMENT CONCLUSION SuperNova Fashions Ltd has undergone major changes in its policies accordingly so that the environmental impacts are reduced thereby increasing the profit by employing new techniques.).

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