B.T.

M profile

Bhiwani textile mills, Bhiwani, popularly known as B.T.M was established

in 1938 as a composite unit in Bhiwani with the name “Punjab cotton mills”.
In the year 1964 the arstwhile ageing, Punjab cotton mills got a new lease of
life when it was taken over by the grasim group of Industries, a prestigious
group headed by honorable Sh. Aditya Vikram Birla.
But after the demise of Sh. Aditya Vikram Birla it is now headed by
Sh. Kumar Mangalam. In 1974 it came under the direct management of
Grasim group. B.T.M is a composite mill having spinning, weaving and
processing divisions.
The spinning divisions where yarn is spun is having 34,576 spindles.
The spinning unit is producing blended yarn of polyester & viscose blends &
pure viscose yarn. The raw material as the name suggests is polyester and
viscose staple fiber
The weaving unit has 120 looms producing polyester viscose blend
suiting and shirting under the name “graviera”. Graviera is good brand
name popularity in the market and is aimed at middle class segment of the
society.
Quality is the watch word of this unit. it is not imposed by checks
and counter checks, it is a part of total manufacturing system. Quality is the
first parameter. That is the reason that the Bureau of International Standards
has conferred the unit with ISO-9002 certificate in 1994.
Modernization, Technological up-gradation and computerization is
an on-going process at B.T.M. The mill has already installed 66 new donear
looms from Switzerland. An attractive feature of spinning division is Savio
Auto Winding machines. one of the most sophisticated in its class. In order
to keep pace with changing time and to combat foreign competition, B.T.M
has stream its master plan of expansion of its spinning unit. A new unit,
Elegant spinning is set up & has 14,000 to 28,000 spindles.
The Research and development of the mills is famous for
introducing new designs with classic colors. Some of the latest innovations
in textile technology in advanced nations find a parallel acceptance in the
working of B.T.M Bhiwani.

Realizing the fact that human asset is the most important of all
assets, B.T.M has introduced the concept of “Participated Management”.
There are 40 quality circles & 20 shops floor constantly engaged in
improving the work culture of the mills. Keeping pace with the need of hour
B.TM is becoming more and more professional in its management. The
philosophy of Birla management center is the guiding spirit to move the
group towards more professionalism.
 Introduction of Grasim

Grasim Industries Ltd is known for its world class textile manufacture. They
are a main part of the textile industry of India. They are one of the leaders in
textile manufacture and are also known all over the world.

Grasim believes in world class manufacturing. The 8 dimensions which they

follow are:

Waste (MUDA) elimination.

Work environment

JIT and stock reduction

Total productive maintenance of equipment, operating conditions and

skill levels.

Quantity first :SQM and best practices

Customer driven: internal and external

Liaisons and understandings

Information system, technology and cash flows.

ABOUT BHIWANI.......

BHIWANI district came into existence on July 22nd, 1972 and is named
after the Administrative city Bhiwani.
Bhiwani has been a prominent center of commerce since time of Mughals.
Bhiwani is also known for its temples and is called as Small Khashi of India
because of numerous temples. `

The erstwhile Punjab cotton Mills at Bhiwani in Haryana was taken over by
Grasim Industries 1964

LOCATION

The Bhiwani District is surrounded by Hissar District on its North, some

area of Jhunjunu & Churu District of Rajasthan on its west and District
Rohtak on east. It is 124 Kilometer from Delhi.

GEOGRAPHY

In North Region of the district there are Alluvial Plains and in

South there are Semi -Desert with remnants of Aravali Range
Mountains. The Soil is loom in the North region and sandy in the Southwest
region of Bhiwani District. The Groundwater is mainly saline with some of
small pockets of fresh water in Southwest. Total area covered by Bhiwani
District is 5,099 sq.km..
Brand portfolio grasim
Brand portfolio graviea
 Main Achievements & 5,S

In 1994 graviera was awarded the prestigious ISO 9002 certification.

Each process form buying the fibre to finished fabric is monitored by
computerized machine and highly observant works and techniques. Being a
composite unit spinning, weaving and processing is done under one roof and
there are strongest quality checks every stage.
Again order to maintain a superior quality of the product various
management practices are being carried out by the top management to give
recommendation to improve the effectiveness in selected functional areas
has formed management quality circiles.
Good quality management procedure can prosper only in clean and
sincere atmosphere and so the top management at BTM have implemented
the 5 technique which has the following meaning :

What is 5,s There are 5 japanese words:-

SEIRI:- shorting out unnecessary items.

SEITOM:- Systematically arrangement of necessary items.

SEISON:- cleaning of work place and mahines.

SEIKETSU:- House keeping maintaining all time.

 SEITSUKE:- Training and self discipline

Objectives of the company

Objectives estabilish the goals and aims of business and

determines shapes of future events. Objectives are the way
of achieving motives for profit or social service main
objectives of Bhiwani Textile Mills as given in its
memorandum of association are :
To introduce new products and create new markets.
Increase productivity of work-force.
Customer service and customer satisfaction.
Improving work culture among the employees.
Increasing quality products and services.
Capitalizing on company strength and use of corporate
assets.
continuous innovation.
To provide the growth rate of about 10% per annum.
Improved the advertising effectveness.
To ensure that a large portion of its sales is directed
towards the
rural sectors and urban sectors.
 Main Units of grasim
Industries
Viscose staple fiber Nagda(M.P)
Rayon Grade Pulp Mannor
(kerla)
Harihar polyfibre
Kumarpattam
(Karnataka)
Rayon Grade Caustic Soda Nagda
(M.P)
Vikram Cement Jawad
(M.P)
Vikram Iron 7 Steel (spong iron) Maharastra
Grasim Cement Raipur
(M.P)
Gwalior Suiting Gwalior
(M.P)
Graviera suiting Bhiwani
(Haryana)
 Vikram Ispact
Raigarh(M.P.)
Aditya Cement
Shambura
Birla Consulting and Software service Mumbai
Birla Telecom Ltd.
Mangalore Refiery &
Mangalore
Petrochemical Ltd
Mangalore
Vikram shipping Mumbai

Aditya Birla Group

The aditya birla group is among India,s largest business

houses. Operating in the country for for over five decades
and globlally
means for nearly thirty years, its revenues today are in
excess of US $5.6 billion,with net earning of US $ 500 million
, a US $ 6 billion asset base, and a market cap of US $ 5
billion and 700000 shareholders.
 Its 40 state of -the -art manufacturing units and
sectorial services, anchored by 72000 employees, criss-cross
16 countries including Thialand, Indonesia, Malaysia,
Philippine, Egypta, Canada, USA, and UK.
A premium conglomerate, the Aditya Birla Group is
a dominant player in all of the sectors in which it operates,
such as aluminiun, viscose staple fibre, copper, cement,
viscose filament yarn, branded apparel, chemicals, carbon
black, fertilizers, sponge iron, insulaters, power telecom,
financial services and more recently, insurance.It is “world,s
largest producer of white cement, the largest single location
refiner of palm oil, *the third largest producer of insulators,
*the fifth largest producer of carbon black, *amongst the
lowest cost producers of aluminium globally and *the largest
fully integrated aluminium producer in India.
In India the group is the single largest producer of
viscose filament yarn , gray cement (at a single location),
white cement and rayon grade pulp, the only producer of
linen and a leader in the ready-to-wear branded apparel.
Grasim, Hindalco, Indian rayon, Indo Gulf and Indal
from its stables –rank among Indians top 50 most respected
and admired corporations.
The group also has a significant presence in the
financial services, power and Telecommunications sectors –
with strategic joint ventures with giants such as-sun life
(Canada) , powered plc (UK), AT&T (USA), The TATA Group
and BPL communications LTD. respectively. In the software
sector, the group is represented through PSI data system
integration and software maintenance services.
On the social front a value based, caring
corporate, The Aditya Birla Group inherently believes in the
trusteeship concept of management. Part of that make a
qualitative difference to the lives of marginalized people.
Carried out under the aegis of the Aditya Birla Centre for
community Initative and Rural development, it is separated
by smt. Rajashree Birla.

Manufacturing Process
Bhiwani textile mills manufacturing products types yarn & fabric. The main
operation involved in the production of yarn & fabric and called spinning
and weaving. Here are the sub sssprocesses carried out in the executing of
these operations.

Carding
Laps from blow room are brought to the carding machines. The main
objectives of carding are opening, cleaning and silver formation of fibre.
Hence, for the first time in the spinning process, the fibres are given the
form of a top. silver infact are thick rope like structures of the fiber kept in
big plastic drums. carding remove every impurity from fiber that had
remained in it even after blowing.

Doubling
Sometimes we required double yarn. this is mostly required to give some
fancy effect. we can multiply 2,3 or more yarn by the process of doubling.
This involves two machines-cheese winding machine and double machine.
cones from winding machines are fed to the cheese winding and double
machine. cones from winding machines are fed to
the cheese winding and we get bobbins, on which 2 or more yarns are would
in a parallel fashion. Then on doubling machine these parallel yarns are twist
according to the specification. Here the bobbins again get converted into
cones.

Drawing
Silvers are converted into more uniform silvers. The main objective of
drawing is parallalization of fibres .It increases the uniformity and evenness
of the fibre.

Drawing in
This is the stage, where basic information takes place irrespective of the
colors. These designs are called weaves & can be of various types-mat, twill,
planes, double weave etc. In drawing in stage, yarn from weaver’s beam is
drawn through healed eye and reed (two parts used on looms to produce
design ) in accordance with the predetermined design for a particular fabric.
Without drawing in process, it is impossible to have desired
design on loom. After drawing in the beam is ready for weaving.

Dyeing and printing:

Fabric can be two types according to the dyeing process: Top dyed:
manufactured from already died yarn, piece/dyed: manufactured from
undyed gray yarn &hence required dyeing. In the dyeing process, the
polyester and viscose parts of the cloth are dyed separately because there
chemicals and condition requirements vary. Polyester part is dyed by using
the disperse dyes and at very high temperature. But viscous require wet dyes
(i.e. the dyes which are easily soluble in water). The fabric is washed after
dyeing both these parts.
Fabric printing is of two types screen printing &roller printing.
After the processing for printing & or dyeing the fabric of every type is
properly washed and dried.

Folding
The finished fabric is brought to this section for checking and folding. It is
also part of quality control at BTM. The fabric is manually checked inch by
inch. This inspection is done for finding any faults and removing them if
removable. If faults cross a limit in certain quality, the fabric is rejected and
sold under seconds.
The checked cloth is folded in the form of ‘Thans’ and ‘pent length’
(P.L.S.) standard length of a than varies from 6 to 12 meters, pent length is a
length is 1.20 meters of cloths, length of cloth lesser than P.L. are graded as-
- Superior : 91cm. To1.19 mts.
- Fants : 45 cm. To 90 cm.
-Rags : 25 cm. To 44 cm.
-cindi : below 25 cm.

Finishing:
Mended clothes are further processed in the finishing section.
Finishing is one of the most important processes, because the fall, luster and
drape of the final product (i.e. cloth) depends largely upon it. Some other
functions that this section can perform are making the cloth fireproof,
shrink- proof, wrinkle proof, water proof etc. mainly three processes are
carried out in this section-processing, dyeing and printing.

Loom shed (weaving):

looms are the actual weaving machines. Here yarn runs in two
directions-lengthwise and breadth wise. The yarn running lengthwise on the
loom is called ‘warp’ and the running breadth wise is called ‘weft’. The
cloth produced at this stage is called ‘grey cloth’. This is produced by
inserting weft yarn in warp sheet according to predetermined design of reeds
and picks. ‘reed’ and ‘picks’ are respectively the number of ends
warpwise and weftwise in one square inch of fabric which are essential parts
of looms..

Mixing and blowing

The two processes are executed on the same machine –Blender. The
objective of mixing is to make a uniform and homogeneous blend of
different types of fibres in fixed ratio. This ratio is fixed by the blend
specification required in the desired final product i.e. yarn. The most
demanded fibre blend is polyester/viscose in the nation 6 6/35, 48/521,35/6
etc. mixing results I loose tufts of blending fibre, which then enter the
blowing process.
The main objectives of blowing process are cleaning, opening and ‘lap’
formation from the tufts of fibre. Laps are nothing but long, uniform sheets
of fibre wound around iron rods. Weight and length of laps are standardized.
Fibre at this stage becomes free from any unwanted particle like dust stone,
sand etc.

Mending:
The grey cloth from the loom-shed is brought for mending. The full length
of the cloth is manually checked here and the defects are removed by hand
scissors and other equipment. Most of the removable defects in fabric get
removed here.
Processing
In this subsection ,the long thread which remain loosely attached to the
surface of the fabric are removed first of all. After that, small hairy fibres
projecting from the surface of the fabric and certain is impurities like dust
and waxy material etc. are also removed. The fabric is then thoroughly
washed to remove mandi from it. It is dried then and passed on a stenter
machine, where by the process of Heat set the shrinkage of cloth is
removed and by chemical processing, lusture & shine are produces

Packaging
Each than is wrapped over a separate sheet of thick card board. Then each
then is packed in a polythene bag and sent to warehouse. Pent length are
sent such to warehouse(i.e. without packing). In warehouse, the thans and
P.L.S. are packed in different packages, according to the order of parties.
The cloth is now ready to be transport to the dealers.

Reeling
Yarn can be wound in the form of hanks also in places of cones if the
customer demands it so. The process of making hanks is called reeling.
Bobbins from ring frame are fed to the reeling machine & we get hanks.

Ring frame
The roving are converted into smaller sized bobbins in this process. The
main objectives of ring frames are to increase the twist and length of the
roving from of fibre and thus convert it into ‘yarn’ – the final product. So
ring frame is the final stage in yarn production. At this stage twists are given
according to the customers specifications. Due to excessive thinning, the
yarn can break here. In order to avoid such breakages and unevenness in the
yarn, the relative humidity is kept at about 65% in this section.

Simplex
The silver drums get converted into smaller roving here. The main
objectives of this process are to increase the length and strength of the rope
from of the fibre. This is the stage prior of spinning , twist is introduced here
and thinning of the rope begins.

Sizing
Sizing is a chemical treating of yarn beams the objective of sizing are:
# To provide further strengh to the yarn to withstand the tension while
running on the loom and hence reduce breakages.
# To protect the yarn from various type of insects.
Various material are used in sizing include-strach adhesives, fitting
materials and insectiside sets. The beam after sizing is called weaver beam

Spinning
This is the process of conversion of fibre into yarn. fabric are two types
natural and syntheic fibre. But B.T.M use of the later only. Polyester,
viscose, Acrylic, Nylon, Orlon, Triolobale etc. are various sub-types of
synthetic fibre, which are being used by B.T.M. The production system of
yarn can be shown as:
Input Transportation Output
(Fibre) Process (spg.) (Yarn)

Warpping
This is the first sub process in weaving. Here the yarn is used to form beams
main objective of wrapping are-
To form a beam
To remove weal places
To remove slub and fluff etc.
Wrapping consists in arranging side by side, a large number of yarn ends to
form a sheet of wrapped round an iron rod. This on iron rod. This sheet on
iron rod is called Beam.

Winding In this process yarn is wound on cones in order to get a

longer and continuous yarn length, suitable for the weaving process. It also
removes weak places in the yarn. The main function of winding machine
therefore are to convert bobbins into cones and remove any slubs or fluffs
from the yarn. Slub is a yarn defect of unevenness.

Weaving
Synthetic yarn is used as the input process and the end product obtained is
fabric. So weaving is the process of converting yarn into fabric.
 World class
manufacturing
As a landmark the switching over to BMC approach by its
successful implementing has paved the path for policies
and plans formulation incorporating the concepts of WCM.
It,s motto is to BEAT THE BEST.

WCM says:
Practice what we preach
Have you defined the QCDI of what you are going
to do ?
Equipment is your livelihood, love and maintain
it.

WCM: The Eight Dimensions

Work
Environmen
Waste t Jit& stock
Eliminatio reduction
n

WCM
Information Total
System CM predictive
Technology Maintenance
CREATING VALUES
 Liason & Quality
Understandin First SQM
g & Best
Custimers Practices
Driven
Internal &
HR Department Structure external

President and unit

head

HR head
( B.k Mohapatra )

Compensation People processing

Incharge Incharge
( Nirbhay gupta) (Lalit dutt )

Recruitment
Incgarge
( Harpreet kaur)

Training Training Training

WCM Officer
officer Officer Officer
Spinning Fabric elegent
(vijay (manohar
(Basant (Srinath
gupta) Sharma)
agarwal) Sharma)
Compensation
& salary
(virender)