|Internship Report on Nishat Textile Mills|
Samar Kamal Fazli.
Muhammad Jamil BHATTI.
August 28, 2006
COMSATS institute of information technology, JINNAH Campus,
Defence Road off Raiwind Road, Lahore
Ph No. 5321090, 9203101 Ext. 215
Muhammad Jamil Bhatti
All the praises are for the almighty, Allah who bestowed me with the ability and potential to complete this Internship. I also pay my gratitude to the Almighty for enabling me to complete this Internship Report within due course of time.
Words are very few to express enormous humble obligations to my affectionate Parents for their prayers and strong determination to enabling me to achieve this job.
I take this opportunity to record my deep sense of gratitude and appreciation to my Internship Advisor Mr. Samar Kamal Fazli, Department of Management Sciences, COMSATS Institute of Information Technology Lahore for his constant encouragement and inspiring guidance with his Wisdom.
I also appreciate the cordial co-operation from all my concern Managers in the different departments of Nishat Mills Ltd especially Capt. M Nasir (CSO) Mr. Asif Javaid GM Spinning Mr. Abdur Rehman, DSM Spinning Unit#3, Mr. Nadeem Ashraf Marketing Executive and Admin & HR management for providing me requisite information and knowledge for compilation of my complete Internship.
I dedicate this to my Beloved Parents for all their love & attention which has made it possible for me to make it up to this point and as well as the Internship Advisor Mr. Samar Kamal Fazli, who bestowed me with the courage, the commitment and the awareness to follow the best possible route, by his unmatchable style and by best possible training.
Table of Contents
Nishat has grown from a cotton export house into the premier business group of Pakistan with 5 listed companies, concentrating on 4 core businesses; Textiles, Cement, Banking and Power Generation. Today, Nishat is considered to be at par with multinationals operating locally in terms of its quality products and management skills.
I recently have done my internship in Nishat Mills Limited, in which I got training from each of its department. The internship basically revolved around the product knowledge training. The system, the style of working & the commitment of the employees in NML is really exemplary.
The difference between the success & failure is doing things right and doing things nearly right, & NML has always tried for success & that is why it is known to be one of the leading organizations in Pakistan. Irrespective of all these positive points of Nishat Mills Limited, I have noticed a few areas where the improvement can really increase the efficiency of NML.
In this report I have given a very brief review of what I have seen during our internship I have mentioned all these as I have made an internship as according to the schedule. I also mentioned about the Textile industry in Pakistan and vision of its industry. Then I have done a detailed SWOT analysis as well as PEST Analysis.
Then I have discussed about my learning in the whole internship that is all about the Textile Terminologies and process of the productions. I have made it possible to write each and every thing that I have learnt there. I have all my practical efforts in the form of this manuscript that’s the asset for my future career.
To transform the company into a modern and dynamic yarn, cloth and processed cloth and finished product manufacturing company with highly professionals and fully equipped to play a meaningful role on sustain able basis in the economy of Pakistan.
To transform the company into a modern and dynamic power generating company with highly professionals and fully equipped to play a meaningful role on sustainable basis in the economy of Pakistan.
To provide quality products to customers and explore new markets to promote/expand sales of the company through good governance and foster a sound and dynamic team, so as to achieve optimum prices of products of the company for sustainable and equitable growth and prosperity of the company.
We work together as a team for implementation and continual improvement of total quality system in order to achieve satisfaction of our internal and external customers.
Textile Vision 2006
An open market driven, innovative & dynamic Textile Sector which is:-
Fully equipped to exploit the opportunities created by the MFA Phase out and this enables Pakistan to be amongst the Top Five Textile Exporting Countries not only in Asia all over the world with the tremendous Textile companies
Low Road Scenario represented a situation where only the historic export growth rates in textile sub-sectors were maintained. The overall average export growth for the textile sector after analysis was finalized at 6% per annum.
Do-Able Scenario envisaged increase in unit price realization of yarn, fabric, textile made-ups and garments with an attempt to maintain the market share in each individual market. It also suggested penetration in the non-quota markets along with increased share of synthetic and blended yarns, fabrics and garments. The overall export growth in this scenario was estimated at 12% per annum.
High Road Scenario the most ambitious of the scenarios that not only adopted the apparel sector as the engine of textile export growth but also recommended diversification in products that hold greatest potential but unfortunately have been neglected e.g. woven garments, sports wear, specialized industrial garments, and women wear. Besides broadening of export product portfolio with extra push in synthetic and man-made fibers, fabrics and garments,
The Textile Industry:
Over the years, Pakistan is said to be the single crop economy i.e. cotton and textile that claims the lion’s share in terms of the contribution in the national economy of Pakistan.
Despite efforts to bring in diversification in country’s overall economic get-up the textile sector continues to be the most important segment of the national economy. Its share in the economy, in terms of GDP, exports, employment, foreign exchange earnings, investment and revenue generation altogether placed the textile industry as the single largest determinant of the economic growth of the country.
Despite harsh and hard international economic conditions, Pakistan’s textile industry has weathered the storm by coming out of the international crisis in a very positive manner.
During the year exports were controlled from falling and significant investment was made in value-added expansion and in Balancing-Modernization- Replacement (BMR).
Besides fall out of the events of September 11, the implementation of WTO’s agreement, various bilateral agreements have been signed and implemented.
As a result global scenario has changed. Government and the corporate textile sector adjusted their policies to achieve maximum benefits of free trade. So, local structure of the corporate culture, investment pattern and fiscal and monetary policies were significantly changed.
IMPORTS textile machinery
Import of textile machinery and equipment has picked up since 1997-98 when a bumper cotton crop was harvested and the Textile Industry reaped massive profits due to lower input cost. In the last five years more than Rs9 billion have been invested for the import of spinning machinery. Nishat is one of the major customers in terms of importing Textile Machinery from almost all developed countries.
It is expected that an additional Rs10 billion would be required for Balancing, Modernization and Replacement (BMR) in the spinning sector during the next three years for producing superior quality yarn besides several units are in various stages of installation in Karachi also.
These facilities would improve value-addition in fabrics, besides increasing the volume of fabrics and quality garments exports from the country.
Textile is the only sector where investment has been substantial and regular during past three years. The most encouraging factor of this investment is diversity.
The entrepreneurs, who earlier concentrated on Spinning and Weaving, have now established compact units adding state-of-the-art finishing units and knitting machines to add value to their products. The latest addition to this is the setting up of denim cloth producing units.
At present, the export competitiveness of the textile industry can be improved by aggressive marketing techniques and quality improvements which have to be taken care of micro-level that is each textile unit should make its own independent efforts to sell its products in different international markets.
All the individual textile units should implement the ISO 9001 program for quality standard and ISO 14000 for environmental standards to counter the threat of globalization.
EXPORTS of Textile
Despite sluggish trends in the international markets, exports of textile manufactures increased from $5.75 billion in 2000-2001 to $5.8 billion in 2001-02. The encouraging factor was the increase in the exports of value-added items. The share of value-added products in total textile exports from Pakistan this year was 57.13 per cent as compared to 54 per cent last year.
Cotton cloth export also increased to $1.13 billion during this period as compared to $1.03 billion in 2000-01, indicating an increase of 9.7 per cent. The exports of bed-wear fetched $918 million against $745 million; showing growth of 23 per cent, while towels exports increased by 12 per cent to $270 million against 242 million.
Readymade Garments improved by 7 per cent to $882 million from$827 million, whereas Made-up articles increased by 6 per cent to $351 million as compared to $331 million.
The exports of five sub-groups i.e. Cotton Yarn, knitwear, Tents, Canvas/Tarpaulin, Art, Silk/Synthetic Textile and other manufactures declined during the period. Cotton yarn, which earned $1.1 billion during 2000-2001, earned $ $911 million.
The textile quota exports to the United States, European Union, Canada and Turkey grew by over 18 per cent with nominal increase in value during the first seven months of the calendar year 2002 compared to the same period last year.
The highest amount of increase of 55 per cent in quota exports followed by US 29 per cent and EU 12 per cent. Exports to Canada declined by 21 per cent in quantity.
In terms of value, exports grew by 30 per cent to Turkey and 13 per cent to the EU. Exports declined in case of Canada by 29 per cent and 9 per for the US. The total exports to the US were 420 million square meters worth $481 million; European Union imported 1058-million square meter worth $509 million. Canada imported 16 million square meters worth $18 million and Turkey, 101 million square meters worth $28 million.
The average unit price of Pakistan’s textile quota exports dropped considerably i.e. 30 per cent in case of US, 9.6 per cent for the EU and 16 per cent in case of Turkey. The only increase 0.21 per cent was recorded in average unit price of exports to EU. The WTO agreement provides for making textile trade completely free from 2005.
The textile export figures for the first ten months of the current year released by the Export Promotion Bureau revealed that the textile quota exports to the US improved by 24 per cent while the increase in exports to EU countries at the end of October 2002 registered an increase of 16.6 per cent in terms of value and 13 per cent in terms of quantity.
To get maximum benefit from quota free regime, all out efforts are needed to boost textile exports and increase access to the international markets. To boost the exports, the State Bank of Pakistan has introduced three facilitating schemes for the exporters namely, Foreign Currency Export Financing Scheme (FCEFS), Political Risk Guarantee Scheme (PRGS) and the Export Guarantee Scheme (EGS). The bank would provide 210 days credit facility to exporters for South America as compared to 120 days credit facility to other markets.
*The Nishat Group* Mian Muhammad Mansha Yaha is the captain of this splendid ship having around 30 companies on board. Mansha, who owns the Muslim Commercial Bank as well, is now setting up a billion rupee ($ 17 m) paper sack project too. He is one of the richest Pakistanis around. Nishat Group was country’s 15th richest family in 1970, 6th in 1990 and Number 1 in 1997. Mansha is on the board of nearly 50 companies. Chinioti by clan, Mansha is married to Yousaf Saigol’s daughter.
He is deemed to have made investments in many bourses, currency and metal exchanges both within and outside Pakistan. He has had his share of luck on many occasions in life and has recently been awarded Pakistan’s highest civil award by President Musharraf. He could have bought the United Bank too, but then who doesn’t have adversaries. Nishat Group of comprises of textiles, cement, leasing, insurance and management companies. If Mansha was bitten by Bhutto’s nationalization stint of 1970, his friends think he was compensated by Nawaz Sharif’s denationalization programme to a very good effect. There is no stopping Mansha and he is still on the move!
The history of Nishat Group dates back to 1951, when Mian Muhammad Yahya founded Nishat Mills Limited.
This man of vision, courage and integrity, Mian Mohammad Yahya was born in 1918 in Chiniot. In 1947 when he was running leather business in Calcutta, he witnessed by the momentous changes that swept the Indo-Pak subcontinent.
This is story of success through sheer hard work and an undaunted spirit of enterprise. Beginning with a cotton export house, he soon branched out in to ginning, cotton and jute textiles, chemicals and insurance. He was elected Chairman of all Pakistan Textile Mills Association. He died in 1969, at the age of 51 having achieved so much in so short time.
After almost half a century of undaunted success, Nishat group is among the leading business houses of the country and ranks among the top 5 groups in terms of assets and sales revenue. The group has its roots firmly planted into four core business namely
Ø Power Generation
The textile business is further subdivided into 2-textile division:
Ø Nishat Faislabad
Ø Nishat Chunian
The textile capacity of the group is the largest in the country. An addition of 20,000 new spindles, 100 new air jet looms and new dyeing plants has increased the existing capacity of 242,000 spindles, 740 looms and dyeing and finishing capacity of 5 million meters. The largest exporters of textile products from Pakistan, for more then decade!
Nishat group has also been a pioneer in power generation in the private sector of the country. Nishat setup the first power generation unit in the private sector in 1995.
In 1992, Nishat Group acquired D.G Khan Cement Company Limited (DGKCC) from the second largest project of the group and is ideally located in the heart of the country, with easy access to transportation all over Pakistan. DGKCC unit No. 1 has a capacity of 2,200 tons per day. A new unit heaving the capacity of 3,300 tons was setup in 1997.
International Finance Corporation and common Wealth Development Corporation have financed this unit. With the addition of unit No.2, DGKCC has become the largest manufacturer of cement in Pakistan.
In 1991, Nishat Group ventured into the financial sector through the acquisition of Muslim commercial Bank. MCB has grown ever since and is now the largest bank in the private sector. MCB has a network of over 1200 branches employing over 12,000 people.
Nishat Mills Limited is a public Limited Company incorporated in Pakistan under the Companies Act, 1913(Now Companies Ordinance, 1984) and listed on Stock Exchanges in Pakistan
Nishat Mills Limited (“Nishat”) is a public company incorporated in Pakistan and listed on all three Pakistani stock exchanges. Nishat is engaged in textile manufacturing.
Which involves spinning, combing, weaving, bleaching, dyeing, and printing, stitching, buying, and selling of textiles? They deal with yarn, linen, cloth and other goods including fabrics made from raw cotton, synthetic fiber and cloth.
The Company is engaged in the business of textile manufacturing and of spinning, combing, weaving, bleaching, dyeing printing, stitching, buying, selling and otherwise dealing in yarn, linen, cloth and other goods and fabrics made from raw cotton, synthetic fiber and cloth, and to generate, accumulate, distribute and supply electricity.
Company is providing quality products to its customers within the Pakistan and outside the Pakistan. Presently company is exporting its all kinds if apparel products.
Nishat competitors are
But main competitors of Nishat Mill are
“Crescent Textile Mills”
Ø Mrs. Naz Mansha
BOARD OF DIRECTORS:
Ø Mrs. Naz Mansha
Ø Mian Raza Mansha
Ø Mian Hassan Mansha
Ø Mr. Muhammad Nawaz Tishna (NIT)
Ø Mr. Faisal Ehsan Ellahi
Ø Mr. Khalid Qadeer Qureshi (Chief FinancialOfficer)
Ø Mr. Muhammad Azam
Ø Mr. Rana Muhammad Mushtaq
Ø Mr.Shehzad Malik (G.M)
Ø Mr.Usman Bajwa
Ø Mr.Badar Rauf
Ø Mr.Ashraf Ali Raza
Ø Mr.Asad Iqbal
Ø Mr.Masood Akhtar
Ø Mr.waseem ul Haque Osmani Chairman
Ø Mian Hussan Mansha Member
Ø Mr. Aftab Ahmed Khan Member
HEAD OF INTERNAL AUDIT:
Ø Mr.Khalid Kabeer
Ø Mr. Muhammad Azam
Ø Mr.Khalid Mahmood Chohan
Ø Riaz Ahmed & Company
Ø Chartered Accountants
Ø Mr. M. Aurangzeb Khan, Advocate,
Chamber No. 6, District Court,
BANKERS TO THE COMPANY:
Ø ABN AMRO Bank
Ø Allied Bank of Pakistan Limited
Ø American Express Bank Limited
Ø Askari Commercial Bank Limited
Ø Credit Agricole Indosuez
Ø Citibank N.A
Ø Deutsche Bank
Ø Faysal Bank Limited
Ø Habib Bank Limited
Ø Habib Bank A.G. Zurich
Ø Mashreq Bank P.S.C
Ø Meezan Bank Limited
Ø National Bank of Pakistan
Ø Standard Chartered Bank Grindlays
Ø The Hong Kong & Shangai
Ø Banking Corporation Limited
Ø Union Bank Limited
Ø United Bank Limited
Nishat Textile Limited has seven spinning units situated in Faisalabad. These units are equipped with the latest machines in all of their departments. In the spinning units the fiber is converted into yarn, and as this the quality of yarn is very important in the textile sector so spinning units have a lot of importance.
Generally the spinning mills mechanism is very similar. It starts from the mixing department where the bales of cotton are mixed and at that section the most visible impurities are taken out. This mixed cotton is then taken to the blow room by a machine. After going through a process it is taken to the card room for the next process.
After the card room the route is taken by keeping in view that whether carded yarn is the end product or the combed yarn. The combed yarn is of better quality and its process is a bit bigger than the other one.
For the carded portion the drawing breakers & drawing finishers are used to prepare the fiber to a certain level so that the process on the simplex machine can be carried out. On the other hand, in the combed portion, after the drawing breaker the cotton goes through the lab former, & after that it goes through the combing machine, where the comer noil and comber sliver are separated.
The comber sliver, after passing through the PC drawing & Drawing finisher goes to the simplex machine. The product that comes from the simplex machine is then taken to the Ring section where the yarn is to be made. Finally after passing through the auto cone the yarn comes in the packing department. In NML the process of Ultra Violet Checking is also practiced to ensure the quality of the yarn.
As this process is very important so there are some common parameters on which the quality of yarn is judged. These parameters have been listed as below:
Important Parameters of Yarn & Fiber:
Important Parameters of the Fiber:
· Micronaire value
· Color grade
· Neps / gram
· Trash percentage
Important Parameters of Yarn:
· Yarn count
· Strength LCSP
· U percentage
· Thin Places
· Thick Places
· IPI (Imperfection)
Yarn Elongation (Flexibility)
· Single Yarn Strength
· Twist Multiplier
Very similar to the spinning units, the weaving units of NML are really very well equipped with the latest machinery to make the best possible product for the customer to gain the customer satisfaction.
Most of the machines in the weaving unit of NML are of new technology & NML has a very good check on the quality of fabric produced by its Quality Control department.
The end product of the spinning unit is the starting point of the weaving unit. When the cones of the yarn are brought to weaving unit, it is then taken to the warping zone in which the beams are prepared.
These beams are then taken to the sizing section where the different chemicals are applied to the yarn so that the weaving of the fabric can be done with the minimum breakage of yarn. After sizing the process of drawing inn is applied so that the yarn could be converted into fabric.
After the drawing inn the beams of the yarn is then taken to the Sulzer Looms so that the yarn is converted into the weaved product. When the greige is made, then it is taken to the inspection department, where a lot of quality check is done. At the first step the fabric is classified into two types, i.e. A grade & D grade.
The D grade fabric is either used in the B grade sale or in gathering of the fresh pieces. While the process of A grade fabric is a bit longer.
The A grade fabric after mending, goes to the checking machines, from where it is taken to the rechecking machines. After rechecking either the greige is rolled or folded & packed according to requirements of the buyer.
During all the above process, quality is the main purpose of the NML people. The weaving units of NML check the product quality as under:
NML (Four Weaving Units) BHIKHI
NML has one of the largest weaving setups in Bhikhi, near Sheikhupura. This Unit is equipped with the later Air Jet looms. The variety level of the product is very good.
In the warping section NML Bhikhi has 5 Benninger Machines which are of Switzerland origin. In the sizing section the NML Bhikhi has 5 machines. As far as the looms are concerned, NML Bhikhi has 389 looms for preparing the greige. Out of these 389 machines 96 are Sulzer Ruti of Switzerland, while other machines are the latest Air Jet machines of Japan origin.
The Bhikhi unit of NML is specially very well known for its product in all over the country.
Quality Control Department:
First of all the people of NML checks the quality of yarn before taking it into the process. Following are the yarn characteristics that are checked before taking it into the process:
· Count Testing
· Strength Testing
· Hairiness Testing
· Thick & Thin bases
At the warping section the following characteristic is checked:
· Breakage Report
When the sizing process is applied, the following two tests are applied:
· Abrasion Test
· Strength Test
After completion of the greige the g/sm test is applied so that to have the best customized product. Finally in the folding section checks are applied at every step of the folding process. The weaving units of NML are known to be the best producers of greige product in Pakistan.
QUALITY CONTROL LAB:
During the production, quality control lab ensures that every work has done according to the standards of NML. Following checks are made at different departments:
Checks while Printing:
Ø Dry Cleaning
Ø Chlorine Test
Checks after Curing:
Checks after Stenter Process:
Ø Light Fastness
Ø Washing (Optional)
Checks after Raising:
The purpose of all these checks is to ensure the Quality of the end product.
QUALITY CONTROL LAB MACHINES:
· Crock Meter:
· Pilling Machine:
· Garment Washing Machine:
· Dura Wash:
· Wascator Machine
· Thumble Dryer
· Light Box
· Auto Wash
· Curing Machine
· Light Fastner Tester
· Air Permea-meter
· Data Color
· Visco Meter
The above are the machine which is used in the Quality Control Lab to ensure the quality at every step.
Processing Unit of every textile mill has a paramount importance because it actually provide the finish fabric product which is either sent to customer either as a piece good or as made up after converting the fabric into the required stitched product. The processing unit of NML comprises of the following department:
Ø Bleaching Department
Ø Finishing Department
Ø Printing Department
Ø Dyeing Department
Ø Folding Department
Ø Quality Control Lab
Ø Digital Design Studio & Engraving Department
Ø Sample Room
Ø Production & Planning Department
The operations of Production & Planning Department are to work as a bridge between the marketing team and the processing people, so this department has the prime importance.
All of the communication which is held between the processing & the export people is done through this department. The finishing department is also very important because it is the center of operations held in the processing unit.
A brief overview on the Processing capacity of NML has been discussed as follow:
The bleaching department of NML is equipped with the latest machinery to compete with the market. Bleaching department has the following machines:
Ø Singeing & De-sizing:
Ø Water Mangle:
The above are the machines & a very brief overview of the machines. The bleaching department is like a back bone of the processing unit. After weaving mill, the fabric is brought to the bleaching department where it is prepared on the above machines so as to be prepared for the Printing or Dyeing.
The Quality Control people ensure the Quality of work in the Bleaching to fulfill the collective goal.
The Printing department of Nishat Mills Limited comprises of three rotaries, i.e. Reggianni, Zimmer & Stork. Along with theses three rotaries, the printing department has three sampling tables to fulfill the sample need of the customers of NML.
There is a mini sampling machine for the sampling section to facilitate their work. The specification & general points about these rotaries are as under:
Ø Reggianni Machine:
Ø Zimmer Machine:
Ø Stork Machine:
The Printing department of NML is working at its best & producing really good stuff. After the printing from the rotaries, the route of the fabric depends on the dye class.
If the reactive dyes have been used, then the fabric will be taken to first of all Ager Machine & then Goller Soaper Washing, then to Stenter finish & finally to the calendar.
On the other hand the fabric treated with pigment dye is taken to the curing machine & from there it is taken to the calendar after the required stenter finish. Now in the following line, we’ll see the specifications of the Curing & Ager Machines:
Ø Curing Machine:
Ø Ager & Curing Machine:
The dyeing department is a major department of NML processing. This includes three machines. These machines have been identified & discussed as below:
Ø Pad Thermosol:
Ø Pad Steam:
Ø Goller Soaper Washing:
So above is a bird’s eye view on the dyeing department of NML.
Finishing department of any textile mill has a very significant importance because it acts like a hub in the Processing. Almost every fabric which goes through processing unit, it has to be passed through the finishing department.
The finishing department of NML Processing unit is famous for its quality work. It comprises of many latest machines which includes Stenters, Cylinders, Raising Machines & Sanforizing Machine.
Types of Finishes:
There are two major types of finishes:
Ø Chemical Finishes
Ø Mechanical Finishes
The finishes in which no chemical is used is called the mechanical finish, a very good example of mechanical finish is Calender Finish. On the other hand the finishes through stenter are known to be the chemical finish. The finishes are of the following types:
Ø Normal Soft
Ø Super Soft
Ø Anti Pilling
Ø Anti Wrinkle
Ø Water Proof
Ø Easy Care
Ø Soil Repellent
The Sanforizing machine is used for relaxing the shrinkage of warp. The machine possessed by NML has a workable width of 114”. It is basically used either on customer demand or in case of Garments. The standard is 5%. NML has one Sanforizing machine in its processing unit.
This basically means to raise the fibers from the surface of the fabric. The machine possessed by the finishing department of NML has a workable width of 114”. NML has one raising machine in its processing unit.
NML has 2 Cylinders. The basic purpose of calendaring is to have the shine & to have better hand feel. These Cylinders are of two different lengths, the workable width of the Cylinders is 100” & 111” respectively.
The above is a brief introduction of the Finishing department of NML.
The folding department of the NML has a daily production of 1,00,000m. The folding department is the last department of the Processing Unit. After the folding unit the fabric is transferred to GSC.
The folding department has two kinds of machines; the kind is rolling machine while the other kind is of folding machines. It depends on the requirement that which kind of machine would be used.
In the folding department of NML latest 4 score method is used for the inspection purposes. Quality checks are made at every step of processing unit.
The Engraving Department of Nishat Textile Mills Limited is equipped with the latest machinery along with the manual machinery for the process of exposing.
In the Engraving Department of NML, the screens are generally prepared which are then used in the printing process.
Sizes of the Screens:
Following are the three repeats of screens which are used in the Engraving Department:
Similarly the widths of the screens are of the following five kinds:
The fifth width is currently not in the use of Engraving department and that are not in used in NML now. The first four kinds are basically in use in the NML.
The selection of the screens depends on the design requirement of the print. The most important thing which should be kept in mind is that only one screen should be used for one color that means the number of screens will be equal to the number of colors which will be used during the printing process.
1. Coating Stage:
The first step which is taken in the formation of the screens is to coat the screen with SCR 100. This coating is done for the purpose of blocking the meshes of the screen so that the required king of design can be made through the screen. The coating of the screen takes almost 8-9 minutes.
2. Heating Stage:
These screens are then heated in the ovens so that to carry out the process in the best possible manner. When the screens are heated in the proper way then they are taken to the exposing machines. The heat is provided to the screens so that to fix the SCR 100 so that the exposing stage should be started.
3. Exposing Stage:
Nishat Textile Mills Limited has two exposing machines, one of them is manual and the other is fully automatic. The automatic machine is the “wax jet”. The process of exposing stage is different for both the machines.
In the process of Manual Machine, it is quite a time taking process. In this machine, the presence of machine operator is very important; otherwise the time for each screen will be higher than the original one.
Earlier most of the work was done through this machine but now the major load has been shifted to “was jet”. Irrespective of these facts the importance of this machine is still there.
All sizes and widths of the screens can be prepared through this machine. Basically the manual machine is used for the word of design studio.
The “Wax Jet” machine is fully automatic. The work done through the digital design studio is done through this automatic machine. The speed of exposing through this machine is relatively higher than the manual machine because there is not such need of operator at every stage of the exposing.
The process at this machine does not effect because of the presence of the operator. The exposing is being done through the wax on this machine that is why it has such a name.
The mechanism of this machine is that the machine is linked with the digital design studio, so the operator can access any of the prepared design in the studio. Then the wax is applied on the screen in such a way that the wax is applied on that place from where the operator want to open the meshes. Then the lighting process is done i.e. the screen goes through high power light.
The result of this process is that the place where only coating is there and there is no wax, at these places the coating got fixed in such a way that the meshes are blocked in a better way. After this Exposing stage the screen is taken to the next stage.
NML has ordered for “ink jet” machine which will enhance the production capability of the engraving department.
4. Washing Stage:
The screens are then taken from the exposing machines to the washing area. This is the area where the screens are washed so that the black portion can be washed from the screens. This is also called the Developing Stage. The screens are then kept on the light stand to see that whether the results are satisfactory or not. When the staff feels that the design is satisfactory then they send this screen to the heating machine for curing.
5. Curing Stage:
The curing is being done through an oven. The screens are kept about 20-25 minutes in the oven. This heat fixes the design on the screen so that after the final touch the screen can be sent to the next department.
6. Endring Stage:
During this stage the ring type iron is fixed on both the sides of the screens so that the screens could be taken to the printing department for printing.
7. Touching Stage
During the touching stage the final work is done. In this stage if there is any extra patch on the screen, then they are blocked with SCR52 so that the correct effect can be drawn on the fabric. This is the final stage of Engraving Department. After this step, the screens are then taken to printing department.
The design studio is a very important department of Processing Unit. The importance of design studio is because of the reason that without its right work nothing correct can be done. The presence of good design studio is very important for any good textile export organization.
The buyer sends the desired design in the following forms:
Ø Through Sketches
Ø Through Fabric Sample
Ø Through CD
Now after having the concept of design, it is then the responsibility of design department to make the screen design, to select the sizes of the screen, to select the repeats of the screens and most importantly to make the films and designs so that to have the same designs during the printing process as required by the buyer.
In the digital design studio the work is being done through the latest machineries and software and dedicated and educated persons are there for the purpose carrying out the process. All of the work in this studio is done on the latest machines and the work can be accessed through the Wax Jet machine.
In the other design studio, the work is being done through the experienced persons. In that studio the guideline is the first thing which is made at the start. After this step, there comes a chain in the design studio such as to separate the colors up to making the and preparing the films which can be used in the engraving department.
NML has two stitching units.
1: One is situated in Faisalabad
2: The other is situated in Lahore.
The bedding section is concentrated in Faisalabad while the Lahore unit is a complete unit which is involved in all kinds of stitching.
The cutting department is the first department of GSC, which takes the fabric. The fabric, which is to be stitched, is brought from the folding department to the cutting department. In this department the fabric is cut according to the specifications & need. From the cutting department the fabric is transferred to the store from where the fabric is issued on the required floor according to the freezing plan.
The cutting department objectives
· Quality control
· Minimize Wastage
So cutting department was performing these responsibilities. Mr. Arif the Cutting supervisor who shared the rules of cutting that is the foundation of the complete stitching department. Those are
One: LENTH FOR LENGTH (L*L)
Two: WIDTH FOR LENGTH (W*L)
The Process flow of cutting department is as below
SAMPLE PROGRAMME CUTTING
Stitching Department (GSC)
Stitching department is one of the well equipped machines department in the field of the Textile in Pakistan that’s why there are most of the loyal customers of the Nishat from all over the world specially WALL MART, TARGET and TARGET. These are the major have chain of stores around the world.
724 helpers are daily wages working as quality checker in the whole stitching department. 400 stitching machines in the whole stitching unit. Every machine operator has a unique no to find out the any type of the fault.
The objectives of the stitching department are
à The cost minimization and
à To minimize wastage
à Best utilization of time
à Quality control by line checker
Types of stitching
à LOCK STITCH,
à CHAIN STITCH,
à TWIN NEEDLE,
à WORK STATION
à Blind stitch
à Over lock
à Flat lock
Dispatch department is performing two functions
à WARE HOUSE,
à MAID-UP DISPATCH
Dispatch department is responsible to dispatch all types of Export after packing. It depends on the marketing department when it should be dispatched. Its not necessary to dispatch daily. Dispatch department is to pack and dispatch report preparation the prime responsibility is to make maid-ups dispatch Report.
Dispatch Department has a continual liaison with Marketing Department and to fix stickers according to the customer demand on the cartoons. The dispatch report also send to the head office and as well as customer. Maximum container capacity is to six containers per day. Work force is use for loading or shipping in container.
à Twenty fitter lengths
à Forty STD 8.5 feet length
à Forty STD = 9.5 height.
From cutting to dispatch process is as below
Cutting stitching Packing dispatch
Along with the cutting section, there is another important depart named as commercial department. The working of commercial department starts from receiving the stitching programs. First of all, they see whether it is a new order or a repeat order. Then they issue a demand order through their Purchase Department. It is the duty of the commercial department to arrange all the equipment needed in the stitching unit for every bulk order. The products which are the responsibility of the commercial department includes label, fusing, polyester rope, stiffener, insert card, poly bag, stickers, size stickers, identification sticker, barcodes, security codes etc.
A freezing plan is made every month so as to maintain & systemize the production process. The stitching units of NML have latest and number of machines to fulfill the customer need & requirements. Total number of helpers in on daily wages in the whole stitching unit is 724. There are 400 machines in the GSC (general stitching company).
Quality is most important consideration while production in NML. This is why the quality checks in stitching department are of very good level. In Nishat Sewing Lahore, Acceptance Quality Level 2.5 & AQL 4.0 is under practice. The Nishat Sewing Lahore is a certified for quality level from many organizations. This shows that the Quality checks in Nishat Sewing Units are of international standards.
As the stitching department is the last department before the dispatch of goods so a lot of responsibility comes on its shoulders. There are sample rooms in the stitching units so as to fulfill the sample stitching requirement for different markets to ensure customer satisfaction.
So the above is the brief overview of some of the NML operations. Now we’ll discuss the chances of further improvement in NML.
Export Marketing Department:
The export department of Nishat Mills Limited is known to be the best marketing department in the whole textile industry because of the commitment and dedication of employees, the determination of work & the best management system.
NML Marketing has a very strong liaison with their customers around the world. That’s why NML has different segments on the basis of different regions like North America, Australia and Europe.
Every region has a different Export Manager and its whole staff. The marketing responsibility is not only to just sales and marketing it has also to find out new horizons and new ways. That’s why Managers visit to new Markets around the world.
HAM TEX FAIR
Hamtex is a fair of textile held in Germany on every January of the year in which all over the world well established organizations make their display centers to attract new customers.
This department is responsible for the export of yarn, grey cloth and processed fiber. This department has to fulfill all the legal requirements and prepare important documents involved in the export of yarn, grey cloth and processed fiber. This department starts working from getting purchase order to deliver the shipment to the buyer.
The export department performs 3 major functions.
Shipment of Yarn, Grey cloth & Processed Fiber
After receiving packing list from shipping department, export departments starts its main functions. It usually prepares the following documents to ensure the timely shipment.
The most commonly documents which export department has to prepare and deal with are:
Letter of Credit (L/C)
Bill of Exchange
Export Declaration Form
Certificate of Origin
Textile Declaration Form
Shipping Bill/Bill of lodging/Air Way Bill
Letter of Credit
Letter of credit is the conditional undertaking on the request of the importer/buyer. It is also called documentary credit defined as;
“A written undertaking by the bank of importer i.e. issuing bank at the request of buyer or importer to make payments at sight or at determinable future date upto stated sum of money within prescribed time against stipulated documents”.
FNML parties are involved in the payment of the goods, i.e., the buyer, buyers bank, beneficiary, L.C. advising bank.
After clearance of the export documents, export department negotiate the papers with bank receive payments from the bank. Then NML local bank sends documents to the buyer bank and foreign bank release payment to NML bank with the permission of the buyer.
Most of the customers are American and U.S. Government allocate quota to third world. Infect quota is a quantitative restriction and more than that can’t be shipped to America from a particular country
CLAIM FOR REBATE
Rebate is actually a “Duty Draw Back”. The duty which an importer pays to government for the product that is re-exported after some process, then government pays back some of its part. This pay back of duty is called rebate.
The past year has been tough for the textile industry as competition is steadily and margin of profits is becoming smaller day-by-day. Our competitors from Asia have come up in a big way with lower prices resulting from lower overhead, cheaper and better raw materials and machinery.
Countries like China, Indonesia, India and Bangladesh played an active role in the fabric market. Improvement in quality and production capability was the main area of concentration.
Market for Yarns and Grey fabrics was diversified to increase the customer base and reduce dependency on the Far East. In this effort business with Malaysia, Korea, Taiwan, UK and South America was initiated in case of Yarns.
A new spinning unit of 21,672 spinning has also commenced, which caters to the weaving units in Sheikhupura.
In case of Grey Fabric market business was initiated in South Africa, North America, Japan, Italy, France, and Sri Lanka etc. Product range was also increased to cater to the differing needs of the buyers. Fancy and special items like Dobby Designs, Bedford Cords, and Cavairy Twills and stretch fabrics were developed which are being sold at premium prices.
NML has constantly updated our machinery, replacing old machines with new ones upgrading the existing set-up, leading to better efficiencies and quality products.
Nishat has established its name in new markets be creating specialized fabrics, designs and also by providing our customers with efficient service and excellent quality.
Leaving behind the traditional way of doing business and in our journey towards excellent it has consistently expanded its buyer base and explored the different markets around the world.
Keeping in view demand of the World market, Nishat Mills Ltd pursued its strategy of value addition and reducing the dependency on Grey Fabrics and Grey Yarn.
Having the foresight to assess that in coming year’s value addition will be the thing of the future, Nishat Mills Limited worked towards the achievement of its goal of future increasing its capability in value addition.
The export of processed fabric and made-Ups has shown market improvement as compared to last year. In Europe, Nishat has made the most growth in the year 1999.
It has placed us successfully in the middle to upper end of the market. Our strength in Europe is the curtain division.
This included yarn dyed dobbies, engineered confections, different finishes and embellished products. The plan is to continue with this winning strategy and at the same time we are trying to find new clients in the high end.
We are also exploring business opportunities in countries like Spain and France where Nishat has very little business at the moment.
North America is the star market for Nishat; it’s a new market for it after breaking up the exclusive arrangement with our previous sale set-up. The quota is coming down in 2005 and we have started to prepare for it internally as well as for the external environment. Bedding is the bulk of the home textile business.
Nishat is in the process of updating its machinery to cater the needs of the wider width fabric requirement for USA bedding business. Nishat is also taking up the social accountability issues very seriously, which are so dear to the American consumers. Lot of big brand US companies have visited us and are discussing the possibilities of a joint venture.
The opportunities are limitless, we have to review and analyze them very thoroughly to associates with the right people in the long run. In the short term we are building a small amount of quota, which will give us recognition as a bedding supplier.
Nishat is very strong in non-quota categories like curtain and table linen. These categories are best served with new product development (NPD). Nishat will coordinate the effort for NPD by all markets to optimize results. Nishat has achieved the highest sales in 1999-2002 for North America market.
On top Nishat has developed more direct and closer relationship with our end customers. Oceanic has been our most lucrative and mature marker. In business terms it is our “cash cow” market.
Primarily due to being a non-quota market it had no real limitations in this market. Despite economic problems in that region, it has maintained our sales figures in the year under review. This market is a good design source for other markets, which is helping us to maintain our print volumes.
Middle East market is composed of South Africa and the new emerging markets like the UAE, Egypt, Saudi Arabia, and Jordan etc. Nishat has dedicated new staff with fresh energy for the emerging market.
They have successfully broken the ground and we have very strong faith that these markets will give us good volumes in the near future. We are also targeting printed apparel business for the first time. The latest addition is the most ambitious Apparel Dyeing plant setup near Lahore, which has started its production.
The effectiveness and productivity of this plant will be further enhanced, as Nishat Mills Ltd moves towards becoming a more vertically integrated organization.
Our dyed fabric has already established its name in the market. It is being exported to some of the leading brands of the world.
Nishat has increasing its profitability by working efficiently, procuring better raw material and most importantly kept a very close association with its costumers.
It visits its business partners frequently and provides them with the best service possible. All of the above mentioned points led to strengthened relationship with its business partners making it very difficult for its competition to penetrate into its market share.
Nishat has provided its staff with better working environment and facilities, which enhanced efficiency and out put.
At Nishat, it is prospering due to our professional commitment toward excellence and giving the best results at all times and against all odds. Its marketing and production teams co-ordinance at all times and it focus remains on maintaining its position as the market leader in the textile sector of Pakistan.
Inquiry costing quote to customer
Processing cost per delivery
Lab dips/strike sample P.O received/Sales Contract sent
Dying/printing program issue
Shipment sample dispatched for approval
Shipment sample approved
Detail of SWOT Analysis
· ISO 9001-2000:
Nishat textile is certified under ISO 9001-2000 and so it meets the requirement of international standard and has a value in the mind of concern people.
· Strong Security System
Nishat textile limited has a greater security system. There are different hidden security cameras which capture the all moments.
· OKTEX 100:
Nishat is also Oktex 100 certified its mean that Nishat is satisfied to not using hazard chemical using.
· High quality product
Nishat textile limited using advance technology like they have modern machinery by which the quality of product produced is very high.
· Latest mechanized machinery.
They are using modern looms which they have purchased from Japan and France. And by using that latest machinery the productivity of the employees are very high.
· Tremendous market positioning
Nishat textile is one of the pioneer textiles in the Pakistan so it got the position in the mind of its customer. And being an old textile company people are loyal with it. Nishat has a better position in the mind of its customers.
· Highly qualified and skilled management
The management of Nishat is skilled they have hired the foreign graduate people in their management and also experienced people from all over the country.
· Highly Motivated Workforce
They are providing better pay to their employees and also bonus to them which motivate the workforce and they are doing well at work setting.
· Adequate financial resources
The owner of the Nishat is one of the richest persons of the Pakistan and they have more plant and investment in other industries like cement, Bank, They have adequate financial resources to meet their requirements.
· Competitive advantage
Because it is an old textile and it has still keep its position in the textile market on all others competitors in the nation wide which is its competitive advantage.
· Equipped with MIS System
They have a management information system by which the departments and employees are connect with each other and they have a data ware house by which they can share their resources easily.
· Own power generation plant
They have own power generation plant and Nishat is the pioneer in the private organization who start the power generation. And also selling to the WAPDA its produced power.
· High cost of production
The production cost is high because of not properly utilization of its resources.
· Centralized decision making
The decisions are made by the upper management which is weakness of the Nishat because they have no proper idea about the situation and their decision can be not fruitful for the company.
· Weak image in the international market
Because of the other textile specialized countries like China, Bangladesh etc the international image in the textile sector is very weak. Those countries providing cheap product to the market then Pakistan’s textile industries.
· Small international market share
Although Nishat has very strong in the national wide but it has small market share in the global textile industry due to the sound competitors like china, and Bangladesh etc[
· Less promotional activities
The advertising and promotional cost of the Nishat textile is very low it can take advantage for more turnouts.
· Lack of benefits and rewards for the employees
Some facilities that other providing to their employees like Transport and medical fee etc Nishat not providing to their employees because of which the productivity of the employees decrease.
· Organization Can expand product lines
Currently the Nishat not dealing in knitwear they can expand their product line by producing knitwear. They have plants and the extra cost for the production will be low for Nishat. And they also have better market repute.
· Organization Can reduce the cost by proper utilization of resources
If the cost of different matters which is not utilizing properly is controlled by the Nishat management they can produce more in a few costs. It has to develop a further systematic process for controlling and managing resources.
· Organization Can hire more well-educated and experienced person
They can take advantages by hiring more skilled people and they should hire young, fresh and energetic staff for their betterment.
· Buyer needs demands changes
Because of the research and development the design and the product of Nishat is just satisfactory as compare to competitors in the globally and they are not fulfilling the demand of customer.
· Political instability
Political instability effects the Nishat because of the quota system the company can be restrict by the government to export.
· Changed of government policies
Government policies are changing day to day so it is a threat for the Nishat to survive in such a changeable situation.
· Globally Economic instability
Because of the economic instability the Nishat affected a lot. Dumping system which is rising on daily basis in the world can create many problems for the company and any uncertainty in the world like 9/11 may affect also the overall export.
The political situation of Pakistan is not satisfactory. Due to the rapid change in the Government every government sets its own new trade policies.
Govt. should apply sustainable policies for the beneficial of the exporters as well as the investors.
The economic condition of Pakistan can also affect the foreign investors increasing inflation rate make the cost of production high and thus reduce the profit margin of the investor.
The change in the lifestyle of the people affects the growing demand of the NTM products. The change in the lifestyle and needs in different demographics also affect the demand of the customers.
Due to all these changes NTM is performing excellent for the excellence organization as well as for the customer.
Technological advancement in all the sectors of the country has changed the entire socio-economic environment. Especially in the textile sector there is a lot of technological development.
NTM Excellent computerized machines and devices are installed in the NTM \has made extension in its present setup by installation of well advanced technology imported from Japan China and France.
Learning as internee
It was a tremendous experience that I have availed with devotion and commitment. I have an interest in textile industry that’s because Textile is the back bone of the economy of the country. But one thing I want to share its not easy that looks it has a great toughness and complications in its process but the overall it was nice and great. Here I am sharing some of my learning regarding my internship in different departments.
· First I met Mr. Yoshifumi Nariyama the sales representative of KANAI from JAPAN who came to introduce some new products in NML. I discussed about the marketing practices going on in the international Textile market. Ie to target your customer after knowing needs with product solution of the customer need.
· In the spinning unit I have learnt about the yarn construction and the yarn specification and the process of cotton to yarn.
· I learnt that every problem is solved with a systematic process like from the root of the problem.
· I also performed some task in the spinning department like how to calculate the no of frames for a specific order and how many days are require for a specific order.
· I learnt about the marketing procedure and required of the documents and dealing with customers. All the record is saved.
· During my internship I learnt about the value that customer is the only who come first. The fulfillment of the demand of customer is our basic motive.
· The quality control as well inception in the textile department should be parallel.
· I learnt about the HR policies that how many types of hiring Nishat textile limited is using. And what are the procedures of the Nishat about HR matters.
· I learnt that in the textile sector the cutting and stitching based on two rules
o (Length) (Length)
o (width) (Length)
Nishat Mills Limited is one of the leading groups in Pakistan. The system, the management style, the policies & decentralized decision making environment is really remarkable. This report is basically an attempt to identify the areas which need to be improved.
In this era of technology, the “Information” is the key to success in the business. This means that the successful businessman will be who will have the right information at the right time. This comment leads to the conclusion that the Information Sharing Process should really be improved.
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 for Improvements are:
· At present facility of bonus is given only to production staff but such incentives should also be given to Head office Staff.
· Special incentives should also be given to Head on Eid and on other special days should be given to the workers.
· Medical facilities are given in mill but such facilities should also be given to management.
· Different training courses should be arranged for the up lifting and improving the quality of work for employees
· They provide transportation facility to only female employees I think male should also be provided with conveyance convenience. This will create the easiness for workers and reduce the wastage of time.
· There is also a problem of work overload for the employees and it should be control properly so that the employees are motivated.
· Employees should be paid extra for the work which they done after working hours.
FORM OF PROXY
being a member of Nishat Mills Limited, hereby appoint _________________
or failing him/her ___________________________________________________
Member of the Company, as my/our proxy in my/our absence to attend and vote for Me/us and on my/our behalf at the Annual General Meeting of the Company to be held on Monday, 31 October, 2005 at 11:30 a.m. at Nishat House, 53-A, Lawrence Road, Lahore.
As witness may hand this ________________day of ________ 2005
Signed by the said member _________________________________
In presence of _____________________________________________
Signature of witness Signature(s) of Member(s)