A Project Report On Reliance Industries Limited Barabanki Division

Submitted To: Prof. Apoorva Anand Submitted By: Ankur Pandey A7605408058 B.Tech.(M&AE) 7th Semester

ACKNOWLEGEMENT

It is our pleasure to place on record my sincere gratitude towards Mr. A.K.Yadav, Mr.Avinash & Mr. Gaurav Sharma, RIL Limited, who spent their precious time providing continuous ideas and expert guidance to our Report work. It was their direction and encouragement at every moment and step that motivated us to steer the research work confidently and successfully. We are also thankful to our Venerable Maj.Gen.K.K.Ohri , whose encouragement, moral support provides the valuable guidance, which has been a source of inspiration to us. We especially thankful to Mechanical staff & All Department that have to provide me valuable guidance, which is helpful to fulfillment our Project Report. We are also thankful to our friends who directly or indirectly helped us lot.

Ankur Pandey B.Tech.(Mech.)

RELIANCE COMPANY BACKGROUND

The Company has a customer base of 105 million including over 2.5 million individual overseas retail customers. It ranks among the Top 5 Telecom companies in the world by number of customers in a single country. Reliance Communications corporate clientele includes 2,100 Indian and multinational, and over 800 global, regional and domestic carriers. A pan-India, next generation, integrated (wireless and wire line), convergent (voice, data and video) digital network that is capable of supporting services spanning the entire communications value chain, covering over 24,000 towns and 600,000 villages has been established by Reliance Communications. Reliance Communications owns and operates the next generation IP enabled connectivity infrastructure comprising over 190,000 kilometers of fiber optic cable systems in India, USA, Europe, Middle East and the Asia Pacific region. Reliance Communications formerly known as Reliance Infocomm, along with Reliance Telecom and Flag Telecom, is part of Reliance Communications Ventures (RCoVL).Reliance Communications Limited founded by the late Shri Dhirubhai H Ambani (19322002) is the flagship company of the Reliance Anil Dhirubhai Ambani Group. The Reliance Anil Dhirubhai Ambani Group currently has a net worth in excess of Rs. 64,000 crore (US$ 13.6 billion), cash flows of Rs. 13,000 crore (US$ 2.8 billion), net profit of Rs. 8,400 crore (US$ 1.8 billion).The Equity Shares of RCOM are listed on Bombay Stock Exchange Limited and National Stock Exchange Limited. The Global Depository Receipts and Foreign Currency Convertible Bonds are listed on Luxembourg Stock Exchange and Singapore Stock Exchange respectively.

Group Profile
Major Subsidiaries Reliance Petroleum Limited Reliance Netherlands BV (including Trevira) Reliance Retail Limited Ranger Farms Private Limited Retail Concepts and Services Private Limited Reliance Retail Insurance Broking Limited Reliance Dairy Foods Limited Reliance Retail Finance Limited Reliance Jamnagar Infrastructure Limited Reliance Haryana SEZ Limited Reliance Industrial Investment & Holdings Limited Reliance Ventures Limited Reliance Strategic Investments Limited Reliance Exploration & Production - DMCC Reliance Industries (Middle East) DMCC Reliance Global Management Services (P) Limited Major Associates Indian Petrochemicals Corporation Limited Reliance Industrial Infrastructure Limited

RELIANCE COMPANY MANUFACTURING FACILITIES (OUTSOURCING) Manufacturing Facilities:

Reliance Industries Limited operates world-class manufacturing facilities across the country at Allahabad, Barabanki, Dahej, Hazira, Hoshiarpur, Jamnagar, Nagothane, Nagpur, Naroda, Patalganga, Silvassa and Vadodara. Allahabad Manufacturing Division is located in Allahabad, Uttar Pradesh. It is equipped with batch polymerization and continuous polymerization facilities. Barabanki Manufacturing Division is located near Lucknow, Uttar Pradesh. It manufactures Black Fibre. Dahej Manufacturing Division is located near Bharuch, Gujarat. It comprises of an ethane / propane recovery unit, a gas cracker, a caustic chlorine plant and 4 downstream plants, which manufacture polymers and fiber intermediates.
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Hoshiarpur Manufacturing Division is located in Hoshiarpur, Punjab. It manufactures a wide range of PSF, PFF, POY and polyester chips. Hazira Manufacturing Division is located near Surat, Gujarat. It comprises of a Naptha cracker feeding downstream fiber intermediates, plastics and polyester plants. Jamnagar Manufacturing Division is located near Jamnagar. It comprises of a petroleum refineries and associated petrochemical plants. The refinery is equipped to refine various types of crude oil (sour crude, sweet crude or a mixture of both) and manufactures various grades of fuel from motor gasoline to Aviation Turbine Fuel (ATF). The petrochemicals plant produces plastics and fiber intermediates. Nagothane Manufacturing Division is located in Raigad, Maharashtra. It comprises of an ethane and propane gas cracker and five downstream plants for the manufacture of polymers, fiber intermediates and chemicals. Nagpur Manufacturing Division is located in Nagpur, Maharashtra. It manufactures polyester filament yarn, dope-dyed specialty products of different ranges, fully drawn yarn and polyester chips. Naroda Manufacturing Division is located near Ahmadabad, Gujarat, is RILs first manufacturing facility. This synthetic textiles and fabrics manufacturing facility manufactures and markets woven and knitted fabrics for home textiles, synthetic and worsted suiting and shirting, ready to wear garments and automotive fabrics. Patalganga Manufacturing Division is located near Mumbai, Maharashtra. It comprises of polyester, fiber intermediates and linear alklyl benzene manufacturing plants. Silvassa Manufacturing Division is located in the Union Territory of Dadra and Nagar Haveli. It manufactures a wide range of specialty products such as Recron Stretch, Linen Like, Mlange, Thick-n-thin and Bishrinkage yarns. Vadodara Manufacturing Division is located in Vadodara, Gujarat. It comprises of a Naptha cracker and 15 downstream plants for the manufacture of polymers, fibres, fiber intermediates and chemicals. Each of these complexes has world class manufacturing facilities.

VISION:

Through sustainable measures, create value for the nation, enhance quality of life across the entire socio-economic spectrum and help spearhead India as a global leader in the domains where we operate.

MISSION:

Create value for all stakeholders Grow through innovation Lead in good governance practices Use sustainability to drive product development and enhance operational efficiencies. Ensure energy security of the nation. Foster rural prosperity.

VALUES:

Our growth and success are based on the ten core values of Care, Citizenship, Honesty, Integrity, Purposefulness, Respect, Responsibility, Safety and Trust.

QUALITY POLICY:

Reliance is committed to meeting customer requirements through continual improvement of its quality management systems.

RIL, Barabanki Division

Barabanki Manufacturing Division located near Lucknow, Uttar Pradesh, is spread over 106 acres. It manufactures Black Fibre. Barabanki Manufacturing Division (formerly known as India Polyfibres Limited) was commissioned in January, 1987 by RPG Group with technical collaboration from M/s. Du Pont, USA to manufacture 15,000 MT per annum of Commodity Polyester Staple Fibre. In 1999, the Company started producing Dope Dyed Black Polyester Staple Fibre. Necessary changes & modifications in the Plant & Machinery were carried out to undertake test / trial runs for ascertaining technical viability, determine modifications & additional equipment required for sustained operations and simultaneously adheres with the desired quality levels. It is for the first time that Black Fibre has been produced by continuous process on PTA route anywhere in the world. Today Barabanki Manufacturing Division is the largest producer of Dope Dyed Black Polyester Staple Fibre in the world and about 20 % of it is exported.

In 2003, company further developed a new product named as Dope Dyed Super Black Polyester Staple Fibre & Tow. In 2004, further capacity of 10,000 MT per annum was added by installing an extrusion based Spinning Plant. With this addition the present installed capacity of Barabanki Manufacturing Division is 40,000 MT per annum

In 2006, a new product "Dope Dyed Navy Blue PSF" was added in its product portfolio. Few more colors like Dope Dyed Dark Grey, Sky Blue, Parrot Green, Chocolate Brown, Renol Red and Coffee Brown can be easily manufactured. Steam is now generated through Husk boiler at low cost. Total number of employees are nearly 500 (50% are on contract basis). The industry produces three-finished product namely; 1. POLYESTER STAPLE FIBRE 2. PARTIALLY ORIENTED YARN 3. POLYSTER FIBRE FILL (PSF) (POY) (PFF) 7

RIL-HMD is a polyster manufacturing site. RIL is the largest manufacturer of polyster fibre in India & is the biggest exporter of polyster fibre in India. The product mix includes POLYSTER STAPLE FIBRE and PARTIALLY ORIENTED YARN in different deniers tailors made to suit various textiles applications, RECRON 3S , POLYSTER FIBER FILL (including conjugate fiber ) and POLYSTER CHIPS quality has been very well accepted in the market and the product has been rated as comparable to the best available internationally. The company provides comprehensive technical service to its consumer and maintains a professionally qualified and experienced staff for this purpose. Product PSF POY PFF Total Capacity 240 TPD 30 TPD 30 TPD 300 TPD

PSF & POY : PSF & POY are used as raw material for the spinners and texturisers who manufactures the final yarn. The yarn is used for manufacturing Fabrics and garments.

PFF : PFF is used for stuffing purposes like pillows, quilts, soft toys etc.

RECRON 3S : It is a short staple fibre that goes to the construction and paper industry who works as a binder to provide strength to the concrete mixture and paper respectively. RAW MATERIAL USED The raw material being used in manufacturing of polyester are: Pure Terephthalic acid : Basic raw material in powder form Mono Ethylene Glycol : Chain terminator in fluid form Antimony trioxide : Catalyst Titanium dioxide (TIO2) : Delusting agent Pet Bottles : nasrala

DEPARTMENT OF RIL-HMD POY POLY SPINNING AND FIBRE LINE MECHANICAL ELECTRICAL QUALITY CONTROL UTILITY INSTRUMENT INFORMATION TECHNOLOGY PURCHASE SALES STORE ACCOUNT DESPATCH MARKETING PURCHASE PROCEDURE

The purchase department follows the below procedure : REQUISITION (REQUIREMENT) Purchase requisition is made by user department and cleared by its HOD. A code is given to each material. INQUIRY (SUPPLIER) - Here inquiry about source of material i.e supplier is done. Quotations are called from different suppliers. COMPARISON SHEET All Quotations are analysed on cost and benefit basis. After proper analysis of Quotations, comparison sheet is prepared and send to user department for their comments. NEGOTIATION Price negotiation is done with the supplier by purchase department. Credit period is decided which is normally 30 days. ORDER The order includes terms and conditions, specification of product, time of delivery, mode and time of payment MATERIAL material is received through material gate.

TPN (TRUCK PARKING NUMBER) When truck containing material reaches the material gate, system generates TPN no. for the truck. Invoice containing information about material is checked by excise department whether material is excisable or not. STORES Stores department receives the material and creates GRN (GOODS RECEIPT NOTE) number for the material received. INSPECTION The user department inspects the material, receives GRN of concerned material. If everything is according to requirement material is accepted otherwise remarks given on GRN. INSURANCE CLAIM If any material is damaged , damage report is prepared for claims.

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PRODUCTION PROCESS CHART

Cotton Bales Mixing

Blend Blow room Silver Ribbon Lap Lap Carding Silver Comber Drawing

Simplex Rovings

Spinning Cops

Baby cone Cone winding Doubling Caps Full cones Packing Yarn Godown

caps Reeling

knots Baling

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Introduction:

Today over 70 to 75% of polyester is produced by CP(continuous polymerisation) process using PTA(purified Terephthalic Acid) and MEG. The old process is called Batch process using DMT( Dimethy Terephthalate) and MEG( Mono Ethylene Glycol). Catalysts like 5b3O3 (ANTIMONY TRIOXIDE) are used to start and control the reaction. TiO2 (Titanium di oxide) is added to make the polyester fibre / filament dull. Spin finishes are added at melt spinning and draw machine to provide static protection and have cohesion and certain frictional properties to enable fibre get processed through textile spinning machinery without any problem. PTA which is a white powder is fed by a screw conveyor into hot MEG to dissolve it. Then catalysts and TiO 2 are added. After that Esterification takes place at high temperature. Then monomer is formed . Polymerisation is carried out at high temperature (290 to 300 degree centigrade) and in almost total vacuum. Monomer gets polymerised into the final product, PET (Poly ethylene Terephthalate). This is in the form of thick viscous liquid. This liquid is them pumped to melt spinning machines. These machines may be single sided or double sided and can have 36/48/64 spinning positions. At each position , the polymer is pumped by a metering pump-which discharges an accurate quantity of polymer per revolution ( to control the denier of the fibre) through a pack which has sand or stainless steel particles as filter media and a spinnerette which could be circular or rectangular and will have a specific number of holes depending on the technology used and the final denier being produced. Polymer comes out of each hole of the spinnerette and is instantly solidified by the flow of cool dry air. This process is called quenching. The filaments from each spinnerette are collected together to form a small ribbon, passed over a wheel which rotates in a bath of spin finish: and this ribbon is then mixed with ribbon coming from other spinning positions, this combined ribbon is a tow and is coiled in cans. The material is called undrawn TOW and has no textile properties. At the next machine ( the draw machine), undrawn tows from severl cans are collected in the form of a sheet and passed through a trough of hot water to raise the temperature of polymer to 70 degrees C which is the glass transition temperature of this polymer so that the polymer can be drawn. In the next two zones, the polymer is drawn approximately 4 times and the actual draw or the pull takes place either in a steam chamber or in a hot water trough. After the drawing is complete, each filament has the required denier, and has all its sub microscopic chains aligned parallel to the fibre axis, thereby improving the crystallinity of the fibre structure and imparting certain strength.

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Next step is to set the strength by annealing the filaments by passing them under tension on several steam heated cylinders at temperatures 180 to 220 degrees C. Also the filaments may be shrunk on the first zone of annealer by over feeding and imparting higher strength by stretching 2% or so on the final zone of the annealer. Next the fibre is quenched in a hot water bath, then passed through a steam chest to again heat up the tow to 100 degree C so that the crimping process which takes place in the stuffer box proceeds smoothly and the crimps have a good stability. Textile spin finish is applied either before crimping by kiss roll technique or after crimping by a bank of hollow cone sprays mounted on both sides of the tow. The next step is to set the crimps and dry the tow fully which is carried out by laying the tow on a lattice which passes through a hot air chamber at 85degree C or so. The two is guided to a cutter and the cut fibres are baled for despatch. The cutter is a reel having slots at intervals equal to the cut length desired 32 or 38 or 44 or 51mm. Each slot has a sharp stainless steel or tungsten carbide blade placed in it. The tow is wound on a cutter reel, at one side of the reel is a presser wheel which presses the tow on to the blades and the tow is cut. The cut fibre falls down by gravity and is usually partially opened by several air jets and finally the fibre is baled. Some, balers have a preweighting arrangement which enables the baler to produce all bales of a pre determined weight.The bale is transported to a ware house where it is "matured" for a minimum of 8/10 days before it is permitted to be despatched to the spinning mill. Most spinning is done using break or open-end spinning, this is a technique where the staples are blown by air into a rotating drum, where they attach themselves to the tail of formed yarn that is continually being drawn out of the chamber. Other methods of break spinning use needles and electrostatic forces. This method has replaced the older methods of ring and mule spinning. It is also easily adapted for artificial fibres. The spinning machine takes the roving, thins it and twists it, creating yarn which it winds onto a bobbin. ABOUT SPINNING: The spinning industry, which has now spread itself over almost the entire inhabitable. Globe in its great centers of population is undoubtedly one the most potent factory the word has in its civilizing influence, and it has probably done has much more or even more in contributing to the welfare of mankind and his progress as any other great branches of the industry. Spinning is in its essential the practice of twisting and in the subject under consideration. The name has been appropriated as a description of a complete process, in which a number of loose fibers are bound together as one thread simply by the means of a twisting operation. The practice of twisting for such a purpose is 13

unquestionably by beginning and end of the whole art of spinning and, upon it is based the whole foundation of the industry. In principle it remains today what it was in the beginning and two great objectives. Viz that of bringing Into a smaller compass and more orderly conditions, a large number of loose fibers to form a strand, and also by this means to enable the bound fibers to offer greater resistance to being pulled as under which results in a greatly increased strength are today the chief aims towards which all operation of modern spinning mill to attain perfection. Wet spinning Wet spinning is the oldest of the four processes. This process is used for polymers that need to be dissolved in a solvent to be spun. The spinneret is submerged in a chemical bath that causes the fiber to precipitate, and then solidify, as it emerges. The process gets its name from this "wet" bath. Acrylic, rayon, aramid, modacrylic, and spandex are produced via this process. Dry spinning Dry spinning is also used for polymers that must be dissolved in solvent. It differs in that the solidification is achieved through evaporation of the solvent. This is usually achieved by a stream of air or inert gas. Because there is no precipitating liquid involved, the fiber does not need to be dried, and the solvent is more easily recovered. Acetate, triacetate, acrylic, modacrylic, polybenzimidazole fiber, spandex, and vinyonare produced via this process. Melt spinning Melt spinning is used for polymers that can be melted. The polymer solidifies by cooling after being extruded from the spinneret. Nylon, olefin,polyester, saran, and sulfar are produced via this process. Extrusion spinning Pellets or granules of the solid polymer are fed into an extruder. The pellets are compressed, heated and melted by an extrusion screw, then fed to a spinning pump and into the spinneret. Direct spinning The direct spinning process avoids the stage of solid polymer pellets. The polymer melt is produced from the raw materials, and then from the polymer finisher directly pumped to the spinning mill. Direct spinning is mainly applied during production of polyester fibers and filaments and is dedicated to high production capacity (>100 ton/day). 14

Gel spinning Gel spinning, also known as dry-wet spinning, is used to obtain high strength or other special properties in the fibers. The polymer is in a "gel" state, only partially liquid, which keeps the polymer chains somewhat bound together. These bonds produce strong inter-chain forces in the fiber, which increase its tensile strength. The polymer chains within the fibers also have a large degree of orientation, which increases strength. The fibers are first air dried, then cooled further in a liquid bath. Some high strength polyethylene and aramid fibers are produced via this process. Energy Conservation Measures and Results These days energy conservation has become an important part of any companys operational plans. It is so not only due to the present worlds focus on the rising global temperature and other environmental issues, but also due to depleting sources of energy. As the worlds energy resources are rapidly depleting, industries world-wide are either looking for alternative sources of energy or are trying to minimize their use of conventional sources of energy. It is being done by making the operations more energy efficient. Indian companies are also focusing on energy conservation. As many as seven Indian energy companies from India have been chosen as the finalists in the Platts Global Energy Awards, an annual program recognizing exemplary industry leadership. These companies are Reliance Industries, HPCL, Coal India, Cairn India, North Delhi Power Ltd., Udhe India and GAIL India.

Reliance Industries Limited (RIL) also has focused its plans on energy conservation. For the last six years a number of practices, studies and improvement projects have been implemented. RIL regularly benchmarks its energy consumption levels with global standards and is constantly efforts are being made to make the operations more energy efficient. The energy consumption of all the manufacturing units and utility blocks are consistently monitored and steps are taken to make these operations such that energy consumption is reduced but at the same time productivity is improved. In its pursuit to make its operations environment friendly, RIL has continued to integrate its ISO:14001 EMS, ISO:9000 QMS and ISO:18001 OSHA management systems. The company has a long term goal of becoming water positive, carbon neutral and also to achieve maximum possible recycling and reuse of wastes. For this the company has a management framework with defined structures, roles and responsibilities, group standards, audits and training programs.

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In the financial year 2009-10 (FY 209-10) RIL has introduced nine new group standards covering various environmental aspects. This was further supported by the development and release of second party audit protocols for the standards. Environment impact assessment and risk analysis were performed for all new and major expansion projects. RIL also issued a RIL group standard and second party audit protocol on 'Environmental requirements for new projects' with an objective to incorporate necessary measures to mitigate adverse environmental impact at the planning stage of project implementation. RIL gives priority to maintenance and performance improvements of all pollution abatement facilities like effluent treatment plants, inside battery limits area, air emission control and waste disposal facilities at its manufacturing divisions. It has also inculcated rain water harvesting and treated effluent recycling at most of their manufacturing establishments. RIL also trains its employees to be more Environment friendly. This is done by conducting internal and advanced training programmes, inter-site meets, virtual classes, etc. involving subject experts; participation at national and international conferences, workshops and courses as well as networking/collaboration with universities, research institutes, regulatory bodies, industrial and professional associations, etc. Also the manufacturing departments celebrate occasions like the World Environment Day, Earth Day, Water Day, Ozone Day, etc. To make harmony with nature a habit, RIL has taken up steps like afforestation, maintenance of green belts, gardens, vermi-compost of waste and its use as manure, reuse of treated water in horticulture activities. Following are the steps taken by RIL in the direction of energy conservation:-

Barabanki Manufacturing Division:Lowest diameter impellers were used in the process of cooling water pumps at utilities. Power consumption was reduced by optimizing lighting load of entire manufacturing division.

Results:Saving in power consumption worth Rs 5 lakh per year has been achieved by installation of the lowest diameter impeller in process cooling water pumps at utilities.

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Operating Cycle: Measures taken by RIL to improve its Production. Enhancing propylene recovery in refinery. Wax reduction for polyethylene plants. High capacity revamps in paraxylene plants. Innovative methods for increasing Benezene/ olefin ratio in alkylation at Lab plant. BENEFITS: Benefit of Rs.15 Crore /annum in cost of FCC catalyst and additive. Benefit of Rs. 4 crore /annum through enhanced sales of spent refinery catalyst to other refineries. Wax reduction in PE production has a potential value generation of Rs. 8 crore / annum. Chemical grade recovery of ammonium sulphate has potential benefit of Rs. 2crore/annum. Purchase Procedure TPN (TRUCK PARKING ENTRY) ENTRY OF TRUCKS WB (WEIGH BRIDGE)

TOL (TRUCK ORDER LINKING) TRUCK ENTERS THE WAREHOUSE

WBN (WEIGH BRIDGE ENTRY) ENTRY TRUCK IS WEIGHTED

PICKING UP NOTE

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INV (INVOICE)

WBX (WEIGH BRIDGE EXIT) MGX (MAIN GATE EXIT)

Purchase to Issue Cycle

Purchase Requisition Note (When plant require material)

Request Quotation (Company ask for quotation from vendor)

Quotations comes

Selection of vendor (On basis of terms and conditions expected by the company)

Put Purchase Order

Material comes

Material goes to the excise section (Capture the invoices)

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Material goes to security keeper (They check the material are as per unit mention in invoices or not)

Material goes in stores Receipt Ward (Here the material check against P.O. and labeling is done)

Material goes to the Inspection Ward On the basis of the Inspection Report they prepare Goods Receipt Note and also check Test Certificate send by vendor and then Inspected Material

Go to Issue Ward (If goods accepted)

Go To Vendor (If goods rejected)

Before sending goods to the Issue Ward goods are insured. And for rejected goods they prepare Goods Rejection Note and also O.G.P. (Out Goods Note) and sent to the vendor. For the liquid chemicals used as raw material storing process are as follows:

Liquid chemical comes in tanker at gate

Tanker goes to excise section (Capture the invoices)

Tanker goes to store (Weight of the tanker with liquid and quality check of the chemical is done)

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Unloading (Tanker is unloaded to respective plant)

/Tanker again comes to the store after unloading (Again weight of the tanker is done without liquid)

ORGANIZATIONAL CHART:

The organization chart is graphic means of showing major departments and divisions of the enterprise and lines at formal authority departmentation is important for a well structured. Here the managing director is the highest authority guiding and controlling the activities of the organization. This organization has five departments namely:-

Production Department Stores Department Marketing Department Personnel Department Finance and Accounts Department

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PRODUCTION DEPARTMENT RAW MATERIAL

The firm mainly purchased cotton, polyster, visco & color chemicals . Raw material purchase based on demand.Customer wants to be rectified.And other raw materials are polyester stable fibre.Visco stable fibre, and silk.Accurlik and raw cotton.Purchases are deliver through lorries based on load lot numbers.

PRODUCTION PROCESS This department is further subdivided into various sections. They are

MIXING BLOW ROOM CARDING COMBER DRAWING SIMPLEX SPINNING WINDING CONE WINDING AUTO CONE WINDING PACKING

MIXING This department plays an important role.In this department,the various varieties of cotton are mixed ,according to their lenth,strength,fineness and maturity to get the

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required counts of yarn i.e.60s,80s etc.Usually four buckets of water and one liter firm soap oil is sprayed on the spread cotton and kept for 24 hours before the next process.

BLOW ROOM Mixed cotton is cleaned by removing the foreign matters and waste.This may consist of seed coats,jute,etc.The output from this process is a uniform and clean sheet like form rolled in a rod and is known as LAP.

CARDING `The proverb of the experts says, well carded is half spun and effective carding ,efficient spinning.All these 4 proverbs demonstrate that the immense significance of carding is the final result of the spinning operation.

Drawing It is the fourth stage in the manufacturing process. In this eight slivers can be converted into single silver. Again 8 single can be converted into one silver. These are 8 machines installed in the drawing room. Processing time Eight sliver completing time is 4 hours.

Simplex operation Sliver is converted into Roving. In this process sliver size is decreased. There are 8 machines located in the simplex operation. Each machine has 120 spindles. Spindles mean rod or shaft rotating which twist the rove.

Processing time 40s and 41 s output get within 2 hours 80s output get within 4 hours

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Doubling Twist the double thread into single thread. There are 32 doubling machines being the doubling section. Each machine has 400 spindles. Twist than yarn according to the order according to the order basis. For Example

2 yarns X 40s Count 2 yarns X 60s Count

= =

2/40s 2/60s

Packing Packing refers to the activities of designing and producing the container or wrapper for a product. There are two type of packing used are as under. Cone packing According to the custmers requirement the packing is done by the packing department. Cone packing is done using man power.

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DRAWING:

The carding canes are arranged two rows of eight canes and sixteen slivers come to a same part in a polished plate though guide rolls. This arrangement is called as creel. Where the sixteen combine to one this term technically called doubling of slivers. Those slivers passed through 3-4 pairs of rollers, which are running in different speeds and it is called as drafting rollers. The sliver material passed through the drafting rollers are pulled and parallelized and delivered in the form of sliver which are collected in the cans.

SPINNING PROCESS:The Rowing Bobbins are fed into spinning frames and here we get the yarn of desired count. The finished product is rolled into paper cones by cone winders. Now the finished product Yarn is ready for sale and dispatch.

CONE WINDING PROCESS The delivered yarn is wound in the bare bobbin, which is done by rings & Travelers. In spinning machine the important parts are creel, drafting rollers, top arm, apron, spindles, rings, and travelers. From spinning ring cops i.e. taken to cone winding (or) reeling Department according to market requirement. The yarns from spinning cops are converted into form of cone, which is around 1.50kg. To get continues yarn knotting (or) splicing is done in this department.

PACKING 40 50 cones are packed in woven sacks and it is ready to into the market.

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Codification
RIL Vadodara complex is huge manufacturing division having different continuous manufacturing production processes. In VMD they are maintaining around 67000 items as the inventory having approximate value of Rs.225 crores. Codification helps in identifying the items individually. The items are known from the codes and not from the name. Materials are entered in the system with complete specification and details like size, name of manufacture, model number, design number, color, height and width of product etc. these information needed for the separation of the products and to assign different codes for different type of product. First of all the codification request is been made for the new product, the form is to be filled with all the information of the inventory and where it is used. After getting the form inventory management department will check for the data validation of the inventory, if any manipulation is there then they have to again fill the form. Then checking of the data is been done for the existing inventory if any existing inventorys sub part is there. The code is been given of 10 numbers. The first two digits are known as the main group. It represents the similar items in a single group, the group is formed with the numbers from 01 to 99. It contains similar products and its spare parts. E.g. 68 it contain all types of pumps and its spares. Next two digits are known as the subgroup, it include 01 to 99 number of group. It shows the manufacturer codes. If the manufacturing code is not available than this group shows the design number. E.g. 6804 It shows the pumps of ---company. Next 3 digits are known as sub-subgroup, again it include groups from 01 to 99. These numbers are indicating the model number or identification or design number or blueprint number. E.g. 680401 this number is for the pumps of ---company having the design number CNU465. Up this six numbers code is known as CODING SCHEMA. Next three digits are showing the serial number assign to a particular part or item. It include the group the groups from 001 to 999. Last digit shows the origin of the product. This number must be 1 or 3. 1 indicates that this product is indigenous and 3 indicate that the product is imported. With this RIL generates the unique number for each and every product or spare. RMMCS is linked with the SAP system. SAP generates the unique serial number for each and every item as soon as RMMCS accepts the code. SAP numbers are just a

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serial number. These codes are maintained centrally so the same codes are used for a single product in all departments of RIL.

Flagging System:
RIL has 167th rank in FORTUNE 500 companies and one of the largest company in the world. In the time of recession management of RIL decides to go for centralization and manage the all departments from the head office. Management is also looking for minimum human efforts in the management work by using the technological changes. In such a huge company it becomes necessary to give more attention towards the inventory. RIL has its own system to manage the inventory i.e. RMMCS and one of the best techniques of managing the inventory is known as Flagging. Flagging prevents the management from purchasing the goods if the similar goods are available in other department so it avoids the unnecessary blockage of money. This system is managed centrally by a team and prevents the duplication of purchase or over stocking of similar kind of goods in the RIL. Suppose the Vadodara department needs the bearing of 14 inches of flag co. and if the similar bearings are available with any other department of RIL than if the Vadodara department could not enter purchase requisition order in the system as that item contain the flag. In this case system shows the name where the similar bearings are available. Vadodara department needs to contact the responsible person in the department having stock of those bearings. If That department did not need that bearings or that bearings are not in regular use than Vadodara department has to get those bearings by generating STO (Stock Transfer Certificate). Suppose those bearings are of regular use or they need it and not an over stock item than they have to conform it and department having the similar stock needs to remove the flag from that item. Once the flag has been removed, Vadodara department can enter a purchase requisition in the system to purchase those bearings. System generates the different type of flag for different reasons depending on the days of storage of that item. 02 flag for duplicate material available. 013 flag for material not moved within one year. 08 flag for moderate material not moved since last 2 years. 03 flag for slow moving material not move for more than 2 years. 05 flag for material stock more than the maximum limit.

System generates the flags only for those materials having cost more than RS.5000 per unit .RIL is using the flagging system and with this system RIL able to reduce the investment in the inventory. This system really helps in managing the inventory and

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reduces the cost associate with the inventory and ultimately all these results in increase in profit by reduction in cost.

Classification of Material in SAP

RIL is centrally managed with the help of SAP system. In SAP system every material name is identified with the code, with this code system identify each material easily.

CODE

MATERIALS

SPAR

SPARES

CACH PAMA FTRM

CHEMICALA& CATALYSTS PACKAGING MATERIAL FINISHED TRADABLE RAW MATERIALS LAB CHEMICALS

LABC

Scrap and disposals After the use of the materials some materials may turn to wastages or useless due to some reasons. So they are to be scraped, not only the materials but also any type of inventory like spares and mechanical will go Obsolescence with the time passing and will be useless for the plant that has to be scraped. First of the plant manager has to prepare MRV (Materials Return Voucher) which include all the details of inventory, with its code and type of inventory and where it is been used with the approval of the head that this is not usable now should be scraped. For the disposal of the scrap they will invite the tender and ask them to visit the scrap yard, the acceptance of the tender will be done by the Mumbai office. The disposal of the scrap is done once or twice a year. In scrap all the materials are to be kept as per their type if they are of electrical then at different place and so as on, and then in electrical each item at specific place like fans at different place, motors at different place. Each department has an authority to sell the scrap but the price of scrap is decided by the head office only.

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QUALITY POLICY
PRODUCING PRODUCTS OF CONSISTENT QUALITY TO MEET THE EXPECTATIONS OF THE CUSTOMERS, THROUGH CONTINOUS IMPROVEMRNT WITH THE INVOL VEMENT OF ALL EMPLOYEES. QUALITY CONTROL DEPARTMENITS This is mainly consists of four departments Raw material quality checking Semi finished/processing goods production quality checking Final product that is yarn checking Final inspection on package stage. QUALITY CONTROL DEPARTMENTS

Cotton Polyester Viscose

Fines, waste, strength, Strength, uniformity, elongation Strength, uniformity, elongation

These are the checkings in the raw material to check the quality. LABARATORY TESTING Micro balance Ulster tester3 Strength Uniformity Micro balance: Co efficient of variation in weight basis checking to use micro balance & rap real and check the count also.

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Black board: Gene al yarn appeance and SQC department. Strength: Lea strength test instrument to check the uniformity percentage. Lap & blow room Weight = co efficient of variation Sliver = count, co efficient of variation uniformity strength

Quality control

On arrival each and every bale of all arrived lots are subject to quality assurance approval. The quality firm cotton is assessed by tests done both manually and electronically. By manual method the cotton is tested using BEAR SORTER.B The electronic method utilize SPINLAB HVI 900 machinery. The testing process is very fast and also accurate. If the lot confirms the basic sample then it is accepted otherwise, it is rejected and returned to supplier and the same is recorded in vendor evaluation record. Product testing It is final testing in the product to find the imperfection. The buyers accept the 495 imperfection within the 100 kilometers yarn. U% Thin Thick Naps Total 12.5 25.0 160.0 297.5 495.0

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It is one of the service departments. It is heart of the company. Store keeping is a service function, which deals with the physical storage of goods under the custodianship of a person called storekeeper or store controller.

Stock maintenance: The storekeeper checks the requirement material once in 15 days. The company is following first in first in out (F1F0) method. This company has the bin card maintenance. It has material name, receiving time, number of items, stock level. The material covered by plastic covers Once in six month the store is to be cleaned The store department should have the insurance coverage. Check the insurance coverage receiving and returning goods packing.

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BOARD OF DIRECTORS

OFFICE MANAGER

FACTORY MANAGER

ACCOUNT

OFFICE STAFFS

SECURITY

SUPERVISORS

FITTERS

ELECTRICIANS

LABOURS

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Supply Chain Management (SCM) is one of the most important parts of any companies operations. At the manufacturing units SCM plays an important part. Towards the end of each month the Marketing department of each unit predicts the likely sales for the month or a specific time period. SCM unit then contacts the production and the operational units, which tells them about the amount of raw material needed. The SCM then starts the process of raw material procurement. This is the start of the SCMs functions, its function starts with the arrival of raw material to the delivery of the final products to the customers. These functions include logistics, distribution, retailers, suppliers, etc. Similarly SCM is a very important of RILs operations. As being a company with a high degree of integration, RILs products are also used as raw materials for its various other plants. So now we take a look at various steps in the RILs SCM. Raw Material Procurement:RILs main raw materials are Crude Oil and Natural Gas, of which RIL imports most of its crude oil requirements. RIL gets natural gas from its D6 gas fields of KG basin. The company brings the gas through pipelines to its Jamnagar refineries. It imports crude oil by ships at the Hazira port. This is one of the most important reasons of refineries being close to ports. For most of its petro-chemical and polymers business, the outputs from the refinery form the raw materials. Suppliers:RIL gets crude oil through suppliers like Cairn India through pipelines and from the gulf countries through ships. The products and bi-products which are formed as a result of distillation of crude oil and natural gas at its refineries, which are required as raw materials at its other plants are distributed through the networks of rail and road. This is usually done by the company Reliance Logistics. Warehousing:The incoming raw materials are then stored at various warehouses. These warehouses have to be safe and large enough so that the materials are remain in the form that they should be in. Also the inventory has to be managed so that the raw materials do not become useless as a result of not being used within its useful life period, so inventory management forms an integral part of RILs SCM. Manufacturing:At its various manufacturing sites throughout the country RIL produces various products. The products like LPG, Aviation Fuel, High speed diesel; Naphtha, etc are produced at its refineries. The products like Poly-Vinyl Chloride (PVC), Polypropylene, 34

Poly Butadiene Rubber (PBR), etc are manufactured at its polymer units. Textiles are manufactured at the textile units. Distribution:SCM oversees the distribution of the final products. The products of RIL, which are either hazardous or inflammable in nature, are generally distributed through pipelines or tankers to the customers or consumers. For example LPG is distributed through pipelines to the houses of the consumers, while fuels are transported through tankers through roads, rail or ships. Products which are non-hazardous are generally distributed through rail and road inland and through ships for exports. Customers:The products reach the customers through wholesalers and retailers, the SCM has to oversee that the products have a continuous flow till the consumers without any glitches. RIL has its own retail outlets for fuel, textiles. It supplies LPG directly to the customers. SCM also has to review the performance each of its control areas and has to gather constant feedbacks about the problems that surface during its operations.

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Conclusion: In a challenging year of demand destruction and global financial crises ,RIL was resilient and continued to innovate to convert the adversity into an opportunity. RIL launched an innovative initiative called Mission Kurukshetra aimed at galvanising and energising the entire organisation to rise to the acassion and help RIL emerge stronger. RIL exported to 123 countries around the world. Exports represent 55% of the RILs turnover. Petroleum products constitute 85% and petrochemicals contribute 15% of the total exports. KG-D6 completed 365 days of 100% uptime and zero-incident production. Gas production from KG-D6 has ramped up to 60 MMSCMD in a short span of 9 months from commencement. Current production of about 60 MMSCMD is from 16 wells. The design capacity of KG-D6 deepwater gas production facilities were assessed and achieved a flow rate of 80 MMSCM. During FY-2009-2010, total gas production was 14,397 MMSCM. Oil production from the D26 field now exceeds 35,000 barrels per day. During the fY2009-2010, total oil production from this field was 4.04 million barrels. The two Jamanagar refineries that RIL operates are not only among the largest in the world, but also are the most complex, with average complexity of more than 12.0 on the nelson complexity index. RIL has become the worlds largest producer of ultra-clean fuel at a single location.

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Limitation:

This project is not far from limitations. The limitations are: o A company generally doesnt disclose its internal policies to outsiders. In such case, it is very difficult to find out and gather complete and true information in the forms of figures regarding financial matters. o The report highly depends on the secondary data and it may be possible that the data from which the report is made may not appear in the report because some data is confidential for the company. o The authenticity of the suggestions and recommendations depend upon the rationality of the data provided to me. o Data for VMD separately are not provided as it is confidential so data are taken on proportionate basis based on the information provided to us.

Bibliography
Web site-www.ril.com Annual report of RIL2009-10 Companys internal portal.

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