Syntech Fibres

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QUALITY CONTROL SYSTEMS STUDY REPORT OF SYNTECH FIBRES FOR THE SUBJECT TOTAL QUALITY MANAGEMENT G ROUP M EMBERS S R . # N AME STUDENT ID 1 SAAD KHAN KAKERZAI SP09-BB-0083 2 ZAIN HASSAN SP09-BB-0111 3 NOUREEN FATIMA SP09-BB-0072 4 FAIZ AKHTAR SP09-BB-0023 S UBMITTED T O SIR SAEED MUJAHID A SSISTANT P ROFESSOR

Transcript of Syntech Fibres

Page 1: Syntech Fibres

QUALITY CONTROL SYSTEMS STUDY REPORT OF

SYNTECH FIBRES

FOR THE SUBJECT

TOTAL QUALITY MANAGEMENT

G R O U P M E M B E R S

SR.# NAME STUDENT ID1 S A A D K H A N K A K E R Z A I S P 0 9 - B B - 0 0 8 32 Z A I N H A S S A N S P 0 9 - B B - 0 1 1 13 N O U R E E N F A T I M A S P 0 9 - B B - 0 0 7 24 F A I Z A K H T A R S P 0 9 - B B - 0 0 2 3

S U B M I T T E D T O

S I R S A E E D M U J A H I D

A S S I S T A N T P R O F E S S O R

M A R K E T I N G D E P A R T M E N T

M O H A M M A D A L I J I N N A H U N I V E R S I T Y ( M A J U )K A R A C H I

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SYNTECH FIBRES

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SYNTECH FIBRES

DEDICATION

Our beloved teachers and parents, whose blessings and

concentration brings us to this stage and who trample their

inclination and longing for up holding our studies.

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SYNTECH FIBRES

LETTER OF ACKNOWLEDMENT

This report is a study and analysis of Quality Control System in an organization named as

Syntech Fibres (Pvt) limited which has been prepared as a part of the course requirement

for Total Quality Management. The material compiled and presented in this report is a

result of hard work.

This report has proved to be a great experience. For this, We would like to thank

our Almighty ALLAH who made everything easier to us and then our Instructor

Mr. Saeed Mujahid who provided us the path of knowledge and guidance.

Sincerely,

Group Members:

Saad KhanZain HassanNoureen FatimaFaiz Akhtar

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SYNTECH FIBRES

TABLE OF CONTENT

S.No Description Page No

1 Organization Overview 5

2 Organizational Hierarchy 6

3 Main Business Function of Organization 7

4 Quality Policy 8

5 Duralene Yarn and Fibre 9

6 About Polypropylene 10-11

7 Production Process 12-16

8 Quality Assurance, Kaizen 17

9 Aqua Clear Filters 18-19

10 Working of Aqua Clear Filter 20

11 Types Of Cartradiges 21-22

12 Comparison with Conventional Media 23

13 Features of Aqua Clear Cartradige 24

14 Standardes 25

15 Production Process 26-27

16 Other Business Function 28-31

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SYNTECH FIBRES

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ORGANIZATION OVERVIEW:

Established in 1987, Syntech Fibres serves customer with Duralene polypropylene fibres and

yarns. Polypropylene is one of the most versatile available today. It is used in highly diverse

products such as apparel, home upholstery, automotive, contact furniture, carpets, and industrial

applications.

Syntech Fibres aims to become the preferred supplier for propylene fibres and yarns. In order to

achieve this ambition, Syntech Fibres works continuously on further product improvement and

offers active support to customers towards the development of new products and areas of

application.

Customers can account on Syntech Fibres continued commitment to research and development.

Over the years, Syntech Fibres has built up to unique know how and expertise in the production

and processing of propylene fibres and yarns. Syntech Fibres is striving continually to improve

and expand the company existing product and application, while at the same time introducing

new products to meet evolving market requirement and customer needs.

As the market leader in polypropylene fibres and yarns, Syntech Fibres ongoing efforts are

aimed as improvement of existing products and development of new products in order to meet

changing customer needs.

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ORGANIZATIONAL HIERARCHY

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MAIN BUSINESS FUNCTION OF THE ORGANIZATION:

Syntech Fibres is mainly producing Polypropylene fibres and Yarns. They are also producing

many downstream products such as upscale office upholstery fabrics, narrow fabrics, area rugs,

filter yarns and filter cartridges in a variety of colors, deniers, cross sections and finishes to suit a

wide range of applications. Yarns include continuous filament flat yarns, BCF yarns, air textured

yarns, interlaced yarns, twisted and plied yarns, fibrillated yarns, industrial sewing yarns and

cords, heat set knit-de-knit yarns, spun yarns, special effect fancy air textured yarns, filter yarn,

roving and monofilaments.

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QUALITY POLICY

To provide quality solutions to meet customer requirements.

To continually improve our quality systems.

To improve the efficiency and effectiveness of our people and processes.

To be the market leaders in polypropylene yarns and filter cartridges.

To maintain a safe working environment.

To comply with all applicable laws.

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CORE PRODUCT

DURALENE POLYPROPYLENE YARNS AND FIBRES:

Syntech fibres are producing best quality yarns and fibres from polypropylene and supplying to

most of the industrial units in Pakistan and as well as exporting it to many countries. Products

using polypropylene fibres and yarns last longer, are lighter, have greater resistance, and are

more advanced, and more efficient than products using conventional materials.

Syntech Fibres are producing silky soft to coarse and tough yarns, 300-10,000 denier range are

available, in 2 to 30 denier per filament and 13 to 100 mm staple lengths, in bright, semi-bright,

semi-dull and dull finishes.

Duralene fibres and yarns can be tailor-made to suit customer applications.

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ABOUT POLYPROPYLENE:

Polypropylene has the lowest specific gravity of all fibres (0.91), making it the lightest of all

textile fibres. Low specific gravity also means that it takes 20% to 41% less polypropylene fibre

to produce “fill” and densities equivalent to fabrics made from nylon, acrylic, polyester,

rayon/acetate, cotton or wool.

Duralene polypropylene yarn is strong, colorfast, and inherently resistant to stains and soils,

abrasion, mildew, perspiration, and inclement weather. These qualities make it an ideal fibre for

home upholstery, automotive, contract furniture, carpets, apparel and industrial applications.

Polypropylene applications for apparel include denim jeans, active wear, undergarments and

socks, and industrial products such as ropes, webbings, filter fabrics, and geotextiles.

Polypropylene has the highest growth rate among man-made fibres and more than twice the

growth rate of any other fibre. With a greater market share than nylon, and second only to

polyester, it is a leading synthetic fibre used for textiles.

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INHERENT CHARACTERISTICS:

Good bulk and cover, very lightweight

High strength (wet or dry)

Resistant to deterioration from mildew, bacteria, perspiration, rot and moisture

Outstanding resistance to chemicals

Abrasion resistant (durable)

Low moisture absorption

Stain and soil resistant, pill resistant, odor resistant

Good wash ability, quick drying, unique wicking

Sunlight resistant (with UV additive), colorfast

Resilient, very comfortable

Low static, low thermal conductivity

Non-allergenic

TYPES DURALENE POLYPROPYLENE YARNS AND FIBRES:

Following are the types of polypropylene yarns and fibres syntech fibres are producing:

Continuous Filament Flat Yarn

Interlaced/Intermingled Yarn

Twisted and Plied

BCF (Bulked Continuous Filament)

Air-Textured

Special Effect Fancy Air-Textured Yarn

Carpet yarns: heat set, single ply, cabled, frieze, knit-de-knit

Industrial Sewing Yarns

Tape Yarn

Fibrillated Tape

High tenacity fibres and yarns

Monofilaments

Staple fibre

Yarn for grass carpets

Fibres for reinforcement of concrete

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PROCUREMENT PROCESS

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PURCHASE ORDER:

Order received from customer according to his specification which he finalized after checking

the color card to see our range of standard colors. From silky soft to coarse and tough yarns, 300-

10,000 denier range are available, in 2 to 30 denier per filament and 13 to 100 mm staple lengths,

in bright, semi-bright, semi-dull and dull finishes.

IMPORTS:

The raw material is imported from the gulf countries such as Oman & Saudia Arabia. It takes

about 2 to 3 months to import raw material. Syntech fibres keep their records/inventory up to

date so that they don’t have to face the problem of inventory ending. A container full of

polypropylene is imported from gulf countries on monthly basis.

WAREHOUSE:

After receiving the order from customer we check that whether we have enough inventory (polypropylene) available in warehouse.

If yes then we sent it to the factory for further processing. If, we don’t have the required inventory available then raw material is imported from gulf countries such as Oman & Saudia Arabia.

When raw material (polypropylene) is received through shipments then it is first sent to inspection laboratories, they take a random sample and test it whether it meets our quality criteria or not. After the clearance report from laboratories the raw material (polypropylene) is sent to the factory for production.

PRODUCTION:

After the receiving of raw material (polypropylene) in the factory. It starts with the following process:

MELTING PROCESS:

The polypropylene is transferred into a container through which it is sucked into the heater and melted at very high temperature so that the polypropylene is transformed into yarn and fibre.

INSPECTION: Workers who are operating the machine check the product quality in order to ensure that the product is according to the specification. They take random samples from every batch. One person is assigned to look after the machine all the time.

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TWISTING:

After the polypropylene is transformed into yarn and fibre then it is twisted into two directions ( S direction and Z direction) in order to strengthen the tenacity of the yarn and fibre.

INSPECTION: During twisting workers are manually working with machine to completely give the proper direction to yarn according to the specification.

COLOR:

After the twisting process is completed the coloring is done as per the customer requirement. There are approximately 600+ colors and it can also be customize according to the requirement.

INSPECTION: As this process is very important and sophisticated, so only specialized worker handle the coloring process by adding the accurate quantity of color as specified.

TEXTURE:

The texture color is made on the requirement of the customer. Customer have to give his specification of two or three color so that his desired yarn and fibre color is made.

INSPECTION: As this process is very important and sophisticated, so only specialized worker handle the texturing process by adding the accurate quantity of textured yarn as specified.

INTER-LACE:

The yarn and fibre is inter-locked after some distance so that the filaments are locked in order to give more strength to the yarn and fibre.

INSPECTION: It is done by the specialized machines but workers are there to inspect the task in order to avoid errors.

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PRODUCTION FLOW CHART

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WAREHOUSE:

After the production the finished fibre and yarn sent to the warehouse for the final testing and

inspection in order to ensure that we have produced the required product and then we sent the

product to the permanent buyers and export with confidence.

TRANSPORTATION:

After the finished good is shifted to the ware house it is then supplied to its customer without any

delay in delivery.

If the customer is of local market then the product is shifted through trucks or some other

medium to the customer and if the customer is from other country then it is transported through

ships to that country.

QUALITY MANAGEMENT SYSTEMS:

Following are the steps taken by Syntech Fibre to ensure quality management systems are

properly implemented as per standards.

WORKPLACE CLEANLINESS:

The working area is very much clean. Each machines works automatically but two to

three workers are assigned to monitor it when working and checking the quality

specification in every batch they produce and as well as they are required to clean their

surrounding parts from dust and other particle to maintain the quality standards.

EMPLOYEE SAFETY:

Syntech fibre provides uniform, gloves and caps to their workers who are working with

machines. Proper training are given to the worker related safety measures such as fire

extinguisher, emergency exits and first aid so that they could positively act in any

unexpected situation.

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QUALITY ASSURANCE:

Quality checks are done in every process to maintain the product is the specification

limit. Proper laboratories are there with certified scientist who checks the random

samples from every batch of production.

“Syntech Fibre believes that if we are not making the product as per the customer

specification, we are doing rubbish”

KAIZEN:

Kaizen is continual improvement, the constant search for a better way, or never ending

job redesign. At Syntech Fibre, all jobs are being continually improved. the company

realizes that the people does their jobs know them better than anyone else, and each team

member with his/her team leader’s guidance is given the right to take part in the design of

the job.

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AQUA CLEAR FILTER:

Syntech fibres are producing best quality industrial and domestic filters from polypropylene and supplying to most of the industrial and domestic units in Pakistan and as well as exporting it to many countries. AQUA CLEAR is the main filter cartridge which is produced for the domestic and industrial purpose.

Pure polypropylene Aqua Clear filter cartridges are free from any extractable and contain no chemicals. They are suitable for use in applications like RO Pretreatment (SDI Reduction), Drinking Water and Beverage Processing, Sea Water Desalination, Gas Purification, Electronics and Electroplating, Photographic Solutions, etc.The standard pure polypropylene cartridge is extractable-free and engineered for superior filtration performance. Available in up to 72 inch (1829 mm) length and 6 inch (152 mm) diameter in a variety of media, cores and extended cores

Aqua Clear filter cartridges offer true depth filtration with superior filtration technology.

Aqua Clear depth filters have revolutionized filtration with a superior technology that overcomes the limitations and drawbacks of other filters.

Aqua Clear technology produces superior depth filters with increased filtration capacity, longer lifetime, and higher performance that reduce overall costs. Aqua Clear filters have high structural integrity combined with a greater void volume, giving a lower pressure drop, much improved dirt holding capacity and efficiency compared to conventional filters. Aqua Clear filters are made of polypropylene, a recognized environmentally safe and recyclable material for purity and ease of disposal.

HOW AQUA CLEAR WORKS:

The patented Aqua Clear process begins with 100% pure polypropylene that is melt-spun (extruded) without the use of any chemicals. The extruded media consists of continuous filaments of multi-lobal cross-section with numerous micro voids between each individual filament. These chemical-free continuous filaments are then randomly oriented to each other, intermixed, looped and entwined into a non-round, highly stable, bulky yarn. The multi-lobal cross-section of filaments combined with the random yarn structure gives much improved void to solid ratio. This improved porosity gives a higher dirt holding capacity and reduced resistance to flow.

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When this media is wound into a filter cartridge, each of the filaments continues, without a break, throughout the length of the yarn, making the cartridge free from any media migration problem. There are no short fibers that can come lose and migrate, a common problem with conventional string-wound filters. Each yarn also traps the randomly protruding short loops of adjacent yarns resulting in a highly stable media structure wherein the yarns are locked in place and prevented from rolling or shifting aside. The stable structure provides an excellent knife-edge sealing property to the cartridge. Under conditions of varying flow and pressure fluctuations, the new cartridge is more resistant to particle unloading.

With the improved media, there are no typical diamond-shaped open spaces (a characteristic winding pattern of typical string-wound media) and the yarn media covers all the area. The liquid flows through the entire yarn structure and contaminant particles are forced to change direction as they proceed through the depth of the cartridge. The physics of flow is such that it becomes possible to trap particles smaller than the size of the complex pathways.

Finally, through improved winding technology, the pitch, number of crossings and space between each yarn is continuously varied and controlled from start to finish in making the cartridge. The inner layers of the yarns are wound close together and the space between yarns is gradually increased towards the outer layers, while the yarns remain locked together because of the random protruding loops. This winding technology gives improved true density grading, trapping coarser particles in the outer layers and finer particles in the inner layers. By maintaining the same winding tension, the structure has the same firmness throughout the depth of the cartridge, giving more consistent and better performance.

Aqua Clear test results have shown that this patented process provides up to twice the dirt holding capacity and filter life at equivalent competitive efficiencies, while reducing pressure drop up to half. All this translates into improved filtration performance and reduced costs.

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WORKING OF AQUA CLEAR

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TYPES OF CARTRIDGE:

Following are the types of cartridges which are produced by aqua clear:

POLYPROPYLENE CARTRIDGE:

 

Pure polypropylene Aqua Clear filter cartridges are free from any extractable and contain no lubricants, wetting agents, emulsifiers, ant-oxidants or anti-static agents, etc. It is certified by NSF International to NSF/ANSI Standard 61 for Drinking Water System Components and Health Effects. Available in up to 72 inch (1829 mm) length and up to 6 inch (152 mm) diameter

POLYESTER MEDIA:

 

Polyester media filter cartridges with stainless steel core are also available for applications where their temperature and chemical resistance is more suitable; e.g. for filtration of edible and petroleum oils, etc.

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REVERSE OSMOSIS CARTRIDGE:

 

Aqua Clear Cartridge for Reverse Osmosis Plants are effective and efficient for removal of silt, sand, rust and other suspended particles from RO feed water.

STRAINER CARTRIDGE:

 

Pure polypropylene strainer cartridge for filtering out large contaminants can be back flushed for longer service life. The unique filter media consisting of continuous monofilaments, is free from media migration, has high dirt holding capacity and low pressure drop. It incinerates to trace ash without harm to the environment.

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COMPARISON WITH CONVENTIONAL MEDIA:

AQUA CLEAR MEDIA

Aqua Clear multi-lobal cross section of individual filaments has more micro-voids giving higher dirt holding capacity and lower resistance to flow.

High bulk, stable, three-dimensional random structure comprising continuous filaments.

CONVENTIONAL MEDIA:Conventional round cross section of individual fibres has fewer micro-voids giving lower dirt holding capacity and higher resistance to flow.

Low bulk, non-stable, round structure comprising short fibres.

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FEATURES OF AQUA CLEAR

No chemicals to leach-out with new melt spinning and yarn forming process. No media migration because the yarn consists of continuous filaments. True graded density - new winding technology gives denser winding in inner layers and

coarser winding in outer layers. High dirt holding capacity and longer life as particles are trapped throughout the entire

cross section of the filter. Better performance - multi-lobal cross section filaments with random 3-dimensional

media structure captures more particles compared to conventional filters. High bulk media having improved void to solid ratio gives higher flow rates with low

pressure drop.

100% polypropylene - wide chemical compatibility and excellent micro-organism resistance.

High structural stability, i.e. no shifting of media, excellent knife-edge sealing. Firmer structure gives improved resistance to particle unloading and more consistent

performance. Incinerates to trace ash with no hazardous volatiles for environmentally friendly disposal.

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NSF STANDARD 61 CERTIFIED:

Aqua Clear Filter Cartridges are certified by NSF   International to NSF /ANSI Standard 61 Drinking Water System Components – Health Effects. This certification demonstrates our commitment towards meeting internationally recognized standards in regards to materials, design, construction and performance.

ISO 9001-2008 MANAGEMENT SYSTEM The basic clauses of ISO 9001-2008 System that is applicable to Syntech fibre are as follows:

Management Responsibility

Quality System

Contract Review

Documents & Data Control

Purchasing

Product Identification & Tractability

Process Control

Inspection & Testing

SIX SIGMA:

Syntech Fiber are producing approximately 20 tons of filter per month in which less than 1% which is 0.6 of the total quality is error or of poor quality which is known as B quality product.

B quality product is basically the product which is not made according to the specification of the customer.

CPA SYSTEM:

CPA stands for Corrective Preventive Actions. This is the unique system they have maintained that anyone in the organization can suggest anything related to the facilities and for the betterment of the process, organization and procedures. Manager checks it if he even rejects it, then it is shown in the top management meeting and the manager tells the reason that this ideas was suggested by this person and I reject it because of that reason so they come to know about it

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and if he accepts it then it depends on the top management how they work on it. So the main reason of CPA is that even a security guard can communicate to the top management.

PRODUCTION PROCESS

ORDER:

The order is received from the customer it could be domestic or international. Whatever the order

type is it is transported to the aqua warehouse department.

WAREHOUSE:

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When the order is received they check whether they can supply the enough requirement or have

to send the requirement to the warehouse of syntech fibre. When the yarn and fibre warehouse

send the raw material they inspect it in there laboratories, when they got the clear chit from the

laboratories then they further send to the production department for production.

FACTORY:

After receiving the raw material the production department of filter start production of plastic

vessels which is the inner part of filter is started.

After the process of plastic vessels is completed then the plastic vessels is send to the filter

department where the technician assign the work to the workers who feeds the specification of

the customer into the computers so that the computer could automatically produce the filter.

The main job of the worker is to monitor the machines that are they performing up to the mark.

INSPECTION:

The worker monitors and inspect the filters at every layer with the specialized

scales which are specially made to check the diameter of the filters.

FINAL INSPECTION:

The finished product is sent to the inspection department for the final testing that it is made

according to the customer requirements. After its clarification it is sent to the finished good

warehouse.

FINSHED GOOD WAREHOUSE:

After the finished good is received in the warehouse. It is transported to the customer without

any delay. If the customer is of domestic market then the goods are sent by road and if the

customer is from international market then the goods are sent through ships to the related

countries.

EXPORTS:

AQUA CLEAR is exporting its finished goods (filters) to 27 countries such as Australia, UK,

USA, Gulf countries.

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OTHER BUSINESS FUNCTION

SALES

The main function of a sales department is to attract and retain customers. Many moving parts

are tied to this but the number one objective is to attract and retain customers. The Sales team in

this organization consists of 8 employees, of them Sales manager is the head of the department.

Sales officers are divided into groups which perform following operations:

To meet the customer demand with appropriate supply.

Recruiting and employing salesmen and fixing their compensation and respective

territories.

Training the salesmen in knowledge of the goods and in methods of selling them.

Supervising and directing the sales activities of the men out in the field, sending them

letters and providing helpful information.

Preparing and furnishing equipment for salesmen in the way of samples, sample cases,

price lists, portfolios.

Cooperating with the advertising department by helping the salesmen utilize and sell the

company's advertising and aiding them to assist customers to make use of advertising

helps, and by obtaining reports from the field concerning the reaction to the company's

advertising and that of competitors.

Cooperating with the production department in the matter of qualities, quantities,

containers, packages and sizes, and reporting their reaction on dealers and consumers.

Study the consumer's psychology, study market fluctuations, prepare sale budgets,

explore new markets and the process begins again - attract and retain customers.

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To help marketing department in meeting the sales volume fore casted by them.

Making investigations of the products or offering to discover new uses and new appeals

to dealer or consumer.

MARKETING

Marketing department in this organization consist of 17 employees. They also work in groups for

specific tasks to increase productivity and business value. Marketing is perhaps the most

important activity in a business because it has a direct effect on profitability and sales. The

marketing section of a business needs to work closely with operations, research and

development, finance and human resources to check their plans are possible. The roles of

Marketing Department are:

Manage advertising & promotions, the most recognized component of marketing is

advertising

Support sales team & distribution partners. Sales support is a critical responsibility of

marketing.

Use sales forecast to plan their production schedules. Sales forecasts will also be an

important part of the budgets produced by the finance department, as well as the

deployment of labor for the human resources department.

A research and development department will need to work very closely with the

marketing department to understand the needs of the customers and to test outputs of

the R&D section.

Monitor the product and services of competitors.

Create new ideas, means attracting more customers and build more strong

relationship with existing customers by giving then unique products and services.

Providing leadership on how to better serve the customer from product development

to making invoices easier to read.

SUPPLY CHAIN

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This is one of the biggest departments in this organization having more than 40 employees.

Supply chain activities transform natural resources, raw materials and components into a finished

product that is delivered to the end customer. Supply chain is performing one the most important

part of this business.

ACCOUNTS

Accounts department in this organization is not so big but important. Basically, Accounts

provides a detailed record of the money coming in and going out of the business and prepares

accounts as a basis for financial decisions. This business function has very important role in any

organization. Accounts department in any company almost performs same functions. Here is

some of the functions that handled by Accounting department:

PAYROLL

The total wages and salaries earned by every employee every pay period, which are called gross

wages or gross earnings, have to be calculated. Based on detailed private information in

personnel files and earnings-to-date information, the correct amounts of income tax, social

security tax, and several other deductions from gross wages have to be determined.

CASH COLLECTIONS

All cash received from sales and from all other sources has to be carefully identified and

recorded. They also make sure that the cash is deposited in the appropriate checking accounts of

the business. Accountants balance the checkbook of the business and control who has access to

incoming cash receipts

CASH PAYMENTS

In addition to payroll checks, they also writes many other checks during the course of a year to

pay for a wide variety of purchases, to pay property taxes, to pay on loans, and to distribute some

of its profit to the owners of the business.

PROPERTY ACCOUNTING

They maintain detailed records of their properties, both for controlling the use of the assets and

for determining personal property and real estate taxes.

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EMPLOYEE COMPENSATION BENEFITS

This covers salaries, bonuses, vacation pay, sick leave pay, Workers' Compensation, and

insurance policies such as medical. The Human Resources Department is responsible for

developing and administering a benefits compensation system that serves as an incentive to

ensure the recruitment and detainment of top talent that will stay on with the company.

EMPLOYEE RELATIONS

HR looks upon the conduct of employee’s and keep track of their behavior if they are not

involved in certain illegitimate activities. With the increased rise in unethical practices and

misbehaviors taking place in today's workplace such as age, gender, race, and religion

discrimination and sexual harassment, there needs to be mandatory compliance with governing

rules and regulations to ensure fair treatment of employees. HR issues notices and record

attendances and behavior of employee in their software module.

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