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We are dedicating our work to our parents and

respected teacher Prof. Bilal Rauf, who have played a
vital role in our studies and have guided us at every
step with their precious ideas. No doubt this
dedication is insufficient and we can never repay for
the role they have played in our studies but we are
sure that their work will prove itself an asset in our
life

 
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We are very thankful to MASTER GROUP OF

INDUSTRIES which gave us valuable information. We
pay gratitude to staff giving valuable information.

We are also very thankful to Mr. Imran Khan who

helped a lot us by giving up to date information.

We are very proud of our teacher Prof. Bilal Rauf

whose help and instructions enable us to bind papers
into project manner. We are very thankful to him.

 
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³The most beautiful things we can experience are the

mysterious .It is source of all true art and science´

(Albert Einstein, 1930)

This project is based on the topic which is assigned

to us by our respected teacher Prof. Amjad, the
organization which we took for research is:

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We have selected Master Group of Industries for TQM Project.

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Master Textile is one of the foremost and leading textile
manufacturers, based at Lahore, Pakistan. Engaged in the export of
quality products like: Yarns, Fabrics, Garments and Home Textile. We
have established a name of credentials owing to the project
commitments, working speed, quality practices and the overall
approach of the company. Our Operating philosophy is to provide
buyers with product that meets their specification, reliably delivered at
a reasonable price in Domestic and International Markets. We offer our
customers a global network of opportunities and the best deal
possible.

::

Master Group of Industries was established in 1963 as a joint venture

with Bayer A.G. of Germany to manufacture foam mattresses. Today,
the Group is one of Pakistan's most dynamic Industrial concerns
commanding well over 50% of the domestic foam market. Even
though the Group's mainstay is foam products, it as rapidly diversified
into other areas such as Textiles, Auto-motive parts, spring mattress
production and General Trading. The group has a fixed asset base of
USD 20.00 million, annual turnover of USD 60.00 million and 2500

 
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employees. The Master Group enjoys impeccable integrity both in the
international and domestic markets.

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Our goal is to strengthen the exports from Pakistan. With this comes
the challenge of achieving international quality standards for both
weaving and dyeing/finishing. Master textile was not only able to
achieve these standards, but in fact raised the benchmark for both
quality and reliability from Pakistan. The first of its kind state-of-art
composite unit in Pakistan was testament to the commitment of the
group¶s 30 year old motto of quality and reliability. The company is
striving to have socially accountable and environment friendly
operations and practices.

: !!:
The group¶s vision program includes expansion of the weaving, Dye
house and garment facilities. We see the broader challenge and
opportunity to increase our share of international business as the
world moves toward globalization. We are developing poly mattresses,
cushions, quilts, bed sheets, bed spread, napkins, wadding, and non-
woven fabric facilities. We aim to invest in future focusing on the
customer¶s needs and intense competition in the international markets.
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The master textile has successfully implemented Total quality
management and has rewarded with following certificates.
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Ý: Prevention of pollution.
Ý: žomplying with suitable applicable environmental regulations.
Ý: Setting environmental objectives and management programs.
Ý: In-house and public awareness.

,:}:!::!-,!::./:0:!1:

Ý: Aiming at the highest level of performance by adoption of

modern resources.
Ý: Train staff and workers for achievement of Excellence in Quality
Assurance.
Ý: Welfare of workers and making valuable contributions to the
economy.
Ý: Support and improve good working practices.

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Master Textile Management is committed to provide and continuously

improve socially and legally accountable practices under SA-8000.

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Based on Air Jet technology our weaving facility has a production of

50,000 meters per day. We are capable of producing fabrics both in
narrow widths for Apparel and wider widths for Home Textiles. We
regularly manufacture Twill, Drill, Poplin, Satin, Rip-stop and Dobby
design fabrics. Yarn counts range from 6/s to 45/s in both cotton and
various polyester cotton blends. We also manufacture fabrics using
two ply yarns. To ensure that the fabrics are of the highest standards
our in-house laboratory regularly test yarns for count variation,
imperfections and tensile strength.
Only after a satisfactory result is the yarn issued for consumption.
After production, we are also equipped to check the fabric's weight,
construction and tensile strength. The fabric inspection and grading is
checked on the Barco computer system. In addition to this our
customers have a choice of different inspection standards like the

 
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Japanese 10 point system, European 4 point system and American
ATžž 10 point system. The inspectors are also trained to maintain
high customer and textile industry standards. We endeavor to provide
our customers with long fabric lengths of up to 800 meters on rolls.

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Master Textile has been supplying Dyed fabrics for the last three years
to various quality conscious companies worldwide. We are capable of
supplying fabrics with specialized finishes such as Sanforizing,
Emerizing, Mircro Sanding, Resin, Air Permeability, Wrinkle free and
Scotchgard. Our fabrics adhere to all internationally accepted
standards. We regularly provide our customers with fabrics achieving
light fastness of 4-5, color fastness, rubbing fastness and dry cleaning
fastness of 4-5. in order to meet the customer's individual quality
standards and finishing specifications, only imported European
Dyestuffs from companies like Dystar, žiba and žlariant are used.
The fabric is inspected by our quality controllers at every stage
of finishing. We use reactive, Vat, Sulpher and pigment dyes for 100%
cotton fabrics. Polyeseter blended fabrics are dyed using disperse with
reactive or pigment dyes. Special care is taken during packing to
ensure that piece lengths meet or exceed customer requirements.
Products made from our dyed fabrics can be found globally in chain
stores such as Marks & Spencers, Steffanels, ž&A, BHS, etc.

 
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Master Textile has been supplying Dyed fabrics for the last five
years to various quality conscious companies worldwide. We are also
supplying printed fabrics for upholstery and apparel use. To satisfy our
customer¶s requirements, we have set-up our own Dyeing and
Finishing Plant. We are capable of supplying fabrics with specialized
finishes such as Resin, Air Permeability, Wrinkle free, Teflon, high
visibility and flame retardant. Our fabrics adhere to all internationally
accepted standards. We regularly provide our customers with fabrics
achieving light fastness of 5-6, color fastness, rubbing fastness and
dry cleaning fastness of 4-5. In order to meet the customer¶s
individual quality standards and finishing specifications, only imported
European Dyestuffs are used. We use sulpher, reactive and vat dyes
for 100% cotton, disperse with reactive or VAT dyes for Polly-cotton
fabrics. We have installed following machinery with workable width of
72´ in the finishing mills:

 
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The garment facility is equipped with 200 stitching machines, and is
located in Karachi; with all necessary facilities to produce casual
sportswear and industrial work wear garments. This stitching unit is
set up on the chain method of production and is capable of producing
2000 garments a day. At the heart of the unit is the Switch Track
Overhead Hanging System to manufacture garments in an efficient
and clean manner. We offer various types on garment finishes such as
Stone, Enzyme, Bleach, Sand, Sandblasted, Silicon, etc.
State-of-art computerized, pattern making and grading machines, as
well as computerized stitching machines are installed to produce high
quality garments. The garments produces includes trousers, shorts,
jackets, blouses, dresses and work wear articles such as Overalls,
žoveralls, Bib-Brace, Trousers, Doctor žoats, Blouses etc..
žurrently, we are shipping casual garments to companies like ž&A,
Kaufhof, žarrefoure, Taco, Primark and Newlook. Work wear garments
are being supplied to leading European companies. During the process
of stitching we have in-line inspection and final inspection process both

 
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of which conform to the AQL 2.5 system. Master Textile Mills Ltd is
your ³one-stop´ Partner for all your garments requirements.

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Some žAD/žAM text GOES here ...

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žutting units working under the
supervision of skilled unit managers, these cutting units are well
equipped with latest machinery including Bullmer Plotter, Spreader and
žutter etc.

!3.:
With over 750 stitching machines, manned with the most skilled and
expert operators, Master is capable of producing about 120,000
dozens per month versatile garments ranging from basic to high
fashion, men¶s, women¶s and kids with maximum flexibility in size and
color assortments. The Quality control and Quality Assurance
departments are in place to make sure the company¶s objective of zero
defect. žomputerized Bar coding and Back Track systems provide
Master 100% predictability and tracking performance.

 
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We have state of the art spinning facilities covering the complete
sphere of yarn manufacturing including ultramodern automated setup
with high speed ring frames. Master's automated spinning facility is
the most modern in the region.

We have the facilities to produce carded as well as combed yarn. The

flexibility of in our house machinery results in manufacturing of yarn
counts from 7 s to 120 s with high uniformity, evenness and low IPI's
which is reflected in our woven products.

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It consists of the latest Reiter [Swiss] machines. It opens the cotton
and removes the contamination, dirt, dust, and trash and foreign
matter and feeds the opened material to the subsequent department
i.e. carding.

 
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: In the blow room cotton is feed. After feed the unwanted
items likes¶ trash particular are collected and disposed.
The trash particular includes puppy trash, seeds, husk,
jute, and poly particular.

: In blow room there are difference kind of cotton is
placed at there specified areas it is necessary to avoid
the mixing of different kind of cotton because it result in
the variation of varn. The flour is also painted to specify
the area boundaries for each cotton walls.

 : The blow room is kept neat and clean so that the dust
and other contamination is might not mix with cotton.
The blow room is also provided with suction fans which
removes light particles from cotton and environment. In
Master Textile there is also a dedusting machine is
incorporated and perform same function.
"
 ": The supervisors and assistant spinning managers are
provided with checklist to coordinate it with non-
managerial staff. The checklist includes the routine
activities that the shift In charge has to perform before
starting the shift. In blow room the checklist includes,
following
1-:Machines physical checking.
2-:Oiling and greasing of major components.
3-:To check the program feeded in the machine and
compare it with the planed program.
4-: To neat and clean the main components of the
machine.

 
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5-:To set and arrange the equipments required to run

the machine.

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: In Master Textile on job training is carried out by
training instructors. On each level training is carried out.
The managers are trained to coordinate work with the
employees similarly the non-managerial staff is trained
to operate machines and other processing activities.

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It consists of Rieter[Swiss] card machines c-51 hi-per & Trutzscheller
Dk 803. It opens the cotton and removes the dirt, dust, and foreign
matter and produces silver in cans for feeding to draw frames. These
cards are with chute feed system and auto leveling to produce high
quality of yarn.

 
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5: ::.:


: The cotton laps are feeded to carding section. The
defected cotton laps are removed.

: In Master Textile there are 2 Blow room lines so the
material obtained from these 2 lines are kept apart from
each other. The flour is also painted and the lap of the
particular cotton is also specifically placed.

 : The carding machine is kept neat and clean from inside
and outside. The sliver drums are also kept neat and
clean so that the trash might not be mixed with sliver.
"
 ": The supervisors and assistant spinning managers are
provided with checklist to coordinate it with non-
managerial staff. The checklist includes the routine
activities that the shift In charge has to perform before
starting the shift. In blow room the checklist includes,
following
1-: The sliver cans should be neat and clean.

2-:The Oil and grease should not be in contact with

sliver.
3-:Do not touch sliver and press sliver with hands.
4-: To neat and clean the main components of the
machine.

 
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5-:To keep the sliver of particular cotton at their

specific place.

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: In carding there are different notice boards to aware the
non-managerial staff. The precautions are there to
handle the material and machinery. The general
supervision is also carried out at regular interval of time.

:
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It consists of Rieter[Swiss] machines SBD-10, RSBD-30, SB-2. These
machines parallelizes the fibers and improves uniformity of produce
even yarn on ring. These drawings are with auto levelling system.

5: :: 3: !:


: The drums of different cottons can be identified by their
specific color. Mostly blue and red cans are used. The
defective cans are removed with regular intervals of
time so that the quality of sliver is not disturbed.

: In Draw frame the sliver cans are feeded to Drawing
machine. They are arranged in a specified area which is
marked by paint. The drums are arranged in line.

 : The Draw frame is also kept neat and clean. The oil and
grease is also avoided with the material.
"
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other. It should not be treated harshly. The empty

drums are removed and send to carding department for
coiling.

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: The quality of sliver is checked after regular interval of
time. The samples are taken to laboratory.

:
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Toyota FL-100 type machines are currently in operation in Simplex
sector. Special type of Flyer on machines is installed to get even
quality roving.

 
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5: :: ,!7:


: 40-60 cans are feeded in the simplex machine. It has
120 spindles having roving over it. The cans re arranged
in a sequence. The old and defective cans are tagged.

: The draw frame sliver cans are feeded to roving
machine. It is necessary to keep them in a particular
order and their mentioned place because the crossing of
sliver cans of different cotton creates the variation in the
final count of yarn.

 : The simplex is also kept neat and clean. The oil and
grease is also avoided with the material.
"
 ": The simplex roving is obtained from simplex machine is
hanged over a creeling stand and transfer to ring
department.

 "
: The quality of sliver is checked after regular interval of
time. The samples are taken to laboratory.
:
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TOYOTA Ring Frames work round the clock at ring section. SKF PK-225
drafting system is attached on these Ring frames. LUWA Air
conditioning systems in Ring department maintain the required R.H
and temperature in the whole ring department to maintain low
hairiness in yarn. žots, Apron and Steel rings of machinery is changed
at proper time.

 
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5: :: .:


: The roving is feeded to ring frame. The defective
parts and roving is removed

: The roving is placed over their specific creeling
position. There are 1024 spindle over a ring
frame. The Bobbins are fitted over spindle.

 : The ring frames are also kept extra ordinary neat and
clean. The machine is provided with suction ducts to
remove fluff.
"
 ": The supervisors and assistant spinning managers are

 
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provided with checklist to coordinate it with non-

managerial staff. The checklist includes the routine
activities that the shift In charge has to perform before
starting the shift. In blow room the checklist includes,
following
1-: The ring frame should be neat and clean.
2-:The Oil and grease should not be in contact with
sliver.
3-:Do not touch roving and press sliver with hands.
4-: To neat and clean the main components of the
machine.
To keep the sliver of particular cotton at their
specific place.

 "
: In Master Textile on job training is carried out by
training instructors. On each level training is carried out.
The managers are trained to coordinate work with the
employees similarly the non-managerial staff is trained
to operate machines and other processing activities.

:!:
We installed new 21 ž Process žoner. We are producing yarn having
low level of contamination. It is a fully computerized system and helps
to determine departmental efficiency round the clock. Yarn hairiness is
controlled on 21 ž Process žoner by its special balloon system.

 
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: The defective bobbins are removed from ring

frame. For each count the bobbin is given a
special number. The bobbins of different color
should not mix with each other. The defective
bobbins are disposed.

: In auto cone machine the bobbins of same color are
creeled. The machine is also marked for specific count of
yarn.

 : The auto cone machine and yarn cone are kept neat and
clean. The waste obtained from each department is
removed
"
 ": The standards for each process are mentioned.

 
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The employees are trained. The boards are also

fitted in departments

 "
: In Master Textile on job training is carried out by
training instructors. On each level training is carried out.
The managers are trained to coordinate work with the
employees similarly the non-managerial staff is trained
to operate machines and other processing activities

.:/!:!,:!::0,,3:

1: !!: /!:!: 0!: :

1. Blow Room žotton Lines Rieter [Swiss] 2

Polyester Lines Rieter [Swiss] 2

2. F-F-Detector Vision Shield Rieter [Swiss] 1

3. žard žard ž51 Rieter [Swiss] 10

Trutzscheller Dk 803 Trutzschller [German] 10

4. Inter/ Drawing SBD 10 Rieter [Swiss] 7

Breaker/Drawing SBD 10 Rieter [Swiss] 7

Finisher/Drawing RSBD 30 Rieter [Swiss] 7

Pre/P/žomber SB 2 Rieter [Swiss] 3

5. žomber E 65 Rieter [Swiss] 5

Unilap E 32 Rieter [Swiss] 1

6. Simplex FL 100 Toyota [Japan] 7

7. Ring Frames RX-240G-TBž-SžD Toyota [Japan] [1008]25

8. Auto Winder Process-žoner 21ž Murata [Japan] 9

9. Yarn-žleaner Uster-Q2 with F-F-ž Uster [Swiss] 480

10. Air/žondition Air/žondition Luwa [Swiss] 1 Set

11. Lab Uster [Swiss] 1 Set

 
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