M52GED ENVIRONMENTAL ENERGY MANAGEMENT

ENVIRONMENTAL MANAGEMENT FACULTY OF BUSSINESS, ENVIRONMENT AND SOCIETY

M52GED ENVIRONMENTAL ENERGY MANAGEMENT

STUDENT NAME- Mr. SHAIK ABDUL WAHAB Student ID- 3928736 Module Head- Mr. I Duckers COVENTRY UNIVERSITY, 2011-12 Submission date- 1ST December 2011

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Contents
M52GED......................................................................................................................................................... 1 ENVIRONMENTAL ENERGY MANAGEMENT .................................................................................................. 1 Module Head- Mr. I Duckers ......................................................................................................................... 1 COVENTRY UNIVERSITY, 2011-12 .................................................................................................................. 1 Submission date- 1ST December 2011 ........................................................................................................... 1 SuperNova Fashion Limited ........................................................................................................................... 3 Manufacturers and Exporters of Quality Clothing Worldwide ..................................................................... 3 INTRODUCTION ............................................................................................................................................. 3 PRODUCTS ................................................................................................................................................. 4 COMPANY PROFILE........................................................................................................................................ 5 RAW MATERIALS ........................................................................................................................................... 6 MANUFACTURING ......................................................................................................................................... 6 Sewing ....................................................................................................................................................... 6 A. B. C. D. E. Industrial Sewing ......................................................................................................................... 7 Pre sewing functions ................................................................................................................... 7 Fabric Edges to be sewn .............................................................................................................. 7 Planning of sewing process ......................................................................................................... 7 Identification of seam lines ......................................................................................................... 7

Significant aspects of sewing .............................................................................................................. 8 Fabric Painting (Only for special orders) ................................................................................................... 8 Printing Process ......................................................................................................................................... 8 MACHINERY ................................................................................................................................................... 8 MAN POWER REQUIREMENT AND ANNUAL LABOUR COST ......................................................................... 8 ENVIRONMENTAL ISSUES .............................................................................................................................. 9 LEGISLATION .................................................................................................................................................. 9 NEW PROPOSITIONS.................................................................................................................................... 10 CONCLUSION ............................................................................................................................................... 14 REFERENCES ................................................................................................................................................ 14

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SuperNova Fashion Limited

Manufacturers and Exporters of Quality Clothing Worldwide

INTRODUCTION
SuperNova Fashion was constituted by Mr. Eashwaran (founder and adviser) who has sound background and 20 years of experience in Textiles and was formed in the year 1999, since there we have grown from a small company to one of the best company in India, after his retirement from appex management now the next generation take the seat of the concern.

WHY US?
We have marked a distinguished position for ourselves in this competitive market by providing finest quality products as per the latest fashion trends. Our products are widely recognized for its quality, cut and designs inputs. We are ahead of our competitors due to following features: * Quality standards * Competitive prices * Innovation * On time delivery * Expert product solutions * Highly skilled professionals * Stock holding and management upon request * Short time deliveries * Handling minimum quantities * Vertical manufacturers * Eco friendly suppliers, processes, products * Skin friendly products Okeo Tex certified vendors * Organic certified vendors GOTS, OE100 * Complaint factories WRAP, SA 8000.

OUR SERVICES
Sampling Development and R&D - The samples are made to clients specifications and our innovative creation based on fashion trend in the global market. Price Negotiation - Competitiveness, Transparency. Vendor selection / Order placement - Choosing the vendors according to the product specification and order placement accordingly. 3|Page

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Order follow up - Periodic production status, Right from laboratory test with international accredited lab and quality control at various stages from fabric to Final Random Inspection.

Logistics and Shipment follow up - Ensuring correct shipping documents and prior approval from the clients before and post shipment ensuring trouble free delivery. Buyer & Seller meet - Planning and organizing the buyers visit to any our factories. Buyers will be taken to vendors and their factories in order to make personal assessment about the vendor. Market information and Fashion trend - Periodical market information such as competitor activities, socio-political activities, industrial problems, currency fluctuations etc., will be informed to the clients. Personalized Follow Up - Frequent visiting across the globe to have a personal encounter with the Company's long list of clients ensures instantaneous updating of fashion, trends, developments and consolidation clubbed with expansion.

PRODUCTS
Mens wear - Shirts, Boxer shorts, Pull on/Constructed waistband Shorts and pants, Trousers, Jeans, Vest Jackets, T-shirts, Jackets (Quilted/Lined), Vests, Over t-shirts, Zipper/Button polo, Mock neck, Crew neck, Tank top, Boxer shorts, Intimates, Bath robes, Track suits Womens wear - Shirts, vests, Skirts, Quilted skirts, Double layer Shorts, Pull on pant, Capri, Bias jumper, Romper, Jump suits, Trousers, Jeans, Scarf Mock neck, Crop tops, Basic T-shirts, Poloshirt, Skirts, dresses, Shorts, Pull on pants, Scarf, Pinafore gowns, Pyjama sets, Pants, Capri, Intimates, Bath robes, Tank top, Track suits, Sweatshirts, Night wears, Bikini wear, Shoulder cover Kids wear - Shirts, Shorts & Pants, Jump suits, Capri, T-shirt, Shorts, Dresses, Jumpsuits, Intimates Infant wear - Romper, Body-suit, T-shirt, Intimates Home Textiles - Napkins, Towels, Bed covers, Pillow covers, Bed sheets, Curtains, Table cloths, Placemats

FABRICS
Woven fabrics - Poplin, Drill, Denim, Dobbies, Flunnel, Suitings, Satin, Voile, Canvas, Jacquards, Yarn dyed check & Stripes, Corduroy Knitted fabrics - Single jersey, double Jersey, Interlock, Single rib, Double rib Derby rib, Flatback rib, Airtex, Pique, Honeycombed, Waffle, Fleece, Pointel, Velour, Terry, 4|Page

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Polar fleece, Jaquards, Herringbone, Flat knit, Feeder strippers, Auto & Engineered Stripes Contents - Cotton, Polyester, Modal, Bamboo, Viscose, Linen, Hemp, Rayon Polyamide, Organic Cotton, all with lycra & without lycra and combination blends of all above. SuperNova Fashion Ltd will always try to pursue good workmanship. With over 10 years of experience in the competitive textile industry, our proficiency as an apparel manufacturer allows us to provide our customers with clothing that is the absolute top class in quality and durability. Our certain range of clothes is hand-made by our finest tailors for a personal touch. The company employs a 100 odd people from all races on various categories such as skilled, highly-skilled, salesmen, cashiers, drivers, storekeepers and so on. The company factory is located in the outskirts of Tirupur (TeOnline), India Our unit is divided into 4 sections. Sections A consists of machineries required for the production, finishing and packaging process, consumes more amount of energy compared to the other three sectors. Sections B contains of a canteen, rest rooms for both male and female and a small lounge for relaxation and recreation. Section C contains office rooms and medical amenities. Section D consists of a midsized go down for the purpose of storage for raw materials and the finished products along with the waste yarn that are to be recycled and is a part of an old warehouse. All the infrastructures in the respective sectors have fire exists in case of mishap.

COMPANY PROFILE
BASIC INFORMATION Company Name: Business Type: Product/Service (We Sell): Product/Service (We Buy): Number of Employees: SuperNova Fashion Ltd Manufacture, export and Wholesale Mens Wear, Womens wear, Kids wear etc. Mentioned below in detail

103 People (Permanent and temporary, contracted)

OWNERSHIP & CAPITAL Year Established: TRADE & MARKET Main Markets: 1. North America 2.Eastern Europe 1999

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3.Africa 4.South America 5.Northern Europe 6.Southern Europe Total Annual Sales Volume: Export Percentage: FACTORY INFORMATION Contract Manufacturing: OEM Service Offered, Design Service Offered, Buyer Label Offered INR 400 Million to INR 600 Million 91% - 100%

RAW MATERIALS
We import high quality yarn, threads, zippers and buttons from India and Bangladesh. In all we have 12 registered vendors for raw materials. We procure mostly polyester and cotton yarn. The price of the raw materials would be estimated upon the type of order we get. If it is a large order, the raw materials we purchase is about 15 Million Rupees (inclusive of taxes, labour charges, handling and transportation). S. No 1 Types of Raw materials Yarn Cotton Polyester Nylon Buttons Round Trouser Jeans Special Units Quantity

Tonnes Tonnes Tonnes Pcs

75 54 14 16million 4.5 million 3 million 500,000 average Or as per order

Zippers Trousers Jeans Threads-all colours

Pcs 2.2 million 3 million 12

Tonnes Table 1- Raw Materials

MANUFACTURING
Sewing
The basic process of sewing involves fastening of leather, fabrics, furs with the help of needle and threads. Sewing is one of the important processes in apparel making. Industrial sewing machines do most of industrial sewing. The cut pieces of a garment are mostly tacked, 6|Page

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or stitched temporarily at the initial stage. The complex parts of the machine then pierces thread through the layers of the cloth, interlocking the thread.

A. Industrial Sewing
Looks to be a simple process, industrial sewing is quite complex involving many preparations and mathematical calculations for the correct seam quality. Quality sewing also depends on the sound technical knowledge that goes into designing pattern and making. Flat sheets of fabric having holes and slits into it can curve and fold in threedimensional shapes in very complex ways that require a high level of skill and experience to manipulate into a smooth, wrinkle-free design.

B. Pre- sewing functions

Before the actual task of sewing begins, there are certain other tasks that have to be taken care of which can be termed as fabric handling functions ply separation, placing the fabric on working table, guiding the fabric towards sewing needle and tension control of fabric during the sewing process. While ply separation, stacks of fabric plies are sequentially positioned with the help of some feeding apparatus in an unloading position. The topmost ply in such a stack is individually and sequentially separated from the stack. In the process, an edge of the separated fabric is presented between the jaws of a gripping device. A proximity switch checks the space between the gripper jaws. When this spacing confirms that only one fabric ply is in place between the jaws, the single ply is transferred over the receiving end of a conveyor for further processing.

C. Fabric Edges to be sewn

Two basic types of stitches- one is that are for joining two parts of cloth together and the other one is done for decorative purposes. Sometimes, both types of stitching have to be done for eg, a pocket has to be joined on three sides with the apparel as well as it may be given some decorative stitches too. At what points and which type of stitching has to be done- all such information is stored digitally on automated devices through CAD and properly sewn.

D. Planning of sewing process

Sequence of seams to be stitched is checked before you start sewing. Which part will be joined first, what stitches will follow one another, etc. are decided. However, some stitches have to be necessarily done before or after another stitch. Like mentioned above, the decorative stitches must be done first followed by the joining stitches

E. Identification of seam lines

Sewing process is performed on seam lines situated inside the fabric edges, some mm inside the fabric's outer line. For the straight lines, the seam line is found by transferring the outer lines inside the fabrics and the intersection of these lines makes the vertices of the seam line. Hence, seam line is parallel to the outer edge and the distance between the two has to be determined as it is different for different parts of the cloth. Seam allowance is the area between the edge of the fabric and the line of stitching. It is usually

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1.5 cm away from the edge of the fabric. Seam allowance is usually 2.5 cm or more for standard home dressmaking. Industry seam allowances vary but they are usually 0.6 cm.

Significant aspects of sewing

There are certain aspects that have to be carefully considered while the sewing process as they are very crucial for high quality sewing. Thread tension and consumption Presser- foot displacement and compressing force Needle penetration force measurement

Fabric Painting (Only for special orders)

Different fabrics such as apparel fabrics or home furnishing fabrics can be crafted beautifully using fabric painting. This technique can also be used for decorating denim jeans, shirts, skirts, t-shirts and jackets.

Printing Process
The Dyes used for printing mostly include vat, reactive, naphthol and disperse colours which have good fastness properties. The pigments, which are not truly dyes, are also used extensively for printing. These colours are fixed to the fibre through resins that are very resistant to laundering or dry-cleaning. Pigments are among the fastest known colours and are effective for light to medium shades. If used for applying dark colours, they may crock or rub off. Cheap prints are made from basic colours mixed with tartar emetic and tannic acid but they are not acceptable in todays market.

MACHINERY
S.NO 1 2 3 4 5 6 7 8 9 LIST OF MACHINARY Sewing Machine Embroidery machine Cutting machine for garments Industrial Sewing machine Household sewing machine Ironing machine Steam Press Hemming Machines Denim Sewing Machines QTY 20 1 1 1 10 10 5 2 3

MAN POWER REQUIREMENT AND ANNUAL LABOUR COST

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S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Description Plant Manager Production and Technical manager Finance and administrative manager Commercial manager Chemist Executive secretary Production supervisors Mechanic Electrician Skilled operators Unskilled workers Accountant Purchaser Sales man Cashier

Req. No. 1 1 1 1 2 1 3 3 3 25 55 2 1 3 1

Annual Salary (INR) 350,500 350,500 245,500 200,000 200,000 200,000 200,000 200 per day 200 per day 180,000 150,000 180,000 200,000 500 per day 180,000

Table 2-Manpower Required Any additional worker employed at per day basis.

ENVIRONMENTAL ISSUES
Environmental issues during the operational phase of textile manufacturing primarily include the following: Hazardous materials management- Dyes and paints. Wastewater- Chemical water but drained properly. Emissions to air- Vapours of paint and dyes Energy consumption- View to minimise working more shifts during daytime. Solid and liquid waste- waste extra cloth sold as cleaning

LEGISLATION
The Health and Safety at Work Part 8. The Safety Representatives and Safety Committees Regulations 1977

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The Management of Health & Safety Regulations 1992 amended 1999 The Health & Safety (Consultation with Employees) Regulations (HSCEC) 1996 The Information and Consultation with Employees Regulations 2004. (house)

Contract Law Employer will ensure the employees health, safety and welfare. Inspecting the workplace. Investigating potential hazards. Investigating reportable accidents, cases of diseases or ill health and dangerous occurrences. It is good practice to investigate all accidents that occur in the workplace.

Besides this there is the common laws and regulations.

NEW PROPOSITIONS
The propositions made from 2006-2011 to mitigate the amount spent, environmental issues. YEAR 2006 Economic/Environmental Strategy Driving force Climatic change and the increase in utilisation cost Improved energy efficiency will achieve the target of reducing Group energy consumption by 19% from that of the 2006 calendar year by 2011. Yearly Future plans accomplishments Accomplishment of 46% reduction in energy consumption with mitigation of utility price increase and daytime machinery operation. Solar panels installation could be possible.

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Management and corporate social responsibility auditing

ISO 9001:2005 accreditation of site.

Site now accredited to ISO 9001:2005 with mature management Reduction of complaints is achieved by proper techniques of abatement, mitigating, odour, emission, noise with upgraded treatment processes. Composting or beneficial application account for 80% of biodegradable waste. The sale of by-products has also replaced landfill.

Achieve EMAS accreditation within 2 years. Upgraded odour control and wet scrubbing plant with bio filters. Sound proofing sewing unit.

Noise and air emission

The odours from the site should not impact the boundaries beyond the site.

Land fill availability and costs

This can be achieved by avoiding waste creation and there by employing the beneficial technique of reuse. Another method is to not keep excess stock.

Shaving reduced and alternate application of waste recovery in case of more waste and thereby increasing profit by 6%.

Table 3-New Propositions-2006

YEAR 2007 Taking into account the environmental drivers such as climatic changes and utility costs we aim to start using renewable sources of energy. This is achieved by generating thermal energy from the waste. This will tremendously reduce gas purchase and also lessen waste disposal. Both the compliance and feasibility trials are successfully completed. The risk assessment is planned with the detailed design of the application process and the methods on how to achieve it with minimum cost. YEAR 2008 Economic/ Environmental Strategies Yearly accomplishments Future plans

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Driving force Climatic change and the increase in utilisation cost Improved energy efficiency will achieve the target of reducing Group energy consumption by 10%. Reduced Carbon Dioxide Emissions and improved efficiency through application of radiant heating, variable speed drive installations, reduced water temperatures. All sites are now accredited to ISO14001:2007 with optimise management system. Continued efficiency gains especially heat recovery systems, application of variable speed drives, boiler decentralisation and radiant heating applications. Reduce risk to forthcoming environmental liability legislation. Seek business case for EMAS accreditation. This ensures a proper management system and low vulnerability towards laws and also improves the aesthetics of the site windows.

Auditing management and corporate social responsibility

ISO 14001:2007 accreditation of site.

Storage systems

Proper storage of fuels, waste and raw materials pre production and post production.

Raw materials used for production are stored efficiently under cool dry containers. The products produced are packed and sealed and finally stored onsite for transport two times a week.

Table 4-New Propositions-2008

YEAR 2009 Economic or Environmental Driving force Climatic change and the increase in utilisation cost Strategized objective Yearly achievements Futuristic action or anticipated deviation Continued efficiency gains especially heat recovery systems, application of variable speed drives, boiler decentralisation and

Improved energy efficiency will achieve the target of reducing Group energy consumption by 10% in the year 2008.

Reduced Carbon Dioxide Emissions and improved efficiency through application of radiant heating, variable speed

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drive installations.

radiant heating applications. Minimise landfill. Thermal Energy Plant with direct waste heat recovery. Sale of all recyclables remains a target

Land fill availability and costs

Avoid landfill by avoiding waste creation, employing beneficial reuse and recycling.

The reduction of shavings by precision splitting and sale of trimmings. Registered and compliant to Packaging Obligations.

Table 5- New Propositions-2009

YEAR 2010 Concentration on yield improvement, along with the strategies; SuperNova Fashion Ltd area yield improvement programmes improve company performance by maximising the quality. View to keep the value of the business high, best quality yarn manufacturers across the world especially in India. Sewing operation facilities need to remain focused on maximising company performance. SuperNova Fashion Ltd Yield Improvement Programmes offer a low risk strategy to improve profitability in a very short time frame. Area gains of 4% to 8% or more are achievable, depending on the type of clothes produced and the degree of comprehensive perception and control of existing products and process. The programmes are carried out systematically in collaboration with the operational team. A key element of the success rate is training labour, concentrating on using raw materials economically, maintaining quality standards, maintaining and improving output rates. As well as significant area gains, the programmes also contribute to easier production management and enhanced competitive advantage. YEAR 2011 The money saved from the profit, low energy consumption, low waste strategy year by year from 2006 to 2010 is used to increase the buying of raw materials in order to supply too many other customers in 2010 and also to build up an efficient pre treatment facility for water discharge. The effluent and the contaminated water are directed into the water treatment system thereby cleaning the discharge making it contaminant free and reusing that for industry purposes. Accreditation of clean water act and clean air act of 2010 and also ISO 14001:2010 adhering to the legislation is prioritized and all employees of all positions are knowledgeable of the laws and regulations of the company along with its policies and work towards a better futures.

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CONCLUSION
SuperNova Fashions Ltd has undergone major changes in its policies accordingly so that the environmental impacts are reduced thereby increasing the profit by employing new techniques. The company has prioritized the effective strategies such as the reduction energy over consumption, water treatment facilities to mitigate environmental problems and also has invested a lot in saving energy keeping in mind the depletion of natural resources. We also have a new 5 year plan in place and if we act accordingly we hope to maximise our profits by 8-18%.

REFERENCES
house, E. p. (n.d.). Retrieved from http://www.edym.com/en/ Safety, H. a. (n.d.). Retrieved from http://www.hse.gov.uk/textiles/audit/part8.htm TeOnline. (n.d.). Retrieved from http://www.teonline.com/knowledge-centre/textileprocesses.html

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