“Parichay“ Induction Program

Date – 19th & 20th August 2021

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Presentation Title – “Parichay” Induction Program

Topic – Introduction of Company
Topic – Brief of Mr. R.K. Dalmia
Topic – Vision & Mission
Topic – Plant & Head Office Reportee
Topic – Our Creations
Topic – Our Brand Customers
Topic – Our Certifications
Topic – Overview of Departments
Topic – Engagement Activities and Celebrations
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Introduction Of Company
• Century Textiles and Industries Limited (CTIL), was incorporated in Mumbai, India, in 1897.
• A state of the art, vertical With an investment of about US$180 million (Rs. 850 Crore) in the year 2009.
• Spread over an area of 43.56 million Sq.Ft. (100 Acres), Birla Century uses the best modern machinery to
produce a wide range of premium textiles ally integrated plant, Birla Century (A Division of CTIL) was set
up at Jhagadia, Bharuch, Gujarat,– from Bottom weights & Suitings to Finer fabrics, household linen etc.
and Capacity of 40 million meter Per Annum.
• Birla Century’s USP is the customization we offer to our clients in terms of the weave, design and texture
of products. We have an extensive network of distributors and dealers in India and we also sell our
exclusive range of home-textiles and other products in the global markets.
• Founded by Shri. B.K. Birla.
• Chairman Mr K. M. Birla
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Introduction of Company
• Conferred with the title ‘Finest Textile Mill in the
1990
World’ by Textile Horizon Magazine

1975 • Textile Division Exported Fabric

1954 • Foray into man-made fabric

• Birla’s Management
1951
• Founded by Shri. B. K. Birla

1897 • Company began Operations

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Brief of Mr. R.K. Dalmia

A Chartered Accountant by qualification, Mr. Dalmia has been with the Group since the last
four decades. He started his stint as Vice-President in The Technological Institute of Textiles
and Sciences, Haryana and subsequently ascended to the position of President in 1983.
Mr. R.K. Dalmia
Sr. President and
Whole-time
In 1985, he was assigned the responsibility of improving the technical performance of Director
Century Textiles’ mill. Under his stewardship, the mill went on to win numerous accolades
from the textile industry. Mr. Dalmia played a vital role in setting up two new divisions of
the Company, i.e. Century Yarn and Century Denim in 1993 and 1997 respectively. He was
also instrumental in the establishment of a new ultra-modern textile mill, near Bharuch in
Gujarat in the year 2008 with 300 looms and over one lac spindles.
Mr. Dalmia has consistently been at the forefront in improving working conditions of
workers across industries, particularly the textile sector.
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Vision & Mission

• Vision –
• To manufacture textile fabrics comparable to international standards and to be a
customer – focused, globally - competitive textile mill through better quality,
latest technology and continuing innovation.

• Mission -
• To manufacture world class cotton fabrics of outstanding quality.
• To give our customers a competitive advantage through superior products and
of value so that we can make every customer smile.
• To encourage people’s ownership, empowerment and working under team
structure.
• To attain the highest level of efficiency, integrity and honesty.
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Plant Reportee
R.K. Dalmia
(Sr. President)

Soumya K. Mohanty
(COO)

Abhijit Bhatwadekar Prashant Sahoo

Rajiv Mehra (Processing Sachin Hada
(F.M. & Spinning (Weaving Head) Head) (IT Head)
Head)
Vijay Sethiya Sameer Bhosle
Deepak Bhatt
Sachin Gadekar (Finance &
(Human Resource (Maintenance
(FQIP Head) Purchase Head)
Head) Head)
Kuljinder Singh
Ajay Popli Tarun Pandey
Saikat Majumder Sandhu
(Costing Head) (QA Chemical
(R&D Head) (Made-ups Head)
Head)
Nilap Patel & Anup Anil Sarse & Shailesh Trivedi
Sharad Chaudhari
Dammani Prashant Dwivedi (Utility & ERTP
(QA Physical
Head)
(PPC Head) (Logistics & Stores) Head)
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Head Office Reportee

R.K. Dalmia
(Sr. President)

Nilay Rathi Arun Sharma

Anurag Sharma Ashish Mehreshi
(Head of (DGM Cotton
CMO (Wider Width) CMO (Narrow Width)
Commercial) Department)
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Our Creations – Products & Finishes

• Products :-
• Shirting – Premium Range elite shirting in elegant designs, weaves and colours is one of the most
popular products from Birla Century.
• Bottom Weight – Birla Century offers luxury suiting fabrics (bottom weight fabric)in myriad shades and
textures to suit every taste.
• Bed Linen – Birla Century is one of the leading bed and bath linen manufacturers in India. Premium
quality household linen from Birla Century includes a wide range of elegantly tailored sheets, and bed
and bath coordinate pieces.

• Finishes :-
• Normal, Bio polish, Stiff, Moisture Management, ETI, Cool IT, Solar Cleaning, Antimicrobial, Anti-pilling,
Super Soft 5 in1, 2 in 1 etc.
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Our Brand Customer

• Major Customers :-
• Macy’s
• Costco
• Fashion Accessories
• William Sonoma
• JC Penney
• Mytex
• Inditex
• M&S
• Madura
• Raymond
• Arvind Brands
• JS Fashion
• Black Berry
• Pantaloons
• Indian Terrain
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Our Certification
Sr.No. NAME OF CERTIFICATION
1 Oeko-Tex Standard 100 - Class I for Yarn and class II for Fabrics & Bed Linens
2 NABL Accreditation for our Testing Laboratory of Birla Century
3 BS OHSAS 18001:2007 , ISO 9001: 2015 & ISO 14001 : 2015
4 Global Organic Textile Standards ( GOTS)
5 Organic Contents Standard (OCS)
6 Supima World's Finest Cottons
7 Egyptian Cotton
8 EnMS Certification-50001
9 STeP-Certification
10 MIG Tags
11 SA 8000 - 2014
12 LEED (Leadership in Energy and Environmental Design)
13 BCI Registered Member ( Better Cotton Initiative )
14 Fair Trade
15 COTTON USA
16 Higg Index
17 The ZDHC Roadmap to Zero Programme
18 "PETA-Approved Vegan"
19 Global Recycled Standard (GRS) 4.0
20 Recycled Claim Standard (RCS) 2.0
21 SMETA (Sedex Members Ethical Trade Audit Report )
22 Global Security Verification
23 Marks & Spencer Accreditation (Buyer's accreditation of TLBC)
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Overview of departments
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Spinning
A process which converts raw cotton into grey yarn.
• Birla Century spinning capacity
• Total Spindles: 102816,Compact – 86448, Normal - 16368
• Count Spun: Ne 40-Ne 200 combed and compact
• Assets: Reiter, Zinser, Schlafhrost, Testing Equipment – USTER
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Spinning
Storage Area for bales in Blow room

Blow Room Line

Carding

Breaker

Unilap

Comber

Finisher

Speed Frame

Ring Frame
U V Light Checking
Autoconer
Xorella Conditioning
Ply Winding (Ply Yarn)
Dispatch Single,Ply ,
Gassed and Double Twisted
Yarn In House Warping /
Weaving/Yarn Dyg

TFO (Double Yarn Twisted)

Gassing Of Yarn

Soft Package Winding

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Weaving
• A combination of various process to convert yarn into a fabric
both in a grey and dyed form.
• Looms – Air jet – (193 wider and narrow width)
Rapier – 118 (includes dobby and name jacquards )
• Fabric range – Suiting, shirting, and sheeting both in grey and
dyed Plains, twills , dobby designs in counts from 20s to 130s of
cotton, linen, modal, excel.
• Assets – Picanol Looms, Karl and Mayor Warping, and Sizing Staubli
Auto Drawing In

Warping / splitting Sizing of Drawing (On

of yarn (On yarn (On auto Weaving
warping & Auto- sizing drawing Fabric (On
corner) machine) looms)
machine)
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Weaving
Dyed yarn Yarn receipt from
receipt from spinning for Weft yarn
yarn splitting warping and weft

Warping

Sizing

Drawing In

Looms

Greige fabric
inspection

Greige fabric
warehouse
Greige fabric
batching
Fabric issue for
processing
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QA Physical
Quality Assurance

Spinning Weaving

Offline Activity Online Activity Online Activity

• Incoming raw Process control Process control

material (cotton studies studies (Warping
& yarn) BKS, Sizing studies,
Loom knotting
• Stage wise in
gaiting & BKS,
process testing
Greige inspection ,
• Final yarn Cross check and
insprction batching)
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Processing
Textile processing involves the use of different types of specialty
chemicals during the course of conversion of textiles into finished
fabrics.
The different processes involve are Pre-treatment (Bleaching), Dyeing
(coloration) .
Printing (localized coloration) and Finishing.
• A combination of process and machine to convert the grey
fabrics in RTS(Ready to stitch)/ wearable fabric
• Processing capacity 110k (3.5 ton yarn dying)
• Facility to process Voil, Suiting, Shirting, Y/D, Blends like Linen, Excel,
Tencel, CVC. Lycra etc.
• Count Spun- Ne 40 – Ne 200 combed & compact
• Assets- Pre-treatment machine, Osthoff, Kusters, Dying machines,
Monforts, Gollers, Finishing, Monforts, Kuster.

Bleaching + Dying Finishing

Mercersier
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Processing
Fabric issue for processing

White Dyed Yarn Dyed

Singeing and Singeing and Singeing and

Desizing Desizing Desizing

Bleaching Bleaching Wash

Mercerization
Mercerization Mercerization
CBP OBA
Finishing Dying
Finishing
Sanforizing Finishing
Calendar Sanforizing
Sanforizing
Sanforizing
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QA Chemical
Quality Control & Assurance

Product development, Process

Testing, Approval & Grouping
control & Chemical testing

Feasibility :Feasibility/Protocol confirmation with customer based on Yardage performance & Data Bank of
QA before execution of order.
• Object: • Object:
• Feasibility for order initiation • Stage wise follow up of yardages
• Stage wise testing of products. • Quality card preparation
• Shade approval • preparation of yardage test report
• Grouping • online monitoring of process parameter
• Sampling • Establishment of new chemicals though
• Outsourcing testing & trail

• • Development of new finishes

Preparation of test report
• Chemical testing & blend analysis
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QA Chemical
• Stage wise testing of products: • Stage wise follow up of yardages: Yardage
• Greige Stage: Tear & Tensile Strength, EPI & receive from R&D for processing.
PPI, Width ,GSM. • Quality card preparation: To prepare quality
• Bleaching Stage: Whiteness, Tegewa, pH, card for assigning route & recipe.
Absorbancy. • Online monitoring of process parameter:
• Mercerise Stage: Whiteness, Tegewa, pH, Online monitoring of process parameter
Absorbancy, Tear & Shrinkage against SOP to avoid deviation and get
consistent product.
• Finish Stage: Full testing as per buyer & BCJ
protocol. • Establishment of new chemicals: To conduct
trial for new chemicals and submit report to
• Shade approval: Visual and digital assessment of
purchase team for further actions.
shade & CSV after dyeing against lap dip & customer
standards. • Development of new finishes: Produced
new finishes by using new developed
• Grouping: Grouping of inspected material based on
chemicals . Prepare and designed USP for
shade. Online feeding of group in SAP.
launching the product in global market.
• Sampling: FOB sample checking approval.
• Chemical testing & blend analysis: Daily
Preparation of sample third party testing & testing of dyes & chemical testing and blend
hand feel approval. analysis of fiber.
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QA Chemical
• Outsourcing: Quality Assurance of Outsourcing • Audits: Coordinate technical compliance
product by testing, Protocol/Feasibility confirmation audit with buyer and third party lab.
& outsource vendor premises visit. Ensure chemical compliances requirement of
• Preparation of test report: Prepare test report plant.
against protocol based on test result. Working on sustainable drive in view of global
market requirement.
Customer/ Feedback Complaints: Handle plant complaints as a single window by QA-Processing. To maintain record,
respond to customer for received customer feedback and analysis of customer feedback for further actions.
Other Initiatives: Certifications / Awards/ Accreditation/Membership: To coordinate and maintain certification of
Birla Century.
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FQIP Finished
1.) FQIP Delivery Receiving

2.) Roll Inspection

3.) Packing of Roll

4.) Double Fold Inspection

5.) Cut looking

6.) Lapping

7.) Stamping & Packing

8.) Carton Packing

9.) Bale Packing

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FQIP Grey
FQIP Grey Process

Inspection as per American

4 point system

Mending & Rechecking

SAP Entry

Ready to warehouse
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Made-ups

1. Towel

2. Bath Accessories

3. Rugs & Mats

4. Blankets & Throws

5. Kitchen/Table top Accessories

6. Bedding Items

7. Curtains/ Window Soft

8. Furniture Accessories
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Made-ups / Home Furnishing

Product Range of Bedding Items of Birla Century:

• Bed Sheets (Includes 1 Flat Sheet +1 Fitted Sheet + 2Pillow Covers)

• Duvet Covers / Shams

• TOB (Top of the Bed) items: Like Comforter / Coverlet / Neck Roll / Decorative Sheet Set / Shams etc.

• Curtains

Cutting Department
• Birla Made-ups having 4 Tables for cutting. 2 Tables are on Manual laying of fabric and 2 tables are on auto
laying with machines.
• Cutting production capacity is 6000 sheet sets per day means 30000 mtrs. per day
• Total contractual manpower strength is around 20 and company on roll app 6
• After cutting quality is checked by Quality department.
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Made-ups / Home Furnishing

Stitching and Packing

• Birla Made-ups having 6 lines and each line contains 22 machines.

• Birla Made-ups production capacity is 5000 sheet sets per day means 25000 mtrs. per day
• Total contractual manpower strength is around 280-300 and company on roll app 35.
• Our main customers are Macy’s , ATC, William Sonoma, CHF, AQ Tex , Mytex etc.
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Flow Chart Made-ups

If any shade
Fabric Receipt
variation is observed
in fabric, it is
returned to WH or
Folding. Issue to Cutting

After cutting Checks table marking

bundling is done Cutting as per before layering &
group wise & SO plan finally layer marking
wise before cutting.
Issue to stitching as Issue to
with Job Card Stitching

Distributes Supervisor & QA will

cutting in lines check & ensure the
as per plan sizes as per plan. One
QA for 3 lines
Checking and thread
trimming of each & Thread trimming
every merchandiser. & 100%
checking
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Pressing & Folding

Poly bag packing

100% Poly bags are

Poly bag Packing Audit checked for correct inlay
cards, Poly bags & labels.

Metal Detection

After audit all the packed

Carton Packing goods are sent for carton
packing through metal
All the passed detector
cartons are stamped SKU wise audit (AQL 2.5)
& transfer to FMG

Transfer to FMG

Final Audit (AQL

2.5)

Dispatch
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Made-ups
Made Ups Machine Details:

Sr. No Machine Name QTY Manufacturer

1 Single needle 113 Juki
2 Double needle 11 Juki
3 Overlock 30 Juki
4 Overlock 2 Juki
5 Boiler 6 Ramsons
6 Pressing Table 23 Ramsons
7 Zigzag 5 Juki
8 Zigzag 6 Puff
9 Button Stitch 3 juki
10 Button Hole 3 Juki
11 PINTECK M/C NISHO 1 Nisho/Golden Wheel
12 B/HEMING M/C 1 Nisho
13 Fagoting 11 Golden Wheel
14 Spreading M/C 2 Eastman
15 Hand Cutting M/C 5 Eastman
16 Hydrolic Press 5 Marco
17 Needle detector 2 Hashima
18 Flat bed flat lock m/c (PEGASUS) 5 pegasus
TOTAL MACHINE 234  
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Research & Development

• Swatch card
• Technical Sheet
• Product Feasibility
• Dying Request
• Lot Card

• R & D Daily Report

• R&D - Pending Order Status
• Internal Calibration Certificate
• Master list of Monitoring & Measuring
Equipment’s R&D
• Sample Analysis
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Research & Development

• Shade matching and Dyeing Request

• Execution of Bulk Order
• Data Compilation
• Control and Amendment of Technical Data
• Internal Calibration Procedure

• R&D Weaving Preparatory

• Splitting and Winding
• R&D WEAVING
• Sample Stitching Cutting & Pasting
• Sample Manufacturing Std process
Parameters for Warping, Sizing
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PPC

Production Planning And Control

Planner Merchandising
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PPC
PPC

Spinning Weaving Process

FQIP Dispatch
Planning Planning Planning

• In- • FQIPD
• Dyed (Capacity
• In-House House(Capa (Inspection
65K ) Narrow Wider
city 60K ) 110K Per Width
• White (Capacity Width
• Yarn-Dying Day)
28.5K)
• Out-side
• Yarn – Dyed
• Out-side (Capacity • Finished
(Capacity 16.5K )
50K) Goods • Exports &
(Ware- Brands • Fabrics
House) • Finer • Made-
Fabric Ups
• Suiting &
Shirting
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COSTING & MIS

Costing is the process of estimating and then determining the total cost of producing a
fabric, including the cost of materials, labour and transportation as well as the general
expenses of the operating the business.

INTRODUCTION TO COSTING
1. Cost Components
2. Introduction of costing tools
3. Controlling Area
4. Process flow of material
5. Cost sheet
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COSTING & MIS

1. Cost Components

• Cost = Total amount of money invested in product.

• Price = Amount of money asked / received in ex-change for a product.
• Profit = Price – Cost
• Revenue = Total pf all receipt from the sale of company’s product during a stated period.

A) Type of Cost

• Fixed = Costs that do not get affected by output of business. E.g. Salary / Wages / Rent / Insurance
• Variable = Costs which vary with output of materials. E.g. Raw Material / Utility / Inventory /
packing material / Dyes & Chemicals etc…
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COSTING & MIS

2. Introduction of costing tools

a) Planning & Budgeting :- Yearly planning for next financial year for product wise costing of Apparels
& Bedlinen segment with Cost, Price & revenue.
b) MIS :- Department wise daily & monthly MIS Budgeted Vs. Actual for identifying any deviation if any
for controlling and smoothing department function.
c) Enquiry Costing :- Pre-order costing done against offer price by customer to evaluate the revenue of
the company.
d) Order Costing :- Once order received by marketing and released for production, final costing will be
generated with reference of enquiry costing for change if any.
e) Valuation :- Valuation is process which is done every month for closing stock of last month
considering Actual Cost incurred for manufacturing material for financial results.
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COSTING & MIS

3. Controling Area

List of Major Area

a. Spinning :- Spinning is department which consume cotton as raw material and give finish output as
Yarn. Major control area is Power, Contractor Labour, Stores & Spares Consumption. Also monitoring
output quality, recovery, production deviation against given target.

b. Weaving :- Weaving department raw material is yarn which is converted into fabric (Apparels &
Bedlinen) by machine for apparels 190AJ & RAPIER and for bedlinen 340AJ. Major controlling area is
production output against given target, Wastage, Utility. Production depends on speed and Efficiency
of machine which directly connected with production.

c. Process :- Process is department which is final output of fabric (Ready to Wear). Three major area in
processing Bleaching, Dyeing & Finishing. Major controlling area is Utility (Steam / Water / Power) and
Dyes & Chemicals.
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COSTING & MIS

4) Process Flow of Material

A) Yarn Procurement :- Source of yarn is In-hpouse Spinning & Outside Purchase

B) Winding :- Major role is convert yarn package from Hard to Soft & Vis Versa
C) Warping :- Major role of warping is to make design wise beam from yarn cone

:- Warping beam gets sized in sizing dep. by using chemicals & Utility for smooth
D) Sizing
runing on loom

E) Weaving :- Sized Beam after drowing gets into weaving department for final greige fabric
F) Greige Inspection :- Greige Fabric inspected after weaving for any damages.
G) Processing
:- Bleaching department role is convert greige fabric into bleach form by using
a) Bleaching
chemical & utility
b) Dyeing :- Bleached fabric gets dyed in dyeing department shadewise
c) Finishing :- Dyed Fabric gets finished in finishing department by using finishing chemicals.
H) Finish Inspection :- Finished fabric gets inspected for shade matching and any other damages.
I) Packing :- Inspected material gets packed as per customer requirement.
J) Transfer to Warehouse :- Packed Material gets trasfer to warehouse for storage.
K) Dispatch to end Customer :- As per delivery date final fabric dispatched to customer from warehouse.
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COSTING & MIS

5. Cost Sheet
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Utility

Utility

Power Water Steam Air Natural Gas Thermic Fluid Chilled Water

• 66 KV Switch
• 37TPH • 3 x 6000 CFM • 3 x 500
• Fresh water
• Natural
Yard with AFBC • 45 lacs Tr/Hr
2x10 MVA From GIDC Gas line
Coal Boiler Centrifugal Kcal/Hr Coal VAM
66/11.5 KV Compressor
from THERMOPAK
Gujarat Chiller
Transformer • Recycled • 20TPH • 1x1500 CFM • 3x30 lacs
Water from Gas Kcal/Hr GAS
Agro Screw
• 4.9MW Coal ETRP Waste Boiler Compressor THERMOPAK
(Cap.2.5MLD)
Base Captive

Power Plant
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Maintenance
Maintenance

Spinning Weaving Processing

Mechanical Mechanical Mechanical

& Electrical & Electrical Loom Shed & Electrical Bleaching
Blow Room
Activities Activities Activities
Preparatory Finishing
Warping
Ring frame Colour
Kitchen
Post
Preparatory
Dying
Luwa Plant
Operation &
Maintenance
 43

Logistics
Logistics

Store Warehouse

• Material Inward
• Warehouse
• Material issue/
management
outward
• Good
• Material Send for
inward/outward
Job work
• Job work
• New Material
• Sales Return
Inspection
• Vehicle
• Waste
arrangement
management
 44

Purchase
Receive Purchase Requisition from User Department through SAP / Min-Max
Stocking
If
clarifications
Required,
Check PR in terms of Refer Back
availability in stock & completeness
of specification

Invite quotation by Sending "Request for Quotation" from Approved / Potential

Suppliers (Can be waived for repeat orders & long term contractual agreement
(s), OEM, Dyes and Specific Chemicals, ARC, Authorized Dealers / Distributors,
Statutory Authority approved agency

Take Technical Approval & Prepare Comparative Statement

Review, Negotiate and Approve Supplier. If vendor is not registered with us,
Create new Vendor as per Vendor Selection Process
 45

Purchase

Review, Approve Place PO to Vendor.

Follow up suppliers for timely delivery and keep requisitioned informed, if

getting delayed. Request Finance Dept. to process Advance Payment if
applicable. Arrange Logistics. For Import PO arrange customs clearance.

Review pending PRs > 15 Days & over due POs, determine causes and take
necessary actions to expedite and prevent further delay and prevent
recurrence. Reminder to be sent to suppliers for pending delivery of material
over 07 days from delivery date.

Perform Vendor and Contractor Evaluation on Yearly Basis.

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Purchase Management
Min
Cost &
Max
Payt
Term

Purchase Paym
i m ely Department Max ent &
T
very imu
deli ality Pric m
Qu e
and
User Supplier
Department
 47

Finance
Key Functions:

1. R2R – Record to Reporting

2. Vendor Management – Import & Domestic
3. Statutory Audit, Internal Audit, Management Audit
4. Monthly , Quarterly & Annual Closing of Accounts
5. Budgets – Opex & Capex
6. MIS
7. Taxation – Direct and Indirect
8. Compliances : Companies Act, SEBI, Ind AS
9. Payroll Processing and Employee Payments
10. GST – Returns and Refunds
11. Insurance
12. Asset Accounting
13. Board Meeting Data & AGM Data
14. Annual Report Data
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Information Technology
In comparison to just two decades ago, we’ve significantly changed the way we
communicate, shop and work.

Information technology is backbone of company for 4 simple reasons

1. Communication 2. Efficiency 3. Competitive edge & 4. Economies

• All the processes are tightly mapped through each other starting from Procurement
to Billing using SAP software and Non SAP software's.

• We are having multiple servers to store all the data and provide to user as per the
requirement and availability in the form of various reports. 3 DC –One in Mumbai,
plant and External cloud DC
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Information Technology
Applications

SAP Non – SAP

• MPLS/ILL connections
• Email(office-365)
• MM
• Active directory
• PP
• Domain
• SD
• Security
• FI/CO
• Firewall
• HR Payroll
• Trend Micro
• PM
• Barco
• QM
• LAMS/VMS/CMS
• Payroll
• CCTV
 50

Human Resource
Human Resource

Performance
Management Contract labour
Recuritment Admin
System Management
Training and • Canteen
Leave
Development • Housekeeping
• Staff Poilcy • Transportatio
• Apprentice
Employee n
• Workmen •
Liasoning Travel Desk
Mediclaim Engagement • OHC
Statutory
Compliances
 51

Employee Strengths :-

Total Employee Strength at Jhagadia Site , Bharuch -

• Staff - 235
• Workman - 1700

Total Employee Strength at Head Office , Mumbai -

• Staff - 55
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Engagement Activites & Celebration :-

Glimpse of Diwali Glimpse of Ganesh Tree Plantation For

Celebration Ustav New Joinee
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Thank You