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Internship Activities Report
BBA (Agri-business) Batch 2nd
At
Sapphire Textile Mills Ltd.
Submitted By:
Muhammad Umair Zulfiqar
CMS id: 163-15-0039
Figure 1Emporium-Mall-Sapphire
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Table of Contents
1. Acknowledgment:.................................................................................................................... 7
2. Executive Summary:................................................................................................................ 8
3. Internship Contact Information.............................................................................................. 10
4. Introduction............................................................................................................................ 11
4.1. Overview of Textile Industry of Pakistan ...................................................................... 11
4.2. Overview of Sapphire Textile Limited: ......................................................................... 11
4.3. Vision:............................................................................................................................ 12
4.4. Mission:.......................................................................................................................... 12
4.5. Mentioning few units of Sapphire Group out of 35-units.............................................. 12
5. Reporting Period:................................................................................................................... 13
6. Accomplishments & Work Performed .................................................................................. 14
6.1. Denim Garments Unit: ................................................................................................... 14
6.2. Denim Garment Process:................................................................................................ 14
6.3. Flow chart for Denim Garments: ................................................................................... 14
6.4. Fabric:............................................................................................................................. 15
6.5. CAD: .............................................................................................................................. 15
6.6. Cutting:........................................................................................................................... 15
6.7. Stitching (Panels and Parts): .......................................................................................... 15
6.8. Total approx. 17 parts of each garment:......................................................................... 16
6.9. Washing:......................................................................................................................... 16
6.10. Different washing techniques:.................................................................................... 17
6.11. Dry:............................................................................................................................. 17
6.12. Finishing, Tagging and Packing:................................................................................ 17
6.13. Checking of garments:................................................................................................ 18
7. Weaving Unit:........................................................................................................................ 18
7.1. Weaving Unit Process:................................................................................................... 19
7.2. Weaving Process Flow Chart:........................................................................................ 19
7.3. Warping Department Hierarchy:.................................................................................... 21
7.4. Sizing:............................................................................................................................. 21
7.5. Sizing Department Hierarchy:........................................................................................ 22
7.6. Leasing Process of sizing:.............................................................................................. 22
7.7. Yarn Beam storage:........................................................................................................ 22
7.8. Maintenance Department Hierarchy in weaving unit of Sapphire:................................ 23
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7.9. Drawing-in: .................................................................................................................... 23
7.10. Production Department Hierarchy:............................................................................. 24
7.11. Weaving Loom: .......................................................................................................... 24
7.11.1. Looms with respect to Manufacturer:..................................................................... 24
Itema: ..................................................................................................................................... 25
Jacquard ................................................................................................................................. 25
Tsudokoma............................................................................................................................. 25
7.12. Looms with respect to shedding mechanism:............................................................. 25
Tappet .................................................................................................................................... 25
Dobby:.................................................................................................................................... 25
Jacquard: ................................................................................................................................ 25
7.13. Looms with respect to picking mechanism: ............................................................... 25
Rapier:.................................................................................................................................... 25
Air jet: .................................................................................................................................... 25
7.14. Types of Looms with respect to width: ...................................................................... 26
7.15. Folding or Inspection department in Sapphire: .......................................................... 26
8. Spinning Unit:........................................................................................................................ 26
8.1. Visit to testing Laboratory: ............................................................................................ 26
8.2. Count lea strength product (CLSP) Test: ....................................................................... 27
8.3. Equipments used in this test:.......................................................................................... 27
8.4. Measurement of Fiber length Test: ................................................................................ 27
8.5. Equipments used in this test:.......................................................................................... 27
8.6. Breaking force, Elongation% and tenacity of single yarn Test:..................................... 27
8.7. Equipments used in this test:.......................................................................................... 28
8.8. Spinning Unit Process:................................................................................................... 28
8.9. Flow chart of Spinning Process...................................................................................... 28
8.10. Blow room:................................................................................................................. 29
8.11. Names & Functions of machines used in blow room section: ................................... 29
8.12. Carding: ...................................................................................................................... 29
8.13. Names & functions of machines used in carding section:.......................................... 30
8.14. Comber: ...................................................................................................................... 30
8.14.1. Names & Functions of machines used in Comber section: .................................... 30
8.15. Drawing: ..................................................................................................................... 30
8.16. Simplex:...................................................................................................................... 30
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8.17. Ring: ........................................................................................................................... 30
8.18. Auto-cone: .................................................................................................................. 31
8.19. Packing and dispatch: ................................................................................................. 31
9. Sapphire Finishing Mills Ltd (SFML):.................................................................................. 32
9.1. Sapphire Dairy and SRL Unit: ....................................................................................... 32
10. Sapphire Dairy Farm:......................................................................................................... 33
11. Retail Store of Sapphire:.................................................................................................... 34
11.1. Hierarchy of Sapphire Retail Store............................................................................. 35
12. SFML-2:............................................................................................................................. 35
12.1. HR Division:............................................................................................................... 36
12.1.1. Policies at Sapphire:................................................................................................ 36
12.1.2. Attendance & Evaluation:....................................................................................... 36
12.1.3. Compensation & Benefits:...................................................................................... 36
12.1.4. Accounts: ................................................................................................................ 36
12.2. HR Division Hierarchy............................................................................................... 37
12.3. PD & PPC:.................................................................................................................. 37
12.4. Cutting:....................................................................................................................... 38
12.5. Stitching:..................................................................................................................... 38
12.6. Simple and Hanger stitching system: ......................................................................... 38
12.7. Types of machines used in SFML-2:.......................................................................... 38
12.8. Quality Control Department:...................................................................................... 39
12.8.1. Finishing, Packing & Dispatch:.............................................................................. 39
13. SFML-1:............................................................................................................................. 39
13.1. Flow Chart of SFML-1............................................................................................... 39
13.2. Greige Store:............................................................................................................... 40
13.3. Inspection: .................................................................................................................. 40
13.4. Pretreatment Department:........................................................................................... 40
13.4.1. Singeing: ................................................................................................................. 41
13.4.2. De-sizing:................................................................................................................ 41
13.4.3. Scouring:................................................................................................................. 41
13.4.4. Bleaching: ............................................................................................................... 41
13.5. Dyeing: ....................................................................................................................... 41
13.6. Types of Dyes............................................................................................................. 42
13.6.1. Reactive dye:........................................................................................................... 42
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13.6.2. Vat dye:................................................................................................................... 42
13.6.3. Disperse dye:........................................................................................................... 42
13.7. Finishing:.................................................................................................................... 42
13.7.1. Peaching:................................................................................................................. 42
13.7.2. Sanforizing:............................................................................................................. 43
13.7.3. Curing: .................................................................................................................... 43
13.8. Folding Department:................................................................................................... 43
14. Dyeing unit: ....................................................................................................................... 44
14.1. Dyeing Unit Process:.................................................................................................. 44
14.2. Dyes & chemicals used in Dyeing unit: ..................................................................... 44
14.3. Types of dyes:............................................................................................................. 45
14.4. Machines used in Dyeing unit:................................................................................... 45
14.5. Finishing department of Dyeing:................................................................................ 45
14.5.1. Slitting:.................................................................................................................... 45
14.5.2. Dryer:...................................................................................................................... 46
14.5.3. Raising: ................................................................................................................... 46
14.5.4. Stenter:.................................................................................................................... 46
14.5.5. Compactor:.............................................................................................................. 47
15. Learning & Knowledge I gained from 2-month internship: .............................................. 48
16. Conclusion: ........................................................................................................................ 49
THE END ..................................................................................................................................... 50
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1. Acknowledgment:
Praise be to Al-Mighty Allah, The Lord of Entire Universe. The Beneficent, the Merciful, Who is
the entire source of knowledge and wisdom. For the completion of this report I am indebted to
plenty of people for their sincere cooperation as well that they extended to me at various stages.
First and foremost problem that I faced is the completion of this report is not gathering data because
of the very cooperative and very professional support of supervisors, entire team and every single
Sapphire employees who gave us their valuable time from their busy schedules. Due to their efforts
I am able to have much knowhow about Sapphire’s processes.
But the main issue I had face was writing the content into report form with sequence because of
our group done internship in inverse working flow e.g. we started from final garment and go back
to the raw form where from the actual process starts like spinning, ginning, warping etc.
Anyhow, it is in fact a matter of great pleasure for me to express my sincere gratitude to our worthy
coordinator Sir Dr. Waqar Akram and Sukkur IBA University management team who put their
efforts for all arrangements of this internship program.
Finally, I am very honor to my Mother and my Uncle Mian Javed from North Carolina, United
States of America (my guardian) and my younger siblings who believed that I can do what I want
and supported me at every single step of my life. My entire achievements till today belongs to my
Mother and Grandmother and my younger siblings who stood like a stone against heavy storm.
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2. Executive Summary:
As we know that textile sectors have played a main role and major contribution in Pakistan
Economy, so, Sapphire Textile is also one of them which is namely known as Sapphire Group of
Pakistan. It was started in 1960 in East Bengal. Well, Sapphire group is divided into many units
including 3weaving units, 11-spinning units, 4-processing units consisting of knits, fiber dyeing,
yarn dyeing and one for woven, whereas 2-stitching units (knits and home textile) and 3-units of
power generation. Sapphire has also started the electric company in 2009 December named with
“Sapphire Electric Company” located in Sheikhupura, Punjab, having capacity of 225 MW
(Gross).
Journey of our internship started from Sapphire Textile Mills Ferozwatwan, Sheikhupura near
Lahore where we were engaged in different four units of Sapphire for one month, in which 1st
week was all about Denim garments in which we got to know about the entire processes of denim
garment making then our 2nd
week was all about Denim fabric that gave us the knowledge about
processes involved in yarn making and then denim fabrics, 3rd
week we started Weaving unit and
seen all the weaving process there and at last 4th
week went to the Spinning unit. In STML our
reporting time was from 9 AM to 5 PM along with their free transportation and accommodation as
well. After passing 1st
month, we moved towards Sapphire Finishing Mills, Lahore where we spent
2nd
month of our internship along with lot of new experiences and learnings, at SFML our timetable
was divided into 4-units, one 1st
week was 2-days in dairy unit and 4-day in Sapphire Retail Limited
and last one day of working week at STM 8, in 2nd
week we went for SFML-2 unit and then our
3rd
week we went to SFML-1 then our last week was being held in Sapphire Fiber & Dyeing unit
where we analyzed the process of dyeing and drying knitted fabric.
After completion of 2 months at Sapphire Textile and Sapphire Finishing Mills, the journey of our
internship came to an end and showered us with new learnings, splendid experiences regarding
textile instead of our no-agricultural background.
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My 2 months of internship at Sapphire made me feel that where I was before and where I stand
now. This was a big difference between theory at the University and practical life at industries.
During my internship at textile industry showed way of creating better links with professional
network to be connected with. I found the best platform for internship in brand company
“SAPPHIRE” for me where I put my efforts to get real work experiences to explore my interests,
polish my skills, and somehow develop professional skills and competencies which are going to
contribute more in upcoming life in job field.
After an experience of 2-months internship, Sapphire has become the one of my dream companies
and I love to work there because of Sapphire’s reputation around the world and their main concern
for employees’ safety along with their best coordination, guidance to new employees and existing
as well.
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3. Internship Contact Information
Student’s Information
Student Name: Muhammad Umair Zulfiqar
Student I.D: 163-15-0039
Student Email: umair.agriba17@iba-suk.edu.pk
Mobile Number: 0300-6633281
Organization’s Information
Internship organization Name Sapphire Textile Mills Limited.
Mailing address 4th Floor Tricon Corporate Center Service Lane
Behind Siddiq Trade Center، Jail Road, Block H
Gulberg 2, Lahore, Punjab
Internship Supervisor’s information
Internship Supervisor Name (Head office
Lahore)
Ma’am Saleha
Internship Supervisor Email saleha.ashfaq@sapphire.com.pk
Mobile Number 0303-4449670
Faculty Sponsor’s information
Faculty Sponsor Name: Sir Dr. Waqar Akram
Faculty Sponsor Contact: 0323-9643876
Faculty Sponsor Email: Waqar.akram@iba-suk.edu.pk
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4. Introduction
4.1. Overview of Textile Industry of Pakistan
Since long, Textile sector of Pakistan is remained a backbone along with provision of employment
and export revenues. Pakistan Textile sector actually contributes 57% in country’s export where
this sector has been a second largest which provides employment. Textile sector of Pakistan has
share of 8.5% in Pakistan GDP and the 8th
largest country which exports the more textile
commodities in Asia.
Pakistan is 4th
large country which produces cotton and 3rd
large in consumption of cotton. Clothing
and Textile Industry have been remained major driver forces of economy since last 50 years and
in future, it will be a main engine for Pakistan’s economy’s future growth. Overall Textile sector
in Pakistan is doing its best but at somewhere it lacks such as no proper department of Research &
Development in cotton sector, no adaptably of modernized equipment, energy and electricity crisis,
On the other hand, Pakistani textile sector is working to overcome these issues.
4.2. Overview of Sapphire Textile Limited:
Sapphire group is textile based industry situated at Lahore, Pakistan which is set as vertically
integrated textile group, manufacturing of cotton, fabric, yarn, and finished garments. Sapphire
textile was found in 1940 in Calcutta, India then it moved towards East & West Pakistan during
time of partition and started its first unit of spinning in West Pakistan which is known as Pakistan
right now. Mian Muhammad Abdullah is the CEO of Sapphire group.
Basically Sapphire group is divided into units including 11-spinning, 3-weaving, 4-processing, 2-
stitching and 3-power generation units and overall Sapphire Group has now 35-units. Apart from
textile sector, Sapphire Group has also indulged in Dairy and Power Generation at Lahore. Well,
the products of Sapphire are exported internationally around 35 countries and Sapphire Group has
an employment of 16000 people.
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4.3. Vision:
To be one of the premier textile company recognized for leadership in technology, flexibility,
responsiveness and quality. Our customers will share in our success through innovative
manufacturing, certifiable quality, exceptional services and creative alliances. Structured to
maintain in depth competence and knowledge about our business, our customers and worldwide
markets.
Our workforce will be the most efficient in industry through multiple skill learning, the fostering
of learning and the fostering of teamwork and the security of the safest work environment possible
recognized as excellent citizen in the local and regional community through our financial and
human resources support and our sensitivity to the environment.
(Source: From official website of Sapphire industry-- http://www.sapphire.com.pk/stml/ )
4.4. Mission:
Our mission is to be recognized as premier supplier to the markets we serve by providing quality
yarns, fabrics and other textile products to satisfy the needs of our customers. Our mission will be
accomplished through excellence in customer service, sales and manufacturing supported by
teamwork of all associates. We will continue our tradition of honesty, fairness and integrity in
relationship with our customers, associates, shareholders, community and stakeholders.
(Source: From official website of Sapphire industry-- http://www.sapphire.com.pk/stml/ )
4.5. Mentioning few units of Sapphire Group out of 35-units
• Reliance Cotton Spinning Mills Limited
• Sapphire Textile Mills Limited
• Sapphire Electric Company Limited
• Sapphire Finishing Mills Limited
• Sapphire Dairies (private) Limited
• Sapphire Power Generation Limited
• Amer Cotton Mills (private) Limited
• Diamond Fabrics Limited
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• Galaxy Agencies (private) Limited
• Hermes Power (private) Limited
• Sapphire Wind Power Company Limited
(Source: From official website of Sapphire industry-- http://www.sapphire.com.pk/stml/
5. Reporting Period:
The tenure of our internship was designed for 2-months. Our internship started 21st January till
16th
of March. 1st month of internship was planned at Sapphire Textile Mills limited (STML),
Ferozwatwan, Sheikhupura. Where our 1st week was started in from 21st January to 26th January in
which we learnt about the process and practices about denim garments where the work and processes
of denim jeans pants and skirts were going, then 2nd week started in denim fabric from January 28th
to February 2nd, our 3rd week started in weaving in which we learnt about the processes and practices
about weaving from 4th February to February 9th and then at last week at STML was in spinning in
which we saw yarn manufacturing processes, started from 11th February to 16th February.
Now, it was time to move towards Lahore for 5th
week of internship at Sapphire Finishing Mills
Limited (SFML) at Raiwind Road, Lahore. Our 5th
week of internship was started from 18th February
to 23rd February 2-days in dairy unit and 4-day in Sapphire Retail Limited and last one day of working
week at STM 8, then 2nd week in SFML was started from 25th February to 2nd march in SFML-2 unit,
in 3rd week we spent in SFML-1 where we learnt about the pretreatment processes and our last week
started from 11th march to 16th march in at Sapphire Fiber & Dyeing unit where we analyzed the
process of dyeing and drying knitted fabric.
So in this way, our 2-month period of internship came to an end productively.
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6. Accomplishments & Work Performed
6.1. Denim Garments Unit:
This unit of Sapphire is actually located in Ferozwatwan near Sheikhupura. We started our internship
from this unit for 1-week, in which we did activities of garments manufacturing till finishing and
packing.
6.2. Denim Garment Process:
The main work being done in this unit was the manufacturing of jeans pants and skirts which were
mostly exported in bulk amount according to order of customer.
6.3. Flow chart for Denim Garments:
Fabric
CAD
Cutting
Sewing and Stitching
Washing
Drying
Finishing & Packing
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6.4. Fabric:
Firstly, fabric is received from different suppliers in market and from Sapphires own produce as well.
the customer contacts with the marketing people in marketing department of Sapphire for order then
an email or list of order is sent to the mill manager, quality head of denim garments as per customer
demand including quality and quantity of product the customer wants. Different types of different
fabrics according to their weight and ounces.
6.5. CAD:
In this section, multiple designs and patterns are developed through software as per customer standards
including patterns such as coin pocket (1), fly part, back panel (L+R), front panel (L+R), Pocket bag
etc.
These process includes PPR (pre-production run), analysis, pattern modification, marker, identification
and bundling.
6.6. Cutting:
After developing designs in cad system, the fabric is brought in cutting department for further process.
Fabric is kept and makes spots on selected parts of fabric with marker then the process of cutting take
place on fabric’s marked spots with the help of electrical cutter machines.
Computer used in cuttings were Toka Tex, Orox cutter and Spreader.
6.7. Stitching (Panels and Parts):
In this section the cutting parts from cutting department are brought and are stitched in order to join
two cut parts with the help of multiple sewing machines like single, double, triple and multiple (having
around 26 needles) needle lock stitch (used for permanent fix), overlock sewing machine, bar-tack
machine, button machine, pocket setter, folders machines and chain stich (flexible fix).
Panels and parts were included: Front, back, left & right side, seams (in & out)
Line Balancing system used in stitching 1) Unit flow system 2) Bundle system
Bundles -> small parts assembly -> Front small parts & back small parts-> attach main panels.
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6.8. Total approx. 17 parts of each garment:
 Belt
 Loops
 Back pockets 2 (Left & Right)
 Back Yoke 2 (Left & Right)
 Coin pocket
 Facings 2 (Left & Right)
 Fly 2
 Pocket bags 2
 Front and back panels 2
6.9. Washing:
In this the fabric is washed through passing from
different process for fading the shades in jeans
such as soaking-- in which we soak the fabric in
solvent similar to water, chemical wash-in
which fabric is washed into different chemical
mixture for the bleach, soda ash, brightener,
softeners of fabric, bio-polishing, enzymes, anti-
microbial agents, anti-back strainers then after
the washing process the fabric is being dried
through drier machines.
Washings depends upon looks. Fresh look, 6 month, 1, 2,3,5,10,20 years. It’s indigo, black or any other
color varies according to garments age.
Wash counter: Resin wash or without water chemical spray used.
Figure 2 Washing machine
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6.10. Different washing techniques:
 Resin wash
 Bleach wash
 Stone wash
 Stone & bleach wash
 Enzymes wash
 Stone enzyme wash.
6.11. Dry:
In this section jeans pants are brought where
patches are made with help of scraping sand paper
and laser machines as per customer requirement.
Machines used for mechanical and chemical
procedures. Sand papers use for giving shades
mechanically and KMnO4 Use for whiter look
and to neutralize the dust of fabric reactions.
Rigid garments: Laser-> Whiskers->Scraping-
>First wash->Spray->Neutralize->2nd
wash->Dry.
6.12. Finishing, Tagging and Packing:
In finishing department, the final product is being inspected for finding the faults to be repair then goes
in tagging section in which different instructions and prices are applied through labelling cards on jeans
as per customer demand and finally after the entire audition the order is packed and dispatched to
customer.
Revert and stud area, labeling, pressing, iron steam, toppers (steam+air)
Figure 3 Denim Pants Dryers
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6.13. Checking of garments:
 Shade
 Shape
 Accessories
 Specifications and measurements
 Sundries (Paper+Tags)
 Stitch
 Folding and Packing
7. Weaving Unit:
After Denim garment unit, we came to this unit, in which we leant about the activities involved in
making fabric through passing yarn from multiple machines till fabric dispatch.
Physical counter/sample
Documented written instruction
Mechanical Head (Machine)
Production Head (Man-power)
PD Head ( Production technician)
CAD Head (Pattern)
QA Person (Assurance as per given details)
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7.1. Weaving Unit Process:
It is basically a process in which we make fabric through interlacing sets of yarn (warp and weft).
Weaving is almost done on looms and consist of 3-functions including shedding, beating and
picking up.
7.2. Weaving Process Flow Chart:
Warping of yarn: In this, They convert
smaller packages of yarn into beams
through machine which has main 2-parts,
first is creel in which cones are hanged into
spindles or skewers and in creel there are
devices attached in creel which identify the
broken yarn and we can calculate creel
capacity through formula:
Creel Capacity= No: of rods *
No: of spindles * 2. And other part is
headstock in which beam is attached on
which the entire yarns coming from
creel are wrapped.
Figure 4 Warping of yarn
Warping of Yarn
Sizing
Drawing -
Weaving Loom
Folding (Inspection)
Packing
Dispatch
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2 Warping room
There are two types of warping, one is direct In which the yarn is wounded parallel on warping
beam and all the yarns are wound at once and used for making fabric of single color. It is also
known as high speed warping or V-type and second is indirect warping in
Which equal length of yarn is fist wound in
Small sections or sheets on drum then from the drum it is transferred to the beam. It is also used
for making fancy fabrics and for repetition of same design. It is also known as H-type Warping
Hierarchy. There are four machines of warping from which three (3) are Benninger and one (1) is
Tsudokoma.
At Sapphire, there is corn form of yarn with the weight of approximately 4.146 pounds and 5.5
pounds.
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7.3. Warping Department Hierarchy:
7.4. Sizing:
It is a process in which we prepare the yarn to bear
the weaver and tear that is going to happen in
weaving shed. Warp beam is raw material of sizing
and weaver is output of sizing. Sizing is done
through using four additives or chemicals including
Starch: which helps to give external strength of
yarn, Poly vinyl Alcohol (PVA): which helps out
to give internal strength of thread, Acrylic: a
binding agent which helps to increase the binding
of recipe towards yarn and Wax: a softening agent
which helps to improve the binding.
Mills Manager
Weaving Manager
Preparatory Incharge
Senior Warper
Warper
Assistant Warper
Helper
Figure 5 Sizing Department
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7.5. Sizing Department Hierarchy:
7.6. Leasing Process of sizing:
7.7. Yarn Beam storage:
There are three stacker machines.Stacker-1 has a
capacity of carrying the 130 beams.Stacker-2 has a
capacity of carrying the 70 beams and stacker-3
has also same capacity of carrying the 70 beams.
Thread
Creel
Sizing
Leasing
Winding
Figure 6 Yarn Beam Storage Area
Preparatory
In charge
Sizing
In charge
Sizer Back Sizer Helper Mixer Man
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7.8. Maintenance Department Hierarchy in weaving unit of Sapphire:
7.9. Drawing-in:
In this the beam is kept on beam stand and a person with entire details of design starts the
drawing in process including the parts like
droppers, healed wires, frame and reeds. Sized
beam is input of drawing-in and pattern is output.
There are manually and automat machines, from
which Sapphire has one automat machines
because of the high cost of machine and have
many manual machines .The speed of manual
machine is 10 to 15 ends per minute and the
speed of automat machine is 140 per minute and
there are three sheds with the production of
180,000 meter in a day.
Maintenance
Foreman
(Professional)
Deputy F.
Assistant F.
Foreman
(Jacquard) Deputy F.
Assistant F.
Foreman
(Tovot)
Figure 7 Drawing-in Machine
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7.10. Production Department Hierarchy:
7.11. Weaving Loom:
It is actually a process in which we form a cloth by interlacing strands of yarn or on looms by
interlacing warp and filling threads
through different machines (looms)
defined below:
7.11.1. Looms with respect to
Manufacturer:
Picanol: In sapphire, the total number of
Picanol machines is 72, picanol
machine is available in two models. One
is optimax and other is omnipus, from
which there are 12 optimax and 60
omniplus machines and are kept in shed number-1.
Production In charge
Shift In charge
Beam Gaiter
Weaver
Helper
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Weaving Loom Department Toyota: In Sapphire, the total number of Toyota machines
is 48 and is available in one only model of JAT-810. There are 36 machines with 340 cm
and 12 machines with 280 cm and are kept in shed-2.
Itema: In Sapphire, the total number of itema machines is 2 available, with only one model of A-
950 and kept in shed-1
Jacquard (Donnier): In Sapphire, the total number of jacquard machines is 4 available, with
model of Staubli-G1000 and Stable-Hesta and kept at shed-2.
Tsudokoma: In Sapphire, the total number of Tsudokoma machines is 237 available, with two
model of Zax-9100 HD professional and Zax-9200 master, from which there are 206 Zax-
9100 HD professional machines and 31 Zax-9200 master
machines.
7.12. Looms with respect to shedding
mechanism:
Tappet: it works for simple designs has 7-frames to
work on it.
Dobby: it works for technical designs and has 16 frames.
Jacquard: it works for complex designs and has no
frame, no limits.
7.13. Looms with respect to picking mechanism:
Rapier: It contains needles. It pushes the weft through needles.
Air jet: It contains compressor which forces weft through air.
3Working of Jacquard Machine
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7.14. Types of Looms with respect to width:
There are looms w.r.t to with are 190 cm, 210 cm, 280 cm, 340 cm, and 360 cm.
7.15. Folding or Inspection department in Sapphire:
There are two sheds, one is narrow
and other is wider. In this we check out cloth
properly and tries to find the fault in cloth and
remove fault. But if at one stage the fault is
mistakenly missed then there is re-inspection
of cloth because of customer standards. Fault
or tension can be occurred due to shade, reed,
emery roller, cloth roller etc.
8. Spinning Unit:
This unit of sapphire is located in ferozwatwan near Sheikhupura. In this we firstly visited to the
laboratory where we did different testing and then we moved to the spinning process, in which
yarn is made through passing from multiple process and machines. So first we move to laboratory
testing and then spinning process.
8.1. Visit to testing Laboratory:
In this department we are going to make different tests like fiber testing, yarn testing etc. so we
take few tests defined below:
27 | P a g e
8.2. Count lea strength product (CLSP) Test:
In this we will find CLSP through finding yarn lea strength and yarn count. For this
testing we have to take sample of 120 yards lea and we make this sample through
using electronic machine names as ” wrapping reel lea maker”, So through this
method we can find the CLSP value.
8.3. Equipments used in this test:
Elestretch XT, wrapping reel and weighing balance—these Equipments are used
to find CLSP value
8.4. Measurement of Fiber length Test:
In this test, we scan beard photoelectrically through using fibro-graph, then we pass the light
intensity through beard at given position, used as number fibers which enhance to that distance
from comb, then the density of sample is potted or canned against comb distance to provide fibro
gram. So in this way we take measurement of fiber length.
8.5. Equipments used in this test:
Fibro-graph—used for taking measurement of fiber length
8.6. Breaking force, Elongation% and tenacity of single yarn Test:
In this test, we basically do activities such as we
make continuous drawing-off yarn, then we make
the thread insertion through air jet. In next section
we do press yarn tightly and elongate till its broken
condition by rollers and in last we remove the
remaining thread pieces into container full of waste
through using compressed air. In this test the
samples are bobbins and cones.
Report of Breaking Force & Elongation made
in laboratory testing
Elestretch XT
28 | P a g e
8.7. Equipments used in this test:
USTER Tensojet—used for single yarn elongation, force breaking.
8.8. Spinning Unit Process:
It’s basically the process in which we take a raw cotton and convert it into yarn which is further
used to make cloth. In spinning unit if there are faults being present in yarn and not found or
identified before weaving or other process then it’s going to be very risky and costly to the
manufacture and spinning process is also known as heart of textile. The Common faults found in
yarn are hairy yarn, contaminated yarn, low yarn strength, thickness and thinness of yarn etc.
further the detailed flow chart of spinning is explained below:
8.9. Flow chart of Spinning Process
BlowRoom
Carding
Comber
Drawing
Simplex
Ring
Auto cone
Packing & Dispatch
29 | P a g e
8.10. Blow room:
It is the initial process of yarn production being processed in Spinning Mills, in which cotton bales
are taken up to blow room for opening and cleaning of cotton bales. Input of blow room is cotton
bales and output is small cotton/tuft. The formation of cotton bale basically is compressing the
cotton. In sapphire blow room they use air current which transfer through pipeline for flowing the
cotton tuft from one machine to another machine.
When there is less use of manual handling than there is more quality of cotton bales. There are
more chances of 1.5% or 7% trash available in cotton bales. there are few basic operations being
performed in blow room are opening the cotton bales for further process, removing of the many
impurities like dust, plastics contamination, tiny broken seeds etc. left in fiber with the help of
machines, detecting metal object in fiber and mixing, blending of different grades of cotton to
make a same.
8.11. Names & Functions of machines used in blow room section:
UNIFLOC. A 11- used for opening cotton bales
UNICLEAN. B 12- works for cleaning the micro tuft
UNIMIX.B 76- ensures homogenous mixing of cotton bale feed including 8 chambers
UNISTORE A.7- combined storage, opening and cleaning machine process
LOPTEX & X-pect 4- used for removing trash and contamination sorting machine
8.12. Carding:
In this section the output of blow room (cotton tuft) is brought to carding section and transformed
into sliver (output of carding) with the help of machines available in carding in sapphire. Carding
is done for many purposes such as: fiber individual itiozation, formation of sliver, cleaning of fiber,
blending of fiber, removing naps of fiber, fiber parralizaton. At Sapphire, there are total 26
machines in Carding Section out of which 18 machines with C-70 model and 8 machines with C-
51 model.
30 | P a g e
8.13. Names & functions of machines used in carding section:
Card C-70 & C-51: both models mainly used for the formation of sliver
8.14. Comber:
In this section we use comber which mainly coverts lap (input)
into combed silver (output) and also used for combing fibers,
creating uniformity in yarn, works to remove the short fiber
through using combs in attached in machine.
8.14.1. Names & Functions of machines used in
Comber section:
Comber Machine
UNIlap—used in comber section
8.15. Drawing:
It’s procedure in which multiple silvers are being transferred through rollers to do doubling and
drafting in order to improve the unevenness of sliver and make parralizaton of fibers through
vanishing the wrists in fiber.
8.16. Simplex:
In this process fibers (slivers) are changed into roving. In simplex section many operations are
being done such as twisting in which we make fibers together twisting and winding in which
rovings are wrapped on bobbins and many more like creeling, drafting etc. in simplex the output
is roving and input is sliver.
8.17. Ring:
After simplex, roving is brought here and being converted into yarn then will be transferred further
into next section where there will be winding of yarn on cone and machines used in ring section
create more heat.
31 | P a g e
8.18. Auto-cone:
It is second last step in which conversion of ring bobbins is done into big packages or cones
throughout machines considering required weight and length and also improvement of yarn quality
is focused during operation and finally cones are sent to packing section for further procedure.
8.19. Packing and dispatch:
In sapphire before packing, the cones are being checked into blue laser light in order to identify
the faults in yarn and after assuring the faults cones are ready to be packed in bags. Lastly after
completion of documentation and revising standards about product the customer wants, the bags
are being marked with name to representing industry and now the product is ready to dispatch the
customer.
Packing Area
32 | P a g e
9. Sapphire Finishing Mills Ltd (SFML):
After spending 1-month in STML at Ferozwatwan then we moved towards SFML Lahore where
we visited 4-units including SFML-1 unit, Dyeing unit, Dairy+SRL unit, SFML-2 unit.
4 With Sapphire Dairy Farm's Veterinary Chief Dr. Naveed & Farm Administrator Mr. Asif
9.1. Sapphire Dairy and SRL Unit:
This is unit of sapphire after dyeing unit where we spent the 2-days of week in dairy farm in which
we learnt about activities done in dairy farm about providing milk, keeping cows etc. and then rest
of 4-days of week, we went to Sapphire retail store. So first we are moving to Sapphire Dairy Farm.
33 | P a g e
10.Sapphire Dairy Farm:
Sapphire dairy is one of the big sector in field of dairies in Pakistan which belongs to Sapphire
group of industries. According to report the annual production of sapphire dairies is approximately
38 billion. Basically this sector was formed in 2008, keeping in mind that we have to provide
better, pure and hygiene milk to the people of Pakistan. If we look at sapphire dairy farm, then
there are different species of cows such as Jersey & Holstein from Australia. In sapphire, the cows
are being tagged or attached a number in ears so that they can easily identify cows.
In sapphire dairy farm, Cows are milked 3-times in a day whereas, the entire milk production from
milking cows is approximately 70000 to 75000 liters in a day. In sapphire the cows are being
milked in a way that all milking cows are brought into room named with “milking parlor” where
cows are milked with the help of milking equipment being attached in cows udders after the
cleaning udders of cows, then the milk is sent to chiller room through passing from pipes.
The milking parlor in sapphire has capacity of keeping 40-cows milked at same time and one cow
takes maximum 15 minutes to provide milk, well after milking all cows, the milking parlor room
is cleaned with clean in Place (CIP) system. The best thing about sapphire dairy farm is that there
is no concept of hand milking because of technology which is most beneficial to them.
In sapphire, when the cows are brought into farm then then all are kept for 40-days known as
“Quarantine process” in which they see either the cows are out of disease or involved in disease,
then the cows which are involved in disease are being vaccinated in order to take them out of
danger or to stop disease from spreading towards other animals and then remaining fine cows are
sent to shed.
34 | P a g e
11.Retail Store of Sapphire:
This is mainly known as retail store where the planning of future prediction is predicted for next
season such as what kind of trends, design, style, and color should be set for launching in market.
After the work of designing, the textile design is set up through using Photoshop then goes for
print. There are employees such as sketcher and plotters who develop different things through
sketching like KHAKHA and plotter share information about embroidery.
The basic purpose of this retail store is to reach the standards of customer which he wants to launch
in market about designs, style, patterns, colors etc. there are many artists, designers, printing
makers, sketchers are present in form of team who work on single product to make it better,
attractive and valuable to be liked by customers.
5 Sapphire Retail Head Office- Tricon Corporate Center, Lahore
35 | P a g e
11.1. Hierarchy of Sapphire Retail Store
12.SFML-2:
This was our last unit in Lahore where our internship has come to an end. In this unit
almost same processing and works were done such as cutting, stitching etc but at
somewhere, the techniques and terms were bit different. So we start in this unit from
HR division, few other departments mentioned below:
Director
General Manager
Deputy General Manager
Manager
Deputy Manager
Senior Asst. Manager
Asst. Manager
Officer
Supervisor
Pattern Master
Cutting Master
Stitching Master
Helper
36 | P a g e
12.1. HR Division:
12.1.1. Policies at Sapphire:
12.1.2. Attendance & Evaluation:
If we focus on policies made by Sapphire for employees & staff working there is very difficult to
handle because main purpose of harsh policies is to be the presence of employees because they are
the big revenue and also there is 24 hours working in sapphire that’s why sapphire can’t bear the
absence of employees and worker, suppose if employees who do entry right after 12:00 AM then
their day is calculated as half da but if they come after 12:30 AM they are absent for whole day
and sapphire never compromise in case of attendance & absence of employees.
In sapphire the evaluation of existed & new employees is evaluated throughout noticing their
behavior, performance, targets achievements and after receiving ratings on evaluation form from
HOD then employees are being decided either to hire or fire for job.
12.1.3. Compensation & Benefits:
In sapphire the employees are awarded with multiple benefits and rewards which are not in cash
but in form of bonuses, foreign tours etc. for the employees’ motivation and benefits such as free
transportation, free lunch & accommodation is free as well.
12.1.4. Accounts:
In sapphire they mainly look accounts such as inventory, production and financial accounts. Here
is 1st
inventory accounts-in which they manage accounts related to raw material of fabric store &
main store like purchasing of local fabric and imported fabric as well as packing material is done
through cooperation with MPC departments and other departments. They also have some amount
in cash for spending on daily operation such as transport petrol, daily expense of maintenance etc.
In Sapphire, when there is time audition then an email is sent to head department by accounting
department for the material inspection and auditing of each department is audited monthly and
once year a third part is hired for auditing in sapphire, in sapphire there is an activity being done
which is post-costing in which they do analyze the costing of from initial purchase of product till
it’s dispatched time.
37 | P a g e
12.2. HR Division Hierarchy
12.3. PD & PPC:
In sapphire there is department named with Product development which works with customer
through marketing department, basically the PD develops the product sample as per customer
standards then PD send that sample to customer through marketing people if customer approves
the sample then the further process is started on customer’s order. There is also another department
named with Production Planning Control which does planning, monitoring and controlling through
the procedure of product development.
This department also works with customer through marketing department, this department
basically does planning on basis of previous records, audition and reports of PPC department which
help PPC department to work better and do execute the departments of cutting, stitching and
finishing through time and action dates given to them.
Manager -2
Senior Deputy Manager - 3
Deputy Manager -3
Senior Asst. Manager -4
Asst. Manager -4
Junior Asst. Manager -5
MTO- 5
Supervisors-5
38 | P a g e
12.4. Cutting:
This is department of SFML-2 unit where pieces are cut down through using electric machines,
here is mostly use of twill fabric and few twill fabrics are washed whereas few don’t need of
washing because of softness. The fabric is sent to Gerber Garment Technology department after
measuring width and cut plan is given to GGT department for switching to next step towards
stitching department as per given time duration and action plan.
12.5. Stitching:
In this section the cut pieces are brought from cutting department, as per stitching schedule the
process is started in which firstly tags are stitched on pants, jackets and in this way after collar,
pleat, labels etc. and two types of stitching are done in SFML-2 as under:
12.6. Simple and Hanger stitching system:
In simple stitching system the work being done was almost same but there were some differences
like the stitched pieces like tags, collar pieces were transferred through trollies to next stich
machine and main problem of simple stitch is disturbance of trollies in a way employees pass by
where as in hanger stitching system those stitched pieces were transferred through hanged hangers
to another but the problem of hanger stitching system is, if there is an absence of one employee
then there will be hindrance to other employees as well due to hangers passing by absent employee
but it’s time saving system where as simple stitching consumes time
12.7. Types of machines used in SFML-2:
Single Needle---—used for light fabric, hard and single plie with model of 7200, 7220 and 7300.
Double Needle---used for pocket attachment and hamming sleeves bottom
Fido Light & Heavy—used for both light and heavy fabric
Kansai—used for belt attachment
39 | P a g e
12.8. Quality Control Department:
After completion of stitching process, the garment is brought in this section where the stitching
quality along with measurement and garment style is checked, in this section garment’s stitching
is check either it is stitched properly or not than with the help of clipper the extra threads hanging
or left in garments are cut for garments beauty and then finally garments is passed to next section
through QC pass sticker. In a day 3-times a line is checked working QC section.
12.8.1. Finishing, Packing & Dispatch:
In finishing garments is brought and auditing is done internally, then garments is sent to packing
section where as per customer standards garments is packed with different tags, labels then packing
is checked regarding boxes style, design, quantity per box, different cards of instructions labelled
on boxes and after final audit from third party, the boxes are dispatched to the customer.
13.SFML-1:
It is a unit of sapphire, located at Raiwind road, Lahore. In this unit we have done activities such
as visit to store, the procedure followed in pretreatment department till dispatching the product and
further is defined below:
13.1. Flow Chart of SFML-1
Greige Store
Pretreatment
Dyeing
Finishing
Folding
Packing & Dispatch
40 | P a g e
13.2. Greige Store:
It is basically store where greige fabric is being brought from weaving mill. While receiving greige
fabric a supplier provides gate pass, packing list which contains entire information about fabric.
The SFML fabric suppliers: Ahmed Fine, Ahmed Hassan, Fazal Rehman, Shafi Textile, Fatima
Enterprises and STML.
13.3. Inspection:
Inspection actually helps to find out faults in fabric such as yarn fault (color variations,
contamination), the fabric which is brought in SFML is of a quality grade and 10% inspection is
taken fabric and also inspection varies according to fabric quantity. In sapphire finishing mills
4point American system is used for grading of fabric inspection. After the entire inspection the
fabric is again sent to store room in dry area and space in fabric store department is 6 to 7 lack
meters and after multiple processes fabric is issued and brought to pretreatment department for
further process.
13.4. Pretreatment Department:
The functions done in this section are defined below
• Singeing
• De-sizing
• Scouring
• Bleaching
Pretreatment Department
41 | P a g e
13.4.1. Singeing:
It’s a process in pretreatment in this we burn the loosest fabrics which are not bound tightly.
Singeing is being done through transferring the fabric from burning flame at maximum speed.
Singeing is done in two ways one is plate singeing and second is roller singeing.
Machines used in singeing process:
Perble singeing- imported from japan
Osthoff singeing-imported from Germany
13.4.2. De-sizing:
It is done for removing the size or starch material from warp yarn through using the few process
such as acid de-sizing, enzymatic de-sizing and oxidative de-sizing. De-sizing is also done for
many purposed such as increasing the power of fabric absorbency.
13.4.3. Scouring:
This kind of treatment is mostly done and preferred for removing the impurities such as dust, greasy
material, lubricant material, waxes material or leaf particles throughout wet treatment in order to
avoid the disturbance with further process like finishing and dyeing. After scouring fabric is
washed so that the chemicals can be removed.
13.4.4. Bleaching:
This process is generally done for changing the fabric into whiteness of fabric, enhancing shininess,
improve smoothness, increasing power fiber to absorb dye through using bleaching chemicals such
as H2o2, NaOCL etc.
13.5. Dyeing:
After pretreatment process fabric is brought to dyeing section where it is dyed according to required
color through passing from machines. There is also dyeing lab known as lap dip where we make
and develop multiple recipes as per customer standards and is good for dyeing the fabric in small
amount before dyeing on bulk production
42 | P a g e
13.6. Types of Dyes
13.6.1. Reactive dye:
This kind of dyeing is only used for cotton fabric and is good for high wet fastness because of the
chemical bonding of dyes and fibers with each other and are soluble in water, these dyes are cheap in
price
13.6.2. Vat dye:
It is also used for cotton fabric as reactive but vat dyes are insoluble in water, vat dyes are also
expensive in terms of price. Sometimes, these dyes are ignored due to causing skin diseases.
13.6.3. Disperse dye:
These dyes are used for polyester fabric and are insoluble in water and are applicable in acidic
conditions. Dyeing of Disperse dyes is done with high temperature about 210-220 Celsius degree
and these dyes can be economical.
13.7. Finishing:
The functions done in this section are defined below:
• Peaching
• Sanforizing
• Curing
13.7.1. Peaching:
There are 9 peaching machines in sapphire which are used to give soften touch to fabric through
entering fabric into machine in which with the availability of small steam spray pipes fabric is
given a moisture in small amount for fabric softness then the fluff attached with fabric is removed
with the help of brush rollers.
43 | P a g e
13.7.2. Sanforizing:
In this section there are 3 Sanforizing machines at Sapphire which strengths fabric like iron
through entering fabric into machine in which water is showered in order to wet the fabric for
evenness of moisture in fabric then passing fabric from rubber belt which is pressed with steam
heated roller for fabric shrinkage, after this fabric is dried with drying cylinders which are heated
up with multiple steams and then fabric is passed through cooling drums for lowing temperature.
13.7.3. Curing:
In this process the polypropylene contamination involved in fabric is removed through passing
from curing chambers attached in machines at high temperature of 210 C for 3 to 4 minutes, thus
fabric becomes free from contamination and fabric is kept in trolley for next process and there are
3-curing machines in sapphire.
13.8. Folding Department:
It is a department in which inspection section, packing and dispatch section are involved. In
inspection as fabric is brought the supervisor handover the responsibility to inspector for inspection
one trolley of fabric for identifying faults including cuts, fade color, metallic or plastic particles
etc. and at Sapphire 4-point American standard system is followed for inspection.
Packing & Dispatch: In
this section rollers of
fabric are packed after
inspection and marking
on each with the
“shipping mark”
according to customer
standard. Packing is done
in different ways as per
customer requirement. In
last after the permission
of quality control
department, fabric is sent
to Dispatch Section
where fabric is further
dispatched to the customer after the entire completion of documents.
Packing Area in SFML-1
44 | P a g e
14.Dyeing unit:
After the SFML-1 section, we went to dyeing unit for 1-week, in which we did activities of dyeing
knitted fabric though using chemicals till finishing department.
14.1. Dyeing Unit Process:
In this department knitted fabric is brought in form of lot making which is dyed through passing
from dyeing machines in sapphire, there is big drum attached with dyeing machines at right side
in which multiple chemicals and dyes are kept for dyeing knitted fabric. One machine takes 2-lots
and 12-13 hours for dyeing process. In machines the process of dyeing polyester takes 3-hours at
130C, where dyeing of cotton takes
also 3-hours for completion of process
but at 60C. There is a software named
with “Orgates software” at sapphire
which is used for maintaining the
check & balance of machines and also
helps to know current operations of
machines being run in unit. There is
also an inventor machine which
actually
Dyeing Department
14.2. Dyes & chemicals used in Dyeing unit:
Anti-creasing chemical
Disperse dye & acid dye
Caustic soda, H2O2 Nacl
and Sodium salphate
45 | P a g e
14.3. Types of dyes:
Iso-thermal dye at 60C
Cooling dye at 80C
Triquious dye at 95C
Procambium dye at 97C
14.4. Machines used in Dyeing unit:
Eco-soft-1--there are total 10-machines, imported from Germany
Eye-master---there are total 3-machines, imported from Germany
14.5. Finishing department of Dyeing:
The functions done in this section are defined below:
• Slitting
• Dryer
• Raising
• Stenter
• Compactor
14.5.1. Slitting:
It is a process in which we turn tubular fabric in order to open the fabric width by slitting fabric
then softeners and other chemicals are applied to soften fabric, then water left in fabric is reduced
and then fabric is properly pressed for chemical penetration.
Machines used in slitting section:
Opening slitting—there is 1-machine, imported from Switzerland Santa
Stretch Squeezer—there are 2-machines, imported from Switzerland
46 | P a g e
14.5.2. Dryer:
In this section slittered/ squeezed fabric is brought from slitting section then slittered fabric is
passed through machines in which wet steams and air blowers dry the slittered fabric. There are 2-
drying machines from which one machine has 4-chambers and other has 3-chambers.
Machines used in drying section:
Santa shrink dryer chambers--- total 2-machines, imported from Switzerland
14.5.3. Raising:
In this the fabric is received from drying section where both dry tubular fabric and dry open fabric
are raisin through passing from machines for bringing
the smoothness in fabric. There are 2-open fabric
raising machines and 4-tubular fabric raising machines
in sapphire dyeing unit.
Machines used in Raising section:
Touch Screen Raising Machines—used for open fabric
raising, imported from china
Riely Fabric Brushing Machine RILAY—used for
Tubular raising, imported from England
Raising Machine
14.5.4. Stenter:
This is process in which dry fabric is passed from machines for stretching the fabric widthwise,
brining uniformity in width and also sets the GSM (weight) of fabric.
Machines used in Stentor section:
Montex Stentor—only one machine with model of E&A KOMB, imported from Switzerland
47 | P a g e
14.5.5. Compactor:
This process is used for both tubular fabric and open fabric
in which we do set fabric Shrinkage, do extra stretching of
fabric, help to reduce thickness in fabric through
compressing fabric.
Machines used in Compactor section:
Tentor Compactor-used for tubular fabric & has one
machine, imported from USA
Tentor compactor—used for open fabric & has one
machine,
Compactor Machine
imported from Italy
7 Ceiling of Sapphire Retail Head Office, Tricon Center, Lahore
6 Office of Sapphire Retail, Tricon Center
48 | P a g e
15.Learning & Knowledge I gained from 2-month internship:
As there is universal rule that the best coordination and cooperation is a key towards enhancing
growth, growth means number employees, employees contribution in achieving goal etc. so the
purpose of mentioning this statement is, the main thing we noticed in sapphire industry during 2
month internship was their the most satisfying coordination and cooperation with employees
including staff, security guards, helpers, cooks along with internees.
Sapphire has created an environment for treating their employees in a way that all employees love
it, want to work in sapphire permanently, the most employees’ dream company and that’s a reason
that approximately more than 16 to 17 thousand people are working there. Sapphire is industry
which not only consist of employees but also the inspiring and motivating people who not only
does their job but also play vital role in retaining employees and that’s why there is very less ratio
of turning over of employees.
The learning I got is that sapphire is industry which not only competes in its field but also do highly
concentration for employees’ safety and all kind of facilities including free transportation, free
accommodation along with purifier drinking water, 24-hours electricity, free internet means
Sapphire don’t compromise regarding employees’ facilities in any situation because sapphire’s
first priority is employees’ satisfaction, safety and happiness.
Another thing we noticed is their problem solving techniques in very soft manner, the problems
they face while achieving big goals, well problems are hesitation but also source of new learning,
information, well overall we found all employees in Sapphire having soft behavior, good
communication skills, cooperative, good guidance, well trained, experienced, inspirational and
motivational people working in Sapphire. So what I think after observation that I don’t see any
other industry like Sapphire having all satisfying factors, advanced technology, good salary
packages, incentives & benefits etc.
49 | P a g e
16.Conclusion:
This 2-month period of internship helped me out to polish my entire skills and knowledge I have
learnt through academic theory, Sapphire was the most suitable platform for me where I was
provided a chance to learn more & more, knowledge, new skills through making myself engaged
in Sapphire activities.
I have spent the most splendid experience with Sapphire during my 2-month internship and
Sapphire showed me a way that I should lead in my future even though in textile sector. During
these 2-months I knew about my weak point on which I worked on.
Sapphire provided me a chance to develop more and more relation with professionals and to be in
touch with them for my bright future. Internship at Sapphire taught me about my responsibilities
that I have to take in professional job-career such as time punctuality, target achievements etc.
these 2 month of internship made me feel that Sapphire is the most comfortable place with loving
& fit environment where I can do job in future without any hesitations.
So, what I believe is, Sapphire doesn’t leave its employee in lurch and always put its all efforts for
accomplishing employee dream, desires and it will be my lucky time to work with Sapphire.
50 | P a g e
THE END
THANK YOU

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Sapphire Textile Mills Limited - Activities Report - Muhammad Umair Zulfiqar - BBA (Agribusiness)

  • 1. 1 | P a g e
  • 2. 2 | P a g e Internship Activities Report BBA (Agri-business) Batch 2nd At Sapphire Textile Mills Ltd. Submitted By: Muhammad Umair Zulfiqar CMS id: 163-15-0039 Figure 1Emporium-Mall-Sapphire
  • 3. 3 | P a g e Table of Contents 1. Acknowledgment:.................................................................................................................... 7 2. Executive Summary:................................................................................................................ 8 3. Internship Contact Information.............................................................................................. 10 4. Introduction............................................................................................................................ 11 4.1. Overview of Textile Industry of Pakistan ...................................................................... 11 4.2. Overview of Sapphire Textile Limited: ......................................................................... 11 4.3. Vision:............................................................................................................................ 12 4.4. Mission:.......................................................................................................................... 12 4.5. Mentioning few units of Sapphire Group out of 35-units.............................................. 12 5. Reporting Period:................................................................................................................... 13 6. Accomplishments & Work Performed .................................................................................. 14 6.1. Denim Garments Unit: ................................................................................................... 14 6.2. Denim Garment Process:................................................................................................ 14 6.3. Flow chart for Denim Garments: ................................................................................... 14 6.4. Fabric:............................................................................................................................. 15 6.5. CAD: .............................................................................................................................. 15 6.6. Cutting:........................................................................................................................... 15 6.7. Stitching (Panels and Parts): .......................................................................................... 15 6.8. Total approx. 17 parts of each garment:......................................................................... 16 6.9. Washing:......................................................................................................................... 16 6.10. Different washing techniques:.................................................................................... 17 6.11. Dry:............................................................................................................................. 17 6.12. Finishing, Tagging and Packing:................................................................................ 17 6.13. Checking of garments:................................................................................................ 18 7. Weaving Unit:........................................................................................................................ 18 7.1. Weaving Unit Process:................................................................................................... 19 7.2. Weaving Process Flow Chart:........................................................................................ 19 7.3. Warping Department Hierarchy:.................................................................................... 21 7.4. Sizing:............................................................................................................................. 21 7.5. Sizing Department Hierarchy:........................................................................................ 22 7.6. Leasing Process of sizing:.............................................................................................. 22 7.7. Yarn Beam storage:........................................................................................................ 22 7.8. Maintenance Department Hierarchy in weaving unit of Sapphire:................................ 23
  • 4. 4 | P a g e 7.9. Drawing-in: .................................................................................................................... 23 7.10. Production Department Hierarchy:............................................................................. 24 7.11. Weaving Loom: .......................................................................................................... 24 7.11.1. Looms with respect to Manufacturer:..................................................................... 24 Itema: ..................................................................................................................................... 25 Jacquard ................................................................................................................................. 25 Tsudokoma............................................................................................................................. 25 7.12. Looms with respect to shedding mechanism:............................................................. 25 Tappet .................................................................................................................................... 25 Dobby:.................................................................................................................................... 25 Jacquard: ................................................................................................................................ 25 7.13. Looms with respect to picking mechanism: ............................................................... 25 Rapier:.................................................................................................................................... 25 Air jet: .................................................................................................................................... 25 7.14. Types of Looms with respect to width: ...................................................................... 26 7.15. Folding or Inspection department in Sapphire: .......................................................... 26 8. Spinning Unit:........................................................................................................................ 26 8.1. Visit to testing Laboratory: ............................................................................................ 26 8.2. Count lea strength product (CLSP) Test: ....................................................................... 27 8.3. Equipments used in this test:.......................................................................................... 27 8.4. Measurement of Fiber length Test: ................................................................................ 27 8.5. Equipments used in this test:.......................................................................................... 27 8.6. Breaking force, Elongation% and tenacity of single yarn Test:..................................... 27 8.7. Equipments used in this test:.......................................................................................... 28 8.8. Spinning Unit Process:................................................................................................... 28 8.9. Flow chart of Spinning Process...................................................................................... 28 8.10. Blow room:................................................................................................................. 29 8.11. Names & Functions of machines used in blow room section: ................................... 29 8.12. Carding: ...................................................................................................................... 29 8.13. Names & functions of machines used in carding section:.......................................... 30 8.14. Comber: ...................................................................................................................... 30 8.14.1. Names & Functions of machines used in Comber section: .................................... 30 8.15. Drawing: ..................................................................................................................... 30 8.16. Simplex:...................................................................................................................... 30
  • 5. 5 | P a g e 8.17. Ring: ........................................................................................................................... 30 8.18. Auto-cone: .................................................................................................................. 31 8.19. Packing and dispatch: ................................................................................................. 31 9. Sapphire Finishing Mills Ltd (SFML):.................................................................................. 32 9.1. Sapphire Dairy and SRL Unit: ....................................................................................... 32 10. Sapphire Dairy Farm:......................................................................................................... 33 11. Retail Store of Sapphire:.................................................................................................... 34 11.1. Hierarchy of Sapphire Retail Store............................................................................. 35 12. SFML-2:............................................................................................................................. 35 12.1. HR Division:............................................................................................................... 36 12.1.1. Policies at Sapphire:................................................................................................ 36 12.1.2. Attendance & Evaluation:....................................................................................... 36 12.1.3. Compensation & Benefits:...................................................................................... 36 12.1.4. Accounts: ................................................................................................................ 36 12.2. HR Division Hierarchy............................................................................................... 37 12.3. PD & PPC:.................................................................................................................. 37 12.4. Cutting:....................................................................................................................... 38 12.5. Stitching:..................................................................................................................... 38 12.6. Simple and Hanger stitching system: ......................................................................... 38 12.7. Types of machines used in SFML-2:.......................................................................... 38 12.8. Quality Control Department:...................................................................................... 39 12.8.1. Finishing, Packing & Dispatch:.............................................................................. 39 13. SFML-1:............................................................................................................................. 39 13.1. Flow Chart of SFML-1............................................................................................... 39 13.2. Greige Store:............................................................................................................... 40 13.3. Inspection: .................................................................................................................. 40 13.4. Pretreatment Department:........................................................................................... 40 13.4.1. Singeing: ................................................................................................................. 41 13.4.2. De-sizing:................................................................................................................ 41 13.4.3. Scouring:................................................................................................................. 41 13.4.4. Bleaching: ............................................................................................................... 41 13.5. Dyeing: ....................................................................................................................... 41 13.6. Types of Dyes............................................................................................................. 42 13.6.1. Reactive dye:........................................................................................................... 42
  • 6. 6 | P a g e 13.6.2. Vat dye:................................................................................................................... 42 13.6.3. Disperse dye:........................................................................................................... 42 13.7. Finishing:.................................................................................................................... 42 13.7.1. Peaching:................................................................................................................. 42 13.7.2. Sanforizing:............................................................................................................. 43 13.7.3. Curing: .................................................................................................................... 43 13.8. Folding Department:................................................................................................... 43 14. Dyeing unit: ....................................................................................................................... 44 14.1. Dyeing Unit Process:.................................................................................................. 44 14.2. Dyes & chemicals used in Dyeing unit: ..................................................................... 44 14.3. Types of dyes:............................................................................................................. 45 14.4. Machines used in Dyeing unit:................................................................................... 45 14.5. Finishing department of Dyeing:................................................................................ 45 14.5.1. Slitting:.................................................................................................................... 45 14.5.2. Dryer:...................................................................................................................... 46 14.5.3. Raising: ................................................................................................................... 46 14.5.4. Stenter:.................................................................................................................... 46 14.5.5. Compactor:.............................................................................................................. 47 15. Learning & Knowledge I gained from 2-month internship: .............................................. 48 16. Conclusion: ........................................................................................................................ 49 THE END ..................................................................................................................................... 50
  • 7. 7 | P a g e 1. Acknowledgment: Praise be to Al-Mighty Allah, The Lord of Entire Universe. The Beneficent, the Merciful, Who is the entire source of knowledge and wisdom. For the completion of this report I am indebted to plenty of people for their sincere cooperation as well that they extended to me at various stages. First and foremost problem that I faced is the completion of this report is not gathering data because of the very cooperative and very professional support of supervisors, entire team and every single Sapphire employees who gave us their valuable time from their busy schedules. Due to their efforts I am able to have much knowhow about Sapphire’s processes. But the main issue I had face was writing the content into report form with sequence because of our group done internship in inverse working flow e.g. we started from final garment and go back to the raw form where from the actual process starts like spinning, ginning, warping etc. Anyhow, it is in fact a matter of great pleasure for me to express my sincere gratitude to our worthy coordinator Sir Dr. Waqar Akram and Sukkur IBA University management team who put their efforts for all arrangements of this internship program. Finally, I am very honor to my Mother and my Uncle Mian Javed from North Carolina, United States of America (my guardian) and my younger siblings who believed that I can do what I want and supported me at every single step of my life. My entire achievements till today belongs to my Mother and Grandmother and my younger siblings who stood like a stone against heavy storm.
  • 8. 8 | P a g e 2. Executive Summary: As we know that textile sectors have played a main role and major contribution in Pakistan Economy, so, Sapphire Textile is also one of them which is namely known as Sapphire Group of Pakistan. It was started in 1960 in East Bengal. Well, Sapphire group is divided into many units including 3weaving units, 11-spinning units, 4-processing units consisting of knits, fiber dyeing, yarn dyeing and one for woven, whereas 2-stitching units (knits and home textile) and 3-units of power generation. Sapphire has also started the electric company in 2009 December named with “Sapphire Electric Company” located in Sheikhupura, Punjab, having capacity of 225 MW (Gross). Journey of our internship started from Sapphire Textile Mills Ferozwatwan, Sheikhupura near Lahore where we were engaged in different four units of Sapphire for one month, in which 1st week was all about Denim garments in which we got to know about the entire processes of denim garment making then our 2nd week was all about Denim fabric that gave us the knowledge about processes involved in yarn making and then denim fabrics, 3rd week we started Weaving unit and seen all the weaving process there and at last 4th week went to the Spinning unit. In STML our reporting time was from 9 AM to 5 PM along with their free transportation and accommodation as well. After passing 1st month, we moved towards Sapphire Finishing Mills, Lahore where we spent 2nd month of our internship along with lot of new experiences and learnings, at SFML our timetable was divided into 4-units, one 1st week was 2-days in dairy unit and 4-day in Sapphire Retail Limited and last one day of working week at STM 8, in 2nd week we went for SFML-2 unit and then our 3rd week we went to SFML-1 then our last week was being held in Sapphire Fiber & Dyeing unit where we analyzed the process of dyeing and drying knitted fabric. After completion of 2 months at Sapphire Textile and Sapphire Finishing Mills, the journey of our internship came to an end and showered us with new learnings, splendid experiences regarding textile instead of our no-agricultural background.
  • 9. 9 | P a g e My 2 months of internship at Sapphire made me feel that where I was before and where I stand now. This was a big difference between theory at the University and practical life at industries. During my internship at textile industry showed way of creating better links with professional network to be connected with. I found the best platform for internship in brand company “SAPPHIRE” for me where I put my efforts to get real work experiences to explore my interests, polish my skills, and somehow develop professional skills and competencies which are going to contribute more in upcoming life in job field. After an experience of 2-months internship, Sapphire has become the one of my dream companies and I love to work there because of Sapphire’s reputation around the world and their main concern for employees’ safety along with their best coordination, guidance to new employees and existing as well.
  • 10. 10 | P a g e 3. Internship Contact Information Student’s Information Student Name: Muhammad Umair Zulfiqar Student I.D: 163-15-0039 Student Email: umair.agriba17@iba-suk.edu.pk Mobile Number: 0300-6633281 Organization’s Information Internship organization Name Sapphire Textile Mills Limited. Mailing address 4th Floor Tricon Corporate Center Service Lane Behind Siddiq Trade Center، Jail Road, Block H Gulberg 2, Lahore, Punjab Internship Supervisor’s information Internship Supervisor Name (Head office Lahore) Ma’am Saleha Internship Supervisor Email saleha.ashfaq@sapphire.com.pk Mobile Number 0303-4449670 Faculty Sponsor’s information Faculty Sponsor Name: Sir Dr. Waqar Akram Faculty Sponsor Contact: 0323-9643876 Faculty Sponsor Email: Waqar.akram@iba-suk.edu.pk
  • 11. 11 | P a g e 4. Introduction 4.1. Overview of Textile Industry of Pakistan Since long, Textile sector of Pakistan is remained a backbone along with provision of employment and export revenues. Pakistan Textile sector actually contributes 57% in country’s export where this sector has been a second largest which provides employment. Textile sector of Pakistan has share of 8.5% in Pakistan GDP and the 8th largest country which exports the more textile commodities in Asia. Pakistan is 4th large country which produces cotton and 3rd large in consumption of cotton. Clothing and Textile Industry have been remained major driver forces of economy since last 50 years and in future, it will be a main engine for Pakistan’s economy’s future growth. Overall Textile sector in Pakistan is doing its best but at somewhere it lacks such as no proper department of Research & Development in cotton sector, no adaptably of modernized equipment, energy and electricity crisis, On the other hand, Pakistani textile sector is working to overcome these issues. 4.2. Overview of Sapphire Textile Limited: Sapphire group is textile based industry situated at Lahore, Pakistan which is set as vertically integrated textile group, manufacturing of cotton, fabric, yarn, and finished garments. Sapphire textile was found in 1940 in Calcutta, India then it moved towards East & West Pakistan during time of partition and started its first unit of spinning in West Pakistan which is known as Pakistan right now. Mian Muhammad Abdullah is the CEO of Sapphire group. Basically Sapphire group is divided into units including 11-spinning, 3-weaving, 4-processing, 2- stitching and 3-power generation units and overall Sapphire Group has now 35-units. Apart from textile sector, Sapphire Group has also indulged in Dairy and Power Generation at Lahore. Well, the products of Sapphire are exported internationally around 35 countries and Sapphire Group has an employment of 16000 people.
  • 12. 12 | P a g e 4.3. Vision: To be one of the premier textile company recognized for leadership in technology, flexibility, responsiveness and quality. Our customers will share in our success through innovative manufacturing, certifiable quality, exceptional services and creative alliances. Structured to maintain in depth competence and knowledge about our business, our customers and worldwide markets. Our workforce will be the most efficient in industry through multiple skill learning, the fostering of learning and the fostering of teamwork and the security of the safest work environment possible recognized as excellent citizen in the local and regional community through our financial and human resources support and our sensitivity to the environment. (Source: From official website of Sapphire industry-- http://www.sapphire.com.pk/stml/ ) 4.4. Mission: Our mission is to be recognized as premier supplier to the markets we serve by providing quality yarns, fabrics and other textile products to satisfy the needs of our customers. Our mission will be accomplished through excellence in customer service, sales and manufacturing supported by teamwork of all associates. We will continue our tradition of honesty, fairness and integrity in relationship with our customers, associates, shareholders, community and stakeholders. (Source: From official website of Sapphire industry-- http://www.sapphire.com.pk/stml/ ) 4.5. Mentioning few units of Sapphire Group out of 35-units • Reliance Cotton Spinning Mills Limited • Sapphire Textile Mills Limited • Sapphire Electric Company Limited • Sapphire Finishing Mills Limited • Sapphire Dairies (private) Limited • Sapphire Power Generation Limited • Amer Cotton Mills (private) Limited • Diamond Fabrics Limited
  • 13. 13 | P a g e • Galaxy Agencies (private) Limited • Hermes Power (private) Limited • Sapphire Wind Power Company Limited (Source: From official website of Sapphire industry-- http://www.sapphire.com.pk/stml/ 5. Reporting Period: The tenure of our internship was designed for 2-months. Our internship started 21st January till 16th of March. 1st month of internship was planned at Sapphire Textile Mills limited (STML), Ferozwatwan, Sheikhupura. Where our 1st week was started in from 21st January to 26th January in which we learnt about the process and practices about denim garments where the work and processes of denim jeans pants and skirts were going, then 2nd week started in denim fabric from January 28th to February 2nd, our 3rd week started in weaving in which we learnt about the processes and practices about weaving from 4th February to February 9th and then at last week at STML was in spinning in which we saw yarn manufacturing processes, started from 11th February to 16th February. Now, it was time to move towards Lahore for 5th week of internship at Sapphire Finishing Mills Limited (SFML) at Raiwind Road, Lahore. Our 5th week of internship was started from 18th February to 23rd February 2-days in dairy unit and 4-day in Sapphire Retail Limited and last one day of working week at STM 8, then 2nd week in SFML was started from 25th February to 2nd march in SFML-2 unit, in 3rd week we spent in SFML-1 where we learnt about the pretreatment processes and our last week started from 11th march to 16th march in at Sapphire Fiber & Dyeing unit where we analyzed the process of dyeing and drying knitted fabric. So in this way, our 2-month period of internship came to an end productively.
  • 14. 14 | P a g e 6. Accomplishments & Work Performed 6.1. Denim Garments Unit: This unit of Sapphire is actually located in Ferozwatwan near Sheikhupura. We started our internship from this unit for 1-week, in which we did activities of garments manufacturing till finishing and packing. 6.2. Denim Garment Process: The main work being done in this unit was the manufacturing of jeans pants and skirts which were mostly exported in bulk amount according to order of customer. 6.3. Flow chart for Denim Garments: Fabric CAD Cutting Sewing and Stitching Washing Drying Finishing & Packing
  • 15. 15 | P a g e 6.4. Fabric: Firstly, fabric is received from different suppliers in market and from Sapphires own produce as well. the customer contacts with the marketing people in marketing department of Sapphire for order then an email or list of order is sent to the mill manager, quality head of denim garments as per customer demand including quality and quantity of product the customer wants. Different types of different fabrics according to their weight and ounces. 6.5. CAD: In this section, multiple designs and patterns are developed through software as per customer standards including patterns such as coin pocket (1), fly part, back panel (L+R), front panel (L+R), Pocket bag etc. These process includes PPR (pre-production run), analysis, pattern modification, marker, identification and bundling. 6.6. Cutting: After developing designs in cad system, the fabric is brought in cutting department for further process. Fabric is kept and makes spots on selected parts of fabric with marker then the process of cutting take place on fabric’s marked spots with the help of electrical cutter machines. Computer used in cuttings were Toka Tex, Orox cutter and Spreader. 6.7. Stitching (Panels and Parts): In this section the cutting parts from cutting department are brought and are stitched in order to join two cut parts with the help of multiple sewing machines like single, double, triple and multiple (having around 26 needles) needle lock stitch (used for permanent fix), overlock sewing machine, bar-tack machine, button machine, pocket setter, folders machines and chain stich (flexible fix). Panels and parts were included: Front, back, left & right side, seams (in & out) Line Balancing system used in stitching 1) Unit flow system 2) Bundle system Bundles -> small parts assembly -> Front small parts & back small parts-> attach main panels.
  • 16. 16 | P a g e 6.8. Total approx. 17 parts of each garment:  Belt  Loops  Back pockets 2 (Left & Right)  Back Yoke 2 (Left & Right)  Coin pocket  Facings 2 (Left & Right)  Fly 2  Pocket bags 2  Front and back panels 2 6.9. Washing: In this the fabric is washed through passing from different process for fading the shades in jeans such as soaking-- in which we soak the fabric in solvent similar to water, chemical wash-in which fabric is washed into different chemical mixture for the bleach, soda ash, brightener, softeners of fabric, bio-polishing, enzymes, anti- microbial agents, anti-back strainers then after the washing process the fabric is being dried through drier machines. Washings depends upon looks. Fresh look, 6 month, 1, 2,3,5,10,20 years. It’s indigo, black or any other color varies according to garments age. Wash counter: Resin wash or without water chemical spray used. Figure 2 Washing machine
  • 17. 17 | P a g e 6.10. Different washing techniques:  Resin wash  Bleach wash  Stone wash  Stone & bleach wash  Enzymes wash  Stone enzyme wash. 6.11. Dry: In this section jeans pants are brought where patches are made with help of scraping sand paper and laser machines as per customer requirement. Machines used for mechanical and chemical procedures. Sand papers use for giving shades mechanically and KMnO4 Use for whiter look and to neutralize the dust of fabric reactions. Rigid garments: Laser-> Whiskers->Scraping- >First wash->Spray->Neutralize->2nd wash->Dry. 6.12. Finishing, Tagging and Packing: In finishing department, the final product is being inspected for finding the faults to be repair then goes in tagging section in which different instructions and prices are applied through labelling cards on jeans as per customer demand and finally after the entire audition the order is packed and dispatched to customer. Revert and stud area, labeling, pressing, iron steam, toppers (steam+air) Figure 3 Denim Pants Dryers
  • 18. 18 | P a g e 6.13. Checking of garments:  Shade  Shape  Accessories  Specifications and measurements  Sundries (Paper+Tags)  Stitch  Folding and Packing 7. Weaving Unit: After Denim garment unit, we came to this unit, in which we leant about the activities involved in making fabric through passing yarn from multiple machines till fabric dispatch. Physical counter/sample Documented written instruction Mechanical Head (Machine) Production Head (Man-power) PD Head ( Production technician) CAD Head (Pattern) QA Person (Assurance as per given details)
  • 19. 19 | P a g e 7.1. Weaving Unit Process: It is basically a process in which we make fabric through interlacing sets of yarn (warp and weft). Weaving is almost done on looms and consist of 3-functions including shedding, beating and picking up. 7.2. Weaving Process Flow Chart: Warping of yarn: In this, They convert smaller packages of yarn into beams through machine which has main 2-parts, first is creel in which cones are hanged into spindles or skewers and in creel there are devices attached in creel which identify the broken yarn and we can calculate creel capacity through formula: Creel Capacity= No: of rods * No: of spindles * 2. And other part is headstock in which beam is attached on which the entire yarns coming from creel are wrapped. Figure 4 Warping of yarn Warping of Yarn Sizing Drawing - Weaving Loom Folding (Inspection) Packing Dispatch
  • 20. 20 | P a g e 2 Warping room There are two types of warping, one is direct In which the yarn is wounded parallel on warping beam and all the yarns are wound at once and used for making fabric of single color. It is also known as high speed warping or V-type and second is indirect warping in Which equal length of yarn is fist wound in Small sections or sheets on drum then from the drum it is transferred to the beam. It is also used for making fancy fabrics and for repetition of same design. It is also known as H-type Warping Hierarchy. There are four machines of warping from which three (3) are Benninger and one (1) is Tsudokoma. At Sapphire, there is corn form of yarn with the weight of approximately 4.146 pounds and 5.5 pounds.
  • 21. 21 | P a g e 7.3. Warping Department Hierarchy: 7.4. Sizing: It is a process in which we prepare the yarn to bear the weaver and tear that is going to happen in weaving shed. Warp beam is raw material of sizing and weaver is output of sizing. Sizing is done through using four additives or chemicals including Starch: which helps to give external strength of yarn, Poly vinyl Alcohol (PVA): which helps out to give internal strength of thread, Acrylic: a binding agent which helps to increase the binding of recipe towards yarn and Wax: a softening agent which helps to improve the binding. Mills Manager Weaving Manager Preparatory Incharge Senior Warper Warper Assistant Warper Helper Figure 5 Sizing Department
  • 22. 22 | P a g e 7.5. Sizing Department Hierarchy: 7.6. Leasing Process of sizing: 7.7. Yarn Beam storage: There are three stacker machines.Stacker-1 has a capacity of carrying the 130 beams.Stacker-2 has a capacity of carrying the 70 beams and stacker-3 has also same capacity of carrying the 70 beams. Thread Creel Sizing Leasing Winding Figure 6 Yarn Beam Storage Area Preparatory In charge Sizing In charge Sizer Back Sizer Helper Mixer Man
  • 23. 23 | P a g e 7.8. Maintenance Department Hierarchy in weaving unit of Sapphire: 7.9. Drawing-in: In this the beam is kept on beam stand and a person with entire details of design starts the drawing in process including the parts like droppers, healed wires, frame and reeds. Sized beam is input of drawing-in and pattern is output. There are manually and automat machines, from which Sapphire has one automat machines because of the high cost of machine and have many manual machines .The speed of manual machine is 10 to 15 ends per minute and the speed of automat machine is 140 per minute and there are three sheds with the production of 180,000 meter in a day. Maintenance Foreman (Professional) Deputy F. Assistant F. Foreman (Jacquard) Deputy F. Assistant F. Foreman (Tovot) Figure 7 Drawing-in Machine
  • 24. 24 | P a g e 7.10. Production Department Hierarchy: 7.11. Weaving Loom: It is actually a process in which we form a cloth by interlacing strands of yarn or on looms by interlacing warp and filling threads through different machines (looms) defined below: 7.11.1. Looms with respect to Manufacturer: Picanol: In sapphire, the total number of Picanol machines is 72, picanol machine is available in two models. One is optimax and other is omnipus, from which there are 12 optimax and 60 omniplus machines and are kept in shed number-1. Production In charge Shift In charge Beam Gaiter Weaver Helper
  • 25. 25 | P a g e Weaving Loom Department Toyota: In Sapphire, the total number of Toyota machines is 48 and is available in one only model of JAT-810. There are 36 machines with 340 cm and 12 machines with 280 cm and are kept in shed-2. Itema: In Sapphire, the total number of itema machines is 2 available, with only one model of A- 950 and kept in shed-1 Jacquard (Donnier): In Sapphire, the total number of jacquard machines is 4 available, with model of Staubli-G1000 and Stable-Hesta and kept at shed-2. Tsudokoma: In Sapphire, the total number of Tsudokoma machines is 237 available, with two model of Zax-9100 HD professional and Zax-9200 master, from which there are 206 Zax- 9100 HD professional machines and 31 Zax-9200 master machines. 7.12. Looms with respect to shedding mechanism: Tappet: it works for simple designs has 7-frames to work on it. Dobby: it works for technical designs and has 16 frames. Jacquard: it works for complex designs and has no frame, no limits. 7.13. Looms with respect to picking mechanism: Rapier: It contains needles. It pushes the weft through needles. Air jet: It contains compressor which forces weft through air. 3Working of Jacquard Machine
  • 26. 26 | P a g e 7.14. Types of Looms with respect to width: There are looms w.r.t to with are 190 cm, 210 cm, 280 cm, 340 cm, and 360 cm. 7.15. Folding or Inspection department in Sapphire: There are two sheds, one is narrow and other is wider. In this we check out cloth properly and tries to find the fault in cloth and remove fault. But if at one stage the fault is mistakenly missed then there is re-inspection of cloth because of customer standards. Fault or tension can be occurred due to shade, reed, emery roller, cloth roller etc. 8. Spinning Unit: This unit of sapphire is located in ferozwatwan near Sheikhupura. In this we firstly visited to the laboratory where we did different testing and then we moved to the spinning process, in which yarn is made through passing from multiple process and machines. So first we move to laboratory testing and then spinning process. 8.1. Visit to testing Laboratory: In this department we are going to make different tests like fiber testing, yarn testing etc. so we take few tests defined below:
  • 27. 27 | P a g e 8.2. Count lea strength product (CLSP) Test: In this we will find CLSP through finding yarn lea strength and yarn count. For this testing we have to take sample of 120 yards lea and we make this sample through using electronic machine names as ” wrapping reel lea maker”, So through this method we can find the CLSP value. 8.3. Equipments used in this test: Elestretch XT, wrapping reel and weighing balance—these Equipments are used to find CLSP value 8.4. Measurement of Fiber length Test: In this test, we scan beard photoelectrically through using fibro-graph, then we pass the light intensity through beard at given position, used as number fibers which enhance to that distance from comb, then the density of sample is potted or canned against comb distance to provide fibro gram. So in this way we take measurement of fiber length. 8.5. Equipments used in this test: Fibro-graph—used for taking measurement of fiber length 8.6. Breaking force, Elongation% and tenacity of single yarn Test: In this test, we basically do activities such as we make continuous drawing-off yarn, then we make the thread insertion through air jet. In next section we do press yarn tightly and elongate till its broken condition by rollers and in last we remove the remaining thread pieces into container full of waste through using compressed air. In this test the samples are bobbins and cones. Report of Breaking Force & Elongation made in laboratory testing Elestretch XT
  • 28. 28 | P a g e 8.7. Equipments used in this test: USTER Tensojet—used for single yarn elongation, force breaking. 8.8. Spinning Unit Process: It’s basically the process in which we take a raw cotton and convert it into yarn which is further used to make cloth. In spinning unit if there are faults being present in yarn and not found or identified before weaving or other process then it’s going to be very risky and costly to the manufacture and spinning process is also known as heart of textile. The Common faults found in yarn are hairy yarn, contaminated yarn, low yarn strength, thickness and thinness of yarn etc. further the detailed flow chart of spinning is explained below: 8.9. Flow chart of Spinning Process BlowRoom Carding Comber Drawing Simplex Ring Auto cone Packing & Dispatch
  • 29. 29 | P a g e 8.10. Blow room: It is the initial process of yarn production being processed in Spinning Mills, in which cotton bales are taken up to blow room for opening and cleaning of cotton bales. Input of blow room is cotton bales and output is small cotton/tuft. The formation of cotton bale basically is compressing the cotton. In sapphire blow room they use air current which transfer through pipeline for flowing the cotton tuft from one machine to another machine. When there is less use of manual handling than there is more quality of cotton bales. There are more chances of 1.5% or 7% trash available in cotton bales. there are few basic operations being performed in blow room are opening the cotton bales for further process, removing of the many impurities like dust, plastics contamination, tiny broken seeds etc. left in fiber with the help of machines, detecting metal object in fiber and mixing, blending of different grades of cotton to make a same. 8.11. Names & Functions of machines used in blow room section: UNIFLOC. A 11- used for opening cotton bales UNICLEAN. B 12- works for cleaning the micro tuft UNIMIX.B 76- ensures homogenous mixing of cotton bale feed including 8 chambers UNISTORE A.7- combined storage, opening and cleaning machine process LOPTEX & X-pect 4- used for removing trash and contamination sorting machine 8.12. Carding: In this section the output of blow room (cotton tuft) is brought to carding section and transformed into sliver (output of carding) with the help of machines available in carding in sapphire. Carding is done for many purposes such as: fiber individual itiozation, formation of sliver, cleaning of fiber, blending of fiber, removing naps of fiber, fiber parralizaton. At Sapphire, there are total 26 machines in Carding Section out of which 18 machines with C-70 model and 8 machines with C- 51 model.
  • 30. 30 | P a g e 8.13. Names & functions of machines used in carding section: Card C-70 & C-51: both models mainly used for the formation of sliver 8.14. Comber: In this section we use comber which mainly coverts lap (input) into combed silver (output) and also used for combing fibers, creating uniformity in yarn, works to remove the short fiber through using combs in attached in machine. 8.14.1. Names & Functions of machines used in Comber section: Comber Machine UNIlap—used in comber section 8.15. Drawing: It’s procedure in which multiple silvers are being transferred through rollers to do doubling and drafting in order to improve the unevenness of sliver and make parralizaton of fibers through vanishing the wrists in fiber. 8.16. Simplex: In this process fibers (slivers) are changed into roving. In simplex section many operations are being done such as twisting in which we make fibers together twisting and winding in which rovings are wrapped on bobbins and many more like creeling, drafting etc. in simplex the output is roving and input is sliver. 8.17. Ring: After simplex, roving is brought here and being converted into yarn then will be transferred further into next section where there will be winding of yarn on cone and machines used in ring section create more heat.
  • 31. 31 | P a g e 8.18. Auto-cone: It is second last step in which conversion of ring bobbins is done into big packages or cones throughout machines considering required weight and length and also improvement of yarn quality is focused during operation and finally cones are sent to packing section for further procedure. 8.19. Packing and dispatch: In sapphire before packing, the cones are being checked into blue laser light in order to identify the faults in yarn and after assuring the faults cones are ready to be packed in bags. Lastly after completion of documentation and revising standards about product the customer wants, the bags are being marked with name to representing industry and now the product is ready to dispatch the customer. Packing Area
  • 32. 32 | P a g e 9. Sapphire Finishing Mills Ltd (SFML): After spending 1-month in STML at Ferozwatwan then we moved towards SFML Lahore where we visited 4-units including SFML-1 unit, Dyeing unit, Dairy+SRL unit, SFML-2 unit. 4 With Sapphire Dairy Farm's Veterinary Chief Dr. Naveed & Farm Administrator Mr. Asif 9.1. Sapphire Dairy and SRL Unit: This is unit of sapphire after dyeing unit where we spent the 2-days of week in dairy farm in which we learnt about activities done in dairy farm about providing milk, keeping cows etc. and then rest of 4-days of week, we went to Sapphire retail store. So first we are moving to Sapphire Dairy Farm.
  • 33. 33 | P a g e 10.Sapphire Dairy Farm: Sapphire dairy is one of the big sector in field of dairies in Pakistan which belongs to Sapphire group of industries. According to report the annual production of sapphire dairies is approximately 38 billion. Basically this sector was formed in 2008, keeping in mind that we have to provide better, pure and hygiene milk to the people of Pakistan. If we look at sapphire dairy farm, then there are different species of cows such as Jersey & Holstein from Australia. In sapphire, the cows are being tagged or attached a number in ears so that they can easily identify cows. In sapphire dairy farm, Cows are milked 3-times in a day whereas, the entire milk production from milking cows is approximately 70000 to 75000 liters in a day. In sapphire the cows are being milked in a way that all milking cows are brought into room named with “milking parlor” where cows are milked with the help of milking equipment being attached in cows udders after the cleaning udders of cows, then the milk is sent to chiller room through passing from pipes. The milking parlor in sapphire has capacity of keeping 40-cows milked at same time and one cow takes maximum 15 minutes to provide milk, well after milking all cows, the milking parlor room is cleaned with clean in Place (CIP) system. The best thing about sapphire dairy farm is that there is no concept of hand milking because of technology which is most beneficial to them. In sapphire, when the cows are brought into farm then then all are kept for 40-days known as “Quarantine process” in which they see either the cows are out of disease or involved in disease, then the cows which are involved in disease are being vaccinated in order to take them out of danger or to stop disease from spreading towards other animals and then remaining fine cows are sent to shed.
  • 34. 34 | P a g e 11.Retail Store of Sapphire: This is mainly known as retail store where the planning of future prediction is predicted for next season such as what kind of trends, design, style, and color should be set for launching in market. After the work of designing, the textile design is set up through using Photoshop then goes for print. There are employees such as sketcher and plotters who develop different things through sketching like KHAKHA and plotter share information about embroidery. The basic purpose of this retail store is to reach the standards of customer which he wants to launch in market about designs, style, patterns, colors etc. there are many artists, designers, printing makers, sketchers are present in form of team who work on single product to make it better, attractive and valuable to be liked by customers. 5 Sapphire Retail Head Office- Tricon Corporate Center, Lahore
  • 35. 35 | P a g e 11.1. Hierarchy of Sapphire Retail Store 12.SFML-2: This was our last unit in Lahore where our internship has come to an end. In this unit almost same processing and works were done such as cutting, stitching etc but at somewhere, the techniques and terms were bit different. So we start in this unit from HR division, few other departments mentioned below: Director General Manager Deputy General Manager Manager Deputy Manager Senior Asst. Manager Asst. Manager Officer Supervisor Pattern Master Cutting Master Stitching Master Helper
  • 36. 36 | P a g e 12.1. HR Division: 12.1.1. Policies at Sapphire: 12.1.2. Attendance & Evaluation: If we focus on policies made by Sapphire for employees & staff working there is very difficult to handle because main purpose of harsh policies is to be the presence of employees because they are the big revenue and also there is 24 hours working in sapphire that’s why sapphire can’t bear the absence of employees and worker, suppose if employees who do entry right after 12:00 AM then their day is calculated as half da but if they come after 12:30 AM they are absent for whole day and sapphire never compromise in case of attendance & absence of employees. In sapphire the evaluation of existed & new employees is evaluated throughout noticing their behavior, performance, targets achievements and after receiving ratings on evaluation form from HOD then employees are being decided either to hire or fire for job. 12.1.3. Compensation & Benefits: In sapphire the employees are awarded with multiple benefits and rewards which are not in cash but in form of bonuses, foreign tours etc. for the employees’ motivation and benefits such as free transportation, free lunch & accommodation is free as well. 12.1.4. Accounts: In sapphire they mainly look accounts such as inventory, production and financial accounts. Here is 1st inventory accounts-in which they manage accounts related to raw material of fabric store & main store like purchasing of local fabric and imported fabric as well as packing material is done through cooperation with MPC departments and other departments. They also have some amount in cash for spending on daily operation such as transport petrol, daily expense of maintenance etc. In Sapphire, when there is time audition then an email is sent to head department by accounting department for the material inspection and auditing of each department is audited monthly and once year a third part is hired for auditing in sapphire, in sapphire there is an activity being done which is post-costing in which they do analyze the costing of from initial purchase of product till it’s dispatched time.
  • 37. 37 | P a g e 12.2. HR Division Hierarchy 12.3. PD & PPC: In sapphire there is department named with Product development which works with customer through marketing department, basically the PD develops the product sample as per customer standards then PD send that sample to customer through marketing people if customer approves the sample then the further process is started on customer’s order. There is also another department named with Production Planning Control which does planning, monitoring and controlling through the procedure of product development. This department also works with customer through marketing department, this department basically does planning on basis of previous records, audition and reports of PPC department which help PPC department to work better and do execute the departments of cutting, stitching and finishing through time and action dates given to them. Manager -2 Senior Deputy Manager - 3 Deputy Manager -3 Senior Asst. Manager -4 Asst. Manager -4 Junior Asst. Manager -5 MTO- 5 Supervisors-5
  • 38. 38 | P a g e 12.4. Cutting: This is department of SFML-2 unit where pieces are cut down through using electric machines, here is mostly use of twill fabric and few twill fabrics are washed whereas few don’t need of washing because of softness. The fabric is sent to Gerber Garment Technology department after measuring width and cut plan is given to GGT department for switching to next step towards stitching department as per given time duration and action plan. 12.5. Stitching: In this section the cut pieces are brought from cutting department, as per stitching schedule the process is started in which firstly tags are stitched on pants, jackets and in this way after collar, pleat, labels etc. and two types of stitching are done in SFML-2 as under: 12.6. Simple and Hanger stitching system: In simple stitching system the work being done was almost same but there were some differences like the stitched pieces like tags, collar pieces were transferred through trollies to next stich machine and main problem of simple stitch is disturbance of trollies in a way employees pass by where as in hanger stitching system those stitched pieces were transferred through hanged hangers to another but the problem of hanger stitching system is, if there is an absence of one employee then there will be hindrance to other employees as well due to hangers passing by absent employee but it’s time saving system where as simple stitching consumes time 12.7. Types of machines used in SFML-2: Single Needle---—used for light fabric, hard and single plie with model of 7200, 7220 and 7300. Double Needle---used for pocket attachment and hamming sleeves bottom Fido Light & Heavy—used for both light and heavy fabric Kansai—used for belt attachment
  • 39. 39 | P a g e 12.8. Quality Control Department: After completion of stitching process, the garment is brought in this section where the stitching quality along with measurement and garment style is checked, in this section garment’s stitching is check either it is stitched properly or not than with the help of clipper the extra threads hanging or left in garments are cut for garments beauty and then finally garments is passed to next section through QC pass sticker. In a day 3-times a line is checked working QC section. 12.8.1. Finishing, Packing & Dispatch: In finishing garments is brought and auditing is done internally, then garments is sent to packing section where as per customer standards garments is packed with different tags, labels then packing is checked regarding boxes style, design, quantity per box, different cards of instructions labelled on boxes and after final audit from third party, the boxes are dispatched to the customer. 13.SFML-1: It is a unit of sapphire, located at Raiwind road, Lahore. In this unit we have done activities such as visit to store, the procedure followed in pretreatment department till dispatching the product and further is defined below: 13.1. Flow Chart of SFML-1 Greige Store Pretreatment Dyeing Finishing Folding Packing & Dispatch
  • 40. 40 | P a g e 13.2. Greige Store: It is basically store where greige fabric is being brought from weaving mill. While receiving greige fabric a supplier provides gate pass, packing list which contains entire information about fabric. The SFML fabric suppliers: Ahmed Fine, Ahmed Hassan, Fazal Rehman, Shafi Textile, Fatima Enterprises and STML. 13.3. Inspection: Inspection actually helps to find out faults in fabric such as yarn fault (color variations, contamination), the fabric which is brought in SFML is of a quality grade and 10% inspection is taken fabric and also inspection varies according to fabric quantity. In sapphire finishing mills 4point American system is used for grading of fabric inspection. After the entire inspection the fabric is again sent to store room in dry area and space in fabric store department is 6 to 7 lack meters and after multiple processes fabric is issued and brought to pretreatment department for further process. 13.4. Pretreatment Department: The functions done in this section are defined below • Singeing • De-sizing • Scouring • Bleaching Pretreatment Department
  • 41. 41 | P a g e 13.4.1. Singeing: It’s a process in pretreatment in this we burn the loosest fabrics which are not bound tightly. Singeing is being done through transferring the fabric from burning flame at maximum speed. Singeing is done in two ways one is plate singeing and second is roller singeing. Machines used in singeing process: Perble singeing- imported from japan Osthoff singeing-imported from Germany 13.4.2. De-sizing: It is done for removing the size or starch material from warp yarn through using the few process such as acid de-sizing, enzymatic de-sizing and oxidative de-sizing. De-sizing is also done for many purposed such as increasing the power of fabric absorbency. 13.4.3. Scouring: This kind of treatment is mostly done and preferred for removing the impurities such as dust, greasy material, lubricant material, waxes material or leaf particles throughout wet treatment in order to avoid the disturbance with further process like finishing and dyeing. After scouring fabric is washed so that the chemicals can be removed. 13.4.4. Bleaching: This process is generally done for changing the fabric into whiteness of fabric, enhancing shininess, improve smoothness, increasing power fiber to absorb dye through using bleaching chemicals such as H2o2, NaOCL etc. 13.5. Dyeing: After pretreatment process fabric is brought to dyeing section where it is dyed according to required color through passing from machines. There is also dyeing lab known as lap dip where we make and develop multiple recipes as per customer standards and is good for dyeing the fabric in small amount before dyeing on bulk production
  • 42. 42 | P a g e 13.6. Types of Dyes 13.6.1. Reactive dye: This kind of dyeing is only used for cotton fabric and is good for high wet fastness because of the chemical bonding of dyes and fibers with each other and are soluble in water, these dyes are cheap in price 13.6.2. Vat dye: It is also used for cotton fabric as reactive but vat dyes are insoluble in water, vat dyes are also expensive in terms of price. Sometimes, these dyes are ignored due to causing skin diseases. 13.6.3. Disperse dye: These dyes are used for polyester fabric and are insoluble in water and are applicable in acidic conditions. Dyeing of Disperse dyes is done with high temperature about 210-220 Celsius degree and these dyes can be economical. 13.7. Finishing: The functions done in this section are defined below: • Peaching • Sanforizing • Curing 13.7.1. Peaching: There are 9 peaching machines in sapphire which are used to give soften touch to fabric through entering fabric into machine in which with the availability of small steam spray pipes fabric is given a moisture in small amount for fabric softness then the fluff attached with fabric is removed with the help of brush rollers.
  • 43. 43 | P a g e 13.7.2. Sanforizing: In this section there are 3 Sanforizing machines at Sapphire which strengths fabric like iron through entering fabric into machine in which water is showered in order to wet the fabric for evenness of moisture in fabric then passing fabric from rubber belt which is pressed with steam heated roller for fabric shrinkage, after this fabric is dried with drying cylinders which are heated up with multiple steams and then fabric is passed through cooling drums for lowing temperature. 13.7.3. Curing: In this process the polypropylene contamination involved in fabric is removed through passing from curing chambers attached in machines at high temperature of 210 C for 3 to 4 minutes, thus fabric becomes free from contamination and fabric is kept in trolley for next process and there are 3-curing machines in sapphire. 13.8. Folding Department: It is a department in which inspection section, packing and dispatch section are involved. In inspection as fabric is brought the supervisor handover the responsibility to inspector for inspection one trolley of fabric for identifying faults including cuts, fade color, metallic or plastic particles etc. and at Sapphire 4-point American standard system is followed for inspection. Packing & Dispatch: In this section rollers of fabric are packed after inspection and marking on each with the “shipping mark” according to customer standard. Packing is done in different ways as per customer requirement. In last after the permission of quality control department, fabric is sent to Dispatch Section where fabric is further dispatched to the customer after the entire completion of documents. Packing Area in SFML-1
  • 44. 44 | P a g e 14.Dyeing unit: After the SFML-1 section, we went to dyeing unit for 1-week, in which we did activities of dyeing knitted fabric though using chemicals till finishing department. 14.1. Dyeing Unit Process: In this department knitted fabric is brought in form of lot making which is dyed through passing from dyeing machines in sapphire, there is big drum attached with dyeing machines at right side in which multiple chemicals and dyes are kept for dyeing knitted fabric. One machine takes 2-lots and 12-13 hours for dyeing process. In machines the process of dyeing polyester takes 3-hours at 130C, where dyeing of cotton takes also 3-hours for completion of process but at 60C. There is a software named with “Orgates software” at sapphire which is used for maintaining the check & balance of machines and also helps to know current operations of machines being run in unit. There is also an inventor machine which actually Dyeing Department 14.2. Dyes & chemicals used in Dyeing unit: Anti-creasing chemical Disperse dye & acid dye Caustic soda, H2O2 Nacl and Sodium salphate
  • 45. 45 | P a g e 14.3. Types of dyes: Iso-thermal dye at 60C Cooling dye at 80C Triquious dye at 95C Procambium dye at 97C 14.4. Machines used in Dyeing unit: Eco-soft-1--there are total 10-machines, imported from Germany Eye-master---there are total 3-machines, imported from Germany 14.5. Finishing department of Dyeing: The functions done in this section are defined below: • Slitting • Dryer • Raising • Stenter • Compactor 14.5.1. Slitting: It is a process in which we turn tubular fabric in order to open the fabric width by slitting fabric then softeners and other chemicals are applied to soften fabric, then water left in fabric is reduced and then fabric is properly pressed for chemical penetration. Machines used in slitting section: Opening slitting—there is 1-machine, imported from Switzerland Santa Stretch Squeezer—there are 2-machines, imported from Switzerland
  • 46. 46 | P a g e 14.5.2. Dryer: In this section slittered/ squeezed fabric is brought from slitting section then slittered fabric is passed through machines in which wet steams and air blowers dry the slittered fabric. There are 2- drying machines from which one machine has 4-chambers and other has 3-chambers. Machines used in drying section: Santa shrink dryer chambers--- total 2-machines, imported from Switzerland 14.5.3. Raising: In this the fabric is received from drying section where both dry tubular fabric and dry open fabric are raisin through passing from machines for bringing the smoothness in fabric. There are 2-open fabric raising machines and 4-tubular fabric raising machines in sapphire dyeing unit. Machines used in Raising section: Touch Screen Raising Machines—used for open fabric raising, imported from china Riely Fabric Brushing Machine RILAY—used for Tubular raising, imported from England Raising Machine 14.5.4. Stenter: This is process in which dry fabric is passed from machines for stretching the fabric widthwise, brining uniformity in width and also sets the GSM (weight) of fabric. Machines used in Stentor section: Montex Stentor—only one machine with model of E&A KOMB, imported from Switzerland
  • 47. 47 | P a g e 14.5.5. Compactor: This process is used for both tubular fabric and open fabric in which we do set fabric Shrinkage, do extra stretching of fabric, help to reduce thickness in fabric through compressing fabric. Machines used in Compactor section: Tentor Compactor-used for tubular fabric & has one machine, imported from USA Tentor compactor—used for open fabric & has one machine, Compactor Machine imported from Italy 7 Ceiling of Sapphire Retail Head Office, Tricon Center, Lahore 6 Office of Sapphire Retail, Tricon Center
  • 48. 48 | P a g e 15.Learning & Knowledge I gained from 2-month internship: As there is universal rule that the best coordination and cooperation is a key towards enhancing growth, growth means number employees, employees contribution in achieving goal etc. so the purpose of mentioning this statement is, the main thing we noticed in sapphire industry during 2 month internship was their the most satisfying coordination and cooperation with employees including staff, security guards, helpers, cooks along with internees. Sapphire has created an environment for treating their employees in a way that all employees love it, want to work in sapphire permanently, the most employees’ dream company and that’s a reason that approximately more than 16 to 17 thousand people are working there. Sapphire is industry which not only consist of employees but also the inspiring and motivating people who not only does their job but also play vital role in retaining employees and that’s why there is very less ratio of turning over of employees. The learning I got is that sapphire is industry which not only competes in its field but also do highly concentration for employees’ safety and all kind of facilities including free transportation, free accommodation along with purifier drinking water, 24-hours electricity, free internet means Sapphire don’t compromise regarding employees’ facilities in any situation because sapphire’s first priority is employees’ satisfaction, safety and happiness. Another thing we noticed is their problem solving techniques in very soft manner, the problems they face while achieving big goals, well problems are hesitation but also source of new learning, information, well overall we found all employees in Sapphire having soft behavior, good communication skills, cooperative, good guidance, well trained, experienced, inspirational and motivational people working in Sapphire. So what I think after observation that I don’t see any other industry like Sapphire having all satisfying factors, advanced technology, good salary packages, incentives & benefits etc.
  • 49. 49 | P a g e 16.Conclusion: This 2-month period of internship helped me out to polish my entire skills and knowledge I have learnt through academic theory, Sapphire was the most suitable platform for me where I was provided a chance to learn more & more, knowledge, new skills through making myself engaged in Sapphire activities. I have spent the most splendid experience with Sapphire during my 2-month internship and Sapphire showed me a way that I should lead in my future even though in textile sector. During these 2-months I knew about my weak point on which I worked on. Sapphire provided me a chance to develop more and more relation with professionals and to be in touch with them for my bright future. Internship at Sapphire taught me about my responsibilities that I have to take in professional job-career such as time punctuality, target achievements etc. these 2 month of internship made me feel that Sapphire is the most comfortable place with loving & fit environment where I can do job in future without any hesitations. So, what I believe is, Sapphire doesn’t leave its employee in lurch and always put its all efforts for accomplishing employee dream, desires and it will be my lucky time to work with Sapphire.
  • 50. 50 | P a g e THE END THANK YOU