Quality Managment in the Textile Industry

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CASE STUDY

Implementing Quality Management in the Textile Industry in Pakistan

304, 3rd Floor, Eden Centre, 43 Jail Road Lahore – Pakistan Ph: (+92 42) 7563645-7562260 Fax: 7552656 E-mail: piqc@brain.net.pk; Web Site: http:///www.piqc.com.pk

PAKISTAN INSTITUTE OF QUALITY CONTORL

© Pakistan Institute of Quality Control – (ICQI'1998)

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Implementing Quality Management in the Textile Industry in Pakistan by

Asif Hussain Group General Manager Quality Assurance & H.R. Development SAPPHIRE Lahore - Pakistan

1.

INTRODUCTION

Generally, there are two types of set-ups of textile manufacturing plants in Pakistan. a) Composite Textile Plants: These types of plants were basically installed till late 1950’s in Pakistan. They comprise of number of yarn manufacturing plants, weaving plants, dyeing plants, made-ups etc at one location. Individual Plants: Due to reasons like government incentives, labour issues, and other comparative advantages, installation of individual spinning and weaving plants became more feasible. Today the textile industry is mainly consisting of these types of individual spinning, weaving, knitting, dyeing and stitching units (plants) in Pakistan. The production capacities of these plants are normally in the following range: • • • •

b)

Spinning Plants Weaving Plants Knitting Plants Dyeing Plants

(with installed capacity of 12500 to 25000 spindles) (with installed capacity of 72 Looms to 102 Looms) (with installed capacity of 10 tons to 20 tons per day) (with installed capacity of 10 tons to 20 tons per day)

The textile industry in Pakistan is mainly owned by number of big groups. Statistics shows that about 75 percent of the textile plants in Pakistan are owned by 25 percent of the big group like Sapphire group, Kohinoor Maple Leaf Group; Gulistan Group, Crescent Group, Ibrahim Group, Master Group, Ilahi Group, Ayesha Group, Chakwal Textile etc. Sapphire is one of the largest textile groups in Pakistan. It owns 20 plants and all of these plants are independent individual units. Sapphire’s head offices are located in Karachi and Lahore. Some of the centralized activities like marketing, purchase and raw material procurement are controlled through head offices. Sapphire was founded in 1969 aiming to produce quality yarn of different counts. In pursuance of the vertical integration policy, Sapphire went into the projects for producing Woven Fabrics, Knitted Fabrics, Yarn Cone Dyeing, Knitted Bleached and Dyed Fabrics. Being export oriented company Sapphire believes in timely deliveries which is one of the most critical parameters. Therefore, to meet the deadlines effectively and have cheaper source of electricity Sapphires’ Power Plants were established at its industrial locations, to provide in-

© Pakistan Institute of Quality Control – (ICQI'1998)

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house consumption. These facilities were expanded to neighboring industries by having a transmission like network. • • • • • •

The total production capacity from 4 Power Generation Plants is 30 MW Eleven Yarn Spinning Plants have a production capability of 60,000 tons of yarn/year Two Weaving Plants have a production capability of 20 million meters of fabric/year One Yarn Dyeing with dyeing capability of 10 tons per day Present production capacity for Knitted Fabrics is 10 tons per day Knitted Fabric Dyeing plant has a production capability of 10 tons per day

2.

WELL BEGUN IN HALF DONE

ISO 9000 Quality Management System (QMS) is a good starting point towards Total Quality Management for the organization in less developed countries. It is also an advance management tool for managing businesses effectively for 20th century and ensuring customers to deliver consistent product & service quality particularly in global markets. Other management tools like ISO 14000 Environment Management System (EMS), Occupational Health & Safety Standards, Product Certification Standards, CE Marking have also joined the race of...
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