Professional Documents
Culture Documents
When Pakistan came into being there was only 16 textile mills out of which only 12
were in operation. It grew to 70 in 1957 as industrial development takes place. Now a
day there are 596-textile mills out of which 442 are in operation. The export revenue
.of textile industry contributes a large share to the GDP of Pakistan
Textiles constitute a major exporting sector for Pakistan, which accounts for about
60%
Of the country’s total foreign exchange earnings. The major export items are yarn,
gray
Cloth, finished cloth, towels and bed sheets and their major customers are the USA,
EU, Japan and Hong Kong. Many textile exports take place under quota arrangements
With the EU and the United States. Gray cloth constitutes roughly 16-18% of total
cloth
.Exports from Pakistan
Nishat gray cloth exports account for roughly 20 % of Pakistani gray cloth exports.
The
Firm has been exporting to the USA for many years, and has only recently started to
.export to EU countries
In Pakistan, the cotton crop season runs approximately from August to March. Prices
are generally high at the start of the season in August/September, and fall later on as
supply increases. Following income tax law, the fiscal year runs from October to
.September for textiles sector
NML started out as a weaving unit with 500 semi-automatic looms; later 10000
spindles were added, laying the foundation on nation’s biggest textiles composite
project. Composite project at Nishat mills limited Faisalabad covering 98 acre of
land is providing all production process under one roof i.e. spinning, weaving,
.processing, stitching and power generation
The Founder
A man of vision, courage and integrity, Mian Mohammad Yahya was born in 1918 in
Chiniot. In 1947 when he was running a leather business in Calcutta, he witnessed the
momentous that swept the indo-pak sub-continent and resulted in the emergence of
Pakistan. Like many of his contemporaries, he also migrated to the new country to
help establish its industrial base. His is a story of success through sheer hard work and
an undaunted spirit of enterprise. Beginning with a cotton export house, he soon
branched out into ginning, cotton and jute textiles, chemicals and insurance. He was
elected Chairman of All Pakistan textile Mills Association (APTMA), the prime
textile body in the country. He died in 1969, at the age of 51 having achieved so much
.success in so short period
PRODUCT LINE
,Products line of Nishat mills limited consists of following items
BEDDING
• Sheet sets
• Quilt cover sets
• Bed spreads
• Comforters
• Bed skirts
• Oxford pillow cases
• Blanket covers
• Sleeping bags
The history of Nishat dates back to 1951, when Mian Mohammad Yahya founded
Nishat Mills. After almost half a century of undaunted success, Nishat Group is
among the leading business houses of the country and ranks among the top 5 groups
in terms of assets and sales revenue. The group has its roots firmly planted into four-
core business namely
1. Textiles
2. Power generation
3. Banking
4. Cement
Nishat Faisalabad
Nishat Chunian
TEXTILE CAPACITY
Production process consists of spinning, weaving, processing, and finishing. The
processing includes dyeing, engraving. The textile capacity of the group is the largest
in the country. An addition of 20000 new spindles, 100 new air jets looms and new
dyeing plant has increased the existing capacity of 24000 spindles, 740 looms and
dyeing and finishing capacity of 5 million meters. The group is the largest exporter of
.textile products from Pakistan for more than a decade
PRODUCTION UNITS OF NISHAT MILLS LIMITED
Spinning
Weaving
Processing
Design studio
Engraving
Rotary screen printing section
Finishing section
Dyeing section
Inspection and rolling section
Quality control section
Production planning section
Stitching units
Power generation
Plant Capacity
Actual Production
Production Machines
SPINNING
Nishat Mills Limited initially started business with 10,000 spindles, which later on
with the gradual increase reached 165,800. The entire machinery is from world-
renowned manufacturers from Japan. A China and Europe. For reaching high quality
standards, research and development is imperative for which Nishat Mills has state of
the art yarn and cotton laboratories with world class scaling standards. Cotton is
procured at the start of the season to avoid any variation, which, can occur in the crop
from time to time enabling the mills to produce a consistent quality all the year round.
For this purpose a fully equipped cotton laboratory with HVI-900/I and ASIF-N is
working day and night during the cotton season to select the best quality crop to be
.purchased
NML spinning is operationally organized into seven spinning units, each with a
distinctive product range and capacity to keep a check on the quality standards, every
cone undergoes inspection before packing to ensure that the buyer gets only the best
.out of the lot
NML spinning is thus renowned for being one of the most trusted brand names in the
.market enjoying the trust and confidence of the consumer’s world over
The major production from the spinning is exported to Japan, Far East, South
America, Europe and the USA. In addition the spinning also provides the same high
.quality yarn to their own weaving mills going into fabric production
A) Machinery Details
Nishat Mills Limited (Faisalabad only) has seven spinning units with a total of
165,880 spindles. Spinning production capacity for both cotton and Blended yarn is
.120 Tons/Day
:Here under are summarized details of spinning machinery
BLOW ROOM (1
CARD (2
3) DRAW
ING
(Toyoda& Howa (Japanese Origin
(Rieter (swiss Origin
COMBER (4
SIMPLEX (5
6) RINGF
RAMES
AUTO CORNER (7
COUNT RANGE
100%Cotton Combed
From New 12/1 to New 32/1
From New 12/1to New 32/1
All double Yarn in 100% Knotless/auto –spliced
BLENDED YARN
Poly cotton
All yarn made at Nishat Mills Limited is ring spun, for both knitting (waxed or UN
.waxed) and weaving
Standard packing 24 cones per carton
.Carton Wt. 100 lbs
(Quantity per FCL 39000 lbs. (40ft High cube container
WEAVING
NML weaving enjoys the reputation for being the market leader in the loom state
fabric business in Pakistan. Their fabrics are not only rated as the top quality but also
enjoy a premium for their superior quality all over the world. Supported by their own
in house spinning units, the weaving sector of Nishat mills limited produces fabric
.range form light to heavy percales to satin and traditional to twill dobby items
Their fabric is well established all over the world with their exports going to the
America the Far East, Africa, Australia Europe and Japan. Besides export they are also
.supplying grey fabric to their dyeing and printing units
:NML FAISALABAD
NML SHEIKHUPURA
(MACHINERY 96 SULZER-ruti- looms (unit -1
PRODUCT RANGE
The products in this unit range are not only the traditional 100% cotton polyester
.cotton fabrics, but also in Dobby items, customized to the buyer need
Established initially by the name of Nishat fabric limited 1992. Subsequently merged
into Nishat Mills Ltd, NML Shiekhupura is one of the most advance unit In the
country equipped with the state of art machinery and back processes, the highly
sophisticated labotary also insured total quality control in yarn purchase and fabric
production, and other64 tsudakoma air yet looms have added (unit 4) recently along
.with the back process
Future programs for the unit include the purchase of some new air yet looms, which
will be give a boost to the production capacity and the product the range the unit will
.also expand subsequently
PROCESSING
Nishat processing plant with monthly capacity of 3 million meters is one of the largest
processing facilities of Pakistan. With and array of month modern machines, it is the
geared to meet the ever increasing the demand of there client. The processing division
has been divided in to different section to facilitate uninterrupted process flow and to
insured quality control at all stages almost 75% chemical and dyestuff being used is of
European origin and independent quality control department with a strong backing of
fully equipped laboratory insured quality standard at all level. The processing plant
has recently been awarded ISO –9001 Certification. Yet another achievement in this
regard by Nishat mills limited.
Bleaching
1. Brushing
2. Singeing
3. Chemicals tanks
Desizing
Scovring
It is done in bleaching machine, it helps to remove artificial spot like oil, grease etc.
PRE-TREATMENT SECTION
DESIGN Studio
The state of the art design studio, known for producing transparencies of the highest
quality, accommodates a STORK STK image 3000,a CST Ramste lll silicon graphic
02 and STORK Drum scanner plotter, along with these a team of convention manual
.color separation artist is also maintained
Design studio is a sub department of processing. Here cloth design is made. Tracers
are there to trace out different pattern and design of cloth. For each type of color
different films are made. Different trace papers that are sued at Nishat are of Kodak
and AGFA. For each color separation, there are positive and negative films. Positive
.film is sent for processing. Ink is used to fill scratches and unwanted graphics
Tracing table is used to examine designs and it helping tracing of design. Germany
waterproof ink is sued to avoid the ink expansion. Digital design studio is also
complementary department of design studio. Where design are made on computer
.program and using information technology
ENGRAVING
Technology advancement in the field of rotary printing necessitates upgrading the
pre-print line-up. NML is reputed for the most efficient use of the STORK engraving
systems for manual exposing. They are known for halftone work in single step
.designing
Living up to this reputation, they have recently added to their line lf production the
“ROTARY WAX JET’ With exposing resolution at 1019dpi and a screen
circumference of 640,820 and 9144mm. Engraving at this high resolution with digital
technology enhances the print quality to a great extent and reduces the existing human
.error margins to the minimum
NML has a well-trained work force to print extremely intricate and complex toe-on –
tone designs. Monthly printing capacity of the section is about 203 million meters.
Besides conventional printing in pigment and reactive dyes, printing in puff effects,
.resist and discharge dyestuff is also done
:MACHINERY
Printing machine Reggiani 126” 16 colors
Printing machine john zimmer 110” 12colours
Printing machine stork 72” 16 colors
• Process
sheet
• Job
description specification
• Audit
report
• ISO
9001
• Assess
ment file
• Purchas
e order
• Work
instruction
• Staff
document
• Worker
document
• Reactiv
e color document
• Standar
d operating procedure
• Custom
er letters and fax
• Organiz
ational chart
• Technic
al literature
• Daily
production report
FINISHING SECTION
Offering optimal final fabric quality and handle very recently this section has been
equipped with a new generation/ Babco-starter. This machine combines tried and
tested drying technology with innovative electronic control system. Ensuring absolute
.reproducibility of fabric qualities and full documentation on the quality control checks
Besides offering normal finished, this section also full fills the demands for scotch
guard protection for soil release and resist finish, peach skin affect finish (emerizing),
,Fire Retardant finish, water proofing, anti crease and easy care finish
:MACHINARY
DYEING SECTION
Nishat provides quality piece died fabrics in heavy twills to some of the world leading
brand names like Gap, Old Navy, Banana Republic, DKNY, Tommy Hilfiger,
CHAPS, and sears, this has been made possible by using high quality grieve from the
mills own weaving units and by using expensive dyestuffs, Highly trained Chinese
technicians keep a close check on all stages of production. Depending upon
.specifications, dyeing in reactive, disperse, pigment. Vat and sulphur is possible
To further enhance their existing dyeing capacity of 1,000,000 meters per month, a
designated Apparel Fabric Dyeing Unit is being set up near Lahore. The machinery
and land have been purchased for this project, which is planned to be operational by
the end of year 2000. This unit, which will have a monthly capacity of 2.5 million
mergers, has been designed to give the optimal results due to the custom built
machinery purchased after careful and lengthy consideration of the technical and
Marketing teams
This would certainly give them an edge over their competitors and would be welcome
addition in the ever-changing apparel fabric market. It will help Nishat mills limited to
.improve its market access and consequently profitability
To roll and pack 100,000 meters per day, this section has 8 rolling Machines; all
equipped with photo censors and inspection frames. Apart from rolling and folding,
the primary responsibility of rolling section is to prevent faulty fabric reaching the
customer; the fabric undergoes a100%inspecion system. To assist in shade checking a
.data color computer system is also used
QUALITY CONTROL SECTION
And independent on line quality control section monitors all production operation to
the required levels. The quality control lab is fully equipped to conduct all relevant
tests. The staff not only keeps control of the bulk production, but also is also actively
.involved in standardization of process routes and operating procedure
Nishat mills limited are committed to move things in direction of TQM. Their prime
Objective is comically produce products for the satisfaction of buyers. For this they
plan thing ahead, fresh ideas are developed, make more effective use of time, put the
right man in the right place, and keep on updating the skills of the employee by
.training
In the factory, in order to motivate employee and workers toward quality management,
,many billboards are they’re containing various statements like
Data flex program is used to save the date at production and planning department.
First export manager creates orders from the customer and record specification of that
.order on a paper. This program is sent to the production and planning department
The cloth required is issued against the grey demand letter. First copy is remained in
production and planning department. And second goes to grey stock room. On this
letter grey issued is returned. It is generally more than demanded cloth because some
cloth expected to be damage. For this job number is issued to work. When grey
material is issued, lot number is given than production and planning department issues
.program according to specification of each processing unit
STITCHING UNITS
Apart of Nishat plan to have a totally integrated textile sector the stitching unit was
set up in 1989.the unit has a string work force of 400 skilled and semi-skilled workers
mainly in cutting, stitching, quality control, folding and packing department. With an
array of 250 modern new generation machines, the stitching, department has an
average capacity to process up to 10,000 bed sets and 2000 curtain pair per day,
approximately 40000 meters of fabric, the assembly line consists of combination of
manual and automated operation designed to provide the required flexibility in its
system to allow processing of a wide product range and versions of its existing
product line the units current product line includes bed sheet, quilt covers, fitted
sheet ,cushion cover, valances, datable linen, baby sets, quilted throwovers and
curtains in various specifications and model customized to the requirements of
individual market . In addition, a range of embellished products with piping, bias
binding, bulk over lock, decorative trimming and bourdon stitching is also being
offered to customers, facility to handle small volumes of decorative embroidery is
also on line.
Quality control procedures are carried out at every stage during production. From
purchasing of material to cutting and stitching right till folding and packing of the final
.product, each aspect is scrutinized and controlled to the international quality standards
Power Generation
The power generation unit formerly known as Nishat Tek Limited, was the first ever
.power generation company in the private sector in Pakistan
Commercial production sanded in 1992 with three KRUPP-Macungie’s with
generating capacity of 5.5 Mw each, Capacity at Faisalabad has since eon increased to
27MW. Supplying power exclusively to NML.Nishata Tek also establishes a power-
generating unit of 6Mw at Shiekhupura to supply power to sulzer unit lll and
.Tsudakoma unit ill. It started commercial operation in September 1995
Market for Yarns and Grey fabrics was diversified to increase the customer base and
reduce dependency on the Far East. In this effort business with Malaysia, Korea,
Taiwan, UK and South America was initiated in case of Yarns. A new spinning unit
of 21,672 spinning has also commenced, which caters to the weaving units in
Shiekhupura.
The export of processed fabric and made-Ups has shown market improvement as
compared to last year. In Europe, Nishat has made the most growth in the year 1999.
It has placed us successfully in the middle to upper end of the market. Our strength in
Europe is the curtain division.
This included yarn dyed dobbies, engineered confections, different finishes and
embellished products. The plan is to continue with this winning strategy and at the
same time we are trying to find new clients in the high end. We are also exploring
business opportunities in countries like Spain and France where Nishat has very little
business at the moment.
Social Responsibility
Nishat is also taking up the social accountability issues very seriously, which are so
dear to the American consumers. Lot of big brand US companies have visited us and
are discussing the possibilities of a joint venture.
Opportunities
The opportunities are limitless, we have to review and analyze them very thoroughly
to associates with the right people in the long run. In the short term we are building a
small amount of quota, which will give us recognition as a bedding supplier
Our dyed fabric has already established its name in the market. It is being exported to
some of the leading brands of the world.
?Market leader in textile sector why
Nishat has increasing its profitability by working efficiently, procuring better raw
material and most importantly kept a very close association with its customers. It
visits its business partners frequently and provides them with the best service
possible. All of the above mentioned points led to strengthened relationship with its
business partners making it very difficult for its competition to penetrate into its
market share.
Professional Commitment
At Nishat, it is prospering due to our professional commitment toward excellence and
giving the best results at all times and against all odds. Its marketing and production
team’s co-ordinance at all times and it focus remains on maintaining its position as the
market leader in the textile sector of Pakistan.