KAL PRINTING UNIT TECHNICAL PROFILE

Knit Asia Limited

Outline

• Space utilization

• Machine summary

• Capacity

• Organogram

• Production flowchart

• Buyer name

• Category of printing

• Quality defect trend

• Expose room

• Color kitchen

• Color sub store

• Stretching process

• Coating process

•Curing process•Basic area of improvement•My study & observation•Problem findings•Solving

KAL-Printing Section Space Utilization

       

  Printing ( Sft )  

  Total Floor Area 8,250  

  2 nos Auto machine used @300sft 600  2 nos Manual table used @404sft 808Fusing Machine used 400

  Office area+ color mixing room+ store used 1066  QA and others used 533

  Total Head Count 65  

       

  Utility  

  Compressor Pre req 7 kg  

  Power Req (KW) 43.5         

05/03/23

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yKAL printing Unit -2 MC Summary (Shafipur)

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Present MC Specifications Present Machine Status

MC Using Model

Using Brand &

Made country

Machine SpecificationIn-Hand

Total MC

Out of Order MC

In-Hand Total

Usable MC

1 Auto printing Sportsman M&R

10 Head, 8-color Max Image size-20’’X20’’

Compressed air Req-100psi,Power req- 3.3KW

1 0 1

Auto printing Sportsman M&R

6 Head, 5-colorMax Image size-20’’X20’’

Compressed air Req-100psi,Power req- 3.9KW

1 0 1

2 Conveyer Dryer Sprint 2000 M&R

Power- 380V, 16amp, 3-phase, Manifold pre-3.2,

BTU/Hr-40000-300000 1 0 1

3 Exposer Table local local 11 pcs light tube 1 0 1

4 Pad Printing B-100 Inkcups

Ink cup size- 90mmImage size- 80mm

Speed one color- 720-2100(IPH)Power- 110V/10amp

Compressed air req- 80psi

1 0 1

Total 5 0 5

Printing Section: Capacity

Production Area Avg Capacity Total Daily Capacity

Table 02 Nos(one-color) 34,000 pcs/day44,000 pcs/day

Machine 02 nos (Multi-color) 10000 pcs/day

Month Production pcs

Sub-Con Pcs Remarks

January 214516February 160508March 186569April 185279May 133426June 516462July 669243August 782579September 373579October 349698

Printing Organogram

Sample coordinator

Expose Man DesignerColor Master

Supervisor Expose Assistant

Operator

Layer man

Dryer Man

Input-output man

QA InspectorColor

Assistant

Loader

Wash Man

Designation PresentManager 1

QA Officer 1Color master 1

Designer 1Asst. In-Charge 1

Supervisor 4QA Inspector 6Exposer Man 1

Operator 18Helper 31Total 65

Production Manager

QA OfficerPrint In-Charge

Printing production Flowchart

Design Making Price Quotation

Screen making & Expose design

Sample Development

Color Making

Sample submit

Sample Approval

Monthly Production Plan

Sample Making

Dyes & Chemical Requisition

Art Work Receive

Fabric Receive

Bulk Fabric Receive

Bulk Production Start

Bulk Production Delivery

05/03/23

Printing Production CapacityProduction (Pcs)

M/C or Table Production Pcs/hr/op

No of operators/

shiftHourly Daily@60% of

observed time Weekly Monthly

Printing Table-1 (One color) 240 5 1200 17,280 1,03,680 4,14,720

Printing Table-2(One color) 240 5 1200 17,280 1,03,680 4,14,720

Auto Machine-1(Multi color) 120 3 360 5,184 31,104 1,24,416

Auto Machine-2(Multi color) 120 3 360 5,184 31,104 1,24,416

Total Output 18 3,120 44,928 2,69,568 10,78,272

Buyer Name

1. LIDL2. ZARA3. MATALON4. UNDIZ5. DACATHOLON6. MORRISON7. PRIMARK8. KIK9. LPP10.MANGO11.BTR12.NOI SOULITION13.ARENA14.AEROPOSTALE15.K-MART16.US POLO17.WOOL WORTH18.JEAN FRITZ19.GKAY STATE20.C.V21.NEXT22.NEWYORKER23.CARTEX24.ZAZA25.SRG26.ADMIRAL27.ELLESSE28.FILA

Category of printing

Rubber DischargeSolventSemi-RubberFoilGlitterEmboss

(Puff) Plastisol

High density

Water/ Pigment Flock

Gel print

Reflective

Reactive

High density

Gel print

Photo print

Photo Print

Water base Rubber base

Foil Glitter base

PUFF Semi-Rubber

Plastisol Discharge

Quality defect trend in 2016 1. Spot(rubber and plastisol

base)2. Size & grading mistake3. Dirty(water base) 4. Crack (plastisol base)

Customer wise error / defects Buyer Problem type

1. LIDL 1. Spot, 2. Size-mistake, 3. Broken Print, 4. Color missing, 5. Color sticky, 6. Bundle mistake, 7. Print side

2. PRIMARK 1. Spot, 2. Size-mistake, 3. Bundle mistake, 4. Print side

3. UNDIZ 1. Spot, 2. Color Bleeding, 3. Color pass, 4. Print side

4. MATALAN 1. Spot, 2. Print side, 3. Grading Mistake, 4. Puff Uneven

5. ZARA 1. Spot, 2. size mistake, 3. color missing, 4. wrong placement

6. KIK 1. spot, 2. color crack, 3. shade variation, 4. gap

7. SRG 1. Spot

Customer wise error / defects Buyer Problem type

8. K-MART 1. Spot, 2. gap, 3. print crack, 4. dirty spot, 5. over lapping

9. MORRISON 1. Spot, 2. dirty, 3. print gap

10. DECATHOLAN 1. Spot, 2. gap, 3. uneven shade

11.MANGO 1. Spot, 2. size mistake

12. LPP 1. Spot, 2. color missing, 3. color gap

13. BTR 1. Spot, 2. color missing, 3. color crack

14. WOOL WORTH 1. Spot, 2. color missing, 3. gap, 4. print side

15. JEANS FIRTZ 1. Spot, 2. size mistake, 3. color missing

Expose RoomStrength

1. Skilled manpower2. Individual dedication to

their responsibility

Weakness

1. Need advanced exposer machine.

2. Damage light must be replaced.

3. Film should be kept in basket

4. Walls should be repaired and repainted

5. Window should be fully replaced by closed wall

6. Need advanced screen chemical attaching machine instead of manual system at present.

7. Sliding door should be placed

Damage exposer light

Open window

Film storage

Damage wall

Open door of exposer room should be replaced with sliding

dark glass door

Wash RoomStrength

Operator perfectly done the screen wash.

Weakness

1. Walls are dirty, need paint

2. Wash basin should be placed outside of the building, near drain,

3. Need high pressure nozzle to clean the screen,

4. Eye wash need to modify

Dirty exposer room

Dirty wash basin

Incorrect eye wash facility

Need High pressure nozzle

• Recommendation

Stretching machine

• Recommendation

Color KitchenStrength

1. color Master knowledge is good,

2. Quick and efficient work force

Weakness1. SOP to be developed by sample

preparation practical work , this can be done by recording the steps immediately after making the chemical mixture . Mixing ratio to be finalized by a team discussion and revalidation . Thus controlled SOP will be finalized.

2. Chemical handling process should be developed, should be introduce mixing machine instead of manual system.

3. Double door is needed

4. Walls should be painted

5. Unnecessary items should be cleaned from the room

6. Record keeping area not sufficient, need shelf,

7. Room should free of dust, need protection in top of the room from where dust are coming.

Color Chemical without Expire date

Dust in the color mixing room

Dirty behind the white cloth of the window

Damage light in the floor

Dirty wall in the color mixing room

Door exit blocked

Recommendation

1. Instead of colored box, we need to use transparent box.

2. Personal protective equipment must be use all time.

Existing Opaque color mixing box

Recommended Transparent color

mixing box

Existing Insufficient space for

record keeping

Recommended file keeping shelf

Recommended Color mixing machine

Existing Manual Color mixing

Color Sub StoreStrength

Chemical are keeping buyer wise.

Weakness

1. Unused basket should be removed from store

2. Remove cloths and make the room free from dust- need overhead cover to reduce dust

3. Weighing machine should be cleaned regularly

4. Use sliding door to reduce dust.

Damage light

Dirty in the upper wall area

Open door

Unused items

Recommendation

Existing weighing machine

Recommended clean with big table

Office AreaStrength

Skilled designer

Weakness

1. Need to repair broken chairs

2. Need shelf for keeping printing records

Damage Chair Need Shelf

Recommendation Need shelf for record keeping

Printing Table-1 & 2Strength

Samples as well as production is doing nicely.

Skilled workforce

Weakness

1. Broken glasses to be repaired or replaced to increase productivity.

2. Need standard racks for storing the screen.

3. Pattern should be kept in boxes and buyer wise systematically,

Broken Glasses

Existing racks to keep screen

Recommended rack

Existing pattern rack Recommended pattern rack

To increase productivity place one big and one

small panels in one table

Next development - One operator multi color can be make which will

reduce head count

Existing work procedure

Existing production table

Auto Printing Machine-1 & 2Strength

Machines are running nicely.

Advanced printing process can be done up to 10-color.

Weakness

1. One damage head should be repaired

2. Two flash dryer should be repaired

Damage flash dryer

Improper work procedure Standard procedure of working

Dryer machineStrength

Efficiency is okay.

Weakness

1. Need to repair belts.2. Speed controller need to

repair.

Damage dryer Belt

Improper work procedure

Damage speed controller

Recommendation Dryer machine belt and speed

controller need to be corrected as early as possible.

SampleStrength

Skilled workforce exist.

Weakness

1. Need expertise in printing sample.

2. Flock print technology need to developed in future.

Quality TableStrength

Skilled Quality inspector

Weakness Reporting system should be improved.

Recommendation Daily quality report should be checked

and take corrective actions to reduce defect.

Idle Pad printing machine

Pad Printing machineStrength

modern high speed quality printing is possible

Weakness Need to commissioning the machine

Printing Section Picture tour

Knit Asia Limited

Operators taking lunch in the production floor

Damage hanging fan

Flammable material in production floor

Flammable and toxic chemical use in production

floor

Mosquito net on M&R machine

Store material must be removed from printing section

Water drinking area

Knit Asia Limited

Unclean drinking water area

Stretching Process Findings & Standard

Stretching Process Findings & Standard

Coating Process Findings & Standard

Coating Process Findings & Standard

Coating Process Findings & Standard

Curing Process Findings & Standard

Machines and other necessary instrument for Printing Item name

QuantityEstimated price

1. Exposer machine 1 pc USD$5,000

2. High pressure hose pipe 10 pc

3. Color mixing machine 1 pc USD$2,000

4. Record keeping shelf 4 pcs USD$100X4= USE$400

5. Screen making instrument 2 pc

6. Transparent boxes for ink 500 pcs

7. Large Basket for film keeping(36X21X50cm) 20 pcs USD$1X20= USD$20

8. Sliding door 3 pcs

9. Temporary roof 3 rooms

10. Recommended screen keeping racks 10 pcs

11. Recommended pattern keeping rack 3 pcs

12. Multi color manual rotating table 3 pcs USD$1200X3 = USD$3600

13. Repair of Printing table 90 ft USED$5X90 = USD$450

Basic Area Of Improvement with Urgency Exposer & wash room 1.Damage lights on exposer machine to be replaced

Color Mixing room 1.Uniform for chemical handling operators.2.SOP composition of sample developing chemical should be written immediately after making chemical.3.Record keeping area not sufficient, need shelf,4.Room should free of dust, need protection in top of the room where dust are coming.

Printing chemical Store room 1.Training & development with practical sessions 2.MSDS for all chemical MUST hang on store .3.Other section item remove from Printing section.

Production & development1.Daily production report(mandatory) 2.Daily Quality report (Mandatory)3.Daily production target need to fix one day before.4.Screen making process should be develop for correct screen tension.5.Screen keeping racks to be increase. 6.Training for the operators to develop skill.7.Printing table MUST be repaired to increase productivity.

Production on table 1.Hourly target and production monitor by management immediately. This is one of the root cause of low productivity.

Auto printing machine and dryer 1.Immediately trained up operators or recruit because 6000 pcs/day production loss due to skilled operator shortage.2.Repair Dryer machine’s speed controller.

Attached technical appendix

My study & observation

Human Resource Accounting(HRA)Type of employees Persons Grade Avg. gross Education Avg. Age Exprence District

Sr. Machine OP. 1 G-03 7362 V 27 8 Tangail

Operator & QI 16 G-04 6939 VIII -HSC 27 4 North bengal

Jr. Operator 1 G-05 6042 V 34 3 North bengal

General Operator 6 G-06 6132 V 31 5 Tangail

Helper 29 G-07 5540 V 38 3 North bengal

Staff (Supervisor) 5 MGT 12792 VII 28 11 Tangail

Shafiqul Islam 1 MGT 55000 BSS (Pass) 40 11 Tangail

Md. Zillur Rahman 1 MGT 29000 BA (Pass) 37 5 Nogaon

Md. Nazmul Hoque (Emon) 1 MGT 22000 HSC 37 1 Jamalpur

Saiful Islam 1 MGT 29705 VIII 27 11 Tangail

Ataur Rahman 1 MGT 20500 SSC 38 4 Jamalpur

Loader 2 S-04 6940 V 38 4 North bengal  65   8553   34 6  

Overall Process Flowchart

Design Published

Preparation of the Screen Board (Hand Made)

Expose Design (Traditional)

Art Film

Using Hand Coated

Prepare Screen Design (Performing Screen Wash by normal water Flow)

Color Kitchen (Mixing the Color

Manually)

Printing Process (Buyer’s

Requirement)

Auto Printing (Auto Machine)

Manual Printing (Handling by Manpower)

Steps for Operation

• Step 1 : Preparation of the Screen Board• Step 2 : Coating Process• Step 3 : Design Process• Step 4 : Color Kitchen• Step 5 : Criteria of Printing• Step 6 : Quality Assurance

Stepwise Process Flowchart

Making the Screen Board

Frame making

New frame Old frame Old machine frame- reuse for 2-3 times

Old screen coated by bar remover

Wash by water flow

Dry

Remove the old mesh

Clean the frame

Dry

Adhesive on the frame & dry

Clean the frame

Dry

Adhesive on the frame & dry

Put the mesh on the frame

Stretch the mesh

Adhesive on the frame & dry

Cut the outside of mesh

Ready to use

Design Process

Color Room

No

Yes

Received Artwork

Check color standard & chemical

Check fabric quality

Select the color for required fabric

Mix the color

Prepare the color combination

Check color shade on fabric

Is it ok? Adjust the recipe

Keep record of mixing recipe

Send to print sample

Color Room

Problem Analysis

• Cause – Effect Analysis ( Fish-Bone Diagram )• Pareto Chart Analysis• Root – Cause Analysis

Cause – Effect Analysis

MAN MACHINE

METHODS MATERIAL MANAGEMENT

Lack of Decision

Lack of System

Not Clean Properly

Lack of Observation

Random Screen Preparation

Improper Machine Setup

Lack of Preventive Maintenance

Unavailability of Proper Machine

Dryer Belt Damage Compressor Failure

Improper Power Sourcing

Frequent Design Change

Improper Mesh Selection

Scheduling Problem

Unknown Production Time

Not Proper Dryer

Improper Planning

Dot Missing

Damaged Screen

Curved Frame

Color Matching Problem

Lack of Sufficient Useable Material

Poor Conservation of Color Ignorance Problem

Improper Training

Lack of Worker Motivation

Frequent Order Change

Pareto Chart AnalysisIdentification of Problem(1st – 13th December, 2016)

Problem Frequency Cumulative cumulative %

Screen not keeping proper place 9 9 12.0

Not proper screen tension 7 16 21.33

Random screen preparation 10 26 34.67

Frame curved 1 27 36.0

Wrong color combination 6 33 44.0

Wrong mesh selection 3 36 48.0

Serial mistake / Design mistake 3 39 52.0

Not proper gumming 2 41 54.67

Design revise 6 47 62.67

Not proper drying 17 64 85.33

Screen shot without pattern 1 65 86.67

Lack of decisions 6 71 94.67

Others 4 75 100

Pareto Chart Analysis

Solving & Improvements

Improvements SN

     Price ref 2 USD

Thailand

 Items need to purchase to remove the CAP 1 Price ref 1 USD

china 

1 Stretching machine,Mass binding machine

1 5000 7400  

2 Tension meter, Screen tension checking machine 1 200 750  

3 Automatic coating Machine, Screen coated machine 1 16000 20250  

4 High pressure hose jet 10 200      5 Color mixing machine small ( 10 liter ) 1 2000      

6 Shelf for file, transparent boxes for ink , large basket for film keeping( 36x21x50 cm),

Lot 400

 

 

 

7 Multi color manual rotating table 3 3600      8 Sliding door , roof 3 sets 500      9. Screen keeping racks, pattern keeping rack , Lot 600      

10. Repair of printing table ( emergency ) with tempered glass 90 ft 450

  

 

11. Expose Machine/unit with dryer, Design expose and coated frame rack

  550013280

 

12. Installation and commissioning, painting , lighting , decoration Lot 1000

  

 

13. Conveyer belt repair of Dryer machine 1 1000      

14. Digital Thickness meter 1 200      

  Grand total   36650 USD , 29 lacs BDT      

Miscellaneous Improvements

• Screen wash table• All walls are painted by white color (lime stone)• Screen frame rack- large (Buyer wise production)• Notice board• Multiple color for entrance wall• Attached (color sub store + color kitchen) & extend

to ceiling with A/C room• Rack arrangement in color kitchen• Expose room should have dark environment(no

window is needed)

Miscellaneous Improvements

• Need sample table• Worker requirement – (2 sample man+ 3 helper);

Auto machine– (2 operator+6 helper); Color kitchen – (1 helper)