Industrial Attachment of aboni textiles ltd

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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTABONI TEXTILES LIMITED

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3

Chapter - I

PROJECT DESCRIPTION

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ABONI TEXTILES LIMITED

TYPE

ABONI TEXTILES LTD. is a joint venture knit composite mill with Denmarkintegrated vertically with knitting & dyeing section set up in the same shed side by side withgarments section established in just outside of the shed. lt is equipped with circular and flatknitting dyeing, and finishing. It produces fine quality cotton and blended knit fabrics in avariety of styles. Jerseys, ribs, piques and other single knit textures are all available currentproduction in tabular exceeds 3 tons per day. Fabric weights range from 130 GSM to 260GSM in styles. Which include jersey, piques, needle out textures and fabrics with Lycra.Aboni Textiles Ltd. lt was established through a technology partnership with TPM of U.K.

The Aboni Textiles Ltd. was the most advanced and high-the equipment from theworld’s leading manufacturers. These machines have been coupled with the best skilledtechnological support-expatriate staff and local experts trained at the suppliers plants.

Year Of Establishment

The Aboni Textiles Ltd. was established on April , 2001.

Location

Aboni Textiles Ltd. is situated at Tetuljhora Union, Hemayetpur, Savar, Dhaka.. It is

located at the southest corner of savar road and about 20 k.m. away from college of Textile

Technology, Tejgaon, Dhaka.

Plot# 169-171, 2-B/1, Darus Salam Road,

Tetuljhora Union, Mirpur, Dhaka-1216,

Hemyaetpur, Bangladesh.

Savar, Dhaka.

SITE LOCATION OF ABONI TEXTILE LTD.

Address Of Mill Address of Head office

5

MIRPUR ROAD HEMAYETPUR

SPONSORS

Aboni textiles ltd. is an industry of “Babylon group”. It works in join venturewith a company come from Denmark. The Danish company sendtheir Representative in the factory location.

PRODUCT MIX

Aboni Textiles Ltd. works as per demand order of the Aboni Knitwear Ltd..Also it produces a fraction of its total production by the order of subcontract of othermill both knitted fabrics & finished fabrics (dyed fabrics) .

ANNUAL PRODUCTION CAPACITY

The circular knitting m/c’s has able to fulfill the fabric requirement for AboniKnitwear ltd. The mill works in two shifts- (a) Shift-A & (b) Shift –B. The annual

production capacity of grey fabric is about 1300 ton collar & cuff is about3285000pcs. & finished fabric with dyeing is about 2500 ton .

PROJECT COST

DHAKA

GAVTOLIBUS STAND

AMINBAZAR

DARUS SALAMROAD

AboniTextileLtd.

SAVAR

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The project cost of Aboni textiles Ltd. is near about 300 million of Bangladeshi taka

DIFFERENT DEPERTMENTS

The mill has different departments working in co-ordination with each other under theproduction manager of dyeing. The Aboni textile mill consists of several depertments.1) Theknitting dept.2) Grey inspection dept.3) The dyeing lab4) Dyeing dept.5) Finishing dept.6)Quality assurance dept.7) Maintenance dept.8) Utility dept.9) Store & Inventory dept.& 10)Administration dept. With all these departments working in a sequence from beginningdepartment to end. The garments section also be added by all those section & considered as apotential department of the mill.

PHYSICAL INRASTRACTURE

The mill is built in such a way that there is possibility for further expansion of themill. The structure such as mill, office buildings, record rooms, guardrooms & dining roometc. are made of solid hard concrete & brick mtls. . The whole area is surrounded by safetybrick wall .The main set up for m/c’s are built of corrugated iron & iron sheet, transparenthard plastics with enough ventilation & scope for passing light & air.

REMARKS

Aboni Textiles Ltd. is going to prove its own standard about product quality in worldmarket as they know that their reputation depends on its quality. They have applied forISO9001 to exert its standard .They expect they shall achieve the ISO9001.

ABONI TEXTILES LTD. AT A GLANCE

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Aboni Textiles Limited

1. Name of the project : Aboni Textiles Limited .

2. Project Proponent : Babylon Group of Companies.

3. Location : Tetuljhara Union, Hemayetpur

Savar,Dhaka

About 2o kms west of Dhaka City and

5 km from Savar.

4. Communication : The project is easily accessible by road.

5. Product Name : Knitted, bleached and dyed fabric.

6. Plant Capacity : 2500 ton.

7. Factory Area : Approx. 25000 sq. feet

8. Major Chemicals Used : Various Chemicals including dyes,

hydrogen peroxide. Sodium, Hydroxide etc.

9. Type of the factory : Vertically integrated.

10. No. of employees : Approx. 200

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Chapter - II

MANPOWER MANAGEMENT

ORGANOGRAM:NESAR AHMED

(MANGINGDIRECTOR)

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Organ gram of maintenance:1. Maintenance manager2. Forman

ARUN KUMARMONDAL

MANAGER(PRODUCTION)

SENIORMERCHANDISER G.M. REZAUL HAQUE

DEPUTY MANAGER(KNITTING)

SYED MD. AZIZURRAHMANM

DEPUTY MANAGER(DYEING)

JUNIORMERCHANDISER

SUPERVISER Md. MAHBUBULALAM

(LAB IN CHARGE)

PRODUCTIONOFFICER(DYEING)

KAMAL UDDINAHMED

(EXECUTIVEDIRECTOR)

JESPER GROS(FACTORYMANAGER)

MR. HUMAYANMANAGER

(MARKETING)

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Organ gram of administration section:

1) Admin officer.

2) Account officer

3) Account officer

Organ gram of store:1. Store in-charge.2. Asst. Store in-charge

SHIFT CHANGE:

The mill is running on two shift

a) Day shift (8 a.m. to 8 p.m.)

b) Night shift (8 p.m. to 8a.m)

Besides the general shift is also available there which duration is 8 p.m. to 6 p.m

through the whole week.

RESPONSIBILITIES OF PRODUCTION OFFICER:

- To ensure the production process control.

- To check the production sequence.

- To assure the quality.

- To control the worker.

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Chapter - III

MACHINE DESCRIPTION

NO. OF MACHINE

Circular knitting m/c = 11Flat knitting m/c = 9

12

Dyeing m/c = 6 (with sample dyeing m/c)Squeezing m/c = 1Dryer = 1Calendering & Compacting m/c = 1Cloth inspection m/c = 5

BRAND NAME

Type of m/c Brand Name Orgin Totalno. ofm/c

Circularknitting m/c

Mayer & Cie Germany 8

Circularknitting m/c

Fukahama Taiwan 3

Flat knittingm/c

Kauo Heng Co.Ltd.

Taiwan 9

Dyeingm/c

Sclavos Greece 4

Dyeingm/c

Longclose England 1

Dyeingm/c

Dilmenler Turkey 1

Squeezingm/c

Santa stress Switzerland 1

Dryingm/c

Santa shrink Switzerland 1

Calendering&Compactingm/c

Santex.Group.com Switzerland 1

ClothInspection m/c

UZU Thailand 5

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LAYOUT OF KNITTING SECTIONW

S N

E

SPECIFICATION OF CIRCULAR KNITTING M/C

S/l no.of m/c

1 2 3 4 5 6 7 8 9 10 11FUKA Mayer Mayer Mayer Mayer Mayer Mayer Mayer Mayer FUKA FUKA-

54321

678910

11

14

Brand -HAM

A

&Cie

&Cie

&Cie

&Cie

&Cie

&Cie

&Cie

&Cie

-HAM

A

HAMA

Type SHBIR-2

FV 2.0 RELA-NIT3.2 II

MVA-3.2

RELA-NIT3.2 II

MVA-3.2

MVA-3.2

RELA-NIT3.2 II

OV-3.2QC

SH-IAG24

SH-IAG24

Gauge 18 18 24 24 24 24 24 24 24 24 18

Cyl.Dia. 38” 34” 30” 24” 26” 20” 24” 30” 30” 34” 36”

Feeder 76 72 96 78 84 63 78 96 96 96 76

Needle 2x2149

2X1920

2268 1800 1944 1512 1800 2268 2x2268

2X2564

2x2036

DrvingPowerMotor

4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W

Work-ing

Volt.

415VOLT

415VOLT

415VOLT

415VOLT

415VOLT

415VOLT

415VOLT

415VOLT

415VOLT

415VOLT

415VOLT

Freq-uency 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz.

Nomi-nal

Speed33

M/MIN

33M/MI

N

33M/MI

N

33M/MI

N

33M/MI

N

33M/MI

N

33M/MI

N

33M/MI

N

35M/MI

N

33M/MI

N

35M/MIN

AirConn-ection

6BAR

6BAR

6BAR

6BAR

6BAR

6BAR

6BAR

6BAR

6BAR

6BAR

6BAR

Year2003 2001 2001 2001 2001 2001 2001 2001 2001 2003 2003

M/CType Rib Rib S/J S/J S/J S/J S/J S/J Inter-

lockInter-lock

Rib

CIRCULAR KNITTING MACHINE:

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Circular Machine is widely used throughout the knitting industry to produce fabric.

This machine can be built in almost any reasonable diameter and the small diameter of unto

5 which are used for wear.

M/C’s for outerwear and under wear may vary from 12” to 60” in diameter according

to requirement. This m/c. can be used either as fabric or for making Garments section

completely with fancy stitch. Latch needles are commonly employed in all modern circular

m/c. Because of their simple action and also their ability to process various types of yarn.

Plain circular m/c. uses only one sets of needles, circular Rib m/c uses two sets of

needle i.e. cylinder needle and dial needle, the inter lock circular knitting m/c also uses two

sets of needle by needles are long and short respectively for both dial and cylinder, that is

why multiple design and thick fabric can be produce with that m/c. that m/c is also called

double jersey m/c.

Some Terms of Knitting M/C

M/c Gauge - needle/inch (Varies according to diameter)

Needle Type - Latch

Needle bed type - single cylinder, double cylinder, Cylinder and dial, long short

needles far cylinder and long short needle for dial.

Two principle operations exist: -

English system- where the cams and yarns stands revolve by needle and fabric take

down is stationary.

American system- where the needles & fabric take down revolves by cams and yarnstands are stationary.

#Main Parts Of Knitting M/C

1) Latch needle

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2) Cylinder3) Dial (In case of double jersey m/c)4) Cylinder driving gear.5) Sinker6) Sinker operating cam.7) Cam box for needle.8) Cam plate for needle.9) Take up roller.10) Stop motion.11) Yarn feeding guide.12) Tension adjustable screw.11) Cone strand.12) Positive feed system.13) Tension pulley.

# Important Parts Of Machine:

Name of parts FunctionMPF Magnet/Air Nozzle To deliver the yarn in proper place

Knot Catcher To hold knot, slub and after holdingstop the machine

Eye pot To pass the yarn smoothlyHose pipe To clean dust

Needle fault detector To detect the needle from breakOil Nozzle To flow oil into needle, sinker

Oil Pipe To pass oilAir flashing Nozzle To flow air into needle, sinker

Air flashing pipe To pass airFabric detector To detect the fabric faultMain Switch To start or off the m/c

Take down light To visualize the fabric while takeoff

Important Equipment Of Circular Knitting Machine:

1. START / STOP / INCH BUTTONS:

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Complete set of easily accessible START / STOP / INCH buttons at top lf eachleg.

2. RATCHET LEVER:Permits hand movement of the machine.

3. AUTO-STOP MOTIONS:Automatic three (3) stage 24v. Yarn motion, positive feed tapes and knitting

zone. Indicator lamps are on individual stop motions and on the main control panel.While the yarn is broken or too tight that we can find the location, which is broken aswall as to repair, meanwhile the motor can break and stop operation at once to keepthe security of machine.

4. FREE STANDING SIDE CREEL:With an active and reserve package for each feed.

5. AUTO-COUNTER:Three- (3) shifts revolution with digital display counter with predetermined

stop, to settle freely the weight or yard of fabrics.

6. VARIABLE SPEED DRIVE WITH MACHINE BRAKE:Transistor inverter provided for free controlled, the process of “V.S. MOTOR-

DRIVE” from slow operation to normal operation is quite and fast brake to preventdamages in case of needles or yarn breakage.

7. FABRIC TAKE-UP SYSTEM:With variable speed control by a belt drive set can be adjusted the speed for

different course of fabric-constant and uniform fabric tension.

8. SAFELY GUARD SWITCH:Machine cannot be started or run with guards open, this guard have reinforced

fiberglass window for easy fabric inspection.

9. AUTO-LUBRICATION:The automatic central pressurized oil sprayer can be adjusted at cycling time

and quantity to make cylinder, dial, sinker ring’s cams, needles and sinkers lubricatedenough, besides it has the function cooling and clearing and clearing.

10. AUTO-LINE REMOVAL SYSTEMS:

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Three fans on each rotating arm for clearing off any dust of creel and knittingzone.

LAYOUT OF FLAT KNITTING SECTION

FLAT KNITTING MACHINE:

7

8

5

6

3

4

1

2

9

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Flat m/C’s are the most important industrial knitting m/C’s. The needles are mountedin beds opposite in an inverted V. formation, are operated by cams in a reciprocatingcarriage.

Two sets of needles normally position at right angle to cach other, Latch needles areCommonly used. Because of the almost unlimited popular in western countries. Their maindisadvantages low productivity compare to other weft Knitting m/c.

SPECIFICATION OF FLAT KNITTING M/C

# Brand name: - KAUO HENG KH-313# Model: - KH-313# Gauge: - 14G# Knitting Width: - 54”# Knitting Speed: - 1.2 m/sec (Varies according to gauge & knitting speed.)# Yarn Carrier: - 12 Yarn. Carries on 3 double rails.# Cam System: - Single system (Tuck on front bed & near bed. High butt &

Low butt system.)# Stitch Density: - Electrical control with stopping motion 00-99 levels.# Racking: - 6 levels to left on right each per time.# Fabric Take Down: - Compound main roller, torque motor control, high

Speed & low speed adjustable.# Stop motion: - Yarn break, knot, needle break, shock, and fabric drop out, wrap

Around check, price count, motor overload etc.# Drive: - Timing belt, no oil speed programming speed.# Top Tension: - Electronic top tension, easy to thread the yarn through.# Operation Lamp: - Green-Normal operation.

Yellow- Abnormal stop.# Power: -220v, 1/3 HP motor.# Control System: - Computer controlling system & L.C.D display.# Wooden Case: - 2250X700X1790 mm.; N/G weight 550-1700 kgs.

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Chapter - IV

RAW MATERIALS

TYPES

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YARN SOURCE

Yarn Types Source Price

Cotton

Prime Spinning Mills.Youth Spinning Mills.Utah Spinning Mills.Square Spinning Mills.Hanif Spinning Mills.

Combed- 3$(approx.)Carded- 2.85$(approx.)

Polyester Cotton

India 2.16$(approx.)

Grey Mélange

Shamim Spinning Mills. 2.75$(approx.)

Lycra (Spandex)Local Market(Made In Korea)

900 tk./kg

Yarn Types Composition % Count Dyed /Undyed

Cotton 100% 24,26,30,34,40 Ne(Both card &comb)

Undyed

Polyester Cotton(PC)

P-65%, C-35% 26, 28 Ne. Undyed

Grey mélange 100% 24 ,26 Ne Dyed

Lycra (Spandex) 100% 40, 20 Denier Undyed

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ANNUALYARN REQUIREMENTS

Monthly yarn consumption is approximately 225 ton/month.So the annual requirement of yarn is approximately 2700 ton/month.

REMARKS

As the yarn consumption totally depends on production & production depends onorder of buyer, so recommendation of yarn type, source, price, reuirements may vary

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Chapter - V

PRODUCTION PLANNING,SEQUENCE &OPERATIONS

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PROCESS FLOW CHART OF ABONI TEXTILES LTD.

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tap positivefeeding arrangement and tension devidce

Knitting

With draw the rolled fabric & weighting

Numbering

Grey inspection

Dyeing & Finishing

Final inspection

Packing

Delivery

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PROCESS DEFINITION

Knitting is the interlocking of one or more yarns through a series of loops. The lengthwise columns of stitches, corresponding to the warp in woven cloth, are called WALES; thecross wise rows of stitches, corresponding to the filling in woven cloth, are known asCOURSES, FILLING KNITS (WEFT KNITS) are those fabrics in which the courses arecomposed of a single strand of yarn, while warp knits are those in which the Wales arecomposed of single strands of yarn. GAUGE Corresponds to the yarn count in a wovenfabric, and is defined as the number of needles or yarns in ½ inches of cloth. The higher thegauge, the more compact and finer the cloth.

PROCESS REQUIREMENTS

In Aboni Textiles Ltd. 3 types of machines are used for producing knitted fabric.These are: -

1. Circular knitting Machine (Single Jersey Machines)2. Circular knitting Machine (Double Jersey Machine)3. Flat knitting Machine.

CONSIDERABLE POINTS TO PRODUCE KNITTEDFABRIC.

1. G.S.M.

It is technical term that indicates the weight of the fabric per square meter.

2. CHANGING OF G.S.M:

(I) Major control by quality pulley.(ii) Minor control by stitch length adjustment.

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Altering the position of the tension pulley changes the G.S.M. of the fabric. Ifpulley moves towards the positive directive then the G.S.M. is decrease. And in thereverse direction G.S.M will increase.

3. POINTS THAT SHOULD CONSIDER IN CASE OF G.S.M. CHANGING:

1. Tension pulley2. Cam position3. Take up motion

4. FACTORS THAT SHOULD BE CHANGE IN CASE OF FABRIC DESIGN ONQUALITY CHANGE:

1. Cam setting2. Tension pulley3. Set of needle4. Size of the loop shape

5. RECOMMENDABLE POINTS OF A BUYER:

1. Diameter of the fabric2. Design of the fabric3. G.S.M. of the fabric4. Total weight of the fabric5. Yarn count6. Types of yarn (combed or carded)7. Color of the fabric.

PRODUCTION CALCULATION:

1. Production /kg/shift at 100% efficiency:

=RPM of m/c X NO. of Needle X no of feeder X SL(mm) X60X8

10X2.54X36X840X2.2046XYarn Count

2. Production in Length/Shift in meter:

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=No. of Course

Course/cm

=M/C RPM XNO of Feeder X60X8 X Efficiency

Course/cmX100

3. Fabrics width in meter:

=Total no of walesWales/cm X100

=Total no of needles Knitting

wales/cmX100

R.P.M. USED IN CIRCULAR KNITTING MACHINE:

M/C Type R.P.M. Use24G S/J 3024G S/J 3724G S/J 3924 G S/J 4824G S/J 4824G S/J 4118 G Rib 2018G Rib 2118 G Rib 2024 G Int 3024 G Int 30

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RELATION AMONG YARN COUNT, GAUGE, S.L., GREY GSM, FINISHEDGSM & M/C DIA. (ACCORDING TO EXPERMENT):

M/CNo.

M/CGAUGE

FabricType

Yarncount.

GreyGSM

S.L.(mm)

FinishedG.S.M

GreyDia

M/CDia.

1 18 G 1x1 Rib 30/1 CC 147-148 2.74 200 45" 38"

2 18 G 1x1 Rib 26/1 CC 170-172 2.74 200 42" 34"

3 24 G S/J-Lycra

30/1 CC ______ 2.80 220-230 35" 30"

4 24 G S/J 26/1 CC 126-127 2.90 160 30" 24"

5 24 G P.PK 26/1GM 160-165 2.65 205-210 32" 26"

6 24G S/J 24/1 KC 140-142 2.86 180 26" 20"

7 24 G S/J 26/1 CC 126-127 2.90 160 30" 24"

8 24 G DoubleLacoste

26/1 PC 158-160 2.80 200 56" 30"

9 24 G P/Int 40/1CC 145 1.65 190 30" 30"

10 24 G P/Int 34/1 CC 162 1.70 220 34" 34"

11 18 G 1x1 Rib 26/1 CC 168 2.74 240 44" 36"

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FLAT KNITTING

PROCESS DEFINATION

Flat m/C’s are the most important industrial knitting m/C’s. The needles are mountedin beds opposite in an inverted V. formation, are operated by cams in a reciprocatingcarriage.

Two sets of needles normally position at right angle to cach other, Latch needles areCommonly used. Because of the almost unlimited popular in western countries. Their maindisadvantages low productivity compare to other weft Knitting m/c.

OPERATION PROCEDURE OF FLAT MACHINES:

To start operation, depress a green button provided at the letf- hand side of themachine. If either of the red buttons fitted at the right and left sides of the machine is pushed,the machine will stop. For manual operaion, first push a black clutch button at the right handlower part of the machine to disconnect the clutch. Next, push away and turn right manualoperation handle. To reconnect the clutch for automatic operation, pull the manual operationhandle. The clutch lever is of 2-step type. When it is set to the 1st step, changeover drum willturn lightly, When performing link fitting to the drum or reknitting, the lever should be set atthis position. the clutch is connected when the clutch lever is raised to the 2nd step.Note :

Before raising the clutch lever don’s fail to push the START switch ( green button).The clutch lever would not be raised unlelss motor is on operation. Forecible raising of theleer will cause machine trouble on speed change mechanism

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PROGRAM SET ON M/C TO PRODUCE PLAIN COLLAR

001 3 45 7 _1_ 000__000__000 1 45 1 000

002 0 45 7 _1_ 000__000__000 0 45 1 000

003 0 45 7 _1_ 000__000__000 1 00 0 000

004 3 45 7 _0_ 001__003__000 1 45 1 004

005 0 45 8 _1_ 000__000__000 1 45 1 000

006 0 45 8 _1_ 000__000__000 1 00 1 000

007 0 00 0 _0_ 000__000__000 1 45 0 000

008 0 00 0 _0_ 000__000__000 1 45 0 000

009 1 22 9 _1_ 000__000__000 1 22 1 000

010 2 60 9 _1_ 000__000__000 0 00 0 000

011 0 00 9 _0_ 000__000__000 0 65 1 000

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012 0 60 9 _1_ 004__011__000 0 00 0 012

013 0 45 7 _1_ 000__000__000 0 45 1 000

014 3 45 7 _1_ 045__000__000 2 45 1 000

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FABRIC ANALYSIS:

1)FABRIC NAME : POLO PIQUE (P.PK)

NOTATION DIAGRAM:∙ ∙ ∙ ∙ ∙ ∙∙ ∙ ∙ ∙ ∙ ∙∙ ∙ ∙ ∙ ∙ ∙∙ ∙ ∙ ∙ ∙ ∙

CAM ARRANGEMENT NEEDLE REPEAT

LEGENDS:

^ ^ ∏ ∏ 1∏ ∏ ^ ^ 2^ ^ ∏ ∏ 3∏ ∏ ^ ^ 4

^ = Knit cam

∏ = Tuck cam

1 = 1 Butt Needle2 = 2 Butt Needle3 = 3 Butt Needle4 = 4 Butt Needle

S W A TC H

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2)FABRIC NAME : DOUBLE LACOST

NOTATION DIAGRAM:

∙ ∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ ∙ ∙ ∙ CAM ARRANGEMENT NEEDLE REPEAT

^ ^ ^ ^ ∏ ∏ 1^ ∏ ∏ ^ ^ ^ 2^ ^ ^ ^ ∏ ∏ 3^ ∏ ∏ ^ ^ ^ 4

S W A TC H

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3)FABRIC NAME : (1X1) RIB

NOTATION DIAGRAM:

∙ ∙ ∙ ∙ .

∙ ∙ ∙ ∙


For dial:

^ ─ 1^ ─ 2

For cylinder :

^ ─ 1^ ─ 2

S W A TC H

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3)FABRIC NAME : (2X2) RIB

NOTATION DIAGRAM:

∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ .


For dial:

^ ─ 1^ ─ 2

For cylinder:

^ ─ 1^ ─ 2

S W A TC H

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4)FABRIC NAME : SINGLE JERSY

NOTATION DIAGRAM:

∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ ∙ .


^ ^ 1^ ^ 2^ ^ 3^ ^ 4

S W A TC H

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5)FABRIC NAME : (1X1) INTERLOCK

NOTATION DIAGRAM:

∙ ∙ ∙ ∙ ∙

∙ ∙ ∙ ∙ ∙


For dial:

^ ─ 1─ ^ 2

For cylinder:

─ ^ 2^ ─ 1

S W A TC H

38

Chapter - VI

QUALITY ASSURENCE SYSTEM

39

QUALITY ASSURANCE PROCEDURE

#1)Body & Rib Inspection:

All rolls are kept in front of the inspection m/c time to time and are inspected over thegreige inspection m/c visually in a pre-set speed against light. For any major or minor faultslike thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, slubs etcare recorded in greige inspection report to classify the fabric based on the four point system.

#2)Collar & Cuff Inspection :

Collar& cuff are inspected visually under the light box, any major or minor faultycollar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round problemetc properly counted and recorded.

#3)Fabric Roll Identification:

Based on the sequence of greige inspection, the inspector serially numbers each rollensuring that all rolls having the knit card with complete details of the roll.

PROCESS REQUIREMENT

#Cloth Inspection M/C:

Name of the m/c: UZU M/c for GarmentModel : UZ 900.31Voltage : 220v Freq.-50/60 Hz.Current : 3 amp.Orgin : Thailand.Serial : 0092522Date : 01/11/2001

#Key Accessories :

Key accessories used for greige inspection process are:- Cutter/scissor Nipper Pointer Weighting balance Inch tape.

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QUALITY STANDARD

Aboni Textile Ltd. maintains the ISO standard in case of quality. Therefore, the fourpoint system is followed to inspect the body & rib fabric. The defects found and points givenagainst are recorded in the inspection sheet. Following table shows the four point gradingsystem followed by greige inspection at Aboni.

Four point grading systemSize of defects Penalty

3 inches or less 1 pointOver 3 inch but not over 6 inch 2 pointOver 6 inch but not over 9 inch 3 pointOver 9 inch 4 point

Following table shows common body and rib faults and response by greige inspectionsection at Aboni Textile Ltd.:-

Rejection criteria for body & ribsNo. Faults Response

1. Needle mark Major needle line is rejected2. Stripe Major needle line is rejected3. Barre mark Rejected4. Contamination & fly Approved for color but for white

shed 1 point is assigned5. Slubs 1 point6. Thick thin place Reject7. Birds eye 1 point8. Pin holes 1 point9. Wrong design Reject10. Mixed yarn Discuss with manager11. Sinker mark Major sinker mark is rejected.12. Missing yarn Use 4 point13. Holes Do14. Oil line/stain Do15. Chemical Do16. Dirt stain Do17. Crease line Do18. Uneven tension Discuss with manager

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Following table shows common collar and cuff fault and response taken by greigeinspection section at Aboni Textile Ltd.:-

Rejection criteria for collar & cuffNo. Faults Response

1. Wrong ply Reject2. Hole Reject3. Needle line Reject4. Slubs Reject5. Wrong design Reject6. Wrong tripping Reject7. Fly & contamination Acceptable for color but not for white8. First round problem Reject9. Uneven tension Discuss with manager10. Missing yarn Reject11. Crease line Reject12. Rust line Reject13. Oil stripe Reject14. Thick-thin Reject15. Wrong tube Reject

Following theory is used to calculation of Acceptance Quality Level:

A.Q.L= Points Counted X 36" X 100Roll Length X Fabric Width

Following table shows the acceptance calculation followed by the greige inspectionsection at Aboni Textile Ltd.:-

Acceptance calculationFactory: Roll yardage (A)

Total points founds(B)

Formula :BA X100 =points per 100 yard

Classification :<= 40 points = A type

41-60 = B type61-80 = C typeabove 80poin = Reject

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RESPONSE OF Q.C OFFICER

Response To Q.C Faults :-

Faults ResponseYarn fault Inform yarn supplierKnit fault Inform knitting department

Response To Machine Fault :-

Faults ResponseAny electrical fault Inform electrical maintenanceAny mechanical fault Inform mechanical maintenance

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Chapter - VII

MAINTENANCE

44

MAINTENANCE:

It is required for proper functioning of knitting machines.

TYPES OF MAINTENANCE:

1. Routine maintenance.2. Unscheduled major maintenance.3. Scheduled minor maintenance.

(1) Routine maintenance: During this maintenance production should be off. During this maintenance cleaning should be done During this maintenance setting should be checked & adjusted if necessary. During this maintenance oiling should be done It takes approximately 5-6 hrs.

(2) Unscheduled major maintenance: It is done suddenly. During this maintenance production should be temporary off. It takes one day (minm) but it depends on availability of parts.

(3) Scheduled minor maintenance: During this maintenance production should be temporary off It takes half a day.

(4) Preventive maintenance: It is done regularly. During this maintenance production should be temporary off. It is one kind of rectifying system..

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MAINTENANCE PROCEDURE:

1. Cleaning procedure of the machine:

Machine generally cleaned during running by theoperator. He uses the air gun to remove dust, hairy fiber, and other foreign matter depositedon the machine. Major cleaning operation is done when machine breaks down.

i. Type of cleaning:

Manual cleaning by compressed air with the air gun.

ii. Cleaning points:

Needle Sinker Creel tube Feeder Yarn Body of the machine

iii. Cleaning frequency:

Daily per shift

2. Oiling procedure of the machine:

Nowadays all knitting machinery has automation.Lubricating system in the machine is automatic. When machine’s different zone feels therequirement of oil then oil circulates to that zone in correct proportion from the oil tank bypumping. Operator just check the oil tank either it is full or empty. When the tank is going tobe empty then operator fill the oil tank by the recommanded oil. If the machine were inactivein auto lubrication then there is a push button, which circulates oil to different zone.

i. Type of oil:

Gear oil 630 (Mobil) Textile oil light (Mobil)

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ii. Type of grease:

EP3 XHP – 222

iii. Name of the greasing points:

Dial gear Cylinder gear Roller gear Chain Sprocket

iv. Greasing frequency:

Not frequently used.

v. Name of the oiling points:

Needle butt Cam Trick Sinker

vi. Oiling frequency:

Daily per shift in running machine Changing of gear oil in dial after 2000 hours.

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3. Setting points and their effect of changing:

Setting points Effects Quality adjustment

pulley (QAP) Yarn tension & stitch length

Gauge meter Cylinder movement (Up & Down), Control yarn tension and stitch length.

Tension bolt on cambox

Cam box movement (Up & Down), Control yarn tension and stitch length.

Spreader bar Grey fabric diameter control, Stitch length control

Fabric takedowntension pulley

In clockwise rotation of button fabrictakedown tension increases & vice-versa

Centering bolt Selection of rib or interlock gaiting Takedown

roller/change wheel Fabric takedown tension control

4. Maintenance schedule of the machine:

Use 15-20 drops of oil per day in each machine dial. Give needle oil daily while the machine is running. Further oil change will be carried out after every 3 months. Grease to be given to all movable parts.

5-6 drops oil to be given in handle of bearing. Additionally it is necessary to clean theball bearings of the electric motor after2000 running hours and to refill them with grease.

5. Preventive maintenance of the machine:

All persons do the maintenance work in the knitting machine should haveadequate knowledge about maintenance of knitting machine.

They will cutoff the electric line, airline, and make them safe beforemaintenance of machine.

Checked that auto circuit breakers are fitted in the machine. Use dust mask. Keep all fire fighting equipment, first aid box ready.

6. Routine maintenance:

In this factory having no routine maintenance of machinery. But generally eachthree months maintenance is done for each machine randomly. Besides when

48

any machine doesn’t run properly then call the maintenance stuffs from themaintenance department. They will solve the problem either mechanical orelectrical.

MANPOWER SETUP FOR MAINTENANCE:

Generally 1 or 2 persons from maintenance department come to solve theproblem of a single machine.

MAINTENANCE OPREATION:

Any problem of machinery in the knitting department shall report to knittingsection and maintenance department.

Knitting technician and maintenance assigned person will thoroughlyinvestigate the problem. Find out the causes of problem determines the degreeof service requires. Estimate spare requirement place requisition for spare to thestore and service the machinery to bring it back to running condition.

All breaks down maintenance works will be recorded in the breakdownmaintenance register.

SERVICING OF CIRCULAR KNITTING MACHINE:

When a machine is selected for production after a long time break then servicing ofthat machine is being essential. Besides due to long running machine sometimes jammed. Soit is required to clean that machine thoroughly. No machine is kept under rest after servicing.

At the start of servicing the machine is run for 30 minutes in empty condition withadding oil. In this time the feeder, holder is parted then they are cleaned by compressed air.Then cam boxes are separated from the machine. After that sinker and needle are removedfrom the machine. Cam boxes and sinker cam bed are cleaned by compressed air. Afterremoving needles the tricks are petrol washed then adding lubricant. During petrol wash themaximum dust is cleaned. The remaining dust is removed manually with care. Duringservicing the damaged needle or sinker are replaced by the new one.

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MAINTEANANCE TOOLS WITH THEIR FUNCTIONS:

Tools & Equipments Functions Adjustable wrench Loosening/tightening bolts Spanner Loosening/tightening bolts Star screw driver Loosening/tightening star screw Flat screw driver Loosening/tightening flat screw Hex screw driver Loosening/tightening hex screw Cutter pliers Cable cutting Combined Pliers Multi purpose Lock pliers Lock setting Pulley key Loosening/tightening Q. pulley Handle To run machine manually Scissors Cutting purpose Plastic hammer Thrusting on rubber coated surface Iron hammer Thrusting on hard surface Shouldering iron Joining circuit Allan key Loosening/tightening Allan nut Nut driver Loosening/tightening nut

YEARLY PREVENTIVE MAINTENANCE SCHEDULE FOR FLATKNITTING M/C

Frequency: Weekly:

- Check each connection of torque control unit.- Check main switch.- Check main switch.

Frequency: Monthly:

- Check & clean dirt at main motor fan cover.- Check safety measure switch.- Check motor terminal.

Frequency: Two months:

- Cleaning the all m/c & equipments.- Check on/off switch.- Check all indicator lamps.- Check temperature sensors.

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Frequency: Six Months:

- Check motor v-belt alignment & tension.- Check all feeders & spring.- Check main drive chain alignment & tension.- Lubrication of all chain , gears & moving parts.

Frequency: Yearly:

- Check belt tension in the main motor tension.- Clean & check bearing in the m/c.- Checking m/c lubricating system.- Greasing of all takedown grease points please.

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Chapter - VIII

UTILITY SERVICES

52

AVAILABLE UTILITY FACILITIES:

1. Generator:

In this factory there are 2 numbers of generator. Among them only one generatoris in running condition, one generator is under standby. Generator number 2 is selected forstandby use. Because it’s fuel is diesel, which is very costly. Here electricity is produced andsupply to the different zones of the factory. Besides RDB's electricity is also available there .But these current is not in use for production because to minimize expense and to avoid loadshedding.

Specification:

Gas Generator Diesel GeneratorName:- Caterpillar. Name:- Petbow Generating setSales model- G3412. S.L. no. 72221, Type- Gc200CosQ-0.8 Hz.-50. Year of manufacture-19973 phase , 10 wire. Rated power-A, K.V.A-250Generator -300volts , 70.2 amps Rated Power Factor - 0.8Excitation- 32 volts , 7.3 amps Maximum site altitude-150Frame- 589 , Rev/min(r.p.m)-1500 Maximum Altitude Temp-40'cMaximum Temp. rise -105'c Voltage-400, Frequency-50Meter altitude-1000 Control system type-GC2001Class-B installation.

2. Compressor:There are 2 compressors in the factory. They are all same in capacity.

There are 2 cylinders for the storage of compressed air. The outside air is first dried thenfiltered before storage and supplied to the factory.

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Specification:

Compressor m/c -1 Compressor m/c –2Dryer:Name- Worthing CressensacOrgin- France.Type- DW 84 / Sl no. CA1071301Year-2002, Product no.-6221339700Dryer V Hz. 234kw 3 ph.Working pressure -16barMaximum pressure-16 barMaximum inlet temp-55'cMaximum ambient temp-43'cRefrigerant type-R404A

Dryer:Name- CECCATO(DLX 77)Orgin- ITALY.Type-0077799 / Sl no. CIA024179Year-2001, Product no.-6221339800Dryer V Hz. 234kw 3 ph.Working pressure -16barMaximum pressure-16 barMaximum inlet temp-55'cMaximum ambient temp-43'cRefrigerant type-R4041A, KG 1000

Compressor:Type- RlR60bX6 , 400v 1P55Refernce-6240330880Sl. No. WC0102646Bar max.-10.5M3/h-432Kw- 45V/ph/Hz.- 400/3/50Wt.-990 kg.

Compressor:Type- 00717398, RL60/8, 400v 1P55Sl. No. CA1024167, 2001Bar max.-8M3/h-432Kw- 45V/ph/Hz.- 400/3/50Wt.-1000 kg.Total Power 45 KW, HP-60

3. Boiler:There is a boilers in the factory to provide steam in the dyeing and garment

section.

Specification:

Name:- Wee Chieftain Cochran Boiler: Data plateS/n:- 23/2885Year Of Manufacture:-2001Design Press:-11 barDesign temp:- 188'cHydraulic Test date:- 1/1/2001Hydraulic Test Pressure:- 16.5

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Boiler Design to -BS2790 -class-IMaximum Continuous Rating:- 5000kg/hr.Maximum Operating Pressure:- 10.34Fuel type:- GasGas minimum supply pressure-58 mbarGas maximum supply pressure-100mbarSupply Voltage:- 400/3ph./50.Hz.

SOURCE OF UTILITY:

#1) Gas.#2) Water.#3) Diesel.#4) Electricity.

55

Chapter - IX

STORE&

INVENTORY CONTROL

56

INVETORY SYSTEM

#) First taking stock report.#) Considering in & out state of stock.#) Then collecting the material according to requirement of different departments.

INVETORY SYSTEM FOR RAW MATERIALS :

ABONI TEXTILES LTD.HEMAYETPUR, Savar , Dhaka.

Physical Inventory of November 2003 As on

SR.No.

CodeNo.

ItemName

Receive ReceiveReturn

TotalQTY

IssuedQTY

IssuedReturn

Total

Total

----------------- ---------------- ----------------- ------------------Reported by Store in charge Store manager Director

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MONTHLY STOCK STATEMENT (MAINTENANCE):


Department: Maintenance Section:Physical Inventory of November 2003 As on

SR.No.

CodeNo.

ItemName


TotalQTY

IssuedQTY

IssuedReturn

Total

Total


58

INVETORY SYSTEM FOR FINISHED GOODS :


Physical Inventory of November 2003 As on

SR.No.

CodeNo.

ItemName


TotalQTY

IssuedQTY

IssuedReturn

Total

Total


59

Chapter - X

COST ANALYSIS

60

PRICE OF PRODUCT:

For costing we consider some parameter: -

Rate/kg

1. Yarn : 171 Tk. ( $2.85)

2. Knitting charge : 9 Tk.

3. Dyeing(average color) : 85 Tk.

4. Commercial : 8 Tk.

5. Process loss (10%)

Knitting=2%

Dyeing =8%

: 26 Tk.

Total 299 Tk.($5.00)

Knitting charge for different types of fabric:

Fabric type Rate/kgSingle jersey : 09 Tk.

1X1 Rib : 17 Tk.

Interlock : 25 Tk.

Polo P.K : 18 Tk.

Lycra s/j : 35/40 Tk.

(2X2) Rib/Interlock : 30/35 Tk.

Lycra rib : 30/35 Tk.

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Dyeing cost:

White : 25/28 Tk.

Average color : 80 Tk.

Black : 40/45 Tk.

Royal blue : 120 Tk.

TC(solid) : 100/120 Tk.

COSTING OF PRODUCTS:

Costing of product depends on the following matters:----

1) Raw material2) Knitting Charge3) Dyeing Charge4) Utility & Depreciation5) Wages & Salary6) Bank liability etc.

62

Chapter - XI

MARKETING ACTIVITIES

63

CONSUMEROF THE PRODUCTS:

There are many buyers and nominated buyer of different countries of this factory.Here some of those are given below.

Buyer Nominated Buyer CountryH & M Nil U.KTesco Nil U.KNewlook Nil U.KBHS Araf(Fielding Group) U.KGreenwoods Men's Fashion U.KRipcurl Oryx FranceE5-Mode Nil BelgiumOniel Multi Source GermanyKarstadt Nil U.KQuelly Nil U.K

PACKAGE SIZE :

Boy's Range:- 2,4,6,8,10,12,14 yrs.Men's Range:- XS,S,M,L,XL,XLL___4XL.Ladies Range:- 38,36,42______52.

LOCAL MARKET:

Having no local market. The product of the factory is completely export oriented.

IMPORTING COUNTRIES:

#1) United Kingdom#2) Belgium.#3) Germany.#4) Hong Kong.#5) France#6) Etc.

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MANPOWER:

Total Manpower of marketing = 5

Marketing Activities is done by the following way

Manager (1)

Merchandiser (3)

Asst. Merchandiser (1)

MARKETING STATEGY:

To ensure the quality about product. . The factory has a target to create market in otherforeign countries like Australia, Japan, Netherlands and other European countries.

DUTIES OF MARKETING OFFICER:

#1) To collect the order from buyer.#2) To determine the price of product.#3) To inform the buyer when the product in process.#4) To ensure the fabric quality, product quality.#5) To concern about the product until the shipment.

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Chapter - XII

CONCLUSION

66

It is my immense pleasure that I have got the chance of taking my industrial

attachment in ABONI TEXTILE LTD. because it is a highly equipped mill of

modern machines and of sound management. I have learnt a lot from its technicians &

personnel. This training has bridged the gap between the theoretical and practical

knowledge. The training partners, on this regard, were also very much co-operative

and friendly. I am sure that the knowledge I have gathered from this training will

make a positive influence in my future profession.

Engineering

Industrial Attachment of aboni textiles ltd