Industrial attachment of padma poly cotton knit fabrics limited

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTPADMA POLY COTTON KNIT FABRICS LIMITED

CHAPTER-I(Project Description)

PROJECT DESCRIPTION

NAME:PADMA POLY COTTON KNIT FABRICS LIMITED.

(Composite Knit Fabrics & Garments Project)TYPE:

Composite knit fabrics and garments (With dyeing and finishing) mill.( 100% Export Oriented Composite Industry).

STATUS: Private Ltd. company

YEAR OF ESTABLISHMENT:1995.

LOCATION & ADDRESS:

a. Corporate Office:Printers Building, 5 Rajuk Avenue,Dhaka-1100, Bangladesh.Tel: 9568917-20, 9555784Fax: 880-02-9562045-46E-mail: padmabdcom.com

b. Factory :131 Tejgaon Industrial Area,Dhaka-1208.Bangladesh.Tel: 9123928-30,Fax: 880-02-9885389E-mail: [email protected]

SPONSORS:Mr. Khan Mohammad Amir

NAME OF ADDRESS OF BANKER:Sonali Bank, Local Office,Motijheel Commercial Area, Dhaka-1000,

Bangladesh. .Fax: 880-02-9561410

PRODUCT MIX:a) Knitted grey fabrics : Plain single jersey, Heavy Jersey, Polo Pique, Lacoste,

Rib &Interlock double jersey , Drop needle, 2/3 Thread fleece(Brushed/ Un-brushed),Collar & cuff etc.

100% cotton, 15% viscose + 85% cotton, 10% viscose + 90% cotton,30% viscose + 70% cotton

b) Knit Garments : T-shirt, Polo shirt, Sweat shirt, Golf shirt, Cardigan, Joggingsuit, Short/Trouser, Legging, Fashion dress & Children wears etc.

ANNUAL PRODUCTION CAPACITY:Production Capacity per day: 10 tonsProduction per day: 7 tons (approx)

FABRICS: A. Knitting Capacity (Per day)1. Single Jersey 9000 kgs2. Pique 9000 “3. Interlock 1800 “4. Fleece 1200 “

B. Dying & Finishing 10 tons

GARMENTS: 1.T-shirt 2000 dozens2. Polo shirt 1500 “3. Sweat shirt 600 “4. Jog-Sets 400 “

PROJECT COST:TK. 40 crs (approx.)

HISTORY OF THE PROJECT DEVELOPMENT:

PADMA PRINTERS|

PADMA POLY COTTON KNIT FABRICS LIMITED.

DIFFERENT DEPARTMENTS:1) Knitting Departments,2) Dyeing & Finishing Departments,3) Garments Departments,4) Engineering Departments.5) Account & commercial section6) Admin section

TOTAL AREA OF THE INDUSTRY : 12500 sq MeterFACTORY LAND AREA : 10000 sq. Meter

BUILDING : 5 Storied.FLOOR SPACE ( Knitting) :22106 SFT

REMARKS:

Padma Poly Cotton Knit Fabrics Limited (PPCKFL) is a member concern ofPadma Group of Companies, a leading house of Industries & Commerce in Bangladesh,having Printing & packaging Industry, paper manufacturing unit, country wide network ofcolor film processing laboratory units, representing world famous Fuji Color Filmproducts, personal, hygiene products manufacturing & real estate development etc.

CHAPTER-II(Man power Management)

MAN POWER MANAGEMENT

MANAGEMENT SYSTEM:

KNITTING SECTION: Four Mechanical Fitters for per shift.One skilled operator and one unskilled operatorfor per knitting machine.

SHIFT CHANGE:Shift of twelve hours. Shift changes after a week on Saturday.

RESPONSIBILITIES OF PRODUCTION OFFICER:From getting an order of upper level all responsibilities are on the production

officers. They work with a troop of operators, helpers, fitters etc. to finish the production indue time. In the meantime production officers bear all hazards, problems. They have toexplain to the manager for any type of production hamper. So, all production activities andits success depend on the production officers.

JOB DESCRIPTION:

SENIOR PRODUCTION OFFICER: In a knitting factory a senior production officerplays a great role in production and man power management who are production related.Here we enlist the duties of senior production officer:

1) Follow up knitting production,2) Regular observation of knitting floor,3) Prepare knitting order status regularly,4) Maintain the quality of the product,5) To help the senior prod. officer & co-operate with others for fulfilling the

required destination.

PRODUCTION OFFICER: Production officer is the right hand of senior productionofficer and he is directly related with production manpower and inform senior prod. officertime to time. Here are his listed duties:-

1) Follow up overall knitting production,2) Decide every m/c utilization during production,3) Recruit new labor,4) To inform the authority on the overall knitting prod. and make it financial

profitable,5) Regular m/c maintenance,6) Maintain sub-contract orders,7) Help knitting manager & also guide the junior officers of the section, etc.

REMARKS:Production runs with the help of mechanical fitters. For any kind of mechanical

fault of any machine they fix and work under technical in-charge. Production officers’takes account of daily production by running after the two supervisors and workers so on.

CHAPTER-III(Machine Description)

MACHINE DESCRIPTION

PADMA POLY COTTON KNIT FABRICS LIMITED (KNITTING SECTION)

MACHINE DETAILS:

M/C TYPE M/C DIA M/CGAUGE BRAND FEEDER NEEDLE CYLINDER M/C MPF BELT

SINGLE

JERSEY

16″ 20 GGTERROT,GERMANY

51 1008 02 02 7400 MM24 GG 1200 01

17″ 24 GG TERROT,GERMANY 57 1280 01 0118″ 20 GG

TERROT,GERMANY57 1128 03 02 7400 MM

24 GG 1356 0119″ 24 GG TERROT,GERMANY 64 1432 02 0220″ 20 GG


24 GG 1500 0521″ 24 GG TERROT,GERMANY 64 1580 02 0222″ 20 GG


7000 MM24 GG 1656 0523″ 24 GG TERROT,GERMANY 70 1732 03 0324″ 20 GG


7000 MM24 GG 1800 0226″ 24 GG ORIZIO,ILALY 84 1920 02 02 8200 MM

7000 MM22 GG 1800 0130″ 24 GG ORIZIO,ILALY 96 2220 03 03 8600 MM

7400 MM28 GG 2620 0230″ 24 GG

CAMBER,ENGLAND90 2256 05 05 8200 MM

28 GG 2640 05FLEECE 30″ 20 GG ORIZIO,ILALY 96 1860 04 04 8600 MM

7400 MMINTERLOCK

30″ 22 GG ORIZIO,ILALY 96 2088*2 04 04 8400 MM7200 MM

RIB 30″ 16 GG ORIZIO,ILALY 60 1500*2 02 02 8400 MM7200 MM12000MM

18 GG 1680*2 02

RIB 30″ 18 GG MAYER,GERMANY 48 1680*2 04 048LOCK/RIB

36″ 18 GG ORIZIO,ILALY 72 2040*2 02 02 8600 MM

FLAT BEDCOLLAR&CUFF

60″ 14 GG FLYINGTIGER,TAIWAN

6 840*2 6 640″ 14 GG MATSUYA,JAPAN 4 560*2 6 552″ 14 GG OHSUNG,KOREA 6 728*2 3 3

MAIN SPECIFICATION

TERROT:

M/c no: 01 M/c no: 02Type : S196 Type : S196Serial no: 075012242 Serial no: 081712237Mfg. year: 6-1997 Mfg. year: 6-1997No. of feeders: 78 No. of feeders: 78

M/c no: 03 M/c no: 04Type : S196 Type : FSB3XSKSerial no: 082012244 Serial no: 002444Mfg. year: 6-1997 Mfg. year: 6-1997No. of feeders: 78 No. of feeders: 78

M/c no: 05 M/c no: 06Type : FSB3XSK Type : FSB3XSKSerial no: 057012676 Serial no: 086112254Mfg. year: 1997 Mfg. year: 1997No. of feeders: 78 No. of feeders: 96

ORIZIO:

M/c no: 01 M/c no: 02Type : JOHNAN Type : JOHNANSerial no: 1019653 Serial no: 1019678Mfg. year: 1995 Mfg. year: 1995No. of feeders: 96 No. of feeders: 96Needle type: Vo15452G002 Needle type: Vo15452G002Sinker type: 206101021G Sinker type: 206101021G

M/c no: 03, 04,05 M/c no: 16,17Type : CMO4A Type : CMOALSerial no: 1019651 Serial no: 1027037Mfg. year: 1995 Mfg. year: 1995No. of feeders: 96 No. of feeders: 72Needle type: Vo9262G002 Needle type: Vo15452G002

Sinker type: Vota7558G003 Sinker type: 206100921700CAMBER:

M/c no: 01Type : QYATTRO11 PLUSHSerial no: 82482Mfg. year: 1993No. of feeders: 96

MAYER & CIE:

M/c no: 01 M/c no: 02Type : MLBF Type : INOVITA3Serial no: 31838 Serial no: 31308Mfg. year: 1990 Mfg. year: 1990No. of feeders: 96 No. of feeders: 96

FLAT KNITTING M/C:

M/c no: 01 (MATSUYA) M/c no: 01 (FLYING TIGER)Type : M-100 Type : SMF121TJSerial no: 6031 Serial no: 180126Mfg. year: 1999 Mfg. year: 1999Gauge: 14 Gauge: 14

CIRCULAR KNITTING MACHINE

Circular knitting m/cs. are widely used through out the knitting industry to producefabric. This m/c can be built in almost any reasonable diameter and the small diameterof up to five, which are used for wear.

Machine for outerwear and under wear may vary from 12 inch to 60 inch in diameteraccording to manufactures requirement. This m/c can be used either as fabric or formaking garments completely with fancy stitch. Latch needles are commonly employedin all modern circular m/c because of their simple action and also their ability to processmore types of yarns.

Plain circular m/c uses only one sets of needles, circular rib m/c uses two sets ofneedles i, e, Cylinder needle and Dial needle, the interlock circular knitting m/c alsouses two sets of needles by needles are long and short respectively for both dial andcylinder, that is why multiple design and thick fabric can be produce with that m/c. Thatm/c is also called double Jersey m/c.

M/c. Gauge – needle/inch (varies according to diameter) Needle Type – Latch Needle bed type – Single cylinder, Double cylinder, Cylinder &

Dial, long or short needles for cylinder and dial. Two principle operation exist:

1. English system – Where the cams and yarns strands revolve by needle andfabric take down is stationary.

2 American system – Where the needles and fabric take down revolves bycams and yarn strands are stationary.

THE PROPERTIES OF RIB FABRICS AND SINGLE JERSEY OR PLAN FABRIC AND MACHINE

Plain fabric and m/c Rib fabric and m/c1. Face side and Back side of fabricare different

1. Face side and Backside of fabricare same.

2. Less expensive 2. Expensive3. Lighter fabric 3. Heavier fabric.4. Produce by S/J m/c. 4. Produce by Double Jersey m/c.5. The m/c. contains no Dial. 5. The m/c. contains Dial.6. The m/c. contains Sinker 6. The m/c. contains no Sinker7. The m/c. contains one set ofneedle

7. The m/c. contains two set ofneedle

8. Extensibility:a) Length wise – 10 to 20%b) Width wise – 30 to 40%

8. Extensibility:c) Length wise – 50 to 80% (for

11 rib)d) Width wise – 30 to 45% (for

11 rib)9. Thickness & Warmth:

Thicker and wormier than plainwoven made from same yarn.

9. Thickness & Warmth:Much thicker and wormier than

plain woven made from same yarn.10. Curling:

Tendency to curl10. Curling:

No tendency to curl11. End use:

Ladies stocking, fine cardigan,men and ladies dresses, sweater etc.

11. End use:Socks, cuffs, warm outerwear,

under wear etc.

IMPORTANT PARTS PER MACHINE

IMOPORTANT EQUIPMENT OF CIRCULAR KNITTING M/C

1. START/STOP/INCH BUTTONS:

Complete set of easily accessible start/stop/inch buttons at top in each leg.

2. RATCHET LEVER:

Permit hand movement of the M/C.

3. AUTO STOP MOTION:

Automatic three stages 24v yarn motion, positive feed tapes & knitting zone.Indicator lamps are on individual stop motions & on the main control panel.While the yarn is broken we can find the location which is broken as well as

Name of parts Number per machineMPF Magnet 90Knot catcher 90

Eye pot 90Hose pipe 02

Needle fault detector 15Oil nozzle 21Oil pipe 21

Air flashing nozzle 300Air flashing pipe 30

Fabric detector 02Main switch 01Fabric light 01

Take down light 02Oil & air pressure 02

to repair, meanwhile the motor can brake and stop operation at once to keepthe security of M/C.

4. FREE STANDING SIDE CREEL:

With an active reserve package for each feed.

5. AUTO–COUNTER:Two shift revolution with display counter with predetermined stop, to settlefreely the weight or yardage of fabric.

6. VARIABLE SPEED DRIVE WITH M/C BRAKE:

Transistor inverter provided for free controlled, the process of “V.s. motor-drive” fromslow operation to normal operation is quite & fast brake to prevent damages in case ofneedles or yarn breakage.

7. FABRIC TAKE UP SYSTEM:

With variable speed control by a belt drive set can be adjusted the speed fordifferent course of fabric-constant and uniform fabric tension.

8. SAFETY GUARD SWITCH:

Machine cannot be started with guards open; this guards have reinforcedfibreglass window for easy fabric inspection.

9. AUTO LUBRICATION:

The automatic central pressurized oil sprayer can be adjusted at cycling timeand quantity to make cylinder, dial, sinker ring’s cam, needles and sinkerslubricated enough, besides it has the function cooling and clearing.

10. AUTO-LINE REMOVAL SYSTEMS:

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

OPERATION PROCEDURE OF FLAT MACHINES:

To start operation, depress a green button provided at the letf- hand side ofthe machine. If either of the red buttons fitted at the right and left sides of the machine ispushed, the machine will stop. For manual operaion, first push a black clutch button at theright hand lower part of the machine to disconnect the clutch. Next, push away and turnright manual operation handle. To reconnect the clutch for automatic operation, pull themanual operation handle. The clutch lever is of 2-step type. When it is set to the 1st step,changeover drum will turn lightly, When performing link fitting to the drum or reknitting,the lever should be set at this position. the clutch is connected when the clutch lever israised 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. Forecibleraising of the leer will cause machine trouble on speed change mechanism.

CHANGING OF THE CARRIAGE TRAVEL WIDTH:

Traveling width of the carriage can be changed in the sequence describedbelow. This change work requires five minutes. During the change work the clutch levershould be set at the position where the over durm would not rotate, even if the manualhandle is turned.

1. Place-u-shape gauge on the right end of the carriage rail.

2. Disconnect the clutch and move the carriage to the right end by means ofthe manual handle.

3. Loosen two carriage position change serews.

4. Shift the crand rod fulcrum of sector wheel in accordance the travel widthscale.

5. Move the sector wheel to the right end disengaging position by manualhandle and secure the handle with set screws (use carriage rail set screws).

6. Move the carriage rightwards until it contacts with the u-shape gauge.Then, upon making certain that the carriage is in contact with the u-shape gauge, tightenthe carriage position change screws.

7. Fine adjust the carriage position screws to assure reliable contact ofcarriage and u-shape gauge. If the left screw is loosende and the right one is tightened, thecarriage can be move rightwards, and on the cantrary, if the right screw is loosened and theleft one is tightened, the carriage can move leftwards. At this time, be careful not to stretchthe chain too tight. The proper chain tension is such that the chain can teach the upper faceof the carriage rail, of picked up at the machine center.

8. Upon cornpletion of the works in steps 1 to 7, unscrew the handle setscrews, tighten the carriage rail, and upon confirming that the carriage travel width hasbeen set as required, start operation.

POSITION ADJUSTMENT OF PRECEDING CAM RELEASING DEVICE AFTERWIDTH CHANGE:

After changing travel width, adjust the position of preceeding cam releasingdevice 3 shown in the illustration below.

1. Loosen 5 and 6 and move 3 left.2. Travel the carring by the manual handle to the left limit position.3. Place bearing 2 located at the right of the carriage in an indent of 1 as

show in the illustration.4. Move 3 to provide a clearance of 1mm between 3 and 1. Then fighten 6

to fix 3.5. Pring 4 in contact with 3 and tighten 5 to secure 4. 4 serves as a mark in

the event when 3 is moved not to hinder the carriage removal.

Area calculation of Knitting Section

Area of circular knitting section = 18932 sq.ftArea of Flat bed knitting section = 3174 sq.ftTotal area of knitting section = 22106 sq.ftTotal area of road in knitting section = 1820 sq.ft

Terrot:T-1to 11Total area for per m/c = 16'6" * 9'6" = 156.75 sq.ftCreel area for per m/c = 2*10*2 = 40 sq.ftWorker area for per m/c = 156.75 – (15 + 40) = 101.75 sq.ftHeight of m/c = 8'2"

T-13 to 24Total area for per m/c = 12'9" * 10' = 127.5 sq.ftCreel area for per m/c = 2*10*2 = 40 sq.ftWorker area for per m/c = 127.55 – (15 + 40) = 72.5 sq.ftHeight of m/c = 8'2"

Camber:Total area for per m/c = 18' * 8' = 144 sq.ftCreel area for per m/c = 63.5 sq.ftWorker area for per m/c = 144 – (27 + 63.5) = 53.5 sq.ftHeight of m/c = 8'

Orizio (8 lock):Total area for per m/c = 15'10" * 7' 6"= 118.5 sq.ftCreel area for per m/c = 2*10.5*2 = 42 sq.ftWorker area for per m/c = 118.5 – (40 + 42) = 36.5 sq.ftHeight of m/c = 8'6"

Orizio (S/J, Fleece, Rib, Interlock):Total area for per m/c = 17'2" * 10' 6"= 180.5 sq.ftCreel area for per m/c = 2*10.5*2 = 42 sq.ftWorker area for per m/c = 180.5 – (40 + 42 ) = 98.5 sq.ftHeight of m/c = 8'6"

Mayer:Total area for per m/c = 12'6" * 8' 8"= 110sq.ftCreel area for per m/c = 2*8'*2 = 32 sq.ftWorker area for per m/c = 110 – (23 + 32 ) = 55 sq.ftHeight of m/c = 8'8"

Matsuya:Total area for per m/c = 5'5" * 1' 2"= 6.6 sq.ftHeight of m/c = 5'8"

Flying Tiger:Total area for per m/c = 10' * 2' = 20 sq.ftHeight of m/c = 7'

Winding m/c:Total area for per m/c = 6'6" * 2' 2"= 14.5 sq.ftHeight of m/c = 4'

Remarks on layout plan:Ventilation system is very poor. The room Height of knitting section is inadequate.

There is no exhaust fan to clean and maintain the temperature of this section.The temperature of this section is more than the natural room temperature because

it absorbs heat from dyeing and finishing section.There is only one toilet which is not sufficient.Grey fabric inspection section should be air conditioned.At least six circular m/c can be easily setup on the basis of present floor condition.Cone storage facilities are not bad.The floor plaster of some place of this section is damaged, so it is necessary to

repair it as soon as possible.Creel of camber m/c is not suitable because it has required more floor space and

also difficult to change package.

CHAPTER-IV(Raw materials)

RAW MATERIALS

INTRODUCTION:Padma Poly Cotton knit Composite Mill takes yarn as its raw materials for its

initial production of knitted fabric to make garments. It has no spinning section of its own.So, it depends on different of spinning mills of home and abroad to collect yarn as itrequires. Here are the details:

TYPES:

Natural and synthetic, Cellulose and non-cellulose all kind of yarn are used asraw materials in this mill. Generally, Cotton, Polyester, Viscose and Nylon are mostly usedin knitting departments.

Material % Count Dyed / undyedCotton 100% 30,26, Ne

(comb)Undyed

Grey mélange P-65 % C-35% 150 den UndyedEcru melange C-85% V-15% 20.26 dyed viscose

fibre (ash shed)Anthra melange C-65% V-35% 20.26 dyed viscose

fibre (ash shed)Cotton+lycra 95%+5% 40/1

Ne(combed)Undyed

PRICE:Price of yarn varies mill to mill and as different count. Here, we collect a price

sheet of overall price for all the spinning mills of home and abroad of different count frommerchandizing section:

SOURCE:The main source of yarn for this mill is the country and neighboring country,

India. Here is the list of its source spinning mills:

1. Pacific Cot spin Ltd. (India) 8. Rahmat Textiles Mills Ltd2. Contermann Peipers (India) Ltd. 9. MSML Textiles Mills Ltd3. Padma (1, 2) Beximco Ltd. 10. UTAH Spinning Mills Ltd.4. Shameem Composite Mills Ltd. 11. OTTO Spinning Mills Ltd.5. Shohagpur Textiles Mills. 12. Comilla Spinning Mills Ltd.6. Welspur Syntex Ltd.(India) 13. Keya Spinning Mills Ltd.7. Square Textiles Mills Ltd. 14. Toplon Hyosung Corporation. (Korea)

for Lycra. 15. Coats Bangladesh Thread. (For flat bed).

ANNUAL REQUIREMENTS:Cotton ----- 2160000 kg/year approx.Polyester --- 180000 kg/year approx.Lycra ----- 4500 kg/year approx.

REMARKS:Padma Poly Cotton knit Fabrics Ltd. is a big buyer of India spinning mills. At

home, Padma (Beximco group) meets the demand or raw materials of this mill. Overallquality of Indian yarn is better than that of our country but ours is more strong than Indian.

SL NO. Yarn Type Yarn Count U.S. Dollar perKg.

01. Combed 30 2.8502. Carded 30 2.4003. Combed 28 2.8504. Carded 28 2.4005. Combed 26 2.8006. Carded 26 2.3507. Combed 24 2.7508. Carded 24 2.3009. Combed 20 2.7010. Carded 20 2.25

CHAPTER-V(Production Planning,

Sequences & Operations)

PRODUCTION PLANNING, SEQUENCES & OPERATIONS

PRODUCTION PARAMETERS:Machine Diameter;Machine rpm (revolution per minute);No. of feeds or feeders in use;Machine Gauge;Count of yarn;Required time (M/C running time);Machine running efficiency.

DESCRIPTION OF PRODUCTION PROCESS:In every mill, there maintains a sequences in production processing.

It is also followed in this mill where I was in industrial attachment. The processsequences are in list below:

1) Firstly, knitting manager gets a production sheet from merchandisersas accordance as consumer requirements. Then he informs or orders seniorproduction officer about it.

2) Senior production officer informs technical in charge and knows aboutm/c in which the production will be running.

3) Technical in charge calls for leader of mechanical fitter troops, theytwo take decision about m/c for production considering m/c condition, productioncapacity, maintenance complexity etc.

4) Production officer with experienced mechanical fitter adjusts requiredstitch length and grey GSM (gram per square meter) for required final GSM.

5) Supervisor check daily production regularity and make operatorsconscious about finishing in due time.

6) Operators operate machine in highly attention as if there were no faultsin the fabrics. If he thinks or sure about any fabric fault, then he call for mechanicalfitter in duty. Mechanical fitter then fixes it if he can or he informs technical in-charge. He then comes in spot.

7) After required production and final inspection in 4-point system, theyare sent in dyeing section.

PRODUCTION DAILY REPORT:

Here is a daily report of production which is kept in Padma Poly Cotton KnitFabrics Ltd.:-

PADMA POLY COTTON KNIT FABRICS LIMITEDProduction Daily Report

Date:13/10/04

M/CNO

M/CDIA(inch)

M/CGAUGE

YARNCOUNT

FABRICTYPE

ACTUALG.G.S.M

FINISHG.S.M

STITCHLENGTH

RUNNINGS.L

BUYER REMARKS

O-1 26 24 24/1 CD S/J 152/55 180 2.80 2.79 Rainbow P.F.DO-2 26 24 24/1 CD S/J 152/55 180 2.80 2.80 Rainbow P.F.DO-3 30 24 26/1CB+20D Lycra S/J 200 250 3.20 3.21 Micro

fibreAvg.

O-4 30 24 30/1CB+20D Lycra S/J 180/85 220 3.10 3.10 Microfibre

Avg.

O-5 30 24 34/1CB+20D Lycra S/J 180/90 180 3.00 3.00 I.Ccompany

Avg.

O-6 30 16 24/1CD+70D 1*1LyRib 280 300 2.80 2.79 Sara lee Avg.O-7 30 18 26/1CB 1*1Rib 155/56 210 2.75 2.76 Tom

tailorWhite

O-10 30 24 26/1CB+20D Lycra S/J 190 250 3.20 3.19 Microfibre

Avg.

O-11 30 24 26/1CB+20D Lycra S/J 200 250 3.20 3.21 Microfibre

Avg.

O-16 36 18 26/1CB 1*1Rib 155/80 210 2.75 2.75 I.Ccompany

LT

T-4 17 24 26/1CD S/J 132/35 160 2.85 2.86 Sara lee Dk.OrangeT-6 20 24 26/1CD S/J 132/35 160 2.90 2.91 Sara lee NavyT-10 19 24 26/1CD S/J 132/35 160 2.80 2.81 Sara lee LTT-11 20 24 26/1CD S/J 132/35 160 2.80 2.79 Sara lee LTT-12 20 24 26/1CD S/J 132/35 160 2.90 2.91 Sara lee NavyT-16 22 24 26/1CD S/J 130/32 160 2.85 2.85 Fakruddin Avg.T-17 22 24 26/1CD S/J 130/32 160 2.85 2.85 Fakruddin Avg.T-18 22 24 26/1CD S/J 130/32 160 2.85 2.85 Fakruddin Avg.T-19 23 24 24/1CD S/J 152/55 180 2.80 2.80 Rainbow P.F.DT-20 23 24 26/CD S/J 130/32 160 2.80 2.80 Fakruddin Avg.T-21 23 24 26/1CD S/J 130/32 160 2.80 2.79 Fakruddin Avg.T-24 24 24 24/1CB S/J 152/55 180 2.80 2.79 Tom

tailorMid

C-1 30 28 24/1CD S/J 152/55 180 2.80 2.81 Rainbow P.F.DC-4 30 28 24/1CD S/J 152/55 180 2.80 2.79 Rainbow P.F.D

We collect a production report of one day:-

PADMA POLY COTTON KNIT FABRICS LIMITEDONE DAY REPORT

M/CSPECIFICATIION

PRODUCTION( SHIFT-A)(Kg)

PRODUCTION(SHIFT-B)(Kg)

ORIZIO-1 126 145ORIZIO-2 85 130ORIZIO-4 168 185ORIZIO-5 165 175ORIZIO-6 96 107ORIZIO-7 159 156ORIZIO-8 124 157ORIZIO-9 81 171ORIZIO-10 128 167ORIZIO-11 137 120ORIZIO-13 133 132ORIZIO-14 127 120ORIZIO-15 8 46CAMBER-3 130 95CAMBER-5 124 114TERROT-4 48 46TERROT-17 77 104TERROT-18 80 74TERROT-19 0 110TERROT-23 92 94TERROT-24 103 97TOTAL = 2643 3097

MONTHLY AVERAGE REPORT:

We see that daily production is approximately 6500 kgs. So, it is seen thatmonthly average production of this factory is:

6500*30= 195000 kgs.

PRODUCTIONS FLOW-CHART:

Executive director takes order from Buyer|

Merchandiser estimates total amount of yarn of production|

Knitting manager gets production order sheet|

Senior Production Officer ordered by K.M. and ordersProduction officer and Technical in-charge.

|Production officer fixes up stitch length and GSM

with mechanical fitter.|

Definite operator operates machine in his full conscious andAttention.

|Mechanical fitter fixes machine if there is any m/c fault.

|Supervisors keep daily production report and assure m/c is OK.

|Fabric roll is checked by a troop of inspectors in inspection unit

and weighted.|

Final product to the required amount is delivered to dyeing unit.

MONTHLY EFFICIENCY:

Daily production – 6500 kgs. Approx.Daily production capacity – 10000 kgs approx.So, monthly production – 6500 *30 kgs.Monthly production capacity – 10000*30 kgs.So, Monthly production efficiency= (6500*30*100)/ (10000*30) %

=65%REMARKS:

As Padma Poly Cotton Knit Fabrics Ltd. is a big project; its production quantityis huge. Production quantity varies as according as buyers demand. It gives approximately200 ton production per month. In Bangladesh, there are a few mills which can producesuch quantity of knitted fabrics.

CHAPTER-VI(Quality assurance system)

QUALITY ASSURANCE SYSTEM

After collecting fabric rolls from different m/cs, they are inspected or assured requiredquality by the quality inspectors as if there were no big production hampered and nocomplain from the buyers. Here are the details about it.

QUALITY ASSURANCE PROCEDURE:1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from

the cloth or batch roller and they are carried to inspection section by the helpers.

2) Almost four inspection workers are for every shift to check the fabric rolls.For any kind of fault they are checked thoroughly. Skilled inspectors find them andindicate them by the scissors in some cases.

3)Quality is specified on the basis of 4-points system. Here is the pointdistribution for different kinds fault in this system:-

SLUB: 1 POINTANY HOLE: 4 POINT

NEEDLE/SINKER LINE: 4 POINTNEEDLE BREAKAGE: 4 POINT

PRESS OF: 4 POINT

THICK THIN DIRT, OIL SPOT, CONTAMINATION:

Upto 3’’ in length: 1 PtUpto 6’’ in length: 2 “Upto 9’’ in length: 3 “Upto 9’’ in length: 4 “

QUALITY Pts / per 100 square meter= (Total point * GSM)/ (Roll weight*10)

Quality inspectors seal on the fabric rolls as ‘CHECK-1’, ‘OK’ & ‘REJECT’as according as quality classification.

QUALITY CLASSIFICATION

1 2 3<20 20-30 30>OK ASK REJECT

LIST OF EQUIPMENTS:

In this factory ‘PADMA POLY COTTON KNIT FABRICSLIMITED’ this is the list of equipments to assure quality:-

1) Inspection m/c # 1(For plain single jersey)2) Inspection m/c #2 (For decorative single jersey as like as Lycra,

Lacoste, waffle, Fleece and all kind of double jersey as like as Rib, Interlock).3) Scissors4) Weight balance & Micro balance5) GSM cutter6) Seal (‘CHECK-1’, ‘OK’, ‘REJECT’.).

Rejection criteria for collar & cuff :

No. Faults Response

1. Wrong ply Reject2. Hole Reject3. Needle line Reject4. Slubs Reject5. Wrong design Reject6. Fly & contamination Acceptable for color but not for white7. First round problem Reject8. Uneven tension Discuss with manager9. Missing yarn Reject10. Crease line Reject11. Rust line Reject12. Oil stripe Reject13. Thick-thin Reject14. Wrong tube Reject

QUALITY STANDARD:

Here is the quality standard:-1) Fabric width 7) Broken needle /2’’2) Fabric length 8) Thick /thin yarn4) Slub 9) Barre/ Stripe3) Fabric weight 10) Dirt5) Hole 11) Oil6) Needle / Sinker line 12) Press off

QUALITY REPORT

GREY FABRIC INSPECTION REPORT

NAME OF THE INSPECTORS: Mr. Safiqul Islam

SHIFT:ASHIFT:B

DATE:15/03/05 M/C NO#: M/C GAUGE: 22

BUYER:SaraleeORDER NO:AE2578FABRIC TYPE: S/J

GREY GSM: 135FINISH GSM: 160FINISH WIDTH:

SHIFT: A SHIFT: BTYPE OF DEFECT R-1 R-2 R-3 R-4 R-5 R-6 R-7 R-1 R-2 R-3 R-4 R-5 R-6 R-7SLUB I I III II III II III I III II IIHOLE I I II I III I I INDL/SINKER LINE I II IIBROKEN NEEDLE/2’’THICK/THIN YARN I I II I II III II I IBARRE/STRIPEDIRT I I I I II I II IIOIL II I I IPRESS OFF I IOTHER SPECIFY

TOTAL POINT(P) 7 6 8 8 13 11 17 9 9 6 11 5GREY WIDTH:ROLL WT(W) 22.5 19.7 24.9 24.5 23.5 22.7 21.6 23 22.2 24.7 21.8 23.7REJECT QTY.(KG)LENGTH(MTR)QUALITY=(P*GSM)/(W*10) 4.2 4.11 4.33 4.4 7.4 6.5 10.7 5.2 5.4 3.2 6.8 2.8

YARN EVALUATION REPORT

PADMA POLY COTTON KNIT FABRICS LTD.QUALITY CONTROL DEPARTMENT

YARN COTTON : ACTUAL COUNT:YARN LOT : STITCH LENGTH:FABRIC CONSTRUCTION: G/G.S.M :CHECKED QTY. : F/G.S.M :

APEARANCENO. OF FAULT

REMARKSGREY FINISH

THICK & THINPLACESSLUBBARRE MARKSNEPSHAIRINESSDEAD FIBREYARNCONTAMINATIONFINAL COMMENTS

# THE ABOVE MENTIONED YARN EVALUATION REPORT PREPARED ONTHE BASIS OF FABRIC APEARANCE.

# BULK PRODUCTION WILL BE FURTHER EVALUATED AND PROBLEMCOMPLAINED BY BUYER REGARDING YARN WILL BE NOTIFIED TOCONCERN PARTY.

PREPARED BY A.G.M (KNITTING & DYEING)

SAMPLE OF FAULTS

REMARKS:

There is hardly any chance of any roll to be passed through production or toany buyers by to by unchecked or disqualified. The inspectors are too much experiencedand they are aware of their duties and responsibilities. Factory authority and the productionofficers are happy and satisfied with their works.

CHAPTER-VII(Maintenance)

MAINTENANCE

Maintenance of machineries is very important for any type of industries and it isa must for a knit composite mill. All machines and machines parts of knitting, dyeing andgarments are maintained with extreme care. Because production quality and quantity, bothdepends on the maintenance with regularity. Poly cotton Knit Fabrics Ltd. leadmaintenance with a troop of skilled mechanical fitters.

MAINTENANCE OF MACHINERY:In the knitting floor of Padma Poly Cotton Knit Fabrics Ltd. all circular and

flat knitting m/cs are maintained regularly and as necessity requirements. Here, differenttype of maintenance of machinery, which is taken, different time on the machineries.

ROUTINE:1) Daily Maintenance: Every machine is taken maintenance daily by the

operators during production. When a production is started by the operator after handingover from previous shift operator, he takes a routine maintenance on the machine. Hecleans the machine, assures yarn is fed to all needles, cleans the eye pot of feeder,memminger, signal lamp sensor etc. Before a while of a roll cut from batch or cloth roller,operator cleans needles, cylinder base plate etc. All around of the machine are kept neatand clean as if there is no dirt with yarn in the fabric.

2) Schedule/Routine Maintenance: Every machine has a schedule ofmaintenance of 10 or 15 days. According to date, schedule maintenance is taken on themachines. Operators are informed about the time of maintenance. After pre-estimatedproduction, they hand over the machine to the fitters. Thus, fitters assure all machines areOK. for any time.

3) Break down maintenance: When product quality hampered and tocomplete production in due time break down maintenance is taken. There are many faultsseen in the fabric during production due to needle, sinker, take down roller etc. Thenoperators inform the mechanical fitters and they fix it.

4) Restorative maintenance: Restorative maintenance is taken for designchange or new design development. According to advice or order of production officer, amachine is fixed for new design and mechanical fitters rearrange cam and needle system.

Planned and preventive maintenance are not taken on the machineries in thismill.

MAINTENANCE OF ‘TERROT’BRAND M/C:

Lubrication:Since the life of the m/c and its correct working depend to a large extend

adequate and proper lubrication. It is recommended that the instructions given in thelubrication charts be followed conscientiously. The Terrot Company can not be needresponsible for faults that arise from wrong or inadequate lubrication.

Oiling Needles & Jacks:Too much oil is preferable to too little. Dark vertical lines in the fabric originate

not from excessive oiling b but from too mach friction between needle and jacks and thetrick walls on account of lack of oil. Should dark vertical lines makes their appearance isrecommended that the appropriates m/c parts be flooded with oil. This will cause heavysoiling or ht fabrics but the trouble will disappear quickly correct quantity of oil then canbe applied. The supply of oil should be reduced if light oil striper appears on the fabric.

The Cleaning of Needle & Jacks:Thin oil is most suitable for this work, about one point heated to a temperature

not exceeding 160ºF poured into the oiling position of the cylinder & dial cam races & inthe heads of the needles while the m/c is running. The fabric will found to be cleaned againafter few yards have been knitted. How often cleaning is necessary will depend upon whatkind of yarn is being used. Synthetic yarn cleaning is taken place at lest monthly, yarn withabsorbent properties being knitted at same time.

General Cleaning Schedule:Long m/c life, maximum output & trouble free running depend upon proper care

and maintenance. A general overhaul should take place annually when single shifts areworked & correspondingly at more frequent interval. When extra shifts are worked. Theoverhaul involves removal of all cam section and removal of needles and jacks from theirtricks, so tat the tricks should be thoroughly the cleaned. Before parts are replaced theyshould be adequately lubricated.

MAINTENANCE OF ‘CAMBER’ BRAND M/C:

Maintenance & Repair:A maintenance schedule of cleaning, checking & lubrication is highly

recommended. Many companies have established that a good schedule will reducebreakable. Maintenance quality maximizes efficiency & prolongs the m/c life.

All electrical repairs should be carried out by a qualified electrician or one ofour service engineers only.

Camber International Ltd. will not be held responsible or liable for invalidity.

Lubrication:Lubrication is very important. The principle of lubrication is to septet the

moving parts subject to friction with a film of oil or grease. This increases the life of m/c.If the m/c has been stopped for a day or more oil will have drained away. Ensure

the m/c is clean then reduce the m/c speed. Run the m/c & flush for about ten m/crevolutions.

The m/c will flush with oil after every bale of fabric for four or five revolution.It is strongly advised that the recommended lubrication be used if lubrication is

preferable.

Cleaning:The m/c should be cleaned after every bale of fabric, and then thoroughly

cleaned after each shift.Switch off and isolate the m/c before cleaning and attach a warning sign to the

isolator switch to avoid accident recommendation.It is better and makes economic sense to regularly clean the m/c.

MAINTENANCE OF ‘ORIZIO’ BRAND M/C:

Air Cleaning System:The upper part of the m/c (stop motion, feeding unit, yarn cones, yarn passage

etc.) is kept clean by electric fans that can be turned off by means of switch.The knitting head is kept clean by electric fans and by3 compressed air nozzles,

which blow in sequences and are located as follows:* One on the sinker cam ring to clean the rear section of sinkers.* One connected to the center rotating part cleans the yarn carries the upper

surface of the sinker cam ring.The nozzles have to be adjusted in such way to avoid any disturbances the yarn

while they are taken by the needles.One mounted on the sinker cam ring, blows downward, its function is to clean

the sinker in the stitch formation area. The air flow from each nozzle is adjustable by themicro tapes.

Machine Cleaning:For a good performance and functioning of the m/c, it is most advisable to carry

out the following operation:Clean with compressed air jet the stitch formation area every time the fabric roll

is removed from the m/c, every 1500 working hours, a more accurate cleaning action oncylinder cam boxes, cams, sinkers etc. with a good detergent solution.

MANPOWER SET UP FOR MAINTENANCE:

There are two shifts in this mill. Two groups of mechanical fitters for fourpersons work for two shifts. Each group having a leader, a needle man and two assistantfitters. Fitters work under the technical in charge for knitting section only. They all arevery efficient and hard working. They can fix any type of mechanical problem ofmachines. No necessity happens to hire others from outside to fix machine maintenance.There are electro-mechanical groups to work for electrical problem of machineries. Theywork for overall factory.

MAINTENANCE PROCEDURE:

1) For there is any mechanical fault of machine which is responsible forproduction hamper, operator informs mechanical fitters in duty. Mechanical fitters comeand observe the problem firstly, and then they begin to fix it.

2) If mechanical fitters be unable to fix it, then they inform technical in-charge,he then comes in spot and fix it.

3) For there is any electrical problem of machine or serious foundingmechanical problem, mechanical and electrical department are informed, they come and fixthe problem. They commence at work after informing of knitting manager. There are twomechanical engineers in the department.

4) For restorative maintenance, senior production officer orders mechanicalfitters to fit required machine for cam and needle arrangement and other necessaryrequirements in case of new design development.

Maintenance sequence of circular knitting machinePower on/off

↓MPF/Positive feeder current line off

↓MPF belt out/loss

↓Yarn cut

↓Fabric out by handle

↓Cleaning and Oiling

↓Cam box out

↓Needle & sinker out

↓Needle & sinker cleaning by oil

↓Cam box cleaning by air

After opening & cleaning, m/c is leveled by using leveling meter and follows the reverse processto ready the m/c.

MAINTENANCE TOOLS & THEIR FUNCTIONS:

S L No. Name of Tools Functions of maintenance Tools01. L-Key Loosen and Tighten the screws.02. Air Suctioner Cleans machine by suctioning.03. Screw Driver To loosen and tighten the screws.04. Dhali (Spanner) Loosen and Tighten nut and bolt etc.05. Star Driver Screw unlocking.06. Pliyers (Nose &Coarse) Tighten screws and nuts.07. Cutting Pliers Cutting thin wire.08. Pulley Key To loosen pulleys.08. Pulley Key To loosen pulleys.

Remarks:

This mill has a strong maintenance fitter’s troop to fix up all types problem. Twogroups of two shifts obey their duties responsibly and sincerely. With their different toolsor equipments they perform their duties skillfully.

CHAPTER-VIII(Utility Services)

UTILITY SERVICES

INTRODUCTION:Padma Poly Cotton Knit Fabrics Limited is a big project and so of course having

a vast project of utility service. From different source it collects necessary utilities at a costto knitting, dyeing & finishing section and garments section. Here is the total account ofutility facilities available.

POWER & UTILITES SECTION:

DESCRIPTION OF MACHINE NO. OFMACHINE

CAPACITY

Generated Power:Prime Power generation, Cruascar GasGeneratorModel FGLD 480 – Origin Spain.

636 KW

Stand by – Diesel Generator, Puma, Origin- England

140 KW

A. Sub station 1000 KVATotal Connected load 1776 KWAir Compressor:Kaeser Screw Compressor, Model AS44,30 KW, 4 M3/Min each.

2 Units 8.00M3/Min

Omgersp:-Rand Reciprocating Compressor,Model-SSR ML-50 57.5 Kw Capacity ofAir Discharge

1 Unit 8.00M3/Min

Ingersoll-Rand Reciprocating Compressor,Model – 3000. 22 Kw

2 Units 4.40M3/Min

SWAN Reciprocating Compressor, Model– C4080 , 10 KW

1.00M3/Min

TOTAL AIR DISCHARGECAPACITY

21.4M3/Min

Kaeser Refrigeration Air Dryer, ModelTE121, 5 KW, Year of Manufacture, 1998

13.00M3/Min

Ingersell Rand Refrigeration Air Dryer,Model- TMS 80.30 KW

6.00M3/Min

DESCRIPTION OF M/C NO. OF M/C CAPACITY

Ingersell Rand Refrigeration Air Dryer,Model TMS 30.2 KW

3.00M3/Min

TOTAL 22.00M3/Min

Water Pumps No. of machine CapacityCentrifugal Pump for water supply toDyeing & Others Section.20 H.P. Pedrollo Pump each pump, 1000L/min Flow rate

4 Units 4,000.00L/Min

10 H.P. Pedrollo Pump Flow rate- 600L/Min

1 Unit 600.00L/Min

5.5 H.P. Pedrollo Pump Flow rate -350L/Min

1 Unit 350.00L/Min

Spare Pump Motor Pedrollo 20 H.P. 1 Unit 1,000 L/Min

BoilerCiever Brooks Boiler 10 Ton/Hr 01 set

REMARKS:As the biggest project the Padma Poly Cotton Knit Fabrics Limited, so the vast

utility systems. There is a skill manpower group of engineers and other technical staffs tolook after these utility services. They have to remain aware of solution on a great sense ofresponsibility for any type of problem due to utility supply

CHAPTER-IX(Store & Inventory Control)

STORE & INVENTORY CONTROL

INTRODUCTION:Inventory is planning and execution involves participation by most of the

fundamental segment of business sales, production, purchase, finance and accounting.Inventory is a wider sense is defined as any idle resource of an enterprise how ever it issemi-finished packing spares and other stocked in order to meet an expected demand ordistribution.

OBJECTIVES OF INVENTORY CONTROL:

1) Financial activities:a) To save amount of investmentb) To know the cash position

2) Property Protection:a) Preventable wasteb) Insurable damagec) Unauthorized use

3) Operating:a) To obtain the best overall balance between production and

inventory carrying cost.b) To minimize losses

c) To avoid stock out and to keep inventory holding costs in costsin balance.

INVENTORY SYSTEMS:For Raw Materials:

In this factory, Padma Poly Cotton Knit Fabrics Limited, rawmaterials are yarn of different type, different count and of different spinning mills of homeand abroad. As according to knitting section demand yarn is either imported or bought fromspinning mills and they are kept in the store for raw materials in accordance with type andcount. As like as polyester, cotton, lycra are kept separately and also to their count variation.Inventory office keeps record of this raw materials amount, their usage and storage.

For Spares:Different spares parts of knitting machines and other equipments are

kept in store as inventory so that there are no time and money losses while it is being used.Here is the list of spare parts as inventory:

1) Needle detector 13) Inverter2) Fan 14) Yarn Guide feeder3) Air gun 15) Oil Nozzle4) MPF belt tensioning device 16) Cam box5) Air nozzle 17) Magnet6) Fabric spreader 18) VDQ pulley7) Fabric light 19) Fan broker8) Compressor line + pipe 20) Oil Meter cover9) Air blower 21) Oil pulsonic10) Memminger 22) Air meter cover11) Oil Tanky 23) Knot catcher12) Fabric roller 24) Feeder ring bolt

For Finished Goods:Finished goods in this mill are the readymade garments. All garments

are being ready in the cartoon according to the piece numbers as buyers choose.Cartoons are kept prepared one upon another for dispatch. Total no. of cartoons ismaintained by the inventory office for finished goods. And at last, they are sent to dispatchafter counting.

For Others:Out of above types there are inventory systems for semi-finished

goods like as dyed fabrics, garments pattern pieces, markers, sewed goods, scrap, surplus,absolute items, garments labels, packages etc. These goods are maintained by the respectiveinventory control office different departments this knit-composite mill.

REMARKS:Proper inventory control of raw materials, semi-finished goods, finished goods

and other miscellaneous goods lead smooth production. As Padma Poly Cotton Knit FabricsLimited follow the correct way of inventory control system, it can have a good and hugeproduction as it demands.

CHAPTER-X(Cost analysis)

COST ANALYSIS

INTRODUCTION:Costing is a very important task for a factory which runs for business purposes.

And it is also strictly followed in the Padma Poly Cotton Knit Fabrics Limited. Costing ofthe products considering the raw materials expenditure, salary and wages of officers andworkers, distributions and advertisement expenses etc. all direct and indirect expenses isdone in this factory. It is determined by a troop of accountants with advice and consultancyof executive director.

PRICE OF THE PRODUCT:Generally price of product is determined by the required profit adding to the total

expenses. So,

Price of products= (Direct expenses + Indirect expenses + FactoryOverhead) + Required profit

COSTING OF THE PRODUCT:Here we collect some cost sheets which help us to know the costing systems:

PADMA POLY COTTON KNIT FABRICS LTD.Utilization and Cost Sheet

A)Yarn Requisition #82

B) Accessories

Buyer : Rainbow Express S.L. Date : 21/09/2003L/c # : 8144656001000201 L/C Value : USD 90.500Article &Fabric :

100% cotton Pique PFD 200-220 GSM& Single Jersey PFD 180 GSM

Order No. : 2030PD, 2029PD &2031 PDOrder Qty : 50,000 pcsShip Date : 25th October 2003 (as per Licence)

SL # Yarn Description Yarn Count Quantity(kgs) Unit Price in USD Total Amount in USD01. 100% cotton Pique Ne 26/1 12700.72 2.35 29,846.6902. 100% Cotton S/J Ne 24/1 8164.72 2.35 19187.092

TOTAL = 20865.44 = 49033.78

S L # Item Description Quantity Unit Price in USD Ttl Amount(USD)

1. Sewing Thread 600.00 cone 2.202. Composition Label 883.33 Doz 0.103. Composition Label 883.33 doz 0.164. Main Label 883.33 doz 0.3005. Size Label 891.67 doz 0.056. Care Label 883.33 doz 0.2607. Horn Button 26.00 GG 12.008. Eyelet 3666.67 doz/set 0.079. Size label 2229.17 doz 0.0510. Composition label 2208.17 doz 0.2611. Care label 2208.17 doz 0.1012. Care & Composition label 1337.5 doz 0.3513. Horn Button 28 GG 3.7514. Gum Tape 80 roll 0.5519. Scotch Tape 75 roll 0.2020. Interlining 18 roll 15.0021. Poly bag (Blister) 437.5 doz 0.4522. PP Belt 10 roll 7.0023. Metal clip 9 box 0.52024. Shoulder Tape ¼ inch 326.67 yds 1.5525. Zipper(Half) Pcs26. Sewing Ticket Doz27. Carton 1300 pcs approx. 1.3028. Mobilon Tape Doz29. Single Poly Doz.30. Tissue Paper Doz31. Spot Lifter pcs32. Size Label 2229.17 Doz 0.05

TOTAL = 7,000.93

PADMA POLYCOTTON KNIT FABRICS LTDInter Office Correspondence

OVER HEAD SHEET

Buyer : RainbowL/C # : 8144656001000201

A) Knitting Charge :

SL#

Description Quantity(kgs) Unit Price in USD Amount in USD

01. Pique 12700.72 0.31 3,937.2202. Single Jersey 8164.72 0.17 1,388.0003. 1x 1 Rib 504.00 0.3106. Interlock 0.3507. Fleece 0.45

Total = 5,325.17

B) Dyeing Charge :

SL#

Description Quantity (kgs) Unit price in USD Amount in USD

01. Dark Shade 0.5502. Medium Shade 0.4503. Light Shade 0.3504. White 0.2005. Wash 20865.44 0.15 3,129.8206. Brushing

Charge0.27

Total = 3,129.82

C) Making Charge :

SL# Description Quantity(doz)

Unit Price inUSD

Amount in USD

01. Polo shirt 2083.33 5.00 10,416.6502. Short Slv T-

Shirt2083.33 2.00 4,166.66

03.Total = 14,583.31

PADMA POLY COTTON KNIT FABRICS LTD.Inter office Correspondence

Estimated Requirement of Dyes & ChemicalsBuyer : Rainbow L/C# : 8144656001000201Order#: 2030PD,2029PD & 2031PD L/C Value: USD 90,500Item : Short Slv T-Shirt & Polo Shirt Order Qty: 50,000 PcsFabric: 100%cottonS/J 180 GSM&100%cotton pique

200-220Reqd.Yarn:

10284 Kgs

SL# List of Dyes & Chemicals Reqd. Qty(kgs) Unit Price(USD) TotalAmount(USD)1 Citamol BL 4.242 ALBATED FFC 120.00 5.50 660.003 Cibafluid C 600.00 1.70 1,020.004 Sirrix 2UD 2.135 Sandopur RSK 2.966 Alcosperse AD 5.157 Drimizen R2R 575.00 2.808 Oxalic Acid 0.90 1,610.009 Sapamine FPS 1.6510 Hydruce 1.1011 Tinoci Arite CBB 240.00 1.7012 Ammunium Sulphate 0.25 408.0013 Formic Acid 1.0014 Acetic Acid 570.00 1.0515 Caustic Soda 665.00 0.60 598.5016 Hydrozen peroxide 665.00 0.60 399.0017 Glober Salt 0.20 399.0018 Soda Ash 0.2519 Setamol BL 1.1820 Invadin Da 240.00 2.9021 Invatex CS 240.00 1.60 696.0022 Invatex PC 240.00 1.90 384.0023 Cibacron Navy W-BT 7.30 456.0024 Cibacron Yellow H-2G 19.7025 Cibacron Red FN3G 20.4026 Sun White BYB 17.2727 Cibacron Red H-B 150% 14.5028 Cibacron Scarlet F3G 27.5029 Cibacron Brilliant Blue FNG 21.0030 Cibacron Yellow FN2R 16.6031 Cibacron Yellow WR 200% 13.7032 Tricon Blue SE 2BT 16.2033 Tricon Yellow SE4GT 10.5634 Tricon Red EFBN-T 11.5735 Tricon n.Blue SE-EXNT 8.8036 Ratnafix G.Yellow MERL 9.63

15037 Ratnafix Red ME-6BL 150 9.2638 Naka Nlack US 2.1339 TaifoxBlack VS-BT 133 5.9340 Traicon Black BSD-T 6.9541 Forcon Brilliant Red SRGL 27.7842 Taisoft ABN 3.1443 Taifix Briliant Blue RTSPC 21.37

Total=

6,630.50

REMARKSCosting is as important as production for a productive factory. Without proper

costing all production curriculums will go to in vain. Cause, a factory cannot reach to itsgoal without achieving good profit and good profit is not possible without skillful costing.Seeing the improvement of Padma Poly Cotton Knit Fabrics Limited day by day, we canassume that it follows the right and proper way of costing with skillful technical persons.

CHAPTER-XI(Marketing activities)

MARKETING ACTIVITIES

INTRODUCTION:Marketing activities are done in this mill, Padma Poly Cotton Knit Fabrics

Limited by a skillful team of marketing officers under the Executive Director. Here are thedetails of marketing activities.

CONSUMER OF THE PRODUCTS:The mill has a great number of renowned and international consumers. Following

are some regular consumers:1) Tom Taylor2) Sara Lee3) I.C. Company4) Rainbow

PRODUCT LEBEL:There are following lebels used by this mill:

1) Care Lebel: It contains washing in hot or cold water, chemical cleaning,drying conditions etc.

2) Size Lebel: It contains size of garments.3) Composition Lebel: It contains the fabric composition of different fibre type.4) Decorative Lebel: Decoration is as buyer or consumer choice wise.

PACKAGE SIZE & LEBEL:Most common sizes are

S - SmallM - MediumL - LargeXL - Extra largeXLL - Very very large

LOCAL MARKET:Padma Poly Cotton Knit Fabrics Limited is 100% export oriented mill. So there is

no local market involved in it. But the knitting section takes some sub-contact for knitting anamount of fabrics from their given yarn.

IMPORTING COUNTRIES:This mill relates to the countries for yarn importing, they are

1) India2) Korea

MANPOWER:Almost ten marketing officers and ten others workers act under the Executive

Director.

DUTIES & RESPONSIBILITES OF MARKETING OFFICERS:

1) Executive director takes order from the buyer and gives order the marketingofficer’s troops to produce a cost sheet.

2) Marketing officers are known the amount and design of product.3) They collect the sample from the buyers and send to knitting and dyeing

section.4) Knitting section adjusts the amount of total yarn and knitting conditions and

dyeing sections adjust the amount of dyes and chemicals. They send a rough calculation tothe marketing section.

5) Marketing officers adjust the amount of garments accessories with the help oftheir own experiences and their knowledge. They also take help of garments in charge.

6) Finally, they adjust their cost sheet after consulting with the Executive Directorand copy several pieces of the cost sheet.

REMARKS:Marketing activities are very important tasks for a productive factory. In this mill,

there having highly qualified marketing officers. As a result, the mill rises up day by day.

CHAPTER-XII(STITCH NOTATION, CAM ARRANGEMENT &NEEDLE REPEAT OF SOME KNITTED FABRIC)

M/c Name: Terrot-20 M/c Ø GG: 23 24 GGFabric : Single jersey S. length : 2.85G.G.S.M : 135 F. Dia. : 60 cm (tube)F.G.S.M : 160Yarn : 26s /1 CB pacific L- 083

SAMPLE NOTATION DIAGRAM

CAM SETTING NEEDLE ARRANGEMENT

N.B: = Knit stitch 3= Three butt needle∆ = Knit cam 4= Four butt needle

3 34 4

∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆

M/c Name: Orizio-10 M/c Ø GG: 26˝ 24 GGFabric : S/J Jycra S. length : 3.10G.G.S.M : 190/195 F. Dia. : 50 ˝F.G.S.M : 210Yarn : 28s /1 CB pacific L- 083 + 20 D lycra full feeder



N.B: = Knit stitch 2= Two butt needle∆ = Knit cam 4= Four butt needle

2 2

4 4

∆ ∆ ∆ ∆ ∆

∆ ∆ ∆ ∆ ∆

M/c Name: Orizio-09 M/c Ø GG: 30˝ 20 GGFabric : Fleece S. length : S/4.20 + B/4.80 + Loop/1.44G.G.S.M : 210/215F.G.S.M : 280Yarn : 30s /1 CD padma L- 3071 + 24s /2 P.C padma L-11

SAMPLE


N.B:― = Miss cam 1= One butt needle∆ = Knit cam 2= Two butt needle

3= Three butt needle4= Four butt needle

12

34

∆ ∆ ∆ ― ∆ ∆ ― ∆ ∆ ― ∆ ∆― ∆ ∆ ― ∆ ∆ ∆ ∆ ∆ ― ∆ ∆― ∆ ∆ ∆ ∆ ∆ ― ∆ ∆ ― ∆ ∆― ∆ ∆ ― ∆ ∆ ― ∆ ∆ ∆ ∆ ∆

M/c Name: Orizio-08 M/c Ø GG: 30˝ 20 GGFabric : Fleece S. length : S/4.24 + B/4.60 + Loop/1.40G.G.S.M : 200/255 F. Dia : 70 / 71 (open)F.G.S.M : 260Yarn : 30s /1 G M 10% L- 95 + 24s /2 P.C padma L-61

SAMPLE


N.B:― = Miss cam 1= One butt needle∆ = Knit cam 2= Two butt needle

3= Three butt needle4= Four butt needle

12

34

∆ ∆ ∆ ― ∆ ∆ ― ∆ ∆ ― ∆ ∆― ∆ ∆ ― ∆ ∆ ∆ ∆ ∆ ― ∆ ∆― ∆ ∆ ∆ ∆ ∆ ― ∆ ∆ ― ∆ ∆― ∆ ∆ ― ∆ ∆ ― ∆ ∆ ∆ ∆ ∆

M/c Name: M/c Ø GG:Fabric : Single Lacoste S. length :G.G.S.M : F. Dia. :F.G.S.M :Yarn :



N.B: = Knit stitch 3= Three butt needle = Tuck stitch 4= Four butt needle

= Tuck cam∆ = Knit cam

3 34 4

∆ ∆ ∆∆ ∆ ∆

M/c Name: M/c Ø GG:Fabric : Double Lacost S. length :G.G.S.M : F. Dia. :F.G.S.M :Yarn :





3 34 4

∆ ∆ ∆ ∆∆ ∆ ∆ ∆

M/c Name: Orizio-16 M/c Ø GG: 36˝ 18 GG

Fabric : 1 1 Rib S. length : 2.75G.G.S.M : 156/160 F. Dia. : 75˝ (open)F.G.S.M : 210Yarn : 26s /1 CB pacific L- 2629

SAMPLE


D L DSL

CS C

N.B:∆ = Knit camL = Long butt needleS = Short butt needle

L LS S

∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆ L L

S S


Fabric : 1 1 Lycra Rib S. length : 2.80G.G.S.M : 220 F. Dia. : 26˝ (tube)F.G.S.M : 280Yarn : 24s /1 CD + 70D

SAMPLE


D L DSL

CS C

N.B:∆ = Knit cam C= CylinderL = Long butt needle D= DialS = Short butt needle

L LS S

∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆ L L

S S


Fabric : 2 2 Rib S. length : 1.75G.G.S.M : 200 F. Dia. : 47˝ (open)F.G.S.M : 260Yarn : 26s /1 CB padma L-2631

SAMPLE


D

C

N.B:∆ = Knit camL = Long butt needleC= CylinderD= Dial

∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆

L L L L

L L L L

M/c Name: M/c Ø GG:Fabric : 2 2 Lycra Rib S. length :G.G.S.M : F. Dia. :F.G.S.M :Yarn :

SAMPLE


D

C

N.B:∆ = Knit camL = Long butt needleC= CylinderD= Dial

∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆∆ ∆ ∆ ∆ ∆ ∆

L L L L

L L L L

M/c Name: Orizio-5 M/c Ø GG: 30˝ 24 GGFabric : Lycra PK S/ L S. length : 2.35G.G.S.M : 150/160 F. Dia. : 57˝(open)F.G.S.M : 175Yarn : 60s /1 CB padma L-6005 + 40D





3 34 4

∆ ∆ ∆∆ ∆ ∆

M/c Name: Mayer-3 (interlock) M/c Ø GG:Fabric : Punto di-roma S. length :G.G.S.M : F. Dia. :F.G.S.M :Yarn :

SAMPLE


D

C

N.B:∆ = Knit camH = High butt needleL = Low butt needleC= CylinderD= Dial

∆ ― ― ∆― ∆ ― ∆― ∆ ∆ ―∆ ― ∆ ―

H L H LH L H L

M/c Name: Mayer-3 (interlock) M/c Ø GG:Fabric : Interlock PK S. length :G.G.S.M : F. Dia. :F.G.S.M :Yarn :

SAMPLE


D

C

N.B:∆ = Knit cam ―= Miss camH = High butt needle = Tuck camL = Low butt needleC= CylinderD= Dial

∆ ― ― ∆ ―― ∆ ― ∆ ―― ∆ ― ∆ ― ∆∆ ― ∆ ― ∆ ―

H L H LH L H L

M/c Name: Interlock -1 M/c Ø GG: 30˝ 22 GGFabric : Plain Interlock S. length : 2.85G.G.S.M : 160/165 F. Dia. : 26˝ (tube)F.G.S.M : 190/200Yarn : 40s /1 CB CLC

SAMPLE


D

C

N.B:∆ = Knit cam ―= Miss camH = High butt needle C= CylinderL = Low butt needle D= Dial

∆ ― ∆ ―― ∆ ― ∆― ∆ ― ∆∆ ― ∆ ―

H L H LH L H L

Fabric: Collar M/c: Flying tiger ( Flat bed)

SAMPLE Block: 01

Block: 02 Block: 03

Block: 04 Block: 05

Jump: 03Time: 02

Block: 06 Block: 07

H L Yarn Speed:2

B K K 5 3 T. down:2

F K K 5 3 Stitch:3

H L Yarn Speed:2

B K K 5 3 T. down:2

F K K 5 3 Stitch:4

H L Yarn Speed:3

B ― ― 5 3 T. down:2

F K K 5 3 Stitch:3

H L Yarn Speed:2

B ― ― Looptransfer

T. down:2

F K K ″ Stitch:4

H L Yarn Speed:3

B K K 5 3 T. down:2

F ― ― 5 3 Stitch:3

H L Yarn Speed:2

B K K 1 1 T. down:2

F K K 1 1 Stitch:4

H L Yarn Speed:2

B K K 1 1 T. down:2

F ― ― 1 1 Stitch:4

Block: 08 Block: 09

Block: 10 Block: 11

Block: 12Jump: 10Time: 4

Block: 13 Block: 14

Block: 15 Block: 15

Jump: 15 , Time: 64

H L Yarn Speed:2

B ― ― 1 1 T. down:2

F K K 1 1 Stitch:1

H L Yarn Speed:2

B K K 5 3 T. down:2

F K K 5 3 Stitch:2

H L Yarn Speed:3

B K K 5 3 T. down:2

F ― ― 5 3 Stitch:3

H L Yarn Speed:3

B ― ― 5 3 T. down:2

F K K 5 3 Stitch:3

H L Yarn Speed:3

B K K 5 3 T. down:2

F ― ― 5 3 Stitch:3

H L Yarn Speed:2

B K K 5 3 T. down:2

F K K 5 3 Stitch:5

H L Yarn Speed:1

B K K 5 3 T. down:1

F K K 5 3 Stitch:7

H L Yarn Speed:1

B K K 5 3 T. down:1

F K K 5 3 Stitch:7

H L Yarn Speed:1

B K K 5 3 T. down:1

F K K 5 3 Stitch:7