Internship Report on Birds Group Ltd

Internship Report On Birds Group of Inderstiy Course Title: Industrial Internship Course Code: Tex-404 Supervisor Nasif Chowdhury Senior Lecturer Department Of Textile Engineering City University,Ashulia, Savar, Dhaka. Prepared by Kawsar Ahmed ID: 12331402 Batch: 22nd Department Of Textile Engineering City University,Ashulia, Savar, Dhaka. Submission Date: 06, December, 2017 I sincerely declare that, this is our Internship Report, prepared by kawsar Ahmed under the supervision of Md. Nasif Chowdhury - Senior Lecturer Department of Textile Engineering, Eng. Md. Arifuzzaman - Assistant Professor and Coordinator Department of Textile Engineering, Dr A K M Saiful Islam - Professor and Head of the Department of Textile Engineering, City University, Ashulia, Savar, Dhaka. We are the sole writer of this report and the details of training and experience contained in this report describe our involvement as a trainee in the field of Textile. I also declare that, all the information contained in this report is certain and corrected by us. Signature of the Supervisor Nasif Chowdhury Senior Lecturer Senior Lecturer & Co-Ordinator (Evening) Department Of Textile Engineering City University,Ashulia, Savar, Dhaka. During the period of eight weeks, starting from September 02, 2017 to November 02, 2017, I was placed as a trainee in the Birds Group of Indestry. And gathered knowledge on textile. Without help and guidance from numerous instances it would not have been possible to learn about textile sector and to prepare this report in its present form. I wish to express our sincere appreciation to all those individuals and organizations who have directly or indirectly contributed towards the preparation of this report and help us on our training time. I particularly express our gratitude to the following: Nasif Chowdhury, Senior Lecturer, Department of Textile Engineering, of Textile Engineering as our supervisor for giving valuable help and advice in the presentation of analytical process and in the display and selection of the content of the report. Saydur Rahman Raju, General Manager of dyeing, Knitting & Garments department, Sagor, junior executive of dyeing department ,Mehedi Hasan Senior Merchandiser Birds Group of Inderstiy for their kind co-operation. Above all, I would like to acknowledge our deep debt to all teachers of our university especially of Garment Manufacturing Technology department for their kind inspiration and help, which remain as the backdrop of all our efforts. Finally, I would like to acknowledge that we remain responsible for the inadequacies and errors, which may remain in the report undoubtedly. Table of Contents Chapter Topics Name Page No. 1 Introduction 5-6 2 Man Power Management 7-9 3 Knitting Section 10-26 4 Dying Section 27-44 5 Finishing 45-52 6 Garments 53-71 7 Quality Assurance 72-73 8 Utility Service 74-76 9 Maintenance 77-79 10 ETP 80-83 11 Store and Inventory Control 84-86 12 Compliance Issue 87-89 13 Conclusion 90-91 Industrial attachment is an important and essential part of 4 year B.Sc. in Textile Engineering Course. Actually industrial attachment is the practical experience for every Textile Engineer which is needed to be familiar not only the industry but also all over the necessary job related to continue in any industry. During student life a student cannot know about the practical condition so its badly needed for every student for attain for the industrial attachment . Birds Group of Indestry. is truly an excellent industry from our point of view. All types of modern technology are well arranged here. Every section in here helps us so much by giving information during our training period which was unbelievable. Specially IT Department maintain the Management Information System a vital role for the companies smooth operation and development, We are so satisfied and lucky student to completed our Industrial Attachment in Birds Group of Indestry.I think this Industrial Attachment will be outstanding helpful in our future career life. 2.1 Man Power Organ gram of Administration: Chairman Managing Director Director General Manager Man power organogram of production Production Director Production Manager Assistant General Manager Quality Manager Admin Manager Admin Assistant Admin Line Chip Supervisor Quality Controller Operator Helper Labor 2.2 Shift Change: There are three shifts per day in hypoid Composite Knit Ltd.So each shifts contains eight hour. Start End 6:00 A.M. 2.00 P.M. 2.00 P.M. 10:00 P.M. 10:00 P.M. 6:00 A.M. 8.00 AM 6.00 PM 2.3 Management System: Four mechanical fitters for per shift. One skilled operator for each machine One helper for two machine Loader for carrying the yarn package 3.1 Process definition of knitting: Knitted fabric generally produced by form of loop. Any circular knitted fabric is composed of row after row of interloping or interlocking of loops. Different types of fabric are made of different method. The gross dimension of knitted fabric is simply a reflection of any shape & size of individual loops. There are several key variables in the production which affect the average shape & size of the loops. After knitting the gray fabric is dyed to required shade & finished to required weight & width. 3.2 Variables of Knitting: During production of fabric in circular knitting machine following parameters must be maintain: Machine Diameter; Machine RPM (Revolution Per Minute); Number of feeds or feeders in use; Required time (Machine running time); Machine running efficiency. Yarn Count Yarn Twist Spinning system No of ply of the yarn Stitch length Yarn tension Take down tension Yarn quality Machine gauge 3.3 Process Flow Chart of knitting: 3.4 Classification of Knitting: 3.5 Following are the Different Qualities of Yarn that are used for Knitting Process: Table-02: different qualities of yarn used for knitting process. Type of yarn Count Cotton 16s ,20s, 24s, 26S, 28S, 30S, 34S, 40S Spandex yarn 20D,40D Grey Mélange (C-90% V-10%) 24S, 26S PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S CVC 24S, 26S, 28S, 30S 3.6 Machine description of knitting section: Circular Knitting Machine : Single Jersey, Double Jersey Single Jersey : 03 Double Jersey : 03 Total no of M/C : 06 No. of line : 01 3.6.1 Circular Knitting Machine: Circular knitting m/cs. are widely used throughout the knitting industry to produce fabric. This m/c can be built in almost any reasonable diameter and the small diameter of up to five, which are used for wear. Machine for outerwear and under wear may vary from 12 inch to 60 inch in diameter according to manufactures requirement. This m/c can be used either as fabric or for making garments 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 more types of yarns. Plain circular m/c uses only one sets of needles, circular rib m/c uses two sets of needles i, e, Cylinder needle and Dial needle, the interlock circular knitting m/c also uses two sets of needles 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. Fig-01: Circular Knitting 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: English system – Where the cams and yarns strands revolve by needle and fabric take down is stationary. American system – Where the needles and fabric take down revolves by cams and yarn strands are stationary. 3.6.2 Important 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 to repair, meanwhile the motor can brake and stop operation at once to keep the 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 settle freely 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” from slow operation to normal operation is quite & fast brake to prevent damages 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. SAFETY GUARD SWITCH: Machine cannot be started with guards open; this guards have reinforced fibreglass 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 cam, needles and sinkers lubricated enough, besides it has the function cooling and clearing. 3.7 Other Machine in Knitting Section: Electric 01. Balance for Fabric Weight. 02. Electric Balance for GSM check. 03. Layout of Knitting Section: 04. Man Power of Knitting Section: Table-03: Man power of knitting section Section No. of Person Manager 01 Production officer 01 Quality Section 02 Knitting Master 01 Fitter man 03 Needle man 03 Supervisor 01 Operator 12 Helper 10 Total 34 3.8.1 SHIFT CHANGE: Shift of twelve hours. Shift changes after a week on Saturday. 3.8.2 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 in due time. In the meantime production officers bear all hazards, problems. They have to explain to the manager for any type of production hamper. 3.9 Recommendation points buyer They mention some points related to production & quality, before production of knitted fabric. Those are follows: Diameter of the fabric and Design of the fabric. Total wt. of the fabric and Color of the fabric. Handling & fastness property. Finishing type of the fabric. Types of yarn, GSM of the fabric and Yarn count. 3.1o Specification of the Machines: Machine No: 1, 2 & 3 (Rib Machine) Technical Data: Machine Diameter: 30 Machine Gauge: 18 No of Feeders: 60 No of Cam: 61 Production Range: Rib Interlock Ottoman Thermal drop Origin: Made in Taiwan Brand Name: LKM Machine No: 4, 5 & 6 Single Jersey machine: Technical Data: Machine Diameter:30 Machine Gauge: 24 No of Feeders: 90 No of Cam: 30 Production Range: Plain & Drop Needle Lactose Pique Feeder stripes. Origin : Made in Taiwan Brand name : LKM 3.11 Different Parts of Knitting Machine: Needle Feeder Sensor Cam Cam Box Singer Singer box Pulley GSM pulley Wheel Take up roller Lycra stapper Lycra Miminger Wheel Miminger Cylinder Wheel premium Lycra Bale Wheel Bale Oil Tank Compressor Oil Pipe Panel board Invetor Motor Motor bale Machine Hand Roller Gate Light Machine Fan Earthing Cylinder spring Gauge Meter Tension Meter Switch Machine piya Gear Oil Box Machine safe Feeder Ring 3.12 Description of Production Process: Hypoid Composite Knit Limited is capable of producing stripes of any width and enormous color. Single jersey fabrics and its derivatives like lacost, polo pique, terry fleece etc., rib and interlock fabrics and its derivatives such as 2x2, 3x3 etc. are produced. Different fabrics can be produced by jacquard m/c by varying the tucking lengths and looping sequence. Collar and cuffs of any designs are produced here in the flat bed m/cs. The jacquard design can be computerized and transferred to the knitting m/c by floppy disks. The yarn that used in the body fabric is also used in producing collar and cuff. GSM It is the critical parameter that is checked and controlled at different staged of processing the fabric after knitting to finishing. Fabric GSM can be controlled by the following ways:  By varying the loop length by VDQ pulley.  By varying the no. of loops by needle gauge setting.  By using different count of yarn. The yarn count, in all cases, has prescribed by the buyers. So m/c setting is the only way to control the grey GSM. The final GSM in the finished fabric depend on the finishing treatments and parameters of finishing machineries. Fabric width Fabric width can be controlled by changing cylinder diameter or by changing m/c. RPM M/c rpm is adjusted with the lead time for production. When lead time is very short then rpm may increase at a certain level for definite count and strength of yarn. So it also depends on the yarn parameter and also with structure to be produced. Loop length Loop length determines the fabric GSM. It can be controlled by changing the dia of VDQ pulley In Mayer & CIE m/c, it can be controlled digitally. No. of feeder or no. of cone It depends on the urgency of production. Available cone packages, color to be knit and structure of the fabric. Needle The fundamental element of construction of knitted fabric is the knitting needle. Needle is the hooked metal part which is used for the formation of loops. The needles are the most important stitch forming elements. During yarn feeding, the hook is opened to release the retrained old loop & to receive the new loop which is then enclosed in the hook. They are displayed vertically up & down and are mounted into the tricks or cuts of the knitting cylinder. All kinds of knitting needle should have the system to make a new loop and return back to the old loop. There are three types of needle namely: 1. Latch needle 2. Spring bearded needle, and 3. Compound needle Sinker Sinker is the second knitting element. It is a thin metal plate within an individual or collective action operating approximately at right from the hook side between adjacent needles. It may perform one or more of the following functions dependent upon the machines action and related sinker shape and movement. Loop formation Holding down Knocking over Fig-03: Sinker In Figure, 1=Butt,2=Butt breadth,3=Height of shank,4=Buldge,5=Neb,6=Length neb,7=Throat angle,8=Sinker platform height,9=Breadth of lower shank,10=Clearance,11=Throat. Cam Cam are the third primary knitting elements which cover the rotary machine drive into a suitable reciprocating action for the needles and other elements. The cams are carefully profiled to produce precisely timed movement and dwell periods. The drive transmitted and adapted via cam followers, leavers, pivots and rocking shafts. One complete revolution of the driving shaft is equivalent to one knitting cycle. Two types of Cams: i. Engineering cams ii. Knitting cams Knit cam b. Tuck cam c. Miss cam Fig-04 Cam Tuck A tuck stitch is composed of a held loop, one or more tuck loops and knitted loops. It is produced when a needle holding its loop also receives the new loop which becomes a tuck loop; it is not intermeshed through the old loop. Fig-o5: Tuck Stitch 3.13 Difference between Single Jersey and Double Jersey M/C: Single Jersey Double Jersey 1. One set needle is used. 1. Two set needle are used. 2. Has sinker. 2. Has no sinker. 3. Inside of m/c is vacuum. 3. Inside is not vacuum. 4. Has sinker box. 4. Has no sinker box. 5. Has sinker ring. 5. Has no sinker ring. 6. Has cylinder only.. 6. Has cylinder & dial. 3.14 Difference between Single Jersey & Double Jersey Fabric: Single Jersey(Plain) Double Jersey(Rib) 1. Face & Back side appearance different. 1. Face & Back side appearance same. 2. Plain fabric has curling tendency. 2. No curling tendency. 3.It is unbalanced fabric . 3. It’s balanced fabric. 4. Less elastic property. 4. More elastic Property. 5. Thickness & weight is half of rib fabric. 5. Thickness & weight is twice of single jersey fabric. 6. Face side contains only face loops and back side contains only reverse loops or all are face otherwise all are back loop. 6. Face side contains both face & reverse loops and back side same. Or one face and one back loop. 7.Plain knit structures are used for basic T-Shirt (men & ladies) , under garments, men vest etc. 7. Rib structure are used for socks, cuffs, waistbands, underwear etc. 3.15 Faults and Remedies their causes in Knitting: 5.15.1 Hole Mark: Causes Holes are the results of yarn breakage or yarn cracks. During loop formation the yarn breaks in the rejoin of the needle hook. If the yarn count is not correct on regarding structure, gauge, course and density. Badly knot or splicing. Yarn feeder badly set. Remedies  Yarn strength must be sufficient to withstand the stretch as well as uniform.  Use proper count of yarn.  Correctly set of yarn feeder.  Knot should be given properly. 3.15.2 Needle Mark: Causes When a needle breaks down then needle mark comes along the fabrics. If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies Needle should be straight as well as from broken latch. 3.15.3 Sinker Mark: Causes When sinker corrodes due to abrasion then sometimes cannot hold a new loop as a result sinker mark comes. If sinker head bend then sinker mark comes. Remedies Sinker should be changed. 3.15.4 Star Mark: Causes Yarn tension variation during production. Buckling of the needle latch. Low G.S.M fabric production. Remedies Maintain same Yarn tension during production. Use good conditioned needles. 3.15.5 Drop Stitches: Causes  Defective needle.  If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.  Take-down mechanism too loose.  Insufficient yarn tension.  Badly set yarn feeder. Remedies  Needle should be straight & well.  Proper feeding of yarn during loop formation.  Correct take up of the fabric & correct fabric tension.  Yarn tension should be properly. 3.15.6 Yarn Faults: Neps, Slubs. Yarn count, Thick/Thin place in yarn, Hairiness. 3.15.7 Oil Stain: Causes When oil lick through the needle trick then it pass on the fabrics and make a line. Remedies Ensure that oil does not pass on the fabrics. Well maintenance as well as proper oiling. 3.15.8 Rust Stain: Causes If any rust on the machine parts. Remedies If any rust on the machine parts then clean it. Proper maintenance as well as proper oiling. 3.15.9 Pin Hole: Causes Due to break down or bend of the latch, pin hole may come in the fabric. Remedies Change the needle. 3.15.10 Grease Stain: Causes Improper greasing. Excess greasing. Remedies Proper greasing as well as proper maintenance. 3.15.11 Cloth Fall- Out: Causes Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles. Remedies Make sure all the latches of needle are closed with feeding yarn after a drop stitch. 3.15.12 Fly: Causes In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. Remedies Blowing air for cleaning and different parts after a certain period of time. By cleaning the floor continuously. By using ducting system for cleaning too much lint in the floor. Over all ensure that lint does not attach to the fabric. 3.15.12 Yarn Contamination: Causes If yarn contains foreign fiber then it remains in the fabric even after finishing, If lot, count mixing occurs. Remedies By avoiding lot, count mixing. Fault less spinning. 3.16 Factors that should be Change in Case of Fabric Design on Quality Change: a) Cam setting b) Set of needle c) Size of Stitch Length Fig-06 Single jersey circular knitting machine 3.17 Key Accessories used in Circular knitting: Yarn feeder guide Needle Sinker Cam Cylinder VDQ pulley Pattern wheel Sinker cam cap Sinker trick ring Dial 3.18 Quality Control Equipment: Yarn tension meter Stitch length meter Magnifying glass GSM cutter etc. 3.19 Relation between m/c dia & Number of feeder of this m/c: Number of feeder = M/C dia 3 Positive feed system and Negative feed system If needle gets required thread without stretch for loop formation, it is called positive feed system. If needle drawls the thread for loop formation called negative feed system. Negative feed system is best. Because a. Easy mechanism. b. No slippage. c. Maximum 4 course length variation. d. To adjust loop length variation. e. No possibility of thread breakage. f. Wide range yarn feeding. V.D.Q V.D.Q means Variable dia for quality. Is used to control fabric G.S.M. 3.20 GSM Calculation: GSM means grams per square meter. In knitting fabric it is the main parameter. It is controlled by loop length. If loop length increases GSM will decrease and vice versa. It is measured by GSM cutter & electric balance. It may also be calculated as below. 3.21 Production Calculation: 3.22 End Products of Knitting Machines: Single Jersey M/C : Single Jersey Plain Single Lacost Double Lacost Single Pique Double Pique Baby Terry Three Thread Fleece Lycra Single Jersey Lycra Single Lacost Double Jersey M/C: 1*1 Rib 2*1Rib 1*1 Lycra Rib 2*1 Lycra Rib Flat Back Rib .23 Fabric Gallery: All samples are collected from Hypoid Composite Knit Ltd. 100% Cotton Single jersey Slub Single Jersey Pique Lacost CVC PC Lycra Rib 1*1 Fleece Tery Interlock 3.24 4-Point System for Fault Inspection for Knitted Fabric: Table-04: 4-Point system for fault inspection for Knitted Fabric: Knitting Fault Point Slub 1 Any kind of Hole 4 Needle Mark/Sinker Mark 4 Needle Broken 4 Set up 4 Dirt, Oil Spot, Thick, Thin, Contamination up to 3” in Length 1 Dirt, Oil Spot, Thick, Thin, Contamination up to 6” in Length 2 Dirt, Oil Spot, Thick, Thin, Contamination up to 9” in Length 3 Dirt, Oil Spot, Thick, Thin, Contamination above 9” in Length 4 3.25 Calculation of Total Fault Based on 4-Point System: Fabric Length: yards Roll weight x 1000 x 39.37 x 1.09361 Finish Dia x Finish GSM Point of fault: Point Total point calculated x 100 x 36 Finish Dia x Fabric length 3.26 Remarks & Conclusion: Grey fabric in the good condition and there are no faults in which it leaves knitting section so that before any bleaching, dyeing or finishing treatment has given to it. So that there are no faults found for knitting of fabric after dyeing process. Also the GSM and diameter of the fabric should meet the requirements. 4.1 DYEING: Dyeing is usually among the last of the long line of manufacturing operations which lead to the end product. 4.2 DYEING CLASSIFICATION: 4.3 Auxiliary Substance of Dyeing: Sequestering agent Defoaming agent.(without defoaming agent dyeing may be uneven) Wetting agent Anticreasing agent Antipilling agent Levelling agent Emulsifier 4.4 Flow Chart of Fabric Dyeing: Fabric received from batching section ↓ Grey fabric inspection ↓ Batching ↓ Turning ↓ Sewing ↓ Fabric loading ↓ Pretreatment (Scouring & Bleaching) ↓ Enzyme (Antipilling) ↓ Dyeing ↓ Washing ↓ Fixing ↓ Softening/Finishing ↓ Unloading the dyed fabric 4.5 RAW MATERIALS FOR DYEING: The raw materials used for production are- Grey Fabric Dyes and Chemicals 4.5.1 GREY FABRIC: Following types of grey fabrics are dyed: Single Jersey. Lycra Single jersey. Slab Single jersey. Interlock. Lacost. Pique. Rib. Lycra Rib. 1×1 Rib 2×1 Rib 2×2 Rib & others Sources: The grey fabrics are produce from this industry. All the grey fabrics that are produce from this industry are dyed in dyeing section. After fulfill all order of this industry sometime they dyed fabric in sub contact. 4.5.2 Most common and usable dyes are: Reactive Dyes (Cotton Dyeing). Disperse Dyes (Polyester Dyeing Dyeing with reactive dye: Reactive Dye Stuff: Reactive groups are present in the molecules of the reactive dyes. These dyes chemically react with fibres hence it is called reactive dyes. These type of dyes posses reactive groups which during the process of dyeing, reacts chemically with the fibre substrate to form a covalent bond so that chemically speaking it becomes a part of the fibre itself. The reaction is as follows- D-F-CH=CH2+ Cell-OH D-F-CH2- CH2-O-Cell Properties of Reactive Dyes:  Anionic in nature  Soluble in water  It forms strong covalent bond with fibre  Their wet fastness & light fastness are good  They have better substantivity  They are used in alkaline condition Influencing factors for dyeing:  The PH of the bath  The temperature of bath  The concentration of the electrolyte  The time of dyeing  The liquor ratio 4.5.3 CHEMICALS USED IN HCKL: Table-08: Aids Chemicals Name Price (Tk/Kg) General Chemicals Caustic Soda 45 Soda Ash Light 34 H2O2 26 Gluber Salts 17 Hydrose (BASF) 100 Common Salt 12 LASCOUR-717 (Detergent) 285 Acid Acetic Acid 65 Buper Acid 140 Softener Liansoft-S 300 (Cationic Softener) 214 Belsoft-200 (Non Ionic Softner) 202 Lian Smith-2231 (Silicon) 324 Power soft -180 380 Resoft NS- (White Softner) Resomine-3000 (Silicon) Softner V-16 200 Anticrease Leancrease-651 10 Rybypon-173 91 Leveling Agent Lianlevel723 (Cotton) 36 Polyester leveling 250 Rubygal CFTR 175 4.5.4 DYES USED IN HCKL: Table-09: Brand Name Origin Dyes Name Price (kg/Tk) Remazol India Remazole red -RR 690.42 Remazole Yellow -RR 692.00 Remazole Blue-RR 840.00 Remazole Brill Blue-R Special 1212.0 Remazole turquoise Blue G 394.00 Remazole Orange-RR 1034.0 Synozole Korea Synowhite 4BK 259.00 259.00 Synozole Yellow K3RS 414.00 Synozole Red K3BS 444.00 Synozole Nave Blue KBF 548.00 Synozole Blue KBR 1110.00 Synozol Red-HB 533.00 Synozol Yellow-HB 551.0 Synozole Nevy Blue-HB 55.00 Dychufix China Dychufix Red 3BXF 236.00 Dychufix Yellow 3RXF 251.00 Dychufix Yellow 4 GL 418.00 Dychufix Black BHC 304.00 Dychufix Orange 2RXF 462.00 Dychufix Black FWN 281.00 Disperse China Desperse Red -60 BFY 800.00 Desperse Yellow-4G 380.00 Desperse Blue 562 RL 675.00 Desperse Blue 60 BGF 875.00 Desperse navy Blue ECOG 400.00 Desperse Black ECOG 400.00 Dis- Orange –HF 700.00 Dis- Red -HF 800.00 Dis- Black-HF 850.00 Dis Navy Blue HF 1100.0 Dis- Blue- HF 1100.00 Dis-Yellow-HF 7500.00 Corazole India Cor- Yellow RD 624.00 Cor-Red RD 600.00 Cor- Blue- RD 656.00 Cor- Orange- RD 1000.00 Cor- Traquise Blue –G 360.00 Cor-Bri- Blue- R- Sp 1120.0 Cor- Bri –Blue- BB 920.00 Libafix Germany Libafix-Amber CA 2450.0 Libafix First Red CA 2250.0 Libafix- Blue -CA 2500.0 9.6 Dyeing Parameters: 9.6.1 PH Levels for Different Stages of Cotton Dyeing: Table-10: PH Levels for Different Stages of Cotton Dyeing: SL PH in different stage PH Range Initial Bath pH 6.5~7.0. Before Enzyme, bath pH 4.5~4.7. After Enzyme & Aquachoron ,pH 5.5~6.0. Before Scouring & Bleaching, pH (With Enzyme) 5.5~5.8. Before Scouring & Bleaching, pH (Without Enzyme) 5.5~5.8. Scouring & Bleaching, bath pH 10.0~10.5. After Scouring & Bleaching, pH 8.5~9.0. Before Leveling Chemicals, pH 6.5~7.0. After Leveling Chemicals, pH 6.7~7.0 After Adding Dyes, pH 6.2~6.35 After Addition of Salt, pH 7.5~8.0. After Addition of Soda, pH 10.5~11.0. Before Hot Wash, Bath pH 6.8~7.2. Hot Wash, bath pH 8.5~8.7. Before Softener, bath pH 7.2~7.8. After Softener Addition, bath pH 6.5~6.8. 4.6.2 PH Levels for Different Stages of Polyester Dyeing: Table-11: PH Levels for Different Stages of Polyester Dyeing: SL Different stages of dyeing PH range 1. Initial bath pH 6.5~7.0. 2. Scouring, bath pH 10.0~11.5. 3. After Scouring, bath pH 8.5~9.0. 4. Before Addition of Leveling Chemicals, pH 6.0~6.5. 5. After Addition of Leveling Chemicals, pH 4.5~4.7. 6. After Addition of Colors, bath pH 4.2~4.3. 7. During Reduction Clearing, bath pH 10.5~11.5. 8. Before Softener, bath pH 6.3~6.8. 9. After Softener Addition, bath pH 5.8~6.2. Table-12: Temperature of dyeing on cotton: For Temperature For cotton scouring 90-98 c For cotton cold wash 60-70c For cotton hot wash 80-90 c For cotton acid wash 50-60 c For cotton dyeing 80 c(for hot brand) & 60 c(for cold brand ) Table-13: Time of dyeing on cotton: For Time For scouring & bleaching 60-70 min For reactive dyeing 60-80 min For disperse dyeing 60-70 min 4.7 Pre-treatment Process: Composition of Cotton: Table-14: Consumption of cotton: Particles Percentage Cellulose 85.5% Moisture 8.5% Fax/Waxes 0.45%-1% Mineral Substance 0.7%-1% Pectins 0.7%-1.2% Proteins 1.1%-1.9% Various Organic Compound 0.5%-1.0% 4.8 KEY ACCESSORIES: Key accessories used in pre-treatment process are: Mixing Tank Machine Tank PH Meter Eye protecting glass Hand gloves Sewing Machine Gum boot Hand lifter for carrying the batch 4.9 Scouring Process: Gray fabric contains fax, waxes, and other impurities. The absorbance of the fabric is adversely affected due to the presence of these impurities. This leads to improper dyeing, printing and finishing in the subsequent process. These impurities are removed from the fabric by a chemical treatment. This chemical treatment is called scouring process. The sequence for scouring process is as follows: Take water in bath at required level Load fabric in the machine Add caustic soda solution Add detergent, sequestering agent,Anti-creasing agent Circular the fabric & raise the temperature at 100°C Continue circulating the fabric for 30 min at constant temp.(100°C) Rinse & Drain Add acetic acid & raise the temperature at 55°C Continue circulating the fabric for 10 min at constant temp.(55°C) Rinse & Drain Add detergent & raise the temperature at 80°C Continue circulating the fabric for 10 min at constant temp.(80°C) 13)Rinse & Drain 4.10 Bleaching Process: Bleaching is a process for removing natural nitrogenous coloring matters e.g.- dirt, dust, husk, broken seed, leaf etc from the fabric and make it white by oxidizing or chemical treatment. The steps of bleaching process are as follows- Take water in bath at required level Load fabric in the machine Add detergent, sequestering agent,Anti-creasing agent, Stabilizer Add caustic soda solution Circulate the fabric & raise the temperature at 60°C Add hydrogen per oxide solution Continue circulating the fabric for 5 min & raise the temperature at 95°C Continue circulating the fabric for 25 min at constant temp.(95°C) Continue circulating the fabric & decreased the temperature at 80°C Rinse & Drain Add Acetic Acid, hydrogen per oxide killer & raise the temperature at 55°C Continue circulating the fabric for 10 min at constant temp.(55°C) Rinse & Drain Add detergent & raise the temperature at 80°C Continue circulating the fabric for 10 min at constant temp.(80°C) Rinse & Drain. 4.11 Product Quality Check: To check the quality of products, following measures are taken- Check the PH of the bath Absorbency of the fabric Hardness of the water Impurities contamination of the water Heating & Cooling of the Machine 4.12 DYEING SEQUENCE WITH RECIPES: Light Color Process 100% Cotton : Machine Wash: Hydrose (2g/L) +Caustic (2g/L) +Foaming Agent (0.5g/L) 30 min at 90oc Machine Washed A. Acid (0.7g/L) 20min at 70oc M/C Neutralized Demineralization: Detergent (1g/L) Sequestering Agent (.5 g/L) Ant creasing Agent (.5 g/L) 20min at 80oc Scouring & Bleaching: Detergent (1 g/L) Sequestering Agent (.5 g/L) Stabilizer (.8 g/L) Caustic (3 g/L) H2O2 (3 g/L) 60min at 98’c Neutralizations (Scouring & Bleaching): H2O2 Killer (.8 g/L) A.Acid (1 g/L) 20min at 80’c Enzyme Wash: A.Acid (1 g/L) Enzyme (1%) 55min at 50’c, PH =4.5 Dyeing: Ant creasing Agent (.5 g/L) Leveling Agent (1 g/L) A. Acid (.2 g/L) Dyes (According to shade %) G. Salt (According to shade %) Soda Ash (According to shade %) 60min at Neutralization: (Dyeing) A. Acid (1 g/L) 10min at 40-50’c Soaping: Soaping Agent (.5 g/L) 20min at 70-80’c Fixing & Softening: Fixing Agent (.5 g/l) 15min at 40’c A. Acid (.5 g/L) Softener (1.5 g/L) 20min at 40’c Drain the bath 4.13 Dyeing Process of Cotton Fabric: Dyeing sequence of cotton: (For white) Dosing at 50° C Wetting agent (Astros Scour B10.P) Ant creasing Agent [Rocklin JES] Sequestering Agent [Astros Quest AC] Fabric Loading Caustic dosing (10 min at 60°C) Stabilizer Neorate PH -5.5 FN (Dosing time 5 min at 70°C) H2O2 (Dosing 30 min at 70° C) (Run time 10 min) Temperature rise 90°C (2°C/min) (Run time 60 min) Cooling 80°C Brightener dosing 30 min Temps raise 98°C (2°C/min) (Run time 40 minutes) Cooling 80°C Rinsing wash Soaping (Sample cutting) Acid (Enzyme if need) Softener Unload 4.14 Dyeing Sequence of Grey Mélange: Process sequence: Water load in the dyeing machine (L: R=1:10) Fabric load in the machine Dosing (1-5) At 50 ºC Dosing hydrogen per oxide At 70ºC × 5 min Steam to 80 ºC Run time 10 min Shade check (not ok) Steam 90 º C × (10+10) minutes Shade check ok Dosing Enzyme at 80 º 10 min (H2O2 killer) Over flow and drain Softener dosing at 62 º C, 70%; 30minutes. Then rest 30% dosing at the same temperature 15 minutes Steam 80 º C Over flow and drain. Color (OBA) dosing at 60 ºC × (10+10+10+10) minutes. Shade check not ok Steam 60 º 10 min Shade check ok Over flow and drain. 4.15 Process Flow Chart of P/C Blend Fabric (65/35): Color: Black M: L -1:10 Polyester Part: Sequence of polyester dyeing with curve: Dosing detergent Dosing at 60°C Acetic acid (for maintained PH =4.5) Leveling agent Buffer solution Dyes Color steam at 130°C Shade check at 80°C If not ok Color add at 60°C Color steam at 130°C Shade check If ok Reduction Cleaning: Hydrous Caustic Acetic Acid Cotton Part: Hot wash (Detergent + caustic + Astros Scour B10.P) Temperature: 95C; Run time: 30 minutes Over flow Drain (Dosing at normal temperature) Run time 20 minutes at the temperature 80° C Acid for Neutralization Overflow Drain (Dosing at60 °C temperature) Run time 5 minutes at the temperature 60° C Leveling agent Salt dosing at 60°C 10 min Color dosing at 25 min at 60° Soda dosing 30 min in 3 steps Color steam 60°C (For normal brand dyes) Color wash Acid Wash Soaping (at 70°C 25 min) Soaping wash (20 min) Fixing if buyers requirement 10min at 80°C Fixing wash 15 minutes Softener (10 minutes) UN load Dyeing curve: - Leveling Buffer soln Acid 130°C × 40 min 60°C Color 20’ 2 °C/min Heating Drain 2 °C/min 20 min at 80°C Reduction Cleaning: -Acetic Acid -caustic -Hydrous Drain/BD 60° C Heating 60 min at 60°C Cotton Part: Anticreaasinagent Leveling agent -Hydrous Unload 50° C Heating 9.15 Sequence of Polyester Dyeing with Curve: Dosing detergent Acetic acid (for maintained PH =4.5) Dosing at 60°C Leveling agent Buffer solution Dyes Color steam at 130°C Shade check at 80°C If not ok Color add at 60°C Color steam at 130°C Shade check If ok Acetic acid =1gm/L Caustic =1 gm/L Hydrose =2 gm/L Reduction cleaning Neutralization by acetic acid (PH=5.5) Unload 9.16 Process Sequence of Viscose dyeing: Water filling Fabric loading Hot Wash, 80°C, 10min Drain Water filling Chemical Auxiliaries (Anti creasing agent, Sequestering agent, Leveling agent) pH check(6.5-7.5) Reactive dye (dosing 30 minutes) (Run 15 Min, Temp50oC) Salt dosing 2 step,60°C Run (15+15)min Soda 60 min dosing Run 60min Shade check Cooling Drain A- Acid (Neutralization) Drain Soaping Drain Hot Wash (2 or 3 times) Cool wash Shade check Fabric unload 4.17 Common Dyeing Faults and Their Remedies: 1. Uneven dyeing: Causes: - Uneven pretreatment (uneven scouring & bleaching). - Improper color dosing. - Using dyes of high fixation property. - Uneven heat-setting in case of synthetic fibers. - Lack of control on dyeing m/c. Remedies: - By ensuring even pretreatment. - By ensuring even heat-setting in case of synthetic fibers. - Proper dosing of dyes and chemicals. - Proper controlling of dyeing m/c 2. Batch to Batch Shade variation: Causes: - Fluctuation of Temperature. - Improper dosing time of dyes & chemicals. - Batch to batch weight variation of dyes and chemicals. - Dyes lot variation. - Improper reel speed, pump speed, liquor ratio. - Improper pretreatment. Remedies: - Use standard dyes and chemicals. - Maintain the same liquor ratio. - Follow the standard pretreatment procedure. - Maintain the same dyeing cycle. - Identical dyeing procedure should be followed for the same depth of the Shade. - Make sure that the operators add the right bulk chemicals at the same time and temperature in the process. -The pH, hardness and sodium carbonate content of supply water should check daily. 3. Patchy dyeing effect: Causes: - Entanglement of fabric. - Faulty injection of alkali. - Improper addition of color. - Due to hardness of water. - Due to improper salt addition. - Dye migration during intermediate dyeing. - Uneven heat in the machine, etc. Remedies: - By ensuring proper pretreatment. - Proper dosing of dyes and chemicals. - Heat should be same throughout the dye liquor. - Proper salt addition. 4. Crease mark: Causes: - Poor opening of the fabric rope - Shock cooling of synthetic material - If pump pressure & reel speed is not equal - Due to high speed m/c running Remedies: - maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature. - Reducing the m/c load. - Higher liquor ratio. 5. Dye spot: Causes: - Improper Dissolving of dye particle in bath. - Improper Dissolving of caustic soda particle in bath. Remedies: - By proper dissolving of dyes & chemicals. - By passing the dissolved dyestuff through a fine stainless steel mesh strainer, so that the Large un-dissolved particles are removed. 6. Wrinkle mark: Causes: - Poor opening of the fabric rope. - Shock cooling of synthetic material. - High temperature entanglement of the fabric. Remedies: - Maintaining proper reel sped & pump speed. - Lower rate rising and cooling the temperature. - Higher liquor ratio. 7. Softener Mark: Causes: - Improper mixing of the Softener. - Improper running time of the fabric during application of softener. - Entanglement of the fabric during application of softener Remedies: - Maintaining proper reel sped & pump speed. - Proper Mixing of the softener before addition. - Prevent the entanglement of the fabric during application of softener. 4.18 MACHINES USED IN DYEING SECTION: Machine No: 01 Name of m/c : Which dyeing machine. Brand : Tong Geng Origin : Taiwan. Capacity : 50 Kg Temperature : Up to 140°c Machine No: 02 Name of machine : Winch dyeing machine Brand : Tong Geng Origin : Taiwan Capacity : 200kg Temperature : Up to 140C Machine No : 03 Name of machine : Winch dyeing machine Brand : Tong Geng Origin : Taiwan Capacity : 400kg Temperature : Up to 140C Machine No : 04 Name of machine : Winch dyeing machine Brand : Tong Geng Origin : Taiwan Capacity : 600kg Temperature : Up to 140C Machine No : 05 Name of machine : Winch dyeing machine Brand : Tong Geng Origin : Taiwan Capacity : 800kg Temperature : Up to 98C Machine No : 06 Name of machine : Winch dyeing machine Brand : Tong Geng Origin : Taiwan Capacity : 400kg Temperature : Up to 98C Machine No : 07 Name of machine : Winch dyeing machine Brand : Tong Geng Origin : Taiwan Capacity : 200kg Temperature : Up to 98C Machine No : 08 Name of machine : slitting machine Brand :ACC Origin : turkey Capacity : 8tons/day Temperature : Up to 140C Machine No : 09 Name of machine : Stenter Machine Brand : ACC model : TPG 2400-6 Origin : turkey Heater type : gas No. of chamber : 06 Power : 152kw Volt : 380 v. Air pressure : 6 Atm Heater pressure : 100 MBar Capacity : 8 tons/day Machine No : 10 Name of machine : Fabric inspection Machine Brand : OSHIMA model : CCS- 2400 Origin : Taiwan 4.19 Management Organ gram of Dyeing Section: 4.20 PHOTO GALLERY OF DYEING SECTION: Fig: 13 Winch dyeing m/c(1 nozzle) Fig:14 Winch dyeing m/c(2 nozzles’) Fig:15 Winch dyeing m/c(3 nozzles) Fig:16 Winch dyeing m/c(4 nozzles) 5.1 Finishing: Textile finishing , in a restricted sense , is the term used for a series of processes to which all bleached , dyed , printed and certain grey fabrics are subjected before they are put on the market . In fact , finishing includes the final treatment of every kind of fabric made from every kind of fiber . According to Textile Terms and Definition the Finishing describe as, “Descriptive processes, physical or chemical, applied to a substrate to produce a desired effect”. 5.2 Objective of Finishing: Improving the appearance – Luster, whiteness, etc. Improving the feel, this depends on the handle of the material and its softness, suppleness, fullness, etc. Wearing qualities, non – soiling, ant crease, ant shrink, comfort, etc. Special properties required for particular uses–water–proofing, flame proofing, etc. Covering of the faults in the original cloth. Increasing the weight of the cloth. 5.3 Finishing Effects: Easy Care. Crease recovery. Dimensional stability. Good abrasion resistance. Improved tear strength. Soft or stiff handle. 7. Shine or luster. 5.4 Flow Chart of Textile Finishing (Open Fabric): Slitting ↓ Stentering ↓ Compacting ↓ Final inspection ↓ Packing ↓ Bailing ↓ Delivery 5.5 Flow Chart of Textile Finishing (Tube Fabric): Dewatering ↓ Drying ↓ Compacting ↓ Final inspection ↓ Packing ↓ Bailing ↓ Delivery 5.6 Types of Finishing: Chemical finishing: Chemical reaction of auxiliaries with fibers. Application of the handle modifying products / additives. Mechanical finishing: Mechanical treatment with machines 10.7 Slitting Machine and Squeezer: Machine specification: Brand name: CORINO MACCHINE Type/model no: Super slit Company: Italy Year: 2011 5.8 Slitter Machine: Slitter machine is used for tubular knit fabric to make it in open form. In open form fabric finishing line; slitter machine is used after hydro-extractor, de-watering and drying machine. Slitting is a process that is applied for cutting the tubular fabric through the intended break Wales line on lengthwise direction prior to stenter processing. During slitting, it is required to be aware about the cutting line otherwise, fabric faults can be occurred there. 5.9 Objectives of Slitting: Following objectives are achieved by the slitting machine. To open tube fabric according to specific needle mark. To prepare the fabric for next stentering process. 5.10 Function of the Machine: Used to remove excess water after pretreatment and dyeing To slit the tube fabric by the knife for opening of the fabric and ready for stentering Delivered fabric in crease free state Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air sprayer It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism. 5.11 Main Parts of Slitter Machine and their Functions: Following are the main machine parts and their functions. 1. Rotary Blade: Rotary blade is used for cutting the fabric through break Wales line. 2. Ring: Ring is use to help the cutting process. 3. Guide Roller: After slitting, plaiting of the fabric is done. Guide roller guides the fabric to plaiting. 4. Plaiting: Open fabric is make plait by plaiting. 5. Sensor: Sensor is used for identify the specific Wales line. It makes sense for cutting through break Wales’s line. 5.12 Checking Parameters of Slitter: Following parameters are checked after slitting: Cutting Line Check: Fabric cutting line is checked by the operator of the slitting machine. Operator checks that the rotary blade cut fabric through break Wales’s line or not. Bow and Slant check: Bow and slant is checked in the delivery side of the machine by the operator. Fabric Faults: Various fabric faults also checked in slitting process. 5.13 Working Principle of Slitter Machine: The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder. After dyeing completed and falling of water from fabric the fabric is fed in slitting m/c. So it is necessary to remove some water initially for the case of further processing in this m/c. The initial squeezer does this work. The de-twisting unit removes twists that may present in tubular rope form fabric. This unit has 3 de-twisting rollers, one rotation drum and 2 feeler rollers with sensors. By these rollers it detects twist in fabric and removes by rotating rope fabric in opposite direction. Before slitting there is a blower which blows air to open the tubular fabric & makes it easy to pass over cigger. The cigger can be extended in circumference and opens the tubular fabric in full circumference. Slitting is done by using open mark detecting golden eye by around knife. Then the fabric passes through the padder where washing or chemical treatment is done. Squeezer is used to remove 60-70% of water. After removing water width is controlled by stretcher and fabric is delivered by folding device. Fig- 17: Line diagram of slitting machine: 5.14 Operational parameter: Set the padder pressure as required (3-7bar) Set the speed as much as possible (30-80m/min). 18 Cutting Knife (round) 19 DETWISTER Fig-18: Fabric Pass through Knife Fig-19: Fabric Pass through Detwister 5.15 Stenter Machine: 5.15.1 Process Definition: Stenter can be defined as a finishing process in which the open width forms of the fabric is treated to set up the required width weight & fabric texture as per customer’s specification. These requirements from the customer are achieved by a single process. 5.15.2 Functions of Stenter Machines: Heat set: Heat setting is done by the stenter for lycra fabric, synthetic and blended fabric. Finishing chemical: Finishing chemical apply on fabric by the stenter. Loop control: Loop control of the knit fabric is controlled. Moisture: Moisture of the fabric is controlled by the stenter. Spirility: Spirality controlled by the stenter. Drying: Fabric is dried by the stentering process. Shrinkage: Shrinkage property of the fabric is controlled. Curing treatment: Curing treatmentb for resin, water repellent fabric is done by the stenter. GSM control: If overfeed increases, then GSM increases and vice versa. Width control: The width is controlled by means of Spreader, Expander. Decrease Bowing effect Softener application Surface coating for Teflon finish. 5.15.3 Components of Stenter Machine: Feed zone Centering device Chemical padding zone Squeezing roller Chemical tray Bowing control zone Bowing roller (rubber roller, no of roller -2) Sensor (no of sensor -6) Uncurling roller Chain entry zone Uncurling device (both side of the chain entry) Sensor (both side of the chain entry) Brush roller (for attaching the fabric with the pin of the chain, no of brush roller -4) Selvedge gumming device with gum box under the chain entry Drying zone Gas rotamatic burner (10) Cooling zone Delivery zone Relax R/r Padder Pin roller PLC profivassleeve converter. Plaiter roller Take up roller 5.15.4 Working Principle of Stenter Machine: The fabric is collected from the batcher to the scray and then it is passed through the padders where the finishes are applied and some times shade variation is corrected.The fabric is entered into the mahlo (weft straigtner) the function of the mahlo is to set the bow and also weave of the fabric is griped by the clips and pins are also provided but the pins has a disadvantage that they pins make holes at the selvedge but the stretchning of the pins are greater than the clips.these clips and pins are joined to endless chain.there are 8 to 10 chambers provided on the machine each chamber contains a burner and filters are provided to separate dust from air.the circulating fans blow air from the base to the upper side and exhaust fans sucks all the hot air within the chambers. Attraction rollers ar provided to stretch the warp yarn. After stentering we can increase the width of the fabric up to 1.5-2 inch.The speed of the machine is about 7-150 m/min.3 meters fabric can run in each chamber.temperature is adjusted that according to the fabric as for, PC 210 c Cotton 110-130 c After dyeing 160-170c and after print 130-140c. 5.15.5 Machine specification: Brand name: Platinum. Country: KOREA. Other specification: Speed range: Max: 110m/min. Use: 10-45 m/min. Temperature range: Max: 500 C Use: 180 C-190C (For half feeder) 190C-200C (For full feeder) No of motor in drying unit: 06 Total no of motor: 06 Max dia: 295cm. Min dia: 95cm. Steam pressure: 2 bar Air pressure: 10 bar Applied for: Open width fabric. 5.16 Compactor Machine: Machine specification: Brand name: FERRARO Type/model no: COMPTEX-RE 2800. Company: ITALY. No of motor: 17 Over feed = Max + 35%, Min -35%. Machine speed = Max 32m/min, Min 4m/min. Temperature range: 100-2000C Maximum width =240cm Minimum width =100cm Applied for: Open fabric Left over feed: -20%+20% Right over feed: -20%+60% High production: -20%+60% Front over feeding cylinder: -20%+60% Middle belt: -20%+60% Fig-20: Compactor process 5.16.1 Function of the Machine: To compact the fabric To control the shrinkage To maintain proper width and G.S.M Heating system: Steam 5.16.2 Main parts of the machine: Heating chamber Blower (2, one at the entry chain zone for uncurling and another at the entry of compacting zone) Synthetic blanket as a conveyor, Folder Exhaust fan Unpinning cylinder (-40%+40%) Belt cylinder (-40%+40%) Uncurling device at entry of compacting zone. sensor brush roller 5.18 Photo Gallery of Finishing Section: Fig-21: De-watering m/c Fig-22: Slitting m/c Fig-23: Stenter m/c Fig-24: Stenter m/c Fig-25: Compacting m/c Fig-26: Tumble Dryer m/c  6.1 Introduction: Garment manufacturing is an assembly- oriented activity with a great range of raw materials, product types, production volumes, supply chains, retail markets and associated technologies. Companies range from small family business to multinationals. 6.2 Flow Chart of Garments Manufacturing Process / Technology: A basic garment manufacturing flow chart is presented in the below: Design ↓ Pattern Making ↓ Fit Sample Making ↓ Production Pattern Making ↓ Grading ↓ Marker Making ↓ Fabric Spreading ↓ Fabric Cutting ↓ Cutting Parts Sorting or Bundling ↓ Sewing ↓ Garments Inspection ↓ Garments Ironing and Finishing ↓ Final Inspection ↓ Garments Packing ↓ Cartooning ↓ Shipment 6.2.1 Each process of garments manufacturing flow chart is discussed in the below with the details: 1. Design: Design is provided by the buyer. After placing an order buyer send the technical sheet and art-work of an order to the merchandiser. This process is done by both manually or by using computer. 2. Pattern Making: By following technical sheet and art-work, pattern of each garment style should be made. It’s done by both manually and by using computerized method. 3. Fit Sample Making: The main target of making a fit sample is to follow the details instruction about that garments style. After making it’s sent to the buyer to rectify. It’s done by manually. 4. Production Pattern Making: For bulk production, allowance added here with net dimension. Production Pattern Making is done by both manually and by using computer. 5. Grading: During an order confirmation, the buyer suggests about the size ratio of that order. So that order should be graded according to the buyer’s instruction. Grading is done by manually or by using computer. 6. Marker Making: Marker is a very thin paper which contains all the parts of a particular garment. To make the cutting process easy, it’s must be needed. Marker making process can be done by both manually and by using computer. 7. Fabric Spreading: To cut the fabric properly fabric is spread in lay form. Fabric Spreading is done by manually or by using computerized method. 8. Fabric Cutting: Fabrics have to cut here according to marker of garments. Fabric Cutting process is done by using manual method or computerized method. 9. Cutting Parts Sorting or Bundling: Here, cutting parts have to sort out or make bundling to send these easily into the next process. This process is done by manually. 10. Sewing: All the parts of a garment are joined here to make a complete garment. Sewing process is done by manually. 11. Garments Inspection: After completing sewing, inspection should be done here to make fault free garments. Garments Inspection is done by using manual method. 12. Garments Ironing and Finishing: Here garments are treated by steam; also required finishing should be completed here. This process is done by using manual method. 13. Final Inspection: Finally the complete garments are inspected here according to the buyer’s specification. Final Inspection is done by manual method. 14. Garments Packing: Complete garments are packed here by using buyers instructed poly bag. Garments packing are done by using manual method. 15. Cartooning: To minimize the damages of garments, all the garments have to cartooned by maintaining buyers instruction. This process is done by manually. 16. Shipment: After completing all the required processes it’s finally send to the buyer. 6.3 Departments in Garment Manufacturing Unit: 6.4 Garments Assembly Machine: 1. Industrial Single Needle Lockstitch Machine. 2. Industrial Double Needle Lockstitch. 3. Industrial Bartack Stitching Machine. 4. Industrial Feed of The Arm. 5. Industrial 4 Needle 8 Thread Kansai Special Machine. 6. Industrial Double 2 Needle 4 Thread Chain Stitch Machine. 7. Industrial Single Thread Chain Stitch Machine. 8. Industrial Overlock Stitch Machine. 9. Industrial Flat Lock Stitching Machine. 10. Industrial Button Holing Machine. 11. Industrial Button Attaching Machine. 12. Industrial Blind Stitching Machine. 13. Industrial Zig Zag Stitching Machine 14. Industrial Rib Cutter Machine 15. Industrial Snap Button Attaching Machine 11.5 Machine Specification: No of the Machine : 01 Name of The Machine : Industrial Lock Stitch Model no : DDL-5530 N Stitch Group : Lock Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 1500-5500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 2.5” Needle Name : DB * 1 No of Needle : One Needle / Bobbin No 1 No of the Machine: 02 Name of The Machine : Industrial Bartack Machine Model no : LK-1850 Stitch Group : Lock Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 1800-3600 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 7” Needle Name : DP * 5 No of Needle : One Needle No of the Machine : 03 Name of The Machine : Industrial 2 Needle Lock Stitch Model no : LH-3188 Stitch Group : Lock Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 4000-4500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 5” Needle Name : DP * 5 No of Needle : 2 Needle No of the Machine : 04 Name of The Machine : Industrial Feed of The Arm Machine Model no : MS-1190 M Stitch Group : Chain Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 5000-5500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 8” Needle Name : UY * 128 GAS No of Needle : 2 Needle No of the Machine : 05 Name of The Machine : Industrial Kansai Special Machine Model no : DFB_1404 PSF Stitch Group : Chain Stitch Brand Name : Kansai Country of Origin : Japan Stitch per Minute : 4000-4500 Seam Class : Bound Seam Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 16” Needle Name : UO * 113 GAS No of Needle : 4 Needle No of the Machine : 06 Name of The Machine : Industrial Double Thread Chain Stitch Machine Model no : MH-481-5 Stitch Group : Chain Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 1800-6500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 Needle Name : TV * 5 No of Needle : One Needle No of the Machine : 07 Name of The Machine : Industrial 5 Thread Overlock Stitch Machine Model no : MO-3616 Stitch Group : Chain Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 6500-8500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 Needle Name : DC * 1 No of Needle : 2 Needle No of the Machine : 08 Name of The Machine : Industrial Flat Bed Flatlock Stitch Machine Model no : W-810B Stitch Group : Chain Stitch Brand Name : Kansai Country of Origin : Japan Stitch per Minute : 6000 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 Needle Name : UY * 128 GAS No of Needle : 2/3 Needle No of the Machine : 09 Name of The Machine : Industrial Button Holing Machine Model no : LBA 781 Stitch Group : Lock Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 3000-3200 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 Needle Name : DP * 5 No of Needle : One Needle / Bobbin No 1 No of the Machine : 10 Name of The Machine : Button Attaching Machine Model no : MB-377 Stitch Group : Chai Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 1500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 4-5” Needl Name : TV * 5 No of Needle : One Needle No of the Machine : 11 Name of The Machine : Industrial Blind Stitch Model no : CMB-3938 Stitch Group : Chain Stitch Brand Name : Brother Country of Origin : Japan Stitch per Minute : 2500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 5” Needle Name : LW * 6 T No of Needle : One Needle No of the Machine : 12 Name of The Machine : Industrial Zig Zag Stitching Machine Model no : LZ-391 N Stitch Group : Lock Stitch Brand Name : Juki Country of Origin : Japan Stitch per Minute : 1500-5500 Seam Class : Super Imposed Needle Size : 9, 11, 14, 16, 18, 20, 21 T.P.I. : 6” Needle Name : DB * 1 No of Needle : One Needle / Bobbin No 1 No of the Machine : 13 Name of The Machine : Rib Cutter Machine Model no : SM-601 Stitch Group : Lock Stitch Brand Name : Idea Country of Origin : China 6.6 Process Flow in Garment Manufacturing Unit: 6.7 Process Flow in Merchandising Department: 6.8 Sampling Department: Responsibilities of sampling department:  Getting clarifications about style details from merchandiser.  Checking pattern’s workability.  Preparation of different samples and getting the buyer’s approval.  Informing quality related problems, encountered during preparing samples, to QC.  Minimizing operations and consumption. 11.9 Fabric Store Department: Functions of the fabric store department Receive the fabric as per BOM Fabric inspection (four point system) Conduct fabric test (e.g. Shrinkage, color fastness etc.) Issue to the production department as per the requirement. Fabric audit procedure 10% random inspection for sampling or lining or net fabric. Inspection for production order fabric as per buyer’s requirement. Perform GSM cutting. Perform shrinkage test. Check the fabric for the bowing or skewing. Check fabrics roll for the defects. Allocate points to the defects. Fig-26: GSM Cutter 6.10 Trims and Accessories Store Department: Functions of the trims and accessories department To receive incoming material. To check material for attribute & variables. To arrange the incoming material in allocated racks. To issue trims as per BOM for sampling and production & other material as per requirement. To maintain a record of incoming & outgoing material. Pic-1: Accessories 6.11 Spreading and Cutting Department: 6.11.1 Spreading and cutting flow process: 6.11.2 Planning: Marker planning: The results of cut order planning are cutting orders that direct marker planning and cut planning. The purpose of marker planning is to determine the most efficient combination of sizes and shades for each order and to produce the best fabric yield and equipment utilization. One cutting order may require several markers to achieve optimum efficiency. A lay is a stack of fabric plies that have been prepared for cutting. Lay planning is the basis of managing cutting room labor and table space. Spreading and cutting schedules are affected by: table length, type of equipment, spread length, spreading time and Cutting time. Marker making: Is the process of determining the most efficient layout of pattern pieces for a specified style, fabric, and distribution of sizes (requires time, skill and concentration) Marker making is a critical step in the manufacturing process. By retaining strict control over this critical step, they keep the fabric consumption as low as possible. It also ensures that the issues that affect quality will be given proper attention. These include placing patterns on grain, keeping patterns paired, and attending to details such as drill holes and notches. Depending on the relative efficiency of each marker produced, the company may save or waste thousands of dollars a year Pic-2 Marker Efficiency: Area of patterns in the marker plan X 100% Total area of the marker plan It is determined for fabric utilization Minimum waste Factors affecting marker efficiency Fabric characteristics (fabric width, length of design repeat etc.) Shape of Pattern pieces (large pieces – less flexibility) Grain requirements 6.11.2 Spreading: Spreading is the processes of superimposing lengths of fabric on a spreading table cutting table or specially designed surface in preparation for the cutting process Spread or lay is the total amount of fabric prepared for a single marker Requirement of spreading : Shade sorting of cloth pieces. Correct ply direction and adequate lay stability.. Alignment of plies. Correct ply tension. Elimination of fabric faults. Avoidance of distortion in the spread. Spreading equipment: Spreading surfaces ( table, pin table, vacuum table) Spreading machines. 6.11.3 Cutting Process Flow Chart of Fabric Cutting Department: Pattern received from pattern department ↓ Cutting ratio received from merchandiser ↓ Marker making ↓ Fabric received from the store ↓ Fabric Checking ↓ Fabric Spreading ↓ Marker placing on to the lay ↓ Cutting the fabric ↓ Numbering ↓ Checking ↓ Sorting and Bundling ↓ Send to the sewing department Cutting Machine: Fig-27: Straight knife cutting m/C Fig-28: Band knife cutting m/c Fig-29: Round knife cutting m/c Fig-30: Die cutting m/c Fig-31: Rib cutting m/c Fig-33: Leaser cutting m/c 6.11.4 Sewing: Process Flow Chart for Garments Sewing Department: Product analysis ↓ Set up target for production ↓ Set up machine layout on the basis of target ↓ Set up operator layout on the basis of target ↓ QC check of product ↓ Line balancing ↓ Line setup ↓ Distribution all the processes ↓ Cutting parts received section ↓ Cutting parts distribution to the operator and helper ↓ Complete parts making individually ↓ Online QC check ↓ Online quality audit ↓ Counting output and checking with the target ↓ Final quality check (for each Garment) Ticketing Tickets carry details: style no, size, ply no, bundle no., date issued, Operations may be incorporated for payment purposes, control of work and facilitating quality control. Sewing Machine: Fig-33: Sewing m/c Stitch forming devices: The bobbin of a lock stitch machine: Fig-34:Raised bed Fig-35 :Flat bed Fig-36: Cylinder bed Fig-37: Feed of Arm Fig-38: Post bed Seams and Stitches: Garments are shaped and formed in three ways: materials molded to a form, fabric pieces cut to shape and assembled by bonding, and Pieces cut to shape and sewn. Classification of seams: Superimposed seam Lap seam Bound seam Flat seam Edge finishing Fig-39: Edge finishing Fig-40: Bound seam Fig-41: Superimposed seam Fig 42: Lap seam Fig-43: Flat seam Stitch Classification: 1.Stitch Class 100 ( Single thread chain stitch ) 2. Stitch Class 200 ( Hand stitch ) 3. Stitch Class 300 ( Lock Stitch ) 4. Stitch Class 400 ( Multi thread chain stitch ) 5. Stitch Class 500 ( Over lock neatening ) 6. Stitch Class 600 ( Covering chain stitch ) 6.12 Cost Sheet & Consumption Sheet Preparation: 6.12.1 Garment Costing: In order to achieve perfect garment costing, one must know about all the activities including purchase of fabrics, sewing, packing, transport, overheads, etc. The freight charges for the Men's Basic T-shirt. Price of garment estimation is given : Particulars Light colors Medium colors Dark colors 34's combed yarn Tk.135.00 Tk.135.00 Tk.135.00 Fabric cost per garment Tk.38.06 Tk.40.13 Tk.44.27 Cost of Trims Tk.0.85 Tk.0.85 Tk.0.85 CMT Charges Tk.11.00 Tk.11.00 Tk.11.00 Cost of accessories Tk.1.35 Tk.1.35 Tk.1.35 Rejection of garments (commonly 3%) Tk.1.50 Tk.1.50 Tk.1.50 Cost of Garment Tk.52.76 Tk.54.83 Tk.58.97 Local Transport Tk.1.00 Tk.1.00 Tk.1.00 Profit@15% appro. Tk.7.90 Tk.8.20 Tk.8.90 Commission/ pc Tk.2.00 Tk.2.00 Tk.2.00 Price of Garment Tk.63.66 Tk.66.03 Tk.70.87 During the fixation of FOB price of a garment following notes are to be followed carefully: 1. Cost of fabrics/Dzn. garments. 2. Cost of Accessories/Dzn.garments. 3. C.M (Cost of Manufacturing) /Dzn. Garments. 4. Cost of embellishment (if any) likes print, embroidery, etc 5. Commercial cost.6.Commission (if any) Fabrics Price: Knit fabric price is the sum of the below factors- 1. Yarn price per kg (approx $6.40) 2. Fabric price per yard (approx $0.15) 3. Dyeing price per kg (approx $1.5) 4. Finishing price per kg (approx $0.50) Thus the fabric price per kg comes ($6.40+$0.15+$1.5+$0.50)= $8.55 Fabrics consumption for a European T-Shirt is 3.00 kgs per dozon. So fabrics price per dozon is (3.00 * 8.55) = $25.65 7.1 Quality Management system in Impress- Birds Group of Industry Quality Assurance On-line Off-line Online quality Control: 7.3. Flow chart for quality assurance Yarn test sample inspection Recorded on yarn test report Grey fabric inspection Finished fabric inspection Recorded on finished fabric inspection report If passed if failed non correctional Rejected Send for lab test Correction able Send for corrective action as required If passed if failed Delivery to finished store send for corrective action as required 8.4 Analysis of different types of faults Recorded on grey fabric 4 point inspection report UTILITY SERVICESS Power & utilities Section: Description of m/c no.of m/c Capacity Generated Power: Prime power generation , 1Unit 636kW Cruascar Gas Generator Model: FGLD 480 Origin: Spain Stand by: Diesel Generator, 1Unit 140 kW puma, Origin: England A. Sub station 1000kVA Total connected load 1776 kW Air Compressor: Kaeser Screw Compressor, 2 Units 8M3 /MIN Model: AS44, 30 kW,4M3/MIN. each Omgersp:-Rand 1Unit 8M3 /MIN Reciprocating Compressor, Model: SSR ML-5057.5kW CAPACITY of air disharge Ingersol- Rand 2 Units 4.40 M3 /MIN Reciprocating Compressor, Model: 3000.22 kW SWAN Reciprocating 1 M3 /MIN Compressor, Model: C4080, 10 kW Total air discharge capacity 21.4M3 /MIN Description of WATER Pump no.of m/c Capacity Centrifugal pump for water supply to dyeing & others Section 1 100m3/h 20HP Pedrollo pump each pump , 1, 000L/min flow rate 4Unit 4,000 L/min 10HP Pedrollo pump each pump , 600L/min flow rate 1Unit 600 L/min 5.5HP Pedrollo pump each pump , 350L/min flow rate 1Unit 350 L/min Spare pump motor Pedrollo 20HP 1Unit 1,000 L/min Boiler: Ciever Brooks Boiler 10 tons /hr 1 set Prime power Generator: Brand name :GUASCOR ORIGIN:Spain Model: FGLD 480 Stand by voltage: 380 Kw,795kVA Prime voltage: 636 Kw,1208kVA Phase: 3 Weight:1845kg Diesel Generator: Brand name :KOMATSU Origin: SINGAPORE Model: EGS 630-3 Stand by voltage: 440Kw,550kVA Prime voltage: 440Kw,550kVA Phase: 3 Weight: 3800kg Boiler: Brand name :Cleaver Brooks ORIGIN: U.S.A Model: CB 700-650 Slno.:L 94002 Max. pressure:200psi MAINTENANCE OBJECTIVES OF MAINTENACE. To keep the factory plants, equipment, machine, tools, in an optimum condition. To ensure specified accuracy to product and time schedule of delivery to customer. To keep the downtime of machines miniumthes to have control over the production program. To keep the production cycle within the stipulated range to modify the machine tools to meet the need for production. Maintenance Tools, Equipments& their function: Name of Tools Functions Hammaer To give shape Slide Wrench Tightening & opening bolt Spanner Tightening & opening bolt PliarCutting,Holding, Joining Wire Hacksaw Cutting. Pipe WrenceTightening ,opening,gripping pipe. Chisel Shaping, Cutting. File Shaping. Clamp Gripping. Name of EquipmentsFunctions Grinding m/c Grinding. Cutting m/c Cutting. Drill m/c Drilling. Shaping m/c Shaping. Lathe m/c To make something. Bending m/c Bending. MAINTENACE PROCEDURE: Normally preventive maintenance is used. During maintenance period following points should be checked. CHECK LIST OF DIFFERENT PARTS Maintenanc : Mechanical Machine : Dyeing SL.Items need to be checked &serviced 1. Grease the m/c bearing. 2. Complete cleaning of m/c. 3. Cleaning of drain valves, replace seals if required. 4. Check air supply filters ,regulators auto drain seals. 5. Clean filters element & blow out 6. Greasing of unloading roller bearing . 7. Checking of oil level and bolts of unloading roller gearbox. 8. Checking of unloading roller coupling and packing. 9. Checking and cleaning (if required )of main vessel level indicator. 10 . Check the oil level of pump bearing and refill if required . 11 . Check the function of heat and cool modulating valves. 12 . Check all door seals. MAINTENANCE: ELECTRICAL MACHINE : DYEING MACHING SL. ITEMES NEED TO BE CHECKED & SERVICED Check & clean fluff & dirt at dirt at all motor fan covers. Check all motors terminals. Check main panels ( by using compressed air ). Check panel cooling fan and clean its filter. Clean main pump inverter and its cooling fan. Check all circuit breaker, magnetic conductors and relays. Check current setting of all circuit preacher and motor over load. Visual checking of all power and control cables. Check all pressure switches. Check calibration of main vessel and all addition tank. Check all pneumatic solenoids. Check calibration of heating or cooling modulating valve. Check setting of tangle sector. Check setting and operation of lid safely switches. Check all emergency switches. Check all indicating lamps. Check all on/off switches. Check all signal isolators. 10.1 Effluent Treatment Plant: The effluent which is treated by a plant that is called effluent treatment plant. In fact water is the heart for dyeing industry & chemical also an important for different stage of dyeing. Now it is quite impossible without chemical continue dyeing. So which chemical we use in dyeing that mixed with water and finally drains. If the chemical mixed water goes outside through river it is very harmful for not only our environment but also all alive animals. 10.2 Types of ETP: There are different types of ETP are available. That’s: Biological ETP Chemical ETP Biological & chemical ETP Physical ETP Table-18: The raw character of this plant: No Chemical characteristics Parameters Unit Amount 1. Ph 11.8 2. Suspended solids Mg/L 378.8 3. Biological oxygen demand (BOD) Mg/L 416 4. Chemical oxygen demand (COD) Mg/L 850 Physical characteristics 5. Color Brown to black 6. Odor No distinct 7. Temperature °C 40°C 10.3 Consumption of chemicals used: Table-19: Consumption of chemical used: Name Lime Ferrous sulphate Poly Aluminium Chloride De-coloring Agent Polymer Antifoaming Agent Acid 10.4 Function of Different Ingredient Use in ETP: Lime: Lime is used to change the color of effluent and also to increase the transparency of the colored water. Ferrous sulphate (Feso4): Ferrous sulphate is basically used for the agglomeration of the colloidal matters present in the effluent. Polymer (polyelectrolytes): Poly electrolytes help to flocculate precipitate for easy deposition at the bottom of the clarifier tanks. H2SO4 or HCL: H2SO4 or HCL is used for controlling the pH of liquor Alum: Alum is used to sediment residual matters from the effluent. Antifoaming Agent: Used for reduction / controlling foam. It is used manually in the distribution tank. Sodium Hypochlorite: It is used to kill the harmful bacteria. It is used in the biological oxidation tank. Urea: To feed bacteria. 10.5 Standard Parameters to Be Maintained: [According to Bangladesh Standards for Waste Water from industrial units, discharge to inland surface water as per ECR 1997] Table-20: Standard parameter needs to be maintained: Parameters Standard Values PH 6-9 DO 4.5-8 BOD 50 COD 200 TDS 2100 Table-21: Parameters in ETP: Parameters Before Treatment After Treatment PH 9-11 7.5 BOD 250 46 COD 400 142 TDS 3500 824 TSS 500 150 DO 1-2 4-6 Color 150 50 Cobalt (Co) 0.02 0.1 Copper (Cu) 0.25 0.01 Mercury (Hg) N/L 0.01 Nickel (Ni) 0.2 0.05 Arsenic (As) N/L N/L Cadmium (Cd) 0.5 0.05 Lead (Pb) 0.1 0.07 Sulphide (S2) 0.05 0.005 Chromium (Cr) 1 0.5 10.6 Working Sequence of ETP: Screen chamber Raw waste water in Settling Tank Multi garage & sand filter Oxidizing Chamber Secondary clarifier Secondary Biological tank Primary Biological tank Disposal safely Slag tank Slag press filter Chemical Reaction clarifier Treated water drain Activated carbon filter 10.7 Photo Gallery of ETP: Fig-44: Equalization Tank Fig-45: pH Control Tank Fig-46: Equalization Tank Fig-47: pH Control Tank 11.1 INTRODUCTION: Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects. Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records. Competence, such as knowledge, skills, experience, and qualifications. Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships. Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes for example. The quality of the outputs is at risk if any of these three aspects is deficient in any way. Quality control emphasizes testing of products to uncover defects and reporting to management who make the decision to allow or deny product release, whereas quality assurance attempts to improve and stabilize production (and associated processes) to avoid, or at least minimize, issues which led to the defect(s) in the first place.[citation needed] For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract. 11.2 OBJECTIVES OF QUALITY CONTROL: Seeking customer’s needs and expectations, and meeting their requirements to the fullest. Knowing and achieving the applicable regulatory requirements. Simultaneously improving market shares. Improving productivity and reducing costs. Providing necessary resources including knowledge and training to employees. Involving people at all levels. Maintaining high standard of safety, health, and environment. 11.3 QUALITY MANAGEMENT SYSTEM IN HCKL: QA QA Off-line On-line On-line quality control: There are two types of online quality control. These are as follows:- 1. Raw material control: Raw material control means control the quality of raw materials (e.g.- quality of grey fabric, dyes chemicals and auxiliary) 2. Process control: Process control means the selection of right process and controlling of some parameters. Such as pH, water hardness, water volume, temperature, reels speed. Pump pressure etc. On-line Tests: Dyed fabric Shade check Wash fastness Water fastness Off- line tests: Off- line tests for finished fabrics are divided into two groups. These are as follows: Physical tests Chemical tests Physical tests: GSM of fabric Abrasion resistance/pilling Dimensional stability Spirality test Color fastness to rubbing test(dry/wet 11.4 LIST OF EQUIPMENT: The list of equipments to assure quality:- Inspection machine. Electronic balance GSM cutter. Measuring tape. Scissors. Indication sticker. 11.5 QUALITY STANDARD: birds group the ISO: 9001:2000 standards in case of quality. Therefore, the four point system is followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by inns. Quality Management System The quality assurance department is assigned to maintain consistently uniform quality of the material in process & various stages of its manufacturing. Objectives of quality control Research Selection of raw materials Process control Process development Product testing Specification test 13.1 Compliance: Compliance means conformity of certain standard. PPC maintain a moderate working condition for their employees. Though it is well established project, there is some lacking of proper compliance issues. Here is list of compliance in which some points are maintained fully and some are partially. Compensation for holiday Sexual harassment policy Child labor abolition policy Anti-discrimination policy Zero abusement policy Working hour policy Hiring /recruitment policy Environment policy Security policy Buyers code of conduct Health care and safety committee Canteen Equal remuneration National festival holiday Overtime register Labor welfare Weekly holiday fund Time care Accident register Workman register Health register Leave with wag Children Day Care 13.2 Health: Drinking water at least 4.5 L/day/employee. Cup availability. Drinking water supply. Water cooler ,heater available in canteen. Drinking water signs in Bangla and English locate min. 20 feet away from work place. Drinking water vassal clean at once in a week. Water reserve at least once a week. Water center in charge person with cleanliness. Suggestion box register. 13.3 Toilet: Separate toilet for women and men. A seat with proper privacy and lock facility. Effective water sewage system. Soap toilet. Water tap. Dust bins. Toilet white washed one in every four month. Daily cleaning log sheet. No-smoking signs. Ladies /gents toilet signs both in bangle and English. Deposal of wastes and effluent. 13.4 Fire: Sufficient fire extinguisher and active Access area without hindrance Fire signs in both languages Fire certified personal photo Emergency exit 13.5 Safety Guard: Metal glows on good conditions Rubber mats & ironers First aid box one Ironers wearing sleepers First trained employees Motor/needle guard Eye guard Doctor Medicine Welfare officer 13.6 Others: Room temperature Lighting facilities Pic-3: Doctor Pic-4: First Aid Box Pic-5: Fire Training There is large difference between the theoretical knowledge and practical experiences. This is truer in case of the study of Textile Technology. Industrial attachment or Industrial training is an essential part for textile education because it minimizes the gap between theoretical and practical knowledge. This industrial training increases our thought a lot about textile technology. It also helps us to know a lot about industrial production process, machineries, and industrial management and made us suitable for industrial life. Besides it gives us the first opportunity to work in industry. So we can say industrial attachment prepare us for the expected destiny of practical life. We have completed our industrial attachment from Birds Group of Inderstiy. During our eight weeks long industrial training, we got the impression that this factory is one of the modern export oriented composite knit garments industry of our country. This factory does not compromise in case of quality. So, they have established on-line and off-line quality control of each product. Besides, they also use the good quality yarn, dyes and chemicals in their production process. Due to this, it has earned a “very good reputation” in foreign market for its quality product over many other export oriented textile mills. It has very well educated and technically experienced manpower to get rid of any defect in production process. It has also a good organizational hierarchy. Limitations of the report Because of secrecy act, the data on costing and marketing activities have not been supplied. We had a very limited time. In spite of our willing to study more it was not possible to do so Some points in different chapters are not included as these were not available. It is not possible to hold the whole thing of a textile industry in such a small frame as this report. So, try our hard to summarize all the information that we are provided. Two month industrial attachment at Hypoid Composite Knit Ltd. was a part of the B.Sc. in textile Engineering course. During the training period the whole 40 days were segmented and scheduled to a systematic routine. There were different sides of operation in textile process. They are- 1. Knitting 2. Dyeing 3. Dyeing Lab 4. Finishing 5. Printing 6. Garments 7. WTP 8. ETP 9. Others All the section, we have visited properly. We visit the factory as a given schedule which is given by the HR Department of the factory. 1st Week Visit All Section Day Working Description Achievement 1st Visit Overall Factory Layout Plan There are more different unites, located in different places such as dyeing, finishing, Garment, ETP, fabric store, Chemical Store etc. 2nd Knitting Section Way of knitting process, knitting floor arrangement, knitting machines, duties of knitting workers. 3rd &4th Dyeing Section Way of dying process, dyeing floor arrangement, different dyeing machines, duties of dyeing workers 5th& 6th Finishing Way of finishing process, knitting floor arrangement , machines (duties of knitting workers 2nd Week in Knitting Section Day Working Description Achievement 1st We saw different types Knitting m/c Now we know about Knitting m/c 2nd Identification of different types of fabrics faults. These sections we are use inspection table & light. We know about different types of fabric faults such as Roun star, Yarn patta, Slub hole, Black spot, Pin hole etc. 3rd Identification of different types of fabrics by helps of Asst.P.O, Worker, Production manager. How GSM come out learn by Production manager. Fabric cut by GSM cuter m/c & weighted digital m/c & multiplying by 100. Than come out GSM We know different types of fabrics suck as Single jersey, Double jersey, Rib Interlock, Terry, lacost, Picky ,Phellip&Waffel. We learn how GSM come out of fabric. 3rd Week in Dyeing Lab & Yarn Dyeing Section Day Working Description Achievement 1st We saw different types of testing machine in the dyeing lab and know the specification of the testing machine. We learn how to test a dyed fabric and shade checking. Also learn how to control uneven shade 2nd We saw different types of testing machine in the dyeing lab and know the specification of the testing machine We learn how to test a dyed fabric and shade checking. Also learn how to control uneven shade. 3rd & 4th Testing Equipment Testing on recipe matching 5th Testing Equipment Testing on recipe matching 6th Testing Equipment Fabric testing 4th Week in Dyeing Section Day Working Description Achievement 1st On the dyeing floor we saw different types of dyeing machine including sample dyeing machine and dyeing machine for bulk production. We Learn the specification of the machine. 2nd On the dyeing floor we saw different types of dyeing machine including sample dyeing machine and dyeing machine for bulk production Different machine structural view. 3rd Walking Discussing with many worker. 4th to 6th Identification of different types of dyeing faults. These sections we are use inspection table & light. We learn how to test a dyed fabric and shade checking. Also learn how to control uneven shade. 5th Week in Sample section Day Working Description Achievement 1st Machine observation. Understanding machine activity. 2nd Seam identification. Good knowledge on seam. 3rd Folder looking Neckline matching on different fabric. 6 th Week in cutting section Day Working Description Achievement 1st Lay plan We see how these are cutter 2nd Fabric spreading Good fabric spreading on fabric ratio 3rd Market lay ratio on color basis Ratio on color basis 4th Machine observation Straight bar cutting machine scissor 7th Week in sewing, finishing Day Working Description Achievement 1st Sewing T-shirt layout 2nd Sewing Polo shirt layout on specific machine 3rd Finishing Folding, ironing quality on fabric 4th Finishing Folding, ironing quality on carton 8 th Week Revue All Section Day Working Description Achievement 1st Review Dyeing Lab, Review Yarn dyeing We understood how to add recipe at required specific fabrics 2nd Knitting, Dyeing, Finishing We had close observed cam setting, cam box activities, dust suction process, recipe of dying process and Stenter machine process subsequently 3rd&4th ETP Waste water refining, sludge removing, how to remove water hardness 5th&6th Review all section of the factory Administration, HRD, worker’s punctuality and fair environment had gone to us. Prime power Generator: Brand name :GUASCOR ORIGIN:Spain Model: FGLD 480 Stand by voltage: 380 Kw,795kVA Prime voltage: 636 Kw,1208kVA Phase: 3 Weight:1845kg Diesel Generator: Brand name :KOMATSU Origin: SINGAPORE Model: EGS 630-3 Stand by voltage: 440Kw,550kVA Prime voltage: 440Kw,550kVA Phase: 3 Weight: 3800kg Boiler: Brand name :Cleaver Brooks ORIGIN: U.S.A Model: CB 700-650 Slno.:L 94002 Max. pressure:200psi Industrial attachment on Impress- Birds Group of Inderstiy. Page 82