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Industrial Attachment at DK Textile Mills Ltd

Introduction

By means of practical knowledge it’s not possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equal important in association with the theoretical knowledge.

The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skill ness about various processing stages.

It also provides us sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on. Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility.

Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at DK Textile Mills Ltd , which is a 100% export-oriented composite Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing.

Chapter – 1

Project Description

Name: DK Textile Mills Ltd

Type: Composite.

GENERAL INFORMATION ABOUT THE FACTORY:

Name of Company : DK Textile Mills Ltd

Factory : DK TEXTILE

: Zamgora, Ashulia,Savar, Dhaka-1349

(Opp.to Fantasy Kingdom)

Tel: +880-4476-600450

Location

DK Textile Mills Ltd Location

Address:

Factory Address : Zamgora, Ashulia,Savar, Dhaka-1349

(Opp.to Fantasy Kingdom)

Head Office : House # 99, Road # 4, Block # B Banani, Dhaka-1213,

Bangladesh Tel: 8802-8827134, 8827151, 9880894

Fax: 8802-9898107

USA Office : 291, Park Avenue

Apt # 46B

Nutley, Nj-07110, USA

Phone: 1-9736673029

Fax : 1-9736673029

Visions:

To be the most preferred garment, home textile, bags and other sourcing agency for global clients and to provide automated warehousing and re-distribution solutions to global clients.

Mission:

To conduct the business of DK Group so as to maintain our reputation for credibility and integrity with our clients, vendors, and employees.

To provide customized sourcing and logistics solutions to global clients having unique requirements. To achieve consistent high quality levels and on-time delivery schedules, through a team of committed personnel and a proven set of vendors with World Class, systematic manufacturing facilities.

To open window for new avenue of business diversity. Our business research and development team always keen to deal new type of product apart from garments and textile items.

Certification and Award: ISO 9002-2000.,WRAP -2009

History of the Company:

Dk textile of Industries Company beginning in the 1998 Dk textile has earned unrivalled success & remarkable distinction in the field of ready-made garments

Banking Information:

Bank used for L.C

a) Jamuna Bank Ltd.

b) Mercantile Bank Ltd.

c) Dhaka Bank Ltd.

d) Pubali Bank Ltd

e) Agrani Bank Ltd.

ASSOCIATED COMPANY:

Dk. Collection Limited

Dk. Textile Limited

Dk. Sweater Limited

Dk. Printing Limited

Dk. Design Limited

Dk. Group Inc.

Building : 5 Strayed building

Land Area : 12,500 Sq ft

Floor Area : Ground Floor = 12000 Sq ft => Dying and Finishing Section

1^st Floor = 10,500 Sq ft => Knitting Section

2^nd Floor = 10,500 Sq ft => Cutting Section

3^rd Floor = 10,500 Sq ft => Sewing Section

4^th Floor = 10,500 Sq ft => Sewing Section

5^th Floor = 10,500 Sq f t=> Others Room

Production Capacity : 45,000 Pcs Basic T-Shirt / Daily

Chapter # 2

MANPOWER

Management System:

The company has skilled administration, management and marketing team guided by proficient, dexterous & experienced leaders to offer right solution for the consumers with the right eminence & with the shortest lead-time for the export market in Bangladesh.

The best use of continuous development of human resources by providing them International standard equal opportunity is the keys for achieving comprehensive competence in all level of the organizational hierarchy.

Shift: 2 shifts per 24 hours.

Total Manpower & Section-wise Manpower:

Total Manpower of Dk Textile : 2024

Knitting section:

Shift-A: 26

Shift-B: 20

Dyeing Section:

Shift-A: 55

Shift-B: 45

Dyeing Lab:

Shift-A: 08

Shift-B: 07

Finishing & QC:

Shift-A: 60

Shift-B: 48

Grey fabric Store:

Shift-A: 30

Shift-B: 26

Chemical Store:

Shift-A: 10

Shift-B: 08

Finish Fabric Store:

Shift-A: 15

Shift-B: 12

Garments Sample Section:

Shift-A:55

Shift-B:50

Garments Bulk Production Section

Shift-A:710

Shift-B:675

Maintenance:

Shift-A: 24

Shift-B: 17

Utility:

Shift-A: 06

Shift-B: 06

General Staff:

Shift-A: 40

Shift-B: 16

Others:55

DK Textile limited Management Organnogram

Director

Production Director

Production Manager

Assistant General Manager

Quality Manager

Admin Manager

Admin

Assistant Admin

Line Chip

Superviser

Quality Controller

Operator

Helper

Labor

Different Department:

Knitting section

Dyeing section

Finishing section

Quality control section

Garments section

Maintenance section-

KNITTING SECTION\

Process Definition:

The fundamental unit of a knitted fabric is the loop. Any circular knitted fabric is composed of row after row of intermeshed loops. Different types of fabric are made of different method of intermeshing the loops. 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 greige fabric is dyed to required shade & finished to required weight & width.

Classification of knitting:

Knitting

Warp knitting Weft Knitting

Circular Knitting Flat Knitting

Single Jersey Double Jersey

Machine List of Knitting Section in Dk :

Specification of Circular Knitting Machine:

Machine no-01

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 84

Cylinder Dia: 24

Gauge: 24

Needle: 2112

Net wt: 2310 kg

Safety rpm: 37

Date of manufacturing: 2007

Machine no-02

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 84

Cylinder Dia: 24

Gauge: 24

Needle: 2112

Net wt: 2310 kg

Safety rpm: 37

Date of manufacturing: 2007

Machine no-03

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 74

Cylinder Dia: 25

Gauge: 24

Needle: 1872

Net wt: 2310 kg

Safety rpm: 28

Machine no-04

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 78

Cylinder Dia: 26

Gauge: 24

Needle: 1944

Net wt: 2310 kg

Safety rpm: 34

Date of manufacturing: 2006

Machine no-05

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 90

Cylinder Dia: 30

Gauge: 20

Needle: 1872

Net wt: 2310 kg

Safety rpm: 30

Date of manufacturing: 2006

Machine no-06

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 90

Cylinder Dia: 30

Gauge: 20

Needle: 1872

Net wt: 2310 kg

Safety rpm: 30

Date of manufacturing: 2006

Machine no-07

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 144

Cylinder Dia: 36

Gauge: 24

Needle: 2712

Net wt: 2850 kg

Safety rpm: 25

Date of manufacturing: 2006

Machine no-08

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 144

Cylinder Dia: 36

Gauge: 24

Needle: 2712

Net wt: 2850 kg

Safety rpm: 25

Date of manufacturing: 2006

Machine no-09

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 144

Cylinder Dia: 36

Gauge: 24

Needle: 2712

Net wt: 2850 kg

Safety rpm: 25

Date of manufacturing: 2006

Machine no-10

M/c type: Single jersey

Brand name: Lisky

Origin: Taiwan

Cam Box: 80

Cylinder Dia: 40

Gauge: 18

Needle: 2356

Net wt: 2290 kg

Safety rpm: 28

Machine no-11

M/c type: Rib

Brand name: Lisky

Origin: Taiwan

Cam Box: 72

Cylinder Dia: 36

Gauge: 18

Needle: 1800

Net wt: 2310 kg

Safety rpm: 28

Date of manufacturing: 2006

Machine no-12

M/c type: Rib

Brand name: Lisky

Origin: Taiwan

Cam Box: 72

Cylinder Dia: 36

Gauge: 18

Needle: 1800

Net wt: 2310 kg

Safety rpm: 28

Date of manufacturing: 2006

Machine no-13

M/c type: Rib

Brand name: Lisky

Origin: Taiwan

Cam Box: 84

Cylinder Dia: 38

Gauge: 18

Needle: 2112

Net wt: 2310 kg

Safety rpm: 37

Date of manufacturing: 2006

Machine no-14

M/c type: Rib

Brand name: Lisky

Origin: Taiwan

Cam Box: 80

Cylinder Dia: 40

Gauge: 18

Needle: 2356

Net wt: 2290 kg

Safety rpm: 28

Date of manufacturing: 2006

Machine no-15

M/c type: Rib

Brand name: Lisky

Origin: Taiwan

Cam Box: 84

Cylinder Dia: 42

Gauge: 18

Needle: 2376

Net wt: 2310 kg

Safety rpm: 28

Date of manufacturing: 2006

Others Machines in Knitting Section:

01. Gray Fabric Inspection M/c

Brand: Uzu cloth inspection machine

Manufacturer: AATPR INDUSTRY CO.LTD.

Model: UZ – 900-3

Origin: Thailand.

02. Electric Balance for Fabric Weight.

03. Electric Balance for GSM check.

Pictures of Knitting Machine of Dk :

Rib Circular Knitting m/c

DIFFERENT PARTS OF KNITTING MACHINE

Creel: Creel is used to place the cone.

Feeder: Feeder is used to feed the yarn.

Tensioning device: Tensioning device is used to give proper tension to the yarn.

VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length.

Guide: Guide is used to guide the yarn.

Sensor: Sensor is used to seen & the machine stops when any problem occurs.

Spreader: Spreader is used to spread the knitted fabric before take up roller.

Take up roller: Take up roller is used to take up the fabric

Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machineto feed the yarn at specific finger.

Rethom: These devise are used in Electrical Auto Striper Knitting machine

PROCESS FLOW CHART OF KNITTING:

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Tension device.

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

RAW MATERIALS USE FOR KNITTING:

FAULTS, CAUSES & THEIR REMEDIES IN KNITTING:

1. Hole Mark

Causes:

Ø Holes are the results of yarn breakage or yarn cracks.

Ø During loop formation the yarn breaks in the rejoin of the needle hook.

Ø If the yarn count is not correct on regarding structure, gauge, course and density.

Ø Badly knot or splicing.

Ø Yarn feeder badly set.

Remedies:

Ø Yarn strength must be sufficient to withstand the stretch as well as uniform.

Ø Use proper count of yarn.

Ø Correctly set of yarn feeder.

Ø Knot should be given properly.

2. Needle Mark

Causes:

Ø When a needle breaks down then needle mark comes along the fabrics.

Ø If a needle or needle hook is slightly bends then needle mark comes on the fabrics.

Remedies:

Ø Needle should be straight as well as from broken latch.

3. Sinker Mark

Causes:

Ø When sinker corrode due to abrasion then some times cannot hold a new loop as a result sinker mark comes.

Ø If sinker head bend then sinker mark comes.

Remedies:

Ø Sinker should be changed.

4. Star

Causes:

Ø Yarn tension variation during production.

Ø Buckling of the needle latch.

Ø Low G.S.M fabric production.

Remedies:

Ø Maintain same Yarn tension during production.

Ø Use good conditioned needles.

5. Drop Stitches

Causes:

Ø Defective needle.

Ø If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.

Ø Take-down mechanism too loose.

Ø Insufficient yarn tension.

Ø Badly set yarn feeder.

Remedies:

Ø Needle should be straight & well.

Ø Proper feeding of yarn during loop formation.

Ø Correct take up of the fabric & correct fabric tension.

Ø Yarn tension should be properly.

6. Oil stain

Causes:

Ø When oil lick through the needle trick then it pass on the fabrics and make a line.

Remedies:

Ø Ensure that oil does not pass on the fabrics.

Ø Well maintenance as well as proper oiling.

DYEING SECTION

Dyeing Machine Specification:

Machine no-01

Machine no-02

Machine no-03

Machine no-04

Machine No : 05

Machine Name (Functional) : Sample Dyeing Machine

Brand Name : BANGLA

Model Name : BANGLA

Country Name : BANGLADESHI

Year of Manufacture : 2003

No of Nozzle : 01 Max capacity : 20kg

Loading capacity : 15-16 kg

Max work temp : 140c

Machine No : 06

Machine Name (Functional) : Sample Dyeing Machine

Brand Name : BANGLA

Model Name : BANGLA

Country Name : BANGLADESHI

Year of Manufacture : 2003

No of Nozzle : 01 Max capacity : 10 kg

Loading capacity : 8kg

Max work temp : 140°c

Machine No : 06

Model : DNBS-1600

Machine Name (Functional) : Squeezing Machine

Manufacturer’s Name : DONGNAM

Manufacturing Country : KOREA

Year of Manufacture : 2006

M/c speed : 80 m/min

M/c dia : 62 inch

Max over feed : 20%

Machine No : 07

Model : DNTD-2400

Machine Name (Functional) : TENSIONLESS DRYER

Manufacturer’s Name : DONGNAM

Manufacturing Country : KOREA

Year of Manufacture : 2001

Chamber : 4

Burner : 4

Blower : 3

Max width : 119 inch

M/c speed : 55 m/min

Max over feed : 40%

Max burner temp : 180°c

Min burner temp : 105°c

Prod/shift : 8 tons/day

Machine No : 8

Model : BM-1004360/PK 11/ FOLDING

Machine Name (Functional) : Compacting Machine

Manufacturer’s Name : Tubetex

Manufacturing Country : U .S. A.

Year of Manufacture : 2006

M/c speed : 60 m/min (max)

M/c speed : 15 m/min (min)

Max width : 60inch

Min width : 16 inch

Max overfeed : 130%

Min overfeed : 105%

Prod/shift : 12 tons/day

Machine No : 09

Machine Name (Functional) : Turning Machine

Brand Name : DONGNAM

Model Name : DNAT-400

Country Name : KOREA

Year of Manufacture : 2006

Raising m/c – 01(Single drum)

Brand name – Lafer

Country – Italy

Cylinder – 1

Drum Speed – 110

Drum Dia – 68 inch

Machine Speed – 40 m/min

Pile Roller – 12

Counter Pile Roller – 12

Manufacturing Year –2002

Raising m/c-02(Double drum)

Brand name – Lafer

Country – Italy

Cylinder- 2

Drum Speed – 110

Drum Dia – 68 inch

Machine Speed – 40 m/min

Pile Roller – 24

Counter Pile Roller – 24

Manufacturing Year –2002

Picture of Raising Machine :

No.Of Sueding m/c: 01

Brand name : Lafer

Country :Italy

Cylinder :1

Company name : SPA Machine Tessili

Model : GSI 106

Drum Speed : 110

Drum Dia : 72 inch

Machine Speed : 40 m/min

Manufacturing Year :2006

Different parts of compacting m/c :

Fig: Feed zone of Compactor Fig: Delivery zone of Compactor

Control board (computerized) Takeout roller Conveyor belt

Fig: Tube tex Compactor Machine.

GARMENTS

General working Procedure of DK TEXTILE LTD.

Order Collection

Merchandising Yarn Selection

Yarn Quantity

Trimmings

Print

Embroidery

Yarn Purchase

Knitting

Dyeing

Cutting

Sewing

Finishing

Packing

Shipment

Garments Cutting Section

Fabric cutting:

The definition of fabric is very complex. In garments industries fabric is cut from lay and spreading accuracy and properly which is termed as fabric cutting.

Flow chart of cutting section:

Fabric checking

Fabric spreading according to the quantity

Marker making

Cutting

Serial given by number sticker

Deliver into sewing section

Requirements of fabric cutting:

§ in cutting

§ Precession of cut

• Clean edge
• Infused edge
• Consistency
• Support of the lay

Method of fabric cutting:

There are three method of cutting are follows:

1. Manual

v Hand operated scissor.

2. Manually operated power knife

v Straight knife

v Band knife

v Round knife

v Die knife

v Notcher

v Drill

3. Computerized

v Knife

v Laser

v water knife

v Plasma torc

Spreading

Spreading means the smooth laying out of the fabric in superimposed layers of specific length. The cutting marker paper is laid in the top of the fabric layers. The maximum width of the cutting marker constrained by the usable width of the fabric. During spreading number of the plies should be not more than three hundreds. The number of lay depends on the thickness of the fabric and the height of the knife.

In DK TEXTILE industry use straight method for spreading .It is the most common method for Bangladeshi garments.

Straight method:

Every ply is placed according to the marker length. It is most common of the garments are used this type of ply.

Features of Straight knife:

1. Possible to cut pattern pieces directly from the fabric lays.

2. Could be used to cut for higher depth of fabric.

3. High cutting speed.

4. Sharp and heavy corners can be cut.

5. Blade could be sharpened by attached grinding facilities.

6. Blade height 10 to 33cm.

7 .Blade stroke 2.5cm to 4.5cm.

.

M/C Specification:

Auto Spreader (4):

M/C No.: 01

Brand Name: Jutex

Country: Germany

Year of Manufacturing: 2006

M/C No.: 02

Brand Name: Gerber

Country: Germany

Year of Manufacturing: 2006

M/C No.: 03

Brand Name: Gerber

Country: Germany

Year of Manufacturing: 2007

M/C No.: 04

Brand Name: Gerber

Country: Germany

Year of Manufacturing: 2006

Hand Cutter (20):

Brand Name: Mack (10)

Country: Japan

Speed: 3000/3600

Volt: 220

Frequency: 50/60 Hz

Phase:1

Blade: Straight bar blade

Brand Name: Blue Streak (10)

Country: USA

Speed: 2850

Volt: 220

Frequency: 50Hz

Phase:1

Blade: Straight bar blade

Auto Cutter (1):

Brand Name: Gerber

Country: Germany

Sewing Section

Sewing

Joining the fabric by the use of needle and thread is called sewing. Sewing section is the biggest section in a garments industry. It is a universal and widely used method of joining fabric. The main purpose of sewing is to produce seam.

Flow chart process of sewing section

Receive bundle of various parts from cutting section

Place it in the end of the line to a helper

Open the bundle

Through it to sewing

Sewing

Finished sewing

Inspection

Send to finishing section

Seam

A line along which two or more fabrics are joined by sewing, fusion, and gluing, stapling or alternative method is termed as seam. Usually near edge of sewn fabric pieces.

Needle

Needle is used to sew the fabric by thread.

Function of Needle

To make a hole in the fabric without damaging the threads of the fabric

To make a needle thread loop.

To pass the needle thread loop through the loop of the lopper thread.

Name of Needle used in DK TEXTILE LTD.

Machine Name Needle for m/c Needle Size

Plain M/c DB 7, 9,11,14,18

Over lock M/c DC 7, 9, 11, 14

Flat Lock M/c UY128 7.9,11,14,16

Button Hole M/c DP x 5 9, 11, 14

Button attach M/c TQ 9, 11, 14

Computer button attach DP x 17 9, 11, 14

Kasai UOX1 9, 11, 14

Feed of the arm TV64\9 9, 11, 14

Some information for needle:

Company Name : Organ

Origin : Japan

Price : 10-30TK (Per needle)

Broken needle policy:

1. If any needle breaks down in the time of work then broken part and needle change from needle man with a new needle.

2. If worker do not find out the broken part then worker inform to supervisor.

3. If worker do not find out broke part then the garment will be reject. Because that garment can be contain this broken part.

Plan of needle policy:

1. Worker should be carefully in time of sewing.

2. Needle selection should be correct.

3. Correct fabric tension and thread tension.

4. Proper needle setting in sewing machine.

Sewing layout of a Men’s T-shirt

Join Parts Name Machine layout

Shoulder joining

Rib making

Neck joining

Tape joining

Neck tope seam

Tape tope seam

Main & size label joining

Sleeve joining

Arm hole tope seam

Side seam

Sleeve Tuck

Sleeve hem

Bottom hem

Flag label joining

Finished garments

Sewing fault

Name of sewing m/c: Which are used in sewing section

1. Plain m/c
2. Over lock m/c
3. Flat lock m/c
4. Kansai m/c
5. Chain stitch m/c
6. Vertical m/c
7. Two needle m/c
8. Feed off the Arm m/c
9. Zigzag m/c
10. Bar tack m/c
11. Button Holing m/c
12. Button attach m/c
13. Snap Button attach m/c
14. Eyelate hole m/c

Description of this machines are bellow:

1. Plain m/c:

Properties:

Ø One needle

Ø Two tensioners

Ø Three guide

Ø One hook

Ø Two thread

Ø One bobbin case

Ø One magnate guide

Applications:

correctly, bar tacking can help support loads of up to 400 pounds (almost 200 kilograms). Many backpacking companies in particular pride themselves on the number of bar tacks integrated into their products, claiming that they will wear harder and longer than the competition

Ø Bottom hemming

Ø Belt top seem stitch

Ø Belt joint stitch

Ø Loop tack stitch

Ø Pocket joint stitch

Ø Jipper joint

Ø Flap make

Ø Flap top stitch

Ø Flap joint

Ø Fly top stitch

Ø Flap 1/4 stitch

Ø Front rise stitch

Ø Back rise stitch

2 Over lock m/c

Overlook stitching was invented by the Merrow Machine Company in 1881.

An overlook stitch sews over the edge of one or two pieces of cloth for edging, hemming or seaming. Usually an overlook sewing machine will cut the edges of the cloth as they are fed through (such machines are called ‘sergers’), though some are made without cutters. The inclusion of automated cutters allows overlook machines to create finished seams easily and quickly.

Properties:

Ø 5 thread

Ø 4 tensioner

Ø 2 knifes (up / down)

Ø 2 needle for 5 thread

Ø 1 needle for 3 thread

Ø 3 looper for 5 thread

Ø 2 looper for 3 thread

Applications:

Ø Over lock stitch

3 Bar tack m/c

Bar tacking is accomplished by sewing a very tight zigzag stitch across the width of the material. In some cases, the manufacturer may go over the bar tacking again, causing the stitch to have an x-like form. Usually, very strong threads are chosen for bar tacking so that they will stand up to high pressure. When done

Applications:

Ø To created barack stitches in garments.

Bar tacking is a specialized sewing stitch designed to provide Immense tensile strength to the garment or equipment it is used on. Bar tacking is commonly used on backpacks, tents, tactical gear, and other heavy wear sewn items where normally sewn stitches might give way at a crucial moment. In general, bar tacking is a sign of good quality, although the rest of the product should always be looked over carefully as well. When a sewing pattern calls for bar tacking, it indicates that the designer feels that section of the pattern is a critical area that needs extra reinforcement and following areas it can used.

Ø Loop attach

Ø Fly make

Ø Pocket side

Ø Front side

Ø Back pocketing

Ø zipper lay

Ø In seem

4. Flat lock m/c

Ø 4 tensioner

Ø 3 thread

Ø Contain a holder

Ø 2 needle

Applications:

Ø Zigzag stitch

Ø Knit hemming

Ø Loop making

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