Industrial Attachment on Zaara Composite Textile Ltd.

view with charts and images

Industrial Attachment on Zaara Composite Textile Ltd.

Project description general information about the factory

Name of the Factory : Zaara Composite Textiles Ltd.

Owner of the Factory : Md. Badrul Hasan

Status : Private Ltd. Company.

House #05, Road#10, Sector-4, Uttara Model Town, Dhaka-1230,Tell: 88-02-8915038, 88-02-8917750.,

Fax: 880-02-8915805,

E-mail: zaara.composite@bracnet.net.

web: www.zaaracompostie.net.

Location of the Mill : Surabari, Kashimpur, Gazipur.

Head office :

Manufacturing & Marketing of high quality knitted fabric.

Commercial production : 2003

Business Line :

Industries of 100% Export oriented Composite Textile. Garments & garments accessories.

Nature of Businesses :

Vision: Building true marketing, innovative vision, and strong revenue based product portfolio, customer satisfaction & understand of global market.

Mission: Each of the activities must benefit & add value to the common wealth of our society. We firmly believe that, in the final analysis we are accountable to each of the constituents with whom we interact; namely our employees, our customers, our business associates, our fellow, citizens & our shareholders.

Infrastructure: Total Area: 100000

Building Space: 1, 10,000

EXECUTIVE TEAM: professionally skilled, highly educated & technically experts a team of 60 of official.

Year turnover: US$0.00-0.00 Million

Production capacity: Knitting : 3000 Kg/day

Dying : 4000 Kg/day

Finishing : 4000 Kg/day

Garment : 30.000pcs/day

LAY OUT OF THE MILL

DIFFERENT DEPARTMENT:

  1. Samples resources & development section.
  1. Store Section
  1. Knitting Section.
  1. Administration Section.
  1. Dyeing Section.
  1. Security Section.
  1. Garments section.
  1. Marketing Section.
  1. Maintenance Section
10. Production planning &control.

PRODCUCT TYPES & VARITIES:

v Single Jersey

v Single Jersey Lycra

v Single Jersey slob

v Lactose

v Pique

v Terry

v 1 ´1 Rib

v 2´2 Rib

v Lycra Rib

v Interlock Plane

v Interlock Lycra

v Mash

v Eyelet

v Collar & Cuff

CHAPTER-2

MANPOWER MANAGEMENT

FACTORY ORGANOGRAM

General Manager (Knitting Dyeing Finishing)
General Manager (Garments)
General Manager (packaging)

KNITTING SECTION

Q.C.Technician
Helper
Squeezer
Helper
Helper
Compactor Operator
Dryer Operator
Finishing Incharge
Helpers
Turning m/c operator
Sewing Man
Helpers
Asst. Operator
Senior operator
Supervisor
PO
Lab incharge
Batch Inchagre
SPO
General Manager

DYEING & FINISHING SECTION

SECTIONWISE MANPOWER

Section Manpower
Knitting Section 53
Dyeing & Finishing Section 84
Garments Section 650
Power generator, Boiler & Utility 29
Inventory/Store Keeper 7
Administration 41
Security 33
Others 3
Total 900

Knitting Section: (Both General & Shifting)

Department Manpower
General Manager 1
Manager 1
Production Officer 1
Q.C. Officer 2
Store Keeper 1
Asst. Q.C 2
Supervisor 2
Fitter MAN 4
Sample man 1
Operator 32
Helper 6
Total 53

Batch Selection Section: (Both General & Shifting)

Department Manpower
Batching In charge 1
Turning m/c Operator 4
Sewing Operator 2
Helper 6
Total 13

Dyeing Section: (Both General & Shifting)

Department Manpower
General Manager Same as Knitting G.S.M
SPO 1
PO 1
Supervisor 2
Senior Operator 16
Asst. Operator 4
Helper 16
Total 39

Finishing Section: (Both General & Shifting)

Department Manpower
Finishing In charge 1
Squeezer Operator +Helper 6
Dryer operator+ Helper 8
Compactor operator+ Helper 10
Total 25
Dyeing QC. Lab Manpower
Q.C In charge 1
Q.C. Technician 6
Total 7

Power Generator, Boiler & Utility: (Both General & Shifting)

Department Manpower
Mechanical Eng. 2
Electrical Eng. 4
Generator Operator 4
Boiler Operator 4
ETP In charge 1
ETP Operator 2
Water Pump operator 2
Helper 10
Total 29

Store section: (Both General & Shifting)

Department Manpower
Store Keeper (Dyeing) 2
Store Keeper (Knitting) 1
Store Keeper (garments) 4
Total 7

Administration: (Both General & Shifting)

Department Manpower
Chairman 1
Managing Director 1
Director 2
Merchandiser 5
Purchase 4
Accounts 4
Commercial 8
Computer Operator 4
Clerk 4
Driver 8
Total 41

Security: (Both General & Shifting)

Department Manpower
Security In charge 1
Guard 20
Arm force guard 12
Total 33

SHIFT CHANGE:

  • Shift of eight hours.
  • Shift changes in every week on Friday.

CHAPTER-3

MACHINE DESCRIPTION

LAYOUT OF KNITTNG SECTION:

Exit

DESCRIPTION OF KNITTING MACHINE:

Knitting division is divided into four sections.

  1. Circular Knitting Section.
  2. Flat Knitting Section.
  3. Inspection section.
  4. Store Section

1. Circular Knitting Section:

In Zaara composite Textile Ltd, this section contains 12 circular knitting machines of different types and made by same manufactures. In this section body fabrics for knit wears are produced. Specifications of the machines are given below.

Type of Mach. M/c No Brand Name Origin Model No M/c Dia M/C Gauge No of Feeder m/c Qty Attch.
SingleJersey 1 Year China Taiwan IC-DM3 21² 24 63 1 With Lyora
2 ,, ,, ,, 23² 24 69 1 ,,
3 ,, ,, ,, 24² 24 72 1 ,,
4 ,, ,, ,, 24² 24 72 1 ,,
5 ,, ,, ,, 25² 24 75 1 ,,
6 ,, ,, ,, 24² 24 84 1 ,,
7 ,, ,, ,, 30² 24 90 1 ,,
8 ,, ,, ,, 34² 24 102 1 ,,
Rib& Interlock 9 ,, ,, ,, 34² 18 68 1 ,,
10 ,, ,, ,, 36² 18 72 1 ,,
11 ,, ,, ,, 38² 18 76 1 ,,
12 ,, ,, ,, 40² 18 80 1 ,,

Total knitting section capacity: 3ton/day

2. Flat Knitting Section (Collar & Cuff):

Generally collar & cuff of knitted garments is produced in this section. There are 2 flat knitting machines of the same type. The specifications of these machines are given below:

Type of Mach. M/c No Brand Name Origin Model No M/c Dia M/C Gauge No of fiddle No of Neddle m/c Qty Attch.
Collar 1 HZ China HL-626S 100² 15 2 150 1
Collar 2 HZ China HL-626S 100² 15 2 150 2

Zaara Capacity: Collar- 200 Pcs

Cuff: 400 Pcs.

3. Fabric Inspection Section:

There are one machine is fabric inspection section. Specification of this machine is given below:

Type of Mach. M/c No Brand Name Origin Model No Speed Manufacture Turning Date
Collar 1 HW ANG SHIN TAIWAN HS-125 50 RPM AUG-7/2006

DESCIRPTION OF BATHING (TURNING MACHINE)

  • Delivery roller (anti-clockwise)

    Cross-sectional diagram of turning m/c:

Special feature of turning m/c:

  • Fabric turning face side to back side y cylinder
  • Rope form delivery by the delivery roller
  • Delivery per house= 417 kg.
  • A large cylinder present
  • An air blower present.

Working Principle

At first, the face sides of the fabrics are placed on cylinder surface and few partitions are entered inside of the cylinder then blower on which pass the fabric inside of the cylinder and turn the fabric. Finally, rope form delivery by delivery roller.

LAY OUT OF THE DYEING LABORATORY:

DESCRIPTION OF DYEING LABORATORY MACHINE:

1. Machine Name : Spectro-Photometer

Machine Function : Data Color

Origin : UK

Model : CE-2180UV

Manufacturer : SDL ATLAS

2. Machine Name : Spectro Dyeing M/C

Machine Function : Sample Dyeing

Origin : TAIWAN

Model : LABORATORY

Manufacturer : DRAGON MACHINARY CO.ltd.

3. Machine Name : Washing Machine

Machine Function : Fastness Washing

Origin : Korea

Model : WF8692NEC SAFETY MARK

Manufacturer : SAMSUNG

4. Machine Name : Tumble Dryer Machine

Machine Function : Drying & Shrinkage

Origin : UK

Model : 27

Manufacturer : SDL ATLAS

5. Machine Name : Crock Meter

Machine Function : Fastness to Rubbing

Origin : UK

Model : M238AA

Manufacturer : SDL ATLAS

6. Machine Name : Verivide

Machine Function : Swatch Matching

Origin : U.S.A

Manufacturer : Verivide

LAYOUT OF DYEING & FINISHING SECTION

Fabric Inspection M/C
Soft Callender
Squeezer M/C

DESCRIPTION OF DYEING MACHINE:

Type of Mach. Brand Name Origin Model No No of Nozzle Capacity Kg m/c Qty
1 Isothermal Dragon Taiwan TWRU-NRW 4 600 1
2 ,, ,, ,, ,, 4 600 1
3 ,, ,, TWRU-NPL 4 800 1
4 ,, ,, ,, TWRU-NPL 4 400 1
5 ,, ,, ,, TWRU-NPL 2 300 1
6 ,, ,, ,, TWRU-NPL 2 300 1
7 ,, ,, ,, TWRU-NPL 2 100 1
8 High Temperature & Pressure Atta. ,, AT-G(L) 1 20 1

Working principle of winch Dying M/C:

The winch dyeing m/c is quite simple and serves for all scouring, bleaching, dyeing, washing-off and softening processes. The m/c contains a length of fabric with the ends sewn together, which is compressed to form a continuous rope. This rope passes from the dye bath over two elevated reels and then falls back into the bath. The jockey or fly roller is free running and winch reel is driven and controls the rate of rope transport and the extent of pleating where the rope accumulates below and behind the winch. Both reels extend the full length of the m/c and accommodate several fabric ropes running side by side.

A perforated baffle separates the liquor in the front of the m/c from the remainder. This part of the m/c is called ‘the salting box’. Both dyes and chemicals are added to salting box during dyeing and gradually mix into the remainder of the solutions. All additions must be made across the full length of the m/c with stirring

Heating is by steam injection from a perforated pipe running along the length of the salting box. A heat exchanger present in the m/c absorbs extra vapor/heat to cool the m/c for safety.

The m/c is preferably closed to avoid steam and heat losses, particularly when dyeing at or near boiling point. The rate of dyeing is partly controlled by the rate of rope cycling and usually increases with increasing winch speed.

So, this is the basic mechanism of winch m/c.

Advantages:

  • Easy to m/c operate, batch load and unload system
  • The several numbers of batches can be dyed at a time
  • Knitted fabric can be dyed easily because of less tension on the fabric
  • High speed, high temperature and pressure causes level dyeing of the fabric.

Disadvantages:

  • Little difficult to maintain uniform heating
  • Initial investment cost is high

DESCRIPTION OF FINISHING MACHING:

Sl. No Type of Mach. Brand Name Origin Model No Capacity m/c Qty
1 Squeezer Dongnam Korea DNBS-14000 Tons/day 1
2 Trumble Bangladesh _ 1000kg / day 1 ton/day 1
3 Dryer Tubular Dongnam Korea DBPD-2400 (3L,3CH) 6 tons/day 1
4 Soft Callender Dongnam Korea DNC-1400 2 tons/day 1
Sl. No Type of Mach. Brand Name Origin Model No Capacity m/c Qty
5 Compactor Tubular Fab-con U.S.A 60 6 tons/day 1
6 Fabric Inspection UZU Thailand UZFQ 10 tons / day 1
7 Air Turning Dongnam Korea DNAT -400 4 tons /day 1

Working principle Squeezer m/c:

The fabric is fed into the machine in a rope form and then it is first de twisted by the detwister. This unit is mounted at the top of the machine. Fabric in rope for goes up into the unit and when it comes down; it takes a uniform cylindrical shape which eases the job of the centering unit, Fabric is then passes through a series of rollers and lastly goes into the squeezing rollers and delivered. This machine has a highest speed of 80 m/min.

Removal of excess water:

the ideal removal of excess water is 40%

If g.s.m before squeezing = 200

and g.s.m after squeezing = 150

22-150

Water remove % = ´100% = 33.33%

150

Then it should increase pressure of squeezing roller.

Cross sectional diagram of dryer heating zone:

Dongnam gas dryer M/c:

Fabric

Dried fabric

delivery

Chamber – 1 Chamber – 2

Special feature of dryer:

Dongnam gas dryer-

  • Gas dryer (two chambers)
  • Maximum temperature increase up to 200°c
  • Three conveyor belts are present
  • Open & tubular both type of fabrics can be dried
  • Min”1 & Max”1 gas pressure control switch present
  • Burner air pressure switch present
  • Vibration occur in heating zone
  • Two burners are present

Working principle of dryer:

After dewatering then the fabric goes through the dryer. The main function of the dryer is given below,

  • To dry the fabric
  • To control the overfeed system
  • To control the vibration which increase the G.S.M

The speed of the dryer depends on the temperature of the m/c & the G.S.M of the fabric. If the m/c temperature is high then m/c speed also high and the m/c temperature is low then m/c speed also low. The temperature of different chambers according to the shade of the fabric.

Special feature of fab-con Compactor:

  • Operating system is computerized
  • Steam bar present which soften the fabric for compacting
  • In compacting zone, edge & retard roller, compacting shoe and steel plates are present
  • A pair of pulley present for fabric diameter control
  • Auto sensor present in conveyor belt
  • Fabric G.S.M, shrinkage and diameter control

Working principle of compactor m/c:

This M/C consists of five major parts and these ares-

Shaper: It looks a ladder which straightens the fabric and passing through the pulley.

1. A pair of pulley: It controls the fabric width according to the buyer’s requirements.

2. Steam zone: It is given steam on the fabric surface for softness which helps in compacting zone to compact the fabric.

Steam spray on fabric surface

4. Compacting zone: It consists of edge roller, retard roller, steel plates and compacting shoe. Fabric’s shrinkage, finished G.S.M and dia permanent by compacting shoe & edge roller at 95°c. Steel plates remove the crease mark on the fabric surface and retard roller smooth the upper portion of the fabric surface at 95 c.

Steel plate Compacting shoe

Fabric

Edge roller

Retard roller

Fabric delivery

Steel plate

5. Folding Zone: Here fabric folding fan moving to and foe movement

CHAPTER-4

RAW MATERIALS

RAW MATERIALS FOR KNITTING

TYPE OF YARN COUNT
Cotton 20S,24S,26 S,28 S,30 S,32 S 34 S, 36 S,40 S
Spandex Yarn 20 D, 40 D
Grey Melange (c-90%, v-10%) 24 S, 26 S,30S
Cotton Melange (c-100%) 24 S, 26 S,28 S

SOURCE OF YARN FOR KNITTING:

Cotton:

  1. Jamuna Spinning.
  2. Padma Textile
  3. HK Spinning
  4. Arif Textile
  5. Prime Textile
  6. Keya Spinning
  7. Shamim Spinning
  8. Square Textile.
  9. Loyal Spinning.

LYCRA:

  1. Elaspan

FABRIC TYPES:

1. Single Jersey

I. Single Jersey (Plain)

II. Single Lacoste

III. Polo pique

IV. Mash

2. Double Jersey

i. 1´1 Rib

ii. 2´1 Rib

iii. 2´2 Rib

iv. Lycra Rib

v. Plain Interlock

vi. Eylat

3. Collar & Cuff

i. Plain collar or solid collar.

ii. Shaving Collar.

iii. Tipping Collar.

iv. Tipping Collar

v. Race Collar

vi. Stripe Collar

4. Different decorative single and double jersey fabric.

CHAPTER-5

PRODUCTION PLANNING AND OPERATION

MAJOR BUYERS OF ZAARA COMPOSITE TEX. Ltd.

  1. TESCO
  2. DEBEN
  3. HAMS
  4. RED HERRING
  5. HENLEY COLLAR
  6. PRIMARK
  7. TRADE UP
  8. BILKA
  9. ZEEMAN

10. PENNY

11. LAHALLE

BASIC PROCEDURE OF PRODUCTION PLANNING AND CONTROL:

A planned work brings success. With out planning nothing is complete within the required time. So planning has its own importance which is intolerable. Planning gives a scheduled task and control completes it successfully. But production planning and control is not an easy task. Its basic working procedure is as follows-

  • Taking order from marketing division.
  • Analyzing the orders.
  • Planning for knitting the fabric.
  • Planning for dyeing the fabric.
  • Planning for finishing the fabric.

It is only a basic procedure. It may change according to the type of order. Sometimes the order is placed only for finishing the materials or only for dyeing the goods. Then some steps are minimizing for planning.

  • Taking order from marketing division:

Zaara marketing division supplied fabric orders to the planning and control division by a specific format.

  • Analyzing the orders:

After getting the fabric order, this section analyzes the orders according to buyers order quantity, type of orders (i.e. type of fabric, color to be dyed etc.), delivery date etc. This section plans for required quantity of fabric to be knitted (order quantity + 10% of the order quantity), knitting balance, fabric to be dyed, dyeing balance, RFD (ready for delivery), RFD balance, delivery fabric & delivery balance etc.

  • Planning for knitting:

This section plans for knitting production. It selects m/c for knitting the fabric, no of m/c to be used, type of yarn used, from which source yarn will be collected, required GSM, width etc. It also gives delivery date of knitted fabric.

  • Planning for dyeing the fabric:

Production planning for dyeing is called “Batch plan”. Batch plan is prepared according to the batch no, fabric construction, color, width, GSM and priority of delivery etc and written in a batch card.

  • Planning for finishing the fabric:

Finishing schedule are same as the dyeing. After dyeing, materials go to the finishing section with the batch plan. Finishing data is written to the batch card and is informed to the planning section. However, this section always forces to all the departments to finish all the work within the delivery time given by the buyers. Thus, it plays a very important role in the success of the company.

PRODUCTION PLANNING AND OPERATIONS OF KNITTING DIVISION:

Process Definition:

Knitting is the interlocking of one or more yarns through a series of loops. The length wise columns of stitches, corresponding to the warp in woven cloth, are called Wales; the cross wise rows of stitches, corresponding to the filling in woven cloth, are called Courses, Filling Knits (Weft Knits) are those fabrics in which the courses are composed of a single strand of yarn, while warp knits are those in which the Wales are composed of single strand of yarn. Gauge corresponds to the yarn in a woven fabric, and is defined as the number of needles of yarns in half inches of cloth. The higher the gauge, the more compact and finer is the cloth.

Description Production Process:

In every mill, there maintains a sequences hi production processing. It is also followed in this mill where we were in industrial attachment. The process sequences are in list below:

1) Firstly, knitting manager gets a production shit from the merchandiser as accordance as consumer requirements then he informs or orders production officer about it.

2) Production officer informs technical in charge and knows about machine in which the production will be running.

3) Technical in charge calls for leader of mechanical fitter troops, they two take decision about machine for production considering machine condition, production capacity, maintenance complexity, etc.

4) Production officer with experienced mechanical fitter adjusts required stitch length and grey GSM for required final GSM.

5) Supervisor checks daily production regularity and make operator conscious about finishing tin due time.

6) Operators operate machine in high attention as if there were no faults in the fabrics. If he thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty. Mechanical fitter then fixes it if he can or he informs technical in charge. Then he comes in spot.

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

Process Requirements:

We have already discussed there are basically three kinds of machine which is used to Produce knit fabric and these are:

1) Circular knitting machine (Single Jersey Machines.

2) Circular knitting machine (Double Jersey Machines.

3) Flat knitting machine.

Minimum Requirement of production Parameters:

For Machine:

1. Machine Diameter

2. Machine rpm (revolution per minute)

3. No. of feeds or feeders hi use

4. Machine Gauge

5. Counter setup

6. Required time (M/C running time)

7. Machine running efficiency

For Yarn:

1. Yarn strength (minimum 13gm/tex)

2. Yarn should be waxed (0.1%-0.3%)

3. Yarn should not dry

4. Right cone angle

5. A tail should be kept during winding

6. Packing density must be maintained

For Lycra:

1. Should be good elasticity

2. Yarn should be uniform

3. Elastic recovery 100%

Other:

1. Needle oil; should be water soluble

2. Belt

3. Grease

4. Kerosene: etc

Considerable Points to Produce Knit Fabrics

When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows-

  • Type of Fabric or design of Fabric.
  • Finished G.S.M.
  • Yarn count
  • Types of yarn (combed or carded)
  • Diameter of the fabric.
  • Stitch length
  • Color depth.

Methods of Increasing Production:

By the following methods the production of knitted fabric can be increased –

1. By increasing m/c speed;

Higher the m/c speed faster the movement of needle and ultimately production will be increased. But it has to make sure that excess tension is not imposed on yarn because of this high speed.

2. By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time.

3. By using machine of higher gauge:

The more the machine gauge, the more the production is. So by using machine of higher gauge production can be increased.

4. By imposing automation in the m/c:

a) Quick starting & stopping for efficient driving system.

b) Automatic m/c lubrication system for smoother operation.

c) Photo electric fabric fault detector.

5. By imposing other developments:

1. Using creel-feeding system.

2. Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage.

3. Using yarn feed control device,

Checklist before operation:

Operator must be checks the following points prior to operation:

1. Machine condition

2. Power supply and air availability

3. Yarn availability

4. Buyers specification

5. Yarn quality

6. Machine adjusts with given parameter (yarn count, stitch length, GSM. Etc.)

7. Oil inlet clean or not

8. Oil drip meter should be adjusted

9. Door should be closed

Safety:

  • Put safety mask during working hours
  • Be cautious while starting the machine. Do not insert hand in the machine while starting operation
  • Do not touch the panel board or love wire in absence of responsible engineer or concerned person.
  • Use proper safety equipment like hand gloves, eye protecting glass, masks etc. during maintenance work.
  • Smocking is strictly prohibited in the floor.

Factors that should be changed in case of fabric design on quality change:

a) Cam setting

b) Set of needle

c) Size of loop shape

Production Calculation:

1. Production /Shifting Kg at 100% efficiency.

RPM ´No of Feeder ´ No of Needle ´ SL (mm)´60´12

=

3527.80´Yarn Count

2. Production /Shift in meter

Course/Min

=

Course /CM

RPM´No. of Feeder ´60´12´Efficiency

=

Course /CM ´100

3. Fabric width in Meter:

Total no of Wales

=

Wales /cm´100

Total no of Needles Knitting

=

Wales /cm´100

CHAPTER-6

PROCESS OF DIFFERENT SECTION

KNITTING SECTION:

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

DYEING SECTION

BATCHING:

FUNCTION OR PUPOSE OF BATCH SECTION:

-To receive the grey fabric roll from knitting section or

other source.

-Turn the grey fabric if require

-To prepare the batch of fabric for dyeing according to the

following criteria –

  • Order sheet (Received from buyer)
  • Dyeing shade (color or white, light or dark)
  • M/C capacity
  • M/C available
  • Type of fabrics (100% cotton, PE, PC, CVC)
  • Emergency

-To send the grey fabric to the dyeing floor with batch

Card.

-to keep records for every previous dyeing .

PROPER BATCHING CRITERIA:

-To use maximum capacity of existing dyeing m/c

-To minimize the washing time or preparation time & m/c stoppage time.

– To keep the no of batch as less as possible for same shade.

-To use a particular m/c for dyeing same shade.

BATCH MANAGEMENT:

Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager .some time planning is adjusted according to m/c condition or emergency.

PROCEDURE OF LAB DIP:

For 100% cotton fabric (all in method) –

  • Fabric weight measured by electric balance.
  • Calculate the recipe.
  • Keep the fabric in the pot.
  • Then required amount of dyes, water, salt, soda and other chemicals are taken to the pot by pipetting.
  • Start the program for dyeing. The dyeing time and temperature depend on types of dyes being used.