General
Information about the factory:
FACTORY
NAME: BEXIMCO TEXTILES LIMITED
LOCATION:
Beximco Industrial Park,
Chokroborty,
(
from DEPZ)
Address:
Operational
HQ
Sarabo, Kashimpur, Gazipur.
Corporate HQ
17 Dhanmondi R/A, Road No. 2
Dhaka -1205, Bangladesh
Phone: 880-2-8611891-5, 8618220-7
9677701-5, 7701165
E-mail: beximchq@bextex.net
Web Site: www.bextex.net
Sponsors:
World Bank, M Arubeni
CDC, DEG.
Sonali
Bank
BEX TEX PROFILE
Factory : Sarabo, Kashimpur, Gazipur.
Date of incorporation : 30 May, 1984
Commercial
production :
1990
Business line : Manufacturing & Marketing
of high
Quality fabric.
Listing status : Public listed company
Stock Exchange listing : Dhaka &
Chittagong
Authorized capital in Taka : 3000 million Taka
Paid up capital : 1,882.50 Million Taka
Factory Equipment : Different types of weaving,
Knitting,
Dyeing, Cutting,
Sewing, Finishing and
Generator machines
Supplied by mostly
Germany, Italy, U.K,
U.S.A.,
Japan, Taiwan etc.
Number of Shareholders
: 37,929
Number of Woven loom installed
: 293
Number of spindled installed : 119,520
Number of Denim loom installed : 56
Number of circular knit machine installed: 30
Production Capacity : 28 Million LM
Number of employees : 5181
Web site: www.beximco.org
Owners of the mill:
- A S F Rahman
Chairman.
- Salman
F Rahman
Vice Chairman.
- M A
Qasem
Director.
- A B
Siddiqur Rahman
Director.
MANAGEMENT TEAM:
- Syed Naved Husain, Chief Executive Officer.
- Sardar Ahmed Khan, Chief Operating Officer.
- Ajay Pratap Singh, Chief Financial Officer.
COMPANY SECRETARY:
·
Md. Asad Ullah, FCS
Mission:
BEX TEX Ltd. is a full
service vendor with strong vertically integrated production facilities as well
as creative & analytical capabilities which clearly set us apart from most
other South Asian vendors. Each of their activities must benefit and 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 valued Customers, our suppliers, our business
associates, our Shareholders and our fellow Citizens.
Vision:
• Gain market
leadership in high value added apparel in USA & Europe.
• Use “Innovation” & “Speed” as prime
drivers, rather than cotton & cheap labor.
• Dominate these markets in high quality:
LAY OUT OF BTL:
ORGANIZATIONAL CHARTS:
1. Organization chart – Overall
Mgr.
Acting
In chargeBDL
Factory
Org. chart for Bextex Ltd.:
2. Org. chart of Beximco Textile Ltd. (Fabric Preparation):
Deputy General
Manager
WeavingManager
Preparatory Manager (Sizing)
Deputy Manager (Winding)
Deputy
Manager(Design) Deputy
Manager(Maintenance)Asst.
Manager(Warping)Asst.
ManagerManpower Management:
Section in
chargeProduction Officer/ Shift in chargeTechnician (Mechanical / Electrical) Senior
Operator Operator Helper
& MoverCleaner
Products:Yarn Products:
- Count – Ranging from 6 – 120
- Fiber – Cotton ( super – combed, combed, carded)
- CVC – 60% cotton, 40% polyester
- TC – 65% polyester-35% cotton; 100% polyester both regular and
sewing thread
Lyocell,
Tencel, Modal, Rayon, Viscose etc.Fabric products:
Solid Dyed
- Poplins
- Twills
- Dobbies
- Oxfords
- Seersuckers
- Canvas
- Ribstops in 100% Combed Cotton
- CVC and CVS/TC
- Stretch
- Satten
Yarn Dyed
- Ginghams
- Stripes
- Fil-a-fils/End-on-ends
- Chambrays
- Seersuckers
- Pinpoint
- Oxfords
- Dobbies
- Plaids in 100% Combed Cotton
- CVC and CVS/TC
- Stretch
- Satten
Finishing
- Wrinkle Free
- Easy Care
- Peach
- Chintz
- Paper Touch
- Teflon Coated
- Water Repellent
- Water Resistance
- Rubberized
Dobby Designs
- Herringbones
- Bedford Cords/Coteles
- Waffles and various structures in 100% Combed Cotton
- CVC and CVS/TC
Yarn Count
- Ranging from 7 to 120
Denim Products:
- Chambray : In classic indigo colors ranging from 4oz
to 5.5oz/Yd2 - Denim (blue) : In classic indigo colors ranging from 4oz
to 15oz/ Yd2 - Denim (black) : In sulfur black color ranging from 4oz to
15oz/ Yd2 - Colored Denim : In a variety of colors – both in sulfur
& reactive dyes(warp dyed) - Over dyed Denim : In a variety of colors on indigo blue
& sulfur black - Stretch Denim : In classic indigo colors ranging from
oz/Yd2
|
Honorable Buyers:
|
WOVEN FABRIC LOOMS:
No. of looms installed: 299
No. of looms actually
operated: 299
Output capacity (Lm.):
Installed capacity:
40,800,000 Lm
Actual
production: 34,966,037 Lm
Process Flow Chart:
Ring Bobbin
Winding (cone / cheese)
 |
 |
|||
 |
|||
Warping
 |
 |
Weaving
Fabric Inspection
Folding
Packing
Delivery
WINDING:
Definition: winding is a process of wounding of yarn to form yarn packages.
Types of winding: there are two types of winding-
- Soft Winding
- Hard Winding.
Machine Specification:
|
Types of Winding |
Brand Name |
Country of origin |
No of M/C |
Speed |
|
Soft Winding |
FADIS Winder |
Switzerland |
2 |
650m/min |
|
HARISH Winder |
Switzerland |
1 |
650m/min |
|
|
RJK Winder |
India |
2 |
650m/min |
|
|
Hard Winding |
Textool Winder |
Switzerland |
10 |
650m/min |
|
RJK Winder |
India |
2 |
650m/min |
|
|
HARISH Winder |
Switzerland |
3 |
650m/min |
|
|
KAMITSU Winder |
Japan |
4 |
650m/min |
|
|
24 |
||||
Key Accessories: Cone
diameter gauge.
Chemical Used: Paraffin wax
(rarely used).
WARPING:
Definition: To convert supply yarn package or reprocessed cone into a sheet of yarn
comprising of predetermined number, length and tension.
Types of Warping:
- Direct Warping: for solid dyed grey
production. - Sectional Warping: for yarn dyed grey
production.
Machine Specification:
Count wise Creel Tension in BENINGER:
|
Types of Warping |
Brand Name |
Country of Origin |
No of M/C |
Creel Capacity |
Speed |
|
Direct Warping |
KAWAMOTO |
Japan |
2 |
550 |
550m/min |
|
BENINGER (ZC-R-1800) |
Switzerland |
2 |
640 |
600m/min |
|
|
Sectional Warping |
BENINGER Supertronic-2200 |
Switzerland |
3 |
720 |
600m/min |
|
COUNT(Ne) |
TENSION(CN) |
|
16 |
27 |
|
20 |
22 |
|
30 |
15 |
|
40 |
11 |
|
45 |
10 |
|
50 |
09 |
|
60 |
07 |
Figure: Warping Section
Sectional Warping Calculation:
Warp Width × Ends/Section
Width (mm) =
Total
no of ends
Total no of ends
Ends/cm =
Warp Width (cm)
dtex× Total no of
ends × Cone figure
Feed 1 =
10 × Warp Width
(mm) × Density
Dtex = Grams/10000 m Yarn
Density = Grams/dm3
Cone Figure = 5
SIZING:
Definition: the process by
which warp yarn is chemically treated for strengthening, reducing hairiness and
to make more flexible.
Machine Specification:
|
Brand Name |
Country of origin |
No of Size Bath |
Beam Creel Capacity |
|
BENINGER Zell |
Switzerland |
1 |
20 |
|
BENINGER Zell |
Switzerland |
2 |
20 |
|
KAWAMOTO |
Japan |
1 |
16 |
Chemical Used for Sizing:
- Adhesive Material:
modified starch, synthetic chemicals e.g. Kollotex 5, Avetex K. - Chemicals: Quicksolon
SPR. - Acrylic Sizing Agent:
e.g. size CA20. - Lubricants Softener:
Solwax -50, Mutton Tallow.
Size Recipe for Grey Yarn:
H2O = 400L
Starch =
PVA (SPR) =
Acrylic (Trisize) =
Soul Wax =
Size Recipe for Dyed Yarn:
H2O
= 490L
Starch =
PVA (SPR) =
Acrylic (Trisize) =
Soul Wax =
- Size Box Temperature = 85°c
- Cylinder Dryer Temperature = 125°c
- Refractrometer is used to check the dispersion
of size materials.
Squeezimg Roller Emersion
Roller
 |
 |
||||||
 |
|||||||
 |
|||||||
 |
Figure:
Size Bath
Figure: Sized Beam
|
M/C |
Total |
Construction |
Refrectrometer |
Pick |
Moisture |
Speed |
Warp |
Size |
Strech |
|
2 |
8450 |
40×40/133×100 |
12 |
17.5 |
6.0 |
40 |
4200 |
4190 |
0.98 |
|
1 |
7080 |
40×40/20×70 |
12 |
16.8 |
6.0 |
38 |
2658 |
2630 |
1.0 |
|
2 |
8450 |
40×40/130×90 |
12 |
16.2 |
6.0 |
40 |
4200 |
4192 |
0.98 |
|
1 |
7080 |
40×40/130×90 |
12 |
16.2 |
6.0 |
38 |
1961 |
1940 |
0.98 |
|
1 |
7080 |
40×40/130×90 |
12 |
16.2 |
6.0 |
38 |
1961 |
1936 |
0.98 |
|
2 |
8450 |
40×40/130×90 |
12 |
15.8 |
6.0 |
38 |
4114 |
4108 |
0.98 |
|
2 |
5900 |
20×16/100×80 |
10 |
14.1 |
6.5 |
30 |
3923 |
3906 |
1.0 |
Chart for different parameters used in sizing for
different construction:
Weaving:
Definition: The process of
interlacement of two sets of yarn named warp & weft by the means of weaving
machine or loom to produce woven fabric is called weaving.
Machine
Specification:
|
Model |
Shedding Device |
Weft insertion capacity |
No of loom |
Maximum RPM |
Country of origin |
|
Toyoda, JAT 600RS190 |
Negative cam shedding |
2 |
82 |
720 |
Japan |
|
Toyoda, JAT 600RS190 |
Negative cam shedding |
4 |
30 |
720 |
Japan |
|
Toyoda, JAT 600RS190 |
Electronic Dobby |
2 |
16 |
620 |
Japan |
|
Toyoda, JAT 600RS190 |
Electronic Dobby |
6 |
16 |
620 |
Japan |
|
Toyoda, JAT 610RS190 |
Electronic Dobby |
4 |
4 |
620 |
Japan |
|
Toyoda, JAT 610RS190 |
Negative cam shedding |
4 |
98 |
720 |
Japan |
|
Toyoda, |
Negative |
6 |
36 |
720 |
Japan |
|
Toyoda, |
Twin |
4 |
10 |
720 |
Japan |
|
Toyoda, |
Positive |
4 |
7 |
1200 |
Japan |
|
299 |
|||||
Lay out plan of Weaving Section:
Figure: Evacuation
plan of loom shed 1, 2
Figure: Evacuation plan of loom shed 3,4
Figure: Loom Shed
Figure: Toyoda, JAT 600RS190
Figure: Toyoda, JAT 710 Eurotech
Chart for loom stops, production, RPM and
efficiency in A shift for different looms (5) which are run by a operator:
Loom No 230:
|
Construction |
Causes of stoppages |
Times |
min |
Production |
Efficiency % |
RPM |
|
40×322 / 120×70 |
Warp Miss |
12 |
52 |
|
29.3 |
|
|
WF1 Miss (1) |
4 |
6 |
||||
|
WF1 Miss (2) |
12 |
19 |
||||
|
WF2 Miss (1) |
0 |
0 |
||||
|
WF2 Miss (2) |
6 |
89 |
||||
|
Manual Stops |
4 |
54 |
||||
|
Others |
1 |
0 |
Loom No 231:
|
Construction |
Causes of stoppages |
Times |
min |
Production |
Efficiency % |
RPM |
|
40×(40+40)/120×70 |
Warp Miss |
13 |
132 |
|
39.4 |
|
|
WF1 Miss (1) |
0 |
0 |
||||
|
WF1 Miss (2) |
2 |
16 |
||||
|
WF2 Miss (1) |
1 |
9 |
||||
|
WF2 Miss (2) |
0 |
0 |
||||
|
Manual Stops |
0 |
0 |
||||
|
Others |
1 |
5 |
Loom No 232:
|
Construction |
Causes of stoppages |
Times |
min |
Production m |
Efficiency % |
RPM |
|
40×40 / 120×70 |
Warp Miss |
15 |
98 |
|
29.2 |
|
|
WF1 Miss (1) |
9 |
16 |
||||
|
WF1 Miss (2) |
2 |
5 |
||||
|
WF2 Miss (1) |
22 |
47 |
||||
|
WF2 Miss (2) |
1 |
1 |
||||
|
Manual Stops |
4 |
51 |
||||
|
Others |
0 |
0 |
Loom No 233:
|
Construction |
Causes of stoppages |
Times |
min |
Production |
Efficiency % |
RPM |
|
40×40 / 180×80 |
Warp Miss |
25 |
130 |
|
55.7 |
|
|
WF1 Miss (1) |
3 |
4 |
||||
|
WF1 Miss (2) |
0 |
0 |
||||
|
WF2 Miss (1) |
4 |
11 |
||||
|
WF2 Miss (2) |
0 |
0 |
||||
|
Manual Stops |
2 |
2 |
||||
|
Others |
0 |
0 |
Loom No 234:
|
Construction |
Causes of stoppages |
Times |
min |
Production |
Efficiency % |
RPM |
|
40×40 / 110×70 |
Warp Miss |
21 |
160 |
|
48.0 |
|
|
WF1 Miss (1) |
1 |
0 |
||||
|
WF1 Miss (2) |
1 |
0 |
||||
|
WF2 Miss (1) |
3 |
3 |
||||
|
WF2 Miss (2) |
0 |
0 |
||||
|
Manual Stops |
0 |
0 |
||||
|
Others |
0 |
0 |
Quality Management System:
Grey
yarn test report:
Date:
25-06-2010
Count:
45/1, CVC
Lot
no: 33/10
|
Property |
Cone |
Cone:2 |
Cone:3 |
Cone:4 |
|
Tenacity |
18.01 |
17.95 |
18.17 |
18.34 |
|
CV% |
9.03 |
8.70 |
10.76 |
8.62 |
|
Elongation |
5.18 |
5.82 |
5.74 |
5.31 |
|
CV% |
11.63 |
9.99 |
10.91 |
12.18 |
|
Max |
20.84 |
22.82 |
22.54 |
21.52 |
|
Min |
14.67 |
13.91 |
14.21 |
14.04 |
Total
test: 4/2000 MTR
Overall
results:
Tenacity
(CN/Tex) =18.12
CV%
of Tenacity =9.29
Elongation
(%) =5.51
CV
% of elongation =12.13
USTER
TESTER:
|
Test |
Thick |
Thick |
Thick |
Neps (+140%) |
Neps (+200%) |
Neps (+400%) |
Hairiness (-) |
Thin |
Thin |
Thin |
|
1/1 |
333 |
65 |
10 |
322 |
125 |
12 |
3.86 |
907 |
122 |
10 |
|
1/2 |
269 |
48 |
10 |
273 |
99 |
12 |
3.79 |
917 |
115 |
5 |
|
1/3 |
250 |
47 |
9 |
258 |
108 |
8 |
3.91 |
785 |
119 |
4 |
|
1/4 |
227 |
35 |
2 |
269 |
87 |
4 |
3.86 |
769 |
112 |
8 |
Grey
yarn test report:
Date:
10-06-10
Count:
40/1, cotton
Lot
no: 08/10
|
Property |
Cone |
Cone:2 |
Cone:3 |
Cone:4 |
|
Tenacity |
19.90 |
19.27 |
19.42 |
19.87 |
|
CV% |
8.02 |
8.20 |
7.74 |
6.79 |
|
Elongation |
6.04 |
5.99 |
6.01 |
6.12 |
|
CV% |
7.02 |
7.43 |
7.11 |
6.09 |
|
Max |
23.51 |
22.95 |
22.45 |
23.20 |
|
Min |
14.85 |
14.14 |
15.86 |
17.37 |
Total
test: 4/2000 MTR
Overall
results:
Tenacity
(CN/Tex) =19.61
CV%
of Tenacity =7.77
Elongation
(%) =6.04
CV
% of elongation =6.92
USTER
TESTER:
|
Test |
Thick |
Thick |
Thick |
Neps (+140%) |
Neps (+200%) |
Neps (+400%) |
Hairiness (-) |
Thin |
Thin |
Thin |
|
1/1 |
116 |
23 |
6 |
192 |
53 |
3 |
4.08 |
360 |
31 |
0 |
|
1/2 |
204 |
35 |
8 |
408 |
123 |
4 |
4.09 |
593 |
39 |
0 |
Grey
yarn test report:
Date:
06-02-10
Count:
20/1 card
Lot
no: 08/10
|
Property |
Cone |
Cone:2 |
Cone:3 |
Cone:4 |
|
Tenacity |
18.53 |
18.46 |
17.50 |
18.18 |
|
CV% |
6.23 |
6.71 |
7.42 |
6.87 |
|
Elongation |
5.50 |
5.54 |
5.41 |
5.61 |
|
CV% |
7.91 |
5.81 |
9.64 |
6.31 |
|
Max |
20.56 |
20.84 |
22.03 |
20.84 |
|
Min |
16.54 |
15.17 |
14.05 |
15.92 |
Total
test: 4/2000 MTR
Overall
results:
Tenacity
(CN/Tex) =18.17
CV%
of Tenacity =6.80
Elongation
(%) =5.51
CV
% of elongation =7.59
USTER
TESTER:
|
Test |
Thick |
Thick |
Thick |
Neps (+140%) |
Neps (+200%) |
Neps (+400%) |
Hairiness (-) |
Thin |
Thin |
Thin |
|
1/1 |
201 |
36 |
5 |
332 |
82 |
7 |
2.80 |
332 |
13 |
0 |
|
1/2 |
207 |
41 |
7 |
388 |
104 |
5 |
3.26 |
493 |
29 |
0 |
|
1/3 |
181 |
24 |
5 |
335 |
88 |
6 |
3.22 |
371 |
14 |
0 |
|
1/4 |
147 |
26 |
6 |
315 |
99 |
0 |
3.13 |
430 |
27 |
1 |
Grey
yarn test report:
Date:
16-03-10
Count:
30/1, card
Lot
no: 20/10
|
Property |
Cone |
Cone:2 |
Cone:3 |
Cone:4 |
|
Tenacity |
17.18 |
17.57 |
17.12 |
17.02 |
|
CV% |
7.55 |
8.22 |
8.80 |
8.28 |
|
Elongation |
4.03 |
4.95 |
4.20 |
4.96 |
|
CV% |
9.34 |
9.11 |
9.06 |
9.55 |
|
Max |
19.80 |
21.81 |
19.98 |
22.04 |
|
Min |
13.84 |
13.59 |
13.73 |
13.50 |
Total
test: 4/2000 MTR
Overall
results:
Tenacity
(CN/Tex) =17.22
CV%
of Tenacity =8.21
Elongation
(%) =4.53
CV
% of elongation =9.26
USTER
TESTER:
|
Test |
Thick |
Thick |
Thick |
Neps (+140%) |
Neps (+200%) |
Neps (+400%) |
Hairiness (-) |
Thin |
Thin |
Thin |
|
1/1 |
475 |
103 |
10 |
891 |
217 |
4 |
4.84 |
850 |
74 |
2 |
|
1/2 |
415 |
77 |
16 |
851 |
217 |
14 |
4.74 |
835 |
71 |
2 |
|
1/3 |
430 |
88 |
9 |
763 |
171 |
3 |
5.22 |
875 |
79 |
1 |
|
1/4 |
417 |
89 |
15 |
752 |
182 |
2 |
5.09 |
820 |
72 |
0 |
Grey
yarn test report:
Date:
07-03-10
Count:
60/1 comb
Lot
no: 6060c/10
|
Property |
Cone |
Cone:2 |
Cone:3 |
Cone:4 |
|
Tenacity |
27.09 |
26.48 |
26.98 |
26.34 |
|
CV% |
8.04 |
8.78 |
8.49 |
7.61 |
|
Elongation |
4.43 |
4.55 |
4.40 |
4.52 |
|
CV% |
8.20 |
8.18 |
9.49 |
9.72 |
|
Max |
34.16 |
30.30 |
32.57 |
29.85 |
|
Min |
19.85 |
19.32 |
18.48 |
23.03 |
Total
test: 4/2000 MTR
Overall
results:
Tenacity
(CN/Tex) =26.72
CV%
of Tenacity =8.23
Elongation
(%) =4.47
CV
% of elongation =8.89
USTER
TESTER:
|
Test |
Thick |
Thick |
Thick |
Neps (+140%) |
Neps (+200%) |
Neps (+400%) |
Hairiness (-) |
Thin |
Thin |
Thin |
|
1/1 |
150 |
8 |
1 |
226 |
35 |
1 |
2.85 |
826 |
100 |
6 |
|
1/2 |
151 |
15 |
1 |
221 |
34 |
1 |
2.19 |
774 |
93 |
8 |
|
1/3 |
132 |
12 |
1 |
248 |
49 |
0 |
2.18 |
794 |
95 |
3 |
|
1/4 |
159 |
16 |
0 |
303 |
68 |
3 |
2.91 |
947 |
168 |
7 |
Quality assurance system
Quality assurance procedure may be divided into two
major parts:
On line quality control.
On Line Quality Control:
On
line quality control is done at different stages, such as :
Winding:
Soft or hard package.
Warping:
Color pattern, width of repeat, section repeat.
Weaving:
Dropper check, loose warp check, reed mark, wrong denting etc.
Off Line Quality Control:
Sample
collection:
One meter sample of every order is collected by online
inspector. Every sample is clearly
identified with a sticker.
QC
department checks the fabric in the loom and at that time the loom remains
stops. He ensure the quality parameter such as free of hole or spot, reed mark,
repeat size, width of fabric etc.
TEST
PROCEDURE
– M/C used: G.S.M. cutter.
-Frequency: Every
order.
-Procedure: 3 samples pieces are cut with G.S.M.
cutter. Find their average wt.
-In case of non-conformity:
To increase G.S.M.: Reduce width mechanically.
To decrease G.S.M: Increase width mechanically
Width Test:
Frequency :
Every order & after every finishing process.
Procedure : Manual measurement by tape.
Pref. Std. : 150+
In case of non-conformity: Re-finish.
Tensile strength:
Mercerize (increase of 5-10%) and re-finish.
Tear
strength:
Pilling
Resistance:
Manufacturer :
James H. Heals.
Frequency : Whenever required.
Fabric inspection:
It
is the responsibility of both the textile supplier and garment manufacturer to
inspect all textiles to ensure their compliance with the buyer standard.
Textile which are being exported to another country for use in the assembly of
a finished product are required to be inspected by the buyer’s designed
inspection service prior to shipment. It is the sole responsibility of the
textile supplier to ensure that the textiles are inspected prior to shipment.
For textiles which are to be assembled in the country of textile origin,
inspection is required only if requested by the buyer. Once requested it is the
responsibility of the textile supplier to ensure that the textiles are
inspected prior to shipment.
The
fabric control service will be divided in the following subgroups:
A. Pre-control: “feel”
examination, appearance, verification of any unpleasant odorous, colors,
shades, weight, listing and ending; verification of dye uniformity between
center and selvedge by means of a special fabric strip “sleeve” and dimensional
checking by means of a steam test, production of the shade continuity
cards.
BControl: All textile inspections will be conducted in
accordance with the 4 point system. The control consists in checking of fabrics
on appropriate machines, permitting complete tension free sliding and measuring
of the fabric.
The pieces will always be processed in rolls or
humpback, never folded in order to avoid permanent creases in the fabric.
Tension free measuring will be carried out
electronically with or without metric labeling on the selvedge and the accuracy
will be guaranteed with a maximum approximation of 0.5%. Measuring will be
expressed in yards.
References
for pattern and finishing will be certified by a fabric swatch indicated by the
Garment conductor, colors by colors chart/shade chart. This sample will be
reference sample taken from the first delivery of the production or a sample
taken from a sample piece. Sample dimensions will be such as to permit
verification of all characteristics, pattern, colors, etc. of the fabric to be
inspected.
TEXTILE SPECIFICATIONS AND EVALUATION
All
textile inspections will be conducted in accordance with the Four Point System.
The
Four Point System derives its name from the basic grading rules:
No more than four
penalty points may be assigned for any single defect.
No more than four penalty points may be assigned to
one linear yard, regardless of the
number of defects within that one yard.
Penalty point evaluation
Defects
in both the warp/weft direction will be assigned points using the following
criteria:
3”
2 points -Defects size exceeding
3 points -Defects size exceeding
4 points -Defects size exceeding
· A continuous
defect running (
or longer shall be assigned four points for each yard in which it occurs within
the shipment.
·The following fabric penalty point grading standards
are to be used when inspecting all textiles. The standards are intended to be
comprehensive; rise to occasion, whenever a specific fabric condition is mot
described. When this occurs, the shipment will be aborted if the inspection was
failed, and the inspection service will contact the garment contractor/supplier
for disposition.
Running
Defect:
· Any
defects found to repeat and/ or run in a continuous manner will constitute a
running defect. Any running defect will be assigned four penalty points for
each yard in which the defect occurs. For a roll containing more than five
continuous yards per100 linear yards with running defects, the whole roll will
be graded as second quality and cannot be shipped.
Full width defects:
· Any roll that contains more than six full
width defects per 100 linear yards shall be graded as second quality and cannot
be shipped.
· No roll
will be accepted as an A grade roll which contains a full width defect in the
first or last three yards. This roll will be graded as B grade.
· No roll will be accepted as first quality
where baggy cloth occurs. A roll which exhibits a noticeable degree of
looseness (waviness) or tightness along either or both selvedge or ripples,
puckers, folds, creases in the body of the fabric and would prevent the fabric
from lying flat when being spread in a conventional manner. This roll will be
graded as second quality and cannot be shipped.
Holes And Dropped Stitches
·Roll length verification:
·30 yards in length shall
be graded as second quality and cannot be shipped. The roll ticket length will
be verified during the inspection
Points Calculation:
Textiles
are evaluated on square yard consumption. The formula used to determine the
point count level of a roll of fabric is as follows:
1. Individual piece: Points per linear yard ×36”×100 square yard
Cuttable width in inches ×inspected yard
=Points
for
yards
Total points per linear yard × 36”×100 sqr yard
2. Average
Shipment piece:
=Average
points per
square yard
· The average point value per shipment
should not exceed 20 points per
and not contain any second quality / rejected roll.
· A grade acceptance- Individual roll within
25 points per
square yards
· B grade
acceptance- Individual roll within 26-30 points per
·100
square yards.
· Maximum
20% of “B” grade fabric yards are allowed with in a shipment.
Maintenance
Maintenance
is a process by which equipment is looked after in such a way that trouble
free. Service and increased machine life can be ensured and specific product
quality required by the customers is sustained.
On
time maintenance increase m/c lifetime & ensures trouble free services.
MAINTENANCE OF
MACHINERY:
 |
Preventive
Maintenance:
Preventive maintenance is a predetermined routine
actively to ensure on time inspection / checking of facilities to uncover
conditions that may lead to production break downs or harmful description.
Break down maintenance:
In this case, repairs are made after the equipment is
out of order and it can not perform its normal functions.
Routine
Maintenance:
Maintenance of different machines is prepared by
expert engineer of maintenance department. Normally in case of dyeing m/c
maintenance after 30 days complete checking of different important parts are
done.
Socket/ Spanner /Impact socket sets: Suitable for
driving metric/AF, BSW,BSFand BA hexagonal nut/BOH.
Table / Drill vice: Ideal for small drilling task.
3. Screw
driver: Ideal for service / repairing loss.
4. Circlip
pliers: Opening & setting of circlip.
5. Pliers
& cutters.
6. Centre
punch: With knurnled grip & squire head with 60* gasket point . Used for
well defined impression for cutting / drilling etc.
7. Pipe cutter
: Used for steel conduct, copper brass or aluminium.
8. Nose
pliers.
9. File set:
Squire, half round, three square, round, flat.
REMARKS:
Maintenance of machines is very essential to prolong
the m/c life and good maintenance is important consideration.
Utility Department
Generator:
Brand
name : Watsila
System
: PLC control
Capacity
: 1 MW each
No
of cylinder : 16
Generator
type : Gas generator (1% gas: 11.5% air)
No
of generator : 9
Overall
efficiency : 80 %
Stand
by diesel generator which capacity is 750 KW and also two gas turbine which
production capacity is 9 MW used for other project in bex- tex ltd .
Maintenance:
# After 750 hours Lube oil is changed, and 40
grade oil is used for this purpose.
# Clean the spark plug after 2000 hour.
Oil
category:
Company:
Mobile
Compressor:
Type
: Screw type rotary compressor
Model
: Atlas (oil free), Fini , ELGI .
13.7m3/min (1)
Oil
category : lube oil (mineral oil)
Speed
: 1450
rpm
BOILER:
Type:
Horizontal fire tube boiler
Manufacturer:
Thermex
Origin:
India
Fuel : Gas
Maximum
pressure: 10 bar
Working
pressure : 9 bar
Heating
surface : 3315 square feet.
Chiller:
Brand
name : Thermex
Origin
: India
Capacity
: 210(3)
ton+500(1)ton ,total=1130 ton
Chemical
: Hydro chem.+ steam,
Lithium Bromide ,
No
of machine : 04
Humidification:
Relative
humidification depends on :
Motor
condition
Room
temperature
Due
point
Return
fan.
The Effluent Treatment Plant (ETP):
The
effluent generated from different sections of a textile mill must be treated
before they are discharged to environment. Various chemicals & physical
means are introduced for this purpose. The effluent treatment plant in Beximco
is chemical biological combination process developed by India.
Flowchart
of effluent treatment:
Raw
effluent
¯
Skin
Chamber
¯
Collection
Sump
¯
Dissolved
air floatation tank
¯
Clarifier
¯
Aeration
tank
¯
Setting
tank
¯
Clear
water,pH check
¯
Carbon
filter
¯