Industrial Attachment at Noman Weaving

Introduction:

Technical education and its adoption in practical field we involved inextricable, without the implementation of the knowledge gather in technical education its success bound to suffer. Therefore this two month industrial training as a practical fulfillment of our B.Sc in Textile Engineering course helps us to accomplished the gap between the theoretical and practical knowledge by providing an elementary idea about industrial environment, processing machines tools equipment, production system and maintenance, administration and management system.

Name of Mill:            Noman Weaving Mills

Type of company:     Fabric Manufacturing

Location :                   Mawna, Sreepur, Gazipur

Address :

 Factory :                    Mawna, Sreepur, Gazipur

Phone :                       06825-51949

Website:                     www.znzfab.com

Year of  establish:     December, 2005

Head Office:

 Adamjee Court,(4th)115-120, Motijheel C/A

Phone :7176207-8

Fax:9564336

E-mail: nomangr@bangla.net

Annual Production capacity

»        Toyota Air jet Loom:4500 Mtr

»        Picanol (Air jet) loom : 9000 Mtr

»        Picanol (rapier) Loom: 2500 Mtr

»        Production per month: 2370000 Mtr

Location of Noman Weaving mills

Total Area of  Land :  32 Bigha

Different Departments:

• Administration
• Planning
• Research & Development (R&D)
• Store
• Weaving preparatory
• Weaving
• Mending & Inspection
• Utility
• Mechanical
• Electrical

No. of Machine :

Toyota Air jet Loom                        :128 Pcs

Picanol (Air jet) Loom        : 64 Pcs

Picanol (rapier) Loom         :40 Pcs5

Layout Plan of Noman Weaving Mills Ltd

Orgaogram  of Noman Weaving Mills Ltd.

Manpower:

Total Manpower in factory: 1129

Management system:

»        Intercom telephone

»        Fax

»        E-mail

»        Written letters

»        Oral

SHIFT CHANGE:

There are three shifts per day in P.T.L. So each shift contain eight hour.

General shift, which is applicable for some officers.

Job description

Production Manager:

• To supervise the personal working under him.
• Making costing sheet for a sample.
• To plan for the sequence of production.
• To arrange necessary raw material for the production problems.
• To find out the possible reasons which are responsible for less production.
• To follow up the instruction of Managing Director and GM as well.

Senior Production Officer:

• Overall supervision  of  production.
• To  discuss with GM &  PM overall production if necessary.
• Communication with warping & sizing officer  for timely production.
•  Checking the production sample according to the buyer sample.
• Control the PO, supervisor, operator, asst. operator and feeder worker.
• Utilization of manpower.

Production officer:

• To collect the necessary information and instruction from the previous shift for the smooth running of  the section.
• To make the junior officer understand how to operate the whole production process.
• To match production sample with target shade.
• To discuss with PM overall production if necessary.
• To execute the overall floor work.
• To maintain tei ing / knotting of loom.
• Any other assignment given by the authority.
  • Maintain environment of the weaving floor.
  • Daily production report submitted to higher authority.

Useable yarn count and Prize

 Sizing Chemical & Prize

Source of Yarn:

      Zubair  Spinning

     Talha Spinning

     Yasmin Spinning

     Sufia Spinning
Production capacity:

Toyota Air jet Loom:4500 Mtr

Picanol (Air jet) loom : 9000 Mtr

Picanol (rapier) Loom: 2500 Mtr

Production per month: 2370000 Mtr

Flow Chart of total Weaving Process

Marketing

GM or PM     Planning      R & D

Approval Sample      Sample

R & D requisition

Yarn form Spinning Department

Winding

Direct             Warping      Sectional

Sizing

Drawing-in & Denting

Knotting & Getting

Weaving

Mending & Inspection

Delivery to Finish

Rewinding

No of Machine: 01

 Cone to Cone Winding Machine (Used for color yarn)

Model No       :           GAD14MD-JBB

No of Spindle :           120

Manufacturer:           Shanghai Nanshi Foreign Economic Corporation & Trading              Company Limited. (China)

Motor R.P.M:            1440

No of Machine: 02

 Cone to Cone Winding Machine

Model No       :           GA-014

Manufacturer:           Tangsi Textile Machinery Company Limited (China).

No of Spindle:            120

Motor R.P.M:            1440

No of Machine: 03 Same as No (02)

No of Machine: 04

High Speed Cone/Cheese Winding Machine.

Manufacturer:           Kinarivala RJK Industries Bapunagar, Ahmedabad (India).

No of Spindle:            120

Motor R.P.M  :           1440

Features of High Speed Warping

1. It is used to make common fabrics in large quantities
2. It is used to produce weavers beam from single yarn
3. The production is high
4. Large amount of yarn is required to produce a weavers beam
5. Sizing is done
6. Simple flanged beam is used and drums are not required

Sectional Warping

In sectional warping equal length of yarn is first wound in small sections or sheets on a drum. Then from the drum it is transferred to the beam. By this process we directly get the weavers beam. This is a two stage method and is used for making fancy fabrics.

Flow Chart of Sectional Warping:

Creel
↓
Drum
↓
Beam (Weaver’s Beam)

 Working Principle of Sectional Warping:

1. Sectional warping is used for short runs especially for fancy pattern fabrics.
2. In this case sections of the warp which may contain up to 1000 ends are first wound onto a drum tapered with a given cone angle.
3. So cross wound sections are combined on the drum & thus each layer of warp contains the same number of ends on the drum.
4. Then the warp threads altogether are transferred onto a weavers beam by unwinding the drum.
5. In this method the warp threads are not necessarily processed in sizing.

Features of Sectional Warping

1. This is suitable for making checked, stripped or other fancy fabric.
2. We directly obtain weaver’s beam from this process
3. As sizing is not done, so multi-ply yarns or yarns which do not require sizing are used
4. Small amount of yarn is required to produce the weaver’s beam
5. Sectional warping is used to produce a warp beam with a greater member if ends
6. The production is less in sectional warping
7. The yarn tension is less uniform

Differences Between Sectional and High Speed Warping

In this Factory has 7 warping Machine. 2are used for Sectional Warping & 5are used for Direct Warping.

Sectional Warping 1

Name :                                    Benninger Supertonic

Manufacture country:          Switzerland.

Creel Capacity:                      570

Model No:                              108EX-S1-S

R.P.M:                                     800 max (Used-200-300)

Drum Diameter:                    3m

Working Length:                  3m

Sectional Warping 2

Name :                                    Benninger Supertonic

Model No:                              108EX-S1-S

Manufacture country:          Switzerland.

Creel Capacity:                      800

R.P.M:                                     800 max (used 200-300)

  Drum Diameter:                  3m

Working Length:                   2.6m

Direct (High Speed) Warping machine total 5:

Machine No. 01

Name :                                    Hacoba

Manufacture country:          Switzerland.

Creel Capacity                        : 720

Machine R.P.M:                     800 max (used 400)

Yarn Used:                            16ne-100ne

Beam Width                          2400mm

Machine No. 02

Name :                                    Schalafhorft

Manufacture country:          Western Germany

Creel Capacity:                      800

Machine R.P.M:                     800 (used 300)

Yarn Used:                             16ne-100ne

Drum Width:                                     2.4m

Sensor system:                      Electrically

Machine No. 03

Name :                                    Karl Mayar

Manufacture country:          Germany

Creel Capacity:                      776

Drum Width:                        2.2m

Machine R.P.M:                     800 (used 400)

Sensor system:                      Electrically

Machine No. 04

Name :                                    Schalafhorft

Manufacture country:          Western Germany

Creel Capacity:                      800

Drum Width:                                     1.8m

Machine R.P.M:                     800 (used 400-500)

Sensor system:                      Electrically

Machine No. 05

Name :                                    Benninger

Manufacture country:          Switzerland

Creel Capacity:                      1224max;

Machine R.P.M:                     1200 (used 400-600)

Sensor system:                      Electricaly

Calculation:

                        Production = surface speed of drum ×π ×dia of drum ×creel capacity

                                           = 20.65× 3.14 × 30 × 544

                                           = 1058744.3 inch/ min

Sizing:

Sizing is the process of applying protective adhesive coating on the yarn surface. This is the most important segment of weaving preparatory process. Because sizing has direct influence on the weaving efficiency. Better the quality of sizing higher the weaving efficiency & vice versa. In fact without sizing, in most of the cases it is almost impossible to run the weaving process. Moreover in case of towel manufacturing rotor (open end) & low twisted yarns are mostly used.

Objects of Sizing

       To protect the yarn from abrasion

       To improve the breaking strength of the yarn

       To increase smoothness of yarn

       To increase yarn elasticity

      To decrease hairiness

      To decrease the generation of static electricity

Effects of Sizing on Yarn Properties
The following properties of yarn are affected by sizing:

      Yarn elasticity.

      Yarn strength.

      Hairiness of yarn.

      Flexibility of yarn.

      Smoothness of yarn.

      Irregularity of yarn.

      Yarn diameter.

      Yarn weight.

Important Machine parts:

• Warp beam.
• Guide Roller.
• Tension Roller.
• Draw Roller.
• Size box.
• Immersion roller.
• Squeezing roller.
• Small cylinder.
• Big cylinder.
• Ribbed roller.
• Delivery roller.
• Emulsifying unit.
• Lease rod.
• Reed.
• Measuring roller.
• Delivery roller.
• Spreading roller.
• Weavers beam.

Useable sizing Agent and their prize

In this Factory has 4 Sizing Machine:

Machine No.1

Name :                                    Karl Mayer Rotor Sri

Manufacture Country:         Germany

Model No:                              BM-E 2600/1000 size-0- Matic rotal

Creel capacity:                       20

Sizing Box:                              2

Dryer system:                        Multi cylinder dryer

No of Cylinder :                     14

Machine No.2

Name :                                     Benninger

Manufacture Country:         Switzerland

Creel Capacity:                      16

Size Box:                                 2

No of Cylinder:                      12

Dryer system:                        multi cylinder dryer

Machine No.3

Name :                                    Sucker Moller (Hacoba)

Manufacture Country:         Switzerland

Creel Capacity:                      24 (use 20)

Size Box:                                 2

No of Cylinder:                      12

Dryer system:                        multi cylinder dryer

Machine No.4

Name :                                    Benninger

Manufacture Country:         Switzerland

Manufacture year:                April,2008

Creel Capacity:                      32

Size Box:                                 2

No of Cylinder:                      14

Multi Cylinder Drying:

1. In this type of m/c, the drying unit consists of 5 to 7 or 11 cylinders having same diameter are used.
2. All cylinders may be steel cylinders or first two cylinders are Teflon coated & rest of are steel cylinder.
3. The cylinders are heated by passing steam.
4. Heat in initial cylinder is low & gradually increases when moved towards final cylinder.
5. If large amount of heat is given to the initial, the sized may be backed.
6. If finer yarn is used, then no need to use excess cylinder.

Advantages:
1. High speed process.
2. Uniform drying.
3. Non- sticky so smooth drying.
4. Drying efficiency high.
5. Less time required.

Disadvantages:
1. For high viscosity, stick properly may observed.
2. For friction, yarn hairiness.
3. Shinning effect.
4. Yarn shape may hamper.
5. Possibility of yarn flaten.

Sizing Calculation:

Production   =  r.p.m  of measuring roller × π  × dia of measuring roller × total capacity

                        = 53.2 × 3.14 ×9×5800

                        =2706177.6 inch/min

                        =75171.6 yds/min

                        =89.49 hank

= 2.98 lbs

Wt of yarn (kg)=(length of warp yds × no of ends)÷(count × 840 × 2.2045)

Wt of un-sized material in gm=(total ends × length mtr)÷Nm

Wt of size warp=(length (size)× no of ends)÷(count × 840 × 2.2045)

Count of size yarn=(count of un-size yarn × 100)÷(100 + % size)

Size liquor pick-up% = wt of size liquor (kg)÷ wt of yarn (raw kg)

Weaving

A)   Design.

1. In Tappet loom.
   1.                                                                    i.      Plain.
   2.                                                                 ii.      Twill.
   3.                                                               iii.      Sateen.
   4.                                                               iv.       Oxford. (Warp rib and weft rib).
   5.                                                                  v.      Queen’s Oxford.
   6.                                                               vi.      Matt.
   7.                                                             vii.      Various types of weave.
   8.                                                          viii.      Diamond.
   9.                                                               ix.      Diaper.
   10.                                                                  x.      Herring bone.
   11.                                                               xi.      Honey comb.
   12.                                                             xii.      The design which are possible in maximum 16 heald frames.

Weaving: –

      Steps involved

• Shedding;
• Picking;
• Beating-up;
• Let-off motion; and
• Take-up motion.

  Shedding

  Appropriate shedding device should be selected.

  Connecting cords for the shed formation should be even and strong.

  The cords should not be directly linked with the heald shafts. In lieu of this the use of loop cord is suggested through which the connecting cord should pass and should be tied by slip knot to either side of the heald shaft.

  Connecting cord from the central bottom of the heald shaft to the paddle should also be tied by slip knot to the loop cord.

  Before weaving it is important to check the formation of uniform shed.

  Instead of using two heald shafts use four heald shafts.

PICKING: –

• Picking should be uniform.
• Too early and too late picking should be avoided.
• All connections of the picking cord should be well balanced
• The picking cord should be even and strong
• The picking handle should be comfortable.
• Direct connection of picking cord to the picker should be avoided. In lieu of this the use of loop cord with picker is suggested.
• For proper picking the loom width should be according to the width of the fabric to be woven.
• The length of the reed should be equal to the distance between sley arms and the reed should be fitted parallel to the sley arms.
• For even picking proper selection of shuttle is necessary.
• The weft thread pirn should not be too tight or too loose.
• The pirn dimensions (length and circumference) should be such that the pirn is properly fitted in to the shuttle.
• Shuttle board (Shuttle race) should be smooth and even.
• Shuttle holder should be properly fitted to the picker. It should not too narrow, too high or too thin.
• The use of proper shuttle eyelets is necessary for getting desired pick supply.
• The use of fur in the inner wall of shuttle is necessary for every fine and smooth weft thread.
• The knots in weft thread should be as minimum as possible.

Beating-up: –

• Uniform beating force should be applied.
• The beating should be in right angle to the fabric. In this regard it is necessary that the distance of both side-hanging noses of the sley should be in equal distance from the cloth guide roller.
• Trembling force should be avoided.
• The beater should be held centrally during beating.
• Far shed beating should be avoided.
• Open shed beating should be avoided. In lieu of this cross pick beating is suggested.
• The weaver should hold the sley cap from the center while giving beating force to the fabric.

Let-off Motion: –

• Too much or too little release of the warp threads should be avoided.
• The release of warp threads should be uniform.
• The tension on warp threads should be uniform.
• The let off motion device should be in both sides of the warp beam.
• The arrangement should be such that the let off motion operates automatically.
• The let off and take up motions should match with each other.
• Leasing rods should function smoothly.

Take-up motion: –

• Winding of the woven fabric should not be too tight or too loose.
• After weaving the winding of the fabric should be carried out at regular intervals.
• Take up motion device should be easily approachable to the weaver.
• If too tight fabric is to be woven, the use of tooth wheels for both take up motions and let off mechanisms necessary. Otherwise, for normal weaving the use of weight system is most appropriate.

Use and Function of Temple

• To maintain a constant width of the fabric parallel to the warp threads.
• Checking the Loom for Errors.

The mistakes are:
-A missed heald eye
-A missed warp yarn.
-Crossed drafted and dented threads
-Too many yarns either in a heald eye or             in a      dent reed.
-Missing dents of the reed.

shed -1

Type of Loom:                       Air Jet Loom

Total Loom:                           128

Company Name:                   Toyota Tsushu

Name of Loom:                    Toyota Air Jet-710

Model:                                    JA2S-340TP-ET-T710 ( JAT-710 ).

Weft Insertion Capacity:      2 color.

Loom Width:                        340cm.

Manufacturer Tappet (cam): 2007, 01.

Manufacturer Dobby:           2007, 04.

Manufacturer Country:        Japan.

Machine Speed:                    600 r.p.m

07 Heald Shaft Loom:           104 pcs.

10 Heald Shaft Loom:           012 pcs.

16 Heald Shaft Loom:           012 pcs.

Total Relay Nozzle:               60

One relay nozzle to another relay nozzle distance: 60mm.

Shed:2

Name :PICANOL AIR-JET

Total loom:                            64

Model Name:                        Ominiplux-800-2P

Loom width:                          190 cm.

Machine Speed:                    1000 r.p.m (max).

Heald Shaft capacity:            12

Manufacturing Country:      Belgium.

Weft insertion capacity:       2 color.

Shedding type :                     tappet

Weaving Shed-3

Types of loom:                      Rapier

Name of loom:                      Picanol Rapier

No of loom:                           40

Picanol optimax:                   17 ( 6 heald shaft ).

Weft insertion capacity:       6 color.

Manufacturing date:            2010

Picanol Gamma:                    23 ( 20 heald shaft ).

Weft insertion capacity:       8 color.

Manufacturing date:            1997

Loom width               :           190 cm or 75 inch.

Different parts of Air Jet loom:

1. EDP(Electronic Drum Pre-winder).
2. Tappet(Cam).
3. Lever and Puller.
4. Reed.
5. Dobby.
6. Easing roller.
7. Back rest.
8. Take up roller.
9. Cloth roller.

10. Weft Feeler.

11. Dummy selvedge stop.

12. Weft cutter.

13. Drop wire and bar.

14. Leno selvedge attachment.

15. Main nozzle.

16. Sub nozzle.

17. Tample.

18. Dummy selvedge system.

19. Monitor and Mother board

20. Pressure control Switch.

21. Grease tank.

22. Calculation:

Production per hr =

 =              yds/hr

Drawing, Denting Section

»        Warp tying or knotting (Quick style) change process.

»        Reaching – in /Drawing – in and beam gaiting.

Drawing-in Draft (DID)

 Before the weaver’s beam is mounted on the loom, each end is threaded through a heald eye and the reed; it also supports a drop wire. The drawing-in draft indicates the pattern of the arrangement of warp ends on different heald frames.

Denting

»        The reed is a comb-like structure consisting of regularly spaced wires. The word dent is commonly used to describe the space between two reed wires.

»        Denting means drawing the warp ends through the dent as required by reed plan and this determines more accurately the width of the fabric and the ends per cm.

»        After these operations, the beam is brought to the loom so that it has the required number of heald frames and the reed as well as a multitude of drop wires. The beam in this state is useful only for the particular job at hand and can rarely be used to produce a different fabric structure without re-looming.

Tying-in

Tying-in is used when a fabric is being mass produced. The tail end of the warp from the exhausted weaver’s beam is tied to the beginning of the new warp. Therefore, if every end on the new beam is tied to its corresponding end on the old beam, the drawing in process can be omitted. Following the tying-in process, all knots are pulled through the drop wires, heddles and the reed. The loom is now ready for operation.

Equipment used in Drawing denting and pinning Section:

Denting plate (Patti):

Drawing Hook:

Drop Wire:

Construction:  61”

Weaving- 3/1 twill

Total Ends- 5900

RPM-750

Efficiency-92%

Warp – 20/1

Weft – 10/1

Warp Wt/yds=((total Ends/ Wt of 1 yarn)+con%+Wastage%

=(Total Ends /Count/1.8515)+ con%+Wastage%

=(5900/16/1.8515)+14.5%+1.5%

=231.46 gm/yds

Weight of Weft in gm=(reed spacePick)/count/1.8515+Wastage%

                                    =(67.58+1.5%

=177.83 gm/yds

Yarn cost

Warp  = =54.62 TK

Weft =  =37.34 TK

Weaving cost= 4814.4 TK per yds

Total cost =(warp yarn cost  +weft yarn cost + weaving)

                        =(54.62+37.34+14.4)

                        =106.37 TK/yds (yarn+ weaving)

FREQUENCY OF INVENTORY UPDATE :

–         Monthly inventory control.

–         Annual inventory control.

SCOPE OF INVENTORY CONTROL:

          -Raw materials

• Yarn .
• Other chemicals.

                     -Finished fabric.

                     -Spare parts.

                     -General store:

                                  Capital equipments.

                                   Accessories.

                                   Stationary.

                                   Maintenance parts.

INVENTORY SYSTEM FOR RAW MATERIALS:

• Raw materials partially received from production  planning & directly

from head office.

• Material receiving & inspection report (MRIR) is prepared. Received

quantity is mentioned and noted down.

• Submitted to Q.C. department. Some are OK & few rejected.
• Entry of data of goods in DATATEX.
• Goods are arranged according to OK or rejected group.
• Department gives store requisition to warehouse.
• As per requisition materials supplied & this record are noted down.

 Power house:

Total generator:                      5

Name of generator:             CATEPILLER

Country of origin:                 Germany

Model of Engine:                   3516

Year of  manufacture:           2006

Maximum Production capacity per machine: 1030 KW

Useable Production capacity per machine: 750 KW

Total Maximum Production capacity: 5150KW/ 5.15 MW

useable Production capacity : 3750KW 3.75 KW

Cost per unit: 1.59 Taka

ELECTRICITY

The main utility electricity is supplied form PDB and also by Generator

GAS

Gas is mainly used for steam production

The gas is used from TITAS

Generally 36 m3 gas is required to produce 1 ton steam

WATER

Continuous supply of water for BTL, BDL & DKL must be ensured by pump.

Mainly two pumps are used for water pick up

 Depth of pump          : 140 ft

Also pump for chemical dosing & Centrifugal pump for yarn dyeing.

BOILER

Pure steam with required temperature must be produced to meet the continuous demand of steam in different sections.

–         Fire tube type boiler is used

–         No. of boiler: (4+1) twine boiler.

1 boiler is operated by using burn gas

2 boiler is operated by Titas gas

–         3 Pass heating system

–         Measuring meter for water supply

–         4” depth greasol insulation so no heat at outside of drum

–         The lower drum is 100% water filled & the top drum is 60% water & 40% steam filled

–         Proper supply of air for gas burnings

–         Boiler capacity                 : 10 ton

–         Steam pressure               : 8.2 bar

–         Steam flow                       : 7 ton (app.)

–         Manufacturer                  : Thermax; India

–         Model                               : TD-100-10-54/6AS/E

–         Fuel                                   : Natural gas

–         Water pressure               : 10.3 bar

–         Evaporation                     : 1000 * 3 kg/hr

–         Output                              : 6.28 x 3 MW

–         Steam Temp.                   : 185⁰C

–         Boiler Temp.(Inner)         : 224⁰C – 275⁰C

Every result is recorded for 4 hours.

Chemicals used for boiler feed water

–         NaCl solution for regeneration

–         NALCO-4654 (Scale remover)

COMPRESSOR

Natural gas is drawn by pipe through the filter above the compressor & the air is compressed. In such a case the air becomes slightly hot. Hence cold water is drawn to reduce the temperature of compressed air. Thus the cold water becomes slightly hot & goes through outlet pipe to the overhead reservoir. Then the water falls slowly through a compressed air along with some vapors are transferred to the reservoir where the vapors are condensed and outlets drop by drop.

Parameters                                        Set value

Unloading pressure                          7.5 bar

Pressure difference               0.6 bar

Oil pressure                                       1.2 bar

Motor running time             15 bar

–         Total no. of compressor = 3 + 3 = 6

–         Capacity               : 774 Lt air / compressor /sec

–         Manufacturer      : Atlas Capco.

–         Country                : Belgium

–         Oil free air is prepared by Electronikon

Chemicals used:

–         Shell Turbo – T – 68

–         Grease

–         Nalco 7328 $ 7330

Chiller

A chiller plant normally consists of evaporator pumps, chillers, condenser pumps, and cooling towers.

Capacity 850RT(ton of Refrigeration)

Chemicals used

–         LiBr (Lithium bromide)

Components Li = 7.99%      Br = 92.01%

S.G. = 3.46 at 25⁰C

MP = 549⁰C

BP = 1265⁰C

–         Lythium Molybodate

–         Octyl Alcohol (2-Ethyl – 1 feanol)

–         Nalco 7328 % 7330

–         Refigerant

COST

            Electricity cost =1.58 TK Unit

            Boiler steam Rate=  5.28 TK  per  M³

Remarks: For smooth running of factory main utilities like gas, electricity or steam is very essential. Sometimes gas pressure is low than required pressure. When the gas pressure is low, then diesel generators run. Government should have to ensure proper gas supply for Industry.

Maintenance of Machinery:

Maintenance may be defined as the chronological activities or as the process of systematic activities done for keeping the m\c or equipments at the heat level for well run or its proper services.

 Maintenance Routine:

Daily and Weekly Maintenance Schedule

Every day:

1). Cleaning of Nozzle support, cutter and tucking housing.

2). Oiling of left hand cutter, center cutter and right hand cutter.

3). Cleaning the cover of the cam box and dobby, and all machine cover.

4). Cleaning and oiling of harness frame L.H and R.H

6). Cleaning Maintenance room and lubricant room.

7). Cleaning of weaver stand weaver side and beam side.

Saturday:

1). General cleaning of right side of machine, motor belt, timing belt and air filter housing.

2). Cleaning and oiling of staubli lever.

 Sunday:

1). Check the oil lever of tappet cam box, dobby, tucker housing, lubrication pump and cam box hydraulic pump.

Monday:

1). Greasing of rod end and back rest roller.

Tuesday:

1). General cleaning of right side of machine, motor belt, timing belt and air filter housing.

2). Cleaning and oiling of staubli lever.

Wednesday:

1). Greasing of press roller, tucking gear ( L.H, Centre, R.H ) and L.H, cutter electromagnetic cutter bracket.

Thursday:

 1). General cleaning of left side of the machine.

Friday:

1). Cleaning the machine using vacuum.

Note: Schedule will be changed depends on new planning.

Maintenance every beam change

A). Machine cleaning

            1). Check for fly or size dust accumulation. (Driving belt and pulley, shedding timing belt and pulley, dropper and contact bar reed and slay main brake) and EDP, electric drum.

            2). Check the air filter.

            3). Check the tucker oil cap (Filter).

            4). Check the oil filter of tappet cam box.

            5). Check easing housing shaft for extra yarn.

            6). Check the tuck in housing gear and gear shaft.

            7). Over all weaving machine.

B). Oiling and Greasing

  A). Check the oil level

            1). Right and Left hand gearing boxes.

            2). Shedding tappet and dobby boxes.

            3). Left hand tucker housing, center tucker housing and right hand tucker housing.

            4). Electronic control take up drive worn box.

            5). Let off drive box.

            6). Oiling the frame link joints.

  B). Greasing

            1). Staubli harness motion lever pins.

            2). Staubli cam motion lever (fixing element).

            3). Electronic control take up drive gear box.

            4). Yarn beam holder, locking pin and roller.

            5). Take up motion roller chain R.H or oil.

  C). Check up the clearance of bevel gear and cam gear.

Quarterly Maintenance

            1). Over hauling of E.D.P (E.D.P pin).

            2). Check up the tensioned spring.

            3). Check up the electromagnetic cutter L/H.

            4). Change oil of tucker box L/H, centre, R/H.

Note: Schedule will be changed depends on new planning.

YEARLY MAINTENANCE SCHEDULE

1). Overhauling of valve and E.D.P pin

            1). Main valve 1 and 2.

            2). Tandem valve 1 and 2.

            3). Cut blow valve 1 and 2.

            4). Sub nozzle valve 15 pcs.

            5). E.D.P pin.

2). Overhauling of take up drive R.H

            1). Check up of indirect take up roller chain. Check that the belt deflection is approx 5 mm.

            2). Check up tension plate.

3). Cleaning of air filter and oil filter of tappet box.

4). Check up easing lever and rod end.

            1). Check the easing rod end for radial looseness or wear.

            2). Check the easing lever pin and bushing for raid looseness of wear.

5). Check up the driving V-belt

            1). Check the driving belt for damage.

            2). Check for fly and oil accumulation.

            3). Check the belt tension.

6). Check up shedding timing belt

            1). Check the shed timing belt for damage.

            2). Check for fly and oil accumulation.

            3). Check the belt tension.

7). Check up E.D.P. and tensor spring

            1). Check the fly and size dust from the electromagnetic pin, measuring band and their surroundings.

            2). Check the reflector of the wind sensor.

            3). Check that a weft is correctly threaded through the leaf spring tenser and adjusted to the optimum tension.

8). Check up dropper box

            1). Check for fly or size dust accumulation.

            2). Remove extra dropper.

9). Check up of harness lever and harness frame

            1). Remove extra heald wire.

            2). Check the harness frame middle support.

            3). Check up the clearance of harness frame and harness guide sideways.

            4). Check up the clearance of harness frame and harness support up and down.

            5). Check up the allen screw of harness frame (re-tightening).

            6). Check up the allen screw of harness lever (re-tightening).

            7). Check up and cleaning harness lever.

10). Check up of the press roller and back roller

            1). Check press roller arm.

            2). Check press roller felt.

            3). Check up the back roller bearing.

11). Check up of L.H cutter and R.H cutter

            1). Check the cutter blade L.H for wear.

            2). Check the cutter blade R.H for wear.

            3). Check the cover of L.H cutter.

12). Check up of oil leak on gear box and easing housing

            1). Check up oil leak on gear box L.H.

            2). Check up oil leak on gear box R.H.

            3). Check up oil leak on easing bearing housing L.H.

            4). Check up oil leak on easing bearing housing R.H.

13). Change oil

            1). Change oil the tucker box L/H, centre@ R/H.

            2). Change oil the left and right gear box.

            3). Change oil the cam box or dobby.

            4). Change oil the let off box.

            5). Change oil the take up box.

14). Apply grease of all greasing point

            1). Press roller.

            2). Harness lever.

            3). Electronic control take up gear box.

            4). Electromagnetic cutter L.H.

            5). Easing rod and easing rod end.

            6). Back rest roller.

            7). Tucker gear shaft.

15). Machine general cleaning

            1). Cleaning of weaver stand.

            2). Cleaning of cover of tappet cam box and dobby.

            3). Cleaning of beam gear and beam cover.

            4). Cleaning of beam side.

            5). Cleaning of weaver side.

            6). Cleaning of all parts and accessories.

Note: Schedule will be change depends on the loom availability.

MONTHLY MAINTENANCE SCHEDULE FOR SIZING MACHINE

HEAD STOCK

1). Main gear box oil lever checking.

2). Gear box arm spindle greasing checking.

3). Drive wheel and V-belt tension checking.

4). Warm gear cleaning and teeth checking.

5). Comb screw thread cleaning spray oiling check.

6). Timing belt teeth gear checking.

7). Beam load and unloading checking.

8). Delivery roller rubber strip checking.

9). Delivery roller gearbox oil lever checking.

10). Comb up and down oscillation checking.

11). Universal join connection checking.

12). Universal joint greasing checking.

13). Weavers beam clamping and unclamping check.

14). Clamping and UN clamping gear checking.

 WAXING DEVICE

1). PT hundred stick edge cleaning checking.

2). Level sensor position checking.

3). Wax storage tank cleaning checking.

4). Steam traps checking.

5). Dividing roller position checking.

6). Cloth roller checking.

7). Moisture sensor roller cleaning.

8). Expansion roller moving check.

9). Steam glove valve licks checking.

STEAM DRYER SECTION

1). Chain drive gear box oil level checking.

2). Cylinder drive motor coupling check.

3). Chain drive spoke gear checking.

4). Chain length checking.

5). Chain spoke bearing check.

6). Chain tensioned wheel checking.

7). Hydraulic oil level checking.

8). Hydraulic knob checking.

9). Cylinder bearing housing check.

10). Cylinder bearing greasing check.

11). Cylinder PT hundred cleaning checking.

12). Cylinder tarpon coating checking.

13). Cylinder steam and condense sifenpipe checking.

14). Cylinder position alignment check.

15). Steam traps checking.

16). Pneumatic control globe valve checking.

17). Pneumatic control globe valve diaphragm checking.

18). Drive chain oiling checking.

SIZING CENTRE

1). Checking drives (visually and by ear).

2). Checking drives parts (shaft, belts, cones etc).

3). Immersion roller bearing and housing check.

4). Squeeze roller and bearing check.

5). Pendulum roller tension spring check.

6). Pendulum roller tension scale check.

7). Guide roller tarpon coating check.

8). Guide roller bearing and housing check.

COOKING

1). Gear box oil level check.

2). Water flow meter check function correctly.

3). Cooking catly steam line checking.

4). Cooking catly fan screw tightens check.

5). Pneumatic and steam valve checking.

6).Storage tank delivery pipe line cleaning checking.

7). Checking bearing of gearbox.

CREEL

1). Check brakes (visually and by air).

2). Checking brakes cylinders for free movement.

3). Checking brakes shoe for wear.

4). Checking beam support hubs for free movement.

5). Checking he axial guides warp beam bearing.

6). Checking the crane and loading equipment.

7). Checking warp beam alignment.

Manpower set up for Maintenance:

General shift

Shift –B

 Maintenance Procedure:

Setting: Setting is the activities to set or install the machine parts or required ancillaries. Adjustment also complementary word to setting used for appropriate setting.

Checking: Checking means investigation of machine condition. It is very important work in case of maintenance. It is very skilled depends work as successful maintenance that depends on correct fault detection.
Repairing: Repairing or altering of spares & equipment (if necessary) is to be detected & necessary measures are taken (repairing\altering\setting\adjustment).
Overhauling: It is the work of maintenance, but not frequent or schedule work. It is done as per as necessary.

 Maintenance tools or equipment and their function:

 Remarks:

Maintenance of m/c’s is very essential to prolong the m/c life and good maintenance is important consideration. In this industry maintenance program is done by expert maintenance team. So very few times production are stopped due to m/c problem.

Buyer of the Products :

• IKEA
• H&M
• Spring Field
• Tesco
• Wal-Mart
• VF-Asia

Importing Countries :

• Germany
• Switzerland
• Turkey
• Singapore
• China
• India

Exporting Countries :

• European Countries.
• USA.
• Canada.

Marketing strategy:

Marketing strategy is a very important factors to sale the products to the buyers. If the Marketing strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing the dealings with the buyer is a very important factor.

In Noman Weaving Mills mainly General Manager, Marketing Executives, Merchandisers & higher officials deal with the buyer. There is some fixed buyer of the industry. The buyer gives their orders continuously all over the year. The marketing officers & the merchandisers communicate with the buying houses to collect the orders. By both side understanding the rate & the order quantity are fixed.

Work of R & D

1. Fabric Analysis

     Weave  ( structure ).

      Order of coloring in warp and weft .

     Sett-ends and picks  per cm Yarn particulars

–          Count

–          -Twist per inch.

–          S or Z twist.

–          Single or fold yarn.

     Crimp% in warp and weft.

     Width of warp in reed.

     Warp length for a given finished fabric length (m).

     Weight of fabric per unit area (gm/sq. m).

     Type of material for both warp and weft.

1. Pattern  Sheet Making
2. Requisition of warp & weft
3. Follow of production of every specific pattern.
4. Daily note the Production of every pattern.
5. Making new creative sample and show the buyer.

Calculation :

Construction: 20×20/98×66

Fabric width: 58 inch

Total ends: 5684

Warp length: 3200 mtr

Here,

            EPI – 98

Length of warp=  Fabric length+(15 to 20 extra for wastage, shrinkage)

PPI – 66

            Yarn count- 20

So, Total ends = EPI × fabric width

                        = 98 × 58

                        = 5684

Reed count = EPI × 0.91

                   = 98 × 0.90

                   =88/2

Reed width = total ends ÷ reed count

                   = 5684 ÷ 90

                  = 63.16

Wt of warp = ( total ends × length of warp) ÷(1000×1.6933×warp count)

                   = (5684×3200)÷(1000×1.6933×20)

                  = 537.08 kg

Wt of weft = ((reed width+6)×PPI× order quantity)÷(1000×1.6933×weft count)

                 = ((63.16+6)×66×3200)÷(1000×1.6933×20)

                 = 431.31 kg

LAB

Veri Vide Color matching cabinet

Model: CAC 60

Origin: James H Heal &Co ltd, Halifax, England.

Object: This is used to assess the change of color during the test of dyed and printed fabric for color fastness to light, washing & rubbing.

Yarn Examining Board

Manufacturer: F.G. BODE & Co.

Origin: Hamburg

Method: ASTM

Object: Used for visual inspection of yarn faults like neps, thick-thin places etc.

Tear testing Machine

Brand Name : James Heal

 Wrap reel

Wrap Reel, manufactured by B-Tex Engineering, is a precision made, robust and reliable reading machine which is used for rapid preparation of accurate lengths of yarn, in hank form, for subsequent weighing and determination of count and strength of the yarn.

Min Labi Deying machine

Name: copower Lab dyeing

Origin : Taiwan

Factory Compliance

• No child labour.
• No forced labour.
• Transport facilities for worker.
• Hours of work.
• Voluntary over time.
• Intervals for rest.
• Weekly holidays.
• Annual leave.
• Festival holidays & leaves with bonus.
• Maternity protection.
• Worker’s welfare committee.
• Mineral drinking water.
• Sanitary facilities.
• First aid box.
• Canteen services.
• Day care centre.
• Health care activities for the worker & employ company doctor.
• Fire extinguisher each & every floor & conduct fire drill at least 12 times a year. We are giving a top priority on prevention of fire and eventual evacuation.
• Other safety department (no discrimination).
• Compensation cases department.
• The development of compliance programmer.
• Environmental developer.
• Smoking free zone.

Fire Bucket :               42 pcs.

Fire Bitter :                 10 pcs.

Fire Hook :                 10 pcs.

Fire Hose :                  57 pcs.

Fire Blanket :             03 pcs.

Gass Mask :               10 pcs.

Hand Mike:                02 pcs.

Booster Pump (capacity): Nill.

Fire Water Drum:      25 pcs.

Dining/Tiffin Room (worker): 03 pcs.

Fire Extinguisher

Fist Aid Box:

 Conclusion:

We are enough fortunate that we have got an opportunity of having a training in this mill during the training period. Technical education and its adoption in practical field we involved inextricable, without the implementation of the knowledge gather in technical education its success bound to suffer. Therefore this two month industrial training as a practical fulfillment of our B.Sc in Textile Engineering course helps us to accomplished the gap between the theoretical and practical knowledge by providing an elementary idea about industrial environment, processing machines tools equipment, production system and maintenance, administration and management system. Our attachment company in Noman weaving, Mauna Chowrasta, Gazipur. The date of the attachment is 15^th October 2012 to 15^th December 2012. Above all this training for 60 days in the Noman Weaving  has given us a new experience for practical life. We tried to gather all necessary information but it is difficult to collect all kind of data. But we try to do our best perform and as the whole industry training was satisfactory. We would like to thank the authority of Noman weaving as well as our honorable teacher for their altruistic help and advice. Besides this attachment gave us the first opportunity to work in an Industry and acquainted us with the internal sight and sound of Textile Industries. We believe with all these, the experience of the industrial attachment will help our future life as a Textile Engineer.