Executive summary

The international Buyers or clients are looking for those countries for producing their apparel products where different types of mills establish as a one stop source for the global apparel market, satisfy and meet customer’s expectation by developing and providing products and services on time, which offer value in terms of Quality, Price, Safety & Environmental impact. And also assure complete compliance with the international quality standards and also to provide the employees internationally acceptable working condition/standards. Bangladesh is one of the best countries for producing textile & apparel product. At this time Bangladesh can challenge with any country for producing apparel product with best quality.  Many countries try to produce good apparel products with best quality and price. So, now-a-days this field becomes very competitive. Bangladesh earns 76% foreign currency from the textile sector. Now-a-days buyer wants 100% quality product. For this reason it is very important to know about the latest technologies in textile sector. To produce a quality product, as a textile engineer I must have a vast knowledge about the production parameters & how to produce a high quality product. To accommodate the theoretical study with technical and practical things industrial training is very important. In my training period, I specially observed that Dacca Dyeing & MFG.CO. Ltd. Produce high quality fabric and fulfill the special requirements from the different types of buyers from following different internationally recommended standard method. In my training period I have learned many things such as different types of machines and their functions, techniques of productions and the management system and Dyeing and printing. So I think this industrial training will help me in future.

1. Introduction

As a mandatory requirement of the Bachelor of the Business Administration (BBA) program under Southeast University, this report entitled – “MARKETING STRATEGIES OF THE DACCA DYEING & MANUFACTURING COMPANY LIMITED” – is a connived depiction of the three months long internship program at The Dacca Dyeing Limited.

The organization attachment started on September 23, 2008 and finished on December 15, 2008. My organization supervisor Md. Major Hussain Imam (Ret.) GM (Admin & Compliance) has helped me to choose the topic of the term paper

1                    The Objective of the Report

General objective is to assess the level of importance the main objective of this training is to comprehend our theoretical knowledge along with the practical knowledge. It also enables us to orient ourselves with the practical environment that we will work in future. We systematically learned about various steps of Yarn processing. Moreover 1er we know about the man management technique and learn about marketing strategy. We also learned about dyeing techniques and quality assurance system.

1.2 Scope of the Report

The presentation of the organizational structure and policy of Dacca Dyeing and investigating the strategies applied by it provide the scope of this report. An infrastructure of the organization has been detailed, accompanied by a global perspective and look into the future. The scope of this report is limited to the overall description of the company, its services, and its position in the industry and its marketing strategies. The scope of the study is limited to organizational setup, functions, and performances.

1.3 Limitations of the Report

1        Large-scale research was not possible due to constraints and restrictions posed by the organization Part on organizational culture was written from individual’s perception and may vary from person to person. In many cases, up to date information was not published. The information regarding the competitors is difficult to get Getting Relevant papers and documents were strictly prohibited.Many procedural matters were conducted directly in the operations by the top management level, which also gave some sort of restrictions.

To protect the organizational loss in regard of maintaining confidentiality some parts of the report are not in depth.

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

2.0 FACTORY NAME: THE DACCA DYEING & MANUFACTURING COMPANY LIMITED.

1. Name of the company:                                               THE DACCA DYEING &                                                                                       MANUFACTURING COMPANY

                                                                                       LIMITED

2. Status :                                                                  Private Limited company

3. Type :                                                                   100% Export oriented dyeing

industry

4. Location :                                                             QC NAGAR,PAGAR,TONGI                  GAZIPUR,BANGLADESH

5. Address :

    Factory :                                                               QC NAGAR,PAGAR,TONGI                    GAZIPUR,BANGLADESH

   Head Office :                                                         SHARIF MENSION,(4^TH FLOOR) 56-    57,MOTIJHEEL C/A,DHAKA-1000 BANGLADESH

6. Established :                                                                 1963

7. Sponsor :                                                              R.AK.MR.NURUL ALAM

8. Product mix :                                                        100% cotton, 100% polyester, Chief    value cotton, P/C

9. Different departments: To run the factory smoothly, there is some department in the factory. They are given bellow:-

2.1 Production side

                                    DYEING & Finishing SECTION

1        Batch section

Dye house

Dyeing lab.

Quality control

Finishing

2.2 MAINTENANCE SIDE

1       Electrical

Mechanical

2.3 MANAGEMENT SIDE

                                    2.3.1 ACCOUNTS & COMMERCIAL SECTION

                                     2.3.2  ADMIN SECTION

1        Time section

Cleaning

Security

Store

2.4 Vision: –

To maximize synergistic benefit, and become a market leader through the pursuit of high productivity, advanced technological innovation and absolute customer satisfaction by leveraging on the strengths of their core business. In other words best one stop Dye apparel supply house and a market leader.

2.5 Mission: –

1        To focus on customer needs and wants continuously and manufacture high standard quality dye apparels.

To establish themselves as the leading provider of knit apparels by serving international market especially for retailer.

To strive to meet challenging market needs through a closer working relationship with business partners, innovative manufacturing process and maintaining standard customer service.

 2.6 Values: –

1.   Customer first.

2.   Pursuit of quality.

3.   Leverage through team work, people are their valuable resources.

4.   Innovation and diversity.

5.   Efficiency improvement and cost control.

6.   Becoming a responsible corporate citizen.

 2.7 Goal: –

Customer satisfaction is their main goal, competitive professional service and price, world class quality, on time delivery, honesty and reliability.

2.8 Compliance:

The factory is full compliance with ILO and Bangladesh Labour Law. Their company policy is as follows: –

1. 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 zo

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

CHAPTER-THREE

MANPOWER MANAGEMENT

3.0 THE DACCA DYEING & MANUFACTURING

COMPANY LIMITED.

ORGANOGRAM

 3.1 MANAGEMENT SYSTEM:

1        Intercom telephone

Fax

Written letters &

Oral

=

3.2 SHIFT CHANGE:

                                                   Per shift is 8hrs

                                                       1^st shift             :   6:00 A.M. – 2:00 P.M.

                                                       2^nd shift            :  2:00 P.M.  – 10:00 P.M.

                                                       3^rd shift             :  10:00 P.M. – 6:00 A.M.

                                                       General shift     :   8:00 AM   – 5:00 PM

3.3 RESPONSIBILITIES OF PRODUCTION OFFICER:

I. To give dyeing program slip.

2. To match production sample with target shade.

3. To collect production sample lot sample matching next production,

4. To observe dyed fabric during finishing running & also after finishing.

5. To identity disputed fabrics & report to P.M/G.M. for necessary actions.

6. To discuss with P.M about overall production if necessary.

7. To sign the store requisition & delivery challan in the absence of P.M.

8. Also to execute overall floor works.

9. To maintain loading’/unloading khata.

10. Any other assignment given by higher authority.

3.4 JOB DESCRIPTION OF PRODUCTION OFFICER: 

REPORT TO:  Sr. Production Officer

JOB SUMMARY: To plan, execute & follows up the production activities &. control the quality production with related activities.

3.5 DUTIES & RESPONSIBILITIES:

Overall supervision of dyeing, finishing production.

Batch preparation & p^H I chock.

Dyes & chemical requisition issue & check.

Write Fabrics loading & unloading time from m/c

Program making, sample checking, colour measurement

Control the supervisors, operator, ass. operator and helper of dyeing m/c.

And also any other over work as & when required by the management.

3.6 JOB DESCRIPTION OF Sr. PRODUCTION    OFFICER

REPORT TO: A.G.M. (production)

JOB SUMMARY: To plan. execute & follows up the production activities & control the quality production with related activities.

3.7 DUTIES & RESPONSIBILITIES:

Overall supervision of dyeing, finishing production. Checks the sensitive parameters of different machine for smooth dyeing Checks the different log books of different areas & report to management Checks out the plan to control the best output from supervisors & workers. To trained up& motive the subordinates how to improve the quality production.

Control the supervisor, operator, Asstt. Operator & helper of dyeing. Maintenance of machine & equipment Any other works & when required by the management.

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

CHAPTER-FOUR

MACHINE DESCRIPTION

PRE-TREATMENT

4.0 There are five processes for pre-treatment. These are given below:

4.1 SINGEING & DESIZEING: 

Name of the machine              :           SING AND DESIZE MACHINE

Brand Name                            :           GOLLER

Manufacturing country           :           Germany

Capacity                                  :           Highest 100 RPM (Rate per minute) Speed

                                                            And normally speed 70-90 RPM

Production                                          :           If machine speed 70 per hour production 4200 meters,

                   If machine speed 80, 90 per hour production 4800, 540 Meters

4.1.1 SINGEING:

Singeing is the process of burning of the fiber hairs projecting through the fabric surface. In a gas-singeing machine this burning is carried out by passing fabric against hot flames under specified conditions.

4.1.2 Checklist:

• p^H, temperature, padder pressure should be observed closely
• There should not be any deviation in parameter.

4.1.3 Frequency:

After every hour

4.1.4 Functions:

         To obtain a uniform & smooth fabric surface by removing hairiness.

         To ensure uniform optical reflectance throughout the fabric surface in subsequent fabric wet process.

4.2 BLEACHING MACHINE:

Name of the machine              :        BLEACHING MACHINE

Brand Name                            :        GOLLER Company

Manufacturing country           :       Germany

Capacity                                  :        Highest Sped 80 RPM (Rate per minute)

                                                         And normally speed 50-70 RPM

Production                              :         121”PC Long width fabrics run 50-55 m/min Per hour

                                             Production 3000, 3300 meters

                                             Short width fabrics run 60-65 m/min per hour production

                                             3600, 3900 meters

                                             PC short width fabric runs 70 m/min

                                             Per hour production 4200 meters

4.2.1 SCOURING – BLEACHING MACHINE:

Parameter Control:

4.2.2 Check list:

• Caustic &  concentration
• Doctor blade position
• Steamer temperature and dwell time
• Auto dosing check
• Appearance of outcoming  fabric
• Padder pressure
• Machine speed

4.2.3 Frequency of check:

       After every hour

4.2.4 Functions:

1       Fabric to be scoured is loaded in the machine

Required amount of water is loaded

Washing agent/ detergent is added

Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda ash) added when the temperature reaches at 50⁰C

When the temperature reaches at 60⁰C then stabilizer is added

Then H₂O₂ is added

Temperature is then raised to 90⁰C and the process is then carried out for 60-90 mins depending on the requirements

The liquors are then drained

Then cold wash at 30⁰-40⁰C, hot wash at 70⁰-80⁰C and acid wash at 60⁰-70⁰C is done

4.3 MERCERIZING MACHINE:

Name of the machine  :        MERCERIZING MACHINE

Brand Name                :           GOLLER Company

Manufacturing country:          Germany

Capacity                      :           Highest Sped 50 RPM (Rate per minute)

Production                 :            40-45 m/min speed for twill, canvas fabrics per hour production

                                               2400, 2700 meters and 50 m/min speed for PC, Poplin per hour

                                               Production 3000 metes.

4.3.1  Mercerizing:

Mercerizing is a physio-chemical process in which cotton fabric is treated with concentrated solution of caustic alkali & subsequently stretched & washed under specified conditions.

Parameter Control:

4.3.2 Check list:

• Caustic lye strength & temperature
• Padder pressure
• Width of outcoming  fabric
• Caustic on fabric at the end of stabilizing zone
• Machine speed

4.3.3 Frequency of check:

After every hour

4.3.4 Functions:

         To increase lusture of fabric.

         To increase the strength of fabric.

         To improve dimensional stability.

       To increase dye absorbency.

4.4 WASHING MACHINE:

Name of the machine  :        WASHING MACHINE

Brand Name                :           GOLLER Company

Manufacturing country:          Germany

Capacity                      :           Highest Sped 80 RPM (Rate per minute)

4.4.0 Functions:

1       All the washing condition and parameter can be controlled

Temp 120⁰C

Solvent – water + glycerin

4.5 DRYER MACHINE:

Name of the machine  :           DRYER MACHINE

Brand Name                :           GOLLER Company

Manufacturing country:          Germany

Capacity                      :           Highest Sped 120 RPM (Rate per minute)

4.5.1 Functions:

To dry the fabric with help of steam

4.6 COLD PAD BATCH MACHINE:

Name of the machine  :           COLD PAD BATCH MACHINE

Brand Name                :           GOLLER Company

Manufacturing country:          Germany

Capacity                      :           Highest Sped 50 RPM (Rate per minute)

Production                 :             per hour production 3000 Meters fabrics

4.7 THERMOSOL MACHINE:

Name of the machine  :           THERMOSOL MACHINE

Brand Name                :           GOLLER Company

Manufacturing country:          Germany

Capacity                      :           Highest Sped 30 RPM (Rate per minute)

Production                  :          When machine speed 25, 27, 30 RPM than per hour

                                                Production 1500, 1620, 1800 meters

Thermosol machine only dyeing for poly cotton fabrics and pigment dyeing

Parameter Control:

4.7.1 Check list:

• Padder pressure
• Level% of color trough
• Temperature of IR section, dryer and thermomax.
• Cooling of fabric by cooling roller
• Machine speed

4.7.2 Frequency of check:

      After every hour

4.7.3 Reactive dyeing procedure:

1.         Stock solution of Dyes is prepared.

2.         Scouring & Bleaching sample is weight for light shade. But for dark shade only scouring.

3.         Sample is weight m/c beaker is washed. Then pipetting of dye solution is completed into beaker according to requirement.

4.         Water is taken according to requirement into that beaker.

5.         Then Glauber salt is weighted and put it into beaker in solid form.

6.         Scouring & bleaching or only scouring weighed sample is wet with cold clear water and squeeze then put it into the beaker.

7.         Then beaker is closed with its cover and set it in Ahiba dyeing m/c.

8.         Set program no. 8.

9.         After complete this program cover of m/c beaker is opened and put Soda ash or Soda ash + caustic according to requirement.

10.       Then cover the beaker & again put it in Ahiba dyeing m/c.

11.       Set program no. according to dye types.

12.       After completion of that program dyed sample is taken out from beaker.

13.       Then wash the sample with cold water.

14.       Then wash with hot soap water.

15.       Then again washed with cold water.

16.       Then dried.

4.7.4 Disperse dyeing procedure:

1.         Stock solution of disperse dyes is prepared.

2.         Scouring & Bleaching Sample is weight for light shade. But for dark shade only scouring sample is weighted.

3.         M/C beaker is washed and pipetted the dye solution, dispersing agent & acetic acid into the beakers.

4.         Water is taken according to requirement into the beaker.

5.         Then sample is wet with cold clear water & squeezed, then put it into the beaker.

6.         Then beaker is closed with its cover and set it in Ahiba dyeing m/c.

7.         Set program no. 16.

8.         After complete of the program cover of beaker is opened and sample is washed but if it is medium on dark shade then reduction clearing is carried out.

9.         Stock solution of reactive days is prepared.

10.       M/C beaker is washed and pipetting of dye solution is completed into beaker.

11.       Water is taken according to requirement into that beaker.

12.       Then Glauber salt is weighted and put it into beaker in solid from.

13.       Then disperse dyed sample is wet with cold clear water and squeeze then put it into the beaker.

14.       Then beaker is closed with its cover and set it in Ahiba dyeing m/c.

15.       Set program no. 8.

16.       After complete this program cover of m/c beaker is open and put soda ash or soda ash + caustic according to requirements.

17.       Then covered the beaker and again put it in Ahiba dyeing m/c.

18.       Set program no. according to dye types.

19.       After complete of that program dyed sample is taken out from beaker.

20.       Then wash the sample with cold water.

21.       Then wash with hot soap water.

22.       Again wash with cold water.

4.8 PRINTING MACHINE:

Engraving section is the most important part of the printing department. Printing department used lot of screen. They used some chemical. These are the following:

4.8.1CHEMICAL FOR PRINTING:

                       1. Photo

                       2. Chromic Acid

                       3. Remover

                       4. Thinner

                       5. Oxalic Acid

Take the order by the buyer, used chemical on the screen and screens 1 hour dry in the dry machine. The screen processes into the Exposing machine. Computers send the command design of the Exposing machine. The Exposing machine print out the command designs.

4.9 STORK MACHINE:

End the Engraving process, screens can send to the STORK Machine. Mainly STORK Machine can only print out from the screen.

4.9.1 STORK MACHINE:

Name of the machine  :           STORK MACHINE

Brand Name                :           STORK Company

Manufacturing country:          Netherlands (Holland)

Capacity                      :           Highest Sped 50 RPM (Rate per minute)

Production                  :          When machine speed 50 RPM than per hour production

                                               3000 meters

4.10 ZIMMER PRINTING:

Zimmer printing Machines can also print out from the screen. Zimmer printing Machines can print out only large size of the screen.

4.10.1 ZIMMER PRINTINE MACHINE: 

Name of the machine  :          ZIMMER PRINTING

Brand Name                :           Kufstein Company

Manufacturing country:          Austria

Capacity                      :           Highest Sped 50-100 RPM (Rate per minute)

Production                  :          When machine speed 50-100 RPM than per hour production

                                               3000, 6000 meters

4.11 LOOP STEAMER:

After processing STORK & ZIMMER Machines fabrics send to the LOOP STEAMER. LOOP STEAMER dry and hard fabrics print.

4.11.1 LOOP STEAMER MACHINE:

Name of the machine  :          LOOP STEAMER

Brand Name                :           STORK Company

Manufacturing country:          NETHERLANDS (Holland)

Capacity                      :           Highest Sped 25 RPM (Rate per minute)

Production                  :          When machine speed 25 RPM than per hour production

                                               1500 meters

4.12 STENTER:

End the LOOP STEAMER processing fabrics send to the STENTER Machine. The main functions of STENTER Machine finishing the fabrics & increase its width.

4.12.1 STENTER MACHINE:

Name of the machine  :          STENTER MACHINE

Brand Name                :           Mahlo Company

Manufacturing country:          INDIA

Capacity                      :           Highest Sped 30-50 RPM (Rate per minute)

Production                  :          When machine speed 30-50 RPM than per hour production

                                               1800, 3000 meters

Parameter Control: For finishing, refinishing & topping:

4.12.2 Check list:

• Pressure
• Temperature
• Speed

4.12.3Frequency of check:

          After every hour

4.12.4 Function:

1.         Apply chemicals.

2.         To dart set the T/C fabric.

3.         Drying of fabric.

4.         To control width.

5.         Curing of fabric.

            6.         Apply pigment dyeing.

7.         To control GSM.

8.         To control shrinkage.

FINISHING:

After dyeing, knit fabric is required to finish. During dyeing all knit fabric are dyed in tubular form. According to buyer’s requirement knit fabric are finished in Open form or tubular form.

4.13 For open form following m/c are required:

4.14 Kier Machine:

4.14.1 Kier Machine:

Name   :           Kier

Capacity:         1400 kg

Origin  :           Bangladesh

4.14.2 Functions:

Towel scouring Bleasing

4.15  Winch   Machine:

4.15.1 Winch   Machine

Name:                                 Winch

Capacity:                  70kg

Origin    :                  China

4.15.2 Functions:

Only for dyeing

4.16 HYDROEXTRACTOR M/C:

Name   :           NGAISHING

Model  :           NS 2542

Serial   :           158

Company :       NGAISHING Development

Origin  :           Hongkong

4.16.1 Function:

To extract water from fabric

4.17 Tumbular DRYER:

Tension less dryer

Model              :           MFG NO-0445

Company         :           LK & LH CO. LTD

Origin              :           Taiwan

Speed              :           10 – 20 m/min

4.17.1 Functions:

To dry the fabric with help of steam

4.18 CALENDER M/C:

Name   :           Softset

Speed  :           100 m /min

                        20-30 m / min

Origin  :           Korea

4.18.1 Parameter Control:

4.18.2 Check list:

• Roller pressure
• Temperature
• Machine speed

4.18.3 Frequency of check:

After every hour

4.18.4 Functions:

1.  To calendar fabric

1. To reduce G.S.M.                       

   Final inspection

Inspection refers to an investigation process of accepting or rejecting the final finished fabric from the bulk. It is an observation process of finding. Out each and every visible fault in the fabric.

Following faults also detect and identify:

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

 CHAPTER-FIVE

 RAW MATERIAL

 5.0 RAW MATERIALS:

Raw material is a unique substance in any production oriented textile industry. It plays a vital role in case of continuous production & for high quality fabric.

5.1 Types of raw material:

The basic raw materials used are:

    fabric

    dyestuffs

    Chemicals & auxiliaries.

5.1.1. FABRIC:

         Fabric is collected mainly from weaving section of BTL. Yarn is collected mainly from Padma Textiles Ltd (1 & 2).

• 100% cotton fabric
• CVC fabric
• P/C fabric
• Lycra twill fabric
• Lycra poplin
• Medium wet twill
• Canvas
• Dense poplin

5.1.2. DYESTUFF:

5.1.3. CHEMICALS & AUXILARIES:

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

CHAPTER-SIX

Process Planning & Operation Sequence

Operation Sequences of Solid Dyed Fabric

6.0 SINGEING – DESIZING PROCESS :

6.1 Singeing :  Singeing is a process for removing projectile fibres from the fabric surface by burn.

 6.2 Desizing :  Desizing is a process for removing sizing materials from the fabric by chemical treatment.

6.3 Process Requirement:

      Osthoff Singeing – Desizing Machine

6.4 Fabric Processed:

• For all cotton fabric
• For blended fabric (PC and CVC fabric)
• For yarn dyed fabric

6.5 Required Materials:

• Compressed air
• Water
• Natural gas

6.6 Desizing Recipe:

Temperature : 70° c           Time : 15-25 seconds

6.7 Operation Procedure:

• The fabric is stitched with the tape fabric.
• After setting machine set-up parameters and filling desizing tank with chemicals the operator turns ON the machine and sets the machine at desired speed.
• Processing continues until a batcher is completed.
• After completion of the batcher, the operator stops the machine and warps the batcher with polythene paper and rotates it in rotary station at speed 7 m/min for a certain time.

6.8 Time Required for batching:

 THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

 CHAPTER-SEVEN

 Quality Assurance

 7.0 QUALITY ASSURANCE PROCEDURE :

7.1 Solid Dyeing Section:

Quality assurance procedure may be divided into two major parts:

1. On line quality control.
2.  Off line quality control.

7.1.1 On Line Quality Control:

On line quality control is done at different stages,  – preparation stage

                                                                                    -Dyeing  &

                                                                                    -Finishing stage.

7.1.2 On line quality control at preparation stage:

Tests are done at three stages here-

1) After Singeing-Desizing:

                                                        – Pick up %

2) After Scouring-Bleaching:

                                                        -P^H test

                                                        -Absorbency test.

                                                        -Size test.

                                                        -Whiteness test

                                                       -Yellowness test

                                                        – Pick- up %

3) After Mercerising:

                                                     -P^H test.

                                                     -Absorbency test

                                                     -Size test

                                                      -Whiteness test

                                                      – Yellowness test

                                                     -Pick-up % test

4)Finishing :

                                          -Shade checking.

                                          -Peach finish quality.

                                                    -Finish type.

                                                    -Hand feel.

7.1.3 TEST PROCEDURE:    

P^H Test:

• Indicator:                          Universal solution (500 ml botle)                                          

EMERCK, India.

• Direction of use:               Use 0.02 ml solution for 10 ml of the liquid under

investigation.

• Test process :                     2-3 drops of water are sprayed over the fabric.

Then add 1-2 drops of PH solution over it. The resultant color is then compared with scale.

• Acceptable Range:            6-7 (not over 7 because more than 7 means

alkanity)

• In case of non conformity: Hot wash.

7.1.4 Absorbency Test:

They use column/ wicking method of absorbency test.    

M/C ,Materials, Chemicals used:

0.4 gm CIBA BLUE FNC is mixed with 200ml water(that is 2gm/l solution of CIB  BLUE FNG)  Beaker stand for holding fabric strip.

Fabric size: 13cm*1cm.

process:

Fabric strip is hanged down from a stick up to the level of dye solution. Then for one minute the strip is kept. Then the height is measured up to which dye solution is absorbed.

Range:

At least 30 mm and up.

In case of non-confirmity:

Padding with wetting agent or rewash or rebleach.

Size Test:

Chemical used :  Iodine solution.

Preparation of Solution :

First 0.1(N) iodine is prepared. From that 1ml solution is taken and 99ml water is mixed to make it 100 ml.

Preparation of Iodine Solution:

Dissolve 10 gm of potassium iodide

           in 100 ml water. Add 0.65 gm iodine and shake up

           complete dissolution. Fill with water ethanol upto 1litre

Application of iodine solution:

Put the fabric sample 1minute into the iodine solution. Rinse shortly with cold water. Dab with filter paper and compare immediately with violet scale.

Acceptable range:

Minimum  6

           Maximum   upto 9

Pick up% :

•   3pieces of fabrics are taken; 1from right, 1 from left, 1 from center.
•   Bag weight is taken.
•   Dry weight of fabric is taken.+ Bag weight.
•   Dry fabric weight =(Bag+ Fabric)- Bag weight
•   Then fabric is washed with hot water and then dried with iron.
•   Then weight of chemical=(wet-dry)fabric weight.
•   Wet -Dry
•   Then pick up%
•   Dry
•   Mercerizing=70-80% pick up.
•   Desizing = 80% and up.
•   Scouring-bleaching= 80% and up.

Whiteness test :

•   Done  in data colour.
•   Range  70-80% (The fabric which will be dyed).

     & 80% and up(For white fabric).

Yellowness test : 

•   Tested in data color .
•   Range    3- 3.5 (Fabric to be dyed).

     &Less then 1.5 (White fabric).

Core  P^H   Test  :

Used for yarn dyed fabric(As yarn dyed fabric is died previously, so it is not possible to test P^H in dyed fabric).  

• 10 gm yarn dyed fabric is taken in beaker.
• 250 ml hot water is added(90C).
• Again warm up.
• Then conditioning until it is cold.
• P^H test by P^H meter.

7.2 Off-Line Quality Control:

7.2.1 Sample collection:

One meter sample of every order is collected by online inspector after stenter finishing and after sanforising. All the finished fabric tested are curried out on this fabric. Every sample is clearly identified with a sticker.

7.2.2 Physical Tests:

Threads per inch(TPI):

The procedure for TPI test of finished fabric is as followed:

            Machine used :           Thread counter.

            Manufacturer  :           James H. Heal & Company, Halifix, England.

            Frequency      :           Every order.

Procedure       :           3 one inch square samples are taken from a

fabric, there samples are taken one from the center, one from the right and another from left. Threads of each sample are counted both weft & warp wise.

Performance Std.:                   + 5%

            In case of non-conformity:     Re-finish.

Fabric weight (G.S.M) :

The procedure for fabric weight test of finished fabric:

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.

                        Gram per square meter (GSM)= Average wt*100

                        Ounce per square meter (oz/yd2)=G.S.M.*0.0296

                        Performance std:         According to buyer’s given std.

                                                            In case of non-conformity:

To increase G.S.M.: Reduce width mechanically.

To decrease G.S.M.:   Increase width mechanically

Width Test :

Machine used  : Measuring tape.

Frequency                   : Every order & after every finishing process.

Procedure        : Manual measurement by tape.

Overall width  : Total width.

Useable width : Width without selvedge.

Pref. Std.         : 150+2 cm or specified by the customer.

Incase of non-conformity:      Re-finish.

Tensile strength :

 -M/C used                   : Alphateus Tensile Tester.

-Frequency                  : Every order.

-Procedure                   : According to customers requirements.

-In case of non-conformity:    To increase tensile strength re-

mercerise (increase of 5-10%) and re-finish.

Tear strength :

– M/C used     : Element Tearing Tester.

– Manufacture : Messmer Instruments Ltd.

– Frequency                 : Every order(only for 100% cotton light fabric).

–  Procedure                 :  According to customers requirements.

– In case of non-conformity:               To increase tearing strength re-mercerise & re-finish.

Pilling Resistance :

– M/C used     : ICI Pilling box.

– Manufacturer            : James H. Heals.

– Frequency     : Whenever required.

– Procedure                  :  BS 5811(36000 rer) ASTM D 3512 & according to

   customer requirement.

-Performance std.:                               Grade 4; Grade 3(For each fabric).

– In case of non-conformity:   Re-singeing followed by resin finish.

7.2.3 Chemical tests :

Fastness to wash :

Fastness to wash is the resistance of dyed fabric to bleed under the action of washing chemicals.

For this test the following reagents are used-

1. ECE reference detergent
2. Sodium Carbonate
3. Distilled water

Testing Procedure:

1. 1.      The specimen measuring 10 cm x 4 cm of material is cut out.
2. Avoid specimen within 5 cm of the selvedge.
3. Cut a piece of multi-fibre 4 cm wide
4. The multi-fibre has selvedge of 10 cm long.
5. Align test specimens and multi-fibre and sew together to form a composite specimen.

There are 5  ISO standard washing fastness tests-

 Assessments :

Compare the contrast between the treated and untreated sample with the changing grey scale and staining of multi-fibre fabric with the staining grey scale in color matching cabinet.

Fastness to rubbing :

Fastness to rubbing is the resistance of dyed fabric to color loss by friction or rubbing.

Crocking cloth:

This is a white unbleached, undyed cotton fabric. For wet rub, crocking cloth will be wetted with water and squeeze to 100% take up.

Procedure :

1. Cut the sample as long as that can cover the metallic mounting plate

2. Two specimens are required for dry rub and two for wet rub testing.

3. For both dry and wet test one specimen will be placed to warp direction and other weft direction.

4. Place the sample with tape under the mellalic mountain plate

5. Then 10 x 10s (to and fro 1 rub/sec) rub is done by turning the handle.

6. Remove the crocking cloth form peg. In wet rub the crocking cloth is dried at room temperature.

Assessment:

Compare the contrast between the treated and untreated white crocking cloth with the staining grey scale and color changing with changing grey scale in a color matching cabinet.

Fastness to perspiration :

The garments which come into contact with the body where perspiration is heavy may suffer serious local discoloration to artificial perspiration solutions are made up as follows –

Wet out the test specimen with adjacent fabrics in mentioned perspiration solutions at room temperature, liquor ratio 50:1 and leave for 30 minutes, pour of the excess solutions, place the test specimen between two glass or acrylic plates under a pressure of 12.5 kilo pascle and placed in a drying oven for 4 hours at 37⁰C. Then the specimen is dried in warm air.

Assessment :

Compare the contrast between treated and untreated dyed sample with changing grey scale and staining grey scale in a color matching cabinet.

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

8.0 UTILITY DEPARTMENT  CONTROL THE FOLLOWING UNIT:

   –   Boiler

   –   Chiller

   –   Gas                                                                                                                            –   Compressor

                     –   Electricity

                     –   Generator

8.1 ELECTRICITY :

The main utility electricity is supplied from PDB and also by generator.

8.2 UNITS OF CHILLER :

• Evaporator
• Absorber
• Generator
• Condenser

Chemicals used in Chiller:

LiBr (lithium bromide) as an absorbent.

Water used as a refrigerant.

8.3 CAPACITY OF CHILLER:

• 210 RT
• 250 RT
• 500 RT

8.4 BOILER:

No of boiler – 4

Capacity      – 20 ton

Fuel             – natural gas

Evaporation -1000×3 kg/hr

8.5 COMPRESSOR:

No of compressor                 : 6 maximum working pressure

Maximum working pressure : 7.5 bar

Rotational shaft speed           : 1485 rev/min

Capacity                                :774 lit/min

8.6 GENERATOR:

Equipment used   : gas generator

Manufacturer       : Wartsila-Frank

No of generator   : 8( 1 self start able& other 7 air + CH4 start able)

                              Gas engine used.

                              16 cyl. Per engine

Overall efficiency: 80%

Heat recovery possible from 4 engines.

Cylinder capacity        : 71.6dm3

Ignition pressure         :90 bar

Piston speed                :9 m/sec

Pressure of gas            :60-62 mili bar

Air pressure                 :7 bar

Electricity take up from PDB:1.5 mw/sec

Mixture of gas air        : 1:18

Capacity                      :1 MW

Total power is then distributed as per requirements of different section in Dacca Dyeing.

8.7 GAS:

Gas is mainly used for steam production.

The gas is used from TITAS

Generally 36m3 gas is required to produce 1 to steam.

8.8 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.

8.9 SOURCES OF UTILITY  :

          · Electricity                          :  PDB & Generator

          · Steam                               :  Boiler

          · Water                                :  Pump

          · Compressed air               :  Compressor

           · Temperature control      :  Chiller

          · Gas                                   :  TITAS

8.10 COST :

 36 cubic meter gas required for 1 ton steam generation.

• ·Required steam/day: 9500 ton
• ·PDB:

        Pick hr: 4.22 tk/unit

        Off pick hr: 3.70 tk/unit

• ·Generator:2.25 tk/unit of  electricity

8.11 Product Quality Check:

Following chemical tests are carried out to check the quality:

• BOD
  ·   COD
  ·   Total suspended solids
• Total dissolved solids
• Color
• p^H

8.12 Typical Output of the Plant:

      ·    Raw effluent treated             15000LPH

      ·    Raw effluent color                  Black

      ·    Raw effluent pH                      11

      ·    Treated effluent color            Light greenish

      ·    Treated effluent p^H                 8.5

      ·    Treated effluent temp            38ºC

      ·    Total suspended solids           35 PPM

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

CHAPTER-NINE

Store & Inventory Control

9.0 FREQUENCY OF INVENTORY UPDATE:

                                                 ·   Monthly inventory control

                                                 ·   Annual inventory control

9.1 SCOPE OF INVENTORY CONTROL:

-Raw materials

           · Dyes store

           · Other chemicals

           · Grey fabrics

-Finished fabric

-Spare parts

-General store:

            · Capital equipments

            · Accessories

            · Stationary

            · Maintenance parts

9.2 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 & noted down.
• Submitted to QC dept. Some are OK & few are 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.

9.3 STAGES OF GREY FABRIC INVENTORY CONTROL:

• After knitting production
• Grey inspection
• Warehouse
• Batch preparation
• Dye house

9.4 STAGES OF FINISHED FABRIC INVENTORY CONTROL:

• Finishing section
• After final inspection
• Warehouse

9.5 STORE CAPACITY:

• Dyes & chemicals            : 100 tons
• Grey fabrics                     : 50 tons
• Yarn store                        : 100 tons

 9.6 PRESENT STOCK OF DYES & CHEMICALS:  

SOLID DYEING DEPT.

LIST OF DYES :                                                                                                     unit:kg

9.10 LIST OF CHEMICALS

PREPARATION CHEMICALS :                                                             unit:kg

 Finishing chemicals(for Pigment):

                                                                                                                      unit:kg 

 THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

CHAPTER-TEN

Cost Analysis

10.0 Processing Cost of Woven Fabric:

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

CHAPTER-ELEVEN

Marketing Activities

11.0 Name of theBuyer/Customer in Dacca Dyeing Manufacturing Company Limited:

           1. IEKA

           2. LITTLEWOOD

           3. JOTEX

          4. DORMA

          5. KOPPERMAN

          6. ASHLY WILES

          7. VIVA

          8. JYSK

          9. ELLOS

11.1 MARKETING STRATEGIES 2006:

The vision for the year 2006 & beyond is of innovation, speed & service driven marketing where by customers faith & Dacca Dyeing’s capabilities are enhanced in a financially beneficial way. IEKA,LITTLEWOOD,JOTEX,JYSK among other is a good example of this strategy as their volume have grown & promised to go further. We are trying to add new customer tour customer profile. Targeting on new customers we participated on different trade fairs all over the world. Through aggressive & dynamic marketing strategies we established ourselves for 2007 as creative, innovative & reliable supplier in this industry. Our strategy to market mostly value added product was also successful. The year 2006 was the most successful year in terms of sales volume & turn over.

11.2 MARKETING STRATEGIES 2005:

Our marketing team remained at forefront of tackling competitive challenges by exploring new territories, customers & products. In the generally prevailing uncertainties & impending liberalization of quota regimes the design team again played a pivotal role in changing the perception of DACCA DYEING as a typically Asian supplier with increased customer contacts, collaborative working methods new value added products like stretch fabric & slub fabric. New finishes such as Wrinkle free, Teflon & combinations of both were added to our range. Our participation in high profile trade fairs such as Tex world in Paris, France & Magic in Las Vegas, USA increased our visibility in the international market & enhanced our reputation. Next, the fastest growing clothing retailer in the UK gave us additional support to our customer list. There was an exponential growth in sales to H&M. IN spite of the difficult conditions; we were able to penetrate new markets in the form of LEVIS Europe & Mexico. Our overall marketing policy of going for quality rather than volumes paid rich dividends & we were able to not only hold onto our existing customer base but venture into new markets.

Source: Annual Report 2005.

11.3 MARKETING STRATEGIES 2004:

The declining retail sales & the losses shown by the big retailers worldwide & the consequent drop in order in the worldwide garment industry provide to be a major challenge to our marketing efforts & strategy. The very fact that in spite of the factors mentioned earlier we maintained more or less the sales of last year, showing a fall on only 3.32% is a credit to our marketing.

In an uncertain world market, we doubled our efforts with our designed team leading the way. We increased our call on the customers & looked for ways to add new ones also. Having established a strong relationship with LEVIS USA & becoming one of their core suppliers, we targeted Levis Europe & Levis Australia also & made in roads there. Next, who we had brought in last year increased their sales with us substantially as did ZARA. Our other customers are loyal to us, in spite of cutting their sales with other. We added new & dynamic designers to the existing team, & can proudly say that our spring & autumn collections were held as some of the best to be presented. These meetings boosted the confidence of existing buyers & attracted new customer. We again participated in Tex world Fair in Paris & our stall was one of the busiest & most visited one in the whole fair

We continued with our strategy to market value added products like yarn dyed & fabrics with special finishes. This is reflected in the increase in our average price per linear meter.

We are now in a strong position to take on the challenge of WTO in the end of 2004 when quotas will be abolished & only those company’s with a reputation for innovation, creativity & reliability & the ones having strong strategic relationship & business alliance will survive & benefit.

Source: Annual report 2004

THE DACCA DYEING & MANUFACTURING COMPANY LIMITED

CHAPTER-TWELVE

CONCLUTION AND REFERENCE

12.0 Conclusion:

Dacca Dyeing Ltd is a private limited company with composite dyeing manufacturer & exporter and BTL. Customer satisfaction is our main goal, competitive professional service, and price, world class quality, on time delivery, honesty and reliability. They want to maximize synergistic benefit, and become a market leader through the pursuit of high productivity, advanced technological innovation and absolute customer satisfaction by leveraging on the strengths of their core business. They focus on customer needs and wants continuously and manufacture high standard quality dyeing apparels.  They establish themselves as the leading provider of dyeing apparels by serving international market especially for retailer. They strive to meet challenging market needs through a closer working relationship with business partners, innovative manufacturing process and maintaining standard customer service. For achieving their goal, Dacca dyeing manufacturing company limitted has recruited a high profiled human resource team. The production is controlled by technical persons. All of the decision makers of production sector in Dacca Dyeing Ltd. are textiles graduates. According to their capacity they have an enriched production team which is very rare in other factories of Bangladesh. The working environment of Dacca Dyeing Ltd. is very good & friendly.  They try to follow al the industrial rules. The management of the Dacca Dyeing ltd is always careful about the satisfaction of the employees. All of the executives & employees of Dacca Dyeing Ltd. are very much cordial & they always appreciate with the learners.

Dacca Dyeing Ltd. wants to get high production & to maintain the quality of the product at a minimum cost. They buy yarn from the different types of spinning mills. There is no yarn testing machine for test yarn. So, sometime they found different types of yarn fault which effect on their production. There is no polar fleece & auto stripe m/c in Dacca Dyeing Ltd. so they are not able to produce all types of dye structure. In dyeing lab Dacca Dyeing Ltd. is using normal pipetting system which can not give the accurate result, but if they use digital pipettting system or dispense type digital pipetting system I think their accuracy will increase to a maximum level. There is no person to input the self shade of different types of lot everyday in the spectrophotometer but for accuracy of the recipe it is very important to input the self shade of different lot of dyes in a regular basis. For dyeing they are using Acme m/c but if they use Fongs, Thies or Sclabos m/c I think their product quality will be higher, because high quality machine gives high production with low liquor ratio with lower amount of chemical.  In garments section, for cutting they usually use manual straight knife cutting m/c and band knife cutting machine, but if they use computerized cutting m/c their accuracy will increase & their efficiency will increase to a maximum leve. If they use embroider and printing machine in their garments, I think, their production will be very high. I think if they improve the above things, their product quality,  efficiency and  accuracy will be increased and  maximum.