Report on Alim Knit BD Ltd (Part 2)

 Machine Description for Finishing Section:

Finishing section is consisting of two lines. They are –

1. Tube line
2. Open line

1. The machine that are used for open line are given bellow –

–          Slitting and Dewatering machine

–          Stenter machine

–          Compactor machine

–          Tumble Dryer

2. The machines that are used for tube line are given bellow –

–          Dewatering machine

–          Dryer

–          Compactor machine

Process flow Chart for Finishing Section:

Description of The Machine for Tube Finish:

A. DEWATERING MACHINE: (M/C Specification)

 PASSAGE DIAGRAM OF SANTEX-AG DEWATERING M/C:

Working principle :

    After completing the dyeing process from the dyeing m/c then the fabrics are ready for de-watering. In de-watering m/c tubular fabrics are mainly processed. There is a magnetic sensor which scene the twist of the fabric and its direction and turn the fabric in opposite direction to remove twist automatically. Here dewatering is performed   De-watering is the process to remove the water from the fabric completely by squeezing and it is done by the padder. A suitable expander is used before the fabric is passed through the nip of the padders, which expands the fabric flat wise and adjust the width.

The expander width is adjusted as S/J- 20%, PK-25%, Int.-35%, Lacoste-40% wider than the required width. There is a pair of rubber coated padder, where water is removed from fabric when passed through the nip of it.

Normally squeezer contain single or double padders where,

    –  One for removing water and

    –  Other for applying finishing chemicals such as softener.

But this finishing is done only for the tubular fabric. Open widths knitted fabrics are applied finishing treatment later in stenter.

 Here present the compressor which given compress air to form ballooning before passing through the padder. This balloon remove crease mark but not form the maximum balloon otherwise shrinkage increase.

In feed & Out feed traverses which present in albatros control the following functions by over feeding system.

–             To control the width (dia) of the fabric.

–             To control the spirality of the fabric.

–             To control the crease mark of the fabric.

–             To control the length of the fabric.

Operational parameter:

–          Speed: As much as possible (40-60 m/min). Higher the GSM lower the speed.

–          Over feed: As required. Higher the GSM higher the over feed.

–          Padder pressure: 3-7 bar as required. Higher the GSM lower the padder pressure.

–          Width: Fabric width is adjusted as per required width.

Different parts of Dewatering m/c :

N.B: Santex contains two baths. One for padder bath and another for softener bath where softener given 1 g/l . The softener bath capacity is 80 liters.

Special features of  Santex-ag m/c :

       –    Single squeeze roller and single padder present.

       –    One for squeezing and other for applying softener finished.

       –    Above 80% water can be removed

       –    Maximum 60 inch diameter can be extended.

       –    Softener tank present.

Maintenance during operation  :

 –    Proper balloon form by compressor air other wise crease mark appears.

 –    Padder contract point adjust perfectly according to the fabric construction otherwise accurate water will not remove.

                     –    Albatros must be clean every one or two hours later.

Parameters Used For Different Constructed Fabric  :

 For COTTON Fabric:

FOR POLYESTER FABRIC:

 N.B : This Data’s are varied depending upon the Gray G.S.M and Finished G.S.M and also on the dia of the fabric. All this parameters are suitable for G.G.S.M range 140~160 to get Fin.G.S.M 170~185 without Lycra Fabric. All This data`s are practiced in mills which may varied factory to factory.

B. DRYER  MACHINE: (M/C Specification)

PASSAGE DIAGRAM OF SANTEX-AG STEAM DRYER  –

                           Chamber – 1                             Chamber – 2

Here ,

  =   Folder belt .

Working principle of dryer :

After de-watering then the fabric through the dryer. The main function of the dryer is given below,

–            To dry the fabric.

–            To control the overfeed system.

–            To control the vibration which increase the G.S.M.

This machine contains two chambers. Two mesh endless conveyors are placed lengthwise to the chamber named conveyor net and filter net, each chamber contain a burner, which supply hot air .This hot air is guided through the ducting line by suction fan .There are nozzles placed in between filter net and conveyor net. When the fabric pass on the conveyor net, hot air is supplied to the wet fabric to dry it. There are exhaust fan which such the wet air and deliver to the atmosphere through the ducting line.

The speed of the dryer depends on the temperature of the m/c & the G.S.M of the fabric . If  the m/c temp. Is high then m/c speed also high and the m/c temp. Is low then m/c speed also low. The vibration speed of the m/c for heavy fabric is 730 m/min and normal fabric is 480 m/min .

 The temp. Of different chambers according to the shade of the fabric –

 Operating parameters:-

• Temperature:-Set the temperature between 120⁰c -130⁰c for white and 150⁰c -170⁰c for color fabric. GSM   temperature  Or, moisture content   temperature
• Set the over feed up to 10~20% or as required to get finish G.S.M.
• Set the speed as much as possible (6~20m/min). GSM   speed

Special  feature of Santex-ag  steam dryer :

–            Steam dryer (two chambers).

–            Vibration occur in heating zone.

–            Process air pressure switch present.

–            Maximum temp. Increase up to 170⁰c.

–            Steam control switch present.

–            Two burners present.

–            Two conveyor belts are present.

Different Sections Of Dryer Machine:

Parameters Used For Different Constructed Fabric :

For COTTON Fabric:

 N.B: For Polyamide: Temp range is 110⁰C~ 115⁰C.Speed range16~18; Overfeed range- 5%. This Data’s are varied depending upon the Gray G.S.M and Finished G.S.M and also on the dia of the fabric. All this parameters are suitable for G.G.S.M range 140~160 to get Fin.G.S.M 170~185 without Lycra Fabric.

Following tings are also considered incase of Dryer machine:

*  If fabric is more Redder than the standard one, then reduce the temperature.

*  If fabric is more Yellower than the standard one, then increase the temperature.

*  If fabric is more Bluer than the standard one, then increase the temperature.

All this data’s are practiced in mills which may vary factory to factory.

C. COMPACTOR  MACHINE: (M/C Specification)

PASSAGE DIAGRAM OF SANTEX-AG COMPACTOR MACHINE:

Working principle:-

The main object of compactor is to make the fabric surface smooth, to control the residual shrinkage, G.S.M and if required fabric width also. To control the residual shrinkage the fabric is previously shrinkage artificially by gathering of loops of knitted fabric and it is set by heat and pressure.  In tube compactor, the dried tubular knitted fabric is face to steam when it passed through the teflon coated conveyor belt. When a cotton fabric absorbs water, it swells and shrinks (particularly in length direction) because the absorbed water allows the cellulose chains to move relative stain free position. Then the fabric is passed through the expander. This m/c contain two compaction units to compact both side of the tubular fabric. Each unit contains a hot rotating cylinder, blanket which rotate in contact with the cylinder and Teflon cover .while passing the expander roller, the fabric is over feeded. The fabric is compacted with the pressure of blanket and Teflon cover while passing through the hot cylinder .Due to compaction stitch length is reduced. Then the fabric is passed through the counting device .Before packing, the fabric is inspected carefully.

Important parts:-

                          -Over feed roller.                         – Steam sprayers.

                           -Expander.                                  – cylinder (2)

                           -Blanket (2)                                – Teflon covers.

Operational parameter:-

    – Set the temperature at 110-139⁰C (as required)

     – Set the overfeed % as required; to increase GSM, overfeed need to    increase to a certain limit.

Function:

                 – Shrinkage control

                 – GSM control

                 – Width control

Special feature of Santex –ag Compactor :

–            Operating system is computerized.

–            Steam bar present which soften the fabric for compacting.

–            In compacting zone, edge & retard roller, compacting shoe and steel plates are present.

–            A pair of pulley present for fabric dia control.

–            Fabric G.S.M, shrinkage and dia control.

Parameters Used For Different Constructed Fabric :

N.B:  All this data’s are suitable for this machine only. All this parameters are suitable for. Grey G.S.M   range 140~160 to get Finished G.S.M 170~185 without Lycra Fabric

Following things are also considered incase of compacting machine:  

        * If fabric is less Reddish than the standard one, then increase the   temperature, reduce steam.

        * If fabric is less Yellowish than the standard one, then increase the temperature, without steam.

        *  If fabric is less Blueish than the standard one, then reduce the temperature, increase steam.

 N.B: Overfeed    Steam   G.S.M

Overfeed   Steam   Stretch    G.S.M

          Teflon speed (+) – More compaction

          Teflon speed (-) – Less compaction, G.S.M    because overfeed is less.

 N.B: ® To remove twisting the tube fabric may be heat set before compacting.

          ® For Viscose with Lycra more overfeed required.

All This data`s are practiced in mills which may varied factory to factory.

Garment: The garment production processing steps and techniques involved in the manufacturing garments for the large scale of production in industrial basis for business purposes is called garments manufacturing technology.

 Garments Manufacturing Process: Stepwise garments manufacturing sequence on M M Knitwear Ltd is given below:    Design / Sketch

Pattern Design

Sample Making

Production Pattern

Grading

Marker Making

Spreading

Cutting

Sorting/Bundling

Sewing/Assembling

Inspection

Pressing/ Finishing

Final Inspection

Packing

Despatch

This is the Basic Production Flowchart of a Garment. In advance some of the process can be added or removed.

Trims and Accessories:

Accessories can be divided into 2 groups:

Sewing Accessories

Finishing Accessories

Sewing Accessories:

02Interlining: Types

Woven/No-oven, Fusible/No fusibleGive strength the Garments as requirementShirts, Pants 03Lining: Support fabricTo support the shell or main fabricIn coat, Jacket

04Elastic: Made of Lycra (Spandex)To support the garments to keep with bodyBabies wear, kids wear, waistband of jacket, Vest or Pullover, Underwear 05Zipper: Contain Tape, Teeth, Stopper & SliderOpening and closing of a particular part of a garmentPants, Sweater, Jacket, Shirt

06Labels: 3 Types

Main, Size and Care Label

To express the company, brand, country name, to express care instructionsAll types of garment

Rib: Collar

To support the neck of garments wearer

Collar of knitted garments such as polo shirt

08Shoulder Pad: Made of foam, paper or plasticTo support the shoulder and giving a shape of a garmentCoat, Jacket etc 09Hook & Loop:

Commercial name VelcroOpening and closing of a particular part of a garment

Pants, Jacket, shoe

Finishing Accessories:

Size of Button: 18L, 24L, 32L1L(Ligne)=0.635mmTo attach the parts of a garmentsShirt, Pant, Sweater 02Snap: Kind of Button with two partsTo attach the parts of a garmentsShirt, Pant, Sweater

 03Shank Button: Kind of Button with hole with a Eyelet Hole

 To attach the parts of a garmentsJeans Pant, Coat 04Eyelets: Metal Part with hole Draw string can passTrousers, Sweaters 05Rivets: Metal Part with pinDecorative purposeJeans Pants, Shirt 06Hook & Eye: Metal PartsClose waist of pantsPants, Ladies Wear 07Draw String: Long Rope type item with stopperTighten a part of a garmentPant, Sweater 08Price Ticket: Also known as UPC (Unit per Price Code). It’s a paper metal tagMention the Price and Bar codeAll types of garments 09Collar Stand

Neck Board

Back BoardGive strength and shape of a garmentShirts 10Hang TagContain garments informationAll types of garments 11Pocket Flasher Used in Back PocketPants 

Quality plan of readymade garments:

 Sample preparation:

On receipt of inquiry from customer 2 to 3 sets of garments as per customers instruction shall first be made in the sample section and then send to the customer for approval. If the customer rise any objection of the sample shall be mended accordingly or again fresh garments is made and send the same to the customer for their approval. The process shall be reputed until approval for sample.

 Merchandising / Purchase / Store:

After approval of sample and receipt of confirm order from the customer required quantity of fabric and accessories shall be procured from agreed sources and stores in the warehouse of the company.

 Layer Placing:

Cutting in charge collect required quantity of fabric from the store department and layers of fabric from 50 to 200 (as per fabric type) shall be placed on the cutting table.

 Cutting:

After layer placing the fabric shall be marked as per measurement and buyer ratio and then cutting by cutter machine.

 Stitching:

The cut fabric shall be checked by quality inspectors then be distributor to the respective sewing operator and stitching shall be carried out as per customer manual.

 Trimming:

The stitched garments shall then be cleaned with the help of thread sucker as per customer’s requirement.

 Pre-Final checking:

After trimming, all stitching site of the garments shall be checked carefully for quality of stitching.

 Final checking:

Whether every aspect of the garments as per customer requirement is ok or not shall be checked carefully.

 Ironing:

After cleaning as per buyer’s requirement, the garments shall then be ironed in the ironing section.

 Get-up check:

As per customer requirements every aspect of the garments shall be checked.

 Tacking:

As per requirements necessary sticker shall be attached to the garments.

Poly packing: As per customer instruction the garments shall be packed in polyethylene bag.

 Assortment:

As per customer work order sheet the garments shall be checked in export cartoons.

Delivery: As per customers shipment schedule the garments shall be ship.

Garments Export Procedure:

 1.Price Quotation/Costing/Production Space:

This is the first step of exporting. Here, the Buyer asking for price, capacity and lead-time.

Costing of a garment depends on three issues:

Fabric Price i.e. Consumption of fabric per Garment

Accessories & Trimmings Cost

CM (Cutting & Making) Cost

The costing is made based on Tech-Pack sent by Buyer.

Tech-Pack (Technical Package)/Order Sheet/PDM (Product Development Manual):

 Garment Sketch: An image or sketch

BOM (Bill of Material) Sheet: Contain Accessories & Packing Type.

Size Specification Sheet: Contain size & shape of all parts & Accessories

Packing Detail: Contain package type, No of material in one package etc.

Hang Tag & Label Placement Details.

The Buyer may send a sample instead of Tech-pack. The price may fix after negotiation with manufacturer. The lead time (Time to complete an order) and production capacity also considered for order confirmation.

 02.       Order Confirmation:

After fixing the price, quantity and lead-time the buyer then send a confirmation order letter via email. This document only ensures the order is given to committed producer if terms & conditions are fulfilled.

 03.       P.O by Buyers:

P.O stands for Purchase Order. It is a Purchase document without Terms & Condition.

 04.       Sales Contract:

It’s also known as Dummy L/C. Before Maturity of Master L/C the producer may need money to buy raw material, for that reason this document works as L/C. Both side confirmation are needed to open this document

05.       Master L/C:

It is the guarantee of payment to the producer from buyer with terms & condition. The most secured process of payment making. Buyers Bank and Producers Bank both handles the L/C. It is open for large volume of goods.

 06.       T&A (Time & Action) Calendar:

The total Action Plan related with an order such as Raw material and Accessories booking, Back-to-Back L/C opening, Worker Training, Target fixing for daily production etc. For less lead-time more line setup P.P Meeting arranging

 07.       Fabric & Accessories Booking:

After calculating Raw material & Accessories demand producer need to book them in respected countries such as china.

 08.       Back-to-Back L/C Opening

It requires importing raw material. Buyer may fix it or not. It needs to open ASAP

 09.       Sampling:

Manufacturer for Buyers approval makes samples. Samplings are 5 types:

 a)      Fit Sample: Made with available Trims & Fabrics. It requires when Buyer need to check the ability of manufacturer to produce the garment. Measurement is the key factor of this sample because it is approved through inspecting by wearing a Dummy.

 b)      P.P (Pre Production) Sample: It is made with required fabric & trims Size and shape also maintain hardly. Without approval this sample by Buyer the Production cant is run. A swatch Card/Board also need to send which contain fabric sample, Trim sample.

c)      Production/Top Sample: During production random product is select and sends for approval of buyer. The buyer’s complains can be handled properly. It ensures least amount of faulty garments

 d)     Garment Test Sample: This sample is sent to Multinational Testing Firm for testing. Generally buyer fixes the testing firm.

 e)      Shipment Sample: Before shipment the Buyers QC (Quality Controller) test the garment by random choosing from the cartons. If every sample overcomes the tests the garments get permission for shipping to the buyer.

 10.       Fabrics & Trim in-house:

After receiving the fabrics and trims producer need to check them correctly

The quantity, desired quality and color of fabric is considered for inspection

Faults are needed to mark and inform the producer as well as buyer immediately

Similar shade fabric rolls must be separate for reducing defected garments making

The accessories and fabric must be sent to buyer (or buyers local office)  for approval

 11.       P.P (Pre-Production) Meeting :

This meeting is essential before production. Generally the Merchandiser, the Production Manager, Cutting Master, Pattern Master and QC (From factory and Buyer) are present in PP meeting. Everybody present the problems and aspects of the production and information related to the order. Merchandiser or respected person will solve or take steps to solve the problems.

 12.       Marker Making & Cutting:

Here marker is designed through CAD software with less amount of fabric wasting. Then the fabric is spread considering same color in one Batch .The challenge of cutting Master is to cut the fabric separately according to shade variation.

 13.       Numbering, Bundling & Sorting:

After cutting the cut fabrics are numbered, bundled and sorted for next step

The these bundled fabric are sent to sewing section

 14.    Production Line Setup:

The production managers then setup the production line for the production. It is fixed during P.P Meeting. It is important to produce more garments in least time

 15.       Bulk Production:

The cut parts of garment then sewn in different sewing line. Every line prepares a single part of garments, and by moving these parts the final garments can be obtained. More floor space required for more production.

Daily production report must be submitted to Merchandiser/PM for maintaining production according to the delivery date. The finishing and packing is done.

 16.       Inline Inspection:

Its very important inspection for garments to increase profit. In every production line one QC is required for checking the garments are sewn properly or not, the measurements are accurate or not. If any problem found the QC then send to the responsible operator to modify the faulty garment.

 17.       Sea Vessel/Cargo Booking:

When production is near to end and with confirmation of buyer the producer then gives a booking for sea vessel. Buyer may fix the logistic firm or not

 18.       Final Inspection Booking:

Before shipment the producer need to invite the buyer’s QC for final inspection. At least 7 days before the invitation must be sent.

 19.       Final Inspection:

The buyer’s QC the check the garments from the lot of cartons. He the choose number of cartons randomly then unpack. He may check 5-10 or more samples of garments and verify. If any problem found he then inform the buyer and buyer will take any decision. If everything is all right he will approve and the goods the ready for shipment.

 Multinational Testing Firm:

 Multinational Testing/ Inspection/ auditing firm is renowned firm all over the world. The test garments sample in different category and then publish a KPI (Key Performance Index). After proper testing and if all parameter fulfilled the requirement they submit an IC (Inspection Certificate) to the Producer.

Famous Testing Firms are following:

SGS

ITS (Intertek Testing Service)

Bureau Veritas

 Carriers:

 The carriers are the company, which transport small goods or documents in any part of the world as soon as possible

Some Carrier Name:

DHL

Fedex

UPS

TNT

Skynet

Aramex

 Logistic Firms:

 They are the firms who transport the bulk goods to desired country by ship. They receive the IC from the producer and submit a Bill of lading.

Some famous logistic firms are:

Maersk Logistic

APL Logistic

MGH

Kuhen & Negel

Export Document for Claiming Payment through L/C:

 BL (Bill of Lading)

Packing List: The list of no of carton and no of garments in a carton

Commercial Invoice.

WATER:

 Water is supplied in different sections continuously by using submersible and centrifugal pumps.

 BOILER:

 Boiler is mainly used to produce and deliver steam to different section as required. In Alim Knit BD Ltd two boilers are used to produce and deliver steam to different section.

COMPRESSOR:

 Compressor is mainly used to deliver compressed air to different section as  required. In Alim Knit BD Ltd three compressors are used to produce and deliver compressed air to different section.

 Specification:

Name                           :           BOGE

      Nos.                             :           03

      Capacity                      :           774 lt air compression / sec

      Origin                          :           Germany

Source of Utility:

Electricity                    :           PDB & Generator

Gas                              :           TITAS

Water                          :           Pumps

Compressed air           :           compressor

Steam                          :           Boiler

 Water Treatment Plant (WPT):

Water for a textile plant may come from various sources.  But this water can not be used directly in textile processing because it contains various salts. These salts are mainly the carbonates (CO₃^2-), Hydrogen carbonates or bi-carbonates (HCO₃^–), Sulphates (SO₄^2-) and Chlorides (Cl^–) of Calcium (Ca²⁺), and Magnesium (Mg²⁺). These are called hardness in the water. These must be removed though water treatment plant.

Effluent Treatment Plant (ETP):

The effluent generated from different sections of a textile industry must be treated before they are discharged to the environment. Various chemicals and physical means are introduced for this purpose.

                        Capacity          :           80m³/ hr

                        Cost                 :           Tk. 2.25 / K

Function of different Unit of Biological Effluent Treatment Plant (E T P):

 ♦Screening unit: It works like a filter. By filtering waste water, it removes threads, pieces of fabrics, small metal pieces etc. In this unit a rotating brush is used for clean the pores if screen. The brush rotates periodically.

 ♦ Storage and Homogenization tank:

Different waste water from varies process is stored and makes a homogeneous mixture by mixing different concentration of waste water.

♦ Neutralization tank:

Neutralization of waste water is performed by dosing 98% H₂SO₄ as required to control the PH

Of waste water PH range 6.5 to 7.5.

 ♦ Distribution tank:

It distributes the water to the biological oxidation tank. Continuous aeration is supplied here. Antifoam is dosed here to control the foaming in the oxidation tank.

 ♦ Biological oxidation tank:

It is the heat of E T P. The entire harmful chemicals are damaged here by breaking their bonds. This is done by bacteria. To ensure the proper function work and growth of bacteria, few conditions must be maintained.

 ○Temperature              : 35º to 37º C

○ PH   (Maximum)     : 6.5

○ Dissolved oxygen    : 4 PPM

 ♦ Sedimentation Tank / Biological feeding tank:

Treated water is overflowed here from oxidation tank. Decolourent is used here to destroy the color of waste water.

 ♦ Settling tank / Sedimentation Basin:

A tank or basin in which waste water is held for a period of time, during which the heavier solids settle to the bottom and the lighter material will floats to the water surface. In this tank sludge is immersed and the harmless water is discharge to ponds, Land, river etc.

 ♦ Sludge Thickener:

Sludge taken here from clarifier. Polyelectrolyte is dosed coagulate the sludge. After one hour of

Polyelectrolyte dosing aeration is stopped and fresh water discharge to drain when sludge is taken. The thickened sludge is transferred to the sludge thickener bed.

♦ Sludge Thickener bed:

Here sludge is dried which is used as good fertilizer as well as fuel of brick field. Sludge is dried under the sunlight.

 Chemicals Used in ETP:

• Ferrous-Sulphate-(FeSO₄-7H₂O)
• Sulphuric-Acid (H₂SO₄)
• Lime
• Polymer
• Sodium-Hypo-Chloride (NaOCl)
• Urea-Fertilizer
• TSP
• De-color

Required Chemical of Biological E T P:

 H2SO4:

Function: Neutralize the waste water controlling the PH. It is auto dispensed in the neutralization tank.

 Polyelectrolyte:

Function: Used for sedimentation / sludge coagulation and also killing bacteria.

 Antifoaming Agent:

Function: Used for reduction / controlling foam. It is used auto / manually in the distribution tank.

 De-colorent:

Function: Used for removing color. It is used auto / manually in the sedimentation feeding tank.

 Sodium Hypochlorite:

 Function: It is used to kill the harmful bacteria. It is used in the biological oxidation tank.

 Product Quality Checked:

• Biological Oxygen Demand (BOD)
• Chemical Oxygen Demand (COD)
• Total suspended solids
• Total dissolved solids
• Color
• pH       etc.

Effluent Analyzing Report:

 Remarks: Waste water from processing industries e g. Dyeing , Printing , Finishing and washing causes great harmful effect on our environmental, As a result agricultural land loses its fertility, natural water becomes polluted aquatic life is destructive and crops are damages.

So, it is important to control ETP plan.

Introduction:

 Mondol Knit Tex Ltd is a big project and so of course having a vast project of utility service. Here the total account of utility facilities is available. The utilities are

a)                              Water

b)                              Gas

c)                              Electricity

d)                             Compressed Air

e)                              Steam.

WATER

Water treatment plant:

(Water Softening Method – Base Exchange Process)

 Source of water is deep tube well.

Production capacity – 80 m³ /hr = 1920000 liter/day

Actual Production – 1500000 liter/day

Required water – 1300000 liter/day

Width – 15´

Height – 6’Diameter – 6´

Height – 15´Diameter – 6´

Height – 15´Salt reqd:

190 kg/day/tank

Regeneration time 1.30 hrCapacity360 Ton  SourceNatural source

Deep tube wellRaw Water TankFilter Tank (1)Filter Tank (2)

 ELECTRICITY

 Gas Generator is used for supplying electricity for the Production & office of the Mondol Knit Tex Ltd

Total power produced by Gas Generator – 945 KW = 1134 KVA

Factory (Dyeing & Knitting) Power Needed for Installation – About 1200 KW

Factory (Dyeing & Knitting) Power needed at running stage – About 720 KW

Power Needed for Office – About 250 KW

Specification of Gas Generator is given below:

 Source of Power used for Garments – DESA

Power Capacity – 750 KVA = 900 KW

There is a diesel Generator in the industry.

Capacity of Diesel Generator – 800 KW

Specification of Diesel Generator is given below:

COMPRESSED AIR

 Compressed air is produced by air compressor.

There are two air compressors for producing compressed air.

Specification of the air compressor is given below:

 STEAM

 Steam is produce by Boiler.

From the Water Treatment Plant, water is stored in a reserve tank and from there water goes to boiler & steam is produced.

 Specification of the Boiler is given below:

 GAS

 The source of Gas is TITAS GAS LTD.

The gas is supplied to gas generator or different section (Boiler- for heating water) from the main line of the TITAS GAS LTD.

Sources of Utility:

Electricity                    : PDB & Generator

Steam                          : Boiler

Water                          : Pump

Compressed air           : Compressor

Gas                              : TITAS GAS LTD.

 Remarks:

The utility systems of Mondol Knit Tex Ltd are great. There is a skilled manpower group of engineers and other technical staffs to look after these utility services. They have to remain aware of solution on a great sense of responsibility for any type of problem due to utility supply.

Maintenance:

The act which is done to Keep the factory plan equipments machine tools etc. in an optimum working condition, minimize the break down of m/c’s  to improve Productivity of existing m/c tools and avoid sinking of additional capacity and to Prolong the useful life of the factory plant & machinery is called Maintenance.

 Objectives of Maintenance:

• To Keep the factory Plants, equipments, Machine tools in an optimum working condition.
• To ensure specified accuracy to product and time schedule of delivery to customer.
• To keep the downtime of Machines to the minimum thus to have control over the production Program.
• To Keep the Production cycle within the stipulated range.

Preventive Maintenance:

In Mondol Knit Tex Ltd. the Preventive Maintenance is a predetermined routine activity to ensure on tome inspection or checking of facilities to uncover conditions that may lead to Production   break downs or harmful depreciation.

 Break down Maintenance:

In this case, repairs made after the equipment is out of order and it can not perform its normal functions.

 In Mondol Knit Tex Ltd follow the above two types Maintenance.

 Maintenance of all Machines in Routine Basis per Week:

9 am to 11 amMondaySqueezer M/c ,Dryer M/C

8 am to 11 amTuesdayLab Dyeing Machinery & Turning M/C10 am to 12 amWednesdayBangla Dyeing M/C9 am to 11 amThursdayCompactor & Heat setting M/C8 am to 10amFridayUtility Lines, Sub-station Compressor, Air Cooler, Pump House, Trolleys.7 am to 10 am

 Manpower set up for Maintenance:

 For electrical Maintenance:

Per shift:

♦ B Sc. Engineer – 1

♦ Diploma Engineer – 1

♦ Senior Technician – 2

♦ Junior Technician – 4

For mechanical Maintenance:

Per Shift:

♦ B Sc. Engineering – 2

♦ Diploma Engineering – 3

♦ Senior Technician – 1

♦ Junior Technician – 4

 Maintenance Tools & Equipments and their functions:

 1. Combination tools (Spanner)

Function: Tightening & Loosening of Nuts & bolts

 2. Socket Ratchet set

Function: Tightening of Nuts & bolts

 3. Slide Range

Function: Tightening & Loosening of Nuts & bolts

 4. Pliers

Function: Tightening & Loosening of Nuts & bolts

 5. Pipe threat Cutting Tools

Function: To Cut the threat in Pipe.

 6. Bearing Puller

Function: To assist the Opening of bearing from shaft.

 7. Pipe Range

Function:  Tightening & Loosening of Pipe Joint

8. Pipe Cutting Tools

Function: For Pipe Cutting.

 9. Hole Punch

Function: Punching the hole.

 10. Divider

Function: For circle marking on metal & wood

 11. Easy Opener

Function: To open the broken head bolt

 12. Heavy Scissor 

Function: Cutting of gasket & steel sheet.

 13. Oil Can

Function: Oiling of moving Parts.

 14. Drill M/C and Drill bit.

Function: For Drilling.

 15. Grease Gum.

Function: For greasing of moving Parts of M/C.

16. Girding M/C

Function: For grinding & Cutting of mild steel.

 17. Welding M/C

Function: For welding & Cutting.

 18. File

Function: For Smoothing the Surface.

 19. Hammer

Function: For Scaling & right angling.

 20. Hacksaw blade.

Function: For metal Cutting.

 21. Handsaw (wood)

Function: For wood Cutting.

 22. Grinding Stone.

Function: For smooth finishing

 23. Grinding Paste

Function: For easy Cutting of metal

 Maintenance Procedure:

Normally Preventive Maintenance is done here. During Maintenance Procedure following Point should be checked:

 ♦Maintenance: Mechanical

♦Machine: Dyeing M/C

 ♦Maintenance: Electrical

♦Machine        : Dyeing

 Remarks: When I was trainee of Alim Knit BD Ltd then I saw that the Maintenance staffs and overhead of Maintenance department were skilled enough and Efficient.

 CONCLUSION:

 There is large difference between the theoretical knowledge and practical experiences. This is truer in case of the study of Textile Engineering. Industrial attachment or, Industrial training is an essential part for textile education because it minimizes the gap between theoretical and practical knowledge. This Industrial training increases our thought a lot about textile technology. It also helps us to know a lot about industrial production process, machineries, and industrial management and made us suitable for industrial life. Besides it gives us the first opportunity to work in industry. So we can say industrial attachment prepare us for the expected destiny of practical life.

I have completed my industrial attachment from Mondol Knit Tex Ltd. During my two-month long industrial training at Mondol Knit Tex Ltd I got the impression that this factory is one of the modern export oriented dyeing knit garments industry of our country. This factory does not compromise in case of quality. So, they have established on-line and off-line quality control of each product. Besides, they also use the good quality yarn, dyes and chemicals in their production process. Due to this, it has earned a “very good reputation” in foreign market for its quality product over many other export oriented textile mills. It has very well educated and technically experienced manpower to get rid of any defect in production process. It has also a good organizational hierarchy.

Some are parts:

Report on Alim Knit BD Ltd (Part 1)

Report on Alim Knit BD Ltd (Part 2)