Industrial attachment of acs textils ltd Bangladesh

As a student ofTextile Engineering Department, the target of should be to know the production process, management system, marketing, production planning, quality assurance, compliance,

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

ACS TEXTILES (BANGLADESH) LTD.

ACS TEXTILES (BANGLADESH) LTD

Tetlabo, Rupgonj, Narayangonj

Abstract

The aim of industrial practice is to make us familiar with any kind of industry, the whole process going on the industry, its environment and also with the management system of

the industry As a student ofTextile Engineering Department, the target of should be

to know the production process, management system, marketing, production planning, quality assurance, compliance, mechanical-electrical department etc It is because of the fact that to run any industry not only production department is obvious but also the capability of managing the whole system is an obvious matter It is also a responsibility

of an engineer is to develop the ongoing process into a better system to cope with the present competition Thus a diversified challenge emerges in front of the manufacturer and other organizations With a view to overcome this consequence a new generation of engineering graduates with leadership skills and management capabilities altogether are in demand

We the students of Textile Engineering Department were sent to different industries and assigned to different tasks We were assigned toACS Textiles Bangladesh Ltd This

report is a presentation of our experience in the Woven dyeing production

Acknowledgement

All praises to Almighty Allah alone, the Most merciful and the most compassionate and His Holy prophet “ Muhammad “ (Peace be Upon Him) the most perfect and exalted one among and of ever born on the earth, who is forever touch of guidance and knowledge for the humanity

I would like to thank Prof SAYED FAKRUL HASAN MURAD, Dean & Head of the department of Textile Engineering, SOUTHEAST University whose directions have taken me to my destination I am also grateful to Dr A.B.M FAYSAL, professor,

department of Textile Engineering, Primeasia University for his scholastic guidance,

constructive criticism, painstaking help constant inspiration and advice from the very

beginning till the completion of this work

I also want to express my gratitude and appreciation to Md Anwar Hossain , Assistant

professor, Wet Processing Technology, SOUTHEAST University, for his encouragement,

valuable suggestion, and guidance and decision which able to help to do this Industrial attachment successfully

This internship report is not the result of individual effort It is a result of wonderful team-work

We are really thankful on Md Abdullahel , Lab Manager and Mohammad Saiful Azam ,

Assistant manager(production),Mr Md Johrul Kabir , General Manager of Admin &

HR, of ACS Textiles Bangladesh Ltd who gave us the approval for making of that regard

We are also really thankful on Mr Tariq Raja, manager of pre production processes Mr Niyaz, manager of weaving, Mr Ramjan, general Manager of weaving at ACS Textiles Bangladesh Ltd to help us for getting information about our internship

We are thankful to all those who supported us and provide us great help for completion

of this task We have tried our level best to prepare this event with high level of accuracy but no one claim to perfect other than Almighty Allah

Production planning &

sequence operation

Sequence of operation 26

Introduction & Basic procedure of

planning & control

27

Scouring & Bleaching 37

One

INTRODUCTION TO ACS TEXTILES (BANGLADESH) LTD

Executive summary

This report is the result of two months internship During the internship it was required

to study the organization, department of the organization and critically relate the theoretical aspects of the Textile to the practical situation

ACS Textiles Bangladesh Ltd operates throughout the world with over 6000employees

as part of ACS Textiles Bangladesh Ltd team ACS collection has a wide selection of quality 100% cotton, CVC, Cotton -polyester, competent professional staff, a team

of talented merchandisers, excellent supplies & support services, and state-of-the-art technology is the driving force behind ACS’s phenomenal growth in the past years ACS has expanded its operations to include the Internet, and has taken advantage of the variety of international trade facilitated by the Web Now ACS is state-of-the-art client/server technology for its market information processes to coordinate its network

of global buyers and agents around the world Environmental Organizational and the individual challenges which are to face by the department of “ACS Textiles Bangladesh Ltd.” The motive of joining the ACS is to have an exposure of textile sector and potential to avail a sound and promising career There are no formal union in ACS Textiles Bangladesh Ltd

Methodology of internship

Every research program should follow some basic form of procedures However mainly this report is written on the basis of experience gathered during the period of Internship We carefully observed the various activities of different department,

especially fabric section of ACS Textiles Bangladesh Ltd A qualitative research is used

to conduct this study

In order to make the report more meaningful and presentable two sources of data and information have been used widely Both primary and secondary data have been used to prepare the report

Initial Conversation

Industrial attachment is the first step to professional life of student, especially of technical Side It’s an indispensable part of study a practically running processing technology of an industrial unit for a student In our university , processing machines are not in continuous running condition, so it would only provide demonstration of mechanical features & processing technology of the material in accomplishment of the theory there of but not of the situational variables to achieve practical knowledge So two months industrial attachment program in a dyeing mill was arranged for us

Textile education can’t be completed without industrial training Because this industrial attachment program minimizes the gap between theoretical and practical knowledge and make me accustomed to industrial environment I got an opportunity to complete

two month long industrial training in ACS Textiles Bangladesh Ltd., which is a 100%

export, oriented Weaving Industry It has well planned & equipped fabric and Yarn dyeing-finishing units in addition to facilitate weaving & woven fabric manufacturing

The rationale behind the existing structure and future expansion of ACS Textiles

Bangladesh Ltd is to capture value-added at each stage of the textile manufacturing

process

Despite Bangladesh’s lack of indigenous cotton production capacity.ACS Textiles

Bangladesh Ltd has leveraged Bangladesh’s labor cost advantage and export

competitiveness to the Maximum

Objectives of Internship

This intern paper has been prepared for fulfilling the following specific objectives:

 To enlarge the dimension of knowledge regarding fabric manufacturing as well

as others

 To define and evaluate the performance of fabric manufacturing Department as well as others

 To observe the effectiveness of fabric manufacturing as well as others

 To get the additional knowledge in different sections of the organization

 To interchange opinions of the officials regarding their organization

 To know the economic condition of Bangladesh through ACS Textiles Ltd of Bangladesh

 To identify the difference between theory (what we have learned from the text) and practice (what is really happened)

 To compare the improvement of the present condition of the ACS Textiles Ltd with the previous years

 To mention the problems that the ACS Textiles Ltd face in the process of production and delivery of garments & give some suggestions

 To identify the strengths, weaknesses, opportunities and threats of the ACS Textiles Ltd

ACS Textiles Bangladesh Ltd. symbolizes trust and quality in Home Textile

Products manufacturing across Bangladesh A 100% British investment, ACS takes

pride in its state-of-the-art composite manufacturing facility with weaving, dying, printing, finishing and packing services which are one of the largest of its kind in Bangladesh

ACS Textiles is a quality conscious company Based on sound policies to ensure the finest quality of the products, the manufacturing processes are compliant with ISO 9001: 2008 standards producing top quality bedding and linen sheets ranging from 200

- 400 thread count percale sheets to satin sheets and duvets, Egyptian and organic cotton and yarn dyed fabric A recent addition to our products is a wide range of towels for all kinds of use

ACS Textiles BD Ltd has come a long way since its establishment in 2004 and, over the years has built a global reputation of excellence matched by only a few others in the textile industry

The manufacturing facility employs over 6000 people and averages about 30,000 pieces

of superior quality textile products per day These high quality ACS Textile products have found their market in European countries such as Italy and France and in Scandinavian Europe namely Sweden, Holland, Denmark and Norway 2008 saw ACS expanding its export clientele to include Australia and North America as well

Our excellence is recognized not only by our customers but also by official authorities for quality standards – Okeo-Tex standard 100 certification further endorses our unswerving commitment to quality

Name Of The Industry:ACS Textiles Bangladesh Ltd

Type of the industry: A foreign invested 100% export oriented home

Our Mission is to be the market leader of home linen (bed linen and towels), by the year

2015 To provide a healthy, safe and competitive work environment for our employees and reward them justly for their efforts

ACS as we see:

Established in 2004 gc and located 16 kilometers from the centre of Dhaka city and on the main road to Dhaka – Shylethighway.ACS represents the aspiration of about 153,546,896 inhabitants in Bangladesh country The factory is a magnificent landmark

in the middle of beautiful valley surrounded by lake, and is only 20kms That is one of half hour drive away from Dhaka airport

Corporate structure:

ACS Textile Bangladesh Ltd Is an industry with an investment of 50 million US dollars and registered with British high commission as 100% British Investment Company All members of the board of directors are British citizen having the separate business in the name of pin mill textile, a company of last 50 years with turnover of 10 million GBP

Corporate culture:

Continuous improvement is an integral part of our corporate culture Nurturing and effectively integrating “ People, Management and Development” is the key focus where corporate culture gives empowerment of employees in taking initiative, involving in decision making, interacting for collective bargaining, self- enhancement opportunities and bringing in changes essential to meet business strategy The management is strongly committed to social compliance issues Our policies strictly prohibit child labor, forced labor, and monetary penalties as a form of disciplinary action We believe in social accountability and thus ACS is involved in development projects in Bangladesh

Quality Control:

ACS maintains stringent quality control practices and conducts computerized testing processes to determine strength of yarn, density of cloth and fastness of colors Quality control processes are set up at every stage of production with the strictest of standards

to adhere to; ensuring all production is of the highest quality

The quality control personnel conduct pre-inspection of goods at different stages to maintain international standards and to screen out defective products at the onset The policy that ACS Textiles (BD) Ltd follows is:

o Provide consistent quality products and services with on time delivery to achieve and enhance customer satisfaction

o Provide a safe & conducive working environment to employees and encourage their involvement in the never ending effort to improve quality of our products and services

o Minimize environmental impact through prevention of pollution, solid & liquid waste management and conversation of natural resources

o Promoting awareness and importance of Quality & Environment among our employees, the community and our suppliers

o Ensure continual improvement and compliance with customer & relevant environmental legislation regulations

Name : ACS Textiles Bangladesh Ltd

Address : Tetlabo, Rupgonj, Narayanganj,

Bangladesh Tel:

+880-2-7452039, +880-2-7452040,

+880-2-7450724, +880-2-7450725 Fax:

880-2-7450786

E-mail : info@acstextiles.com

Legal status of company : Limited company

Year of establishment : 2004, 13th April

Sponsor

Banks : Southeast Bank

Dilkusha commercial area Dhaka-1000

Dutch Bangla Bank Mothijhil commercial area Dhaka-1000

Bank Al-Falah Ltd

Rajuk Avenue Mothijhil commercial area Dhaka-1000

Insurance :American Life Insurance Company

ALICO Building, 18-20 motijhil C/A P.O Box 9, Dhaka-1000,Bangladesh Tel: +880-2-9561791, +880-2-7160025 Fax: +880-2-9558682

E-mail: american.life@alicobd.com

Total land area :5,50,000 square fetes

Production capacity :1,05,000 meters per day

Total employees :Approx 6000

Total consumer :Above 60

Annual capacity :31,00000 meters

Standard certification program :BSCI global standard (for client: V&D

OEKO-TEX standard 100 Test no.07KA.56878 ISO certification (in the pipeline) SA-8000 certification (in the pipeline)

Membership :Bangladesh Textile Mills

Association(BTMA) Membership no 0002-0179-0401

Export Promotion Bureau (EPB) Enrolment no TM12

Narayanganj Chamber Of Commerce & Industry

Registration no 465 of book 5

Foreign Investors chamber of commerce & Industry

Registration no 122 of book 2

Valid Licenses and Certificates : Factory license

Fire license Boiler license Trade license Export license Import license Environmental clearance license Income tax certificates

Group insurance certificate Acid using license

Factory achievement :

National Export Trophy 2008-2009

C Weaving Preparatory& Design

LOBLAWS

HBC

3rd shift : 10.00 P.M – 6:00 A.M (shift C)

General shift : 9:00 A.M – 6:00 P.M

LAY OUT OF WOVEN DYEING

Final Inspection Yarn Dyeing

Two

PRODUCTION PLANNING & SEQUENCE

OPERATION

Introduction and Basic Procedure of Planning and

Control:

A planned work brings success Without planning nothing is completed within

the required time So planning has its own importance which is intolerable, “Planning” gives a scheduled task and ‘Control’ completes it successfully But production planning

and control is not an easy task So BEXIMCO has a self-sufficient and high-performance

department called “Production Planning & Control” Its Basic working procedure is as

follows-

1 Taking orders from marketing division

2 Analyzing the orders

3 Planning for weaving the fabric

4 Planning for dyeing the fabric

5 Planning for finishing the fabric

6 Cost analysis & load time

It is only a basic procedure It may change according to the type of order

Sometimes, order is places only for finishing the material or only for dyeing the white goods Then some steps are omitted from the planning procedure

1 Taking orders from marketing division:

BEXIMCOmarking division supplies Fabric Orders to the BTL Planning and control division by a special format

2 Analyzing the orders:

This section analyzes the orders according to buyers, Order Quantity, type of orders (i.e type of fabric, color to be dyed etc.), delivery date etc Then it selects which M/C to use, no of M/C to use, time required for production etc This section plans for required quantity of fabric need to be dyed Dyeing balance, RFD (Ready for delivery), RFD balance, delivered fabric and delivery balance

3 Planning for weaving:

This section plans for weaving production It selects machine for weaving the fabric for specific type of fabric, type of yarn used, required GSM, width etc It also gives

delivery data for woven fabric It also places orders for buying of yarn from spinning mills by a specific schedule

4 Planning for dyeing the fabric:

Production planning for dyeing is called ‘Batch Plan’ According to the batch no and color, width, style and construction the batch plan is made For easy understand this section gives some ‘T’ Cards ‘T’ card are serialized according to the priority of delivery The batches and ‘T’ cards also serialized as to dye light shade at first and lastly the dark shades, so that faulty shades can be converted to dark color later

5 Planning for finishing the fabric:

Finishingschedule is same us the dyeing After dyeing the material goes to the finishing section with the process rout card Finished data is written to the rout card and is informed to the planning section

However, this section always enforces to all the departments to finishing all the works within the delivery time given by the buyers This section delivers materials to the garment factory in the lead time Thus it plays a very important role in the success of the company

Three

PREPARATION UNIT

Singeing and Desizing

It is a process to remove dirt, dust, husk, leaf from the fabric and transfer it into

permanent white by chemical treatment in cold condition

Process Requirement:

Equipment Used:

OSTHOFF singing and Desizing machine

Key Accessories:

Fork lifter, wooden plate, sewing machine, A-frame or batchers etc are the key

accessories for singing for white cotton fabric and special yarn dyed fabric (PC-015)

In addition to the aforesaid tools mixing tank, reserve tank, pH meter polythine paper, rotation station, hand gloves, eye protecting glass, clip/finger clip etc are some additional tools/ accessories used for the following fabric process-

 For all cotton color fabric

 For all cotton color peace finish fabric

 Singing and Desizing for yarn dyed fabric and PC / CVC fabric

 Singing and cold bleach for PC / CVC fabric

 Only Desizing for PC / CVC / yarn dyed peach finish fabric

 Singing and cold bleach for Bull-Twill (Heavy fabric)

Material and Chemical used:

Steam, compressed air, water, natural gas, Desizing agent, wetting agent, sequestering agent and dearating

Singeing, Desizing and Cold Bleach recipe :

Follow the bulk recipe by fabric type

Natural gas for burner, steam, compressed air, water N/A

Follow the bulk recipe by fabric type

steam, compressed air, water

Sequestering Agent Dearating agent Desizing agent

Follow the bulk recipe by fabric type

Fig: Singeing &desizingmachine

 Production Procedure:

Machine set-up for singing and desizing for all cotton color fabric:

Reserve chemical (1000-2000)liter 1000L 1000L

Flame intensity (1-20) m.bar 11-13 m.bar 11-15 m.bar

Pressure (1.3-1.5) bar (1.2-2) bar (2-2.5) bar

Fabric position Face or Bake Face Face

A-frame position Set nicely Set nicely Set nicely

Machine set-up for singing for white cotton fabric and special yarn dyed (PC-015) fabric:

Machine set-up

Burner position 1, 2, 3 3rd -

Flame intensity (1-20) m.bar (14-18) m.bar -

Pressure (1.5-2) bar (1.8-2) bar (1.5-2) bar

Fabric position Face or Bake Face Face

A-frame position Set nicely Set nicely Set nicely

Machine set-up for desizing for all cotton color peach fabric:

Pressure (1.5-2) bar (1.8-2) bar (1.5-2) bar

Fabric position Face or Bake Face Face

A-frame position Set nicely Set nicely Set nicely

Machine set-up for singing desizing for yarn dyed fabric and PC / CVC fabric:

Reserve chemical (1000-2000)liter 1000 L 1000 L

Flame intensity (1-20) m.bar (14-16) m.bar (11-15) m.bar

Pressure (1.5-2) bar (1.8-2) bar 2 bar

Fabric position Face or Bake Face Face

A-frame position Set nicely Set nicely Set nicely

Machine set-up for singing and cold bleach for PC / CVC fabric:

Machine set-up

Burner position 1, 2, 3 2nd position -

Chemical level (700-1400) L (750-800) L (1000-1200)L

Reserve chemical (1000-2000)liter 1000 L 1000 L

Flame intensity (13-16) m.bar (13-16) m.bar (11-15) m.bar

Pressure (1.3-1.5) bar (1.8-2) bar 2 bar

Fabric position Face or Bake Face Face

A-frame position Set nicely Set nicely Set nicely

Machine set-up for desizing for PC / CVC yarn dyed peace finish fabric:

Reserve chemical (1000-2000)liter 1000 L 1000 L

Fabric position Face or Bake Face Face

A-frame position Set nicely Set nicely Set nicely

Speed, Flame

intensity, Burner

position, Padder

pressure

Reference are given in parameter set table

Machine set-up for singing and cold bleach for Bull-twill:

Machine set-up

Chemical level (700-1400) L (750-800) L

Reserve chemical (1000-2000)liter 1000 L

Fabric position Face or Bake Face

A-frame position Set nicely Set nicely

Bull-l

T.C Pocketing/Voi

Check list before production:

Operator must check the following before starting production of the fabric named

bellow:

o All cotton colored fabric = Singing &Desizing

o All cotton colored peach finish fabric = Desizing

o Yarn dyed & P.C/C.V.C fabric = Singing &Desizing

o P.C/C.V.C fabric = Singing & Cold bleach

o P.C/C.V.C / yarn dyed peach finish fabric = Desizing

o Bull-Twill / Heavy fabric = Singing & Cold bleach

o White cotton fabric & Special yarn dyed (PC-015) fabric = Singing

(Without Chemical)

Item to be checked:

o Machine parameters are set

o Manpower is available

o Chemicals are available

o All accessories are available

o Fabric Stitch with tape fabric is done

o Sewing thread (cone) is available

24 hours But in case of only singing of white cotton fabric and special yarn dyed 015) fabric the batcher need not to set into the rotation station In the rotation station the batcher rotates and the chemicals distributed equally in the fabric

The quality of the product depends on various parameters like the machine speed, temperature, pressure, flame intensity, chemical level burner position and pH value etc The operator must check the above parameter carefully during processing to avoid any defect

Product quality check:

During production the operator will check frequently the pH level of the solution by pH meter or litmus paper check The operator also check the cosmetic defect like projectile hairy fiber by paralelly looking at fabric, fabric position, crease on the fabric, fabric sewing and any other abnormalitic that can be detect by naked eye

Scouring and Bleaching

Material / chemical used:

Water , steam, compressed air, NaOH, H2O2, stabilizer, wetting agent, detergent,

sequestering agent, and deatering agent

A chemical solution is prepared for fabric processing as per recipe provided below:

Chemical composition (ml/kg of fabric) With conveyer

Scouring recipe for PC/ CVC:

After cold bleach recipe for all white fabric:

(ml/kg of fabric) with conveyor Light fabric