Industrial attachment of givensee group of industries ltd.

University education provides us vast theoretical knowledge as well more practical knowledge, despite of all these Industrial Attachment helps us to be familiar with technical support o

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

Givensee Group of Industries Ltd.

INTRODUCTION

By achieving practical knowledge it is possible to apply the theoretical knowledge

in the practical field For any technical education, practical experience is almost equality necessary in association with the theoretical knowledge.

The industrial attachment is the most effective process of achieving practical experience University education provides us vast theoretical knowledge as well more practical knowledge, despite of all these Industrial Attachment helps us to

be familiar with technical support of modern technology, suitability about various processing/operation stages

It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management,

production planning and control, production cost analysis, inventory

management, purchasing, utility and maintenance of machinery and their

operation technique etc The above mentioned cannot be achieved successfully

by means of theoretical knowledge only Industrial attachment makes us reliable and improves courage and inspiration to take self-responsibility

We had the opportunity to perform the industrial attachment with Givensee

Group of Industries Ltd During 42days (6-Weaks) long attachment, We studies the

man, Machine, material expects of the Batching, Dyeing section (Knit fabric), Finishing section, Quality Control, Lab, Knitting section, store & inventory control

of the mill According to my studies there we have prepared the following report and would like to present

We have prepared this report according to the guideline given by the University authority, which will lead to a strong guideline and milestone for our future

career

Object of Industrial Attachment

B Sc in Textile Technology is the combination of Theoretical knowledge along with the practical experience We as the Graduates of Textile Technology must acquire adequate practical knowledge to combat with the challenge that we will face in future This is why 'the mid-course' industrial training has been included in our academic curriculum

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 wet processing

Moreover we know about the man management technique We also learned about dyeing techniques and quality assurance system

CHAPTER-1

PROJECT DESCRIPTION

Company Profile

Introduction:

Hotapara Garments LTD.was established in late 2005 and is currently one of the largest

knitwear manufacturing factories in Bangladesh It has been exporting automatic circular

knitted items to North American and European retailers Its operations are spread over a floor space of more than 180000 sq Ft With a net export of over USD 12 Million in 2011, we are ready to support our customer with their new knitwear collections for the upcoming seasons Hotapara Garments LTD can produce various types of fabrication such as Single Jersey, Rib, Interlock, Pique, and Drop Needle, 2-Thread / 3-Thread Fleece and feeder stripe repeats

Ourdyeing section has capabilities of dyeing under atmospheric pressure in case of cotton fabric andalso it can dye viscose, nylon and polyester fabrics under pressure dyeing conditions Some ofour common product lines are T-shirt, Polo shirt, Knitted Jackets and bottoms

Hotapara Garments LTD has a successful record of customer satisfaction It is also a highly Compliant unit in terms of social standard It has a very strong quality management team, whoare continually reporting their finding to the board of directors This ensures our

commitment tothe customers on their quality requirement

Hotapara Garments LTD has a daily production capacity of 40,000 pieces of T-shirts, Polo shirts and other knitted items and its major raw materials such as yarn and accessories are sourced fromother group sister concerns such as Givensee Spinning Mills LTD and GivenseeGarment, Accessories LTD

Our Spirit:

Our Market base experience, research techniques and razor- sharp analytical skills have

enabled us to leverage opportunities in our existing and emerging markets

Our Vision:

To become the largest multinational embellishment corporate in garments Industry

Infrastructure:

Being one of the earliest composite units in Bangladesh, HGL has a very robust infrastructure in Terms of machinery, floor layout and space distribution The factory is well equipped with top of.The line machinery along with adequate a pares in order to ensure smooth operation and efficient performance

Factory Address BOKRAN, MONIPUR GAZIPUR

Head Office Givensee Group of Industries

House # 06, Road # 13 Sector # 03, Uttara Model Town Uttara, Dhaka, Bangladesh

Tel: 8932813, 8913802 8961936jkj

Mail: rubel@givenseegroup.com

Production Capacity 1.2 MILLIONE PER MONTH

Knitting Capacity 8000KGS PER DAY

Minimum Order Quantity 5000 PCS

Shipment lead time

associated with

60 DAYS

Knit Dyeing Section:

Store house for Dyeing & Chemicals

6.Waffle or Thermal Fabric

7.Terry Fabrics - blended or 100%

Cotton

8.Four track fancy design fabric Strip fabric

9.Three thread fleece 10.Heavy Jersey

Annual Raw Materials Requirement:

Production Capacity:

GARMENTS

Woven Items : 300,000 pcs per month

Knit Items : 800.000 pcs per month

Sweaters : 1,400,000 pcs permonth

TEXTILE Yarn : 900,000 lbs

Knitting : 240,000 kg Dyeing : 300,000 kg

Gazipur

4 ZAHINTEX INDUSTRIES 5 ZAHINTEX INDUSTRIES 6 Araishaprashad, Kaultia, Gazipur

6 ZAHINTEX INDUSTRIES 9 Bishia, Kuribari,

CHAPTER-2

MANPOWER MANAGEMENT

MANPOWER MANAGEMENT

Management System:

 Buyer sample is send to Responsible Management

 Matching is done by lab in charge

 Sample is prepared by Ass Dyeing Manager

 Sample is send to the buyer for approval

 Approved sample is returned and taken as std Sampleforbulk production

 Asst Dyeing Manager gives responsibilities to production officer

 Then production officer, with the supervisors start bulk production

 On line and off line quality check is dome by Lab in charge and A D.M

 After dyeing finishing in charge controls the finishing process with the supervision of production officer

 After finishing the material is checked by Ass Dyeing Manager

 Finally D.M checks the results with A.D.M and decision is taken for delivery

Shift Schedule:

Per shift is 12 hrs

1st shifts 8 am -8 pm

2nd shifts 8pm -8am

DEPERTMENT NO.OF EMPLOYEE

DYEING SECTION No of employee

Operator 20

CHAPTER-3

LAY OUT PLAN

CHAPTER-4

MACHINE DESCRIPTION

DYEING SECTION

• Total Dyeing Machine: 27

• No of sample Dyeing Machine: 12

• No of Bulk Production Dyeing Machine: 15

:KOREA : DNAT-400 : DONG NUM : 20000 : To reverse the fabric front side to back side

Machine Name Brand Model Origin Capacity /

Benefits of overflow winch machine:

1 Efficient washing effect

2 Less water consumption

3 Less temperature shocks when filling with cold water

4 Precise calculation of water consumption

Fully automatic function:

1 Automatic salt & soda dosing system

2 Automatic chemical injection system

3 Automatic heat exchanging process

Components of M/c:

1 Mixing tank:There is a tank in this machine Every chemical are used to put here Here all the chemicals, dyes & salt are mixing for delivery into machine

2 Unloading reel: The fabric is used to unload from the machine by this part The number

of unloading reel is equal to the number of nozzle in the machine It is rubber coated which helps to unload fabric easily

3.Monitor:It is situated at the right side of the machine The commands are shown in the monitor & the operators can work from these commands There are also some buttons for working properly & to obey these commands

4 Alarm Box: There is an alarm box on the upper side of the machine There are also some buttons to operate the machine & to stop the alarm

5 Three detectors:There are 3 detectors on the above of the nozzle are as follows:

a Temperature detector: It is at the left side between these 3 detectors which can detect the temperature of the main tank

b Fabric turning pressure detector: It is at the middle of these 3 detectors It can detect the pressure at which the fabric turning

c Atmospheric pressure detector: It can detect the atmospheric pressure of the main tank

6 Plain board:It is situated at the right side of the machine

7 Waterlevel:There is a water level to know the amount of water in the main tank

It does not give correct result but it can give an approximate result

Process Requirement:

Software used:

In this factory for total dyeing management usedSETEX – GERMANY

Key accessories used in this factory for pretreatment to complete dyeing are:

N.B:Fixing process is done during dark or deep shade

N.B: SAS: If shade% is more than salt is added before dyes add Sometimes salt is adding two

times in deep shade

DAS :If shade% is less then salt is added after dyes adding

Work instruction of Bulk dyeing Machine:

 At first should to clean the machine

 Should to check electrical connection of the machine

 Should to take the working description of daily work from shift operator,

 Senior production officer or production officer

 To take the fabric from supervisor of batch section according to

 Production plan +Batch lot No for coloration

 By observing the indicated program of the machine described abovethe fabric dyeing program sheet, should to set the program no kept @ computer memory attached with the dyeing machine

 Should to be kept/write down the batch no./program no./party

 Name/order ref./color name/into dyeing m/c/ comp memory

 Should to use the color into m/c

 M/c should to run /set by program no

 Dyes/chemical should to mix from the given chart /chart got from m/c

 During the running of program

 Coloration running according to the computer program of m/c

 Sample should to collect from the coloring processed fabric into m/c

 When computer panel program show sample

 To check shade, collected sample is sent to the lab,

 Water inside m/c is drained out if the sample is "ok" by lab

 Hot wash is done by filling the water inside m/c of the colored fabric

 After the drain out of water soft wash of the fabric is done using soft

 Wash chemical by filling water into m/c

 Then dyed /colored fabric is dropped from the m/c if s sent to the

 Dewatering section with batch card by trolley

Checklist before operation:

 Checking the program

 Machine set-up

 Fabric weight

 Fabric quality

 Yarn quality

 Collar design (Tipping/ solid)

 Rib designs (Normal/Lycra)

Lab Section

Wet Lab Machine

Machine name Brand Origin Model Serial no Test Name

Capacity (pot)

Qty

Spectrophotometer

DATA

Electronic Balance

Lab Dip Dyeing

Lab Dip Dyeing

Lab Dip Dyeing

Lab Dip Dyeing

Physical & Chemical Lab Machine

Machine

name Brand Origin Model Serial no Test Name

Test method

Qty

FOM71-98670116

Color Fastness to Perspiration

Knitting Machine Profile

Utility Section

Utilities & Supporting Equipment

Gas generator Austria 1064 Kw 3

Diesel generator UK 400 Kw 3

Gas boiler LC - 11 Taiwan

Air compressor USA 13 m3/hrs 11

Air dryer USA 13 m3/hrs 15

CHAPTER- 5

RAW MATERIALS

RAW MATERIAL

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 The EKCL always try to use high quality raw material to export high quality and world class product

Types of Raw material:

Chemicals& Auxiliaries

Agent

Thailand

29 Glauber Salt Electrolytes Singapore

CHAPTER-6

PRODUCTION PLANNING &

SEQUENCE & OPERATION

PRODUCTION PLANNING, SEQUENCES & 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 Esquire Knit Composite Limited’s has a high-performance department called "Production Planning & Control" Its Basic working procedure is as follows –

 Taking orders from marketing division

 Analyzing the orders

 Planning for knitting the fabric

 Planning for dyeing the fabric

 Planning for finishing the fabric

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 for planning procedure

Taking orders from marketing division:

EKCL marking division supplies Fabric Orders to the EKCL Planning and control division by a special format

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 to be knitted

(Order quantity + 6% of Order Quantity), knitting balance, fabric need to be dyed Dyeing

balance, RFD (Ready for delivery), RFD balance, delivered fabric and delivery balance

Planning for knitting:

This section plans for knitting production It selects machine for knit the fabric for specific type

of fabric, type of yarn used, required GSM, width etc It also gives delivery data for knitted fabric It also places orders for buying of yarn from spinning mills by a specific schedule

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 'ROUTE CARD.' cards "ROUTE CARD' cards are serialized according to the priority of delivery The batches and "ROUTE CARD ' cards also serialized as to dye light shade at first and lastly the dark shades, since faulty shades can be converted to dark color later

Planning for finishing the fabric:

Finishing schedule is same as the dyeing After dyeing the material goes to the finishing section with the batch plan Finished data is written to the batch card and is informed to the planning section

However, this section always enforces to all the departments to finish all the works within the delivery time given by the buyers This section delivers materials by truck, micro, air etc to the customer within the meantime Thus it plays a very important role in the success of the

company