Industrial attachment of mitali fasions ltd

Process flow chart of knitting: Sample fabric Design analysis Machine selection Setting the machine for the specific design Yarn in cone form Feeding the yarn cone in the creel Drye

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

INDUSTRIAL TRAINING IN MITALI FASIONS LTD

(MITALI GROUP)

INTRODUCTION

The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skillness about various processing stages.

It also provides us sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc The above mentioned can not be achieved successfully by means of theoretical knowledge only This is why it should be accomplished with practical knowledge in which it

is based on Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility

Textile education can‘t be completed without industrial training Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment We got an opportunity to complete two-months long industrial training at Mitali Fashions Ltd In the field of ever changing moderns fashion work Mitali Fashions Ltd considers it

prime mission to every new test Which & demand of customers from around the World & all strains human culture Mitali Fashions Ltd acts on the basis premise that fashion is an exploration in to the

images people seek to convey about themselves & the way they live It has well planned & equipped Knit fabric dyeing-finishing and Garment units in addition to facilitate knitting and knitwear manufacturing

We have prepared this report as required in competition of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for our future carrier.

FACTORY INFORMATION

Annual Turnover : Tk 10, 00, 00,000 to 12, 00, 00,000

Certification &Awards : ISO 9001:2000 & WRAP

Production Capacity : Knitting 16,000 SFT 12 Tons/Day

M ITALI F ASHIONS L TD

A BSCI, WRAP, OEKO-TEX, ISO & SEDEX STANDARD COMPANY

M ITALI has been established since 2000 and has rapidly become a major supplier of

ready-made garments from Bangladesh

When it comes to ready-wear manufacturing, Mitali Fashion is a cut above the rest Mitali

Fashion is a 'tells a tale of' a company that has everything right about it -its people, its

technology, its systems, its customers and its location

At Mitali Fashions Ltd we endeavor to provide our customers with an exceptional service of

the highest standard and quality to guarantee client satisfaction

Today, Mitali‘s success is a result of state of the art equipment and experienced personnel

from the management team to the factory force With a team of such quality Mitali is able to

run a highly efficient and competitive production unit, enabling us to meet the industries

continuous increasing standards and demands

As Mitali‘s reputation grows, so does interest from other countries

Our high quality product ranges include Knitwear, Woven and Sweaters for Ladies,

Mens and Children.

Mr Syed Abu Yousuf Abdullah,

Managing Director of the Group

Mitali Fashions Ltd was established in 2000s under the leadership of Mr Syed Abu Yousuf Abdullah,

Managing Director of the Group From humble beginnings, Mitali Fashions Ltd became a Group of companies With their leadership, Mitali has expanded rapidly over the years & become one of the largest and 100% export oriented composite knit garments industry in Bangladesh Mr Syed Ehsan Abdullah, Mrs Mafruza Chowdhury, Mrs Maisha Abdullah Ahammad and Mrs Tania Ahmed are the Directors of the Group

Mitali Fashions Ltd is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh

As time is essential to space so is taste to its products The secret is love-which, paired with meticulous efficiency and a keen sensitivity to style, makes Mitali Fashions Ltd an emerging brand destined to light up horizon of fashion

Mitali Fashions Ltd has team of skilled and dedicated technocrats backed by adequate number of modern USA and European machinery and equipments to match international standard of all kinds of knitwear products

The mission and vision of Mitali Fashions Ltd is to manufacture and deliver high quality readymade garments (RMG) to its customers The core objective is to attain and enhance customer satisfaction by

providing on time delivery of desired quality readymade garments and also to increase efficiency of workforce

To attain these objectives, the management of Esquire Knit Composite Ltd has decided to adopt the following-

1 To increase awareness regarding customers requirements throughout the organization

2 By providing training to develop efficiency of the employee

3 To collect customer‘s feedback regularly to know about their conception about their company and to take timely appropriate action

4 To reduce the percentage of wastage / rejection minimum by 2% per annum‘s implement and monitor ISO 9001:2000 quality management system within the organization

West East

North

Mitali Fashions

1 Security office

2 Gas Pump

3 Knitting sectionUnit – I & Air Compressor Room (1st Floor) + Garment section (2rd -4th Floor)

4 Color Store (1st Floor) + Medical Care (2nd Floor) + Quarter (3rd Floor)

5 Chemical Store

6 Fabric dyeing (Unit – I ) &Tube finishing section + Boiler Room

7 Dyeing Lab + Open Finishing Section

Main Gate of the Mitali Fashions

13 ETP Plant

14 Under Constructed Building

P a g e | 1 3

Mitali Fashions Ltd was established in 2000s under the leadership of Mr Syed Abu Yousuf Abdullah,

Managing Director of the Group From humble beginnings, Mitali Fashions Ltd became a Group of companies With their leadership, Mitali has expanded rapidly over the years & become one of the largest and 100% export oriented composite knit garments industry in Bangladesh Mr Syed Ehsan Abdullah, Mrs Mafruza Chowdhury, Mrs Maisha Abdullah Ahammad and Mrs Tania Ahmed are the Directors of the Group

Dyeing & Finishing Section

GM AGM Manager

Batch Incharge

Finishing Incharge

Lab Incharge

Incharge

Sewing man Turning m/c

Sewing man Squeeze

Lab Technician

Managing director

Finance HRD Factory Manager

Merchandiser Manager

Senior Merchandiser

Mit ali

Group can produce wide range of products and they deals with some renowned buyers from Europe and USA market some of those are with whom they worked and those whom they are still working Main buyers name of the company are given below-

PARTY NAME YARN CATEGORY RATE $ (KG) RATE (Tk /

KG)

QUANTITY (KGS)

Shameem Spinning 20s/1 CVC 2.70 158 400.00

Shameem Spinning 30s/1 CVC 2.80 163 500.00

Padma Textile Mills 30s/1 CVC 3.00 175 3628.80

Square Textile Mills 24s/1 Comb 2.95 172 850.00

Square Textile Mills 12s/1 Card 2.05 120 500.00

Square Textile Mills 10s/1 Card 1.65 96 1850.00

Prime Composite Mills 32s/1 Comb 2.95 172 2550.00

Pacific Textile Mills ltd 20s/1 Card 2.58 151 2000.00

Luksme Textile Mills ltd 26s/1 Card 2.62 153 2000.00

Mosharaf Textile Mills

ltd

30s/1 Card 2.62 153 3250.00

Prime Composite Mills 32S/1 Comb 2.95 172 22500.00

PHP Textile Mills ltd 24S/1 Comb 3.02 176 10000.00

Badsha Textile Mills ltd 34S/1 Comb 3.25 190 20000.00

Shamsuddin Spinning 24S/1 Comb 3.00 175 6700.00

Shamsuddin Spinning 26S/1 Comb 3.00 175 4350.00

Tara Textile Mills ltd 20S/1 Comb 3.00 175 1500.00

Israq Textile Mills ltd 30s/1 Card 2.55 149 661.84

Shamsuddin Spinning 30s/1 Comb 3.05 178 1150.00

Shamsuddin Spinning 26s/1 Comb 3.00 175 1800.00

Prime Composite mills 20s/1 Card 2.40 140 1400.00

Prime Composite mills 24s/1 Comb 2.85 166 1900.00

Prime Composite mills 26s/1 Card 2.82 165 650.00

Prime Composite mills 30s/1 Card 2.82 165 350.00

Hanif Spinning Mills 28s/1 Comb 3.05 178 3800.00 Square Textile Mills 26s/1 Comb 2.95 172 500.00 Square Textile Mills 24s/1 Card 2.50 146 500.00 Square Textile Mills 10s/1 Card 1.65 96 600.00 Shameem Spinning 30s/1 CVC 2.80 163 1600.00 Square Textile Mills 30s/1 Comb 3.00 175 1000.00

2 DIFFERENT YARN AND COUNT FOR KNITTING:

01 Carded Yarn 100% Cotton 10s, 12s, 16s, 20s, 20/2, 22s, 24s, 26s,28s,

 1 x 1 rib & others

 Collar & cuff

01 Solazol Black sp GRI 300

02 Reactofix Red ME4BL 262

03 Cottofix Red ME4BL 262

04 Reactofix Orange ME2RL 294

Remarks:

best quality yarn They uses the best quality dyes like REMAZOL, REACTRON, REACTIVE, TERACIL etc During the time of using dyestuff they give importance upon the quality of dyes than the price of the dyes and chemicals

PROCESS DEFINITION

Knitting is the interlocking or intermeshing of one or more yarns through a series of loops The length wise columns of stitches, corresponding to the warp in woven cloth, are called WALES; the cross wise rows of stitches, corresponding to the filling in woven cloth, are called COURSES, FILLING KNITS (WEFT KNITS) are those fabrics in which the courses are composed of a single strand of yarn, while warp knits are those in which the Wales are composed of single strand of yarn GAUGE corresponds to the yarn in a woven fabric, and

is defined as the number of needles of yarns in half inches of cloth The higher the gauge, the more compact and finer is the cloth

Lay-Out of Knitting Section

(Unit-I)

Rib

m/c

Rib m/c

Rib m/c

S/J m/c

S/J m/c

S/J m/c

S/J

m/c

S/J m/c

S/J m/c

S/J m/c

S/J

m/c

Rib m/c

S/J m/c

S/J m/c

S/J m/c

S/J m/c

S/J m/c

S/J

S/J m/c

S/J m/c

Rib

Rib m/c

Process flow chart of knitting:

Sample fabric

Design analysis

Machine selection

Setting the machine for the specific design

Yarn in cone form

Feeding the yarn cone in the creel

Dryer Washing m/c

Entrance Stair

Table Table

S/J m/c

Air Compressor m/c Room

Window Window

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension devices

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

Fig: PAI LUNG Knitting Machine Fig: FUKAHARA Knitting Machine

Fig: Mayer &Cieknitting machine

Fig: Image of Dust Removal Fan of Knitting M/c

Fig: Image of VDQ Pulley of Knitting M/c

Fig: Image of Positive Feeder of Knitting M/c

Fig: Image of Yarn Feeder Guide & Needle Action With Yarn of Knitting M/c

Fig: Image of Cam Box With Cam of Knitting M/c

Fig: Image of Cam setting to the Cylinder

Sequence of yarn feeding:

Parts of knitting Machines:

Creel:Creel is used to place the cone of yarn

Feeder:Feeder is used to feed the yarn to make a fabric

Tensioning device:Tensioning device is used to give proper tension to the yarn

VDQ pulley:VDQ pulley is used to control the GSM by controlling the stitch length

Guide:Guide is used to guide the yarn

Sensor:Sensor is used to seen & the machine stops when any problem occurs

Spreader:Spreader is used to spread the knitted fabric before take up roller

Take up roller:Take up roller is used to take up the fabric

Fixation feeder:These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at

Vertical column of loops produced by same needle in knitting cycle is called the Wales of the fabric

A wale is a predominantly vertical column of intermeshed needle loops generally produced by the same needle knitting cycles i.e The number of vertical columns of loop of knitted fabrics is called wale

1 In case of circular weft knitting machine & Tricot warp knitting machine [Gauge, N= Number of needle per inch.]

2 In case of Raschel warp knitting machine [Gauge, N= Number of needle per two inch.]

 One butt needle

 Two butt needle

 Three butt needle

 Four butt needle

The most widely used needle is latch needle

Fig:Main parts of latch needle

Cam:

There are three types of cam used in circular knitting machine:

Sinker:

It is a thin metal plate with an individual or collective operation approximately at right angles at the hook side between adjacent needles

Function of sinker:

In circular knitting m/c sinker helps to form the loop by holding down the yarn

Loop forming sequence of latch needle:

End products of Circular Knitting Machine:

Considerable points to produce knitted fabrics:

When a buyer orders for fabric then they mention some points related to production and quality Before production of knitted fabric, these factors are needed to consider Those are as follows-

 Type of Fabric or design of Fabric

 Finished G.S.M

 Yarn count

 Types of yarn (combed or carded)

 Diameter of the fabric

Relationship between knitting parameter:

1 Stitch length increase with decrease of GSM

2 If stitch length increase then fabric width increase and Wales per inch decrease

3 If machine gauge increase then fabric width decrease

4 If yarn count increase (courser) then fabric width increase

5 If shrinkage increases then fabric width decrease but GSM and Wales per inch increase

6 For finer gauge, finer count yarn should use

7 Gray GSM should be less than finish GSM

Production Parameter:

 Machine Diameter;

 Machine rpm (revolution per minute);

 No of feeds or feeders in use;

 Machine Gauge;

 Count of yarn

Methods of increasing production:

By the following methods the production of knitted fabric can be increased –

 By increasing m/c speed:

Higher the m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed

 By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time

 By using machine of higher gauge:

The more the machine gauge, the more the production is So by using machine of higher gauge production can be increased

 By imposing other developments:

 Using creel-feeding system

 Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage

 Using yarn feed control device

 Using auto lint removal

Production calculation:

 Production/shift in kg at 100% efficiency:

count Yarn

mm SL Needle of

No Feeder of

)(

 Production/shift in meter: