Industrial attachment of MM KNITWEAR Ltd

I got an opportunity to complete two month long industrial training in M M Knitwear Ltd , which is a 100% export, oriented composite Knit Dyeing Industry.. ⇒ To set the sequential work a

Department of Textile Engineering

Report on 2 months Industrial Attachment

As a curriculum in Wet Processing Technology (From 05th February to 06th April, 2011)

At first my gratefulness goes to Almighty Allah to give me strength and ability tocomplete the industrial training and this report You have made my life more bountiful.May you name be exalted, honored and glorified

Now I wish to take this excellent opportunity to thank a lot of people who haveassisted and inspired me in the completion of my training period:

I express my gratitude to Prof Syed Fakhrul Hassan Murad, Head, Department

of Textile Engineering, and my supervisor, to whom I am extremely indebted for histremendous support and guidance throughout my training period Being working withhim I have not only earned valuable knowledge but was also inspired by hisinnovativeness which helped enrich my experience to a greater extent His ideas and way

of working was truly remarkable

I would like to thank the management of the M M Knitwear Ltd for giving me theopportunity to do the industrial training successfully and also their valuable suggestions

My deepest appreciation goes to Mr Nurul Islam, General Manager, M M Knitwear Ltd.for his permission to conduct my industrial training without which it would beuncompleted The generous support is greatly appreciated

I would also like to thank executives, senior executives and other officials of M

M Knitwear Ltd for helping me to complete industrial training successfully Mygratitude also goes to all the employees of M M Knitwear Ltd for their sincere co-operation, support and valuable advices

Last but not least, thanks go to my precious family for their never ending love andinspire at every stages of my life Without their continuous support I realize that I wouldnot be a person I am right now

1 Project Description 5

1.1 COMPANY PROFILE 6

1.2 location: 7

1.3 Basic lay-out of the factory 8

1.4 Vision and Mission 10

1.5 Different Departments 11

1.6 Remarks 11

CHAPTER – II 12

2 Man power management 13

2.1 Dyeing & Finishing Section 14

2.2 Knitting section 15

2.3 Management System 16

2.4 Duties & Responsibilities of Production Officer 16

2.5 Duties & Responsibilities of Senior Production Officer 17

2.6 Duties & Responsibilities of GM (Production) 17

2.7 Remarks 17

CHAPTER – III 18

3 Machine Description 19

3.1 Lay-out Of Dyeing & Finishing Section 19

3.2 Dyeing Machinery 21

3.3 Finishing Machinery 26

3.4 Description of Machinery 27

3.4.1 Working principle of dyeing machinery 27

3.4.2 Working principle of finishing machinery 28

3.5 Remarks 40

CHAPTER – IV 41

4 Raw material 42

4.1 Grey Fabrics 42

4.2 Dyes 42

4.3 Chemicals 44

4.4 Remarks 44

CHAPTER-V 45

5 PRODUCTION PLANNING,SEQUENCES & OPERATION 46

5.1 Process flow chart of knit dyeing 46

5.2 Dyeing work flow chart 47

5.3 Dyeing Parameters 48

5.4 Description of production process 49

5.5 Dyeing Recipe 52

5.6 Finishing 55

5.7 Finishing machine setting 56

5.8 Daily Production Report 58

5.9 Monthly Average Production 58

5.10 Remarks 58

CHAPTER – VI 59

6 QUALITY ASSURANCE SYSTEM 60

6.1 Quality Policy 60

6.2 Quality Assurance Procedure 60

6.3 Inspection area 61

6.4 PROBLEMs ENCOUNTERED IN DYEING 62

6.5 Process of Shade Matching 64

6.6 List of Equipments 64

6.7 Quality Standard 65

6.8 Remarks 65

CHAPTER- VII 66

7 Maintenance 67

7.1 Maintenance of Machinery 67

7.2 Routine 67

7.3 Manpower Setup for Maintenance 68

7.4 Maintenance Procedure 68

8 UTILITY SERVICES 74

8.1 Utility Facilities Available 74

8.2 Source of Utility 74

8.3 Capacity and Other Technical Details 74

8.4 Cost of different Utilities 77

8.5 Remarks 77

CHAPTER – IX 78

9 STORES & INVENTORY CONTROL 79

9.1 Scope of Inventory Control 79

9.2 Frequency of Inventory Update 79

9.3 Inventory Control System for Raw Materials 79

9.4 Inventory Control System for Finished fabric 80

9.5 Inventory Control System for Spare Parts 80

9.6 Remarks 80

CHAPTER-X 81

10 COST ANALYSIS 82

10.1 INTRODUCTION 82

10.2 Costing elements 82

10.3 Knitting Charge of Different Fabrics 82

10.4 Dyeing Charge of Different Fabrics 83

10.5 Finishing Charge of Different Fabrics 83

10.6 COSTING OF THE PRODUCT 84

10.7 Remarks 84

CHAPTER – XI 85

11 MARKETING ACTIVITIES 86

11.1 Consumer of Products 86

11.2 Country of Export 86

11.3 Local Market 86

11.4 Marketing Strategy 86

11.5 Duties & Responsibilities of Marketing Officer 87

11.6 Remarks 87

CHAPTER –XII 88

12 Effluent Treatment Plant (ETP) 89

12.1 Process Flow chart of Biological Effluent Treatment Plant 89

12.2 Function of different Unit of Biological Effluent Treatment Plant (E T P) 90

12.3 Product Quality Checked 91

12.4 Remarks 91

CHAPTER –XIII 93

13 Conclusion 94

13.1 SOME SUGGESTIONS 94

13.2 Limitations of the report 95

Introduction :

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 M M Knitwear Ltd , which is a 100%

export, oriented composite Knit Dyeing Industry It has well planned & equipped fabric

and Knit dyeing-finishing units in addition to facilitate Knitting and Knit wear

manufacturing

The rationale behind the existing structure and future expansion of M M Knitwear

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

Despite Bangladesh’s lack of indigenous cotton production capacity, M M Knitwear Ltd

has leveraged Bangladesh’s labor cost advantage and export competitiveness to the

Maximum

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Industrial Attachment Objectives

⇒ To familiarize with the factory and production.

⇒ To set the sequential work and factory layout

⇒ To keep a motel on the deviation between theory and industrial bulk

production

⇒ To correlate between institutional and industrial working techniques

and procedures

⇒ To observe the management system

⇒ To have a concept on production planning, costing, marketing

techniques etc

⇒ To know about waste reduction and utilization

⇒ To know about how a technical person developed quality of products

at various steps (knitting, dyeing, finishing and garments making)

⇒ To have a proper knowledge on the product development to customer

handling

PROJECT DESCRIPTION

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Industrial Attachment Project Description

M M Knitwear LTD

1 PROJECT DESCRIPTION

M M Knitwear Ltd has started manufacture and export of garments since 2001

The beginning M M Knitwear Ltd has a very good reputation as a financially sound and

ethical business house It has a long term association with selected factories, some of

them are certified in terms of social and quality compliance by world’s highest rating

bodies, and outstanding sourcing capabilities Thus M M Knitwear Ltd has been able to

prove itself to be a reliable supplier for knit item in any style and design

Specializing in all kinds of knitted items It is housed in its own building surrounding an

area of 310,000 sq ft And 4,300 workers and stuff

The determination to achieve superior customer service and on time delivery has earned

M M Knitwear Ltd recognition as an invaluable player and the desire to succeed in

customer satisfaction with every order makes the M M Knitwear Ltd team even stronger

it’s these fundamental that keep this unit in the game and wining every time

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GENEREL INFORMATION ABOUT THE FACTORY

Industrial Attachment Project Description

1.1 COMPANY PROFILE

Name of the project : M M knitwear LTD.

Type of the project : 100% Export oriented Knitwear industries

Year of establishment : It was established in the July2001

Address : Factory, Ambag road, Konabari , Nilnagar

Gazipur, Bangladesh

Head office : House #16, Road #10, Sector # 1,Uttara Model Town

Dhaka-1230, Bangladesh

Investors : Md Mofizul Islam, Managing Director

History of the project : M M Knitwear has started manufacture and export of

Dyeing & Finishing Capacity : 7250 Tons (Around)

Knitting Capacity: 3250Tons (Around)

Sewing: 50000 pcs/day (Average)

Area : 310,000 sq ft.

TANGAIL ROAD

dhaka

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Industrial Attachment Project Description

1.3 Basic lay-out of the factory

6

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7

1

1 : Security office.

3 : Fabrics Store (Gr.Floor)+Knitting (2ndFloor+3rd floor),

Human Resources Department (HRD)(4thFloor),

Marchanding section (5thFloor), garments(6th Floor – 9th floor)

4 : Yarn store (Gr Floor)+ +Garment section(1st Floor – 7th floor)

5 : Fabric dyeing & finishing section

7 : Generator house, Water Treatment Plant(WPT), Maintenance building

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Industrial Attachment Project Description

1.4 Vision and Mission

The mission and vision of M M Knitwear 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 M M Knitwear 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

Main Production : Basic T-Shirt, Tank top, Long Sleeve- Shirt, Polo

Shirt, Shorts, Ladies & Kids Knitwear & all kinds

of knit garments & Knit fabrics

Last year Export Turnover : 18.50 Million U.S Dollars

The annual Production capacity of M M knitwear Ltd is an approximate idea, it may

vary

Buildings- one ten storied building, one six storied building, and 1 dyeing shade

Buildings are made by brick

Total Area of Industry : 3,00,000 Sq.Ft

1.6 Remarks

The company owns 300000 Sq Ft of high land property at Ambag,Konabari,Gazipur,Dhaka; which is 10 km from the Gazipur Chourasta Charming

sights along with natural beauty of rural areas with no hazards or air pollution attracts the

foreign buyers during their visits The company has the desire to achieve recognition of

the project as the ‘M M Industrial Park’ and to set up within the park area industries and

health care center in near future Plans include for Acrylic Yarn manufacturing unit,

Packaging unit, Designing unit and Hospital

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CHAPTER – II

2 MAN POWER MANAGEMENT

The company has skilled administration, management and marketing team guided by

proficient, dexterous & experienced leaders of offer right solution for the consumers with the

right eminence & with the shortest lead-time for the export market in Bangladesh The best

use of continuous development of human resources by providing them standard equal

opportunity is the keys for achieving comprehensive competence in all level of the

organizational hierarchy

M.M knitwear ltd the Managing Director/ Chairman who controls the entire factory And

the others respective department chief controls their department in this factory

In this below the organ grams of administration and the others department is showing:

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Medical Officer

Nurse

Deputy Chief Egg.

Deputy

Account

Officer

Accounts

Officer Assistant Accounts Officer Senior Clark Junior Clark Peon Electrical Eng Mechanical Egg Sub assistant Eng Foreman Sub assistant Eng Foreman Director, H R Dept. Managing director Assistant

General

Manager ( ADMIN) Security Officer Assistant Security Officer Marketing

Officer Security Guard Security Havilder Asst Chief store Manager Asst Officer Store

officer Foreman Store Manager Assistant

Manager (ADMIN)

Administration Officer

Assistant Administration Officer

Peon

Administration Assistant

Industrial Attachment Man power Management

2.1 Dyeing & Finishing Section

Squeeze Operator Dryer Operator

Lab Technician

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Store Incharge Knitting Master Supervisor

Fitter man

Operator

Fitter man

Operator AGM

PO

Industrial Attachment Man power Management

⇒ Buyer sample is send to G.M

⇒ Matching is done by lab in charge

⇒ Sample is prepared by dyeing master

⇒ Sample is send to the buyer for approval

⇒ Approved sample is returned and taken as STD Sample for bulk production

⇒ Asst dyeing master gives responsibilities to production officer

⇒ Then production officer, with the supervisors start bulk production

⇒ On line and off line quality check is done by lab in charge and asst dyeing master

⇒ After dyeing finishing in charge controls the finishing process with the supervision of

production officer

⇒ After finishing, the material is checked by dyeing master

⇒ Finally G.M checks the result with dyeing master and decision is taken for delivery

2.4 Duties & Responsibilities of Production Officer

1 To collect the necessary information and instruction from the previous shift for the

smooth running of the section

2 To make the junior officer understand how to operate the whole production process.

3 To match production sample with target shade.

4 To collect the production sample lot sample matching next production.

5 To observe dyed fabric during finishing running and also after finishing process.

6 To identify disputed fabrics and report to PM/GM for necessary action.

7 To discuss with PM about overall production if necessary.

8 To sign the store requisition and delivery challan in the absence of PM

9 To execute the overall floor work.

10 To maintain loading/ unloading paper.

2.5 Duties & Responsibilities of Senior Production Officer

1 Overall supervision of dyeing and finishing section

2 Batch preparation and pH check

3 Dyes and chemicals requisition issue and check

4 Write loading / unloading time from machine

5 Program making, sample checking, color measurement

6 Control the supervisor, operator, asst operator and helper of dyeing machine

7 Any other work as and when required

2.6 Duties & Responsibilities of GM (Production)

1 Overall supervision of dyeing and finishing section.

2 Check the sensitive parameters of different machines for smooth dyeing.

3 Check the different log books and report to management

4 Check the plan to control the best output.

5 To trained and motive the subordinates how to improve the quality

production

6 Control the supervisor, operator, asst operator and helper of dyeing m/c.

7 Maintenance the machinery and equipments.

8 Any other work as and when required

2.7 Remarks

The manpower management system of M M Knitwear Ltd is well arranged Every

officers & stuffs are responsible for their duty But there are only three textile engineers in

the industry (General manager, Production manager and Production officer) It is not

sufficient for smooth production More technical people is required

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CHAPTER – III

MACHINE DESCRIPTION

13

1313

131313

1317

1516

12

14

Industrial Attachment Machine Description

13 Dilmelner high pressure Dyeing m/c

14 Office & Online QC

3.2 Dyeing Machinery

In dyeing section of M M Knitwear Ltd, there are 22 Dyeing Machines, among of

them 7 m/c’s are for sample dyeing and 15 m/c’s are for bulk production

Industrial Attachment Machine Description

Industrial Attachment Machine Description

Industrial Attachment Machine Description

Soft Setting calendar machine :

3.4.1 Working principle of dyeing machinery

The dyeing m/c’s has a large tank where the fabric is loaded through out the nozzle It has

a good arrangement of water line (in let & out let), steam line, heat exchanger, liquor

circulating motor and a chemical dosing tank The loaded fabrics are circulating through

out the nozzle continuously and the dyeing take place by the supplying of dye liquor by

the liquor circulating motor when the fabric is passed over the drawing reel It has also a

control panel, which automatically control the production parameter But it should firstly

set manually In case of low temperature machine it can raise up the temperature only

95o C (maximum) where as a low temperature machine can raise up the temperature up

to140o C During unloading of fabric drawing out reel is used

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Industrial Attachment Machine Description

Fig: HTHP winch dyeing machine

3.4.2 Working principle of finishing machinery

3.4.2.1 Slitting machine

The slitting m/c has 4 units - initial squeezer, de-twisting, slitter and padder After dyeing

completed and falling of water from fabric the fabric is fed in slitting m/c So it is

necessary to remove some water initially for the case of further processing in this m/c

The initial squeezer does this work The de-twisting unit removes twists that may present

in tubular rope form fabric This unit has 3 de-twisting rollers, one rotation drum and 2

feeler rollers with sensors By these rollers it detects twist in fabric and removes by

rotating rope fabric in opposite direction Before slitting there is a blower which blows air

to open the tubular fabric & makes it easy to pass over cigger The cigger can be

Chemical dosing tank Fabric

through the padder where washing or chemical treatment is done Squeezer is used to

remove 60-70% of water After removing water width is controlled by stretcher and

fabric is delivered by folding device

Slitting machine contains the following Parts

Set the padder pressure as required (3-7bar)

Set the speed as much as possible (30-80m/min)

Function of the Machine:

 To slit the tube fabric by the knife for opening of the fabric and ready for

stentering

 Before squeezing balloon is formed with the help of compressed air

passing by a nozzle or air sprayer

feeding mechanism

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Industrial Attachment Machine Description

Problem causes by the Machine

 Photo sensor may failure

 For that fabric may be cut to the other line

 It may cause folding problem

 Bowing

 Spirality

3.4.2.2 Squeezing/Dewatering machine

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

Different parts of dewatering m/c

Tube tex dewatering machine contains two unit & two bath One is for extraction and

another for processing where softener or other chemical are applied for giving extra

finish

Maintenance during operation

 Proper balloon form by compressor air other wise crease mark appears

 Padder contract point a just perfectly according to the fabric construction otherwise

accurate water will not remove

 Albatros must be clean every one or two hours later

Function

 Reduce water from fabric

 Fabric open from rope form

Industrial Attachment Machine Description

Controlling parameter

If pressure is increase, shade will be light

Problem causes by the Machine

After de-watering the fabric is passed through the dryer 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 temperature 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

Special feature of Tube Tex steam dryer

Maintenance during operation

Temperature: Set the temperature between 1200C -1300C for white and 1500C -1700C for

color fabric If GSM is high then temperature will be high or, moisture content is high

temperature will be high

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) if GSM is high then speed will be high

Industrial Attachment Machine Description

Problem causes by the Machine

Shade variation due to uncontrolled temperature

More roller speed caused the Wales distortion

For Lycra heat setting is more necessary

If heat is more Lycra fabric can be extended and create low GSM fabric

Light shade due to high temperature

3.4.2.4 Stenter machine

Stenter Machine is generally used to finish the open fabric This stenter machine consists

of eight chambers; each contains one burner, two blowers, two ducting line, nozzles and

suction fan attach with the suction line The burner produces hot flue gases which guided

though the ducting line by the help of blower There are nozzles placed above and bellow

the rail When the fabric passed through the rail, then hot air is sprayed to the above and