1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Niagara Textile Ltd 2 ACKNOWLEDGEMENT A number of people have made significant contributions in preparing this report. Their insights, advice and suggestions helped me a lot. I would like to pay special thanks to Prof. Syed Fakhrul Hassan, the Head of the department of Textile Engineering, “Southeast University”, for continuously guiding us about the development and preparation of the report. He has enriched us with necessary ideas and concepts for incessant improvement of the report. I would also like to express my heartfelt thanks to my supervising teacher Mr. Adnan Zaber Mahmud for his encouragement & valuable suggestions for incessant improvement of the report. I would like to express our sincere gratitude to Md. Abraruzzaman Diamond, General Manager, “ Niagara Textile Ltd”, who has allowed me to work in his organization within a congenial atmosphere during the industrial training period. I recognize Md. Feroj Iftekhar, Deputy Manager (Admin) for managing my internship and for providing sincere help in all administrative and technical matters while working in the organization. My heartfelt thanks go to him for allowing me to perform my industrial attachment in the NIAGARA Textiles Limited. I express my heartiest thanks to Deputy Manager & Assistant Manager, Knitting, Dyeing & Fishing, Garment, Accessories and merchandising for helping to get proper information about every section during industrial training. I would like to especially thank to my all of seniors of my university whom are working in the “NIAGARA Textiles Ltd.” for helping me practically & for showing me the right path. My sincere appreciation goes to the entire “NIAGARA Textiles Ltd.” team for extending their hands of cooperation throughout the training period. 3 Executive Summary Since 1980 to till date the Apparel sector of Bangladesh has conceded through different huddles & obstacles and now has reached a stage where it can compete with all its competitors in price and quality as well as assortment in this scenario. Niagara Textile LTD. is a young & dynamic composite Knit Garment Industry. Though incorporated in the year 2000 as a private limited company it came into existence in late March 2001. The mill being established at Chandra circleUnion-Atabaha, Kaliakair Gazipur, Bangladesh aspires to create a niche within a short period of time in the highly competitive global market of knit garments. Promoted by a team of young and dynamic visionaries, Niagara Textile LTD is a 100% export oriented composite knit garment industry. It possesses all the latest machineries from the European countries with few from the United States of America, Japan, & Taiwan. The entire plant has been installed & erected by foreign and local engineers jointly under the same roof. The total plant is located in total 16 floor with an area of more than 2,65,500 square feet. The factory is well equipped with high performance machinery and experienced technicians & a group of Smart executives are engaged here to ensure the Compliance management for quality and customer happiness. We can produce international standard fabric and garments of any quality and quantity. Niagara Textile LTD always keeps pace with latest technology of Textiles industry. The products of the unit have been classified in such a manner which shall meet the increased demand of the Europeans, USA etc. market fulfilling all the criteria required by the buyer. Introduction 4 If the theoretical knowledge is a glass of water then the practical knowledge would be drinking of the water. It is always very easy to make a man understand about a firebox by showing and lighting practically rather than describing theoretically who has not ever seen a firebox. So, for any technical education the practical experience is the most important as well as the theoretical knowledge. As we are studying in a technical line, it is always important for us to gather the practical knowledge. Through our study life the only biggest chance for us to combine the theoretical knowledge with the practical knowledge is the “Industrial Attachment period” that comes only once in the education life. So we can easily realize the importance of Industrial Attachment. And in addition the knowledge we gathered from the industrial training reflects in the report of industrial attachment note book. So industrial attachment is the process where the trainee can blend his theoretical knowledge with practical knowledge increasing his/ her ability of work, skillness, performance and attitude and so on. It also provides sufficient knowledge about production management, productivity evaluation, work study & efficiency, industrial management, production planning and control, production cost analysis, inventory management, utility, maintenance and so on. Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and also improve courage and inspiration to take self-responsibility. As Industrial training is an integral part of the study for the students of Textile Technology, so after the final exam of 4 th year 2 nd semester, I have taken this training at “NIAGARA Textiles Limited”, a 100% export oriented apparel manufacturing industry. I tried my best to prepare this note book applying my best efforts. I tried to gather all the necessary information to make it a valuable for me as well as for everyone. I think it will help me a lot in future in my practical life. Place: I have performed our industrial training at “NIAGARA Textiles Limited” which is located at Chandra circle, Union-Atabaha, Kaliakair, Gazipur, Bangladesh. This is a 100% export oriented knit garments factory. It consists of knitting, knit dyeing, finishing & knit garments. Duration: Total duration of training period was from 15 th October 2012 to 15 th December 2012 (eight weeks). 5 Table of Contents Acknowledgement………………………………………………………01 Executive Summary…………………………………………………….02 Introduction…………………………………………………………… 03 Table of Content ……………………………………………………… 04 Chapter No Topic Name Page Number 01 GENERAL INFORMATION ABOUT THE FACTORY 05-19 02 KNITTING 20-29 03 BATCH SECTION 30-32 04 DYEING SECTION 33-46 05 LAB DIP DEPARTMENT 47-51 06 FINISHING SECTION 52-63 07 QUALITY ASSURANCE SECTION 64-67 08 GARMENT’S SECTION 68-100 09 MARCHENDISING 101-108 10 QUALITY CONTROL LABORATORY 109-111 11 PRODUCTION PLANNING & CONTROL 112-113 12 MARKETING ACTIVITIES 114-116 13 MAINTENANCE SECTION 117-120 14 UTILITY SECTION 121-124 15 COMPLIANCE 125-127 16 CONCLUSION 128-130 6 CHAPTER 1 GENERAL INFORMATION ABOUT THE FACTORY 7 1.0 General Information about the Factory Textiles and Clothing are the leading industries of Bangladesh in Respect of foreign Currency Earning and Employment. We are a Knit Composite Unit Having Knitting, Dyeing, and Finishing & Sewing Units under the same roof. It is housed in its own building surrounding an area of 2,65,500 Sft. feet included Office, CAD & Sample 1 floor, Knitting 2 floor, Dyeing 1 floor, Dyeing Finishing 1 floor, Cutting 1 floor, Printing 1 floor, Sewing 8 floor, Finishing 1 floor & total 16 floor, in our highly protected area surrounded by wall and 4996 workers and stuff. Niagara never allows slave, child or prison labor or even force labor. It always provides all necessary safety measures & ensures the workplace safe, healthy & comfortable. Niagara is going ahead to achieve their vision plan with our dynamic team members. Effluent Treatment Plant (ETP) established for hazard free environment. The determination to achieve superior customer service and on time delivery has earn Niagara’s recognition as an invaluable player and the desire to succeed in customer satisfaction with every order makes the Niagara’s team even stronger its these fundamental that keep this unit in the game and wining every time. Since the beginning it 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 Niagara’s has been able to prove itself to be a reliable supplier for knit item in any style and design. Niagara is also ISO & WRAP certified. 8 9 1.1 Factory Profile In Brief Corporate and Financial Information Corporate Name : Niagara Textiles Limited Incorporation : C-41635(994)/2000 Type of ownership : Private Limited Company Nature of the Project : 100% export Oriented Company Number of Owners : 04 Motto : Niagara is committed for excellence Workforce : 5000 (Approx.) Membership : BGMEA – BKMEA – Membership no : 594-A/2001 IBWF – Year of the establishment : 2000 Year of the Operation Started : 2001 Our Bankers : Shahjalal Islami Bank Ltd. Islami Bank Bangladesh Ltd. Bank Alfalah Ltd. Dutch Bangla Bank Ltd. General Terms : All payments have to be made with confirmed Irrevocable letter of credit at sight. Our Wings : Knitting Dyeing Printing Garments - Cutting - Sewing - Finishing 10 Contact Address : Our Board of Directors Chairman : Mr. Ahsan Habib Managing Director : Mr. Md. Nurul Hasan Director : Md. Shahinoor Islam Contact Person Concern department Contact Information Md. Abraruzzaman Diamond Genaral Manager Plant Email:diamond@niagaratex.com G M Taj Mahmud Deputy General Manager Marketing E-mail: taj@niagaratex.com Md. Mabubur Rahman Manager – Merchandising Merchandising E-mail:mahbub@niagaratex.com Md. Faruque Hossain Manager – Compliance Compliance E-mail: faruque@niagaratex.com Md. Feroj Iftekhar Deputy Manager, Admin Administration Email: feroj@niagaratex.com Head Office : 27, Bijoy Nagar Suit No. C – 1 (1st floor) Dhaka - 1000 Bangladesh Phone # 088-02- 9352328, 9340945, 9347303 Fax # 088-02-9353480 Web Address: www.niagaratex.com E-mail: info@niagaratex.com Factory : Niagara Textiles Ltd Chandra circle Union-Atabaha, Kaliakair, Gazipur, Bangladesh Tel: 88 02 9289127, 06822 – 51233-4 Fax: 06822 – 51231 Web Address: www.niagaratex.com E-mail: info@niagaratex.com [...]... needs and expectations of customers for reliability, safety, economy and on-time delivery of shipments To achieve this objective, Niagara Textiles Ltd provides all the necessary resources to ensure a well equipped and adequately trained, and experienced manpower to take proper care of customer requirements Niagara Textiles Ltd Emphasized that quality is the shared responsibility of its entire staff The... No of machines 22 53 SET 2.1 Knitting: I started from knitting section as a part of my industrial training To be a good Textile Engineer it is necessary to know about different types of knitted fabric used in dyeing section and also need to know different fabric faults, raw material of fabric, fabric composition, fabric production process, quality assurance system and last of all maintenance system of. .. speed of the m/c Defective needle Yarn is not properly fed during loop formation Insufficient yarn tension Badly set yarn feeder Defective needle Breakage of hook of needle Breakage of latch of needle Change of alignment of latch Due to improper schedule maintenance D Oil mark/ Grease mark:  Excess oil/grease use in the m/c  Leakage in the oiling system  Bad quality lubricant is used  Mixing of one... shirt and different types of Men’s, Lady’s & Kid’s wear in varies kinds of knit fabric 1.3 Office Staff: A large team of Technical personnel are directly working, assisting the workers & Coordinating pattern, cutting, sewing, quality & finishing-packing About 575 people are working as a Supervisor, Line chief, Floor in-charge, Section Manager 1.4 Quality Policy: Niagara Textiles Ltd Is totally committed...  Jamming of needle and sinker E Design variation:  Variation of stripe in the m/c  Wrong cam arrangement F Count variation:  Different count of yarn package in the same lot  Different quality of yarn use in the same order  Variation of count in the same package in different places G GSM variation:  Variation in the stitch length  Wrong position of the VDQ pulley  Improper tension of the fabric... machine This is done by cleaning the machine after every 7 days This is basically the servicing of the machine This is done because      To maintain the quality of the fabric To reduce the fabric fault Removal of dust from the m/c Cleaning of different parts of the m/c Overall to increase the production of the m/c During servicing the following things are checked weather they are in good condition... Sinker Cam Cam Box Cylinder Full Body Remarks: Production runs with the help of mechanical fitters For any kind of mechanical fault of any machine the fix and work under technical in charge Production officers take account of daily production by running after the supervisor & workers so on 30 CHAPTER 3 BATCH SECTION 31 3.0 Objective of Batching:            To receive the grey fabric roll from... Fabric Inspection & Grading Based on the Forty points System: The inspection and grading of fabric quality is one of the important functions of Quality Control in the grey finished state, the grading of fabric is a difficult task, taking two primary considerations: as the frequency of effects and the seriousness of defects The grading has two primary functions: first, to classify the fabrics according... account of points made to insure proper grading b) All fabric must meet specifications c) At the end of each piece of fabric, the inspector will add up total points and decide whether the piece can be shipped as first quality d) The quality control supervisor must approve the grading of all quality levels and check the lower quality e) Major or unsightly defects in the first and last yard of a roll of piece... and develop our workers and staffs through different types of training and counseling programs  We are always very much concerned about the safety issues of our workers We manage all necessary functions of safety issues very carefully  Subsidized lunch for staff  Free snacks for workers  Full time free of medical service provide by a professional doctor  Provision day care center for workers children . 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Niagara Textile Ltd 2 ACKNOWLEDGEMENT A number of people have made significant contributions. international standard fabric and garments of any quality and quantity. Niagara Textile LTD always keeps pace with latest technology of Textiles industry. The products of the unit have been classified. niche within a short period of time in the highly competitive global market of knit garments. Promoted by a team of young and dynamic visionaries, Niagara Textile LTD is a 100% export oriented