Mizan Howlader
Mizan Howlader
An Industrial Attachment
By
Md. Mizan Howlader
DEPARTMENT OF AMT
BGMEA University of Fashion & Technology
26, August 2016
Page 1 of 65
An Industrial Attachment
By
Md. Mizan Howlader
ID: 122-421-0-45
Submitted to the:
DEPARTMENT OF
APPAREL MANUFACTURE & TECHNOLOGY (AMT)
BGMEA University of Fashion & Technology
In partial fulfillment of the requirements for the award of the degree
Of
BACHELOR OF SCIENCE IN APPAREL MANUFACTURE & TECHNOLOGY
August 2016.
Page 2 of 65
Letter of Transmittal
Dear Madam,
Here in my internship reports that fulfills partial requirements for Degree of B.Sc in
Apparel Manufacture & Technology. It is very important for a student of Science and
Information to undergo a project/practical field of study.
I completed my internship report on A Industrial report at M.M Knitwear Ltd. In the
report, I have tried to accommodate my valuable comments & suggestions. In this
concern, if you need any further clarification, please email/call.
Thank you for your kind cooperation. Without your support, this internship report
would not have been completed. So I am submitting the final version of my internship
report and requesting your acceptance.
Regards,
Md. Mizan Howlader
ID: 122-421-0-45
Batch: 122 (AMT-4)
Page 3 of 65
DECLARATION
I hereby declare that, this Internship paper has been done under the supervision of Ms.
Ishrat Jahan, Lecturer, Department of AMT, BGMEA University of Fashion &
Technology. I also declare that neither this internship report nor any part of this
internship report has been submitted elsewhere for award of any degree.
Supervised By:
Submitted By:
Md. Mizan Howlader
ID: 122-421-0-45
Batch: 122 (AMT-4)
Department of
Apparel Manufacture & Technology,
BGMEA University of Fashion & Technology
Internship Period:
Page 4 of 65
All praises belong to Allah, the creator of the Universe, the sustainer & to whom I
must return.
I would like to thank my honorable Head of the department, Dr. Mohammad
Sujauddin, Associate Professor, Head of the Dept. of AMT.
I would like to thank my honorable course teacher & supervisor Ms. Ishrat Jahan,
Lecturer, Department of AMT BGMEA University of Fashion & Technology for his
guidance, help and encouragement throughout the progress of the internship report. I
am very grateful for her kind advice and instructions.
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. My
gratitude also goes to all the employees of M.M. Knitwear Ltd. for their sincere cooperation, support and valuable advices.
I would like to thank Mr. Shajal Kumar Saha, Sr. Merchandiser to giving me chance
under his Umbrella.
I would like to thank Md. Feruz Alam Mamun, Asst. Merchandiser to work with
him. He teaches me lots of things about merchandising profession.
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I also give thank some other person, Staffs who motivate us thoroughly and the other
people, who have made a significant contribution to make this report successful. Their
guide lines, suggestions & inspiration helped me a lot.
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EXECUTIVE SUMMARY
The Industrial Attachment is the most effective way for Apparel Manufacturing
student to be achieved the knowledge about the practical field of the Textile
Manufacturing. It brings an opportunity to all the learners to enrich their academic
knowledge by practicing with the experts of the practical field of textile.
M.M. Knitwear Ltd. is one of the major garments manufacturing organization in
Bangladesh. This organization increasingly reducing its rejection and rework rate inprocess and final garments in order to ensure product quality and delivery time as per
buyer requirement and increase profitability. MM will ensure sufficient training and
suitable work to increase productivity and skills of the employee.
In this report I tried to cover a short profile of M.M. Knitwear Ltd. and major
customers of M.M. Knitwear Ltd. and their different activities.
It is my pleasure that I had an opportunity to complete my two month internship at
M.M. Knitwear Ltd. which is one of the most modern industries of the country.
Page 7 of 65
TABLE OF CONTENTS
SL
NO
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
CONTENTS
Cover Page
Submission Details
Letter of Transmittal
Declaration
Acknowledgement
Executive Summary
Table of Contents
Chapter One:
Introduction
General Discussion
Company Profile
The M.M. Knitwear Story
Quality Policy
Welfare Facilities
Buyers
Certification
Map
Layout of M.M
Chapter Two:
HR & Compliance
Introduction
Section Wise Manpower
Management Medium
Organgrams of Administration
Management System
compliance
Code of Conduct of SA 8000
Code of Conduct of BSCI
Code of WRAP
PAGE
NO
1
2
3
4
5
6
7
11
12
13
13
14
15
16
17
18
19
19
19
20
21
21
23
24
25
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3
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
Chapter Three:
Different Departments
Different Departments
Chapter Four:
Knitting Division
Introduction
Types of Knitting
Organgram of Knitting Division
Knitting Division
Circular Knitting Unit
Flat Knitting Unit
Narrow Fabric Unit
Quality Control Unit
Summary
Chapter Five:
Dyeing & Finishing Division
Introduction
Flow Chart of Dyeing
Organgram of Dyeing & Finishing Section
List of Machineries
Raw Material for Dyeing
Grey Fabric
Finishing Section
Process Flow Chart of Finishing
Objective
Finishing Effects
Finishing Machinery
Function of The SLITTING Machine
Function of Squeezing/Dewatering machine
Function of Dry Machine
Function of STENTER Machine
26
27
27
28
28
29
30
30
30
30
31
31
32
33
35
35
36
36
37
37
37
37
38
38
38
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Chapter Six:
Testing
6.1
6.2
6.3
6.4
6.5
6.6
6.7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9.1
9.2
9.3
9.4
9.5
10.1
10.2
10.3
10.4
10.5
10.6
10.7
Introduction
Types of Test in Laboratory
Stock Solution Preparation
Physical test
Chemical test
List of Machine in Laboratory
Quality Standard
Chapter Seven:
Garments Division
Sample Division
Cutting Section
Embroidery Section
Screen Printing Section
Sewing Section
Finishing
Office Staff
Quality Team
logistic team
Auditing Team
List of the Machines
Chapter Eight:
Quality Management System
Quality Policy
Quality Assurance Procedure
Inspection Area
Knitting Faults
Dyeing Faults
Finishing Faults
Problems Encountered in Dyeing
Process of Shade Matching
Chapter Nine:
Effluent Treatment Plant (ETP)
Effluent Treatment Plant (ETP)
Function
Required Chemical
Quality Checked
Process Flow Chart
Chapter Ten:
Maintenance & Utilities
Maintenance of Machinery
Types
Manpower setup for Maintenance
Maintenance of Dyeing Machine
Maintenance of Stenter Machine
Maintenance of Dewatering Machine
Dryer Machine
39
39
39
39
40
40
41
42
43
44
44
45
45
45
45
46
46
46
47
47
48
49
49
49
49
51
53
53
54
54
55
56
56
56
57
57
58
59
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10.8
10.9
10.10
10.11
10.12
11.1
11.2
11.3
Compactor Machine
Boiler Machine
Tools & Equipments
Utilities Services
Source of Utility
Chapter Eleventh
Conclusion
Conclusion
Limitation of the Report
Recommendation
References
59
60
60
61
61
62
62
62
64
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CHAPTER-01
INTRODUCTION
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Main Product
Production Capacity
(Pcs/Day)
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improvement synonymous with total quality management pay attention to detail and
strict adherence to buyers requirements in terms of quality and design.
1.5 Welfare Facilities:
Induction of workers Welfare committee aimed at improving workers morale,
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1.6 Buyers:
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1.7 Certification:
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1.8 Map:
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4
1
Security office.
Administration office
:
:
st
th
Yarn store (Gr. Floor)+
NTRY+Garment section(1 Floor 7 floor)
E
X
I
T
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CHAPTER-02
HR & COMPLIANCE
2.1 Introduction:
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
director
Bangladesh. M.M. Knitwear ltd the Managing Director/Managing
Chairman who
controls the
entire factory. And the others respective department chief controls their department in
this factory.
Director, H R Dept.
Department
Accounts
Knitting
Deputy
Dyeing & Finishing,
Lab Officer
& QC Chief Egg.
Deputy Account
ETPs
Garments
Power, Boiler, Utility & Maintenance
Inventory
Administration
Electrical
Security
Others
Total
2.3 Management Assistant
Medium:
Accounts Officer
Intercom telephone
Fax
E-mail
Written letters & Papers
Oral
Senior
Sub assistant
Foreman
Manpower
150
Marketing 320
Store
Assistant Officer
General
Manager
10(ADMIN)
3590
50
10
77 Officer
SecurityAsst. Chief store Man
Mechanical
Officer
55 Assistant
Egg.
Manager (ADMI
44
4306
Sub assistant
Assistant
Security
Officer
Foreman
Asst. Officer
Ad
Store
Security
Havilder
2.4 In this below the organ grams of administration and the others department is
Junior
showing:
Medical Officer
.Security
Guard
Peon
Nurse
Page 20 of 65
officer
Assista
Foreman
Adm
master.
After dyeing finishing in charge controls the finishing process with the
2.6 COMPLIANCE
2.6.1 Introduction:
Social Compliance / Social Accountability is an important parameter in international
business today, and buyers from major markets global markets, are increasingly
insisting on adherence to social compliance norms.
2.6.2 .Ethical Trading Practice:
M.M. Knitwear Ltd. recognizes that there are legal and cultural environments in
which factories operate. These ethical principles set forth the basic requirements of
Babylon factories in order to do business with its customers abroad.
M.M. Knitwear Ltd. makes ceaseless effort to promote best practices and continuous
improvement of ethical issues in all its manufacturing units. For easy access to the
issues, Babylon posted contents in the Notice Boards of factories in both Bangla and
English.
2.6.3 The issues are:
Laws & Regulation:
M.M. Knitwear Ltd. facilities operate in full compliance with the laws and regulations
of the jurisdictions in which they manufacture.
Employment Age:
Workers may not be younger than 18 years of age.
Forced Labor:
Page 22 of 65
M.M. Knitwear Ltd. facilities do not use involuntary or forced labor indentured,
bonded or otherwise.
Wage and Benefits:
MM facilities compensate their employees fairly by providing compensation packages
comprising wages and benefits that, at the very least, comply with legally mandated
minimum standards. Each employee is provided with a clear, written accounting for
each pay period. Employees are compensated for overtime according to local law.
Hours of Work:
M.M. Knitwear Ltd. facilities ensure employees Hours worked shall not, on a
regularly scheduled basis, exceed the legal limitations on regular and overtime Hours
in the jurisdiction in which they manufacture or 60 Hours per Week including
overtime. Except in extraordinary business circumstances, all employees are entitled
to one day off in every seven-day period.
Health and Safety:
M.M. Knitwear Ltd. facilities provide their employees with a clean, safe and healthy
work environment, designed to prevent accidents and injury to health arising out of or
occurring during the course of work. All MM facilities comply with all applicable,
legally mandated standards for workplace health and safety. All the workers and staff
enjoy free medical treatment. Company doctors are available full time.
Discrimination:
M.M. Knitwear Ltd. respects cultural differences, employment including hiring,
remuneration, benefits, advancement, termination and retirement based on ability and
not on belief or any other personal characteristics. MM facilities do not discriminate
on the basis of race, age, color, national origin, gender, religion, sexual orientation,
disability or similar factors.
Harassment:
M.M. Knitwear Ltd. facilities treat all employees with respect and dignity. Babylon
facilities do not subject employees to corporal punishment, physical, sexual,
psychological or verbal harassment or abuse.
Womans Rights:
Page 23 of 65
M.M. Knitwear Ltd. facilities ensure women workers receive equal treatment in all
aspects of their employment. Pregnancy test is not a condition of employment, and
pregnancy testing to the extent provided by MM facilities will be at the option of
the worker.
Monitoring and Compliance:
M.M. Knitwear Ltd. facilities maintain on site all documentation necessary to
demonstrate compliance with Global Compliance Principles. MM and its subsidiaries
undertake affirmative measures, such as announced and unannounced on-site
inspections of production facilities, to monitor compliance with Global Compliance
Principles. MM facilities allow customers representatives full access to production
facilities, employee records and employees for confidential interviews in connection
with monitoring visits.
2.7 Code of conduct of SA 8000 follow by M.M. Knitwear Ltd.:
1. Child Labor: No workers under the age of 15; minimum lowered to 14 for
countries operating under the ILO Convention 138 developing-country
exception; remediation of any child found to be working.
2. Forced Labor: No forced labor, including prison or debt bondage labor; no
lodging of deposits or identity papers by employers or outside recruiters.
3. Health and Safety: Provide a safe and healthy work environment; take steps
to prevent injuries; regular health and safety worker training; system to detect
threats to health and safety; access to bathrooms and potable water.
4. Freedom of Association and Right to Collective Bargaining: Respect the
right to form and join trade unions and bargain collectively; where law
prohibits these freedoms, facilitate parallel means of association and
bargaining.
5. Discrimination: No discrimination based on race, caste, origin, religion,
disability, gender, sexual orientation, union or political affiliation, or age; no
sexual harassment.
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Management Practice.
Documentation.
Working Time
Remuneration.
No Discrimination.
Working Conditions.
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Dormitories.
Environment
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Page 27 of 65
CHAPTER -03
Different Departments
To ensure smooth running of various activities, some departments are available they
are given bellow:
KNITTING SECTION:
1.Knitting
2.Inspection
KNIT DYEING SECTION:
1.Batch section
2.Store house for dyes & chemicals
3.Dye house
4.Dyeing & QC lab
5.Finishing
GARMENTS SECTION:
1.Merchandising
2.Sample
3.Production
MAINTENANCE:
1.Electrical
2.Mechanical
ACCOUNTS & COMMERCIAL SECTION
ADMIN SECTION
Page 28 of 65
CHAPTER-04
KNITTING DIVISION
4.1 Introduction:
Knitting is defined as the construction of fabric by interlocking loops of a single yarn
with the help of hooked needles. Each raw of such loops hanging from the one
immediately preceding it. Interloping consists of forming yarns into loops. The loops
are held together by the yarn passing from one to the next
Knitting may be done by hand or a machine. By hand, there are numerous styles and
methods. Flat knitting, which can be done on two straight needles or a circular needle,
produces a length of cloth, while circular knitting, which is done on circular or
double-pointed needles, produces a seamless tube.
4.2 Types of Knitting: There are two types
a. Warp Knitting.
b. Weft Knitting.
4.2.1 Warp Knitting:
In warp knitting, one or two yarn produce vertical column of loops and fabric is
produced in length way. Each loop in the horizontal direction is made from a different
thread and the no of threads used to produce such a fabric is at least equal to the
number of loops in horizontal raw. e.g. Net, Mesh fabric etc
4.2.2 Weft or Circular Knitting:
In a Weft knitted structure, a horizontal raw of loops can be made by using one thread
and the thread runs in horizontal direction. e.g. single jersey, rib, interlock etc
Page 29 of 65
PO
STORE INCHARGE
KNITTING MASTER
SUPERVISOR
FITTER MAN
FITTER MAN
OPERATOR
OPERATOR
Origin
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Taiwan
Japan
Japan
Japan
Nos
05
02
02
02
02
01
02
01
04
03
09
11
10
10
09
07
04
02
03
03
03
03
02
04
01
02
02
01
Page 31 of 65
They have computerized flat knit machines branded around star, kauo heng, Jy lee
having jacquard option to produce different types of collar, Cuff and bottoms.
4.7 Narrow Fabric Unit:
They have a narrow fabric unit to produce better quality accessories of garments like
twill tape, dusting etc
4.8 Quality Control Unit:
They have a Ill equity quality control unit to product the best quality for my
customers.
Table 4.2: Quality Control Unit
1
No
8
0
s
No
GERMANY
Yarn Tension Tester Made by SCHMDT from GARMANY
2
0
s
No
3
0
s
No
4.9 Summary:
Table 4.2: summary of Knitting
Total
Floor Space
Total Capacity
Manpower
158 sets
80,000 sq. feet
28,000 Kgs/Day (Average)20,000 Pw Collar/Day
(Average)20,000 Yds Tape/Day (Average)
390 personnel
Page 32 of 65
CHAPTER-05
DYEING & FINISHING DIVISION
5.1 Introduction
Dyeing means to color the whole fabric using different chemicals & dyestuff.
Although dyeing is a chemical operation, most of the simpler processes may be
carried out on the small scale by sensible people who have very little chemical
knowledge, nevertheless, following a set of instruction in ignorance of the reasons
behind their formulation is unlikely to lead to the deeper understanding of textile
coloration that is needed by professional people in the coloration industry.
Consequently this chapter has been included the working knowledge of chemistry.
5.2 Process flow chart of dyeing:
Grey fabric receive from knitting section
Batching
Fabric loading
Pretreatment
Dyeing
After treatment
Fabric unloading
Flow chart 5.1: dyeing Department
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PM
APM
SPO
Batch in charge
Finishing in charge
Lab
In charge
Sewing man
Lab technician
PO
Sewing man
APO
Squeeze
Supervisor
Operator
Dryer
Q.C. technician
Helper
Operator
Sr. Operator
Helper
Compactor Operator
Asst. Operator
Operator
Helper
Page 34 of 65
Capacity
Nos
Air Compressor
Air Compressor
Air Compressor
7.5 M3/Min
1 sets Germany(Rollair)
Air Compressor
4.6 M3/Min
1 sets Germany(Rollair)
Compare
5 M3/Min
Sample Winch
15 Kgs/Batch 4 sets
China(Suntex)
10
Sample Winch
30 Kgs/Batch 2 sets
China(Suntex)
11
Sample Winch
10 Kgs/Batch
1 set
Bangladesh
12
Sample Winch
20 Kgs/Batch
1 set
Bangladesh
13
Sample Winch
50 Kgs/Batch
1 set
Bangladesh
14
15
16
17
18
19
20
Fongs ( China )
21
Fongs ( China )
22
Fongs ( China )
23
Fongs ( China )
24
Fongs ( China )
Origin/Brand
Turkey(Mersan)
UK (Cochran)
2 sets Germany(Rollair)
1 sets
U.K
Page 35 of 65
Sl.
Capacity
Nos
25
26
27
28
29
30
31
32
33
34
35
36
37
RollerSun-Supper S
Tenter(98&8Chember)
Korea(Ilsung)
38
Slitting Machine
Italy(Bianco)
39
40
41
Brushsueding M/C
3 set
Origin/Brand
USA(Tubetex)
Italy(Laffer)
700 kgs/Day
1 Set
Italy
1 Set
Italy
Page 36 of 65
Page 37 of 65
Shade check
Open width
Tubular form
De-watering
De-watering
Slitting
Drying
Stentering /Dryer
Open compactor
Final Inspection
Final Inspection
Packing
Delivery
Packing
Delivery
Flow chart 5.3: Process flow chart of finishing
etc.
Iaring qualities, non- soiling, anticrease, antishrink comfort etc .
Special properties for particular uses -water -proofing flame proofing etc .
Covering of the faults in the original cloth .
Increasing the Iight of the cloth .
Crease recovery.
Dimensional stability
Shine or luster
5.12
or air sprayer
It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism
Dia/width control
Apply chemical
Softening agent
Brightening agent
GSM control
Apply chemicals
Apply softener
Drying of fabrics
Width control
Curing of fabric
GSM control
Shrinkage control
Spirality control
Pigment dyeing
Surface coating
Heat setting
Page 40 of 65
CHAPTER-06
TESTING
6.1 Introduction:
Textile dyeing is combination of some series processes such as scouring , Bleaching ,
dyeing & after treatment which can be carried out at stages of fiber processing in
different forms like stable , yarn , fiber. Pretreatment is the preparatory process of
textile dyeing. It is also called the HEART OF DYEING.
6.2 Types of Test in Laboratory:
There in two types of test done in laboratory,
1. Physical Test
2. Chemical Test
6.3 Stock solution preparation:
In practice 1% stock solution is very common used in dying process. In Laboratory
work, 1.0 gm solid ( 100% concentration ) dyestuff / chemicals taken in a conical flax
& poured 100 ml of warm water ( 45 0c) to dissolve the reagent to make 1% stock
solution.
In the case of liquid ;
Take 10 ml liquid in a beaker; making it 100 ml by pouring necessary amount of
water is prepared 10% solution
Yarn grade
Gsm test
Shrinkage test
Spirality test
Tensile test
Abrasion resistance
Pilling resistance
Page 41 of 65
Lycra% determination
Crease resistance
chemical solubilitytest
Croc meter
Light box
Electric balance
Washing machine
Tumble Dryer
Perspire meter
10 Pilling Tester
11 Rota Wash
12 Electrolux Wascator
13 STD Front Tumble Dryer
14 Lab Oven & Incubator
15 PH Meter / Temperature Meter
Nos
Origin/Brand
1
set
2
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
set
1
U.S.A
U.K
Korea
U.K
U.K
U.S.A
Italy
Italy
U.K
U.K
Page 42 of 65
16
set
1
set
Wash Fastness:
Fastness to washing DIN EN ISO 20105 C 03: 60c : at least 4 -5.
Staining on Cotton, Polyester, Polyamide, Wool : at least 4.
Rubbing Fastness:
Fastness to rubbing DIN EN ISO 105 X 12: Dry at least 4 & It at
least3.
Page 43 of 65
CHAPTER-07
Garments Division
7.1 Sample division:
The style done by designer or developer.
Particular purchase order.
Basic block
(Without any allowance)
Working pattern
(To make of garment according to design)
Sample making
(Sample is made by sample man)
Approved sample
(Sample approved by buyer)
Costing
Page 44 of 65
Development sample
Salesman Sample
Photo Sample
Approval Sample
Size set Sample
Mock up Sample
Pre-production Sample
Production Sample
Shipping Sample
7.1.3 Summary:
Cutting Table: 11 cutting table of (70-90 feet each) in fmy separate floors.
Floor Space: 40,000 sq. feet.
Total Capacity: 65,000 Pcs / Day (Average)
Manpower: 370 personnel
Page 45 of 65
Page 46 of 65
7.7 Office staff A large team of Technical personnel are directly working, assisting
the workers and Coordinating pattern, cutting, sewing, and quality, finishing-packing.
About 200 people are working as a supervisor, line chief, Floor in charge, section
manager.
7.8 Quality Team Independent quality team of 454 people is working to ensure
customers required quality standard. Factory regular AQL system is 2.5 but in certain
case it depends on customer requirement.
7.9 Logistic Team A team of 15 personnel working under the General Manager to
ensure proper and timely documentation to continue smooth procedure of Export
import , Banking and other logistic support.
Page 47 of 65
No. s
777
08
593
17
06
06
24
14
105
278
06
05
10
23
24
06
140 Sets
05
06
01
01
05
2085
Origin
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Taiwan
Japan
Japan
Japan
Japan
BD
Japan
Thailand
USA & China
CHAPTER-08
Quality Management System
8.1 Quality Policy:
Page 48 of 65
It is the policy of M.M. Knitwear Ltd. to produce quality dyed knit fabrics that meet
the customers expectations & needs. To implement this policy the top management of
Landmark Textile Mills Ltd. is committed to provide adequate Resource in terms of
good raw materials and trained personnel & continually improve / upgrade its
processes and systems. The quality control policy of Landmark Textile Mills Ltd. is
stated below
finishing.
Maintain chain of responsibility.
Follow strict stuffing, auditing and reporting.
Use inspection machines in required points.
Maintain standard AQL.
Sufficient lighting and sanitation.
Final inspection prior to packaging.
Meeting the appropriate expectations of clients.
In laboratory.
In dyeing section
In finishing section
Hole
Slub
Needle mark
Stripe
Missing yarn
Contamination
Uneven shade
Running shade
Fastness property
Dye spots and marks
Page 50 of 65
GSM variation
Spirality
Shrinkage control
Marks
Making sure that the operators add the right batch of chemicals at the same
time & temperature in the process.
Check the water supply daily especially ph, hardness & Na2CO3 content.
Batch to batch processing may vary due to the improper calculation of dyes and
chemicals and improper strength of salt soda and H 2O2 etc. Beside hardness of water
and caustic may lead to an improper shade.
8.8 Process of Shade Matching:
The required shade provided by the buyer is reproduced in the lab in lab
dyeing machine after the recipe prediction. The lab in-charge first uses the Computer
Color Matching System, to obtain the closest shade match recipe. Then he consults
the shade card and Pantone book to verify the obtained recipe. If he thinks that certain
changes in the recipe are necessary, he then alters the recipe according to his
experience. This recipe is used to dye a sample of 5 gm fabric in the lab dyeing
machine with following parameters.
a) Temperature and time
Cold Brand Reactive Dye - 65 c temp; 60 min
Hot Brand Reactive Dye - 98 c temp; 60 min
Turquoise Color (Cotton) - 85 c temp; 60 min
Polyester - 130 c temp; 30 min
b) M:L ratio
The samples are usually dyed using 1:10 ratio.
c) Pentone Book
Pentone Textile Color Selector
Total shade 1701
Color numbering system 6 digit + suffix
First two digits
11 to 19 ( range of lightness)
01 to 64 ( range of hue)
01 to 64 ( range of chroma)
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Chapter-9
Effluent Treatment Plant (ETP)
9.1 Effluent Treatment Plant (ETP):
The effluent generated from different sections of a textile industry must be treated
before they are discharged to the environment. Various chemicals and physical means
are introduced for this purpose.
Capacity
80m3/ hr
Cost
Tk. 2.5 / m3
: 35 to 37 C
PH (Maximum)
: 6.5
Color
PH
etc.
9.5 Process Flow chart of Biological Effluent Treatment Plant:
Fabric Dyeing
Acid Dosing
Homogenizing Tank
Distribution Tank
Antifoaming
Dosing
Biological Oxidation Tank
De-colorant
Dosing
Sedimentation Tank
Sludge Thickener
Polyelectrolyte Dosing
Dry Sludge
Filter Press
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CHAPTER - 10
MAINTENANCE & UTILITIES
10.1 Maintenance of Machinery
Maintenance of machinery is very essential mechanical effort for achieving smooth
running of different machines. Maintenance is a process by which equipment is
looked after in such a way that trouble free services and increased machine life can be
ensured and specific product quality required by the customers is sustained. On time
maintenance increase m/c lifetime & ensures trouble free services.
10.2 It has 2 types of Maintenance:
1. Break down maintenance
2. Routine maintenance
Maintenance
Routine Maintenance
Mechanical Maintenance
Electrical Maintenance
Mechanical Maintenance
Electrical Maintenance
Figure 10.1: maintenance
10.3 Manpower Setup for Maintenance
10.3.1 for electrical Maintenance: Per shift:
B Sc. Engineer - 1
Diploma Engineer - 1
Senior Technician 2
Junior Technician 4
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No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
1.
2.
3.
5.
4.
5.
6.
7.
8.
Checking of motors
1.
2.
3.
4.
5.
6.
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1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
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1.
2.
3.
4.
5.
6.
7.
8.
19.
20.
Avometer/Voltmeter
Steel tape
anything
To measure voltage
To measure length, width &
height
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CHAPTER 11
CONCLUSION
11.1
Industrial attachment or, Industrial training is an essential part for textile education
because it minimizes the gap between theoretical and practical knowledge. These
Industrial training increases mine thought a lot about Apparel technology. It also helps us
to know a lot about industrial production process, machineries, and industrial
management and made me suitable for industrial life. Besides it gives us the first
opportunity to work in industry.
I have completed my industrial attachment from MM Knitwear Limited.
This factory does not compromise in case of quality. So, they have established on-line
and off-line quality control of each product. Besides, they also use the good quality yarn,
dyes and chemicals in their production process. Due to this, it has earned a very good
reputation in foreign market for its quality product over many other export oriented
textile mills. It has very Ill educated and technically experienced manpower to get rid of
any defect in production process. It has also a good organizational hierarchy. At last, I can
say industrial attachment prepare us for the expected destiny of practical life.
11.2 Limitations of the report:
Because of secrecy act, the data on costing and marketing activities have not been
supplied.
I had a very limited time. In spite of my willing to study more it was not possible
to do so
Some points in different chapters are not included as these Ire not available.
It is not possible to hold the whole thing of a textile industry in such a small frame
as this report. So, try my hard to summarize all the information that I are
provided.
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11.3 Recommendations
Knitting production needs to increase as Ill as technical persons need to be
employed there?
More skilled labor should be used in a project and the overall efficiency will
increase.
Dyeing floor should keep always neat and clean. It kept It after unloading the
fabric from the dyeing machine specially, for Athena. Water must be swept time to
time.
During the transport of the fabric and during the loading of the m/c, fabrics get
soiled due to their drawing over the floor. This makes the fabric/part of the fabric
dirty. It may require more scouring/bleaching agent or may create stain.
Due to the pressure of higher production some times machine operators do not
maintain accurate time according to the actual process so that less quality product
is produced and may reject. So my suggestion is to increase machine and reduce
the pressure on the operator.
Should increase understanding between the top level personal and floor level
personal.
Finishing section need to be enlarged Ill as more technical persons need to be
employed there.
The m/c stoppage time should be analyzed and minimized. The maintenance
should be carried out when the m/c is out of action (Wherever possible) and
routine maintenance should be carried out regularly.
In knitting and finishing section every workers should use mask to make protect
them from fly. Otherwise the exhaust air system should be more effective.
Workers are not interested to wear their gown & hand gloves.
In the Laboratory there is no technical person, a textile engineer may be employed
here.
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References:
1.
2.
3.
4.
5.
6.
www.google.com
www.mmKnitwear.com
www.slideshare.com
www.textiletoday.com
www.scholargoogle.com
www.eprothomalo.com
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