Name: Mahbuba Siddiqa Moumi

ID: 2017000600007
 Country of origin: Bangladesh
Location: Madhabdi, Norshindi, Bangladesh
Size: 980386sft (22 Acre)
SITE ANALYSIS
Programs

• Main factory
✓ Vehicular Entry ✓ Pump room
✓ Pedestrian Entry ✓ AC Plant
✓ Guard Room ✓ Laboratory & Research room
✓ Loading-Unloading area ✓ Finish Good Storage
✓ Fabric and Trims Inspection Room ✓ Production Room
✓ Fire Stair ✓ Waste material room
✓ Electrical Room ✓ Day Care
✓ Raw material storage ✓ Toilets
✓ Health care ✓ Prayer Space
✓ Kitchen
✓ Dining

• Complex Area
✓ Grocery shops/Food Courts
✓ Restaurant ✓ Library
✓ Multipurpose Hall ✓ Residence for Workers
✓ Mosque ✓ Administrative Building
✓ Ware House
Program Analysis

• Spinning factory • Textile factory

1. Blow room – 31,063sft 1. Weaving zone – 10,000sft

2. Drawing – 8,142sft 2. Packing – 8,000sft

3. Combing – 10,000sft 3. Raw material storage – 1,500sft

4. Spinning (ring+simplex) – 12,522sft 4. Finish material storage- 1,500sft

5. Packing – 8,835sft 5. Inspection room – 650sft

6. Raw material storage – 2,500sft 6. Electrical room (2) - 120sft

7. Finish material storage- 1,500sft 7. Circulation 20% = 5,000sft

8. Inspection room – 650sft Total- 26,770sft

9. Electrical room (2) - 120sft
10. Circulation 20% = 15,000sft

Total- 90,332sft
Combine Factory Program Factory Complex Program

1. Guard room (2) – 25+25 = 50sft 1. Multipurpose Hall – 2500sft

2. Healthcare – 1250sft 2. Restaurant – 5000sft
3. Daycare (25% kids, 50 kids) – 1850sft 3. Mosque – 3000sft
4. Dining (200 people) – 3000sft 4. Food court – 2000sft
5. Kitchen (200 people) - 2000sft 5. Park – 5000sft
6. Laboratory & research – 2500sft 6. Library (small) – 2000sft
7. CCtv control room – 1500sft 7. Office Building – 5000 sft
8. Toilet (4 zone) – 512*4 = 2050sft 8. Dormitory (150 people)
9. Prayer space- 1000sft • Living area (120sft per head) – 18,000sft
10. Lobby & buyers waiting lounge – 2,000sft • Dining – 3000sft
11. Circulation 20% = 4000sft • Kitchen – 2000sft

Total – 21,200sft • Toilet – 1500sft

• Guest house = 8000sft
• Circulation 20% = 11,600sft

Total – 69,600sft
• Factory area total – 138,302sft
• Factory Complex Area – 69,600sft
Total –207,902sft
- 5 Acre (approximately) in total
SPINNING MILL
• Blow room is the starting of the spinning operation where the fiber is opened, cleaned, mixed, micro
dust removed and evened thus passed to carding machine without increasing fiber rupture, fiber neps, broken
seed particles and without removing more good fibers.
(Mixing, blending, cleaning)

Bale opener Mixer

• Carding, in textile production, a process of separating individual fibers, using a series of dividing and redividing steps,
that causes many of the fibers to lie parallel to one another while also removing most of the remaining impurities.

• Breaker Drawn Frame is a machine for combining and drawing slivers of a textile fiber (as of hemp for rope
manufacture or cotton for spinning). Drawing is the operation by which slivers are blended, doubled and leveled.
• To convert or transfer the opened and cleaned cotton fiber into a sheet form of definite width and uniform unit length
is called Lap Former.

• A combing machine is a one type spinning machine for spinning process of yarn which has comb to straighten
the fibers and extract neaps, foreign matter and short fibers. Combing machine is used to produce higher count
yarn(stronger , more even, more compact, finer, smother).
• Finisher Draw Frame is done to give further strength and stability to the silver. The drawn silver from breaker
Draw frame is again drawn .

• Simplex for spinning process is an industrial machinery used for spinning process of Textile technology to
transform the drawn sliver into roving. The main function of simplex machine is the attenuation of drawn sliver
and insert small amount of twist to give required strength of roving.

• The machine in which the final draft is given to the roving and converted to yarn is called ring frame.
Layout of Ring Spinning Unit
Production & Man force Analysis
Needed Machine for a Spinning Mill
•We know, 1 Cotton Bale net weight is
Blow Room 174 kg.
No Name of Mechine Type No of Mechine •Required Cotton bales - 364 bales /
1. Uni Floc A12 2 day (around 60,204 kg)
2. Uni Clean B12 2 •1,32,860 / year
3. Uni Mix B76 2
4. Uni Store A78 2 •Plant production per day - 54600 kg
5. Metal Particle Eliminator FA121 2 of yarn/day, which is 90% of the total
Carding raw material)
No Name of Mechine Type No of Mechine •1,99,88,787 kg/year
6. Card C60 16
Draw Frame
No Name of Mechine Type No of Mechine
7. Breaker RSBD-50 5 •Total 20,000 spindel spinning Unit
8. Finisher RSBD-50 5 •Size of the area: approximately 4.5 acre
Simplex
No Name of Mechine Type No of Mechine
9. Simplex FT60 23
Total: 83 Mechines For 20000 spindel
Ring spinning unit.
No Name of Mechine Type No of Mechine
10. Ring G-32 13
Laboratory
No Name of Mechine Type No of Mechine
11. Uster Teaster 3 UT3 1
12. Uster Tensojet UTJ-TE 1
13. Ring Wrapping Reel 1
14. Lea Streangth Tester 1
15. Wrapping Drum 1
Packing
No Name of Mechine Type No of Mechine
16. Packing Mechine G-32 6
Needed MANFORCE for a Spinning Mill
SI. No Description Number
1. Spinning Manager 1
2. Asst. Spinning Manager 1
3. Production and Tech Manager 1
4. Production Head 1
5. Mainttenance Head 1
6. Shift Leader 1
7. Production Supervisor 6
8. Mechanical maintenance supervisor 1
9. Electrical Supervisor 1
10. Machine Operators 40
11. Mechanic 10
12. Electrician 5

13. Quality and Labrotary Manager 1

14. Process testers 6
15. Marketing Manager 1
16. Finance Manager 1
17. Accountant 3
18. Clerks 3
19. Chasier 1
20. Store Keepers 4
21. Guard 7
22. Messenger and Cleaner 1
23. Driver 3
24. Cleaner 20
120
Spinning Factory Layout For My Design
Spinning Factory Layout For My Design
Case Study
Noman Weaving Mills Ltd.
Mawna, Sreepur, Gazipur
Noman Weaving Mill Location
GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD

➢ Name of the factory : Noman Weaving Mills Ltd.

(An enterprise of Noman Group)

➢ Location : (kewa westside), Mawna, Sreepur, Gazipur.

➢ Business Type : 100%Export Woven Factory

➢ Status : Private Ltd. Company.

➢ Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120,

Motijheel C/A, Dhaka-1000.

➢ Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282

History of the project development:

Land purchase : June 2006

Machine setup : December 2006

Year of production : January 2007

Total area of land : 25 Bigha

Production floor:

(a) Airjet floor : 47581 sft

(b) Sizing shed : 44762 sft
(c) Sectional warping : 18036 sft
(d) Picanol floor :11620 sft

No. of machine:

(a) Toyota air jet loom : 128 pcs

(b) Picanol loom : 40 pcs

Production capacity:

(a) Toyota airjet loom : 45000 Mtr

(b) Picanol loom : 9000 Mtr
Total production : 54000 Mtr
Per month production : 1404000 Mtr

Man power:

Officer Staff Worker

a) Male : 41 Male : 93 Male : 418
b) Female : 01 Female : 02 Female : 144

Total manpower of the factory : 699 people

Products
#
 Poplin
 Voile
 Matt
 Canvas
 Oxford
 Stripe Fabrics
 Check Fabric
 Stripe Satin
 Five ends Satin
Manufacturing Products of the company

Denim Twill Grey Check Stripe

fabric fabric fabric fabric fabric
➢Flowchart Of Woven Fabric Production
Yarn from
inventory
Storing Winding

Inspection Warping

Weaving sizing

Winding on
Looming weavers beam

Denting Drawing
Weaving
preparatory
process Weft Warp yarn
yarn processing
processi •Winding
ng •Warping
•Sizing
• Weft yarn
•Drawing and
(Cone form)
Denting
•Knotting
•Looming
Winding
Winding is the process of transferring yarns from ring,bobbin,hank etc.
into a suitable package.

Machine name: Cone Winding Machine

Origin :China
Model :GA014MD-120
Spindle:
120
Input
:Cone
Output:
Cone
Warping
The parallel winding of warp ends from many winding packages onto
a common package is called warping.

Machine Specification
 Name of the m/c: Benninger
 Name of origin: Switzerland
 Creel capacity : 1224
 RPM : 750
 Beam width : 2400 mm
Sizing
The process of applying a protective adhesive coating upon the warp
yarns surface is called sizing.

Machine specification
 Machine Name :Benninger
 Origin : Switzerland
 Cylinder : 14
 R.P.M :160 Max
 Lease rod : 29
 Beam capacity : 32
 Cylinder Temperature : 145 degree
Loom #01

AIR jet
Machine specification
 Name of the machine : Toyota
 Brand : Toyota JAT 710
 Origin : Japan
 RPM : 800
 Shedding : Tapped & Dobby
 Weft insertion : By Air
 Operating system : Computerized
Loom #02
Machine specification

Name of the Machine : Picanol

#1 Optimax Picanol Gamma
#2 Gamma
 Origin : Belgium
 R.P.M :
#1 Optimax-650
#2 Gamma 8R-500
 Loom type : Rapier
 Shedding system : Tappet &Dobby

Picanol Optimax
Maintenance

The main purpose of regular maintenance is to ensure that all

equipment required for production is operating at 100% efficiency at
all times.

Types of Maintenance:
(Ⅰ).Reactive Maintenance
(Ⅱ).Periodic Maintenance
(Ⅲ).Proactive Maintenance
Utilities used in the industry

➢ Natural gas generator

➢ Compressor
➢ Chiller
➢ Boiler
➢ Power Plant
Store & Inventory Control
Inventory control is important to maintaining the right balance of
stock in warehouses.
Amber Denim Loom Shed
Amber Denim Loom Shed
Country of origin: Bangladesh
Location: Gazipur, Bangladesh
Client: Showkat Aziz Russell
Architect: Jubair Hasan
Design: 2013
Size: 283,280 m²
Completed: 2015
Top view

The Amber Denim Loom Shed is a

project that was initiated by Amber
Denim Ltd. The structure is located
inside the Amber Denim factory
compound, in the Gazipur area of
Bangladesh.
What started as a project to
welcome guests and buyers,
evolved into an activity space for
workers and visitors of the factory,
improving their welfare.

The design, by Jubair Hasan of Archeground, takes its inspiration from a traditional Bengali pavilion – a
simple post-and-beam structure with pitched roof that can be found in villages all around Bangladesh.
Design Concept

Jubair Hasan wanted to create a

building that reflects the design of a
traditional Bangladeshi pavilion – a
semi-open, simple post-and-beam
structure with pitched roof, that can be
found in many villages in the country.
He felt compelled to do this because
nowadays there are fewer and fewer
people living in the villages, and the
construction techniques to make these
pavilions are slowly disappearing.

The loom shed was built on a vacant land in the back end of the
factory’s compound.

It is a rectangular single story

building, spanning north to south,
with the longer facade of the
building facing to east and west,
inspired from the traditional Bangali
pavilion.
Reacting to the initially stated requirements,
the architect placed the two main areas of this
building in its two ends: the visitors’ lounge
closer to the end where most visitors will enter
the building, and the more noisy looming
machines area in the farther part, closer to the
workers’ compound, where fewer visitors
would enter first.
Site Plan
Ground Floor Plan
A waterbody was introduced to enhances the beauty of the site and also absorb the dust through water, as
loom produce dust much.
Structure, Materials

Structure, materials, technology The main structure of the

building is post-and-beam, with pitched roof, employing 10-
inch gas pipes that the company had previously bought but
had not used.Since the length of a single pipe is 40 feet (12
metres), the architect thought there was enough length and
strength for this pipe to serve as the building’s main
structure.

The roof covering is using custom concrete roof tiles

made on-site.

The roof covering is of custom-made concrete roof

tiles, produced on site. Fewer and fewer buildings in
Bangladesh use roof tiles, and the technique of
making them is slowly disappearing. Jubair Hasan saw
10” unused gas pipe that the company had previously bought, it as part of his obligation to maintain the presence of
but did not used, have been reused as main building this material, which is why he used roof tiles for this
structure. building.
Walls are made of local bamboo that is dipped in a chemical solution and then treated with oil (chorsh polish) and
bobhakali (a type of local sand) to give a dark and coarse finish.

The floor is in concrete with a cement finish. Even though the inspiration of the structure comes from traditional
Bengali pavilions, the construction technology used in this building is a relatively modern welded steel structure,
concrete/cement-based materials, and bamboo with chemical treatment.
 Buyers are driven in the loom shed where they can
see the quality of the products and how the factory
is operated.

Workshops about safety, efficiency and other

aspects of work are organised in the shed.
 The main structure of this building is
post-beam structure, with pitched roof.

Bamboos used for the facades protected well

from the rain and water, by the roof’s overhang
 The position of the building has created an
open-field that is often being used by factory
workers for recreational activities or other
factory gathering events.

Only toilets and storage areas have solid walls.

Partitions for other areas, are using bamboo walls.
Thank You!