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Dye House Project- Ocean Lanka (Pvt) Ltd. Contents Declaration Chapter 1 1. Curriculum vitae 2. Reference letter from the current Employer 3. Certified copies of Qualifications and Academic Records 4. Continuing professional Development Record Chapter 2 1. Career Episode 1 2. Career Episode 2 3. Career Episode 3 Summary statement

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Page 1: Dye House Projectonly

Dye House Project- Ocean Lanka (Pvt) Ltd.

Contents

• Declaration

• Chapter 1

1. Curriculum vitae

2. Reference letter from the current Employer

3. Certified copies of Qualifications and Academic Records

4. Continuing professional Development Record

• Chapter 2

1. Career Episode 1

2. Career Episode 2

3. Career Episode 3

• Summary statement

Page 2: Dye House Projectonly

DECLARATION

I do hereby declare that the details mentioned herein with regard to my personnel details,

Academic details, professional training are true to my Knowledge. All the particulars

mentioned in each section of my Curriculum Vitae can be verified individually.

This Project is a unique experience I have gone through while in the service of Ocean Lanka.

Calculations, adopted theories, calculated risks, assumptions are all used in the designing or

initial stage of each episode.

…………………………………….. …………………………………….

K.H.Sanjaya Silva Date

Page 3: Dye House Projectonly

DYE HOUSE PROJECT

� Company & Process……………

Established in 1994, Ocean Lanka is the largest manufacturer of Weft Knitted Fabrics in the

island located in Biyagama Export processing Zone and jointly owned by Fountain Set (Hong

Kong), Brandix and Hirdaramani with over 1800 employees. A well-established, respected and

fast moving company manufacturing and supplying weft knit fabrics (Single Knits, Double

Knits, Flat Knit, Prints & Yarn Dyed) to the Sri Lankan apparel industry for a growing number

of international brands, including Victoria’s Secret, Next, Marks and Spencer and Nike.

Ocean Lanka possesses the total Textile manufacturing process and facility except for Yarn

making. This includes Yarn, greige (Raw cloth) & finished fabric ware houses which can

accommodate more than production & output demand. The process mainly comprised of

Yarn processing, Yarn dyeing, Piece (raw cloth) Dyeing, Fabric treatment & finishing, Fabric

Printing and Quality Control. There are few other sub processes which support the main

process units. Generally Ocean lanka makes approximately 2,000,000 lbs. of finished fabrics

per month (there could be higher or lower values depending on the Brand and season

demands).

Page 4: Dye House Projectonly

Problem & Cause……………………..............

In general, a Project is defined as a collaborative enterprise, involving research or design that

is intentionally planned to achieve a particular Goal or a solution to a prevailing problem. But

it is rather temporary than permanent social systems or work systems that are constituted

by teams within or across organizations to accomplish particular tasks under time

constraints. Or in simple terms a temporary specified task with scope, time, cost and quality

limitations. In that context, the Project in this Episode was designed to provide a reliable

solution the said production capacity problem which has hampered the Dyeing Department

performance for a long time. Hence this episode will be segmented to present a clear view

relate to the cause, remedy, design, works and the final result.

In order to achieve the expected finished fabric quantity, there are certain Dye production

quantity have to be met. This depends on the machine output/cycle /Day. Further, there are

more than 3,000 Fabric types Ocean lanka has developed and has the capacity to manufacture

–this is an on-going process and new fabrications (total fabric making process) are being

added continuously. This has added more dye batches where existing number of Dye

machines cannot handle in given time. All these incidents has created an unwanted delay time

in Dye process due to elongated Queue time in Dye machines. There are 68 Dye Machines

with only 10 machines which have high temperature recipe.

This problem has created 17-14 days queue in most of the smaller capacity machines ranging

from 30 lbs to 250lbs. The analysis has shown that this trend has created by the Brand

Demand; created by the consumer Demand & trend; which has reduced more Bulky Dye

orders and demand was focused on smaller Quantities. –Refer Table 1

Page 5: Dye House Projectonly

In order to find the cause for this, machine queue data from 2012 & ongoing (2013) were

compiled. The purpose of this exercise was to come up with the right combination of machine

capacities.

Table 1

Ocean Lanka Data – Dyeing Department Machine Queue in days up to 2013 January

Dye M/C GN 8T ECO6T EC04T TSF6T TSF 3T

Type , No # 28,29

#

30,31,38,40

#

34,37,39,41 # ,12,13,14 # 17,18,19

& Capacity 3600 Lbs. 3000 Lbs. 2000 Lbs.

1500-2100

Lbs.

700 - 1050

Lbs.

2012 m/c

queue 3.3 5.3 7.6 5.9 6.8

2013 m/c

queue 6.9 7.6 13.5 9.2 14.4

Average

m/c

queue 5.1 6.45 10.55 7.55 10.6

# of

batches

@ mc

queue 16.32 41.28 67.52 48.32 50.88

Dye

M/C ECO2T ECO1T TSF 2T ECO1T AU 1T

AU

1T

AU

1T AU 1T Winch

Type & No # 36,42 # 43,46 # 15, 16 #44,45

#

47,48,49 # 50,52 # 51

#

53,54,55,56 # 1,2,3

Capacity 1000 Lbs. 500 Lbs.

450 -

700 Lbs.

250 <

Lbs.

130 <

Lbs.

66 <

Lbs.

11 <

Lbs. 22 < Lbs.

90 <

Lbs.

2012

m/c

queue 4.9 10.2 14.4 15.4 14.1 12.4 5.3 3.8 5.9

2013

m/c

queue 6.9 12.6 16 13.3 15.7 8.7 8.5 6.2 6.9

Average

m/c

queue 5.9 11.4 15.2 14.35 14.9 10.55 6.9 5 6.4

# of

batches

@ mc

queue 18.88 36.48 48.64 45.92 71.52 33.76 11.04 32 30.72

Dye M/C Winch Winch AK S T AF1T

Type & No # 8,9,4,5 #6,7,10, 11 # 1,2 #57

Capacity 50 < Lbs. 30 < Lbs. 15 Lbs.

660 <

Lbs.

2012 m/c

queue 4.8 7.3 7.4

Page 6: Dye House Projectonly

2013 m/c

queue 4.2 5.75 3.4 1.8

Average

m/c queue 4.5 6.525 5.4 1.8

# of

batches @

mc queue 28.8 41.76 17.28 2.88

This analysis was the prime evidence to raise a case against Production delays and On-Time-

Delivery issues. Hence it was decided to replace existing machines with high temperature,

low-liquor ratio machines which will consume less Electricity, Steam , Chemicals (Dye stuff)

etc..

Assumptions & Aims………………………

--- The Obvious primary aim of this project is to reduce the prevailing machine delays, which

has caused the company in terms of On-Time-Delivery rating, defects appeared after Dyeing

due to greige fabric in idle for longer periods, low production.

----The second aim of the project is to reduce the water usage as Textile Dye process is one of

the most water consuming production process anywhere in the world. Although there are

other inventions like Air Flow machines (a Forced draft is used to create the turbulence inside

the machine to support the dye absorbing process) and most advanced models like

“Waterless Dye machines” (Already one of the most sought after Brand has started an

Experimental Factory process in Asian region) . In the Textile Dye terminology, the water

contribution is known as Liquor ratio (L/R); the ratio between Dry weight of the Fabric and

the water requirement for dyeing process (Although there are more sub processes connected

to the total Dye process like Scouring, Washing –as many washing cycles as the particular

fabrication specified, Rinsing etc. which may need different water quantities, the Liquor ratio

is referred to the water quantity required for the total process as an average). In the Ocean

Lanka case, the average L/R was between 8:1 to 9:1. The magnitude of this number will be

visible when we consider an average monthly Dye production of 2,000,000 lbs. (this may vary

between 2 million – 2.5 million)

Hence monthly average Dye production – 2,000,000 lbs (909,090 Kgs)

Water consumption @ Dyeing 8:1 Liquor ratio + - 7,272,720 ltr

(But total water consumption was averagely 50ltr/ lbs of finished fabric)

The Specifications of the Machine Model selected for the Project mentions the factory tested

L/R as 4:1 but we assume the practical value to be between 5:1- 6:1 due to waste between

sub processes, drain efficiencies etc... Hence this was one of the Intended targets of this

Project. As per the manufacturer’s specifications, they will achieve this through the inside

structure- the change in the fabric path inside the Dye chamber, the high temperature option

will reduce the water quantity needed to dissolve the specified dye quantity and the final

Page 7: Dye House Projectonly

absorption will be faster, Change in the Dye Process Recipe will reduce the time taken for the

process through improved methodology, Change in the Dye Cycle

---- The third aim is to regularise the working temperature of Dye machines. Cotton fabrics

needs lower Temperature surrounding whereas Lycra based or Polyester needs high

temperature dye solution to achieve high efficiency. With existing machines, the Production

Planning & Control Department have to choose Dye batches & swap them across varying

Machine capacities and varying Temperature classes.

----The High Temperature option will give the total Dye cycle time to be shorter than the

current process as the Dye solution will reach the desired temperature faster. This is the most

important goal in this venture as it will give the Machine Cycles per Day from 1.6 (current

value) to a minimum of 2 or could be more (the target would be to reach 2.5)-Refer the

projected values.

Estimated targeted reduction in Dye cycle time –Sub processes in start to finish

Sub Process Old machines New machines Time saved

Scouring 3 hrs. 2 hrs. 1 hr

Dyeing 4 ½ - 5 hrs. 3 ½ hrs. 1 hr

Soaping

Softening & Fixture

3 hrs.

1 hr.

2 hrs.

1 hr.

1 hr.

11 ½ hrs. 8 ½ hrs. 3 hrs.

In order to achieve this, we have look in to several machine manufacturers and finally

decided on a Model which can provide (as per the specifications),

Fongs TEC3 high temperature Dyeing machines

Model MINITEC3-1T

Lift reel speed < Max. > - 350 M/min

Capacity - 120 kg

Basic machine

Main kier with self-lubricating PTFE tube, pipework, base frame & layout roller, Variable

loading adjuster, Fabric lifting system with frequency inverter speed control, Nozzle

Fabric tangling releasing device, Heat exchanger with Fuzzy Logic temperature control, - Pre-

filter, Lint collector, Stainless steel centrifugal pump with driving motor, Modulation fill,

Programmable drain and rinse valves, Frequency inverter for varying the speed of main pump

motor, Fresh water metering fill by level control,

Service tank, includes:

* Analog dosing system

(Valid in main tank temperature below 105 deg.C)

* Pneumatic operating valves

* Modulation dosing valve

* A feed pump with stirring function

-Seam detector

-Stainless steel control cabinet with power unit

Page 8: Dye House Projectonly

* FC30 program controller

* Operating panel

* Pneumatic control box

* CF card assembly (capacity not less than 1GB)

Programmable fills & drains, Constant temperature control for service tank by indirect steam

heating instead of the standard -1, AIR+ Advanced intelligent rinsing system

MSR-D Multi-saving rinsing system (For connecting to high temperature underground tank)

- Salt dissolving tank 1

- Second service tank, capacity equal to the first service tank

- Constant temperature control for the second service tank (capacity equal to the first service

tank) by indirect steam heating instead of the standard

- MST Multi-function vertical stock tank

Machine

Fabricated with SS, grade 316Ti/316L/316/1.4571/1.4404/

1.4401 for major parts wetted by dyeing liquid and subject to pressure loading (whilst parts

wetted by dyeing liquid only are fabricated from grade 316L/1.4404).

PD5500 by BSI. Design temperature 140 deg.C. Design pressure 3.0 bar (44 psi). Safety

pressure relief valve for kier, set at 3.0 bar (44 psi) with normal operating pressure at 2.8 bar

(41 psi). Fabric storage chamber, self-lubricating PTFE tube, An XL size nozzle suitable for

fabric weight ranging from 300g/m to 700g/m is provided for each tube.

The nozzle pressure is indicated by a pressure gauge;

Fabric Transportation System

Fabric Lifting System - lifter reel with high traction bars. Each lifter reel is driven by motor

with frequency inverter for speed control. A lifter reel speed indicator in m/min is provided

Automatic tangle release system, the fabric is unloaded from the machine by stainless steel

take-off roller with reduction motor, Seam detector.

Circulation System

The collecting channel is suitably located inside the storage chamber to enhance the rinsing

process. With overflow valve, a centrifugal pump driven by a 3-phase AC motor with

Frequency inverter for controlling the nozzle pressure, Pre-filter, Lint collector, Pipework and

Level Measurement, A safety valve is also provided, The machine is filled and drained by

pneumatic control valves, A level indicator with magnetic float and red-white roller indicator

show the process liquid inside the machine, Fresh water metering fill by level control.

Service Tank

The dyestuff and chemical additives can be prepared in the service tank which is equipped

with pneumatic injection valve (valid in main tank temperature below 80 deg.C

Feed pump stirring function, analog dosing system (valid in main tank temperature below

105 deg.C) and salt dissolving function.

Heat Exchanger

The temperature of the process liquid is controlled by heat exchanger with modulation valve,

diaphragm ON/OFF valves and steam trap.

The performance

Heating rate: from 25 - 100°C, average 5 °C/min from 100 - 130°C, average 2.5 °C/min

Page 9: Dye House Projectonly

(At saturated steam pressure of 7 bar)

Cooling rate: from 130 - 100°C, average 3 °C/min, from 100 - 80°C, average 2 °C/min

(At cooling water supply pressure of 3 bar, 25 °C)

The main switch cabinet is arranged to provide the following programmable machine

functions

(When it is set in the auto mode):

* Programmable fill / drain / overflow rinsing

* Main pump and lifter reel auto control

* Programmable temperature control

* Operator call signal for loading, unloading, sampling, add and program end

* Programmable dosing function

Process time

Standard

Loading

profile

Regarding the working pressure and temperature of TEC machines,

- That temperature inside the kier (Dye vessels of the machine) is created by heat

exchanger (outside the kier). 2.8 bar pressure allows temp inside kier goes above 100

degree Celsius without evaporating dye bath;

Dye Machine Replacement Project -PHASE 01

Page 10: Dye House Projectonly

M/C

No Type

Priority of

removal Replaced by

Capacity

(Kg)

Replacing

Priority

Adding

Capacity

(Lbs.)

Removal of

Current Effective

production (Lbs.)

25 GN 1 1C MINI 264 1 150 -

26 GN 2 1C MINI 264 2 150 -

27 GN 3 1C 550 3 500 -

5 AK 4 1C 550 4 500 -

7 AK 14 2C 1,100 5 1,000 -

8 ECO 18 3C 1,650 6 1,500

2,000

3 AK 15 2C 1,100 7 1,000 -

4 AK 6 1C MINI 264 8 150 -

6 AK 7 1C MINI 264 9 150

150

22 AK 8 1C MINI 264 10 150

400

23 AK 9 1C 550 11 500 -

20 GN 10 1C 550 12 500

300

21 GN 12 1C 550 13 500

3,500

9 ECO 16 2C 1,100 14 1,000

1,600

10 ECO 17 3C 1,650 15 1,500

1,600

32 MK 13 1C 550 16 500

3,500

33 GN 11 1C MINI 264 17 150

200

35 AK 5 1C MINI 264 18 150 -

36 ECO 18 1C 550 19 1,000

37 ECO 19 3C 1,650 20 1,500

2,000

13,948 12,550

1C MINI 7

1C 8

2C 3

3C 3

4C 0

6C 0

21

Page 11: Dye House Projectonly

Methodology……………………..

It was discussed and decided by the Project team to carry out the necessary works as below,

Procedures planned…………..

Project Brief

Project includes replacing of New Dyeing machines with existing & machine relocation

Department –Dyeing

New Machines – total of 34 machines, 22 in phase 1 (2013) and 12 in phase 2 (2014)

Relocation of selected existing machines – Selected locations in the Yarn Dyeing Building

Page 12: Dye House Projectonly

Project Staff

Project Supervisor –Roy Britton Steam, Compressed air, Condensate, Water, waste water -Dhammika Udage

Electricity –Wijitha Prishantha

Floor & Civil works – Mahesh Laknath

Machine handling – Prabhath Ramanayake

Objective

Reduce waiting time in the Dyeing department

Optimize the Production, Reduce water, Steam, Chemical usage

Project Definition

Scope, Description & Process

Main Project – Machine removal & New Machine installation

Engineering team selected –

Dhammika Udage– Removal & New connections of all Steam lines, Compressed air Lines,

Water Lines, Machine drains including Steam flow meter, ADU’s, Water meters

Wijitha Prishantha– Removal & New connections of all Electrical connections including Total

load calculation+ 15% extra capacity, New Distribution board and line drawing.

Mahesh Laknath- Preparation of Floor with chipped concrete sufficient gradient towards the

Shoe drain, Shoe drains, Mounting Structure concrete, 3 step stairs, Roller Ramp, common

platform for machines, main drain connections, and Floor finish.

Prabhath Ramanayake- Dismantling & removing Old Machines transferring to New Dyeing

area, Exhaust line, Mount, Install & commission.

Project Resourcing

Budget

Allocation for New machines – CIF US$ 2,200,000/- (Phase 1) & CIF US$ 2,100,000/- (Phase 11)

Allocation for Removing, Relocation & Installing new machines - US$ 850,000/-

Page 13: Dye House Projectonly

Documentation & Logistics…

TITLE : AIRFLOW MACHINE INSTALLATION

BOQ NO : DH 5

Bills of Quantities

Labour

Cost

Material

Cost Total Cost

General

Summery Rs.

72,000.0

0

190,880.0

0

262,880.0

0

Total Machine Nos 13.00

Total Cost Rs. 262,880.00

Contingency @

5% Rs. 13,144.00

Total Cost Rs. 276,024.00

Ite

m

No

Description Unit Qty. Labour

Rate Amount Rs.

Material

Rate

Amount

Rs.

Total Cost

Rs.

1 "H iron

150X100/6mm) Lth 2.00

22,000.0

0 44,000.00 44,000.00

2 "C" Channel

(150X100/6mm) Lth 4.00 9,500.00 38,000.00 38,000.00

3 Tore steel (10 mm) Lth 20.00 800.00 16,000.00 16,000.00

4 MS plate 10mm

Nos 1.00

30,000.0

0 30,000.00 30,000.00

5 Anchor bolt (12

mm) Nos 18.00 145.00 2,610.00 2,610.00

6 Anchor bolt (14

mm) Nos 15.00 160.00 2,400.00 2,400.00

7 Anchor bolt (16

mm) Nos 20.00 175.00 3,500.00 3,500.00

8 Cement Bgs. 20.00 930.00 18,600.00 18,600.00

9 River Sand Cub 1.00

11,000.0

0 11,000.00 11,000.00

10 Metal 3/4" Cub 1.00 9,000.00 9,000.00 9,000.00

11 Anticorrosive

paints (Green) 4Lts

1.00

3,000.00 3,000.00 3,000.00

12 Oil primer 4Lts 1.00 3,500.00 3,500.00 3,500.00

13 Thinner Nos 2.00 1,000.00 2,000.00 2,000.00

14 Paint Brush 2" Kg 2.00 350.00 700.00 700.00

15 Paint Brush 3" Nos 2.00 385.00 770.00 770.00

16 Grinding wheel 4

1/2" Nos 4.00 525.00 2,100.00 2,100.00

17 Wire brush Nos 4.00 300.00 1,200.00 1,200.00

18 Welding rods

2.5mm Kg 10.00 250.00 2,500.00 2,500.00

19

Labour charges of

fabricating cost

/footing

concreting/finishin

g work

Ite

m 1.00 72,000.00 72,000.00

72,000.00

TOTAL CARRIED TO SUMMERY 72,000.00 190,880.00 262,880.00

Page 14: Dye House Projectonly

Project progress…………………

Floor (Foundation)

The existing floor is craggy and damaged. It was decided to Re-concrete the Floor to have an

even surface in order to support smooth mounting of machines

Hence to have a sufficient mass and stiffness to permit the machine to operate in or near a

state of equilibrium we’ve decided to lay Grade 30 concrete since lack of mass and stiffness

causes normal operating forces to generate abnormal vibration levels that reduce useful life .

GRADE 30 Concrete Delivery specification

Page 15: Dye House Projectonly

To lay the new foundation, Old machine Plinths were removed and the floor was prepared

with dowel pins (6” x6”). Although the new Concrete layer was laid, 14 out of 34 new

machines will be mounted on plinths in order to make the working level (machine operator’s

hip level). Hence individual concrete plinths were formed with the floor re-concreting.

Anchoring

Anchor bolts were used to secure the machine to its foundation. Marking for machine

placement was started soon after the 14 day concrete curing period. J-bolts were fixed into

the concrete as it is poured. Size bolts to ensure adequate holding torque and to prevent

them from loosening over time. Exercise care when selecting the grade of bolt, and

determine if the mounting pattern will be rigid enough to lock mounting plates to the

foundation.

Leveling

Before the machine was placed in line with anchor bolts, leveling of the allocated area was

finally checked. It was found that with few exceptions, machinery is designed to operate on a

true horizontal plane. When taking the old plinth level (highest level) & the craggy floor level

(lowest level) the difference was 156mm. To have an economical concrete solution, old

plinths were demolished but even then in actual concrete pouring period some areas were

filled to 200mm whereas the lowest was 72mm.

Initially a Survey telescope was used to level the new concrete floor. The results were within

the tolerance limit, it was not necessary to level each allocated area but a liquid level was

used to level each machine properly. Shims with different thicknesses were used to provide

full footprint support giving a rigid connection between the mounting feet and the

foundation.

Alignment

Page 16: Dye House Projectonly

As for the total alignment of all parts of the machine, final requirement is proper alignment of

the machine's Main vessel, Plaiting Device, Salt Tank, Service Tank, Preparation Tank and

Heat Exchanger. Total machine Leveling was done to ensures that the entire machine-train is

level to the earth.

In progress----

Moving new machine parts to

the designated location

Page 17: Dye House Projectonly

For the Mintec3-1T-120kg machines, as per the description of 0.7 m height drainage, 0.8

height concrete base for dyeing machines and 1 m height working platforms, attached

please see the reference layout drawing. Regarding the 1 m working platform:

- Due to piping arrangement, service tank cannot be move closer to ground level. For

operator to input the chemical / dyestuff, would you consider to plan

some steps in the machines’ 0.8 m height concrete bases.

- When you prepare the 1 m height platform, please also prepare handle around the

platform to protect the workers.

- Please note that the fabric trolley cannot be move too close to the machine. However

for the 120kg which does not carry too much fabric, we don’t think it will create

problem.

Dismantling existing machines

while other machines are in

operation

Page 18: Dye House Projectonly
Page 19: Dye House Projectonly

The commissioning procedure of the high temperature Dye machines all share a common

procedure as,

Post Installation review……..

Ocean Lanka has reviewed the performance of replaced Dyeing machines after the first year

of operation (first 21 machines –other 12 machines were commissioned on 3rd quarter 2014)

• Remove old technology, costly spare parts in different type of machines.

• Improved its technical features including more reliable measures. Instead of old

MIR/MSR function, introduced AIR+ function to automatically control the salt level

inside the machine.

• Can measure the energy consumption (Electricity) machine itself and can monitor

them well.

• Water fill controls through flow meter (Main process inlet), all the controls, and

programs operated to the accurate water flow meter readings. Improved the accuracy

of water consumption levels.

• Reduced the batch cycle time. Could improve the batches per day from 2 to 3. In some

ISO thermal programs it is 2 to 4 per day.

• The reduced liquor ratio-led to reduce the water, steam, power consumption and

enormous saving on the chemicals.

• Improved evenness in internal Dye concentration.

• Improved internal fabric movement by controlling plaiter and the lifter reel.

• Introduced new internal lint (fabric dust) collection pump which improve the quality of

the fabric, reduce loose lint.

• Improved ergonomics-worker operational easiness. They can work on the floor –

previously they have to work on platforms.

• Use of Preparation tanks saved the batch cycle time, heated exit water when cooling,

prepared chemicals.

Page 20: Dye House Projectonly

Post Project Machine Queue data

Mini

Chamber

01 (250)

Chamber

02 (500)

Chamber

03 (750)

Chamber

04

(1000)

Chamber

06

(1500)

Jan 4.9 4.5 1.6 2.4 1.9 2.7

feb 6.5 7.6 1.9 4 3.1 3.3

mar 11.6 6.2 2.2 5.2 3.8 5

apr 12.6 9.6 3.2 9 6.8 6.5

may 13.4 10.8 4.5 9.8 11.1 13.6

jun 10.6 12.1 7 22.4 17.1 14.1

jul 12.1 12.5 10.9 11 14.6 14.1

aug 9.1 8.3 13.9 10.2 12.7 12.5

sep 11 11.6 17.5 11.9 9.1 5

oct 5.7 12.2 8.1 8.8 4.2 3.4

nov 5.2 6.9 6.4 5.7 4.8 4.3

dec 3.1 2.8 3.6 5.7 2.7 3.7

The sequence of old machine capacity reduction & new machine capacity addition

Year / month

Old Machine

Capacity in Old

Dye House

New Machine

Capacity in Old Dye

House

Dec-12 45440

Jan-13 45440

Feb-13 45440

Mar-13 45440

Apr-13 45440

May-13 38640

Jun-13 41940

Jul-13 41940

Aug-13 41940

Sep-13 37450 0

Oct-13 28850 8575

Nov-13 28850 13525

Dec-13 28850 15725

Jan-14 28850 15725

Feb-14 28850 15725

Mar-14 28850 15725

Apr-14 24300 15725

May-14 17100 15725

Jun-14 0 26175

Jul-14 33875

Aug-14 35,625.00

Sep-14

Page 21: Dye House Projectonly

Oct-14

Nov-14

Dec-14

• Remove old technology, costly spare parts in different type of machines.

• Improved its technical features including more reliable measures. Instead of old

MIR/MSR function, introduced AIR+ function to automatically control the salt level

inside the machine.

• Can measure the energy consumption (Electricity) machine itself and can monitor

them well.

• Water fill controls through flow meter (Main process inlet), all the controls, and

programs operated to the accurate water flow meter readings. Improved the accuracy

of water consumption levels.

• Reduced the batch cycle time. Could improve the batches per day from 2 to 3. In some

ISO thermal programs it is 2 to 4 per day.

• The reduced liquor ratio-led to reduce the water, steam, power consumption and

enormous saving on the chemicals.

• Improved evenness in internal Dye concentration.

• Improved internal fabric movement by controlling plaiter and the lifter reel.

• Introduced new internal lint (fabric dust) collection pump which improve the quality of

the fabric, reduce loose lint.

• Improved ergonomics-worker operational easiness. They can work on the floor –

previously they have to work on platforms.

• Use of Preparation tanks saved the batch cycle time, heated exit water when cooling,

prepared chemicals.

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

50000

De

c-1

2

Jan

-13

Feb

-13

Ma

r-1

3

Ap

r-1

3

Ma

y-1

3

Jun

-13

Jul-

13

Au

g-1

3

Sep

-13

Oct

-13

No

v-1

3

De

c-1

3

Jan

-14

Feb

-14

Ma

r-1

4

Ap

r-1

4

Ma

y-1

4

Jun

-14

Jul-

14

Au

g-1

4

Sep

-14

Oct

-14

No

v-1

4

De

c-1

4

Machine capacity change in New & old Dyeing machines

Old Machine Capacity NewMachine Capacity

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----The second aim of the project is to reduce the water usage as Textile Dye process is one of the

most water consuming production process anywhere in the world. Although there are other

inventions like Air Flow machines (a Forced draft is used to create the turbulence inside the machine

to support the dye absorbing process) and most advanced models like “Waterless Dye machines”

(Already one of the most sought after Brand has started an Experimental Factory process in Asian

region) . In the Textile Dye terminology, the water contribution is known as Liquor ratio (L/R); the

ratio between Dry weight of the Fabric and the water requirement for dyeing process (Although there

are more sub processes connected to the total Dye process like Scouring, Washing –as many washing

cycles as the particular fabrication specified, Rinsing etc. which may need different water quantities,

the Liquor ratio is referred to the water quantity required for the total process as an average). In the

Ocean Lanka case, the average L/R was between 8:1 to 9:1. The magnitude of this number will be

visible when we consider an average monthly Dye production of 2,000,000 lbs.

The Specifications of the Machine Model selected for the Project mentions the factory tested L/R as

4:1 but we assume the practical value to be between 5:1- 6:1 due to waste between sub processes,

drain efficiencies etc... Hence this was one of the Intended targets of this Project. As per the

manufacturer’s specifications, they will achieve this through the inside structure- the change in the

fabric path inside the Dye chamber, the high temperature option will reduce the water quantity

needed to dissolve the specified dye quantity and the final absorption will be faster, Change in the

Dye Process Recipe will reduce the time taken for the process through improved methodology,

Change in the Dye Cycle

---- The third aim is to regularise the working temperature of Dye machines. Cotton fabrics needs

lower Temperature surrounding whereas Lycra based or Polyester needs high temperature dye

solution to achieve high efficiency. With existing machines, the Production Planning & Control

Department have to choose Dye batches & swap them across varying Machine capacities and varying

Temperature classes.

----The High Temperature option will give the total Dye cycle time to be shorter than the current

process as the Dye solution will reach the desired temperature faster. This is the most important goal

in this venture as it will give the Machine Cycles per Day from 1.6 (current value) to a minimum of 2 or

could be more (the target would be to reach 2.5)-Refer the projected values.

Estimated targeted reduction in Dye cycle time –Sub processes in start to finish

Sub Process Old machines New machines Time saved

Scouring 3 hrs. 2 hrs. 1 hr

Dyeing 4 ½ - 5 hrs. 3 ½ hrs. 1 hr

Soaping

Softening & Fixture

3 hrs.

1 hr.

2 hrs.

1 hr.

1 hr.

11 ½ hrs. 8 ½ hrs. 3 hrs.

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Ocean Lanka (Pvt) Ltd

DYE HOUSE PROJECT (Project Pre-Costing Approval)

Job Details. Budget.

Value

Estimated

Value

Contract

Offered

Contract

Offered

(Rs.) (Rs.) (Rs.) (US$)

(1 US$= SLR

128/= )

(1 US$= SLR

128/= )

(1 US$= SLR

128/=)

1 CIVIL

1 Ready mixed concrete (GR30) 1,818,750.00

2 MATERIAL PURCHASES

2.1

Material charges for floor

concreting/slop

maintaining/expansion joint

cutting/chipping/dowelling/BRC

mesh laying/power

troweling/shoe drain foaming

1,620,500.00

2.2

Material charges for machine

footing frame fabricating

platform fabricating

4,370,010.00

2.3 Material charges for machine

footing concreting 666,605.00

LABOUR CHARGES

3

Labour charges for floor

concreting/slop

maintaining/expansion joint

cutting/chipping/dowelling/BRC

mesh laying/power

troweling/shoe drain foaming

1,580,000.00

4 Labour & material charges for

expansion joint sealing 1,300,000.00

5

Labour charges for machine

footing frame fabricating

Platform fabricating

230,000.00

6 Labour charges for machine

footing concreting 514,000.00

7

Labour & material charges for

Epoxy flooring at trolley path

way

568,750.00

8 Material charges for wall &

truss painting 145,660.00

9 Labour charges for wall & truss

painting 176,000.00

10

Labour & material charges for

Mac foil relaying/sheet

removing & relaying/finishing

work

715,000.00

11

Labour & material charges for

AL doors & windows repairing

& replacing

150,000.00

12 Contingency (10% from total) 1,385,527.50

Total For civil(with 10%

contingency) 15,240,802.50

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2 ELECTRICAL

1 Electrical Cables 5,279,287.50

2 Cable Trunking 2,769,000.00

3 Power Distribution Panels (2

Panels) 716,950.00

4 Wiring Accessories 199,400.00

5 Panel Earthing 200,000.00

6 Labour charges Cable Trunking

& Cable Laying 400,000.00

7 Trunking Supports & Fasteners 400,000.00

8 Printing Sub Power distribution

Panel Modification 200,000.00

9 Contingency (5% from total) 508,231.88

Total For Electrical(without 5%

contingency) 10,672,869.38

3

MECHANICAL, Piping ,

Accessories

1 Service Line Pipes

1.10 Service Line Pipes for Minitec

Machines (SS and CS Pipes) 1,080,100.00

1.20 Service Line Pipes for Miditec

1T Machines (SS and CS Pipes) 1,322,100.00

1.30 Service Line Pipes for Miditec

2T Machines (SS and CS Pipes) 1,066,150.00

1.40 Service Line Pipes for Miditec

3T Machines (SS and CS Pipes) 779,775.00

2 Fittings and other Accessories for Service Lines

2.10

Fittings and Accessories for

Service Lines - Minitec

Machines 3,868,431.00

2.20

Fittings and Accessories for

Service Lines - Miditec 1T

Machines 3,906,606.00

2.30

Fittings and Accessories for

Service Lines - Miditc 2T

Machines 3,499,640.00

2.40

Fittings and Accessories for

Service Lines - Miditc 3T

Machines 2,727,720.00

3 Material for Service line Laying, Bracketing,

Insulation & Jacketting

3.10

Service line Laying, Bracketing,

Insulation & Jacketting- Minitec

Machine 408,800.00

3.20

Service line Laying, Bracketing,

Insulation & Jacketting-Miditec

1T Machines 429,570.00

3.30

Service line Laying, Bracketing,

Insulation & Jacketting-Miditec

2T Machines 326,980.00

3.40

Service line Laying, Bracketing,

Insulation & Jacketing-Miditec

3T Machines 271,860.00

4 Consumable

and

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Workmanship

4.10 Consumable and Installation -

Minitec Machines 497,000.00

4.20 Consumable and Installation -

Miditec 1T Machines 633,000.00

4.30 Consumable and Installation -

Miditec 2T Machines 445,000.00

4.40 Consumable and Installation -

Miditec 3T Machines 364,500.00

5 Contingency (5% from total) 1,081,361.60

Total For Mechanical with 5%

contingency 22,708,593.60

4 Machinery

1.00 MINITEC3-1T X 7 Units (CIF)

73,902,080.00

577,360.00

2.00 MIDITECC3-1T X 6 Units (CIF)

73,620,480.00

575,160.00

3.00 MIDITECC3-2T X 4 Units (CIF)

66,570,240.00

520,080.00

4.00 MIDITECC3-3T X 3 Units (CIF)

61,943,040.00

483,930.00

TOTAL COST FOR THE NEW

DYEING MACHINES

276,035,840.00

2,156,530.00

Total for the project Phase I

41,405,376.00 48,622,265.48

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Three Chamber High Temperature Dye Machine

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High Temperature Drain arrangement

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Post-Project Time Management Analysis

ID Name Duration Start Finish

0 DYE HOUSE PROJECT - ACTIVITY - (PHASE 02) 154.13 days 5/4/14 8:00 AM 9/29/14 3:00 PM

1 REMOVE THE GN-28,GN-29 10 days 5/4/14 8:00 AM 5/13/14 2:00 PM

2

FLOOR PREPARATION & OLD MACHINE

CONCRETE PLINTH REMOVING 5 days 5/18/14 8:00 AM 5/22/14 4:00 PM

3

FLOOR CONCRETING & POWER TROWELING

WORK GN-28,GN-29 AREA 1 day 5/23/14 8:00 AM 5/23/14 5:00 PM

4 CONCRETE CURING PERIOD 7 days 5/24/14 8:00 AM 5/30/14 3:00 PM

5

FLOOR CONCRETING & POWER TROWELING

WORK TSF 17,18,19 AREA 1 day 5/26/14 8:00 AM 5/26/14 5:00 PM

6 CONCRETE CURING PERIOD 7 days 5/27/14 8:00 AM 6/2/14 3:00 PM

7 MACHINE UNLOADING 6 days 5/30/14 8:00 AM 6/4/14 3:00 PM

8 INSTALLATION OF MD3-05 6 days 6/5/14 8:00 AM 6/10/14 3:00 PM

9

MD3-05 MACHINE WIRING WORK & PIPING

WORK 7 days 6/11/14 8:00 AM 6/17/14 3:00 PM

10

MD3-05 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 5 days 6/18/14 8:00 AM 6/22/14 3:00 PM

11 REMOVE THE ECO - 34 5 days 6/23/14 8:00 AM 6/27/14 5:00 PM

12

FLOOR PREPARATION & OLD ECO -34 AREA

MACHINE CONCRETE PLINTH REMOVING 3 days 6/28/14 8:00 AM 6/30/14 3:00 PM

13

FLOOR CONCRETING & POWER TROWELING

WORK ECO - 34 AREA 1 day 7/1/14 8:00 AM 7/1/14 5:00 PM

14 CONCRETE CURING PERIOD 7 days 7/2/14 8:00 AM 7/8/14 3:00 PM

15 INSTALLATION OF MD6-01 8 days 6/5/14 8:00 AM 6/12/14 3:00 PM

16

MD6 - 01 MACHINE WIRING WORK & PIPING

WORK 10 days 6/13/14 8:00 AM 6/22/14 1:00 PM

17

MD6 - 01 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 7 days 6/23/14 8:00 AM 6/29/14 3:00 PM

18 REMOVE THE ECO - 30 5 days 6/30/14 8:00 AM 7/4/14 5:00 PM

19 INSTALLATION OF MD2-07 5 days 6/11/14 8:00 AM 6/15/14 3:00 PM

20

MD2-07 MACHINE WIRING WORK & PIPING

WORK 7 days 6/16/14 8:00 AM 6/22/14 3:00 PM

21

MD2-07 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 5 days 6/30/14 8:00 AM 7/4/14 5:00 PM

22 INSTALLATION OF MD2-08 5 days 6/13/14 8:00 AM 6/17/14 3:00 PM

23

MD2-08 MACHINE WIRING WORK & PIPING

WORK 7 days 6/18/14 8:00 AM 6/24/14 3:00 PM

24

MD2-08 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 5 days 7/5/14 8:00 AM 7/9/14 3:00 PM

25 REMOVE THE TSF-12,TSF -13,TSF-14 15 days 7/10/14 8:00 AM 7/24/14 12:00 PM

26

FLOOR PREPARATION & OLD MACHINE

CONCRETE PLINTH REMOVING 7 days 7/25/14 8:00 AM 7/31/14 3:00 PM

27

FLOOR CONCRETING & POWER TROWELING

WORK GN-28,GN-29 AREA 1 day 8/1/14 8:00 AM 8/1/14 5:00 PM

28 CONCRETE CURING PERIOD 7 days 8/2/14 8:00 AM 8/8/14 3:00 PM

29 INSTALLATION OF MD6-02 8 days 6/29/14 8:00 AM 7/6/14 2:00 PM

30

MD6-02 MACHINE WIRING WORK & PIPING

WORK

10 days 7/7/14 8:00 AM 7/16/14 3:00 PM

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31

MD6-02 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 7 days 7/17/14 8:00 AM 7/23/14 3:00 PM

32 INSTALLATION OF MD4-02 7 days 7/8/14 3:00 PM 7/15/14 12:00 PM

33

MD4-02 MACHINE WIRING WORK & PIPING

WORK 8 days 7/15/14 8:00 AM 7/22/14 3:00 PM

34

MD4-02 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 6 days 7/24/14 8:00 AM 7/29/14 3:00 PM

35 REMOVE THE ECO-31,ECO-36,ECO-37 13 days 7/30/14 8:00 AM 8/11/14 12:00 PM

36

FLOOR PREPARATION & OLD MACHINE

CONCRETE PLINTH REMOVING 7 days 8/12/14 8:00 AM 8/18/14 3:00 PM

37

FLOOR CONCRETING & POWER TROWELING

WORK GN-28,GN-29 AREA 1 day 8/19/14 8:00 AM 8/19/14 5:00 PM

38 CONCRETE CURING PERIOD 7 days 8/20/14 8:00 AM 8/26/14 3:00 PM

39 INSTALLATION OF MD2-05 5 days 8/8/14 3:00 PM 8/13/14 12:00 PM

40

MD2-05 MACHINE WIRING WORK & PIPING

WORK 7 days 8/13/14 8:00 AM 8/19/14 3:00 PM

41

MD2-05 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 5 days 8/20/14 8:00 AM 8/24/14 3:00 PM

42 INSTALLATION OF MD3-04 6 days 8/8/14 8:00 AM 8/13/14 3:00 PM

43

MD3-04 MACHINE WIRING WORK & PIPING

WORK 7 days 8/14/14 8:00 AM 8/20/14 3:00 PM

44

MD3-04 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 5 days 8/25/14 8:00 AM 8/29/14 5:00 PM

45 INSTALLATION OF MD4-01 7 days 8/27/14 8:00 AM 9/2/14 3:00 PM

46

MD4-01 MACHINE WIRING WORK & PIPING

WORK 8 days 9/3/14 8:00 AM 9/10/14 3:00 PM

47

MD4-01 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 6 days 9/11/14 8:00 AM 9/16/14 3:00 PM

48 INSTALLATION OF MD1-08 5 days 8/27/14 8:00 AM 8/31/14 3:00 PM

49

MD1-08MACHINE WIRING WORK & PIPING

WORK 6 days 9/1/14 8:00 AM 9/6/14 4:00 PM

50

MD1-08 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 4 days 9/17/14 8:00 AM 9/20/14 4:00 PM

51 INSTALLATION OF MD1-09 5 days 9/1/14 8:00 AM 9/5/14 5:00 PM

52

MD1-09 MACHINE WIRING WORK & PIPING

WORK 6 days 9/6/14 8:00 AM 9/11/14 3:00 PM

53

MD1-09 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 4 days 9/21/14 8:00 AM 9/24/14 4:00 PM

54 INSTALLATION OF MD2-06 5 days 9/4/14 8:00 AM 9/8/14 3:00 PM

55

MD2-06 MACHINE WIRING WORK & PIPING

WORK 6 days 9/9/14 8:00 AM 9/14/14 3:00 PM

56

MD2-06 MACHINE COMISSIONING & HAND

OVER TO PRODUCTION 5 days 9/25/14 8:00 AM 9/29/14 3:00 PM