industrial attachment of jinnat apparels ltd

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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTJinnat Apparels Ltd.

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CONTENT

CHAPTERS ------------------------------------------------------------PAGE NO.

CHAPTER – I (INTRODUCTION & PROJECT DESCRIPTION) ----- 04

CHAPTER – II (MANPOWER MANAGEMENT) -------------------------- 08

CHAPTER – III (MACHINE DESCRIPTION) ------------------------------ 11

CHAPTER – IV (RAW MATERIALS) ---------------------------------------- 17

CHAPTER – V (PRODUCTION PLANNING, SEQUENCES& OPERATIONS) ---------------------------------------------- 19

CHAPTER – VI (QUALITY ASSURANCE SYSTEM) -------------------- 33

CHAPTER – VII (MAINTENANCE) ------------------------------------------- 38

CHAPTER – VIII (UTILITY SERVICES) ------------------------------------ 42

CHAPTER – IX (STORE & INVENTORY CONTROL) ------------------ 44

CHAPTER – X (COST ANALYSIS) ------------------------------------------- 45

CHAPTER – XI (MARKETING ACTIVITIES) ---------------------------- 47

CHAPTER – XII (CONCLUSION) --------------------------------------------- 49

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CHAPTER – I(PROJECT DESCRIPTION)

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1.1 INTRODUCTION

Industrial attachment is an essential part of 4-years B.Sc. in Textile Technologycourse of College of Textile Technology under University of Dhaka. I had the opportunityto perform the industrial attachment with Jinnat Apparels Ltd. (a sister concern of DBLGroup). During 45 days long attachment, I studied the man, machines, material aspects ofthe circular knitting section, quality control section, planning section, grey fabricinspection section and finished fabric inspection section of the mill. I also had a short visitin the garments & dyeing section of the factory. According to my studies there I haveprepared the following report and would like to present.

1.2 SISTER CONCERNS OF DBL GROUP:

SerialNo.

Name Type Address

1 Dulal Brothers Ltd. Garments Farmgate, Dhaka.2 Fashion Concern Ltd. Garments Farmgate, Dhaka.3 Jinnat Apparels Ltd. Knitting & garments Kashimpur, Gazipur.4 Flammingo Fashion Ltd. Garments Kashimpur, Gazipur.5 Jinnat Fashion Ltd. Garments Kashimpur, Gazipur.6 Parkway Packaging &

PrintingPrinting Kashimpur, Gazipur.

7 Mymun Textile Ltd. Dyeing Kashimpur, Gazipur.8 Hamza Textile Ltd. Dyeing Kashimpur, Gazipur.9 Matin Spinning Mills Ltd. Spinning Kashimpur, Gazipur.

1.3 PROJECT DESCRIPTION

Jinnat Apparels Ltd., where we completed our Industrial Attachment is a sisterconcern of DBL (Dulal Brothers Ltd.) GROUP. DBL Group is a rapidly developinggroup of Industries of Textile sector of Bangladesh. It has a bunch of organizations underits ownership.

a. NAME OF THE PROJECT:Jinnat Apparels Ltd. (JAL), a sister concern of DBL(Dulal Brothers Ltd.) Group.

b. TYPE: Knitting & Garments.

c. YEAR OF ESTABLISHMENT: 2000

d. PROJECT COST: 400,00,00,000 TK.

e. ADDRESS: Sardaganj, Kashimpur, Gazipur.

f. LOCATION: Jinnat Apparels Ltd. is situated at Sardaganj, Kashimpur, Gazipur. It islocated at the East Side of Nabinagar-Kaliakair road and about 45 km away from Collegeof Textile Technology, Tejgaon, Dhaka.

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ChondrarMore

Fig: Location diagram of Jinnat Apparels Ltd.(JAL).

g. DIFFERENT DEPARTMENT:1. Knitting Department.2. Garments Departments.3. Merchandising Department.

h. ANNUAL PRODUCTION CAPACITY: 2600 tons per year.

SripurBustand

KashimpurBazar

E.P.Z

Abdullahpur

Nabinagar

Ashulia

N

W E

S

JAL

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1.4 LAY OUT PLAN OF FACTORY PREMISES:

1.5 PRODUCT MIX:

Jinnat Apparels Ltd. is equipped with circular knitting and finishing. It producesfine quality and blended knit fabrics in a variety of styles. Jerseys, Rib, piques, Interlockand other knit textures are all available.

Current production in tubular and open width exceeds 10 tons per day. Fabricweight from 150 to 260 GSM in styles which include jersey, pique, interlock and fabricwith Lycra.

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Our mill produces the following products:a) Knitted grey fabrics : Plain single jersey, Heavy Jersey, Polo Pique,

Lacoste, Rib & Interlock double jersey , Drop needle, 2/3 Thread fleece(Brushed/ Un-brushed), Collar & cuff etc.

b) Knit Garments : T-shirt, Polo shirt, Short/Trouser, Fashion dress &Children wears etc.

1.6 JINNAT APPARELS LTD. (JAL) AT A GLANCE

1. Name of the project : JINNAT APPARELS LTD. (JAL)2. Project proponent : DBL Group of industries.3. Location : Sardaganj, Kashimpur, Gazipur.4. Communication : The project is easily accessible by road.5. Product name : Knitted goods.6. Plant capacity : 2600 tons per year.7. Amount land : 60 Bigha8. No. of employees : About 2250

1.14 REMARK:Jinnat Apparels Ltd.is a member concern of Padma Group of Companies, a leading

house of Industries & Commerce in Bangladesh, having Printing & packaging Industry,paper manufacturing unit, country wide network of color film processing laboratory units,representing world famous Fuji Color Film products, personal, hygiene productsmanufacturing & real estate development etc.

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CHAPTER – II(MANPOWER MANAGEMENT)

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Jinnat Apparels Ltd. is well equipped with highly efficient team of management,which is very essential for smooth running of a factory.

2.1 ORGANOGRAM OF JAL:

Chairman

Managing Director

Finance Director

Production Director

General Manager

GarmentsManager Manager

Production Officer Production Manager

Knitting Master Q.C. Manager

Chief Fitter Supervisor

Supervisor/Fitter Line chief

Operators Line Quality Controller

OperatorsHelpers

Workers

2.2 MANAGEMENT SYSTEM:KNITTING SECTION: Four Mechanical Fitters for per shift.

One skilled operator and one unskilled operatorfor per knitting machine.

2.3 SHIFT CHANGE:Shift of twelve hours. Shift changes after a week on Saturday.

Knitting

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2.4 STAFF OF KNITTING SECTION (Circular & Flat):

Serial No. Designation No. of Employees01 Asst. Manager 0102 Production Officer 0203 Knitting Master 0104 Knitting Supervisor 0805 Field Supervisor 0206 Operator 5307 Helper 1108 Senior Fitter 0109 Asst. Fitter 0610 Quality Supervisor 0411 Quality Inspector 0312 Quality Helper 0413 Store Officer 0114 Store Keeper 0615 Asst. Store Keeper 0216 Junior Supervisor 0217 Work Study Officer 0118 Time Keeper 0219 Driver 0620 Office Boy 0721 Car Helper 0222 Cleaner 05

FLAT KNITTING01 In-charge 0302 Operator 2003 Helper 15

2.5 JOB DESCRIPTION:

a. SENIOR PRODUCTION OFFICER:In a knitting factory a senior production officer plays a great role in

production and man power management who are production related. Here we enlist theduties of senior production officer:

1) Follow up knitting production,2) Regular observation of knitting floor,3) Prepare knitting order status regularly,4) Maintain the quality of the product,5) To help the senior prod. officer & co-operate with others for fulfilling the

required destination.

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b. PRODUCTION OFFICER:Production officer is the right hand of senior production officer and he is

directly related with production manpower and inform senior prod. officer time to time.Here are his listed duties:-

1) Follow up overall knitting production,2) Decide every m/c utilization during production,3) Recruit new labor,4) To inform the authority on the overall knitting prod. and make it financial

profitable,5) Regular m/c maintenance,6) Maintain sub-contract orders,7) Help knitting manager & also guide the junior officers of the section, etc.

2.6 RESPONSIBILITIES OF PRODUCTION OFFICER:

From getting an order of upper level all responsibilities are on the productionofficers. They work with a team of operators, helpers, fitters etc. to finish the productionin due time. In the meantime production officers bear all hazards, problems. They have toexplain to the manager for any type of production hamper. So, all production activitiesand its success depend on the production officers.

2.7 REMARK:

Production runs with the help of mechanical fitters. For any kind ofmechanical fault of any machine they fix and work under technical in-charge. Productionofficers’ takes account of daily production by running after the two supervisors andworkers so on.

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CHAPTER – III(MACHINE DESCRIPTION)

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3.1 CIRCULAR KNITTING MACHINE:

Circular knitting m/cs. Are widely used through out the knitting industry toproduce fabric. This m/c can be built in almost any reasonable diameter and the smalldiameter of upto five, which are used for wear.

Machine for outerwear and under wear may vary from 12 inch to 60 inch indiameter according to manufactures requirement. This m/c can be used either as fabric orfor making garments completely with fancy stitch. Latch needles are commonlyemployed in all modern circular m/c because of their simple action and also their abilityto process more types of yarns.

Plain circular m/c uses only one sets of needles, circular rib m/c uses two setsof needles i, e, Cylinder needle and Dial needle, the interlock circular knitting m/c alsouses two sets of needles by needles are long and short respectively for both dial andcylinder, that is why multiple design and thick fabric can be produce with that m/c. Thatm/c is also called double Jersey m/c.

M/c. Gauge – needle/inch (varies according to diameter) Needle Type – Latch Needle bed type – Single cylinder, Double cylinder, Cylinder &

Dial, long or short needles for cylinder and dial. Two principle operation exist:

1. English system – Where the cams and yarns strands revolve by needleand fabric take down is stationary.

2 American system – Where the needles and fabric take down revolvesby cams and yarn strands are stationary.

3.2 IMPORTANT PARTS PER MACHINE:

Name of parts Number per machineMPF Magnet 90Knot catcher 90

Eye pot 90Hose pipe 02

Needle fault detector 15Oil nozzle 21Oil pipe 21

Air flashing nozzle 30Air flashing pipe 30Fabric detector 02

Main switch 01Fabric light 01

Take down light 02Oil & air pressure 02

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3.3 IMOPORTANT EQUIPMENT OF CIRCULAR KNITTING M/C:

a. Start/Stop/Inching Buttons:Complete set of easily accessible start/stop/inch buttons at top in each leg.

b. Ratchet Lever:Permit hand movement of the M/C.

c. Auto Stop Motion:Automatic three stages 24v yarn motion, positive feed tapes & knitting zone.

Indicator lamps are on individual stop motions & on the main control panel. While theyarn is broken we can find the location which is broken as well as to repair, meanwhilethe motor can brake and stop operation at once to keep the security of M/C.

d. Free Standing Side Creel:With an active reserve package for each feed.

e. Auto Counter:Two shift revolution with display counter with predetermined stop, to settle freely

the weight or yardage of fabric.

f. Variable Speed Drive with M/C Brake:Transistor inverter provided for free controlled, the process of “V.s. motor-

drive” from slow operation to normal operation is quite & fast brake to prevent damagesin case of needles or yarn breakage.

g. Fabric Take-up System:With variable speed control by a belt drive set can be adjusted the speed for

different course of fabric-constant and uniform fabric tension.

h. Safety Guard Switch:Machine cannot be started with guards open; this guards have reinforced

fiberglass window for easy fabric inspection.

i. Auto Lubrication:The automatic central pressurized oil sprayer can be adjusted at cycling time and

quantity to make cylinder, dial, sinker ring’s cam, needles and sinkers lubricated enough,besides it has the function cooling and clearing.

j. Auto-line Removal System:Three fans on each rotating arm for clearing off any dust of creel and knitting

zone.

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3.4 SPECIFICATION OF CIRCULAR KNITTING M/C:

M/cNo.

M/c. Name M/c. Type Dia.(inch)

Gauge No. ofNeedles

No. ofFeeder

01 Mayer &Cie(Germeny) Single Jersey 30 24 2260 9602 Mayer &Cie(Germeny) Single Jersey 36 24 2712 11403 Mayer &Cie(Germeny) Single Jersey 36 24 2712 11404 Fukuhara(Japan) Single Jersey 30 24 2260 9805 Fukuhara(Japan) Single Jersey 36 24 2712 11807 Mayer &Cie(Germeny) RIB 36 18 22016 7408 Mayer &Cie(Germeny) RIB 36 18 22016 7410 Mayer &Cie(Germeny) Fleece 30 20 1872 9612 Terrot(Germeny) RIB 36 16 21800 6413 Terrot(Germeny) RIB 36 16 21800 6414 Mayer &Cie(Germeny) RIB 34 18 21920 7215 Mayer &Cie(Germeny) RIB 34 18 21920 7216 Mayer &Cie(Germeny) RIB 34 18 21920 7217 Mayer &Cie(Germeny) Fleece 30 20 1872 9618 Mayer &Cie(Germeny) Fleece 30 20 1872 9620 Mayer &Cie(Germeny) Fleece 30 20 1872 9621 Mayer &Cie(Germeny) Interlock 30 22 22064 9622 Mayer &Cie(Germeny) Interlock 34 22 22340 10823 Mayer &Cie(Germeny) Interlick 34 22 22340 10824 Mayer &Cie(Germeny) RIB 30 16 21512 6325 Mayer &Cie(Germeny) Fleece 30 20 1872 9626 Mayer &Cie(Germeny) Fleece 30 20 1872 9627 Mayer &Cie(Germeny) Fleece 30 20 1872 9628 Mayer &Cie(Germeny) RIB 30 16 21512 6329 Mayer &Cie(Germeny) RIB 34 16 21704 7230 Mayer &Cie(Germeny) RIB 34 16 21704 7231 Mayer &Cie(Germeny) RIB 34 16 21704 7232 Mayer &Cie(Germeny) RIB 34 16 21704 72

3.5 TOTAL NO. OF CIRCULAR KNITTING M/C AT A GLANCE:

M/C Type M/C No. Total No of M/C Ground TotalSingle Jersey 01, 02, 03, 04, 05,33,34 07

30RIB07, 08, 12, 13, 14, 15, 16,

24, 28, 29, 30, 31, 3213

Interlock 21, 22, 23 03Fleece 10, 17, 18, 20, 25, 26, 27 07

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3.6 LAY OUT PLAN OF CIRCULAR KNITTING SECTION OF J.A.L.

Compressor room05 04 28 01 02 03

Toilet

OfficeStore

32 29 27 07 08

31 30 26 13 12 10

25 14 15 16 17N

W E 24 21 20 18

DoorS

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Fig: Lay out plan of circular knitting section of J.A.L.

INSPECTION

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3.7 SPECIFICATION OF FLAT KNITTING M/C:

SerialNo

M/C Name MaximumWidth(cm)

M/CType

M/CGauge

No. ofFeeder

No. ofNeedle

01 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X202 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X203 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X204 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X205 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X206 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X207 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X208 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X209 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X210 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X211 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X212 SHIMA SEIKI(JAPAN) 152 V-Bed 14 8 840X2

3.8 LAY OUT PLAN OF FLAT KNITTING SECTION OF J. A. L.

Fig: Lay out plan of flat knitting section of J.A.L.

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3.9 COMPARISION BETWEEN THE PROPERTIES OF PLAIN FABRIC &MACHINE AND RIB FABRIC & MACHINE:

Plain fabric and m/c Rib fabric and m/c1. Face side and Back side of fabric aredifferent

1. Face side and Backside of fabric aresame.

2. Less expensive 2. Expensive3. Lighter fabric 3. Heavier fabric.4. Produce by S/J m/c. 4. Produce by Double Jersey m/c.5. The m/c. contains no Dial. 5. The m/c. contains Dial.6. The m/c. contains Sinker 6. The m/c. contains no Sinker7. The m/c. contains one set of needle 7. The m/c. contains two set of needle8. Extensibility:

a) Length wise – 10 to 20%b) Width wise – 30 to 40%

8. Extensibility:c) Length wise – 50 to 80% (for 11

rib)d) Width wise – 30 to 45% (for 11

rib)9. Thickness & Warmth:

Thicker and wormier than plainwoven made from same yarn.

9. Thickness & Warmth:Much thicker and wormier than plain

woven made from same yarn.10. Curling:

Tendency to curl10. Curling:

No tendency to curl11. End use:

Ladies stocking, fine cardigan, menand ladies dresses, sweater etc.

11. End use:Socks, cuffs, warm outerwear, under

wear etc.

3.10 REMARK: Ventilation system is very poor . The room Height of knitting section is

inadequate . There is no exhaust fan to clean and maintain the temperature ofthis section. The temperature of this section is more than the natural room temperature

because it absorb heat from dyeing and finishing section. There is only one toilet which is not sufficient. Grey fabric inspection section should be air conditioned. At least six circular m/c can be easily setup on the basis of present floor

condition. Cone storage facilities are not bad. The floor plaster of some place of this section is damaged , so it is necessary to

repair it as soon as possible. Creel of camber m/c is not suitable because it has required more floor space and

also difficult to change package.

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CHAPTER – IV(RAW MATERIALS)

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4.1 INTRODUCTION:Jinnat Apparels Ltd. takes yarn as its raw materials for its initial production of

knitted fabric to make garments. It has no spinning section of its own. So, it depends ondifferent of spinning mills of home and abroad to collect yarn as it requires. Here are thedetails:

4.2 TYPES:Natural and synthetic, Cellulosic and non-cellulosic all kind of yarn are used

as raw materials in this mill. Generally, Cotton, Polyester, Viscose and Nylon are mostlyused in knitting departments.

4.3 RAW MATERIALS USED:

Material (Yarn) Count TypeCotton (100%) 20/1 CardedCotton (100%) 24/1 CardedCotton (100%) 26/1 Carded/ CombedCotton (100%) 28/1 Carded/ CombedCotton (100%) 30/1 Carded/ CombedCotton (100%) 34/1 Carded/ CombedCotton (100%) 40/1 Carded/ CombedLycra (100%) 20D/40D

CVC (Chief Value Cotton)Cotton + Viscose

PolyesterMilance Carded/ Combed

Note: Use of colored yarn varies according to buyer’s requirements.

4.4 PRICE:Price of yarn varies from mill to mill and as different count.

4.5 SOURCE:The main source of yarn for this mill is the country and neighboring country,

India. Here is the list of its source spinning mills:

1. Hanif Spinning Mills Ltd.2. Prime Spinning Mills Ltd.3. Padma Spinning ( Beximco Ltd. )4. JK Spinning Mills Ltd.5. Keya Spinning Mills Ltd.6. UTAH Spinning Mills Ltd.7. Square Textiles Mills Ltd.8.Rahmat spinning ltd.9.Amber spinning ltd.10.Gulshan spinning ltd.

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4.6 ANNUAL REQUIREMENTS:Cotton ----- 2624300 kg/year approx.Polyester --- 1100 kg/year approx.Lycra ----- 600 kg/year approx.

4.7 REMARKS:Maximum portion of the raw materials are purchased from our local market and

the rest are from India & Korea. This raw materials are tested first before going forproduction.

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CHAPTER – V(PRODUCTION PLANNING, SEQUENCES & OPERATIONS)

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5.1 PRODUCTION PARAMETERS:Machine Diameter;Machine rpm (revolution per minute);No. of feeds or feeders in use;Machine Gauge;Count of yarn;Required time (M/C running time);Machine running efficiency.

5.2 DESCRIPTION OF PRODUCTION PROCESS:In every mill, there maintains a sequences in production processing. It is also

followed in this mill where I was in industrial attachment. The process sequences are inlist below:

1) Firstly, knitting manager gets a production sheet from merchandisers asaccordance as consumer requirements. Then he informs or orders senior productionofficer about it.

2) Senior production officer informs technical in charge and knows about m/cin which the production will be running.

3) Technical in charge calls for leader of mechanical fitter troops, they twotake decision about m/c for production considering m/c condition, production capacity,maintenance complexity etc.

4) Production officer with experienced mechanical fitter adjusts required stitchlength and grey GSM (gram per square meter) for required final GSM.

5) Supervisor check daily production regularity and make operators consciousabout finishing in due time.

6) Operators operate machine in highly attention as if there were no faults inthe fabrics. If he thinks or sure about any fabric fault, then he call for mechanical fitter induty. Mechanical fitter then fixes it if he can or he informs technical in-charge. He thencomes in spot.

7) After required production and final inspection in 4-point system, they aresent in dyeing section.

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5.3 PROCESS FLOW CHART OF KNITTING:

Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positivefeeding arrangement and tension device

Knitting

Withdraw the rolled fabric and weighting

Numbering

Inspection

5.4 COUNT OF YARN REQUIRED FOR GSM SETTING:

YARNCOUNT

FINISHED GSMSingle Jersey(Plain) 1x1 Rib Plain Interlock

20/1 200-220 260-280 --

24/1 180-200 240-260 --

26/1 160-180 220-230 270-280

28/1 140-160 210-220 255-270

30/1 130-140 180-200 240-255

34/1 120-130 -- 220-240

40/1 110-120 -- 190-200

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5.5 RELATION OF GSM WITH OTHER PARAMETERS:

5.5.1 SINGLE JERSEY:

FabricType

M/c Diax Gauge

GrayDia

(Inch)

FinishedDia (Inch)

YarnCount(Ne)

GrayGSM

FinishedGSM

StitchLength(mm)

Color

Plain

30x24 38-43 30-33 24/1 138-140 180 2.85-2.90 Dark30x24 38-43 30-33 24/1 142-145 180 2.85-2.90 Light30x24 38-43 30-33 24/1 152-155 200 2.68-2.75 Light30x24 38-43 30-33 24/1 147-150 200 2.85-2.88 Dark36x24 50-52 37-

38/72(op)24/1 138-140 180 2.85-2.88 Dark

36x24 50-52 37-38/72(op)

24/1 142-144 190 2.75-2.80 Dark

36x24 50-52 37-38/72(op)

24/1 142-144 180 2.85-2.88 Light

36x24 50-52 37-38/72(op)

24/1 148-150 200 2.68-2.75 Dark

36x24 50-52 37-38/72(op)

24/1 152-155 200 2.65-2.68 Light

30x24 42 31 28/1 118-120 160 2.80 Medium30x24 42 29-31 30/1 1202 160 2.58-2.60 Dark30x24 42 29-31 30/1 1232 160 2.55-2.58 Light30x24 42 29-31 34/1 1102 150 2.52 Dark

Plain(Lycra)

30x24 37-40 20-22 34/1 + 20D 1402 180 2.70 Medium30x24 42 29-31 34/1 + 20D 1504 200 2.68-2.70 Medium30x24 42 29-31 30/1 + 40D 1454 200 3.00 Medium36x24 38-42 33-35 34/1+20D 1402 180 2.90 Medium36x24 42 29-31 34/1 + 20D 1432 190 2.85 Medium36x24 42 29-31 34/1 + 20D 1482 200 2.90 Medium36x24 42 29-31 30/1 + 20D 1502 200 2.70 Medium

Lacoste

30x24 46 42-43 26/1 1602 220 2.58-2.60 Medium30x24 46 42-43 28/1 1552 210 2.62 Medium30x24 46 42-43 30/1 1502 180 2.40 Medium36x24 53-55 49-50 26/1 1652 225 2.55-2.56 Medium36x24 53-55 49-50 30/1 1352 180 2.70 Medium36x24 53-55 49-50 34/1 1252 160 2.55-2.58 Medium

Pique 36x24 52 50 26/1 1352 190 2.90 Medium36x24 53-55 49-50 34/1 1252 160 2.60 Medium

5.5.2 INTERLOCK:

Fabric Type M/cGauge

YarnCount(Ne)

GreyGSM

FinishedGSM

StitchLength(mm)

Color

PlainInterlock

2230/1 190-192 260 1.62-1.63 Dark30/1 175-180 240 1.68 Light30/1 180-185 250 1.65 Dark34/1 158-160 220 1.62 Light

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5.5.3 RIB:

FabricType

M/cDia x

Gauge

GreyDia

(Inch)

FinishedDia(Inch)

YarnCount(Ne)

GreyGSM

FinishedGSM

StitchLength(mm)

Color

1x1 Rib

30x16 37-39 30-31 20/1 195-200 260-265 3.15-3.17 Dark30x16 37-39 30-31 20/1 190-195 260-265 3.17-3.20 Medium30x16 37-39 30-31 20/1 186-192 260-265 3.20-3.25 Light34x16 41 35.5-36.5 20/1 200 260-265 3.20 Dark34x16 41 35.5-36.5 20/1 200 260-265 3.25 Light34x16 41 35.5-36.5 24/1 155-160 230-240 2.80 Light34x16 41 35.5-36.5 24/1 170-175 240 2.75-2.77 Medium34x16 41 35.5-36.5 24/1 190 250 2.60 Medium34x16 41 35.5-36.5 26/1 150-155 220-230 2.80-2.85 Medium34x16 41 35.5-36.5 26/1 155-160 230-240 2.75-2.80 Light34x18 41-42 34-35 26/1 155-160 220-230 2.80-2.83 Dark34x18 41-42 34-35 28/1 155-160 220 2.65-2.70 Medium36x16 42-45 31-34 26/1 156-160 230-240 2.70 Medium36x16 41 31-34 28/1 155 220 2.65 Medium36x16 41 31-34 30/1 140-145 200 2.65 Medium36x18 41-43 35-37 26/1 170-172 240 2.85 Medium36x18 41-43 35-37 28/1 168-170 220 2.50 Medium36x18 41-43 35-37 30/1 145-150 190-200 2.50-2.60 Medium

RibLycra

34x16 38-40 32-35 26/1+40D

190 270 2.80 Medium

36x16 38 31.5 30/1+40D

190 260 2.70 Medium

36x18 40 35 30/1+40D

180 240 2.75 Medium

2x1 Rib 36x18 45 37 26/1 170-172 240 2.85 Medium

5.6 RELATION OF YARN COUNT WITH STICH LENGTH IN FLAT KNITTING:

Yarn count No. of ply Stitch lengthBody Tube

30/1 4 27-30 35-3830/1 5 33-35 39-4528/1 4 28-30 36-4126/1 4 31-33 38-4224/1 4 33-36 39-4520/1 3 31-33 38-42

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5.7 LENGTHWISE ALLOWANCE TABLE:

Name of product Allowance length (in cm.)Collar 1Cuff 1-1.5Bottom 2-3

5.8 G.S.M. CONTROL:1. Major control by quality pulley.2. Minor control by stitch length adjustment.

5.8.1 NECESSARY INFORMATION

a. G.S.M.:

It is technical term that indicates the weight of the fabric per square meter.

b. Changing of G.S.M.:

The GSM of the fabric is change by altering the position of the tension pulley. Ifpulley move towards the positive direction then the GSM is decrease and in the reversedirection GSM will increase.

c. Points that should consider in case of g.s.m. changing:

i) VDQ (Variable Dia. Quality Control) pulley diameter.ii) Yarn count.iii) M/C gauge.iv) Cam positionv) Take up motion

d. Factors that should be considered for changing of fabric design on:

i) Cam arrangement changing.ii) Needle butt setting & needle dropping.iii) Using of different colors in selected feeder.iv) Using of jacquard mechanism.v) Size of the loop shape

e. Recommendable points of a buyer:

i) Dia of the fabricii) Design of the fabriciii) GSM of the fabriciv) Total wt. of the fabricv) Yarn countvi) Types of yarn

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vii) Color of the fabricviii) Finishing of fabric.ix) Handling & fastness property.

f. Gauge number that are usually seen in different m/c:

i) Incase of rib m/c. 16 to 18 G are normally used. But incase of improvedquality yarn 20G M/cs are used in European country.

ii) Single jersey m/c are normally found 20,24,28etc. Gauges.

g. Relation between yarn count and m/c gauge seen in different m/c.:

We know,G2

Ne =-------------18

Where, Ne = English Cotton CountG = M/c. gauge.

h. Maximum and minimum g.s.m. Of a fabric for a particular yarn:

Types of m/c Yarn count Maximum GSM Minimum GSMSingle Jersey m/c 20/1 240 120Single Jersey m/c 30/1 165 100

Rib m/c 20/1 380 190Rib m/c 30/1 180 130

i. Chemical that used in needle, sinker or m/c cleaning:

i) Needle and sinker: Petrol + Needle oil mixture.ii) Cylinder: At first wash with petrol and finally wash with needle oil.

j. Oil require per hour for each m/c:

More than one liter.

k. Production per shift for each m/c:

Types of fabric Yarn count Hours M/c. R.P.M. Fabric wt. (kg)Single Jersey 30 12 30 145Single Jersey 20 12 30 200

Rib 30 12 20-25 180Rib 20 12 20-25 250

l. Weight losses after finish the fabric:6-7% weight losses on the basis of whole wt.

m. Weight increases per square meter after finish the fabric:15-16% weight increases per square meter.

29

5.9 PRODUCTION CALCULATION

1. Production/shift in kg at 100% efficiency:

countYarnmmSLNeedleofNoFeederofNoRPM

2046.28403654.210

1260)(..

countYarnmmSLNeedleofNoFeederofNoRPM

80.3527

)(..

2. Production/shift in meter:

100/1260.

/.min/

cmCourseEfficiencyFeederofNoRPM

cmCourseCourse

3. Fabric width in meter:

100/.

100/.

cmWalesknittingNeedlesofnoTotal

cmWaleswalesofnoTotal

5.10 WORKING PARTICULARS

a. Working hours: Two shift each of 12 hours.

# M/c cleaning and maintenance at the time of shift running# M/c stoppage & cooling during shift changing for half an hour.

b. Type of fabric produced:

Single Jersey, Single polo pique, lacoste, honeycomb, rib,waffle,mesh, fleece andmany others designed fabrics.

c. Needle breaks: 5 Nos. /day 13 machine.Causes:

a. Irregularities in yarn (Thick place, neps & slubs)b. Faulty needle latch.c. Dirty machine condition.d. Needle trick jamming.e. Worn out needle trick.f. High yarn tension.g. Improper lubricationh. Complexity of designi. Use of more yarn in a feeder

30

j. Negligence of operatork. Wrong selection of machine gauge

Remedies:a. Proper lubrication & cleaning of machineb. Involvement of automation systemc. Application of schedule maintenanced. Proper yarn & tension settinge. Using of fault free yarn (high quality combed yarn)f. Extra care during producing of complex designg. Skill ness & awareness of operatorh. Correct selection of machine gauge for a specific fabric

d. Adjusting points of the knitting machine:

a) Feeder to needle (horizontal distance, 1 to 2 sinker thickness)b) Feeder to needle (vertical distance, by feeder adjustment)c) Dial to Cylinder distance.d) Sinker groove to Cylinder groove.e) Tension and loop length.(VDQ pulley dia. Adjustment)f) Yarn tension adjustment (Tension control knob on cam box)g) Adjustable speed in motor driving shaft.h) Change pinion in take up roller to perform tension.

e. Auto stop motion in knitting machine:

a) Gate openb) Needle breakagec) Motor drive faultd) Yarn breakage bothe) Fabric cut & fall down.f) Oil & pressure air problem.g) Completion of selected target.h) Photo electric celli) Take up problem.

f. Wastage of the factory:

a) Empty cartoon & other packing wastage.b) Yarn and fabric wastage due to packing pin marks, yarn irregularity, reconing,

knotting, replacement of new package in the knitting m/c, threading of knitting elements.c) Wastage due to major defective fabric, lack of supervision and worker’s

negligence.d. Wastage due to sample making & testing

g. Maintenance:

a) Break down maintenance during design changing & m/c break down.b) Scheduled maintenance one time per two month.

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5.11 METHODS OF INCREASING PRODUCTION:

By the following methods the production can be increased –

1. By increasing m/c speed:Higher the m/c speed faster the movement of needle and ultimately production

will be increased.

2. By increasing the number of feeder:If the number of feeder is increased in the circumference of cylinder, then the

number of courses will be increased in one revolution at a time.

3. By using machine of higher gauge:The more the machine gauge, the more the production is. So by using machine of

higher gauge production can be increased.

4. By imposing automation in the m/c:a) Quick starting & stopping for efficient driving system.b) Automatic m/c lubrication system for smoother operation.c) Photo electric fabric fault detector.

5. By imposing other developments:a) Using creel-feeding system.b) Applying yarn supply through plastic tube that eliminates the

possibilities of yarn damage.c) Using yarn feed control device.d) Using auto lint removal.

5.12 CAUSES OF LOOP LENGTH VARIATION:1. Fluctuation in yarn variable:

a) Due to count variation.b) Due to twist variation.c) Due to insufficient M.C. or M.R.d) Due to package hardness.e) If frictional property of yarn is not maintained.

2. Fluctuation in m/c variable:a) If temperature of the m/c is not standard.b) If m/c gauge is not accurate.c) If m/c cam setting is not properly maintained.d) If needle timing and knock over is not accurate.e) If take down tension is wrong.f) If sinker timing is not correct.g) Improper yarn tension.

3. Robbing back:Due to 15% of yarn robbed back from old loop to newly formed loop.

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S5.13 STITCH NOTATION, CAM ARRANGEMENT & NEEDLE REPEAT OFSOME KNITTED FABRIC:

FABRIC NAME: SINGLE LACOST

1. Stitch Notation:

Fig. Looping diagram

2. Cam arrangement & Needle arrangement:

i) Using two track cam:

▲ ▲ ▲ T ▲▲ T ▲ ▲ ▲

ii) Using three truck cam:

ii) Using four truck cam:

▲ ▲ ▲ T ▲▲ T ▲ ▲ ▲▲ ▲ ▲ T ▲▲ T ▲ ▲ ▲

Fig.- Cam arrangement Fig.- Needle arrangement

▲ ▲ ▲ T ▲▲ T ▲ ▲ ▲▲ ▲ ▲ T ▲

12

12

3

12

34

= Knit stitch = Tuck stitchK = Knit camT = Tuck cam

1 = 1 Butt Needle2 = 2 Butt Needle3 = 3 Butt Needle4 = 4 Butt Needle

33

FABRIC NAME: DOUBLE LACOST

1. Stitch Notation:




▲ ▲ ▲ ▲ T T▲ T T ▲ ▲ ▲


▲ ▲ ▲ ▲ T T▲ T T ▲ ▲ ▲▲ ▲ ▲ ▲ T T


▲ ▲ ▲ ▲ T T▲ T T ▲ ▲ ▲▲ ▲ ▲ ▲ T T▲ T T ▲ ▲ ▲


= Knit stitch = Tuck stitchK = Knit camT = Tuck cam


12

12

3

12

34

34

FABRIC NAME: SINGLE JERSEY

1. Stitch Notation:




▲ ▲ ▲ ▲ ▲▲ ▲ ▲ ▲ ▲


▲ ▲ ▲ ▲ ▲▲ ▲ ▲ ▲ ▲▲ ▲ ▲ ▲ ▲


▲ ▲ ▲ ▲ ▲▲ ▲ ▲ ▲ ▲▲ ▲ ▲ ▲ ▲▲ ▲ ▲ ▲ ▲


12

12

3

12

34

= Knit stitchK = Knit cam


35

5.14 FABRIC PRODUCED IN J.A.L.:

Fabrics name SAMPLEFace Back

Single Jersey(Plain)

Single Jersey(Lycra)

Single Lacoste

Double Lacoste

Polo Pique

11 Rib

21 Rib

Rib (Needledropped)

Flat by Rib

Plain Interlock

36

Stripped Interlock

Mesh

Interlock Lacoste

Fleece (2 Thread)

Fleece (3 Thread)

5.15 REMARK:

As Jinnat Apparels Ltd. is a big project; its production quantity is huge.Production quantity varies as according as buyers demand. It gives approximately 200-210 tons production per month. In Bangladesh, there are a few mills which can producesuch quantity of knitted fabrics.

37

CHAPTER – VI(QUALITY ASSURANCE SYSTEM)

38

6.1 CONTROL OF FABRIC QUALITY:

Control of the quality of the cloth being knitted is the knitting mechanic’s majorresponsibility. Fabric set-ups and m/c maintenance, although necessary, must be put intotheir proper order of importers. To set-up a fabric and run it on a well-maintained m/c,when its quality is questionable, is senseless.

The mechanic must be able to diagnose a problem on a m/c and render animmediate cure. To do this, he must have a thorough knowledge of what causes a defectin fabric. When the cause is known, correction will soon follow.

6.2 LIST OF EQUIPMENTS:

The list of equipments to assure quality:-1) Inspection m/c2) Scissors3) Weight balance & Micro balance4) GSM cutter5) Seal.6) Marker

6.3 FABRIC DEFECTS:

Defects in circular knitted cloth fall into the following major groups: verticallines, barre, holes and snags, tuck or double stitches, these will be discussed seriatim.

a. Vertical lines:This defects can be caused by defective needles or defective trick walls. If the

trick walls are worn or not evenly spaced, the needles will knit at different speed. Thisuneven movement of the needles will cause uneven stitches which is turn can causevertical lines.

If a wall is too big for the needle, the needle will have a sideward motion, whichwill cause formation of a wide wale in the fabric. When the trick walls are not evenlyspaced, the needles will knit a certain points wide and narrow stitches in the fabric. Thesewill also cause unsightly lines.

Dirt may often get into the tricks pushing the needles outwards (cylinder) orupward (dial) causing irregular vertical stitches. Bent and worn needles will cause thefabric to have wider Wales in certain places.

Needles with chipped latches, butts, hooks, cheeks, a protruding rivet or brokenspoons will cause fuzzy and irregular vertical lines. Needles with bent latches will causevertical tears or ladders in the fabric. Too much lubrication or the use of improper needleoil often causes oil or dirt strakes.

Dark black vertical lines may be caused by dirty tricks, which cause the needles torun high and rub against the cams. Not enough lubrication may also be the cause of blackvertical lines.

39

b. Barre or uneven courses:The following may cause these faults :

1. Improper cam adjustment,2. Uneven yarn tension,3. Different yarn thickness or shaded yarn dyes,4. Dial not in even relationship to cylinder and5. Defective take down mechanism

With the use of positive feeding devices, the stitch cam adjustment isVery accurate. The most important thing to remember when adjusting stitch cams is tokeep the ratio of the dial stitch to the cylinder stitch the same at all the dial and cylinderfeeds.

It must be remember that a positive feed system (tape) will feed the same amountof yarn to all feeds regardless of stitch adjustment. This stitch adjustment controls thetension only.

In the case of pique fabric or any similar kind, the odd feeds must be done at thesame tension, but the even form the odd feeds so long as they are all the same. We knownow that the yarn tension will control the length of stitch.

It is very important that any surfaces that the yarn runs over or through mist beclean of any instruction which will caused irregular tension.

A defective takes down mechanism which pulls tight and then soft will cause areas on the fabric to be loose and tight. The take down mechanism must pull evenly at alltimes to maintain a fabric with even courses.

If dial is not in the proper relationship to the cylinder, fabric of uneven stitchlength will produced. The dial and cylinder relationship should be inspective at least oncea year to maintain proper running conditions.

Uneven thickness of the yarn is one of major causes of barre. The mechanic isreally helpless in the situation. The only thing he can do is to learn to recognize thiscondition and notify the throwster immediately.

Badly wound yarn also will cause uneven tension. In most cases a positive feedsystem will eliminate this defect, but if one used the mechanic should have the yarnrewound. In the case of dyed yarn shaded the mechanic is helpless in such a situation, hemust notify the throwster immediately.

c. Holes and Snags:Holes in most cases are caused by excessive tension of the yarn. If stitch cams are

adjusted too deep and there is excessive tension in the yarn, it wills beak, causing a hole.If the dial height is too high these will also cause a tremendous strain on the yarn.Other factors that produce excessive tension on the stitch are as follows:

1. Too tight a take down pup,

40

2. The positive feed system operating improperly,3. Badly wound yarn,4. Yarn with thin or weak spots.5. Dirty or clogged surface in which the yarn passes through or on,6. Yarn warp around.

Snags in most cases are usually caused by badly wound yarn which ata low tensions and then suddenly jerks and runs at a high tension. This high tension willsusually a line of holes from one to nine inches.

d. Drop Stitches:This defect occurs when the needle tails to take new yarn of when the needle fails

to take new yarn or when the needle losses its loop.

One of the major causes of this problem is an improperly set yarn carrier. If theyarn is not fed directly into the hook of the needle, there is a good chance that the needlewill not take the new yarn.

If the stitch cam is set too far back there will be too much yarn is the needle loop.Because of this loop will be so loose that it can fall causing a drop stitch.

Other possible causes of droop stitches are: the take down mechanism is too loose,not enough tension on yarn, dial height too high, needles, yarn in wrong hole of thecarrier, dial needle latch closing under yarn carrier and dial needle latch closing near thehole of the carrier.

e. Tuck Stitches or Double Stitches:This defect occurs when the needle does not cast off its old loop. In most cases

this defect can be traced to an improperly set stitch cam.

If the needle is not drown far enough back the old loop will remain on the needle.On the other hand, if the stitch cam is set too far back, too much yarn will be going toneedle. In this case this needle will be unable to knock over such a large loop.

Other possible causes of Tuck Stitches are as follows:

1. Take down mechanism set too loose,2. Needles move too freely in their slots,3. Dial height set too low,4. Defective needles,5. Needle trick walls clogged with dirt etc.

41

6.4 QUALITY ASSURANCE PROCEDURE:

At first gray fabric is inspected thoroughly with the help of the inspection machineif any defect is present there.

The faults that are identified in quality control section are:

H=Hole S=SlubsOS=Oil Stain SM=Sinker MarkRS=Rust Stain FL=Fly YarnGS=Grease Stain PH=Pin HoleMSM=M/C Stoppage Mark YC=Yarn ContaminationDS=Drop Stitch BE=Birds EyeD=Dirt BR=BarrieNL=Needle Line WD=Wrong DesignUT=Uneven Tension TT=Thick & Thin placeOL=Oil Line

Points given for different faults:

Fault Length in inch Penalty Points0-3 13-6 2

Any Hole 46-9 3

Upto-9 4

Fabric Grading:

Point Range Fabric ClassUpto 20 Points / 100 m. AUpto 20 – 30 Points / 100 m. BUpto 30 – 40 Points / 100 m. CMore than 40 Points / 100 m. Rejected

In quality control section gather knowledge about different faults and theirremoval process and suggestion for the fabric to finishing department.

42

6.5 QUALITY REPORT

GREY FABRIC INSPECTION REPORT

NAME OF THE INSPECTORS:

SHIFT:ASHIFT:B

6.6 REMARKS:

There is hardly any chance of any roll to be passed through production or toany buyers by to by unchecked or disqualified. The inspectors are too much experiencedand they are aware of their duties and responsibilities. Factory authority and theproduction officers are happy and satisfied with their works.

DATE: M/C NO#: M/C GAUGE:

BUYER:ORDER NO:FABRIC TYPE:

GREY GSM:FINISH GSM:FINISH WIDTH:

SHIFT: A SHIFT: BTYPE OF DEFECT ROLL-1 ROLL-2 ROLL-3 ROLL-1 ROLL-2 ROLL-3SLUBHOLENEEDLE/SINKER LINESTAINTHICK & THINYARN CONTAMINATIONBARRIE/STRIPEDIRTOIL MARKPIN HOLEDROP STITCHM/C STOPAGEOTHER SPECIFYTOTAL POINT(P)GREY WIDTH:ROLL WT(W)REJECT QTY.(KG)LENGTH(MTR)

43

CHAPTER – VII(MAINTENANCE)

44

7.1 MAINTENANCE OF MACHINERY:

Maintenance of machineries is very important for any type of industriesand it is a must for a knit composite mill. All machines and machines parts of knitting,dyeing and garments are maintained with extreme care. Because production quality andquantity, both depends on the maintenance with regularity. Jinnnat Apparels Ltd. leadmaintenance with a troop of skilled mechanical fitters.

Two types of maintenance are carried out. They are -a. Break down maintenanceb. Schedule maintenance

a. BREAK DOWN MAINTENANCE:This type of maintenance is carried out only when machine remains

stop due to-a. Break down for mechanical faultb. Break down for design changing

b. SCHEDULE MAINTENANCE:Every machine has a definite maintenance schedule which is

performed after a certain periodic interval to ensure –a. Smooth production processb. Sound running of machinec. Longer useful life of machined. Better quality of producte. Lower rejection of machine partsf. Lower load on operator

7.2 FUNCTION OF MAINTENANCE:a. Inspection:

Faulty parts are identified &their present condition are checked. And alsoavailability of stand by equipments are also checked.b. Lubrication:

Before starting maintenance all moving & frictional parts are lubricated soto facilitate &draw off the parts.c. Record & analysis:

Previous records & history of the maintenance are checked and analyzed.Before maintenance the following records should be checked:

i. Operating manual of the m/c ii. Maintenance manualiii. History card iv. Inspection cardv. Log book

d. Planning & scheduling:Taking of proper plan & making of specific schedule how the maintenance

should be performed properly.e. Operation:

The maintenance operation is performed as stated below.f. Replacement of faulty parts

The faulty parts which are identified replaced by new parts.

45

g. Storage & recordThe faulty parts which are rejected stored properly & keep top to bottom

record of this operation.

7.3 ROUTINE:1) Daily Maintenance: Every machine is taken maintenance daily by the

operators during production. When a production is started by the operator after handingover from previous shift operator, he takes a routine maintenance on the machine. Hecleans the machine, assures yarn is fed to all needles, cleans the eye pot of feeder,memminger, signal lamp sensor etc. Before a while of a roll cut from batch or cloth roller,operator cleans needles, cylinder base plate etc. All around of the machine are kept neatand clean as if there is no dirt with yarn in the fabric.

2) Schedule/Routine Maintenance: Every machine has a schedule ofmaintenance of 10 or 15 days. According to date, schedule maintenance is taken on themachines. Operators are informed about the time of maintenance. After pre-estimatedproduction, they hand over the machine to the fitters. Thus, fitters assure all machines areOK. for any time.

3) Break down maintenance: When product quality hampered and to completeproduction in due time break down maintenance is taken. There are many faults seen inthe fabric during production due to needle, sinker, take down roller etc. Then operatorsinform the mechanical fitters and they fix it.

4) Restorative maintenance: Restorative maintenance is taken for designchange or new design development. According to advice or order of production officer, amachine is fixed for new design and mechanical fitters rearrange cam and needle system.

Planned and preventive maintenance are not taken on the machineries in thismill.

7.4 MANPOWER SET UP FOR MAINTENANCE:

There are two shifts in this mill. Two groups of mechanical fitters for fourpersons work for two shifts. Each group having a leader, a needle man and two assistantfitters. Fitters work under the technical in charge for knitting section only. They all arevery efficient and hard working. They can fix any type of mechanical problem ofmachines. No necessity happens to hire others from outside to fix machine maintenance.There are electro-mechanical groups to work for electrical problem of machineries. Theywork for overall factory.

Manpower set for different m/c maintenance:# For single jersey m/c: 3-4 person/ hrs.# for double jersey m/c : 7-8 person/ hrs

7.5 MAINTENANCE PROCEDURE:

46

1) For there is any mechanical fault of machine which is responsible forproduction hamper, operator informs mechanical fitters in duty. Mechanical fitters comeand observe the problem firstly, and then they begin to fix it.

2) If mechanical fitters be unable to fix it, then they inform technical in-charge,he then comes in spot and fix it.

3) For there is any electrical problem of machine or serious foundingmechanical problem, mechanical and electrical department are informed, they come andfix the problem. They commence at work after informing of knitting manager. There aretwo mechanical engineers in the department.

4) For restorative maintenance, senior production officer orders mechanicalfitters to fit required machine for cam and needle arrangement and other necessaryrequirements in case of new design development.

Maintenance sequence of circular knitting machine:

Power on/off↓

MPF/Positive feeder current line off↓

MPF belt out/loss↓

Yarn cut↓

Fabric out by handle↓

Cleaning and Oiling↓

Cam box out↓

Needle & sinker out↓

Needle & sinker cleaning by oil↓

Cam box cleaning by air

After opening & cleaning ,m/c is leveled by using leveling meter and follow the reverseprocess to ready the m/c.

7.6 MAINTENANCE TOOLS & THEIR FUNCTIONS:

47

S L No. Name of Tools Functions of maintenance Tools01. L-Key Loosen and Tighten the screws.02. Air Suctioner Cleans machine by suctioning.03. Screw Driver To loosen and tighten the screws.04. Dhali (Spanner) Loosen and Tighten nut and bolt etc.

7.7 REMARK:

This mill has a strong maintenance fitter’s troop to fix up all types problem. Twogroups of two shifts obey their duties responsibly and sincerely. With their different toolsor equipments they perform their duties skillfully.

48

CHAPTER – VIII(UTILITY SERVICES)

49

8.1 UTILITY FACILITIES AVAILABLE:

UTILITY FACILITIES SOURCEElectricity REB & GeneratorWater PumpAir Compressor

8.2 POWER HOUSE:

Total Generator: 4 pcs.

Parameters Generator-1 Generator-2 & 3 Generator-4

Model 450 400Manufacturer Caterpillar Caterpillar KOHLAR.Country USA USA USARated power prime 410 kva ;328kw 365 kva ;292kw 200BRRated voltage 400/230v 400/230v 115/200/230/400vRated Frequency 50 Hz 50 HzRated Current 591.8 A 526.8A 1004/577/502/289ARated rpm 1500 1500 1500

Phase 3 3 3

Fuel Diesel Diesel Diesel

8.3 COMPRESSOR ROOM:

Total Compressor: 2 pcs.Model: SF 100Manufacturer: BOGE KOMPRESSORENFilter type: A/F/V 120Filter element type: 1/120 AMaximum operating pressure: 16 BARMaximum operating temperature: 60°C

8.4 PUMPS:

Water Pumps No. of machine Capacity10 H.P. Pedrollo Pump Flow rate- 600 1 Unit 600.00L/Min

50

L/Min5.5 H.P. Pedrollo Pump Flow rate -350L/Min

1 Unit 350.00 L/Min

Spare Pump Motor Pedrollo 20 H.P. 1 Unit 1,000 L/Min

8.5 COST OF DIFFERENT UTILITIES:Electricity cost:

REB =3.8 TK / KW-HRDiesel generator = 6.50 TK / KW-HR

8.6 REMARKS:

As Jinnnat Apparels Ltd. is a large project, it has vast utility systems. There isa skill manpower group of engineers and other technical staffs to look after these utilityservices. They have to remain aware of solution on a great sense of responsibility for anytype of problem due to utility supply.

51

CHAPTER – IX(STORE & INVENTORY CONTROL)

52

There are two bonded wire house & two store room for storing and inventorycontrol.

9.1 INVENTORY SYSTEM FOR RAW MATERIAL:The main raw material of knitting is yarn, which is stored in two

stages such as-a. Long time storageb. Storage before production

Long time storage:Amount of yarn which are required for the production of several months

as prerequisite .This yarns are stored as production requirement in the bonded wire house.

Storage before production:The amounts of yarn which are loaded in the store room concern with the

production section for continuous speed of production from bonded wire house. Thoseyarn lots are selected to store which will be used for current production.

9.2 INVENTORY SYSTEM OF SPARES:The main spare of a knitting factory is needle which is needed to replace

continuously when production runs. The others spares are cylinder, cam, sinker, changepinion, positive feeder, toothed belt etc .If a machine is innovated its slightly effectedparts will be stored as spare after repairing needed. And these parts are used inconjunction with new parts.

9.3 INVENTORY CONTROL OF FINISHED GOODS:The gray fabric produced are stored firstly in the store concerned with the

inspection room and after completion of a shift this fabrics are sent to fabric section ofbonded wire house with final inspection report. Then theses goods are sent to thefinishing section or to thee buyers as required. After dyeing & other finishing presses thisfabrics are stored in finished fabric section & wastages are stored in wastage section ofbonded wire house. These wastages can be used for various purpose of a factory.

9.4 OTHER INVENTORIES:Other inventories like empty packages or packages with few yarns &

cartoons are stored in wastage room. From this packages with few yarns are used forsample production. Mechanical equipments for maintenance are stored in mechanicalroom, lubricants are stored in lubricant room & a drum is kept in the shed as stand byrequirement.

9.5 REMARK:Proper inventory control of raw materials, semi-finished goods, finished goods

and other miscellaneous goods lead smooth production. As Jinnnat Apparels Ltd. followthe correct way of inventory control system, it can have a good and huge production as itdemands.

53

CHAPTER – X(COST ANALYSIS)

54

10.1 INTRODUCTION:The process by which the setting price of a product is calculated is called Costing.

Here,Setting Price = Sum. of the cost + Profit margin.

Cost elements are as below:1.Production Cost

a. Material costb. Labor costc. Making cost

2. Marketing & Selling costa. Transportation costb. Advertising costc. Commission of sales executives

10.2 PRICE OF THE PRODUCT:

Generally price of product is determined by the required profit adding to thetotal expenses. So,

Price of products= (Direct expenses + Indirect expenses + FactoryOverhead) + Required profit

10.3 COSTING OF THE PRODUCT:

Let,Count of yarn = 30/1 NePrice of yarn per kg. = 2.80 $

Particulars Cost (Tk.) Total Cost (Tk.)Cost of raw material / kg. 184.80Knit charge / kg. 10.00Process loss (5%) 9.25Price of Gray Knitted Fabric (S/J) per kg. 204.05Dyeing cost (Avg. color) 120.00Process loss (10%) 32.40Dyed fabric cost 356.45Packing cost 3.30Total cost of dyed fabric 359.75Fabric price (with 25% margin) 449.69Fabric consumption/ doz. = (Body length + Sleeve length) x Chest length x 2 x GSM x12/10000000

Garments specification:Body length=78 cmSleeve length=33 cmChest length=62 cm

55

GSM=210

Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000= 3.469 kg

Fabric consumption/doze (with 10% wastage) = 3.816 kg

Body fabric cost / doz. =(449.70x 3.8)=Tk.1708.86

Cost of collar& cuff/doz =Tk.198Cost of Trims=Tk.148Cost of Trims (with 5% Process loss) =Tk.155.40Production Cost of Garments/ doz=Tk.2062.10Garments Price/doz (with 25% Profit) =Tk.2577.60=$39.05

10.4 PRICE RANGE OF DIFFERENT PRODUCTS:T-Shirt = $0.75 - $4.50 /PcsPolo Shirt =$2.00 - $6.50 /PcsKids Wear ==$0.75- $2.15 /Pcs

10.5 KNITTING CHARGE OF DIFFERENT FABRICS:

Fabric name Charge per kg(Tk)Single Jersey 08-10

Single Jersey with Lycra 30-32Single locoste 15-18

Double lacoste 16-20Single Pique 15-18

Double Pique 16-20Rib 18-20

Rib with Lycra 32-35Interlock 28-32Fleece 25-28

10.6 REMARKSCosting is as important as production for a productive factory. Without proper

costing all production curriculums will go to in vain. Cause, a factory cannot reach to itsgoal without achieving good profit and good profit is not possible without skillful costing.Seeing the improvement of Jinnat Apparels Ltd. day by day, we can assume that itfollows the right and proper way of costing with skillful technical persons.

56

CHAPTER – XI(MARKETING ACTIVITIES)

57

11.1 INTRODUCTION:Marketing activities are done in this mill, Jinnat Apparels Limited by a skillful

team of marketing officers under the Executive Director. Here are the details of marketingactivities.

11.2 BUYERS OF THE PRODUCTS:The mill has a great number of renowned and international buyers. Following

are some regular buyers:1) Wal-Mart2) H&M3) Carre-Four4) Texebo5) Well-Lord6) VF-Asia7) Echo8)Tescho

11.3 PRODUCT LEBEL:There are following lebels used by this mill:

1) Care Lebel: It contains washing in hot or cold water, chemicalcleaning, drying conditions etc.2) Size Lebel: It contains size of garments.3) Composition Lebel: It contains the fabric composition ofdifferent fibre type.4) Decorative Lebel: Decoration is as buyer or consumer choice wise.

11.4 PACKAGE SIZE & LEBEL:Most common sizes are

S - SmallM - MediumL - LargeXL - Extra largeXLL - Very very large

11.5 LOCAL MARKET:Jinnat Apparels Limited is 100% export oriented mill. So there is no local

market involved in it. But the knitting section takes some sub-contact for knitting anamount of fabrics from their given yarn.

11.6 IMPORTING COUNTRIES:This mill relates to the countries for yarn importing, they are

1) India2) Korea3) China

11.7 MANPOWER:Almost ten marketing officers and ten others workers act under the Executive

Director.

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11.8 DUTIES & RESPONSIBILITES OF MARKETING OFFICERS:

1) Executive director takes order from the buyer and gives order the marketingofficer’s troops to produce a cost sheet.

2) Marketing officers are known the amount and design of product.3) They collect the sample from the buyers and send to knitting and dyeing

section.4) Knitting section adjusts the amount of total yarn and knitting conditions and

dyeing sections adjust the amount of dyes and chemicals. They send a rough calculationto the marketing section.

5) Marketing officers adjust the amount of garments accessories with the helpof their own experiences and their knowledge. They also take help of garments in charge.

6) Finally, they adjust their cost sheet after consulting with the ExecutiveDirector and copy several pieces of the cost sheet.

11.9 REMARKS:

Marketing activities are very important tasks for a productive factory. In thismill, there having highly qualified marketing officers. As a result, the mill rises up day byday.

59

CHAPTER – XII(CONCLUSION)

60

College of Textile Technology has given me the field to perform the industrialattachment with Jinnat Apparels Ltd. This attachment seems to me as a bridge tominimize the gap between theoretical and practical knowledge. Undoubtedly, thisattachment paved the way to learn more about Textile Technology, industrial practices,and industrial management and production process. Besides, this attachment gave us thefirst opportunity to work in an Industry and acquainted us with the internal sight andsound of Textile Industries. I believe with all these, the experience of the industrialattachment will help our future life as a Textile Technologist.

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industrial attachment of jinnat apparels ltd

Engineering