industrial attachment of viyellatex group
TRANSCRIPT
Industrial attachment Page no. 1
VIYELLATEX GROUP
INDUSTRIAL TRAININGCourse Code: Tex -4036
INDUSTRIAL ATTACHMENTVIYELLATEX GROUP
Industrial attachment Page no. 2
VIYELLATEX GROUP
CHAPTER:01
PROJECT DESCRIPTION
1. Name of the Company: VIYELLATEX GROUP
2. Status: Private Ltd. Company
3. Type: 100% Export oriented composite knit Dyeing Industry
4. Year of establishment: 2001
5.Year of starting production: 2002
6. Location: Gazipura, Tongi
7. Address:
Factory : 297, Khortoil, Tongi, Gazipur- 1712
Head office: 297, Khortoil, Tongi, Gazipur- 1712
Tel. No. 8819281-2 Fax No. 880-2-8810445
E-mail : [email protected]
8. Sponsors: Mr. Rezaul Hasnat
9. Product Mix: 100% cotton,
100% polyester
a) Spun
b) Filament
Nylon
Chief Value Cotton (CVC)
Polyester Cotton blend
Grey mélange (15% Viscose 85% cotton
10% Viscose 90% cotton
30% Viscose 70% cotton)
Ash mélange (1% Viscose 99% cotton)
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VIYELLATEX GROUP
10. Production Capacity:
a) Knitting section 19Tons per day (Body fabric)20,000 pcs (Collar & cuff)
b) Dyeing Section 28 Tons per day
c) Garments Section 18 million pieces per year
11. Project cost: 20 million $
12. Different Departments: a) KNITTING SECTION:
Knitting
Inspection
b) DYEING SECTION:
Batch section
Dye house
Dyeing lab.
Quality control
Finishing
c) GARMENTS SECTION:
Merchandising
Sample
d) MAINTENANCE SECTION:
Electrical
Mechanical
e) STORE SECTION
13.Supporting department:
a) Personnel administration
b) HRD
c) Marketing
d) Procurement
e) Finance and accounting
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VIYELLATEX GROUP
f) Security department
13. Total Manpower:
a) Knitting section 250
b) Dyeing Section Dyeing- 300Finishing- 250
c) Garments Section 3200
14. Major customers: a) Marks & Spencer
b) S. Oliver
c) ESPRIT
d) Tesco
e) Puma
g) GAP
h) G.Star
i) Wool worths
j) TU
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VIYELLATEX GROUP
W
Maintenanceroom
Maintenanceroom
Maintenanceroom
Was
hing
Groundfloor
LIFT
LIFT
LIFT
LIFT
2
1
3
4
7
6
5
Emer
genc
yEx
itSt
airs
Emer
genc
yEx
itSt
airs
Receptionroom
IT, guest &conference room
Office
Office
ProductDevelopment
Office
Restroom
Dinning and Prayer room
Workshop
Sewing floor
Cuttingroom
CADRoom
Central store (Fabric& accessories)
Sewing floor
Sewing floor
Medicalcentre
Inspectionroom
Finishingsection
Chemicalstore
Rawmaterialstore
Garmentsstore
Child carecentre
Store Room
ViyellaTex LTD(Dyeing andfinishing)
Maintenancemanager
LabmanagerTe
xtile
Tes
ting
Corp
orat
ion
1st floor
Gro
und
Cen
tral
stor
e
Fashionplastic &packageLTD
ETP
cont
rol
cent
re ETP
Boilerroom
Boilerroom
Substation &maintenanceroom
Cargolift
WTP Oxidationplant
Generatorroom
Chemicalroom
Fashion plastic &packaging sub stationroom
RMS room Securityroom
Store
Bondedwarehouse
Generator room
Generator room
Garden & rainfall
Mai
n ga
te
Pocket gate
Was
hing
Embr
oide
ryPr
intin
g
Yarn
Sto
re
1st floor
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VIYELLATEX GROUP
Mohakhali
Airport
Uttara modeltown
Tongi busstation
Station road,tongi
Collegegate
Gazipura,tongi
Barobari
Boardbarzar
Nationaluniversity
Ashulia
BishwaEstema
Shatrashta
College ofTextileTechnology NS
Location Of TheVIYELLATEX Group
VIYELLATEX
NS
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VIYELLATEX GROUP
15. Physical Infrastructure:
The mill is built in such a way that there is possibility for further expansion of the mill. Thestructure such as mill, office buildings, record rooms, guardrooms & dining room etc. are madeof solid hard concrete & brick mtls. . The whole area is surrounded by safety brick wall .Themain set up for m/c’s are built of corrugated iron & iron sheet, transparent hard plastics withenough ventilation & scope for passing light & air.
Remarks:
VIYELLATEX LTD. is a well established knit composite industry. The industry standson industrial area of Gazipur. VIYELLATEX GROUP. is a Group of Companies, Viyella spinning,Youngone’s fashion LTD, Viyella knitting and dyeing,. VIYELLATEX LTD. is going to prove itsown standard about product quality in world market as they know that their reputation depends on itsquality. VIYELLATEX LTD. is a profitable project and contributes the economy of our country.
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VIYELLATEX GROUP
CHAPTER -02
MAN POWER MANAGEMENT
Organogram of manpower:
Company Organogram
Finance
CHIEF EXECUTIVE OFFICER (CEO)
CHIEF OPERATING OFFICER (COO)
HEAD OFPRODUCTION
HEAD OFMERCHANDISING
HEAD OFCOMMERCIAL &ACCOUNTS
HEAD OFBU HRD
HEAD OFQUALITYASSURANCE
HEAD OFDESIGN &PRODUCTDEVELOPMENT
HEAD OFPLANNING/ IE
HEAD OF ACCOUNTS & COMMERCIAL
ACCOUNTS DEPARTMENT COMMERCIAL DEPARTMENT
FAVP(Preparation of Financial
Statement & Group Cheque Issue)
PRINCIPAL OFFICER(Salary & Wages)
OFFICER(Petty Cash &Staff Salary)
IMPORT DIVISION(In-Charge & FAVP)
EXPORT DIVISION(In-Charge & FAVP)
PRINCIPAL OFFICER
Sr OFFICER SPO OFFICER
Jr OFFICER
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VIYELLATEX GROUP
Organogram from knitting
Organogram of Dyeing
DGM/AGM
Manager / Asst. Manager(Store)
Sr. Executive/ Executive
Jr. Executive(Yarn)
Jr. Executive(Grey Fabric)
Store Asst.(Yarn)
Store Asst.(Grey Fabric)
Loader(Yarn)
BatchHelper/Loade
r
Manager/Asst. manager(Technical)
Sr. Fitter / Fitter
Asst. Fitter
Servicingman
Needle man
Servicinghelper
Manager / Asst. Manager(Prodn & Plan)
Knitting Master/Executive (Flat)
Operator /Asst. Operator
Sr. Fitter /Fitter
Helper
Sr. Executive(Prodn,Plan & Sample)
Executive /Jr. Executive(Prodn, Plan & Sample)
Sr. Supervisor/ Supervisor
Asst. Operator
Sr. Operator/ Operator
Production Helper
Samplesupervisor
Sample asst
DGM/AGM
Manager
Planning
Asst.Manager
Sr.Executive/Executive
Jr.Executive
Sr.Supervisor/Supervisor
Production
Asst.Manager
Sr.Executive/Executive
Jr.Executive
Sr.Supervisor/Supervisor
Store
Asst.Manager
Sr.Executive/Executive
Jr.Executive
Sr.Supervisor/Supervisor
Washing
Asst.Manager
Sr.Executive/Executive
Jr.Executive
Sr.Supervisor/Supervisor
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VIYELLATEX GROUP
JOB DESCRIPTION ( IN GARMENTS SECTION)
TITLE: DEPUTY GENERAL MANGER
Job summary: Overall supervision of Garment Section.Responsibilities: Has the responsibilities for running the garment department including
production planning, operation control, measuring and monitoring ofproduct and the process.
Establishing and maintaining identification and traceability requirement. Inspection test status, taking corrective and preventive action. Controlling nonconforming products at intermediate and final stages in
Garment Department. Analyzing product and process performance form measurement process
to identify area for improvement. Provide supports for approval and maintenance of equipment related to
Garment Department and training of stuff in the department.
TITLE: PRODUCTION MANAGERJob summary: Overall supervision of sewing section.Responsibilities: Receives cutting fabrics according style, color and size form cutting
section. Prepare sewing lines of floor & report to A.G.M. in three time everyday Distribute the cutting fabrics according to style, size & color to the
respective line supervisors. Control the Sewing In charge, Q.C, Assist Q.C., supervisor, Asst. Supervisor,
quality Inspector, Operator & helper Maintain floor discipline & cleanness. Any other works as & when required by the management.
TTILE: Q.C. (SEWING)Job summary: Directly control the quality of complete garment in the sewingline.Responsibilities: Check every complete garment, oil mark, dirty spot, yarn marks, fabric
fault. Check the ironing of complete garment. Control the measurement and tolerance. Prepare the pre-final quality control report. Checks getup property. Shade matching base to base & country wise. Any other works as and when required by the management.
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VIYELLATEX GROUP
TITEL: Q.C. (CUTTING)
Job summary: Overall supervision of cutting section.Responsibilities: Prepare batch wise cutting report and send to the authorized person. After complete the fabrics cutting report to A. G. M. of garment. Prepare weekly cutting report. Control the pattern master, Cutting master, Cutting supervisor, Cutting
man, Neck man, Cutting helper & Labor Control the cutting quality for bulk production, shrinkage & consumption. Look after the cutting & band knife machine.
TITEL: SEWING IN CHARGE
Job summary: Overall supervision of sewing sectionResponsibilities: Receives cutting fabrics according to style, color & size from cutting
section. Prepare sewing lines of floor & report to A. G. M. in three time everyday. Distribute the cutting fabrics according to style, size & color to the
respective line supervisors. Control the sewing in charge Q.C., Asst. Supervisor, quality inspector,
operator & helper. Maintain floor discipline & cleanness. Any other works as & when required by the management
TITEL: FINISHING IN CHARGE
Job summary: Overall supervision of finishing section.Responsibilities: Looks after the overall finishing section Supervising the poly packing & cartooning. Maintains shipment schedule Procurement of required accessories & cartoons Maintain the daily finished garments record Any other works as & when required by the management
REMARKS :Production runs with the help of mechanical fitters.for any kind of mechanicalfaults of any machine they fix and work under technical in-charge.
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VIYELLATEX GROUP
CHAPTER -03MACHINE DESCRIPTION
SL ITEM DESCRIPTION (MESUREMENT) PCS.
1 Gerber Cutter L=174inch, W=109.5inch 1
2 Band Knife L=59.5inch, W=83inch 1
3 Straight Knife 18
4 Spreader Machine L=108inch, W=100inch 4
5 Spreader Table L=32.53m, W=2.23m 2
6 Spreader Table L=32.53m, W=1.1371m 1
7 Spreader Table L=32.53m, W=2.74m 1
8 Manual Table L=12.59m, W=2.236m 1
9 Manual Table L=10.76m, W=1.5238m 1
10 Scissor 70
11 Small Table L=38.5inch, W=30inch 98
12 GSM Cutter 1
13 GSM Weight Machine 1
14 Fabric Weight Machine 1
15 Input Rack L=470inch, W=40inch, Height=84inch 12Self,Capacity=KD-5000, TESCO-1500 Per Self
7
16 Input Fabric Rack L=90inch, W=72inch, Height=72inch Per Self,Capacity=1500-1600kg
6
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VIYELLATEX GROUP
Some industrial sewing machine
Name No. ofneedle
Thread Stitchlength (mm)
SPM
Lockstitch m/c
1/2 5mm 1500-5500
Chainstitch m/c
1/more 1/more 1.4-4.5mm
1800-6000
Overlock/ overedge m/c
½ 2-5 4mm 6500-8000
Zig-zag m/c
1 2 2-2.5mm
5500
Flatlock m/c
Up to4
4-9 SPI 8-16
6000
Blindstitch m/c
1 1/2 3-8mm 2500
Button8holing m/c
Bartack m/c
Smocking m/c
33 66
Work AidsThe extra m/c parts which may be attached to speed up to the production and improve
quality in sewing m/c are called work aids .Some work aids are:
1.Guide
2.Compensating foot
3.Specialized pressure foot
4.stitching zig
5.Rack guide
6.Light
7.Folder
8.Slack feeder
9.Elastication
10.thread cutting
11.Latch back device
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VIYELLATEX GROUP
Specification of Cutting Machines
Spreader Table (Tube):Model: SY: 100Fabric Ply: 7cmLength: 35 ydsWidth: 52 inchBrand:Gerber (USA)
Spreader Table (Open):Model: SY: 100Length:35 ydsWidth: 80 inch
Auto Spreader Machines:(3)Model: SY101Brand: Gerber (USA)Speed:75 m\min
Auto Spreader Machine:(1)Brand: AutexCountry: Spain
Computerised Cutting m/c: (1)Model: Gerber Cutter GT 7250Brand:Gerber (USA)Serial number: 7552Year built: December 2002Cutting Time: 1-15minutesCapacity: 50000 gts\day
Band Knife:Model: EC-900NBrand: EastmanCountry: USA
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VIYELLATEX GROUP
Straight Knife
Number of m\c: 18
Active=14, Inactive=4
Brand: KM-14
Eastman-4
Knife Length=12inch
Knife Length used in cutting=7-8cm
M\c no. Brand name Serial Speed Volts AMPS Cycle Phase
1 Eastman 2F61378-5 2850 220 4.2 50 1
2 Eastman 2F61159-5 2850 220 4.2 50 1
4 Eastman 2F61163-5 2850 220 4.2 50 1
5 KM 242430 3000-3600 220 3.3\2.6 50\60 1
6 KM 264021 3000-3600 220 3.3\2.6 50\60 1
10 KM 276350 3000-3600 220 3.3\2.6 50\60 1
11 KM 270124 3000-3600 220 3.3\2.6 50\60 1
12 KM 270152 3000-3600 220 3.3\2.6 50\60 1
13 KM 276369 3000-3600 220 3.3\2.6 50\60 1
14 KM 270149 3000-3600 220 3.3\2.6 50\60 1
15 KM 247606 3000-3600 230 3.3\2.6 50\60 1
16 KM 264059 3000-3600 220 3.3\2.6 50\60 1
17 KM 276337 3000-3600 220 3.3\2.6 50\60 1
18 KM 261615 3000-3600 220 3.3\2.6 50\60 1
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VIYELLATEX GROUP
SEWING SECTION
List of Machineries
SL Sewing Machine Quantity Brand
1 1-Needle Lockstitch (auto thread trimmer) 471 Juki, Brother, Sunstar,Puff
2 1-Needle Chain Stitch, Flatbed 10 Joje, Feiyue
3 Vertical Trimmer 25 Juki, Sunstar
4 2-Needle Lockstitch 6 Sunstar
5 2-Needle Chain Stitch, Flatbed 16 Kansai, Joje, Feiyue
6 Multi Needle Chain Stitch 10 Kansai
7 4-Thread Over Lock (With electrical chaincutter)
201 Juki, Pegasus, Kansai
8 2- Needle Piping (Backtape) 11 Pegasus, Kansai
9 2/3-Needle Covering Stitch (Flatlock) 167 Juki, Pegasus, Kansai
10 Zig-Zag Machine (Computerized) 2 Juki, Sunstar
11 Bartack Machine (Computerized) 30 Juki, Brother, Sunstar
12 Button Hole Machine (Computerized) 23 Juki, Brother
13 Button Sewing Machine (Computerized) 23 Juki, Brother
14 Smocking Machine (12 & 33 needle) 2 Kansai
15 Shirring Machine 1 needle elastic threads (12ndl)
1 Kansai
16 Picoting Machine 2 Kansai
17 Rib Cutting Machine 12 Idea, Iu-922
18 Blind Stitch (Overlock) 4 Pegasus
19 Heat Transfer Machine 13 Lee way, Local
20 Hot Fixing Machine 4 Salli
21 Snap Button 13 Nyto, Uzu, Max
22 Fusing Machine 8 Hashima
23 Shaddle Stitch 4 Joje
Grand Total=2248
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VIYELLATEX GROUP
NEEDLE GROUPS & SIZE
Machine Name Needle Group SizePM DB*1 9PM DB*1 11PM DC*1 14OL DC*1 9OL DC*1 11FL UY*128 9Picoting FL UY*128 11BH Tone DB*5 11BS DP*17 11Kansai Special UO*113 11
Nobilon Tape: Used in shoulder
Accessories used in Garments Sewing:1. Button2. Thread3. Zipper4. Main Label5. Logo6. Sticker
Allowance: (ILO)1. Relaxation Allowance: 3%2. Fatique Allowance: 3%3. Personal Needs: 4%4. Contingency Allowance:1%5. Delay: Depends on Breakdown)
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VIYELLATEX GROUP
Machine Band Country
SUNSTAR KOREA
KANSAI SPECIAL JAPAN
JUKI JAPAN
PEGASUS JAPAN
BROTHER JAPAN
PUFF JAPAN
FIG:BAND KNIFE FIG:STRAIGHT KNIFE
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VIYELLATEX GROUP
FIG:AUTO4 SPREADER FIG: GERBER CUTTER
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VIYELLATEX GROUP
Fig:SMOCKING M/C
No of needle: 33No of needle thread:33No of looper thread:33Country origin:Srilanka
REMARKS:Viyella tex group well planned factory.Every thing which required for good workingcondition is present here.All section in garments are well furnished.
2
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VIYELLATEX GROUP
CHAPTER -04RAW MATERIALS
In garments section different types of raw materials are used .They are describebelow
1.Fabrics:(Feed back from viyella tex knitting section)
1. Single jersey2. 1*1 Rib3. 2*2 Rib4. Interlock5. 3- thread fleece6. 2- thread fleece7. Single lacost8. Auto striper Rib9. Double lacost10.Auto striper Single jersey11.Auto striper lycra Single jersey
12.2.Thread:(Feed back from WELL,Coats Sylko,Purl,Merathon,Air Plane,Basic)13.Spun polyster-4000m/cone14.Filament thread -4500m-5000m/cone15.Metal thread(gold,silver,bronge) -2500m-3000m/cone16.Nylone thread17.Aramid thread18.Soft cotton thread19.Glaced cotton thread20.silk thread
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VIYELLATEX GROUP
Thread required for
Basic T-shirt -120m-130mBasic Polo-shirt -140m-180m
Basic Trouser forFleece fabric -250m
Rib fabric -175m-180mSingle jersey -150m-160m
Package:Spool -100m-500mCop -1000m-2500m
Cone- 5000mVicone-filament thread & soft thread
ContainerLarge pakage-20000m
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VIYELLATEX GROUP
SHORT NOTEThread Consumption: (Depends on G.S.M)
Plain machine:
Single Jersey: 2.5-2.75/inchRib/Fleece:3/inch
Overlock:
Single Jersey/Rib: 19-20/inchFleece:25-27/inch
Chain:
Single Jersey/Rib:5-6/inch (Single needle) 11-12/inch (Double needle)
Fleece: 8/inch (Single needle) 16/inch (Double needle)
Flatlock:
Single Jersey/Rib: 2 needle + 1 looper: 14/inch 3 needle + 2 looper: 29/inch
2 needle + 2 looper: 20/inchFleece: (Same as Single Jersey/Rib)
Smocking machine: 8/inch
Button holing m/c:2 round: 25-30/inch
1 round: 22-23/inch
Button attaching m/c: 2hole:14/inch 4hole:16/inch 6hole:20/inch 6hole (Puma): 36/inch
Bartack: 28/(1/2)inch
Thread need for Garments making:Basic T-Shirt:120-130mBasic Polo-Shirt: 140-150mBasic Trouser: Fleece: 250m
Single Jersey/Rib: 175-180m
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VIYELLATEX GROUP
3.Trimmings:
ChainZipperLabel & motifButton :plastic,metal,wooden,horn.chalk,printed button2-hole button3-hole button6-hole button(desin for PUMA)Interlining :tearable,soft,hard,fusion.LinningHook & loop fasteningLace braid &elasticCare label code forWashingChlorine bleachIroningDry cleaningDry condition
Remarks:Viyella tex compomsite mill is self sufficient for collecting it fabrics .But it collectsthread & others trimmings & accessories from differents sources.
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VIYELLATEX GROUP
CHAPTER -05PRODUCTION PLANNING SEQUENCE & operation
PROCESS FLOW CHART( CAD DEPARTMENT)
MERCHANDISING CUTTING
Art work + Spread Sheet RCVD buyar approvalFrom Merchandiser Master Pattarn
Making Pattern Completion of Gradingas per Spread Sheet+ Art Work As per spec sheet / sample
Computer processing Grading pattern with marker sendtoOrder Model cutting section for Trial cut / Sizeset
Marker Making Pattern update after getting sizesetAs per Color Art Work Report as per color wise
Manual Work for neck rib+ The separate color patternComputerBinding or Back Tape marker making as per ratio
Marker Delivery to Concern Delivery to cuttingMerchandiser for approval production
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VIYELLATEX GROUP
LAYOUT PLAN OF CUTTING SECTION
LAYOUT PLAN OF CUTTING SECTION
LAY OUT PLAN OF SEWING FLOOR ( 2nd floor right)
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VIYELLATEX GROUP
Cutting Section (Sequence)File collect from merchandiser
Fabric collect from store
Marker come from CAD
Fabric spreading (Lay)
Marker setting on the lay
Cutting(By using Straight knife, Band knife, Gerber cutter)
Sticker attach & hand check
Reject part change
Bundling
If required Print / Embroidery
Store on input rack
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VIYELLATEX GROUP
LINE BALANCING OF A LONG PANT
SL PROCESS MACHINE QTY FOLDER GUIDE SO ASO1 Care label joint PM 1 N/A PG 1 12 Back rise joint OL 1 N/A N/A 1 13 Front rise joint OL 1 N/A N/A 14 Fly inside overlock OL 1 N/A N/A 15 Back rise top FL 1 N/A NG 16 Fly false tack PM 1 N/A PG 17 Front rise top FL 1 N/A NG 18 Fly top FL 1 N/A NG 1 19 Pocket side tack PM 1 N/A PG 110 Pocket opening 2 part tack PM 1 N/A PG 111 Pocket opening top FL 1 N/A TG 1 112 Pocket tack with side PM 1 N/A PG 113 Pocket bag overlock OL 1 N/A N/A 114 Side seam OL 1 N/A N/A 2 115 Side seam top FL 1 N/A NG 1 116 Waist band make PM 2 N/A PG 117 Waist band contrast rib tack PM 1 N/A PG 118 Hole stitch HS 1 N/A N/A 1 119 Elastic make PM 1 N/A PG 120 Waist band round tack PM 1 N/A PG 121 Waist band joint OL 1 N/A N/A 122 Waist band top FL 1 N/A NG 1 123 Drawcord make PM 1 N/A PG 1 124 Drawcord tack PM 1 N/A PG 225 Pocket flap make PM 1 N/A PG 1 226 Flap top PM 2 N/A PG 127 Pocket folded tack PM 1 N/A PG 1 128 Pocket box top PM 1 N/A 1/16 CL 129 Pocket rolling FL 1 N/A TG 130 Pocket joint with lower panel PM 2 N/A PG 1 131 Pocket panel 1/16 top PM 2 N/A 1/16 CL 132 Pocket panel 1/4 top PM 2 N/A 1/4 CR 133 Pocket joint with body PM 1 N/A PG 1 134 Pocket 1/16 top PM 1 N/A 1/16 CR 135 Pocket flap joint + 1/16 top PM 2 N/A PG 236 Pocket flap 1/4 top PM 1 N/A 1/4 CR 137 Inseam OL 1 N/A N/A 138 Leg hemp tack PM 1 N/A PG 1 139 Leg hemp FL 1 N/A TG 1 140 Leg top FL 1 N/A TG 141 Bartack BTK 1 N/A N/A 1 3
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VIYELLATEX GROUP
LINE BALANCING OF A SHORT SLEEVE polo-SHIRT
SL PROCESS MACHINE QTY FOLDER GUIDE OP HP1 Placket Rolling PM 1 N/A PG 1 2
2 Placket Join PM 1 N/A PG 1 1
3 Placket Kacha PM 1 N/A PG 1
4 Placket Inside Fals Tack PM 1 N/A PG 1 1
5 Nose Tack PM 1 N/A PG 1 1
6 Placket 1/16 Top PM 1 N/A 1/16 CL 1
7 Placket Box PM 2 N/A PG 2
8 Shoulder Joint OL 1 N/A N/A 1 1
9 Care Label Joint PM 1 N/A PG 1
10 Collar Joint VT 1 1 cm N/A 1 2
11 Back Neck Tape Joint PM 1 1 cm N/A 1 1
12 Back Neck Tape Top PM 1 N/A 1/16 CL 1
13 Sleeve Hemp FL 1 N/A TG 1 1
14 Sleeve Joint OL 2 N/A N/A 2 1
15 Sleeve Opening Tack PM 1 N/A PG 1 1
16 Side Seam OL 2 N/A N/A 2 1
17 Sleeve 1/4 Tack PM 1 N/A 1/4 CL 1
18 Body Hemp FL 1 N/A TG 1 1
19 Side Seam Tack PM 1 N/A PG 1
20 Side Vent Top PM 2 N/A 1/4 CR 2
21 Hole Stitch HS 1 N/A N/A 1 1
22 Button Stitch BS 1 N/A N/A 1 1
23 Main Label Attach HEAT SE 1 N/A N/A 1 1
24 Bartack BTK 1 N/A N/A 1 3
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VIYELLATEX GROUP
LINE BALANCING OF A SHORT SLEEVE T-SHIRT
SL PROCESS MACHINE QTY FOLDER GUIDE SO ASO
1 Front part shearing SM 1 N/A N/A 1 2
2 Arm hole + Neck shape tack PM 2 N/A PG 2 1
3 Shoulder joint (1) OL 1 N/A N/A 1 3
4 Back neck piping joint PM 2 1CM TG 2 2
5 Neck binding FL 1 8MM TG 1 1
6 Neck binding tack PM 1 N/A PG 1
7 Shoulder joint (2) OL 1 N/A N/A 1 1
8 Neck binding 1/4 tack PM 1 N/A 1/4CR 1
9 Care label joint PM 1 N/A PG 1
10 Sleeve overlock OL 1 N/A N/A 1
11 Sleeve rolling FL 1 N/A TG 1 1
12 Sleeve joint OL 2 N/A N/A 2 2
13 Sleeve opening tack +Underarm tack
PM 2 N/A PG 2
14 Side seam OL 2 N/A N/A 2 1
15 Sleeve 1/4 tack PM 1 N/A 1/4CR 1
16 Bottom overlock OL 2 N/A N/A 2 1
17 Main label joint PM 1 N/A N/A 1 4
18 Label joint PM 1 N/A N/A 1
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VIYELLATEX GROUP
Merchandising
Garment merchandising is an intricate and detail oriented job. If it can be done properlycan be very rewarding. On the country, if it is done with lack of knowledge, insufficient skilland thoroughness, it can be destructive.
In the VIYELLATEX GROUP, very skilled and experienced personnel run themerchandising section. After receiving an order, the merchandiser with the help of patternmaster calculates the total consumption of fabric. Then according to the cost detail sheet andthe price mentioned by the buyer costing is done. After the price is negotiated with the buyerorder is placed to the suppliers of raw material and accessories.
The manufacturing factory as per the requirement suppliers the fabric and a ledger ismaintained regularly to assess the production status. The accessories such as label, button,zipper, sewing thread, packing materials are collected from outside [sometime mentioned bythe buyer] through back-to-back L/Cs. The merchandising department also looks for thesources for procuring yarns to produce fabric.
Merchandising section monitors the production status regularly and ensures timelydelivery of the shipment.
Job responsibilities of Merchandising Team:
Job responsibilities of Merchandising TeamDEVELOPMENT AND COSTING
01 Reviewing the development packs RCVD from buyer. Put the developments into work with product development team. Clarify all necessary info with buyer as much as possible. Follow up on the delivered sample deadline. Work out the initial costing (all costing must be checked by
merchandising manager) Price negotiation with buyer. Follow up with buyer reg. the feed back of the sample and costing
ORDER CONFIRMATION
02 Quoting the delivery dates to buyer after checking factory’s capacitysituation.
Checking all the details in the order sheet once received form buyer. Communicate with buyer reg. any discrepancy in the order sheet. Passing the correct order sheet to all concerned dept i.e. planning,
production, commercial etc.
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VIYELLATEX GROUP
Job responsibilities of Merchandising Team
SAMPLING
03 Updating production development tem reg. different samplerequirement of buyer at various stage (sales man, fit , sz set, ppsample etc)
Coordinating all fabric + trims which are required for samplingpurpose.
Coordinating print, embroidery, wash for sampling. Checking all the technical aspects of samples before releasing to
customer. Checking all the aesthetic aspects of samples before releasing to
customer Checking the quantity requirement of each sample. Checking the necessary paper work of reach sample. Follow up the buyer reg. each sample comments.
BULK FARBIC
04 Work out the consumption for each new styles from CAD. Provide fabric booking to fabric department with correct quantity
and all necessary information. Follow up on the labdips/ strike off submission and chase approval
comments. Follow up on the fabric delivery against critical path Follow up on all fabric approval related issues. Prioritizing the fabric delivery schedule based on the garment
delivery dates.BULK TRIM
05 Preparing the cost sheet/ check list for individual trims required for astyle.
Chasing the trim details from the buyer. Submitting required trims to buyer for approval. Provide booking for individual trims to the approved source. Chasing the P/I from the most ensure ontime delivery. Monitoring the B/B L/C or TT payment status. Sourcing all trims form the most commercially viable source. Follow up with suppliers to ensure ontime delivery. Lialise with store in order to ensure all trims RCVD in correct
quantity and quality.ESTABLISHMENT
06 Chasing the correct artwork for all print/embroidery from buyer. Develpping the design in the best possible method Provide capacity booking to print /embroidery plant in advance. Submitting print/embroidery strike off for buyer’s approval
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VIYELLATEX GROUP
Passing approved copy of the strike off to the print/embroidery plant. Negotiating the price with the subcontractors. Monitoring the panels sent and receive dates to ensure smooth
production flow Communicate with supplier for general issues.
FILING & CORRESPONDENSE
07 Maintaining style file for all running orders Maintaing the development file. General correspondence with buyer and suppliers. Critical correspondence with buyer and suppliers Weekly updates for buyer, such as audit schedule, production status
etc.MEETING
08 Meeting with foreign buyers and suppliers. Meeting with local buyers and suppliers. Internal meeting with production, planning, quality, commercial and
HRD.
Remarks:
VIYELLATEX GROUP. has a well learned marketing & merchandising team. They alwayscommunicate with the buyers. VIYELLATEX GROUP. has some fixed buyers. Themarketing section also looks the quality & quantity buyers.
Chapter-06
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VIYELLATEX GROUP
QUALITY ASSURANCE SYSTEM
QUALITY CONTROL OF PRIECE GOODS:To get quality products it requires good quality control of piece goods.Even the most modern manufacturing methods cannot ensure quality ofthe product if the material is defective. Fabric and the end product mustmeet the expected requirement of the valued customer. It is theresponsibility of the manufactures and the fabric suppliers to ensure thequality. Standar
All holes regardless of 8size will be penalized 4 points No linear yard is to be penalized more than 4 points The average point value per shipment should not exceed 28 points
per 100 square yards Individual rolls exceeding 40 8points will be rejected and put out of
2production process The maximum number of 1-point defect per 10 square yards is 20.
But the average number of 1-point defects must be 14 or less perfabric delivery.
MAJOR & MINOR DEFECTS:MAJOR DEFECTS:A defect that if so conspicuous that it would cause the item to be a‘Second ’ is called a major defect. [A ‘Second’ is a garment with aconspicuous defect that affects the saleability or serviceability of theitem.]
MINOR DEFECTS:A defect that would not cause the product to be termed a second eitherbecause of severity or location. When inspecting piece goods prior tocutting, it is necessary to rate questionable defects as major.
GENERAL PROCEDURE:i. Fabric / Garments are placed for visual Inspectionii. An inspection table which is used to check the roll of fabric visually
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VIYELLATEX GROUP
Types of fabrics faultSlub (Major)Knot (Major)Missing yarn (Major)Spot (Major)Contamination (Major)Weaving FaultThick yarn (4 point)Stop markDyeing stainHole (4 point)Crease & stick markJerk inOil Spot (4 point)
Quality control in sewing sectionFront joint
↓Make Section
↓Collar closing
↓One robbing QC check
↓Output table checking
Working procedureFront Joint 1 QC check 100%Make Section 1 QC check 100%Collar closing 1 QC check 100%One robbing QC check full timeOutput table 4 QC check 100%
Input section (Quality Checking)Label measurementLabel placementShoulder pointBack yoke attachmentBack partBox platePocketd Group in all steps of production maintain and ensure the quality ofpiece goods and as well as the end product. The process of piecegoods inspection of Standard Group is described below-
Piece Goods Inspection:
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VIYELLATEX GROUP
It is ensured by the Standard Group that suppliers carries out 100%inspection prior to shipment. In addition 15% random inspection basedon 4-point system has to be carried out and a report must besubmitted to the group. Upon receipt of that report the inspectionteam of the group again inspect the goods and accept / reject those.
Quality to inspect:At least 10% goods covering all the lots of every colour and dye ofeach shipment is inspected prior to spreading.
Selection of Rolls:At least one roll of each colour is inspected.
Defect Classification:
The 4-point system followed by the group is described below:Size of Defects Penalty point
Defects up to 3” in length 1 point
Defects up to 6” length 2 point
Defects up to 9” length 3 point
Defects over 9” length 4 point
Qualitypts/100 sq meter=(Total point*G.S.M)/( roll weight*10)
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VIYELLATEX GROUP
Make SectionV-V measurementBand overallBand widthCollar pointTop stitchBand rollingCuff overall measurementCuff rollingTop stitch
Collar ClosingSize labelV-V measurementCollar to collar band jointBand down stitchShoulder joint accuracySleeve length
Quality Control Finishing SectionGet up checkingCollar closingSide seamSleeve placket attachCuff attachBottom hemBack yokeEvery parts of a body
RecordsRecords of check list for inspection of accessories and packing
materialRecords of swatch cards of approved accessoriesRecords of production swatchRecords of daily QC reportRecords of cutting problem reportRecords of inspection report during embroidery
REMARKS: Quality of viyella tex group is very good. 4-point system is used toassure quality. From knitting to finishing in garment section quality is checkedstep by step.
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VIYELLATEX GROUP
Chapter-07MAINTENANCE
Name of different maintenance equipment’s or tools:1. Screw driver (Flat & Star)2. LN key3. Hand Socket Wrench Set4. Manual & Digital Slide Calipers5. Slide Wrench6. T – Wrench7. Pipe wrench8. Dull Wrench9. Phile (Half round, round, triangular, flat, square)10. Pliers (Normal & Nose)11. Stop ring pliers (Inside & Outside)12. Timing gauge13. Table vice14. Hand vice15. Hack saw16. Hack saw frame17. Hand drill machine18. Stand drill machine19. Hammer20. Ball pin Hammer21. Mobil gun22. Grinder23. Welding machine24. Drill bit25. Top bit26. Top bit drill27. Varnier outside calipers28. Tester29. Multi meter30. Sucker31. Shouldering wire32. Electronic balance33. Digital lux
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VIYELLATEX GROUP
SEWING MACHINE LUBRICANTPHYSICAL AND CHEMICAL PROPERTIES
SPECIFICATION EJ58/0521 Supplier MOBILE OIL CORP2 Viscosity ISO VG223 Color CLEAR + 30 (SAYBOLT)4 Relative density 0.849 G/CM3
5 Flash point 2040C6 Pure point -12.50C7 Viscosity at 40C 21.0 CST8 Viscosity at 1000C 4.3 CST9 Usage for FOR E, L, M, W ETC
TO MAINTAIN MACHINE TROUBLE FREE:The following instruction must be carried out to secure the utmost inproduction and to the prolong the life of your machine-
Before morning start To oil every moving parts with one or two drops of oil To check whether needle is correctly set or not damage To check whether threading is correct To check whether chaining thread of approximately 10 mm long
remain behind pressure foot.
PLAIN MACINEChanging Over The Specified Voltage And Changing The Fuse
Be sure to turn off the power to the machine before starting theprocedure
Insert a slotted screwdriver into the slot of change over the voltageand set the voltage to a desired voltage. Set the operating voltage to theposition with ‘’ mark
Replacing the fuseBe sure to turn off the power to the machine before starting the procedureStarting the procedure and remove the cap from the fuse holder. Then, takeout the fuse and replace it with a new one.
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VIYELLATEX GROUP
Error MessageThe error will be shown by the number of times of flashing on an off of theLED lamp in the control box when any error is detected during operation.
No of timesof LEDFlashing
ErrorDescription
Item of confirm
1 DefectiveED-2
Check whether connector of the ED-2is securely inserted
Check whether adjustment of materialdetection is properly performed
2 Abnormalmemory
Turn OFF and return ON the powerswitch
3 Abnormalsynchronizer
Check whether connector of thesynchronizer is securely inserted.
4 Abnormalpanelcommunication
Check whether the panel cordconnector is disconnected or loose
5 Motor lock Check whether thread is caught in themotor pulley shaft
Check whether anything is entered inthe motor pulley cover
Check whether the v-belt is not on themotor pulley
Safely CircuitryThe machine incorporates the following safety circuitry
If the V-belt is not on the motor pulleyIf the sewing machine is driven with its V-belt off, the safety
circuitry is actuated in about 2 seconds to stop the whole operation. If thishappens, turn the power OFF, properly mount the V-belt before turning thepower ON again. This safely circuitry is also actuated when the sewingmachine has been subjected to any abnormal load.
If a needle position detector has failedFailure of the upper or lower needle stop position detecting function is
automatically directed by the safety circuitry. Then, the machine actuatesas one with a clutch motor, and it is possible for the motor to be used in thisstate until it is repaired
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VIYELLATEX GROUP
OVER LOCK MACHINE
To protect against possible personal injury due to abrupt start of the m/c, besure to start the work after turning the power off and ascertaining that themotor is at rest.
Position of the needle thread take up and the needle thread eyelet The needle thread take up shall be positioned at the lower dead pt. Position of the looper thread take up and the looper thread guide Checking the cartridge filter and replacing it after a long period of
usage, cartridge filter may become clogged with dust Insert a cartridge
Remove first oil discharging screwRemove screw and lift top cover just above until it comes off
Dimensions use to adjust the looper and the needle guard Lubrication
Remove the oil capPoor juki m/c oil 18 into the oil reservoirSupply oil until the pointer bar almost reaches the upper red markerline when oil guage is observed from the side.
BUTTON ATTACHING MACHINE:Checking the needle
Always check that the tip of the needle is not broken and also theneedle is not bent before starting sewing
Cleaning the Rotary HookPull the shuttle race cover toward you to open it and then remove the
bobbin caseOpen the setting claw in the direction indicated by the arrow and
then remove the shuttle race body and the shuttle hookClean all the dust and thread ends from around the driver, the top of
the rotary hook thread guide and the shuttle race
Lubrication Fill the arm-side oil tank with oil Fill the bed side oil tank with oil Add oil to the felt of the shuttle race base
When setting up the sewing machine and when it hasn’t been used foran extended period of time, be sure to add 2-3 drop oil to the feltIf using the liquid cooling tank, fill it with silicon oil.
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VIYELLATEX GROUP
BUTTON HOLING MACHINE
Turn off the power switch before carrying out cleaning, otherwise themachine may operate if the treadle is depressed by mistake, whichcould result in injury.
Be sure to wear protective goggles and gloves when handling thelubricating oil and grease so that they do not get into your eyes oronto your skin otherwise inflammation can result.
Furthermore do not drink the oil or eat the grease under anycircumstances as they can cause vomiting and diarrhea, keep the oilour of the reach of children.
Cleaning Remove lint and dust from the thread passages Remove lint and dust form around the work clamp Remove the bobbin case and remove lint and dust from around the
shuttle Clean away any thread scraps and cotton dust from around the lower
thread trimmer mechanism.
BAR-TAKE MACHINE:Maintenance of Bar-take machine Adjust the height of the needle bar Adjusting the needle to shuttle relation Adjusting the lift of the work clamp foot Adjusting the rising amount of the thread tension dist The moving knife and counter knife Cleaning the filter Draining waist oil Replacing the fuse
REMARKS: This mill has strong maintenance fitter`s troop to fix up theproblem. They are very active to perform their duty.S
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VIYELLATEX GROUP
KNITTING SECTION
INTRODUCTIONKnitting is one kind of fabric manufacturing process in which fabric is produced byinterlooping among loops formed by single or several yarn feeding simultanesously.Knittedfabrics produced with stitch formation.Stitch is most important structural element of knitted fabrics .The stitch consists of a head,two legs ,two feet and upper&lower connection point.
Knitting Process Flow Chart
Yarn collect by cone package from spinning
Setup yarn on creel
Yarn passage through different tentioner and possitive feeder
Adjust stitch length and GSM by VDQ pulley
Produce ½ inch fabric and inspection
Knitting the fabrics and without any fault / If fault correct it
Cut the roll of fabric
Marking theroll
Inspection and grading according to Quality Control
Transferred the fabric to grey store.
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VIYELLATEX GROUP
MACHINE DESCRIPTION
SLNO.
M/CNO.
Model Type of m/c Dia &Gauge
No. offeeder
No.ofneedle
Safetyrpm
Brandname
1. 061612
PL-XRA/CE Rib 38”*18 76 2124 23 PAI LUNG
2 061610
pL-XS4B/A/CE Single jersey 36”*24 144 2712 25 PAI LUNG
34567 05119
4PL-XS3B5MW/A/B/CE
Single jersey30”*24
90 2256 25 PAILUNG
89101112 Single jersey 26”24 78 1856 22 FUKUHA
RA1314 07082
8PL-XS3B/A/CE Single jersey 26”24 78 1856 22 PAI
LUNG15 05119
4PL-XS3B5MW/A/B/CE
Single jersey 30”*24 90 2256 25 PAI LUNG
16 051194
PL-XS3B5MW/A/B/CE
Single jersey 30”*24 90 2256 25 PAI LUNG
17 051194
PL-XS3B5MW/A/B/CE
Single jersey 30”*20 90 2256 25 PAI LUNG
18 051194
PL-XS3B5MW/A/B/CE
Single jersey 30”*24 90 2256 25 PAI LUNG
19 051194
PL-XS3B5MW/A/B/CE
Single jersey 30”*24 90 2256 25 PAI LUNG
20 36”*22 CAOTRR21 36”*18 24 CARROT22 06061
3PL-XS3B/A/CE Single jersey 24”*24 72 1800 40 PAILUN
G23 06061
3PL-XS3B/A/CE Single jersey 24”*24 72 1800 40 PAILUN
G24 05119
2PL-XS3B/A/CE Single jersey 25”*24 74 1872 42 PAILUN
G
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VIYELLATEX GROUP
25 051192
PL-XS3B/A/CE Single jersey 25”*24 74 1872 42 PAINGLU
26 061242
PL-XF3B-LD/C Single jersey 30”*20 90 1872 25 PL
27 061242
PL-XF3B-LD/C Single jersey 30”*20 90 1872 25 PL
28 Single jersey 36”*22 72 2484 25 PL29 PL-XD2B/CE Interlock 36”*22 72 2484 25 PL30 06061
7PL-XRA/CE Rib 38”*18 72 2160 23 PL
31 060618
PL-XR2B/CE Rib 38”*18 76 2124 23 PL
32 060618
PL-XR2B/CE Rib 38”*18 76 2124 23 PL
33 060618
PL-XR2B/CE Rib 38”*18 76 2124 23 PL
34 Single jersey 30”*24 32 MAYER& CIE
35 Single jersey 30”*24 32 MAYER& CIE
36 O70832
PL-XRA/CE Rib 40”*18 80 2256 22 PL
37 O70832
PL-XRA/CE Rib 40”*18 80 2256 22 PL
38 070821
PL-XR2B/CE Single jersey 42”*14 84 2370 21 PL
39 070821
PL-XR2B/CE Single jersey 42”*14 84 2370 21 PL
40 070831
PL-XRA/CE Rib 36”*16 72 1800 25 PL
41 051192
PL-XS3B/A/CE Single jersey 25”*24 74 1872 42 PAINGLU
42 051192
PL-XS3B/A/CE Single jersey 25”*24 74 1872 42 PAINGLU
43 070828
PL-XS3B/A/CE Single jersey 26”24 78 1856 22 PAILUNG
44 070828
PL-XS3B/A/CE Single jersey 26”24 78 1856 22 PAILUNG
45 NOT FOUND FUKUHARA
46 061610
pL-XS4B/A/CE Single jersey 36”*24 144 2712 25 PAI LUNG
47 Rib PAILUNG
48 Single jersey 30”*24 PAILUNG
49 051195
PL-XSCS/6 Single jersey 30”*24 42F*6C
2256 20 PAILUNG
50 051196
PL-XSCS/6 Single jersey 30”*24 42F*6C
2256 20 PAILUNG
51 06123 PL-XDCS/E-U Rib 36”*18 54 2040 16 PAILUN
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VIYELLATEX GROUP
V-Bed Knitting machine specification:
M/CNO.
MODEL NO. GAUGE DATE
1 M-100 14 10.20002 M-100 14 10.20003 M-100 14 10.20004 M-100 14 10.20005 M-100 14 10.20006 M-100 14 10.20007 M-100 14 04.20018 M-100 14 04.20019 M-100 14 04.2001
9 G52 06124
0PL-XDCS/E-U Rib 36”*18 54 2040 16 PAILUN
G53 07082
3PL-XSCS/6 Single jersey 30”*24 42F*6
C2256 20 PAI
LUNG54 07082
2PL-XSCS/6 Single jersey 30”*24 42F*6
C2256 20 PAI
LUNG55 06082
4PL-XSCS/6 Single jersey 36”*24 50*6(
Sinker)
2256 22 PAILUNG
56 070825
PL-XSCS/6 Single jersey 36”*24 50 2712 19 PAILUNG
57 Single jersey 26”24 78 1856 22 FUKUHARA
58 Single jersey 26”24 78 1856 22 FUKUHARA
59 Single jersey 26”24 78 1856 22 FUKUHARA
60 Single jersey 26”24 78 1856 22 FUKUHARA
61 VXC-3.2S Single jersey 30”*28 FUKUHARA
62 VXC-3.2S Single jersey 30”*28 FUKUHARA
63 VXC-3.2S Single jersey 30”*28 FUKUHARA
64 VXC-3.2S Single jersey 30”*28 FUKUHARA
65 VXC-3S Single jersey 28”*24 FUKUHARA
66 VXC-3.2S Single jersey 32”*24 FUKUHARA
67 VXC-3.2S Single jersey 32”*24 FUKUHARA
68 VXC-3.2S Single jersey 36”*24 FUKUHARA
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VIYELLATEX GROUP
10 M-100 14 04.2001
11 M-100 14 04.200112 M-100 14 04.200113 M-100 14 04.200314 M-100 14 04.200315 M-100 14 04.200316 M-100 14 04.200317 M-100 14 04.200318 M-100 14 04.200419 M-100 14 04.200420 M-100 14 04.200421 M-100 14 04.200422 M-100 14 04.200423 M-100 14 04.200424 M-100 14 04.200425 M-100 14 04.2004
FLAT BED M/C CAPACITYProductin/1 hr= 21 pcs (m/c manufacture date 2003,2004 =13)Total production=13*21*8=2184 pcs/shiftProductin/1 hr= 14 pcs (m/c manufacture date 2000,2001 =12)Total production=12*14*8=1344 pcs/shiftTotal production=3528 PcsNote: All m/cs are conventional . There is no modern m/s. It is not suitable for industry.
FABRIC WIDTH: Two types of fabric width1) Open width2) Tubular width
Difference between Open width & Tubular widthOpen width Tubular width
Mark line contains for fabric cutting No mark lineFabric dyes in open form Fabric dyes in tubular formOpen width is double than tubularwidth
Tubular width=1\2*open width
For single jersey For Rib, Interlock
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VIYELLATEX GROUP
Production Calculation:
asM/CNO.
M/C Dia&Gauge
Fabrictype
Productionkg/shift
Yarn type S.L/GG
1 38”*18 Rib 126 30’s CB 2.522 36”*24 Single
jersey115 26/1 CD 2.70
3 36”*18 Rib 78 26/1 D/L SCHOCO 2.654 36”*18 Rib 72 34/Spun poly 2.405 36”*18 Rib 72 28/1 CD 2.406 30”*24 Single
lacoste65 26/1 CD 2.62
7 30”*24 Singlejersey
107 28/1 CD 2.75
8 28”*24 Singlejersey
100 26/1 CD 2.70
9 30”*24 Singlejersey
112 28/1 CD 2.75
10 30”*24 Doublelacoste
72 28/1 CD 2.62
11 26”*24 Singlejersey
110 26/1 CD 2.84
12 26”*24 Singlejersey
85 2.75
13 26”*24 Singlejersey
86 26/1 CD 2.84
14 26”*24 Singlejersey
110 26/1 CD 2.70
15 30”*28 Singlejersey
64 34/1 CD+20Dlycra 3.02
16 30”*20 Fleece 55 34/1 CB+75D Poly 28017 30”*20 Fleece 55 34/1 CB+75D Poly 23018 36”*2419 30”*2420 36”*22 Fleece 45 150/2 Poly+20D Lycra 21521 36”*18 Rib 80 28/1 CD+40D Lycra 28022 24”*24 Single
jersey90 26/1 CD 2.70
23 24”*24 Singlejersey
80 26/1 CD 2.70
24 25”*24 Singlejersey
90 24/1 CD 2.70
25 24”*24 Singlejersey
90 24/1 CD 2.70
26 30”*20 Singlejersey
80 34/1 CD+12/1 CD 235
27 30”*20 Singlejersey
88 34/1 CD+12/1 CD 235
28 36”*22 Single 34/1 CD+20D Lycra 3.02
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VIYELLATEX GROUP
jersey29 36”*22 Interlock 70 150D Poly+20D Lycra 21530 38”*18 Rib 125 30/1 2.5231 38”*18 Rib 115 30/1 CD+40D Lycra 20032 38”*18 Rib 112 30/1 CB 2.7533 38”*18 Rib 110 30/1 CB 2.7534 30”*28 Single
jersey70 34/1 CB 2.52
35 30”*28 Singlejersey
34/1 CB 2.52
36 40”*18 Rib 140 34/1 CB 2.6837 40”*18 Rib 140 34/1 CB 2.6838 42”*18 Rib 130 34/1 CB 2.5239 42”*18 Rib 135 34/1 CB 2.5240 36”*18 Rib 90 28/1 CD+40 Lycra 28041 25”*24 Single
jersey100 24/1CD 2.84
42 25”*24 Singlejersey
100 24/1CD 2.84
43 26”*24 Singlejersey
110 28/1 CB 2.70
44 26”*24 Singlejersey
100 28/1 CB 2.70
45 30”*20 Singlejersey
123 28/1CD 2.98
46 36”*24 Singlejersey
30/1 CB 2.68
4748 30”*24 Single
jersey98 26/1 CD 2.75
49 30”*16 Doublejersey
36 24/2GM+22/2L+ZADE+M.Navy
4.23
50 30”*24 Singlejersey
22 28/1metal+white+black+30/1GHTR
2.75
51 36”*18 Rib 26/1 TAVPEMARL/SCHOCO/OFFWHITE/ROSE
2.65
52 2.8053 30”*24 Single
jersey19 20/1 D/Y DK-
CALICO+RED3.20
54 30”*24 Singlejersey
22 28/1D/Y+WHITE+BLACK+30/1GHTR
2.75
55 36”*24 Singlejersey
28 28/1 WHITE+ DK+DKNAVY+30/1 GHTR
2.75
56 36”*24 Singlejersey
30 28/1 WHITE.30 g.mtl+28/1CB
2.70
57 26”*24 Singlejersey
110 28/1 WHITE.30 g.mtl+28/1CB
2.70
58 26”*24 Single 112 28/1 WHITE.30 g.mtl+28/1 2.68
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VIYELLATEX GROUP
jersey CB59 26”*24 Single
jersey108 26/1 CD 2.75
60 26”*24 Singlejersey
90 26/1 C D 2.70
61 30”*28 Singlejersey
60 40/1 CB-PT44O8 2.52
62 30”*28 Singlejersey
53 40/1 CB-PT44O8 235
63 30”*20 Fleece 75 34/1 CV+75D Poly+10/1 cvc 23564 30”*24 Fleece 76 34/1 CB+75D Poly+1`2/1\2
CB2.70
65 28”*24 Singlejersey
92 28/1 CB 2.75
66 32”*24 Singlejersey
146 28/1 CB 2.75
67 32”*24 Singlejersey
168 28/1 CB 2.75
68
Total production/shift =5242 kgTotal inactive m/cs =8
KNITTING
MACHINS
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VIYELLATEX GROUP
Types of YarnYarn:
1. Combed (60\1,50\1)2. Carded(34\1)
CVC=Chief Value of Cotton (60%Cotton+40%Polyester,65%Cotton+35%Polyester,70%Cotton+30%Polyester)
PC=Polyester-Cotton (60%Polyester+40%Cotton)Mellange:
1. Anthra (5%Viscose+95%Cotton)2. Ecru (2%Viscose+98%Cotton)3. Normal (10%Dyed+90%Undyed)
*100% Cotton Mellange : 10%Dyed+90%Undyed , 10%Dyed+90%Undyed
COSTING OF YARN
Combed yarn:Count Price ($/KG)
40/1 3.70/7234/1 3.40/4232/1 3.3530/1 3.3028/1 3.2526/1 3.20/2224/1 3.1522/1 3.15/10
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VIYELLATEX GROUP
20/1 3.05Carded yarn:
Count Price ($/KG)34/1 3.0530/1 2.95/9028/1 2.8226/1 2.8024/1 2.6022/1 2.4520/1 2.2516/1 1.9012/1 1.80/8510/1 1.757/1 1.70
Spandex:Count Price ($/KG)
20D 13.7040D 8.8070D 8.60
Machine Maintenance Flow ChartBelt open
Thread cutting
Running machine with oil
Fabric cutting
Cam box open
Needle open
Clean cylinder & dial
Separate reject needle
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VIYELLATEX GROUP
Creel capacity:Single jersey (PAI LUNG)=31*9=279Single jersey (FUKUHARA)=26*8=208CARROT=16*8=128MAYER & CIE=24*8=192
CONCLUSION
Bangladesh export 37%(2007) knitted fabrics to differnt countries such as USA,UK,Germany but cotton produce 0% in Bangladesh.It is a great problem for us. On the other hand cotton produce in USA 23% ,China
37%,Pakistan 10%,India 23%,Uzbek 6%(2007).From knitting section we can learn about different types of m/cs, m/cs design change,production capacity, helping us.it will be very helpful for our practical life.layout plan,knitting elements,fabrics faults & solution etc. Thanks to knitting AUTOSTRIPER=126*4=504
DYEING SECTION
Flow chart of dyeing SectionGrey fabric from knitting section
Batching
Dyeing
Transfer to finishing
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VIYELLATEX GROUP
Flow chart of finishing Section
Flow chart for Peach finish/Brush:SlittingStenterSueding/RaisingStenterCompacting
For Lycra:SlittingHeat SettingSewingDryingSlittingStenterCompactin
Finishing section
Open fabric Tube fabric
Slitting machine
Stentering
Compactingmachine
Finalinspection
Dewatering machine
Drying machine
Tube Compactingmachine
Finalinspection
Line Diagram of Jet
Dyeing M/c
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VIYELLATEX GROUP
No of Machine for Dyeing and Finishing Section:
Specification of Different Machines:
DYEING SECTION:
Dyeing Machine. 01(Fongs)_Type Jet Dyeing MachineManufacturer name FONG’SCountry ChinaModel No. ECO-38-2TYear of manufacturing 2003Temp. Range 00-980CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 500 KG
Dyeing Machine.02(Thies)Type Jet Dyeing MachineManufacturer name THIESCountry GermanyModel No. D-48653 COESFELDYear of manufacturing 2004Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo Of Nozzle 04
Dyeing Section1. Dyeing Machine 152. Sample Dyeing Machine 07
Finishing Section1. Super Slitter 032. Dewatering Machine 023. Stenter 024. Dryer 025. Tube compactor 026. Open width compactor 027. Raising Machine 028. Sueding Machine 029. Turning Machine 0110. Slitting & Dewatering
Machine01
Industrial attachment Page no. 57
VIYELLATEX GROUP
Dyeing Machine. Thies-03Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653 COESFELDYear of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4
Dyeing Machine. THIES-04Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. ECOSOFT PLUSYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1
Dyeing Machine. THIES-05Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41350Year of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 500 KGNo. of Nozzle 2
Dyeing Machine. THIES-06Type HTHP Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41354Year of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed Air
Industrial attachment Page no. 58
VIYELLATEX GROUP
No. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4
Dyeing Machine. FONGS-07Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 200 KGNo. of Nozzle 1Permissible Working Pressure 380 KpaTest Pressure 585 Kpa
Dyeing Machine. FONGS-08Type Jet Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1Permissible Working Pressure 380 KPATest Pressure 585 Kpa
Dyeing Machine. FONGS-09Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-3TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 750 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 585 Kpa
Industrial attachment Page no. 59
VIYELLATEX GROUP
Dyeing Machine. FONGS-10Type High Speed jumbo Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 8Production Capacity 1120 KGNo. of Nozzle 4Permissible Working Pressure 350 KpaTest Pressure 520 KPa
Dyeing Machine. FONGS-11Type HSJ Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 8Production Capacity 840 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 520 Kpa
Dyeing Machine.FONGS-12Type HSJ Dyeing MachineManufacturer name FONGSCountry ChinaModel No. HSJ-SR-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 3Production Capacity 560 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 520 KPa
Industrial attachment Page no. 60
VIYELLATEX GROUP
Dyeing Machine.FONGS-13Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 6TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 1680KGNo. of Nozzle 6
Dyeing Machine.FONGS-14Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 840 KGNo. of Nozzle 3
Dyeing Machine.FONGS-15Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 1120 KGNo. of Nozzle 4
Sample Dyeing Machine.FONGS-01Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINA
Industrial attachment Page no. 61
VIYELLATEX GROUP
Model No. P-D 5500-2000-CAT -2Year of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 25KGNo. of Nozzle 1
Sample Dyeing Machine.THIES-02Type Sample Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653-COESFELDYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Inhalt Capacity 523 LitreNo. of Nozzle 1
Sample Dyeing Machine.FONGS-03Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 30KGNo. of Nozzle 1
Sample Dyeing Machine.FONGS-04Type ALL FIT-120 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed Air
Industrial attachment Page no. 62
VIYELLATEX GROUP
No. of Motor 9Production Capacity 120 KGNo. of Nozzle 1
Sample Dyeing Machine.FONGS-05Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2006Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 30 KGNo. of Nozzle 1
Sample Dyeing Machine.FONGS-06Type ALL FIT-60 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 60 KGNo. of Nozzle 1
Sample Dyeing Machine.FONGS-07Type ALL FIT-60 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 60 KGNo. of Nozzle 1
Industrial attachment Page no. 63
VIYELLATEX GROUP
FINISHING SECTION:
Finishing:Textile finishing , in a restricted sense , is the term used for a series of processesto which all bleached , dyed , printed and certain grey fabrics are subjected beforethey are put on the market . In fact , finishing includes the final treatment ofevery kind of fabric made from every kind of fiber .
Objective of finishing:- Improving the appearance – Lustre , whiteness , etc .- Improving the feel , which depends on the handle of the material and its
softness , suppleness , fullness , etc .- Wearing qualities , non – soiling , anticrease , antishrink , comfort , etc .- Special properties required for particular uses – water – proofing , flame –
proofing , etc. .- Covering of the faults in the original cloth.- Increasing the weight of the cloth.
Types of finishing:1) Chemical finishing:
1) Chemical reaction of auxiliaries with fibers.2) Application of the handle modifying products / additives.
2) Mechanical finishing: Mechanical treatment with machines. Finishing effects: Easy – care Crease recovery. Dimensional stability. Good abrasion resistance. Improved tear strength. Good sewability Soft or stiff handle. Shine or luster
Industrial attachment Page no. 64
VIYELLATEX GROUP
FINIS
HING
MAC
HINS
(OPE
N
LINE)
Slitting,De-
watering &
Detwisting
m/c
St
en
te
rRaising
m/c
Seudi
ng
m/c
Open
Compa
ctor
Industrial attachment Page no. 65
VIYELLATEX GROUP
Open fabric line for finishingSlitting and dewatering machineMachine specification:
Brand name: CORINO MACCHINEType/model no:Company: ItalyYear: 2005No of motor: 08
Function of the Machine: Used to remove excess water after pretreatment and dyeing To slit the tube fabric by the knife for opening of the fabric and ready for
stentering Delivered fabric is crease free state Before squeezing balloon is formed with the help of compressed air
passing by a nozzle or air sprayer It can control the diameter of fabric and GSM and shrinkage by over
feeding mechanism To impart soft finish to the fabric by using required softener.
Main parts of the machine:- Squeeze roller (to remove water)- Stretcher (to control width)- Over feeding wheels (to control GSM)- De-twisting device (To delivery the fabric roll in untwisted form)- Folding device (to delivery the fabric in folded form)- Squeezing roller- Padder for softener
Controlling points or Control system:1. Overfeed control2. Pressure3. Speed control4. Width control
Power consumption:Voltage: 400VFrequency: 50HzMaximum power: 24kwatt
Manpower Required:Worker: 02
Industrial attachment Page no. 66
VIYELLATEX GROUP
Production:Capacity: 10 tones/shiftActual production: 7 tones/shift.
Utility:i) Waterii) Electricityiii) Compressed air or Processed air (to form the tube fabric into ballon with a
view to remove crease)
Feed roller pressure:
Bar PSI Kg Lbs1 14.5 90 2002 29 205 4503 43.5 315 7004 58 425 9405 72.5 540 12006 87 650 1440
Work instruction:
Fabric Type Pad pressure Speed Over FeedS/J 2.5 – 3 40 -50 40PK 3 40 -50 401x1 Rib 3 -3.5 50 -60 25
Minipadder
De-twister
Rubber coatedpadder
Wooden padder
Plaiter
Camera
Dancing roller
Dancingroller
Fabric path of Slitting, De-watering &De-twisting m/c
FeedDelivery
Industrial attachment Page no. 67
VIYELLATEX GROUP
2x2 Rib 3 – 3.5 60 40P/I 3 – 3.5Mer S/J 2 40 40Mer PK 2.5 40 40Mer 1x1 Rib 2.5 – 3 50 25Mer 2x2 Rib 2.5 – 3 60 40Mer P/I 2.5
Find out the limitations and faults of the machine and advise for removing these.i) Workers does not record the pressure, in dia and out dia of different fabric in
record bookii) Workers set the pressure of squeeze roller for different fabrics same. But
higher GSM fabric needs more pressure than lower GSM fabric. So removalof excess water is not sufficient.
iii)
Stenter machine
Machine no. 01Machine specification:
Brand name: BRUCKNER +MAHLOType/model no: 72276-0463Company:Country: GermanyYear: 2004
Other specification:Speed range:
15-30 m/min (for knit)15-80m/min (woven)
Temperature range: 20-2500CNo of motor in drying unit: 29Total no of motor: 49Maximum width = 102Minimum width = 30Steam pressure: 2 barAir pressure: 10 barApplied for: Open width fabric
Industrial attachment Page no. 68
VIYELLATEX GROUP
Machine no. 02M\c specification:
Brand name: SUN SUPER.Country: KOREA.
Other specification:Speed range:
Max: 110m/min.Use: 45 m/min.
Temperature range:Max: 500 CUse: 180 C (For heat set).
No of motor in drying unit:Total no of motor:Max dia: 295cm.Min dia: 95cm.Steam pressure: 2 barAir pressure: 10 barApplied for: Open width fabric
Fabric path of stenter
Overfeed & pinning
Fabric in the chain
Industrial attachment Page no. 69
VIYELLATEX GROUP
Extra attachment:iv) Mahlo attachment for bowing control.v) Selvedge gumming devicevi) Selvedge cutting device
Function of the Machine:i) Dryingii) GSM control:If overfeed increases,then GSM increases and vice versa.iii) Width control :The width is controlled by means of Spreader,Expander.iv) Shrinkage controlv) Decrease spriralityvi) Decrease Bowing effectvii) Softener applicationviii) Surface coating for Teflon finishix) Soil release chemical finishx) Heat set for cotton lycra fabric
Main parts of the machine:i) Feed zone
-Centering deviceii) Chemical padding zone
-Squeezing roller-Chemical tray
iii) Bowing control zone-Bowing roller (rubber roller, no of roller -2)-Sensor (no of sensor -6)-Uncurling roller
iv) Chain entry zone-Uncurling device (both side of the chain entry)-Sensor (both side of the chain entry)-Brush roller (for attaching the fabric with the pin of the chain, no of
brush roller -4)-Selvedge gumming device with gum box under the chain entry
v) Drying zone-Gas rotamatic burner (10)
vi) Cooling zonevii) Delivery zoneviii) Relax R/rix) Padderx) Pin rollerxi) PLC profivassleeve converter.xii) Plaiter rollerxiii) Take up rollerxiv) Wheel
Burner used in Bruckner:Radiomatic burners are used.The parameter of radiomaticburner is as follows
Capacity:150kwVoltage:230-240VFreequency:50-60HzFuel:Natural gas
Industrial attachment Page no. 70
VIYELLATEX GROUP
Pressure:50 mbarFunction of angular roller:
Stripe controlBowing controlStraightness of fabric
Chemical used:Silicon softener (It is used to soft and slippery of the fabric)
Manpower Required:Worker: 6
Production:Capacity: 5 tones/shiftActual production: 3.5-4.5 tones/shift.
Heating arrangement:No of Rotamatic burner: 10There are 5 heating chamber in this machine. Each chamber has two burners which isplaced two sides of the machine.
Chamber Burner Burner01 1A 1B02 2A 2B03 3A 3B04 4A 4B05 5A 5B
Temperature:Maximum = 2500CSample = 1100CAverage = 130-1700C
Utility:i) Gasii) Electricityiii) Compressed air.
Parameters used for different types of fabric:
BRUCKNER
Fabric Req.GSM
FinishGSM
R F B Temperature Speedm/min
Overfeed
S/J 140 - 68” 71” 67” 140 14 60%” 160 150/52 56” 64” 60” 150 20 10%” 180 170/72 54” 56” 54.5” 110 12 60%“ 190 188/90 58” 61” 57” 110 15 60%H/J 280 270/75 64” 67” 62” 110 7 50%Loopback
280 255/60 74” 78” 75” 110 9 60%
Fleece 260 260/65 74” 80” 75” 110 9 60%1×1 rib 240 224/26 72” 75” 74” 110 10 60%
Industrial attachment Page no. 71
VIYELLATEX GROUP
SUNSUPER
Fabric Req.GSM
FinishGSM
R B F Temperature Speedm/min
Overfeed
S/J 190 178 58” 56” 60” 110 24 50%S/J(c.v.c) 180 180 56” - 59” 110 35 50%H/J 280 276 70” 72” 73” 120 18 50%1*1 Rib 240 244 72” 73” 75” 120 18 40%Boltonstripe
330 335 62” 66” 70” 130 16 60%
Fleece 280 270 76” - 78” 110 16 50%
Open compactorMachine no. 01Machine specification:
Brand name: HELIOT InternationalType/model no: HC2000GLCompany: FranceNo of motor: 08Over feed = m/minMachine speed = m/minSpeed range: 13-22m/minTermperature range: 100-1400CMaximum width 86Minimum width 36Applied for: Open fabricLeft over feed: -20%+20%Right over feed: -20%+60%High production: -20%+60%Front over feeding cylinder: -20%+60%Middle belt: -20%+60%
Check point:1. Check steam & air line pressure2. adjust felt temperature3. Blanket pressure:3.5-4.0-4.5
Some instructions for optimum performance:
1. Center the felt blankets on the cylinder. Ensure that all cylinders are running parallelrelative to each other. Adjust the limit switch against the edge of the felt.
2. Place the felt under tension. Upper felts tension-2 bar, Lower felt tension-1 bar.3. raise the heated drum working temperature to 200 f| & set the speed to 11-22
yd/min(10-20 m/min)4. Open the humidification ramp in order that felts are in a steam atmosphere.5. As soon as these conditions are reached, let the felt run for 2.5 m
Industrial attachment Page no. 72
VIYELLATEX GROUP
Machine no. 02Machine specification:
Brand name: FERRAROType/model no: COMPTEX-RE 2800.Company: ITALY.No of motor: 17Over feed = Max + 35%, Min -35%.Machine speed = Max 32m/min, Min 4m/min.Termperature range: 100-2000CMaximum width =240cmMinimum width =100cmApplied for: Open fabricLeft over feed: -20%+20%Right over feed: -20%+60%High production: -20%+60%Front over feeding cylinder: -20%+60%Middle belt: -20%+60%
Function of the Machine:1. To compact the fabric2. To control the shrinkage3. To maintain proper width and G.S.M
Heating system:Steam
Main parts of the machine:1. Heating chamber2. Blower (2, one at the entry chain zone for uncurling and another at the
entry of compacting zone)3. Synthetic blanket as a conveyor,4. Folder5. Exhaust fan6. Unpinning cylinder (-40%+40%)7. Belt cylinder (-40%+40%)8. Uncurling device at entry of compacting zone.9. sensor10. brush roller
Additional attachment:i) Selvedge cuttingii) Selvedge safetyiii) Pinning safetyiv) Selvedge unrollingv) Selvedge dryingvi) Steam zone heating
Industrial attachment Page no. 73
VIYELLATEX GROUP
Controlling points:- Water pressure 2.5 lb- Air pressure 4 lb
- Steam pressure 6 lb
Manpower Required: Worker: 06Production: Capacity: 5 tones/shifActual production: 4 tones/shifUtility: Steam Electricity, Compressed air.
Special finishing machineSueding
A sueder is sometimes referred to a s a sander since the machine consists of one or morerolls covered with sand paper as the abrasive. Fabrics traveling over these rolls develop avery low pile and the material's surface can be made to feel like suede leather. The hand willdepend on the fiber composition, the filament count in the yarn and the intensity with whichthe fabric is worked.Filament fabrics can be made to feel like a spun fabric and all fabrics will have a softer hand.
Brush: The brushes of Sueding mcs are made up of Silicon carbide.
Sueding machine
Machine parts:Suction hood
Industrial attachment Page no. 74
VIYELLATEX GROUP
Fabric slowing rollerDrag cylinderSueding brushFeeding rollerFolding unitInlet tighter
Machine specification:Brand name: Lafer SPAType/model no: GSI106Company: ItalyYear: 2002
Other specification:No of motor: 08Winch speed: 10-30m/minMachine speed: 50m/min (max)Drum speed: 30-35-50 rpm (Max 70)Pile roller no: 06Pile made of PlasticPlaiter tension: 6kgTaker in tension: 20kgFabric return driver Tension: 25kgDrum Tension: 50kgSpeed range: 10-40 m/minNo of cylinder/drum:
2 for double cylinder1 for single cylinder
No of pin roller: 24 2 = 4824 1= 24Cylinder r.p.m (General): 100Tension: 3 kg
Manpower Required:Worker: 03
Production:Capacity: 40 tones.
Raising m/c:In which process a layer of fibers lifting from the body of the fabric to achievesoft and lofty effect on the surface is called raising.
Raising machine -1 (Single drum)Machine specification:
Brand name: Lafer SPAType/model no: GRI 124CCountry: ItalyYear: 2002No of motor: 04No of pile roller: 24Machine speed: 50Drum speed: Max 120
Industrial attachment Page no. 75
VIYELLATEX GROUP
Manpower Required: Worker: 05Production : Capacity: 2 tones/shift
Actual production: 1 tones/shift.Utility : Electricity, Compressed air.
Raising machine-2 (Double cylinder)
Machine specification:Brand name: Lafer SPAType/model no: GRI 224ACountry: ItalyYear: 2003No of cylinder: 2No of pile roller: 24+24Machine speed: 50Drum speed: Max 120No of motor: 05Speed range: 20-30 m/minNo of cylinder/drum: 1No of pin roller: 6Cylinder r.p.m (General): 100Tension: 3 kg
Production: Capacity: 5 tones/shiftActual production: 3 tones/shift.
Utility : Electricity, Compressed air.
Industrial attachment Page no. 76
VIYELLATEX GROUP
Tube fabric line for finishingDewatering machine -1
Dewatering MachineNo. of the machine 02Manufacturer name Heliot InternationalCountry FranceModel No. EXP-24CSpeed 90 m/minUsed Utilities Water Electricity, Compressed AirNo. of Motor 06
Slitting machine
Sutter SlitterManufacturer name AKABCountry SwedenModel No. CR-2400Year of manufacturing 2003Used Utilities Electricity, Compressed AirNo. of Motor 03
De-twister
Rubber coatedpadder
Conveyor belt
Width controller
Industrial attachment Page no. 77
VIYELLATEX GROUP
Tensionless Dryer MachineFunctions:
1. To dry the fabric with help of steam2. To control the shrinkage3. To prepare for next subsequent process4. To dry tubular and open width fabric without tension
Machine specification:Brand name:HELIOT internationalSerial no: D700HWTCompany: FranceSpeed range: 4-30m/minTemperature range: 110-1600CEach motor required 300 watt.No of motor: 08Worker: 04
Main parts of the machine:1. Heating chamber (2)2. Blower (8)3. Synthetic blanket as a conveyor4. Folder5. Exhaust fan
Production:Capacity: 10 tones/shiftActual production: 8 -9 ton/shift.
Heating arrangement:Heating chamber: 3No of rotamatic burner: 3
Heating system:1. Gas fired
Temperature of the machine:
PV PV PV129.50C 1300C 1350CSV SV SV1300C 1300C 1350C
Utility:1. Gas (to make fire)2. Electricity (to rum the machine)3. Compressed air (to spread the fire)
Industrial attachment Page no. 78
VIYELLATEX GROUP
Parameters used for different types of fabric:
Types offabric
Buyer Batch Color India
Outdia
Overfeed Machine speed
Temperature
Vibration
Collar TESCO White 6 (m).10(monitor)
6 1300C 120
5885 Blue 6 .10 7.0 1400C OffS.Oliver
5843 0147 6 .10 4.0 1600C Off
11 Rib 6.10 7.0 1300C 120TESCO 5870 White 36 34 6.10 7.5 1300C 120
5874 Helapink
6.10 8.5 1400C 120
5888 Black 38 36 6.10 7.0 1500C 120ESPRIT
5836 Black 38 35 6.10 5.0 1600C
22 Rib W.W 1480/06 Blue 6.10 5.0 1500C 12052 Rib M&S Sample Pink 6.10 5.0 1400C 120Interlock 1300C 120Singlelacost
TESCO 5882 RED 6.10 8.0 1400C 120
Doublelocost
EMA 5828 White 46 44 9.10 5 1400C 120
Fabric path Dryer
Conveyor belt
FeedDelivery
Conveyor belt
Feed roller
Vibrating roller
Burner
Industrial attachment Page no. 79
VIYELLATEX GROUP
Find out the limitations and faults of the machine and advise for removing these.
i) Selvedge drying system is not properly functioning.ii) Maximum over feed of the machine is +60%.iii) When the steam temperature is 1000C-1200C, then delivered fabric temperature is
45-500C. But there is no cooling zone in this machine to reduce the excesstemperature. So a cooling zone in delivery zone can be attached.
Tube compactor machine -1,2
Machine specification:Brand name: HELIOT InternationalType/model no: HCPPICompany: FranceNo of motor: 07Over feed = 40m/minMachine speed = 25m/minSpeed range: 16-35m/minTermperature range: 110-1450CMaximum width 52Minimum width 16Applied for: Tube fabric
Manpower Required:Worker: 06
Production:Capacity: 5 tones/shift or 10 tones/dayActual production: 4 tones/shift.
Heating arrangement:Temperature: 1100C
Utility:Steam, Electricity, Compressed air.
Industrial attachment Page no. 80
VIYELLATEX GROUP
REMARKS:VIYELLATEX GROUP. is a well equipped industry. As the quality of the
machineries of dyeing, finishing & testing section are good, so the quality level of theproduct is also good.Sequence of Operation for Knit Dyeing:
Grey fabric received from knitting section
Batching
Fabric turning
Loading to the m/c
Select production programme
Pre-treatment (Scouring & Bleaching)
Select recipe for Dyeing
Recipe confirmed by DM/SPO
Dyeing
Post Treatment
Unload
Steamarrangement
Upper shoe
Lowershoe
Bigcylinder
Fabric Path of Tube Compactor
Feed
Delivery
Feed roller
Industrial attachment Page no. 81
VIYELLATEX GROUP
Production Parameters:
1) PH
- During H2O2 bleaching PH 9.2-12(Alkaline)- During reactive dyeing PH 10.5-12.5(Alkaline)- During disperse dyeing PH 4.5-6.0 (Acidic)
2) Temperature:- For cotton scouring: 900-950C- For cotton cold wash: 300-400C- For cotton hot wash: 700-800C- For cotton acid wash: 600-700C- For cotton dyeing: 80-900C (For hot brand)
600C (For cold brand)- Polyester dying: 1000-1300C
3) Time:- For Scouring: 60-90 minutes- For Disperses dyeing 60-90 minutes.
4) M: L ratio:- For reactive dyeing M: 1 ratio maintained between 1:6 to 1:10.
Description of Production Process:Washing for colored fabrics: The colored fabrics, to be washed is loaded in the machine Required amount of water is taken. Felosan NOF (detergents) added & washing continued at 800 C for 20 minutes. Cold washing
Scouring-bleaching: Fabric, to be scoured is loaded in the machine Required amount of water is loaded Washing agent| detergent is added Steam pipes are on & scouring agents (i.e., caustic soda/ soda ash) added when the
temperature reaches at 700 C Then H202 is added. Temperature is then raised to 1050 C & the process is then carried out for 60-90
minutes depending on the requirements. The liquors are then drained. Then wash with Felosan NOF (detergent) at 980C for 5 min.
Industrial attachment Page no. 82
VIYELLATEX GROUP
Then cold wash, at 350-450C & acid wash, at 600-700C is done.Dyeing: After acid wash all liquors are drained out. Required amounts of water is taken Then leveling agents, anti-creasing agents, de-foaming agents are added according to
the requirements. Steam pipes are on & after 10-15 minutes dyes are added. Salts are added and runtime is 15-20 minutes. Then soda ash, after another 35minutes. Then the temperature is raised slowly up to the mark. The process is carried on & samples are taken after every 30-40 minutes to match
with the target shade. It continues until shade matching. If the sample is matched, then the liquor is drained out. Then cold wash at 350-450C. Wash with Cibapon R (Washing agent) for 5 minutes. Acid wash at 550C is done. Fixing agent is added at 450C for 15 minutes. Then softener is added at 450C for 15 minutes.
Dyeing Curve:
600C
900C&10’
CBB+NOF
Caustic H2O2
1050C& 30’
700C
600C
980C&10’
Drain
Drain
Acid PCAcid Bioace
900C&10’
CS
DrainDrainDrain
NOF
Scouring & Bleaching Curve
600C&10’
550C&30’
A. Acid+C+DBC
Color Dosing(20’)
Salt
Soda Dosing(35’)
CheckShade
Dyeing Curve
10
R
Acid Bioace
Drain
550C& 30’
HotWash
450C& 30’
EC
450C& 30’
Acid Softener
ColdWash
FabricUnload
15’ 20’ 20’
Industrial attachment Page no. 83
VIYELLATEX GROUP
Production Flow Chart:
Production flow chart for 100% cotton fabric:
Dyeing procedure for dark shade
Felosan NOF/Wetting agent = 0.5g/lKappazon H53NEU/Stabilizer (H2O2) = 0.5 g/lAnticreasing agent = 1.0 g/l [Only for S/J]
60oC x 5'Caustic → 2 g/l
60oC x 15'Hydrogen peroxide → 2.5 g/l [Dosing 10']
(60oC - 80oc)Temperature rise up to 105oC
30'Acetic acid → 1.0 g/l
H2O2 killer → 0.5 g/l
60oC x 10'Acetic acid → 0.8 g/l (To control pH = 4.5-5.5)
Enzyme → 1.5 g/l
55oC x 45' - 60'Kappaquest FE / Sequestering Agent → 0.35 g/l
90oC x 5'Sarabid LDR → 0.5 g/l (leveling agent)
60oC x 5'Gluber Salt (Runtime → 10')
60oC x 10'Dye stuff
60oC x 35' Runtime 20'Soda ash
60oC x 40' Runtime 60'Bath drop after shade matching
Hot rinse
60oC x 10'
Industrial attachment Page no. 84
VIYELLATEX GROUP
Soaping
80o - 95oC x 10'Cold rinse
45oC x 10'Neutralize (Acetic acid = 0.5 g/l)
45oC x 10'Fixing
40oC x 15'Softening
Unload
Dyeing procedure for Light / Medium ShadeFelosan NOF/ Wetting agent = 0.5 g/lKappazon H53NEU /H2O2 Stabilizer = 0.5 g/lAnticreasing agent = 1.0 g/l
60o x 5'Caustic = 2 g/l
60oC x 15' [Dossing]Hydrogen peroxide (H2O2) = 2.5 g/l
(60o - 80oC)Temp rise up to 105oC & Run - 30'
Acetic acid = 1.0 g/l
H2O2 killer / Kappaquest FE = 0.5 g/l
60oC x 10'Acetic acid = 0.8 g/l [To control PH - 4.5 - 5.5')
Enzyme = 1.5 g/l
55oC x 45' - 60'Sequestering agent = 0.35 g/l
90oC x 5'Sarabid LDR /Levelling agent = 0.5 g/l
Anticreasing - 0.5 g/l
60o x 5'Dye stuff
60o x 35' - Run time - 20'Glauber Salt
Dosing - 60o x 10' - run time - 20'Soda ash
60 x 40'
Bath drop after shade matching
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Hot rinse - 10' x 60oC
Soaping80o - 90oC x 10'
Neutralization / Acetic acid45oC x 10
Cold rinse - 45o x 10'
Softening
Unload
Dyeing Procedure for White Colour
Felosan NOF/wetting agent → 0.5 g/lKappazon H53NEU /Stabilizer → 0.5 g/lAnticreasing agent → 1.0 g/l [Only for S/J]Caustic → 3 g/l
60oC x 15'Hydrogen peroxide → 10.0 g/l
60oC x 10'Syno white 4BK/Optical brightener (60o → 80oC)
105o x 60'Acetic acid → 1.0 g/l
NT x 10'Acetic acid → 0.8 g/l [To Control PH- 4.5 - 5.5]Enzyme → 1.5 g/l
55oC x 45' - 60'Sequestering agent → 0.5 g/l
90oC x 5'Acetic acid → 0.35 g/lSoftener → 1.5 g/l
40oC x 10'N. Hot
Unload
Remarks:
VIYELLATEX GROUP., strictly follow up the production parameters like time,temperature, M:L ratio, PH etc. As they do some difficult shade, it takes more time for theproduction of the batch and the dyeing process may vary from the dyeing flow chart fordifferent types of fabric & different types of shade.
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WORKING PROCEDURE FOR LABSAMPLE IN (FABRICS)
Physical Test Wet Lab.
Color fastness to light Bursting strength Color Fastness To Washing Dimensional Stability Pilling Crocking Prepare the sample
Pre-Production Sample Final SampleEvaluate the Sample Wash the sample according to buyer measure
Test TeststReport Making Tumble dry
Prepared the ReportKeep the sample Flat in conditioned temp
Pass Fail at least two hours before measurePass Fail
Delivery Refinish Measure the sampleGo for the final Refinish
Need to test again Prepared the ReportNeed to test again
Pass Fail
Ready to deliver Refinish
Need to test again
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1.Procedure of the Different Tests:
Different types of fastness tests of the dyed fabric are done in quality controldepartment of the VIYELLATEX GROUP LTD. Different types of method (Standard orbuyer’s recommended) are followed for different types of tests. The process of the differenttests of fabrics & lab. dip dyeing is described in the following section:Color Fastness Test ProcedureColor Fastness:
The “color fastness” of a colored textile is defined as its resistance to these changeswhen subjected to particulates of conditions. It follows that color fastness must be specifiedin terms of these changes and expressed in terms of the magnitude.
1. Color Fastness to Wash Test
Required materials:1. Sample size 40 100 mm2. Multifiber at 40 100 mm3. ECE detergent (WOB) – 4g/L4. Sodium Perborate (Na2BO3.H2O2.3H2O2-1g/L) - 1g/L5. Distilled water6. Normal cold water7. Steel balls
Required instrument:1. Rota Wash2. Scissor3. Stitch machine
Procedure :
1. Cut sample & multifibre at 100 400 mm and then stitch.2. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the
sample.For Marks & Spencer, the solution is taken by the following formula:
(Sample fabric + Multifibre weight) 50 ml3. The sample is kept in 600C for 30 minutes in Rota Wash Machine4. Rinse the sample twice with cold water.5. Dry at 60°C by hanging or by Flat iron pressing but temperature should not
be more than 150°C.Report:
Dry the specimen and the change of shade & degree of staining is measured by GreyScale & Staining Scale.
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2. Color Fastness to Perspiration Test
Test specimen: Sample fabric – 50 mm 50 mmMultifibre fabric – 50 mm 100 mm Cut the multifibre into two piece Sandwich the test specimen between two piece of multifibre
Testing Solution:
1. Alkaline Solution:Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/LNaCl – 5.00 g/LDisodium hydrogen orthophosphate (Na2HPO4.2H2O) – 2.5 g/LPH – 8 (Adjust by 0.1 N NaOH)
2. Acidic Solution:Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/LNaCl – 5.00 g/LSodium di-hydrogen orthophosphate (NaH2PO4.2H2O) – 2.2 g/LPH – 5.5 (Adjust by 0.1 N NaOH)
Method:- The composite specimen is put in a peri dish (2 specimen of a sample).- Solution (Alkaline & Acidic) is taken in the two peri dish. Here, M:L is taken
1:20.- Bubble is made out from the specimen by tapping.- The specimen is put for 30 minutes.- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.- Excess solution is poured off.- Peri dish with composite specimen & glass plate is placed into the incubator at
(372) 0C for 4 hours.- The specimen is dried (Temp 600C)
Report:- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.3. Color Fastness to Water Test
Test specimen: Sample fabric – 50 mm 50 mmMultifibre fabric – 50 mm 100 mm Cut the multifibre into two piece Sandwich the test specimen between two piece of multifibre
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Testing Solution:Water is taken as required
Method:- The composite specimen is put in a peri dish (2 specimen of a sample).- Water is taken in the peri dish as required.- Bubble is made out from the specimen by tapping.- The specimen is put for 30 minutes.- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.- Excess solution is poured off.- Peri dish with composite specimen & glass plate is placed into the incubator at
(372) 0C for 4 hours.- The specimen is dried (Temp 600C)
Report:- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.
5. Color the Fastness to Rubbing (Dry & Wet) TestSample:
- Dyed fabric – 15 cm 5 cm- White Test Cloth - 5 cm 5 cm
Procedure:- White test cloth is put on to the grating and stag by steel wire.- The sample is run twenty times manually for ten seconds. and the rubbing
fastness of the sample cloth and degree of staining is accessed.- For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked
and squeeze. The wet rubbing cloth is placed on to the grating and stag withstainless steel wire and run ten times manually then assess the staining on to therubbing cloth and the rubbing fastness of the sample cloth is accessed.
Report:- Change of shade of the sample is measured with grey scale and degree of staining
of the white test cloth is measured by Staining Scale.
There are also some tests are done in the lab. And the process is described below-
A. Measuring the Dimensional Stability (Shrinkage & Spirality):
Sample: Two piece of 50 cm 50 cm fabric is taken for test.
Procedure:a. Conditioning: Put the sample in table for 4 hrs for conditioning before starting
test.
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b. Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample(3 sides) by over lock sewing machine.
c. Put sample in washing machine and run according to buyer’s choice.d. Drying: All Buyers’ requirement is tumble Dry except ECHO SCOURING is
flat dry.
SHRINKAGE TEST CALCULATION:Before wash – After wash
Shrinkage % = X 100Before wash
Spirality test calculation:S = (S1+S2) / 2
Spirality = (S+S L)/100.Suppose,
S1 = The right side distance of the specimen from the stitch line afterwash.S2 = The left side distance of the specimen from the stitch line afterwash.L = Length before wash
B. pH of a Dyed Fabric TestTest specimen:
2 gm of dyed fabric is taken. The fabric is cut into pieces of (0.5 cm 0.5 cm)
Procedure:1. The sample is taken into conical flax.2. 100 ml distilled water (slightly warm) is taken into the conical flax.3. The conical flax is put on the Magnetic Stirrer for 30 minutes.
Report:The PH of the conical flax is measured by Digital PH meter.
Remarks:VIYELLATEX GROUP. always aware about the quality of the product. The quality
of the product is always approved by the buyer. They follow the quality standard: ISO -9002:2000. VIYELLATEX GROUP. is well equipped for checking the quality of theproduct. They sent the quality report to the buyer time to time/batch to batch.
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PrintSample Preparation
After getting work order from product development dept.
Prepare design according to outwork
Screen preparation
Sample preparation
Approved Sample
Bulk productionBulk Production:
Screen Preparation
Print Paste preparation
Printing is done on the mc or manually
Drying
Curing
Final InspectionPrinting m/cs:1. Flat bed Screen Printing (04 m/cs)
Red Chili( USA )No of Head-10Stroke-02
Conveyor Dryer(04 M/cs )Radicure(USA)
Three chambers:Chamber 1-Temp.-200 CChamber 2-Temp-200 cChamber 3-Temp.-200c
Expose Room:1. Sensitizing emulsion-Polymer type,Photocure TXR -97%2. Hardener-3%3. Mesh-90-1304. Heat
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Heat Press machine-02 m/csTemperature-160 cPressure-5-6 KgTime-3-5-10-15 seconds.
Types of Printing in VIYELLATEX GROUP:1. Pigment printing2. Plastic printing3. Rubber printing
Capacity:Average 30000 pcs/day.
EMBROIDERY SECTION:No of machines:08Brand Name:TajimaCountry:JapanNo of Head:20Electronic multiheaded automatic embroidery machines20 Head machine-0712 Head machine-01Highest RPM-1200 (It depends on design of fabric)The following types of stitches are used here:
Run stitchTatami stitchSateen stitchMotif stitchJig-jag stitch
Threads Used in Embroidery Section:Polyester, Cotton, Rayon, Metalic threads
Capacity: 3000pcs/shift(1 shift = 12 hr
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CHAPTER 08
UTILITY SERVICEIntroduction:
VIYELLATEX GROUP LTD. is a big project and so of course having a vastproject of utility service. Here the total account of utility facilities are available. The utilitiesare
a) Waterb) Gasc) Electricityd) Compressed Aire) Steam.
WATERWater treatment plant:
(Water Softening Method – Base Exchange Process)
Source of water is deep tube well.Production capacity – 80 m3 /hr = 1920000 liter/dayActual Production – 1500000 liter/dayRequired water - 1300000 liter/day
TechnicalDetails
Raw Watertank
Filter Tank (1) Filter Tank (2) HardnessRemoving Tank
Size Length – 30´Width - 15´Height – 6’
Diameter – 6´Height - 15´
Diameter – 6´Height - 15´
Salt reqd:190 kg/day/tankRegenerationtime 1.30 hrCapacity 360 Ton
Source Natural sourceDeep tube well
Raw WaterTank
Filter Tank (1) Filter Tank (2)
ELECTRICITY
Gas Generator is used for supplying electricity for the dyeing, knitting & office of theVIYELLATEX GROUP LTD.Total power produced by Gas Generator – 945 KW = 1134 KVAFactory (Dyeing & Knitting) Power Needed for Installation – About 1200 KWFactory (Dyeing & Knitting) Power Needed at Running stage – About 720 KWPower Needed for Office – About 250 KWSpecification of Gas Generator is given below:
Technical Details Generator DataType Gas Generator
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Manufacturer Cummins Power GenerationNo. of Gas Generator 03Model No. 315 GFBAManufactured Country EnglandYear of Construction 2002Rated Power PrimeRated 315 KWPower Factor 0.8Voltage 400Rated Current (amp) 568Frequency (Hz) 50Rotating Speed (RPM) 1500Battery Volts 24Control System PCCPSite altitude before derate 800 MASLSite ambient temp. before derate 400C
Source of Power used for Garments – DESAPower Capacity – 750 KVA = 900 KWThere is a diesel Generator in the industry.Capacity of Diesel Generator – 800 KWSpecification of Diesel Generator is given below:
Technical Details Generator DataType Diesel GeneratorManufacturer CATERPILLARNo. of Diesel Generator 02Model No. SR4B | SR4Manufactured Country U.S.A.Year of Construction 2004Rated 649 H.P. or 484.0 KWRotating Speed (RPM) 1500Voltage 400Rated Current (amp) 723Maximum Temp. 1050C by Resistance
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COMPRESSED AIR
Compressed air is produced by air compressor.There are two air compressors for producing compressed air.
Specification of the air compressor is given below:
Technical Details Air Compressor 1 Air Compressor 2Type Atlas Copco Atlas CopcoManufacturer Atlas Copco Airpower Atlas Copco AirpowerModel No. GA 30 GA 55Manufacturer Country Belgium BelgiumYear of Construction 2002 2004Maximum Working Pressure 10 bar 10 barFree air delivery 78 liter/sec 145 liter/secNominal Shaft Power 30 KW 55 KWRotational Shaft Speed 3000 r/min 3000 r/minGross Weight 995 Kg 1550 Kg
STEAMSteam is produce by Boiler.From the Water Treatment Plant, water is stored in a reserve tank and from there water goesto boiler & steam is produced.Specification of the Boiler is given below:
Technical Details Boiler DataType Fire Tube BoilerManufacturer OMNICAL BORSIG ENERGYModel No. DDHI 60 – 10Manufacturer Country GermanyYear of Construction 2002Thermal Capacity 3.9 MWMaximum Steam Out 6 ton/hourMaximum WorkingPressure
10 bar-g
Content up to NW 10940
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GASThe source of Gas is TITAS GAS LTD.The gas is supplied to gas generator or different section (Boiler- for heating water) from themain line of the TITAS GAS LTD.
Sources of Utility:Electricity : PDB & GeneratorSteam : BoilerWater : PumpCompressed air : CompressorGas : TITAS GAS LTD.
Remarks:
As the biggest project the VIYELLATEX GROUP., so the vast utility systems.There is a skill manpower group of engineers and other technical staffs to look after theseutility services. They have to remain aware of solution on a great sense of responsibility forany type of problem due to utility supply
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CHAPTER: 09STORE AND INVENTORY CONTROLCHAPTER 1Inventory Control:
Store is the place where every type of raw materials, spares, finished goods are keptin proper system. Inventory control means the accurate calculation and data of every type ofraw materials spares and finished goods in time to time store 4 inventory control arenecessary, because –
1. To know about the required amount of raw material2. To know about the job no – which would be processed3. To be continued the production process4. To find out the profit or loss of a company5. Stock and stock value for consumption measuring
Frequency of Inventory Update:- Monthly inventory control.- Annual inventory control.
Scope of Inventory Control:- Raw materials
Dyes store. Other chemicals. Grey fabrics.
- Finished fabric.- Spare parts.- General store:
Capital equipments. Accessories. Stationary. Maintenance parts.
Inventory System for Raw Material:- Raw materials partially received from production planning & directly from head office. Material receiving & inspection report (MRIR) is prepared. Received quantity is
mentioned and noted down. Submitted to Q.C. department. Some are OK & few rejected. Entry of data of goods in DATATEX. Goods are arranged according to OK or rejected group. Department gives store requisition to warehouse. As per requisition materials supplied & this record are noted down.
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In VIYELLATEX GROUP LTD. there are different inventory systems for different rawmaterials.
Grey Fabric Store:-All the grey fabrics are stored in the fabric store near the batch section. Different types
of fabric are listed in the sheet according to fabric types, quantity and consumer’srequirement. Fabrics GSM, shrinkage, diameter & other properties are also taken intoconsideration. The batches are prepared by taking the required fabrics from the grey store.
Stages of Grey Fabric Inventory Control:
After knitting production. Grey inspection. Warehouse. Batch preparation. Dye house.
Dyes And Chemicals:-There is a different store for dyes and chemicals. Varies types of dyes and chemicals are
stored here according to dyes and chemicals companies. Different types of dyes andchemicals are listed in a sheet. In the sheet the stored quantity of dyes and chemicals are alsoincluded. Every day the sheet is updated and a copy of this sheet is supplied to the dyeingmanager, dye house and lab section.
Spares:-In VIYELLATEX GROUP LTD. required amount of spears of different machines are
stored in the mechanical store room. All the spears are listed in a sheet which is controlledby the mechanical & maintenance personnel. Spares are arranged in the store roomaccording to there size, quantity & requirements. There are shelf's in the store room to keepthe small spare parts.
Finished Goods:-VIYELLATEX GROUP LTD. supplies its finished dyed fabrics to its garments
section. So, dyed finished fabrics are stored for short time in the finishing section. All thedelivered fabrics are noted on the tally khata according to the lot no, quantity, fabricsdiameter, buyer's name, Color & considering other technical parameters.
Stages of Finished Fabric Inventory Control:
Finishing section. After final inspection. Warehouse.
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Others:There is a central store at VIYELLATEX. In that store the various types offorms, papers; stationary & other necessary goods are kept.
Inventory Procedure Bin Card Store Requisition Store Ledger Account Daily Inspection & Package Report Monthly Stock & Consumption Report Monthly L/C wise Delivery Report Received Delivery & Balance Stock
Remarks:-VIYELLATEX GROUP. has individual stores for raw materials, finished goods etc.
There is not enough space to store the finished goods. It requires increasing the store area.In VIYELLATEX GROUP. the store for inventory control is satisfactory. Sometime, theyfluctuate from ideal process otherwise they are ok.
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CHAPTER :10
COSTING
Introduction:
Costing is a process by which the setting price of a product is calculated. It is a veryimportant task for a factory which runs for business purposes.And it is also strictly followed in the VIYELLATEX GROUP. Costing of the productsconsidering the raw materials expenditure, salary and wages of officers and workers,distributions and advertisement expenses etc. all direct and indirect expenses is done in thisfactory. It is determined by a troop of accountants with advice and consultancy of executivedirector.
Costing Of the Product
The following points are considered for costing any dyed product in VIYELLATEX.1. Total dyes & chemical cost2. Total utility cost3. Salary4. Payment5. Transport cost6. Lunch7. Entertainment cost8. Miscellaneous cost9. Government cash incentive
Price of the Product:Generally price of product is determined by the required profit adding to the total
expenses. So,
Price of products= (Direct expenses + Indirect expenses + FactoryOverhead) + Required profit
Price Range of Different Products:T-Shirt = $0.75 - $4.50 /PcsPolo Shirt =$2.00 - $6.50 /PcsKids Wear ==$0.75- $2.15 /Pcs
Knitting Charge of Different Fabrics:
Fabric name Charge perkg(Tk)
1. Single Jersey 092. Single Jersey with Lycra 30
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3. Single locust PK 164. Double lacost PK 165. Single PK 166. Double PK 167. Rib 178. Rib with Lycra 309. Interlock 2510. Auto striper 8011. Auto striper with Lycra 10012. Fleece 22-25
Dyeing Charge of Different Fabrics:
Name of fabric process Charge perkg(Tk)
1. White with Enzyme 352. White without Enzyme 303. Avg. color with Enzyme 854. Avg.color without Enzyme (Light&
med.)75
5. Deep shed with Enzyme (Black) 1106. Deep shed without Enzyme (Black) 957. Only wash (Tubular) 258. Only wash (Open) 459. Double dyeing (Face & Back) 115
Finishing Charge of Different Fabrics:
Name of fabric process Charge perkg(Tk)
1. Slitting only 52. Stenter only 253. Compacting only 154. Stenter + Compacting 355. Stenter + Compacting+ wash 506. Tube Compacting 10
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Costing Of the Product:Let price of yarn is $ 3.00/ kg.Process loss of yarn for knitting (10%) = $0.30Knitting fabric cost = $3.30Cost of dyes & chemicals = $2.50Process loss for dyeing (12%) = $0.30Dyed fabric cost = $ 6.10Packing cost = $0.05Production cost of fabric=$6.15Fabric price (with 25% margin) =$7.79
Fabric consumption/ doz. =(Body length + Sleeve length) x Chest length x 2 x GSM x12 /10000000
Garments specification:Body length=78 cmSleeve length=33 cmChest length=62 cmGSM=210
Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000= 3.469 kg
Fabric consumption/doze (with 10% wastage) = 3.816 kgBody fabric cost / doz. =$(7.79x 3.816)
= $29.73Cost of collar& cuff/doz = $ 4.00Cost of Trims=$ 2.25Cost of Trims (with 5% Process loss) = $2.36Production Cost of Garments/ doz=$36.09Garments Price/doz (with 25% Profit) =$45.12
Remarks:Costing is very important for a productive factory. Without proper costing all production
curriculums will go to vain. Because a factory cannot reach to its goal without achievinggood profit and good profit is not possible without skillful costing. In VIYELLATEX Thereare some skillful personnel to do this job.
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CHAPTER:11MARKETING ACTIVITIES
Name of the Buyer:
Buyer1) Marks & Spencer (M&S)2) S. Oliver3) TESCO4) PUMA5) ESPRIT
6) G.Star
Product Label:Product label differs from buyer to buyer. The product labels are
prepared according to the fabric criteria & the buyer requirements. Sample of some productlabel are given bellow:-
Main label Care label Size labelNot provided Not provided Not provided
Package Size & Label Market:
Package size & label differs from buyer to buyer. The Package size & label areprepared according to the buyer requirements. Normally the following package sizes areused:-
60 x 40 x 40 cm.58 x 33 x 44 / 43 / 42 cm.58 x 33 x 25 cm.58 x 33 x 13 / 16 / 18 cm.
Importing Countries:There are some countries which are importing goods from VIYELLATEX GROUP LTD.Which are given below- United State of America England Germany Denmark Europe Europe Union
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Manpower of Marketing:
Marketing plays a vital role in the field of displaying / showing the goods criteria of theproducts to the buyer & to communicate with the buyer. There are about 20 people in themarketing section of the industry.
Marketing Strategy:Marketing strategy is a very important factors to sale the products to the buyer. If the
marketing strategy is not so developed, it will be very hard to reach the goal. In case ofgarments marketing the dealings with the buyer is a very important factor.
By both side understanding the rate & the order quantity are fixed.A well defined marketing strategy has the following characteristics:
Good quality Low price or competitive price Prompt service Good commitment Good business communication
Duties & Responsibilities Of Marketing Officer:
Job summery:i) Market searchii) Market developmentiii) Customer’s motivationiv) Production follow upv) Technical assistance of customer
Dealing with the buyer & convince the buyer is the main duty of marketing officer. Amarketing officer also has some other duties. The main duties & responsibilities of amarketing officer are given bellow- To prepare cost sheet by dealing with the buyer. To take different steps by discussing with the high officials & merchandisers To maintain a regular & good relationship between commercial officer &
merchandisers To maintain a communication with the buyers and buying houses Communicate with better criteria of the products
Actually the responsibilities & duties of marketing officer begins from getting order of buyer& ends after receiving foods by the buyer. So, he should be always smart, energetic &sincere.
Remarks:
VIYELLATEX GROUP. has a well learned marketing & merchandising team. Theyalways communicate with the buyers. VIYELLATEX GROUP. has some fixed buyers.The marketing section also looks the quality & quantity buyers.
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CHAPTER :12
CONCLUSION
Conclusion:
We have completed our industrial attachment successfully by the grace of Allah.
Industrial attachment sends us to the expected destiny of practical life. The completion of thetwo months Industrial attachment at VIYELLATEX GROUP, we have got the impressionthat factory is one of the most modern export oriented knit composite complex inBangladesh. Though it was established only a few year’s ago, it has earned “very goodreputations” for its best performance over many other export oriented textile mills.
During our training period, talking with the clients of this mill we knew that the mill isfulfilling the country’s best export oriented white finished fabric as well as very goodcolored fabric due to its modern machinery & good management system.Mill is settled with utility to give all convenient supports to the productions for twenty-fourhours. It had self-power generator system to satisfy total power consumptions of the mill.We are enough fortunate that we have got an opportunity of having a training in this mill.During the training period we are received co-operation and association from the authorityfull & found all man, machines & materials on appreciable working condition. All stuffs &officers were very sincere & devoted their duties to achieve their goal.
There are some suggestions from us within our limited knowledge
Some Suggestions: The dyeing floor is watery most of the time: it should be cleaned all the time. To increase overall efficiency, more skilled labor should be used in a project. The m/c stoppage time should be analyzed and minimized. The maintenance should
be carried out when the m/c is out of action (wherever possible) and routinemaintenance should be carried out regularly.
There should be a yarn dyeing project. Sitting arrangement of production officers should be improved.
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Limitations of the Report: Because of secrecy act, the data on costing and marketing activities has not been
supplied in details. In spite of our limited time, we could not study in detail.
Some of the points in different chapter are not described as these were not available.
The whole process is not possible to bind in such a small frame as this report, henceour effort spent on summarizing them.
Lastly:We tried our best to gather all necessary information but it is true that within this
short period it is quite impossible to achieve 100% success but as a whole this industrialtraining was a satisfactory one and once again wed would like to thank the authority ofVIYELLATEX GROUP. as well as our honorable teachers far their altruistic help andadvice. We are fortunate enough that we have got an opportunity to have training in thismill. During the training period we have received enough co-operation and association fromthe authority and found all personnel. All stuffs and officers were very sincere and devotedtheir duties to achieve their goal.