Industrial Attachment for Spinning Mills

PABNA TEXTILE ENGINEERING COLLEGE

SALGARIA , PABNA

INDUSTRIAL ATTACHMENT REPORT FROM 28TH SEPTEMBER TO 30 NOVEMBER

THE DELTA SPINNING MILLS LTD. Zarun(South) Kashimpur, Gazipur,

SUPERVISING TEACHER

MD. AHMED ALI

CI

PABNATEXTILE ENGINEERING COLLEGE

SALGARIA , PABNA

PREPARED BY

HADIULLAH RAHAMAN B.sc. in Textile Engineering(1st batch)

ROLL NO. : 070043

REG. NO. : 4512

SESSION: 2006-2007

1

INDEX

1. Acknowledgement--------------------------------------------------------------- 02

2. Introduction----------------------------------------------------------------------- 03

3. General Information------------------------------------------------------------- 04

4. Location of mill------------------------------------------------------------------- 05

5. Lay out of ring-------------------------------------------------------------------- 06

6. Lay out rotor---------------------------------------------------------------------- 07

7. Organ gram of factory----------------------------------------------------------08-10

8. Manpower of organization-----------------------------------------------------11

9. Name of departmental head---------------------------------------------------12

10. Process flow chart of the mill--------------------------------------------------13

11. Raw material used----------------------------------------------------------------14

12. Spin plan----------------------------------------------------------------------------15

13. Machines & equipments ------------------------------------------------------16-27

14. Wastage of different section---------------------------------------------------28

15. Process sequence-----------------------------------------------------------------29-32

16. Quality management system--------------------------------------------------33

17. Lab Equipments------------------------------------------------------------------33

18. Scope of quality assurance and testing-------------------------------------34-36

19. Bale Management----------------------------------------------------------------37

20. Quality Standards----------------------------------------------------------------37

21. Information about slub yarn---------------------------------------------------38

22. Maintenance of Machinery----------------------------------------------------39-51

23. Utility Department--------------------------------------------------------------52-57

2

24. HR &

Admin----------------------------------------------------------------------58-5925. Inventory

system----------------------------------------------------------------60-6126. Marketing

Information----------------------------------------------------------6227. L/C opening

system-------------------------------------------------------------6328. Involvement in Social

Development-----------------------------------------6429. Conclusion----------------------------------------------------------------

----------65

We were very fortunate to carry out our industrial attachment

training at

The Delta Spinning Mills Ltd. So, at this point we would like to

express our

gratitude to everyone related . First of all our heartiest thanks to

our Training

Supervisor Md.Ahmed Ali, Chief Instructor of Yarn Spinning

Department of PTEC; Special thanks to Md.Bokhtiar Rahman,

Chief Instructor of the Department of Garments Technology of PTEC

for arranging our Industrial Attachment at The Delta Spinning Mills

Ltd. It is their logical guideline, constant inspiration, necessary

instruction and proper supervision that have helped us to complete

the training successfully.

3

We also express our heartiest gratitude to the authority of The

Delta Spinning Mills Ltd. Special thanks goes to Engr. Md. Tariqul

Islam, Deputy

General Manager of QA; Engr. Md. Moshiur Rahman, DGM of

production, Anjan Chowdhury, PM of production for supervising

our training in a

systematic schedule and all sort of help.

Finally we place our sincere acknowledgment to all those

officers, staffs

and technicians of The Delta Spinning Mills Ltd. who have helped us

to

overcome different problems in different situation that have made a

Successful completion of our training.

4

The Delta Spinning Mills Ltd. is a well reputed spinning mill

in Bangladesh. It is the sister concern of The Delta Group. The area

of mill is about 26 acres. It is fully 100% export oriented spinning

mill. It is located in Zorun South, Konabari, Gazipur. The Mill is

established in 2006. The owner of this mill is Engr. Faruq Hossain.

The Delta Spinning Mill is ISO certified by ISO 9001:2008.

The Delta Spinning Mills Ltd. is a truly undertaking. The

Spinning Devision has the capability to offer a complete product

range for the 100% export quality yarn to EU & American market.

The goal of the Spinning Division is to become the preferred partner

for sourcing high quality value added yarn from Bangladesh. With

an emphasis on developing local human resource, the Spinning

Division has the potential to make an important contribution to the

nation’s growing RMG export sector.

5

Name Of the Mill: The Delta Spinning Mills Ltd.

Zarun(South) Kashimpur,

Gazipur, Bangladesh.

Head Office: House# 389, Road# 6

DOHS Baridhara, Dhaka – 1206.

Phone: 880-2-8813636-7, 8824092

Fax: 880-2-8840263

E-mail: [email protected]

Date of Establishment:

Ring Unit: 2006

Rotor Unit: 2008

Production Capacity:

Unit

Total

Spindles Count

Range

Production

Capacity

(MT/day)

Ring 42,336 Ne 7s to 40s approx

28~32

Rotor 960 Ne 12s to

20s

approx

3~4

Location of the Mill:

6

Mymensing- Dhaka road

Ch ow ras ta

Ch an Kasimpur dra Ro ad

Layout Plan of Ring Unit:

7

Cotton Club

Delta composite

The Delta Spinning Mills Ltd.

Kashimpur Jail

Delta Accessori

Delta Blended yarn

8

Rin

g S

ecti

on

Back P

rocess

Card

ing

M

ach

ine

A

uto

Con

er

Raw

Cott

on

G

od

ow

n

Lay-out Plan of Rotor unit:

9

Blo

w R

oom

Card

ing

Mach

ine

Dra

w F

ram

e

R

oto

r M

ach

ine

A/C

Pla

nt

Design of Organization

Production Department Organogram

HR And Admin Organogram

Organogram of the Factory: Departmentwise:

Chairman and MD

Commercial Director

All Departmental Heads

Second man

Officer and Office Staff

DGM Production

Manager Production

Shift in Charge

APO

Worker

10

Quality Department Organogram

Maintenance Department Organogram

Head of HR and Admin

Security Officer

Medical Officer

Executive

Supervisor

Guard

Officer and Office staff

Assistant

Executive

Officer

Lab Assistant

Lab Boy

DGM Quality

DGM Utility

11

Utility Department Organogram

Executive

Maintenance Officer

Worker

DGM Utility

Manager Generator

Manager E and E

Senior Engr. CBC

Assistant Engr. A/C

Worker Assistant Engr.

Worker Worker

12

List of workers of different department

Department Category Number of workers

Maintenance

Electrical Maintenance 16Blow roomCarding &Card shop

80

Draw frameComber &Simplex

15

Ring Frame 40Winding 40

Utility

Chiller, Boiler, Cooling Tower & Pump

13

A/C Plant, Compressor 15Power Generation & Distribution

15

Workshop 15

Production

Mixing & Blow room 45Carding and Preparatory section

71

Ring section 160Winding Section 100Packing Section 50Research & Development section

7

Rotor UnitProduction 86Maintenance 10Utility 9

Total Workers 877

Total workers 877Total Staff 60Total Officers 52Grand total of manpower

989

Name of the owners & Departmental Head:

13

Chairman – Engr. Faruq Hossain

Director Commercial – Md. Shahidul Alam

DGM Production – Engr. Moshiur Rahman

DGM Quality – Engr. Tariqul Islam

DGM Utility – Engr. Abul Kased

DGM Maintenance – Engr. Abul Kased(temporary)

DGM Marketing – Md. Shah Jamal

GM Finance –Md. Ruhul Amin

Manager Store – Md. Kamal Molla

Manager HR& Admin – Md. Abdul Khaleq

Sponsored by Islami Bank Bangladesh Ltd.

Total Floor Space:

Total floor space is 1,31,000 square feet. Vision:

The visions of The Delta Spinning Mills Ltd are –

# To provide an efficient back-linkage support for the

ready-made garments industry in Bangladesh by

producing export quality cotton hosiery yarn.

# To provide sufficient monetary profit to the Group.

# To train and develop skilled manpower for the industry.

# To reduce the employment problem in Bangladesh by

creating

employment opportunities.

Process Flow Chart of The Delta Spinning mill:

14

Karded Process Combed Process

Bale Management (Mixing)

Unifloc-A11

Uniclean-B11

Unimix-B70Unimix-B70

Uniflex-B60 Uniflex-B60

Vision Shield-ED35 Vision Shield-ED35

Condensor- Condensor-A21

Carding-C60

Breaker Drawing-SB- Precomb Drawing-SB-

Unilap-E32

Comber-

Postcomb Drawing-RSB-Finisher Drawing-RSB-

Simplex-FL-100,FL-

Ring-RX240,K44,BT-702Winding-Muratec-

Packing

Yarn Conditioning

15

Raw Material Used:

Raw material is a vital factor for the productivity, quality and profitability

of a factory. As The Delta Spinning Mills Ltd is a cotton spinning mill, its main

raw material is cotton. As cotton is not grown in our country, all of these

cotton are imported from foreign countries. The factory has used the

following cottons in the past years:

Australian cotton, America, India, CIS, Thailand, Zimbabwe, Turki,Syria, Chad, Egypt, China, South pacific cotton etc.

The factory requires around 35 Metric Tons of raw cotton per day.

For the rotor unit, around 30 % to 40% virgin cotton and 60% wastage of the ring unit is used as raw material. A mixing ratio is as follows –

Virgin Cotton (CIS) – 40% – 2400kg Noil – 35% – 2100kg Pneumafil – 10% – 600kg Dropping-1 – 15% – 900kg Total – 100% – 6000kg

Raw Material Inventory:

16

The factory consists of a Raw Cotton Godown. It can store up to 7000 cotton bales of 220kg each. That means it can store around 1500 Metric Tons of raw cotton at a time. Spin Plan 100% Karded Yarn

Machine

Spinning Schedule Production Schedule

Types of m/c

Delivery unit per m/c

Utilization%

Count/Hank/Ktex

Doubling

T.M.

Speed

TPI Calculated production/m/c(Kg/day)

Production Effi%

Practical production/m/c(Kg/day)

Waste%

Total production reqd.(Kg/day)

Actul no. of m/c

Total m/c reqd.

Winding

72 102

28 1600 18.52

3497

70 2448

0.6 20000 8.17 8

Ring Frame

1008

101

28 3.7

16000

18.52

672 96 645 2.5 20120 31.20

31

Simplex

144 105

0.75

1100 1.05 4344

75 3258

0.5 20623 6.33 6

Finisher D/F

1 98 5.3 8 650 4961

85 4217

0.5 20726 4.92 5

Breaker D/F

2 99 5.3 6 650 4961

85 4217

0.2 20830 4.94 5

Card 1 100

6 195 1685

95 1601

6 20871 13.04

13

Blow room Total

4 22124

Raw material reqd.

14.3

23009

17

As stated earlier, the factory consists of two lines. One is the Ring line and

the other is the Rotor line. A short description about the machineries of these

lines are given in below :-

Blow Room:

The blow room consists of :-

Unifloc :

Model A11‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Brand Rieter‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Country of origin Switzerland‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Year of manufacture 2006‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

18

No. of m/c 02(1 for ring and other for ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

rotor)

Production capacity 1400 kg/hr‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Uniclean :

Model B11, B12 (Ring, rotor)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Brand Rieter‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐


Year of manufacture 2006‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

No. of m/c 02 (Ring and Rotor)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Production

capacity 1200kg/hr,1400kg/hr(ring,Rotor)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

19

Unimix:

Model B70,B71 (Ring,Rotor) ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Brand Rieter‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐


Year of manufacture 2006,2008‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

No. of m/c 03 (2 ring+1rotor)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Production capacity 800 kg/hr‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

20

Uniflex :

Model B60‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Brand Rieter‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐



No. of m/c 05 (4ring+1rotor)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Production capacity 600kg/hr‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

21

Vision shield :

Model ED-35‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Brand Jossi‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐



No. of m/c 04 (only for ring)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Condensor :

Model A21‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

22

Brand Rieter‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐



No. of m/c 05 (4 ring+ 1 rotor)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Carding :

Model C60‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Brand Rieter‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐



No. of m/c 23 (19 for ring and 4 for rotor)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

23

Production capacity------------------------70 kg/hr,100 kg/hr (70 kg for ring and 100 kg for rotor)

Breaker Drawing: Model-----------------------------------------SB-D-40 Brand------------------------------------------Rieter Country of origin----------------------------Switzerland Year of manufacture-----------------------2006 No. of m/c------------------------------------8 Production capacity------------------------707 m/min

24

Unilap : Model-----------------------------------------E 32 Brand------------------------------------------Rieter Country of origin----------------------------Switzerland Year of manufacture-----------------------2006 No. of m/c------------------------------------3 Production capacity------------------------97 m/min

Combing: Model-----------------------------------------E 65 Brand------------------------------------------Rieter

25

Country of origin----------------------------Switzerland Year of manufacture-----------------------2006,2008 No. of m/c------------------------------------15 Production capacity------------------------46 kg/hr

Finisher Drawing: Model-----------------------------------------RSB-D40 Brand------------------------------------------Rieter Country of origin----------------------------Switzerland Year of manufacture-----------------------2006 No. of m/c------------------------------------9 (6 for ring line and 3 for rotor line) Production capacity------------------------657 m/min

Simplex : Model-----------------------------------------FL-200, FL-100

26

Brand------------------------------------------Toyota( Both model) Country of origin----------------------------Japan Year of manufacture-----------------------2008,2006 No. of m/c------------------------------------10 (FL-200 2 pieces) Production capacity------------------------27 m/min

Ring Frame: Model-----------------------------------------K 44+, RX-240, BT-702 Brand------------------------------------------Rieter, Toyota,Rieter Country of origin----------------------------Switzerland, Japan, India Year of manufacture-----------------------2008,2006 No. of m/c------------------------------------(5+31+6)=42 Production capacity------------------------180 GPSS

27

Winding : Model-----------------------------------------Uster Quantum-2, 21C Brand------------------------------------------Savio, Muaratec Country of origin----------------------------Italy, Japan Year of manufacture-----------------------2008, 2006 No. of m/c------------------------------------14 (4+10) Production capacity------------------------1600 m/min

28

Conditioning : No. of m/c : 01 Model : 1200 kg Brand : Seizer Country of origin : India Year of manufacturing : 1996

Rotor : Model-----------------------------------------BT-923 Brand------------------------------------------Rieter Country of origin----------------------------Switzerland Year of manufacture-----------------------2008 No. of m/c-----------------------------------03 Production capacity------------------------650 kg/shift

29

Wastes produced at different production process:

Blow Room (4-5%) : Droppin-1, Droppin-2 Fine dust

Carding (5-6%) : Flat strip Licker-in

Drawing (0.5%) : Filter Waste, Sliver waste Sweeping dust

Lap Former (0.5%) : Sliver waste, Lap waste

Comber (10-20%) : Lap Sweep Noil

Simplex (0.5%) : Sliver Roving Apron Clearer waste Sweep waste

Ring Frame (3%) : Roving ,wooden roller clearer, Bonda,Soft waste, Pneumafil , Sweeping .

Winding (0.5%) : Hard Waste Sweeping Invisible waste

Rotor : Pneuma dust Hard waste Sliver waste Soft waste

30

Blow Room :

The cotton comes in compact bale form, which are not suitable for

processing. So it have to be opened, cleaned and made free of

contamination

before processing. To obtain consistent parameters throughout the

process,

the cotton have to be mixed uniformly. All these tasks are carried out

in the

blow room. At first the Unifloc plucks raw cotton in lump form and

sends these to Uniclean through air transportation for coarse cleaning.

After the heavy particles being removed, the cotton is blended and

mixed in the Unimix. Then it is taken for fine cleaning in Uniflex. After

that the material is scanned for contamination and made free of it by

Vision shield. These machines use optical and sonic principles for

detection of contamination. Then they are de-dusted in the machine

Conensor and sent to the carding machine for further processing via

chute line.

Carding:

The carding machine mainly removes the Neps, short fibers and remaining

impurities in the cotton fiber and forms carded sliver. Mainly impurities are

removed at the taker in and the neps and short fibers are removed by action

between the cylinder and flat. It is called the heart of cotton spinning because

the quality of a cotton spinning mill is greatly dependent upon the

performance of the carding machine. The card slivers are delivered in card

sliver cans which are then fed to the breaker drawing frame.

31

Breaker / Pre-comb Draw Frame:

In the breaker draw frame 5 to 6 carded sliver cans are fed at a time and are

drafted to one drawn sliver. By this, the fibers in the sliver becomes more

oriented, parallelized and the irregularity of the strand decreases. Produced

drawn sliver cans are then either fed to the finisher if it is card process or fed

to the lap former if it is combed process.

Lap Former:

For combing, the material have to be presented to the comber machine is a

lap form. So to convert the slivers into mini laps, the lap former is used. Here

23 to 24 drawn sliver cans are doubled and drafted together to form lap. The

lap is then fed to the comber machine.

Comber:

The comber machine mainly combs out the lap and removes any kind of

neps, short fiber or other impurities present in it. It also parallelizes the strand

to the maximum degree. As a result the yarn produced from this sliver

possesses better quality and aesthetic properties. The produced combed sliver

is then fed to the finisher / post-comb drawing machine.

32

Finisher / Post-comb Drawing Frame:

The finisher is the last machine where the irregularities in the strand can be

modified easily and any fault after this will pass on to the yarn. So this

machine is of great importance. That is why this machine is equipped with an

auto-leveler. The auto-leveler continuously scans the incoming slivers and

increases or decreases the draft in the drafting zone to minimize any thick or

thin place. 7 to 8 breaker or comber sliver cans are fed together. This machine

is monitored continuously and carefully. The produced finisher sliver cans

are then fed to the simplex machine.

Simplex:

In the ring frame, if the yarn is produced directly form sliver, then a very

high amount of draft will be necessary, which will be un-manageable. That is

why the material is gradually drafted and an intermediate strand named

roving is produced. A slight amount of twist is also inserted in the roving to

ensure breakage free winding and unwinding of it on the roving bobbin. Then

the rovings are fed to the ring frame.

33

Ring Frame:

In the ring frame, finally the yarn is produced by drafting the roving. Here

twist is inserted in the yarn to obtain required strength. Twist is inserted by

means of ring traveller. The number of turns that the spindle rotates at one

revolution of the front roller is the number of twist that are inserted on the

unit length of yarn. Then the yarn are wound on ring bobbins. When the

bobbins are full, they are doffed from the machine automatically by SCD

(Stationary Cone Doffer) mechanism.

Auto Coner:

The auto coner is a machine for automatic winding of yarn on cross wound

34

packages. The yarn is wound on paper cones. It represents an autonomous,

compact winding machine, which is equipped with a splicer and electronic

yarn clearer in each winding unit. The EYC continuous scans the yarn for

faults using either capacitative or optical principle or both. When a fault is

found then it cuts it out. Then a upper and lower arm catches the yarn and

brings the two ends to the splicer where they are joined together. The joining

is done by means of compressed air. Thus the finished cones are produced

which are then heat set and packed in required form of packaging.

Heat Setting Machine:

Heat setting is mainly done to stabilize the twist in the twisted yarn, reduce hairiness and increase the moisture content in the yarn packages. The yarn cones are arranged on trolleys. Maximum 6 trolleys can be fed to the machine. After that the machine door is closed. Then vacuum is created inside the machine and water at 550C is sprayed inside the chamber. Due to negative pressure, the water becomes steam. There the yarn packages are heat set in the steam for 45 minutes. Then they are brought out and sent for packing.

Rotor Machine:

In the rotor machine, the yarn is produced directly from sliver. The sliver is

opened into individual sliver in the opening unit and then individualized

fibers are deposited in rotor groove. From there they are bounded around an

open end of yarn and thus rotor yarn is formed. The produced yarn is directly

wound on a paper cone package. So here the simplex and auto coner is not

required.

35

In The Delta Spinning Mills, responsibility of quality management is

carried

out by the Quality Assurance Department Lab. The lab is lead by the

DGM of

QA . The lab carries out tests on materials at every stage of processing

starting from the raw cotton to finished yarn. By this they provide the

assurance of obtaining consistent quality throughout the process and

in the finished yarn. A brief description about the lab and its quality

management process is given in the later section.

Lab Equipments:

Serial

Name of the Machine

ModelManufactu

rer&

Country of Origin

Year of Manufact

ure

Purpose

1 USTER® Evenness Tester

4-SE ZellwegerSwitzerland

2006 To test evenness, imperfection and hairiness of yarn and other strands such as roving and sliver.

2 USTER® Tensionjet– 4

PR503Delta Range

ZellwegerSwitzerland

2006 To test count of yarn directly

3 USTER® AFIS-PRO

AFIS PRO

Zellweger UsterUSA

2006 To test Neps, length and maturity related properties of cotton fibers

4 USTER® HVI HVI – Spectrum

Zellweger UsterUSA

2006 To test important parameters of cotton fiber.

5USTER® Stelometer

754 Zellweger UsterGermany

2006 To test strength and elongation of cotton fiber

6 Electronic TEM1ZweigleGermany 2006

To measure moisture content

36

Moisture Meter of textile materials

Scope of quality assurance and testing:

Here the task of quality control starts from the raw material. At first

when

the raw cotton arrives, the lab boys collect samples from each bale and

give

respective numbers to each bale. Then the samples are tested in H.V.I.

machine. From the obtained results, the bales are categorized in

suitable categories for bale management and stored in the warehouse.

Then the raw cotton is fed to the blow room through the bale

management system. The bale management system is a vital task of

the QA department and will be described separately in later portion.

In blow-room, the fibers are opened and cleaned by beaters. Here if over

beating takes place then there is a chance of fiber damage. So, the QA

department tests cotton sample before and after every beating position to

check the cleaning efficiency and fiber damaging. From there, necessary

actions are taken. Different wastes that are collected at the fiber deposition

plant of blow room are also studied to assure proper removal of trash particles as well as least possible wastage of cotton fiber. Also the QA

department monitors the setting and performance of the contamination

separator of the blow room.

In the carding machine the Ktex of the produced sliver is checked once

37

per shift. The performance of the carding is evaluated by testing m/c and

sliver of the carding in USTER-5 and AFIS. From there the Neps Removal

Efficiency, SFCw, SFCn, UQL etc are seen to evaluate its performance and

necessity of gauge change, grinding and wire change of cylinder, licker-in and

flat is determined. The card sliver is tested in USTER-5 once

per shift to test its Unevenness (U%) and coefficient of variation of mass

(CV%).

In breaker draw frame, mainly the grain/yd of sliver is tested once per

shift. Other than this also the sliver is tested in USTER-5 to

determine the length of the fibers in strand to set the proper roller gauge in

the roller drafting zone. The breaker sliver is tested once per shift in USTER-5

to determine its Unevenness (U%) and coefficient of variation of mass (CV%).

In lap former, the lap thickness is measured mainly.

The Comber is a very crucial machine. Its performance plays a vital role on

the quality of the combed yarn. So, the performance of the comber is assessed

by testing the material before and after it. From there the nep removal

efficiency of the machine is determined. Also the noil is tested to see whether

long fibers are being wasted during the processing. From there, the necessary

38

changes in the setting of the machine is carried out. The grain/yd of combed

sliver is checked once per shift. The combed sliver is also tested once per shift

in USTER-5 to determine U%, CV% etc and any periodic faults from the spectrogram.

The finisher draw frame is a very vital machine in respect of quality

control. As it is the last machine fitted with an auto leveler, it is the last step

where the mass variation of sliver can be maintained. For this here the

grain/yd of sliver is checked at every hour. If the variation of the finisher

sliver can be controlled, then there will be less variation and imperfection in

the yarn. Also the calibration of the auto-leveler is done when necessary by

the QA department. The finisher sliver is tested once per shift in USTER-5

to determine its U%, CVm%, CV3m% and to see whether there is any periodic fault from the spectrogram.

In case of testing of carding, breaker draw frame and finisher draw frame,

a schedule is maintained so that all the machines are tested within a fixed

period of time.

In simplex, the hank is mainly tested once per shift. Also the roving is

tested in the USTER-5. A schedule is maintained so that all the spindles of simplex machines are tested over a period of time.

The yarn of ring frame, rotor machine and auto-coner are tested to

39

determine their count. This test is carried out at each shift for each count and

lot. Testing is carried out in USTER-5 Tester in the same manner to

determine the U%, CV%, Relative count, +50% thick places, -50% thin

places, +200% Neps (ring yarn), Imperfection index, hairiness, standard deviation of hairiness, periodic faults etc. From there necessary actions are taken to eliminate or reduce the faults. The CSP (Count Strength Product) of the yarn are also tested to determine the bundle yarn strength which is very important for knitted fabric. The TPI (Twist Per Inch) of yarn is tested at the beginning of each lot.

The setting of drafting gear in drawing frame, simplex and ring frame is

given by the QA department and is implemented then by the maintenance

department. The QA department on the basis of trial and experiment does

the selection of proper roller gauge and spacer in the drafting zone of simplex

and ring frame. Also the setting of the EYC (Electronic Yarn Clearer) is

determined by the QA department. This ensures that most of the faults that

are present in the yarn are cut out during winding on paper cone and fault

free yarn are delivered to the customer.

The moisture content in the yarn packages after heat setting are also tested

by the QA department. Thus the proper time of heat setting can be

maintained to deliver yarn with required amount of moisture content.

Bale Management:

Bale management is the judicious selection of cotton bales in the

laydown in order to obtain consistent quality as well as economic

spinning performance. For this at first samples are collected from

100% bales. The samples are tested in HVI and from there, the bales

40

are categorized. The categorization is done on the basis of different

fiber properties. Here it is done on the basis of Mic and chrome (+b)

value. At first all the bales are categorized. Then from there they gives

the list of bales for each lay-down of required number of bales. The

average fiber properties from lay down to lay-down is kept constant.

The list is sent to the warehouse. From there the store personnel

procures the bales according to the category and send a list of the ID.

No. of the bales. Then the QA personnel again checks whether these

bales fulfill the requirements. Then from there the lay-down plan is

prepared. During preparing it, one thing should be kept in mind that

bales of same categories should not be placed right next to each other.

Then according to the lay-down plan the bales are arranged under the

bale plucker.

Quality Standards:

In The Delta Spinning Mills Ltd, they maintain their whole process in

a way so that the finished yarns as well as all the processing strands

comply with the

quality standards. In the QA lab, always the standard temperature

(27±2°C) and Relative Humidity (65%) is maintained.

41

The Delta Spinning Mills produce one kinds of yarn called slub yarn. Slub yarn is one kind of yarn which contain irregularity in a uniform distance. A model parameter of slub yarn is given below :-

Length Minimum (mm)

Length Maximum (mm)

Wide Initial (mm)

Wide Final (mm)

Pause Length

110 380 1.0 1.0

Ramp 10 10 1.0 1.6Slub Length 45 65 1.6 1.6Ramp 10 10 1.6 1.0

Pause Length Ramp

Slub Length

Maintenance of Machinery

42

All the textile machinery both process and related ones are high performance

machinery and they have to maintained well to ensure their high performance

and efficiency. Also proper maintenance ensures their long operating life. The

following types of maintenance are carried out in the factory –

# Schedule Maintenance: Here mainly all the machines are checked

on the basis of a fixed schedule of time. Different machine parts are

opened, cleaned, lubricated, gauged and replaced if necessary.

# Predictive Maintenance: This type includes maintenance of machine

parts on the basis of suspicion that they consists problem and will

cause greater problem in future. It also includes the gear changes that

are done to adjust count, ktex etc of machinery and overhauling.

# Breakdown Maintenance: When a machine stops due to failure of

machine parts, then it is called machine breakdown. The maintenance

that is done to repair and make it ready to run is called breakdown

maintenance.

43

The points that are checked during the maintenance of different machines as well as different lubricating points are given in the following section –

Blow-room:

Maintenance Points:

Machine Name

Maintenance Point Work to be Done

Unifloc A11Fan Impeller Checking .

Inside Swivel Tower unit Cleaning.

Take-off Roller/Retracting Roller/Swivel Flaps

Cleaning and Checking.

Covering belts/Ducts Cleaning, Checking and Tension.

All types of Belts/Rollers Cleaning, Checking and Tension.

All drive Chain Cleaning, Checking, Tension and Oiling.

Guard Checking.

Gear Motor of Retracting Rollers

Check Oil Level.

Tooth Segments Checking.Brake Lift Drive Check Oil Level.

UniClean B11/B12

Sealing Strips (Lock Roller) CleaningGrid Bar CleaningInside of Drum and Grid adjustment

Cleaning

Perforated sheet for dust extraction

Cleaning, Checking, Adjusting

V-Belt for Drum Drive Tension

Lock rollerdrive chain Cleaning,Checking

44

Inner part of the spike feed lattice

Cleaning

Unimix B-70/B-71

All types belts Checking, TensionAll drive Chain Cleaning, checking,

tension, OilingSeparating vanes, Exhaust air chambers

Cleaning

Storage section inner chamber CleaningRivets & spikes of spiked feed latice

Cleaning, checking

Roller Checking

Conveyor belt Checking, Cleaning

Closing flap & spike feed Checking

Spike feed lattice bearing Checking

Cotton filter Tension

All Gear box Check oil level

Stripping roller checking

Uniflex B-60

Lamella chute CleaningAll drive chain Checking, Cleaning,

OilingSaw tooth roller Checking, Cleaning Grid Bar Checking, CleaningAll Seals Checking

Condenser A-21

Drum seal Checking

Stripper Cleaning, Checking

All types belt Cleaning , Checking, Tension

Perforated drum inside or outside

Cleaning

All bearing checking

Take off roller Cleaning

Outside the m/c Cleaning

Material in , out and exhaust line

Checking,Cleaning

45

Lubrication Points

Machine Lubricating Points

Lubricants Intervals

Unifloc-A11 All roller chain Mobil Gear 632 or ChainSpary Hotemp 2000 Spary

25 to 45 Days

Unimix B-70 All roller chain Mobil Gear 632 or ChainSpary Hotemp 2000 Spary

25 to 45 Days

Uniflex B-60 All roller chain Mobil Gear 632 or ChainSpary Hotemp 2000 Spary

25 to 45 Days

Uniclean B-11 Chain of lock roller

Mobil Gear 632 or ChainSpary Hotemp 2000 Spary

25 to 45 Days

Carding:

Maintenance Points:

SL NO.

Maintenance Point Work to be done

01. Carding element Cleaning02. All bearing condition checking 03. Flat to cylinder setting Checking

04. Front auto leveler surroundings Tension,Cleaning 05. Cylinder inside Cleaning 06. Cylinder gasket Checking 07. Stripping knife Checking08. Can turntable Cleaning09. Card clothing condition Checking

10. All suction points Checking, Cleaning

11. Detaching unit Cleaning

12. Chute Cleaning

13. All types belts Tension, Checking

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14. Flat drive belt Tension

Lubrication Points:-

SL NO.

Lubricating Point Suggested Lubricating

Intervals

01. Cylinder bearing Grease EP-2 (10-14) months02. Bearing of the card

flats,cleaning brush and cleaning comb

Grease EP-2 (10-14) months

03. Card flat drive Kluber plex BEM34-132

(10-14) months

Unilap:

Maintenance points:

Maintenance Area

Maintenance Points Work to be done

Table calendar

Top cleaning device & bottom cleaning device

Clean and check its physical condition

Suction UnitMote knives, waste suction pipes Clean and check

suction properlyFilter Clean and check

conditionSliver feed

frameSliver guide, guide rolls Clean properly and

check settingDrafting system

Top & bottom rollers , tension bar Clean, check gauge and reset if required

Drive units All belts and chains Clean, check tension, greasing and apply grease if required

Safety device

Safety switch, pneumatic switch Check functioning

Lubrication Drafting gear box, main gear box and all greasing point

Check oil level and put oil if required, also check greasing

Gear Units Setting gear Clean and check gear meshing,

47

vibration, abnormal sound etc.

Lapping unitLap guide plate Clean and check

conditionCondenser roller Clean properly

Electrical function

Motor, electronic board, limit switch, proximity switch etc.

To be cleaned and checked by electrical persons.

Nut and bolt Drafting gear box, main gear box, lap roller drum, lap plate etc.

Tightness check and make correct if required.

Trolley Trolley wheel, pneumatic system Clean the wheel and the outer surface

Comber:

Maintenance Points:

Maintenance Area


Delivery Unit

Feed table, trumpet, calendar roller, table funnel

Clean and check condition, adjust if required

Top combs, clearer rolls and flats, bearing of the bottom roller, circular comb, filter, spring assemblies


Nipper, nipper lever on in-feed side, circular comb brush


Feeding throats, feed roller, nipper lips, top detaching roller, fleece guide plates, top delivery roller, lap plate

Clean and check condition and gauge, adjust if required

Draft system Stripper, Top and bottom roller Clean properly, check physical condition

Belt tension and condition

Timing belt, flat belt, V-belt Clean all the belt, check tension and adjust if required

Setting and condition of top comb, circular comb brush

Gauge check and adjust if required

48

Gauge points Roller, nipper feed plate, nipper gauge, bottom detaching roller gauge

Gauge check and adjust if required

Machine Side Outer surface of the machine and condition

Clean properly

Gear BoxOil level in gear box Check oil level and

apply oil if necessaryAll gear Check gear condition,

correct if requiredCan changer Chain tension on turn table Clean and check

condition, adjust if required

Greasing points

Bearing, bush of the top detaching roller

Clean and check, grease if required

Drafting roller, strip nipper frame, lower delivery and table calendar


Batt tension roll axles and other greasing points


Nut-Bolts Top comber nipper, circular comb, top roller pressure, main gear box, index wheel, all pulley, can wheel, coiler wheel, lap feed plate, lap roller nut-bolt.

Check tightness and make correct if required.

Electrical parts

Motor, motor fan, photo-cell, limit switch, electronic board, connection cable

Check and clean by electrical person

Finisher Draw Frame:

Maintenance Points:

Maintenance Area


Auto leveler Funnel, scanning roller, contact roller, gatherer, nail and stripper

Clean and check their condition, make correct if required

49

Drafting Zone

Top & bottom roller Clean and check its gauge, reset if required.

Pressure bar, round guide bar, top roller, weighing frame, funnel, condenser, trumpet, coiler

Clean properly, check physical condition

Suction system

Filter box, filter screen, fan blade

Clean properly and check filters and blade condition.

Can changer

Can Plate Clean and check that it works correctly

Gear Clean, check meshing condition, vibration, abnormal noise etc.

Power cylinder Clean and check that it is working correctly.

Belt tension and condition

Flat belt, V-belt, timing belt Clean all the belt, check tension & adjust.

Gear box Planetary gear box Check oil level and put oil if required

Nut-Bolt Top roller lock, pulley nut-bolt, creel nut-bolt, drafting zone nut-bolt

Check tightness and make perfect tightness

Electrical parts

Motor, fan, limit switch, proximity switch, creel light barrier

Clean and check by electrical persons

Outer Surface Outer surface of the whole machine

Clean properly

Simplex:

Maintenance Points:Maintenanc

e AreaMaintenance Points Work to be done

Back Side

Creel Clean and check bearing condition

Balancing spring and chain Clean and check greasing

CWC Clean and check belt tension and condition

Creel chain Clean and check greasing

50

Grease level in the grease pump

Check grease level and apply grease if required, Check grease pump

Photo cell Clean by soft clothRack groove Clean and check

greasing

GE head

Belt tension and its condition Check and adjust if necessary

Lifter gear box, main gear box

Check oil level and filter and put oil if required

Gear setting Check gear meshing, observe vibration, sound etc.

Bearing and greasing point Check bearing condition, vibration and sound, check greasing and apply grease if required

All nuts and bolts Check tightness and make it correct if required

OE HeadSensor Clean all the sensor

with soft cloth.Blanching chain Clean and check

greasing

Drafting Zone

Traverse bar and sliver guide Clean, check settingTop & bottom roller Clean, gauge check and

adjust if requiredCondenser assembly Clean, check assembly

and make correct if necessary

Top & bottom clearer cloth Clean, check conditionNeck bearing of bottom roller Clean, check cover

missing or broken, nipple missing or broken, replace if required

Cradle unit Clean and check functioning and wear and tear

Pressure arm Check height gauge and re-adjust if required

Top & bottom apron Clean properly with suitable detergent, check condition for replacement

51

Flyer rail & Bobbin rail

Bobbin Rail & Seal Open the cover, Clean it & check the gear condition

Flyer cap Clean and set properlyFlyer and its gear Clean, check gear

meshing conditionShaft Clean and check

conditionOuter surface Outer surface of the machine Clean the outer surface

properly

Ring Frame (RX-240):

Maintenance points:

SL NO.


01. Top cot roller and cradle Cleaning 02. Travers track of roving guide Checking, Adjusting03. Gear Bearings Checking04. Top and bottom apron Cleaning05. Teeth surface of all gears at head stock Cleaning, Checking 06. Mesh clearance of the gears Checking07. Fluted roller bearings Checking08. Bottom fluted roller Cleaning09. Suction tube Checking, Adjusting10. Top & bottom apron Washing 11. Gauge of traveler Checking, Adjusting12. Spindle blade Checking13. Ring rail height gauge Checking, Adjusting14. Top roller gauge Checking, Adjusting15. Ring rail position gauge Checking, Adjusting

16. Balloon control ring center Checking, Adjusting

17. Top roller arm pressure gauge Checking, Adjusting

18. Lappet rail height gauge Checking, Adjusting

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19. Filter box Checking

Lubrication Points :-

SL NO.

Lubricating Point Suggested Lubricants

Interval

01. Tim pulley shaft bearing Mobilux EP-2 (05-07) Months02. GE gearing Mobil gear oil

632(05-07) Months

03. Spindle bolster Mobile velocite oil 6

(05-07) Months

04. Drive shaft bearing Mobilux EP-2 (05-07) Months05. Tape tension pulley bearing Molilith SHC-100 (05-07) Months06. Screw shaft lifting gear Mobilux EP-2 (05-07) Months AUTO DOFFER07. Spar gear in the gear box Mobilux EP-2 (05-07) Months08. Screw shaft in the power

cylinderMobilux EP-2 (05-07) Months

09. Taper roller bearing in the power cylinder

Mobilux EP-2 (05-07) Months

10. Crank lever bracket Mobilux EP-2 (05-07) Months

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Auto Coner:

Maintenance Points:

Maintenance Area

Maintenance Point

Work to be done

Waxing Device

Waxing shaft Cleaning and checking any damaged(cut)

Pressure fork Cleaning and checking any damaged(cut)

Locking flap Remove the yarn accumulation and cleaning

Yarn trap Remove the yarn accumulationGuide Plate Cleaning the wax properly

Splice Unit

Splice cutter Cleaning and apply R.S. – 400Prism and its cover

Cleaning the prism by compressed air

Untwist nozzle Clean/wash by petrol & brush, checking the position

Clamping guide Cleaning by clothPointer Checking the position of similarityFeeder arm Checking the position

Tension Device

Rubber sleeve CleaningSensor (Tension) Cleaning carefully and adjust if

requiredCutter Cleaning and apply RS-400 sprayLower end sensor

Cleaning the sensing area

Cradle Holder

Package adapter Check for unobstructed rotation Sliding part (cradle)

Cleaning and apply silicon oil

Cradle sensor Check its cover and screw

Magazine

Circular magazine

Dis-assy, check, clean and refixing

Chute door Cleaning, centering checkEjector Cleaning & movement checkBobbin peg Cleaning

Conveyor belt

Deflection roller Remove loose yarn ends from the deflection rollers

Tensioning Device

Remove cover from the belt tensioning device of the conveyor belt and remove yarn laps / jam if required

OHTCRail CleaningFilter Cleaning by compressed airShifter Cleaning and put one drop silicon oil

54

Suction end and Head stock Cleaning the fly waste from head stock and suction device compartment

Checking and

Gauging

Suction arm Checking (adjust if required)Cradle vibration Checking (adjust if required)Paper cone to drum

Checking (adjust if required)

Bobbin peg centering

Checking (adjust if required)

Dust collection assym. (OHTC)

Checking (adjust the alignment if required)

EYC Checking the sensitivityAll kinds of nut & bolt

Nut-bolt checking, tightening if required

Lubrication Points:

Lubrication Points Used Lubricants IntervalsLubricate the RH package adapter Silicon oil (S-1000) 1 monthApply the maintenance spray (RS-400) on both splice cutter and lower yarn cutter

Maintenance spray RS-400

1 month

Lubricate the LH package adapter Shell Alvania grease – R2

4 months

Lubricate the RH package adapter Kluberplex BE 32-222

1 year

Lubricate the suction drive motor Shell Alvania grease – R2

4 months

Lubricate all internal rotating parts Lithium grease containingMos2 / Molykote spray

4 months

Lubricate all bearing points of the gear

Lithium grease containingMos2 / Molykote spray

8 months

All toothed wheel and toothed segment of central housing

Shell Alvania grease – R2

8 months

Lubricate the yarn guide drum Shell Alvania grease – R2

2.5 years

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Utility Department

The utility department undertakes the following units –

o Power generation.

o A/C Plant.

o Fibre Deposit Area

o Chiller Boiler.

o Water supply

o Fire fighting system.

o Yarn Conditioning Plant

o Compressor

Power Generation:

The factory generates its own power from natural gas. It has six

generators of 1145 KW each. The generator’s specification are as

follows-

No of generators : 6

Model : G-3516 B

Manufacturer : Caterpillar

Country of Origin : U.S.A.

Compression ratio (Air : Gas) : 11.7 : 1

Engine Type : 4stroke engine

Engine rpm : 1500

Total Plant Capacity : 6.87 MW

Power Transmission By : BBT

Starting Motor rpm : 1500

Ext. rpm : 65000

Year of Manufacture : 2006

56

A/C Plant:

The factory consists 4 A/C plants. These are for back process,

ring unit, finishing unit and rotor unit. The main task of A/C plant is to

maintain

specific humidity in the factory shed. For this it circulates the inside air.

The

air is sucked through return ducts, humidified in the water house and

again

supplied through supply dampers. Outside air is mixed to some ration

if

necessary. The temperature can also be controlled if cool water is

sprayed in

the water house. The following RH. Conditions are maintained in the

floor –

Back process 48 to 55%

Ring unit 48 to 52%

Finishing unit 60 to 65%

Rotor unit 60 to 65%

The A/C plants of ring unit are of LTG and those of rotor unit are of

Best

Air. The main impact of humidity and temperature controlling is on the

57

machine performance, machine life and on personnel. Under favorable

condition, the machines will run smoothly and their lifetime will also

increase. Also the operators will feel comfortable and their

performance will

be optimum. Otherwise all these will suffer.

Chiller :

The main purpose of chiller is to supply chilled water to the A/C plant. Here

there are three chillers .

Hot water chillerModel : LWM-W067

Cooling Capacity : 520 µsRT Heating Source : Hot Water Serial No. : 060101104800201C

Manufacturer : LSCountry of origin : South KoreaYear of Manufacture : 2006

Steam Fired chillerModel : LSH-W 070S

Cooling Capacity : 630 µsRT Heating Source : Steam Serial No. : 060101104800101C


Gas Fired chillerModel : LDF-S070S

Cooling Capacity : 650 µsRT Heating Source : Gas

58

Serial No. : 060101104800301H


Total Capacity of Chiller is 1800 µsRT

The hot water chiller runs on the hot jacket water from the generator. The steam

fired chiller runs on steam produced using exhaust gas of the generators.

Temperature maintained within the mills shade is as follows:

Back Side : 26 to 30˚C Ring : 28 to 30˚C Winding : 26 to 30˚C Rotor : 26 to 30˚C

Boiler:

In Delta Spinning Mill boiler is used to generate steam. This steam is used in chiller. Boiler specification is given below:-

Model : WHR-4250/10 Brand : Schneider-Kessel Berlin Year of Manufacture : 2006 Steam Capacity : 4.25 t/h No. of m/c : 1 Maximum working pressure : 10 bar

59

Compressor:

In spinning factory, compressed air is necessary for operating of various

machines. Moreover it is also used for different cleaning purpose. The task of

compressed air supply is carried out by compressor machine. The factory

consists of the following compressor machines –

No of machine : 3Model : L-55 Country of origin : Germany.Year of Manufacture : 2006Type : Screw TypeCapacity : 3000Pressure capacity : 10 bar max.

Yarn Conditioning Plant : In yarn conditioning plant yarn is used to stabilize the twist. Sometimes here give some weight into yarn. YCP specification is given below:- No. of m/c : 01 Model : 1200 kg Brand : Seizer Country of origin : India Year of manufacturing : 1996

60

IMPORTANCE OF RH AND TEMPERATURE:

The atmospheric conditions with respect to temperature and humidity

play very important role in the manufacturing process of textile yarns.

The properties like dimensions, weight, tensile strength, elastic

recovery, electrical resistance, rigidity etc. of all textile fiber whether

natural or synthetic are influenced by Moisture Regain.

Moisture regain is the ratio of the moisture to the bone-dry weight of

the material expressed as a percentage.

Many properties of textile materials vary considerably with moisture

regain, which in turn is affected by the ambient Relative Humidity (RH)

and Temperature. If a dry textile material is placed in a room with a

particular set of ambient conditions, it absorbs moisture and in course

of time, attains an equilibrium.

Some physical properties of textile materials which is affected

by RH is given below:

Strength of COTTON goes up when R.H.% goes up

o Elongation % goes up with increased R.H.% for most textile

fibers

o the tendency for generation of static electricity due to friction

decreases as RH goes up

o At higher levels of RH , there is also a tendency of the fibers to

stick together

Temperature alone does not have a great effect on the fibers. However

the temperature dictates the amount of moisture the air will hold in

61

suspension and , therefore, temperature and humidity must be

considered together.

ISO Standard # 139 defines Standard Atmospheric Conditions :

Temperature of 68° ± 4°F (20±2° C)

Relative humidity of 65% ± 2%

Fire Fighting System :

Cotton fiber catches and spreads fire very fast. So any kind of

accidents

related to fire generation can turn into a devastating calamity in a

cotton

spinning mill. That is why the factory has a well equipped fire fighting

system.

Water lines are spread though-out the factory. Water is pumped by

means of the main fire fighting pump. Other than this, there is also a

jockey pump which maintains the water pressure through-out the pipe

line.

Also there are extinguisher of both CO2 and ABC powder type. A

skilled team

of fire fighters always remain alert within the factory. Fire drills also

take place regularly.

HR and Admin DepartmentDefinition of HR and Admin :

The policies and practices one needs to carry out the people or

human resource aspects of a management position including,

recruiting, screening, training, rewarding and appring. This is HR or

Human Resource. The main object of HR is to make a man into

resource.

62

Admin administrate the all department. Admin department

does the appointment, labour welfare, labour department,

recommendation, staffing etc.

Two types recruiting system:-

I. Internal

II. External

In Delta Spinning Mills viva board consists of minimum 3 person. They

are :-

I. HR Head

II. Departmental Head

III. 3rd Person

Leave Days of Delta Spinning

Mill

According to labour law 1 year leave days of the mills given below :-

Name of Leave How many days Overtime

Week end leave 52 days No

Casual leave 10 days No

Medical leave 14 days No

Earn leave 16 days Over time will be

given

Festival leave 11 days Over time will be

given

According to 26 days working days over time calculation :- Overtime=Basic/208 * 2 * Hours

63

Salary

The entry level salary of the production worker is 2200 taka.

The entry level salary of the quality lab assistant is also 2200 taka.

The entry level salary of the maintenance worker is 2500 taka.

But the entry level salary of the officers such as APO, PO, Executive are

Negotiable.

Inventory System:

The inventory system can be divided into four major types:

1. Raw cotton inventory.

2. Wastage cotton inventory.

3. Finished yarn inventory.

4. Spare parts and materials inventory.

The inventory in maintained in First in First out system. When the

store

receive some goods, they write a note about it in the received khata

and inform

the concerned department about it. The concerned department then

inspects the

64

goods and approve those if are satisfactory. Then the MRR (Material

Receiving

Report) is made. Then BIN card for that particular item is made which

contains

its name, part no, card no, amount and other necessary informations.

Then the

material is stored in the store. In case of raw cotton after sampling and

numbering the bales, they are stored in the raw cotton godown.

If any department requires any item, they prepare a requisition slip

(SR) for

that particular item and send it to store. The store then checks its

availability and

delivers as required.

The daily production of finished yarn of different lots are given to

the store

form the production department by means of a “Transfer Memo”. The

store

produces its daily and monthly production report based on it. Then

according to

the order of the marketing department, the yarns are delivered to the

buyers.

Also the different wastes produced from different department are

measured and

handed over to the store in the same procedure.

65

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.

Marketing Information:

The marketing activities of The Delta Spinning Mills are carried out

from the

corporate head office. The marketing activities are shortly described in

the

following portion –

66

At first market research and survey is carried out. The customer’s

wants are

specified and also the other products available in the market are

studied. Then

samples are made and delivered to different customers for approval.

When

approved, a Proforma Invoice containing product quantity, validity,

count etc

are given to the customer. Then the customer open L/C. Then

depending on the

customers urgency, the production plan is made and the factory begins

production according to it. Then Delivery Order is made and delivery of

yarn is

carried out to the customers according to it.

Then documentation is done according to L/C. The documents

include Bill of

exchange, delivery chalan, Commercial Invoice and Packing list. The

bill of

exchange and the delivery chalan is acknowledged by authorized

person from

buyer’s side. The buyer also issues an Inspection Certificate (IC) if the

goods

fulfill the requirement. Then Copy of these documents as pe L/C are

submitted

to the bank. The bank the then endorses the Bill of Exchange and

delivery chalan

67

& forwards these to the buyer’s bank. Then the buyer’s bank gives a

maturity

date. The whole correspondence is done in terms of USD. Then at the

end of

maturity period, the amount is received in the bank account according

to the

L/C.

L/C OPENING FLOW CHART

Requirement of material with specification

To inform about requirement to the head of the management

Management will search for the requirement

Various company response with those specification

The management will select some offers

Then discussion will held among two management

Then negotiation will take place among management and agencies

Management will sign the agreement with the selected company or agencies

68

Customers:

Delta Composite Pacific Denim Hamim Royal Denim Astro Knitware Alim Tex Fariha Knitware Metro Knitting & Dyeing Babyllon Group (Aboni Textiles Ltd.)

After Sales Service:

Maintain the relation with the buyer. Respond to any quality complain. Ask for further order.

Involvement in Social Development:

The Delta Spinning Mill provides primary medical services to all its workers

and staff by maintaining a two bed health care center operated by an M.B.B.S.

Submission of the final PI

Bank will open L/C

69

doctor. It also organizes an Annual Internal Sports Program for all its staff.

It also allows training programs and industrial visit programs for the students of different textile educational institutes.

Technical education and its adoption in practical field are involved

inseparably. Without the implementation of the knowledge gathered in technical

education, its success is bound to suffer. Therefore, this two months long

industrial attachment training, as a partial fulfillment of our B. Sc. in textile

technology course helped us to accomplish the gap between the theoretical and

practical knowledge by providing an elementary idea about industrial

environment, processing machines, tools, quality management, quality

equipments, production system, maintenance, administration and management

system.

The Delta Spinning Mills Ltd is such an well equipped, well staffed, well

planned, well organized and well administrated mill that it has become a role

model for all the industries in Bangladesh. Other than producing export quality

cotton hosiery yarn, it is also developing a skilled manpower which is very

important and fruitful for the Textile Industry in Bangladesh.

We tried our best to utilize our training program by collecting all the

70

knowledge and information. But were not 100% successful due to

shortage of

time. But all our success is well contributed by our teachers and the

staff of

TDSML. For all these we would like to thank them all from the deepest

corner of

our heart and hope that all these will be greatly helpful for our

professional life.

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Documents

Industrial Attachment for Spinning Mills