Industrial Attachment on Hams Washing & Dyeing Ltd

Industrial attachment HAMS washing & dyeing Ltd

Chapter-1

Bangladesh University Of Textiles Page 1


In troduc t ion

As a part of course curriculum of Bangladesh University of Textiles, we were send for

industrial attachment for two months starting from 1st July 2012 to 31st August, 2012 to

HAMS Washing & Dyeing Ltd. During the attachment we worked as a trainee textile

engineer and had to attend the official working days in general working times i.e. 9 am to 5

pm.

AIM AND OBJECTIVES OF INDUSTRIAL ATTACHMENT

To enhance our University learning experience through involvement in industrial and

commercial field, thus enabling us to relate theoretical concepts with practical

situations;

To develop our ability to evaluate issues and situations critically and propose well

considered options and solutions;

To develop and enhance our professional awareness and communication skills;

To provide experiences that will enable us to achieve a breadth of understanding that

will form a framework or agenda for our final year of study.

The experience offered by industrial training varies. However, by the end of the

placement we were expected to have substantially met most or all of the following

objectives:

Undertaken problem solving activities in the workplace;

Further developed my communication skills;

Shown the ability to accept responsibility, work independently, manage my own time

and schedule my work;

Understood the constraints of a formal working environment and the benefits of team

work;

Appreciated the relevance of my academic work and have applied this to new

situations;

Used new tools and techniques to supplement those covered on my scheme of study;

Bangladesh University Of TextilesPage 2


Acquired the experience to understand, discuss and evaluate the professional issues

relating to textile engineering.

Gained an understanding of which final year courses will provide the best foundation

for my int ended career.

SUPERVISION DURING THE INDUSTRIAL ATTACHMENT

During our industrial attachment we were overseen by our industrial tutor. We kept a

log of our activities during my industrial attachment in a diary supplied from our institute,

which was re-checked and signed by our industrial tutor.

We were also visited by our academic professionals of different departments whom

discussed about our progress with our industrial tutor. Thus we had the opportunity to learn

from our academic tutors in a practical field.

A routine was maintained to meet with our head of department. Once in every 15

days we met with our head of department and discussed about solutions of some problems

that we had in the industry.



Chapter-2



Projec t Descr ip t ion

This chapter contains general overview of the industry where we have carried out the

industrial attachment.

OVERVIEW

Company Name: M/S HAMS WASHING & DYEING LTD.

Company Nature: Privet Limited Company

Established Date: September, 1998

Location: Tejgaon Industrial Area, Dhaka

Project Cost: 57.04 Cror Tk.

Total area: 20,000 Square Feet (approx.)

Man-power: 350

Business field: Readymade Garments Washing & Dyeing

Main product: Denim long pant, short pant, overall skirt, cotton

sweater .

Manufacturing capacity: 2000 Dozens/Day



Layout Plan of Washing Section



o Garments Wash o Acid Wash

o Heavy Garments Wash o Bio Wash

o Pigment Wash o Bleach Wash

o Sand Blasting / Spray Blasting o Stone Wash

o Tinting Wash o Deep Dye

o Stone Enzyme Wash o Tie Dye

o Sand Wash o Silicon Wash

o Enzyme-Silicon Wash o Whickering

Types of wash:

Local Buying House:

Washing Capacity:

o Dye & Tint 12000 PCs/day

o Enzyme Wash 15000 PCs/day

o Bleach Wash 20000 PCs/day

o Enzyme Stone Wash 16000 PCs/day

o Pigment Wash 25000 PCs/day

o Garments Wash 40000 PCs/day

o Enzyme Silicon Wash 25000 PCs/day

o Avg. All type of Wash 22000-23000 PCs/day


o Li & Fung (BD Ltd.) o Linmark

o Nor Wester o ABA Group

o Pelican Resources inc. o Auchan

o Lindex o Texel Ltd.

o JC Penny o NASSA

o DAC Pacific o Tex-EBO

o Epic Designers


Major customers:

o JC-Penny

o Primark

o Vermukt

o Walmart

o K-Mart

o Route-66

o Fashion Traders

o Auchan

Product or , Item:

1. Washing of Denim gmts

2. Washing of Knit gmts

3. Washing of sample gmts

4. Different types of Dry wash.

Sales & Marketing policy: Improvement through Research and

development for better marketing.

Banks: 1. Premier Bank Ltd. Gulshan Branch

2. National bank.

Address: 190, Tejgaon I/A, Dhaka-1208, Bangladesh

Telephone: 9885674, 9886406(off.) 8814365, 8814923(fac.)

Fax: 880-2-9881067

e-mail: [email protected]

Web: www.hamsgroup.com

Different departments: Sample section, Washing & Dyeing section, Drying

section, Sand Blasting section, Quality assurance section, Laboratory, Storage

section.

Sister Concern: HAMS Fashion Bijoy (Pvt.) Ltd.


http://www.hamsgroup.com/

mailto:[email protected]


HAMS Fashions Ltd. Fashion-2000 Ltd.

Pacific Label Ltd.

HISTORY

Md. Shafiqur Rahman, founder & managing director of this company, is a textile

engineer himself who provided service for five year in garments washing and dyeing sector.

In September 1998 with five local made garments washing and dyeing machine he launched

M/S HAMS WASHING & DYEING LTD. The commitment was “TO MAINTAIN

QUALITY AND TO DELIVER TIMELY” and still strongly believes it.

REMARKS:

Within five years the industry earned good reputation in garments washing & dyeing

sector. Now HAMS WASHING & DYEING LTD. is one of the leading garments washing

& dyeing industry in Bangladesh.

The industry is now equipped with modern washing & dyeing machines. The total

numbers of machine are three times than the initial set up.



Chapter-3



Man power Management

The company includes over 150 employees with some highly skilled personnel. Most

of the staffs are self-motivated and hard working.

ORGANOGRAM

MAN POWER-ADMINISTRATION:

SL. No.

Designation

No. of Post

Gender Qualification LocalForeign expert

1 Managing Director 1 MaleB.Sc. in Textile

Technology

2 Director(admin) 1 Male Bachelor

3 Director(production) 1 MaleB.Sc. in Textile

Technology

4 Director(marketing) 1 Male Bachelor

ORGANOGRAM-ADMINISTRATION:

Managing

Director

Director (Admin.)

Manager

(Account)Manager (Admin.) Manager (Compliance)



ORGANOGRAM-PRODUCTION:

Managing

Director

Director

(Production)

Production

Manager

Asst. production

manager

Supervisor

(Washing)

Supervisor

(Dyeing)

Supervisor

(Drying)

Supervisor

(Sand

Blasting)

Machine OperatorMachine

Operator

Machine

Operator

Machine

Operator

Assistant

Operator

Assistant

Operator

Assistant

Operator

Assistant

Operator



ORGANOGRAM-QUALITY CONTROL:

Production Manager

Super Visor

(Quality)

Assistant (Quality)

ORGANOGRAM LABORATORY:

Production Manager

Machine Operator

(Sample washing

machine)

Assistant

(Laboratory)

Machine Operator

(Sample drying machine)

Assistant Operator Assistant Operator

ORGANOGRAM MAINTENANCE:

Production manager

Supervisor

(Maintenance)

Technician

Assistant



ORGANOGRAM FINANCE:

Director (Finance)

Accountant

Asst. Accountant

Shift Change: 12 hours shift (two shifts per day).

Responsibilities of Production Manager:

To give washing & dyeing slip.

To match production sample with target sample.

To collect production sample for sample matching for next production.

To identify disputed garments & report to director.

Also execute overall floor works.

To maintain loading & unloading record.

Any other assignment given by higher authority.



Chapter-4



Machine Descr ip t ion

There are three (3) sample washing machines and fifteen (15) industrial machines in

washing section, seven (7) guns in sand blasting section, one (1) sample drying and twelve

(12) industrial drying machines in drying section, four (4) hydro extractors in hydro

extraction section. There is a modern sample washing machine, a modern industrial washing

machine in washing section and a modern hydro extractor in hydro extraction section. The

industry is in the process of upgrading it’s existing machines. Specifications of some

incoming machines are also given in this chapter.

GARMENTS WASHING & DYEING MACHINES

SAMPLE WASHING MACHINES

No. of machines: 03

Specifications:

° Capacity: 30 kg

° Inner Cylinder: 28”X34”

° Thickness of inner drum: 3mm

° Outer Cylinder: 34”X40”

° Motor (HP): 1HP, 0.75KW

° Power Consumption: 2.3 Amp

° Steam Consumption: 2 HP, 31 Kg

° Water Inlet: 2”, 1 way in.

° Steam Inlet: 1”, 1 way in.

Water Discharge: 3”, 1 way out.

Manufacturing company: Bengal Heavy Electric Engineering.

Manufacturing country: Bangladesh.

Features:

° Single door design for general washing, sample washing.

° Machine body and essential parts are made of stainless steel.

° Preset front and backward rotation.

° Conventional machine.



INDUSTRIAL WASHING MACHINES

No. of machines: 10

Specifications:

° Capacity: 200 kg

° Inner Cylinder: 42”X88”

° Thickness of inner drum: 3mm

° Outer Cylinder: 54”X960”

° Motor (HP): 10HP, 7.5KW

° Power Consumption: 17 Amp

° Steam Consumption: 15 HP, 230 Kg

° Water Inlet: 2”, 2 ways in.

° Steam Inlet: 1”, 2 ways in.

° Water Discharge: 3”, 2 ways out



Features:






Fig: side loading washing m/c (vertial)



MORDERN SAMPLE WASHING MACHINES

No. of machines: 01

Specifications:

° Capacity: 35 kg (Dry: Wet =1:10)

° Inner cylinder: 950 mm dial X 500mm

° Wash motor: 0.75 KW

° Extract speed: 200 RPM

° Main door opening: 500 mm dial

° Water connection consumption: 25 mm dial, 120 litres.

° Drain: 75 mm dial, 1 way out

° Steam connection consumption: 15 mm dial, 25 Kg/hr.

° Electric heating: 12 KW

° Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H)

Manufacturing company: STEFAB INDIA LIMITED

Model no: LXS 35.

Manufacturing country: India.

Features:

° Single door, front-loading, open pocket.


° Automatic timed. Auto reverse. Automatic 5 water level & auto digital

temperature control.

° Electric solenoid water & steam valves.

° Non-clog motorised drain valve.

° Full electric protection.



MORDERN INDUSTRIAL WASHING MACHINES

No. of machines: 01

Specifications:

° Capacity: 280 kg (1:10)





° Inspection door opening: 300 mm dial


° Drain: 115 mm dial, 2 ways out


° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.


Manufacturing company: STEFAB INDIA LIMITED,

Model no: LXS 280.


Features:










Fig: Front loading washing m/c (horizontal)



HYDRO EXTRACTORS

No. of machines: 03

Manufacturing company: Tongxin Ltd.

Manufacturing country: China.

Features:

° Due to its solid constructions it can be positioned onto firm floorings to

operate.

° It has excellent electrical layout in prevention of electricity leakage, shock,

which is important in wet conditions in the operations.

° Machine operations are made easy, with convenient start-stop operations for

maximum efficiency.

° The inner stainless steel is well balanced, thus achieving longer life span and

assuming energy efficiency of machine.

° Shock absorbers are well paced in the three suspension points to reduce

vibrations.

° Stainless steel constructions in major parts ensure durability.

Specifications:

° Model no: SHE-42° Capacity: 280 LBS° Inner cylinder: 1067dial X 419mm° Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H). ° Wash motor: 7.5 KW° Extract speed: 860 RPM

MODERN HYDRO EXTRACTORS

No. of machines: 01



Features:

° Full stainless steel outer drum and inner basket. Strong welded construction.

Basket can be dismantled without dismantling outer casing. Electrically

interlocked top lid stops the machine when opened. Three position drain

connection. Outer casing mounted on heavy galvanised plate base frame.

Long rust free life and strength.

° Direct drive. Basket is directly mounted on to a specially designed high

torque heavy-duty motor resting on spigot of the base frame with built-in



rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick self-

balancing. Noiseless & vibration less operation.

° Automatic timed. Automatic DC injection for braking. Safety devices against

single phasing reverse phasing & motor overload. Great convenience &

safety. No foot pedals, no levers, no brake liners, no maintenance.

Specifications:

° Model no: HX 50

° Capacity: 80 Kg

° Inner cylinder: 1000dial X 300mm

° Volume: 235 Litres

° Basket speed: 750 R.P.M.


° Drain: 75 mm dial




Fig: Hydro extractor m/c



SAMPLE DRYING MACHINES

No. of machines: 01

Specifications:

° Capacity: 18 Kg

° Basket size: 700 mm (dial) X 470 mm


° Dry clean motor: 0.37 KW

° Extract motor: 1.5 KW

° Extract speed: 220 rpm

° Loading door opening: 400 mm (dial)

° Base tank capacity: 250 Litres

° Filter tank capacity: 250 Litres

° Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H)



Features:

° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer

body not painted. Long rust free life and sheen.

° Built in solvent filter housed in the top tank receives soiled from the base tank

through a powerful centrifugal pump which pushes the soiled solvent through

several fine mesh cylindrical filters for reuse. Maximum recovery of clean

solvent.

° Low spin extract. Separate motors for dryclean & extract. Vibrationless

during extraction. Low spin extract makes articles lighter to unload. No

solvent dripping. No wastage of solvent.

° Automatic timed. Auto reverse. Full electrical protection against single

phasing & motor overload. Operator’s convenience & machine safety.

Efficient cleaning.



Fig: Gas dryer



INDUSTRIAL DRYING MACHINES

No. of machines: 11

Specifications:

° Capacity: 35 Kg

° Basket size: 950 mm (dial) X 500mm


° Dry clean motor: 0.75 KW

° Extract speed: 200 rpm

° Loading door opening: 500mm (dial)

° Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H)



Features:

° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer

body painted.

° Low spin extract. Vibration less during extraction. Low spin extract makes

articles lighter to unload.

° Automatic timed. Full electrical protection against single phasing & motor

overload. Operator’s convenience & machine safety. Efficient cleaning.



INDUSTRIAL WASHING PROCESSING & DYEING MACHINES No. of machines: 06

Specifications:

° Capacity: 280 kg (1:10)





° Inspection door opening: 300 mm dial


° Drain: 115 mm dial, 2 ways out


° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.


Manufacturing company: STEFAB INDIAL LIMITED,


Features:










HYDRO EXTRACTOR MACHINE:

No. of machines: 01

Specifications:

° Model no: HX 50

° Capacity: 80 Kg

° Inner cylinder: 1000dial X 300mm


° Basket speed: 750 R.P.M.


° Drain: 75 mm dial




Features:

° Full stainless steel outer drum and inner basket. Strong welded construction.

Basket can be dismantled without dismantling outer casing. Electrically

interlocked top lid stops the machine when opened. Three position drain

connection. Outer casing mounted on heavy galvanised plate base frame.

Long rust free life and strength.

° Direct drive. Basket is directly mounted on to a specially designed high

torque heavy-duty motor resting on spigot of the base frame with built-in

rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick self-

balancing. Noiseless & vibration less operation.

° Automatic timed. Automatic DC injection for braking. Safety devices against

single phasing reverse phasing & motor overload. Great convenience &

safety. No foot pedals, no levers, no brake liners, no maintenance.



INDUSTRIAL SAND-BLASTIG GUNS No. of machines: 07

Specifications:

° Model: SBT-650

° Capacity: 200 Litres

° Dimension: 800mm X 1000mm X 1250mm

° Sand contains: 200 Kg

Manufacturing company: Made in China

Features:




OTHER COMPONENTS/ACCESSORIES

No. of cabinets: 07

Hopper (for controlling dust in cabinets): 02

Helmet: 07 Pcs

Musk: 07 Pcs

Gloves: 07 pairs.

Air preserver-1, capacity of 2000 c.c.

Air preserver-2, capacity of 900 c.c.


GARMENTS SAND-BLASTING MACHINES


Spray machines: 03 Nos.

Manufacturing country: Hong Kong

Compressor: 03 Nos.

Two compressors with same following specifications.

o Brand: ELGI

o Capacity: 10 Jule/Bar

o Made in INDIA

One compressor with following specifications:

o Brand: OSD

o Made in ITALY

o Includes Change Over

o MCCB


Boiler:

Brand name: Sacca

Manufacturer: Made in ITALY

Production capacity: 1.5 Tons/Hr.

Pressure: 7.5 Jule Bar (5.0 Bar used)

Supply system: Automatic Pressure control.

Chimney: 50 Feet with 12-inch diameter.

Generator

Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"

production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA),

"SINCRO"(SI) alternators. All alternators are three phase, four pole, single bearing,

synchronous type, cosj=0.8, 50Hz.

Water supply pump: 03 Nos.

02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse

Power.

01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power.


OTHER MACHINES


REMARKS

No live industry can keep place with the advance of technology without continuous

renewal & transformation of its production facilities. Existing equipments must be kept on

the defensive, compelled always to justify its tenure against the challenge of new & more

modern machines. If any piece of existing equipment fails to meet this challenge, it must be

displaced, regardless of its age or condition & regardless of whether it is physically “worn

out”.

Keeping the above in view, this industry is always replacing its existing machines in

order to increase productivity & improve quality.



Chapter-5



Raw mater ia l s

Different sections of the industry require raw materials i.e. chemicals of various

types in different quantity. Most of the chemicals are purchased locally. A few are imported

directly.

RAW MATERIALS USED IN GARMENTS WASHING

Caustic Soda (NaOH)

° Type : Alkali

° Unit price : Taka 24 per Kg

° Source : Clariant ( Switzerland ) / Dystar ( Germany )

° Uses : (Neutralize acidic materials, saponify glycerides

(waxes and oils), solubilize silicate

° Monthly requirements: 4050 kg (approximately)

Soda Ash (Na2CO3)

° Type : Alkali

° Unit price : Taka 14 per kg

° Source : Dystar ( Singapore ) / Clariant ( Germany )

° Uses : Used to alkaline the solution/medium. Control PH


Wetting agent:

° Type : Combination of Detergent & Surfactant



° Uses : Emulsify oils, fats and waxes; remove oil-stains;

Suspend materials after they have been removed.

Reduce surface tension & minimize inter facial

tensions.

° Monthly requirements: 2000 kg (approximately) Anti-back

° Type : Anti back staining agent


° Source : India, China



° Uses : Prevent back staining


Acetic Acid

° Type : Organic acid



° Uses : Used to make solution/medium acidic. Control PH


Sodium Hypo Chloride (NaOCl)

° Type : Oxidizing agent


° Source : India, China

° Uses : Used to uniform lightening of the colour of the indigo

or sulphur dyed garments in bleach wash.


Bleaching Powder [Ca (OCl)Cl]

° Type : Oxidizing agent

° Unit price : Taka 21 per kg (KCI, 33% Chlorine), Taka 105 per kg

(Japan, 65% Chlorine)


° Uses : Used to decolouration of fabric

° Monthly requirements: 3590 kg (KCI), 142 (Japan) (approximately)

Enzyme

° Type : Enzyme

° Unit price : Taka 300 per kg (liquid), Taka 400 per kg (powder)


° Uses : Used to breaks down the long starch molecular chain

into smaller sections, that can be easily washed from

garments.

° Monthly requirements: 1500 kg (liquid), 1000 kg (powder) (approximately)

Silicon



° Type : Softener



° Uses : Creates the fabric surface oily/ used for lubrication


Softener Flax

° Type : Softener



° Uses : Soften fabric handling


Potassium Permanganate

° Type : Decolouration agent

° Unit price : Taka 80 to 370 per kg

° Source : India, Bangladesh

° Uses : Used to decolouration of fabric

° Monthly requirements: Locally purchased when required.

Sodium Meta bi Sulphate

° Type : De-chlorination agent



° Uses : Used to neutralize activity of chlorine on

fabric/solution




Peroxide (H2O2)

° Type : Oxidising agent



° Uses : OH- ions destroy the colouring material and improve

whiteness


Common Salt

° Type : Salt

° Unit price : Taka12 per kg


° Uses : Used as electrolyte for solution, improves shining of

fabric.


RAW MATERIALS USED IN GARMENTS DYEING

The following raw materials are used in garments dyeing in addition to some of the

raw materials already listed above.

Dyestuff

o Type : Direct dye

o Unit price: Taka 300-1200 per Kg

o Source: Clariant ( Switzerland ) / Dystar ( Germany )

o Use: Cotton & Viscose garments dyeing.

o Monthly requirements: Depends on ordered quantity.

o Type: Reactive dye

o Unit price: Taka 275-850 per Kg.


o Use : Cotton & Viscose garments dyeing.




o Type : Pigment dye

o Unit price: Taka 300-500 per Kg


o Use: Cotton & Viscose garments dyeing.


Glauber salt

o Type : Salt

o Unit price: Taka 14 per Kg

o Source: Bangladesh

o Use: Levelling agent.


Fixing Agent



o Use: Colour fixation.


Dispersing agent



o Use: Assists in the process of particle size reduction of dye.


REMARKS

The monthly requirements of raw materials vary depending on the type of washing &

ordered quantity. Sometimes the price of the materials also varies due to the availability of

the materials in the market.





Chapter-6



Produc t ion P lann ing , Sequences & Opera t ions

Production process consist of different types of washing methods such as normal

wash, bleach wash, stone wash, acid wash, enzyme wash, super white wash, dirty wash etc

and dyeing methods with reactive, direct, sulphur etc dyes are done. Recently sandblast and

chemical sprayer added to the production process.

PRODUCTION FLOW CHART OF GARMENTS WASHING

Batching

Pre-treatment

Washing

Hydro

Extraction

Drying

Quality Control

Storage



PRODUCTION FLOW CHART OF GARMENTS DYEING

Batching

Pre-treatment

Dyeing

Sample Check

Hydro

Extraction

Drying

Quality Control

Storage



PROCESS TECHNIQUE OF SOME WASHING & GARMENTS DYEING METHODS

NORMAL WASH:

Batch 60 PCs. Liquor 400 Litre

Step 01 Water is added (400 Lt)

Desizing

Garments are added

Machine started running

200 gm Detergent added

Temperature raise to 60°C

Time 5-10 minutes

Drop the liquor

Add water and cold wash




Softening

Garments are added


240 gm Softener added

Temperature Cold

Time 5-10 minutes

Drop the liquor

Unlaod garments on trolley



Step 03Load the garments on m/c

Hydro

Extracting

R.P.M 700-900

Time 3-5 minutes

Unload the garments on trolley

Unload the garments

Trolley



Step 04 Load the garments on dryer m/c

Drying

Temp 60- 70°C

Time 40-50 minutes

Time 10-15 minutes for cold dry

Unload the garments

Quality checking



ENZYME-BLEACH WASH WITH TINTING:



Desizing

Garments are added


500 gm Soda Ash added

500 gm Caustic Soda added

200 gm Bio. D added

Steam to raise temp 60°C

Process time 25 minutes

Drop liquor

Wash down twice




Enzyme Wash


200 ml liquid, 400 gm powder

type Enzyme added

150 ml Acetic Acid Added

200 gm Anti back added

10 Kg Peumic Stone added



Drop liquor




Bleaching


4 Kg KCI (35% Cl2) added




Drop liquor




Neutral Wash


500 gm Hypo sulphide added



Drop liquor




Tinting


0.02% Direct Brown GTL &

0.01% Direct Black V-200 added

4 Kg Salt added



Check Shade

Drop the liquor



Step 06 Garments are then taken out

Drying

Hydro extracted

Send to dryer for drying of

garments.



CAUSTIC WASH:



Desizing

Garments are added



320gm Caustic soda added


Time 20-60 minutes

Drop the liquor




Add water 300 lit

Temperature cold

Acetic acid 150gm added

Time 5 minutes

Step 02Neutral wash


Softening

Garments are added



200gm Acetic acid added

160gm silicon softener added

Temperature Cold

Time 15 minutes

Drop the liquor




Step 03 Load the garments on m/c

Hydro

Extracting

R.P.M 700-900

Time 3-5 minutes



Drying

Temp 60- 70°C

Time 40-50 minutes


Unload the garments

Quality checking



PIGMENT WASH:



Desizing

Garments are added



320gm Caustic soda added

600gm Soda ash added


Time 20-60 minutes

Drop the liquor





Softening

Garments are added



200gm Acetic acid added

160gm silicon softener added

Temperature Cold

Time 15 minutes

Drop the liquor




Step 03 Load the garments on m/c

Hydro

Extracting

R.P.M 700-900

Time 3-5 minutes



Drying

Temp 60- 70°C

Time 40-50 minutes


Unload the garments

Quality checking



ACID WASH

Batch 100 PCs.Liquor 500

Litre


Desizing

Garments are added




200 gm Bio. D added



Drop liquor

Wash down twice




Normal

Wash


Steam to raise temperature 40°C


Drop liquor

Take out the garments

Hydro extract the garments

Dry the garments



Step 03Load the pre-treated & dried

garments in another washing machine

Acid Wash


Add stones soaked with potassium per magnate

double the volume of garments

Continue machine running for 7 minutes

Unload the garments from the machine

Step 04Load the garments into another washing

machine

Neutral

Wash

Water is added (500 Lt)


1.5 Kg detergent is added



Drop liquor




Neutral

Wash


500 ml Auxalic Acid added


Check Shade

Drop the liquor

Garments are then taken out

Hydro extracted

Send to dryer for drying of garments.



COTTON GARMENTS DYEING PROCESS (Sample Dyeing)

Batch 1.4 KgLiquor

14 Litre


Desizing

Garments are added




100 gm Bio. D added


Process time 45~60 minutes

Drop liquor


Hot Wash






Drop liquor

Step 03

Scouring &

Bleaching

Water is added 14 litre

Start machine running

Added 1 litre H2O2

50 gm Stabiliser added



100 gm Bio-D added

Process temp 80° C


Drop the liquor


Hot Wash






Drop liquor


Neutral Wash


200 ml Acetic Acid added


Drop the liquor


Dyeing

Start machine running

560 gm Salt is added

Reactive dye (T. Blue. G) - 0.2% &

Drimerine – Blue K2RL-0.03% is added

20% Soda Ash is added

Processing temp 80° C

Processing time 60 minutes

Drop the liquor




Washing


1 % Detergent is added



Drop liquor

Again Add water of 14 litre


Drop liquor

Unload the Garments

Hydro extractor

Drying



Dry process

Hand scraping Sand blasting Whiskering Grinding Destroy P.P spray Resin application Wrinkle (permanent) Overall wrinkle Laser draw

Hand Scraping:Hand scraping is generally being done in rigid form of garments to get distress look. Locations can be front thigh & back seat or it can be over all as per standard. Emery paper is being used to scrape the garments in particular placement & design.Emery paper comes in different number generally starts from 40 till 600 and above, higher the number finer the emery paper, lower the coarseness of the paper. In garments industry from 220, 320& 400 numbers papers are most popular & widely used.The most important factor is to select right number of paper according to the fabric strength & intensity need. Scraping can be done on inflated rubber ballons for better effect (horizonta or vertical its up to operators convinence),even it can done plain wooden board of garments size & hand pressure should be uniform in order to get better results.Sand BlastingSand blasting is recently popular dry process. It is a mechanical process by which we can fadding effect/old looking effect on heavy garments like denim, twill etc by the action of aluminium oxide which looks like sand. Sand blasting is applied on specific area of a garments.Sand blasting is performed with combine the wash like bleach wash, enzyme wash,normal wash, stone wash & tinting/over dyeing.

Process of sand blasting: The garments to be sand blasted are placed on the bed in a closed chamber Aluminium oxide is very hard, fine, sharp. Aluminium oxide through by gun with dry air to perform sand blasted action. The gun has a switch to start and stop the flow of aluminium oxide. The flow of aluminium oxide on fabric is done at an angle 10-20 degree. Higher the blowing angle higher the fadding effect. Sand blasting is a hazardous process and its area is isolated from other producion

areas. Producion per gun per hour varies from 25-50 garments, depending on the area. After prodution chemical treatment are required as per buyer requirements.



Operator should wear protective wear includes glass,helmet,gloves,uniform,masks etc.

Whiskering: We need a rubber board. Design should be placed on rubber board. Then the board is placed inside the garments Hand rubbing is done on the upper side of the garments. After wash design produced. It may be rectangular or circular. Wet wash is must.

Grinding:Grinding is done on pocket edges & bottom hems edges by running against abrasion surface or stone to achieve worn out effect. Many different make of machines & pen grinding tools are avilable in the market which runs with pneumatic system.



Destroy:One o the most popular distressing effect currently. Destruction is an art which makes denim look unique and used. To make destruction pen type stone tools being used in mid of wash process to apply on desired area. It can also be achieved by cutting it through knife the warp yarns & keep the weft yarn as is to show white thread. Holes can also be made by cutting weft & warp yarns. These are manual processes & every garments will look unique & different than others.



P.P Spray:PP spray is done on denim garments to achieve local abraded area to appear whiter than back ground indigo color shade. This can be applied by spray gun or by towel dipped into pp solution & rubbed on desired area followed by neutralization in wet wash process. This process sone in rigid after doing hand scrape or in the middle of the wash. Doing after bleach or enzyme cycle will give more natural & whiteb effect than doing in rigid form. There are many additives that can be added in order achieve desired intensity and out look.The same way bleach solution can also be spray or rubbed on the garments on desired area. But this process is more complicated & neeed high skilled operator to execute it followed by immediate neutralization.There are many parameter to control during pp spray or bleach spray……… spray gun pressure, width of spray,flow and way of spraying.



Resin Application:Resin being used for achieving 3D effect,rigid look,etc. this process can be done by spraying or dipping the garments into resin ,catalyst,silicone,PU solutionin right combination according to the fabric strength & desired effect needeed.After aplication of resin solution in right proportion,make manual desinig as needed on the thigh hip & back knee area to get 3D effect. After making it , it should be dried with hot press or by hairb dryer & then must be cured in woven at right temperature , time as mentined in resin product manual.

Permanent wrinkle:This is one of the most popular dry process recently and being done on front thigh, front knee, back knee. Resin is applied on the required area where wrinkle is to be done. Then garments is squeezed by machine or by hand and clip is placed on the dsign to keep in riginal design. Then garments with the resin is kept in woven for half an hour for permanency of wrinkle. Next wet is done as per buyer demand.



Laser Draw:Wrinkle effect or burn out effect is produced by laser ray. If the production area of wrinkle is more than laser draw is done on the required area of the garmnets. The effect is produced by burning out the fibre of garments surface. The system is controlled by computer. The required design is kept inside computer. There is a chamber where garments are placed to get the required effect. There is also a switch controlled by oprator to controll laser draw and to get desired design on desired area.



PRODUCTION REPORTS

Date:05.08.2012

Sl. No.

Name ofBuyer

Name ofGarments

Order/Style no.

Types ofProcess

Total received

(pcs)

DeliveryAmount

(pcs)

Balance (pcs)

1 Snoopy Utah Washing

Sand Blast 17745 14899 2846

2 Snoopy Yoke Design G-21 Sand Blast + Bleach

4129 778 3351

3 Caree Four

Tusuka Fashion

100341/2 Rewash 5100 3576 1524

4 Etam Aba Fashion Enzyme Silicon 18935 15127 3808

5 Caree Four

Aba Fashion Enzyme Silicon 19576 15679 3897

6 Etam Export Knit 6094619 Enzyme Silicon 8696 8124 572

7 Texel Sportx Gmts. 100093 Enzyme + Dyed 7990 7191 99

8 Texel Sportx Gmts. 100093 Enzyme Wash 7628 5500 2128

9 Primark Universal 52510 Sand Blast + Dyed

1200 1200

10 RN Sha Sha Gmts.

1161R Sand Blast + Dyed

5793 3767 2029

11 RN Sha Sha Gmts.

8488 Sand Blast + Enzyme

2934 798 2136

12 Nor Wester

Leader Gmts. 25021XZ

Sand Blast + Enzyme

7404 2932 3122

13 Nor Wester

Leader Gmts. 25027XZ

Sand Blast + Enzyme

5903 1500 4633

14 Nor Wester

Fasnoor Gmts.

25069XZ

Enzyme Silicon 5155 4506 649

15 Nor Wester

Tamanna Ltd. 25074/75 Silicon Wash 4527 3769 758

Grand Total 3275



Chapter-7



Maintenance is considered as important as other engineering functions. It makes responsible

for provision of a condition of machines, buildings and services that will permit

uninterrupted implementation of plans requiring their use.

OBJECTIVES OF MAINTENANCE:

To keep the factory-plants, equipments, machine tools etc. in an optimum working

conditions.

To ensure specified accuracy to products and time schedule of delivery to customers.

To keep the down time of machines to the minimum thus to have control over the

production program.

To keep the production cycle with in the stipulated range.

To modify the machine tools to meet the augmented need for production.

To improve productivity of existing machine tools and to avoid sinking of additional

capital.

To reduce the maintenance costs as for as possible thereby leading to a reduction in

factory overheads.

To prolong the useful life of the factory, plant and machinery, while retaining their

acceptable level of accuracy of performance thus avoiding or prosponding incurring

of heavy capital expenditure involved in their replacement.

ECONOMIC CONSIDERATION OF MAINTENANCE

It is very profitable activity & ensures maximum productivity at minimum costing.

It improves product quality.

It ensures less time to produce a specific product.

It improves machine accuracy.

It maintains a long life of the machine.

No chance of back order.


M a i n t e n a n c e


MAINTENANCE FLOW CHART

Head of

Maintenance

Technician

Assistant

FUNCTIONS OF MAINTENANCE PERSONNEL

Inspection or Check-Ups:

° External inspections: Watching and detecting defects form abnormal sound,

vibration, heat, smoke etc when machine is in operation.

° Internal inspections: Inspection of parts such as gears, bushes, bearings,

tolerances in the parts etc. when machine is under pre-planned shutdowns.

° Inspections of important machines: Machines, which can disrupt whole of

the production, are delicate and require much time for the repair. Attentions

are given for inspection of these machines and schedule for inspection,

cleaning lubrication are done rigidly.

° Inspections of ordinary machines: Frequency of inspection of ordinary

machines is kept as low as they do not affect the production.

Lubrication: Mechanical components like gears, bearings, bushes and other friction

surfaces etc. give good performance for long periods when they are systematically

lubricated. Systematic lubrication means the application of right type of lubricants at

the right time, at right place and in right quantity. For lubrication, a lubrication

schedule should be prepared and that should be followed strictly. Here lubrication is

done whenever is needed.

Planning and scheduling: Every preventive maintenance work should be pre-planned

in detail on the basis of the analysis done on the past records. A scheduled programme



thus prepared should be followed strictly. Thus programme should be in detail specifying

the point-requiring daily, weekly, monthly, half yearly or yearly attention.

Records and analysis: Good record keeping is essential for good maintenance, as it

helps in for casting maintenance. For this purpose following records are generally

maintained:

° Operation manual

° Maintenance and instruction manual

° History Cards and History Registers

° Spares Procurement Registers

° Spare Procurement Register

° Inspection Register

° Log books

° Defect Register etc.

Training of Maintenance personnel: For the success of maintenance a sound

training is essential for the maintenance personnel. Hence the technicians and

supervisors are trained to carry out maintenance, inspection and repaired in a

systematic way.

Storage of Spare Parts: Sometimes machine remains idle for want of spare parts for

considerable time and thus it affects considerable loss of production. Hence it is

essential to keep the spare parts so as to avoid loss of production.

Maintenance practices are made from the following ways:

Capital replacement: capital replacement is undertaken if analysis reveals that the

retention of equipment no more remains an economical proposition.

Provision of stand-by-capacity: Stand by capacity is often provided for items of

equipment that we are critical to production. It is sometimes an economical

maintenance practice to install such spare capacity to be put into operation while the

original unit is under repair or is over-hauled.

Break-down maintenance: Break-down maintenance practice allows a machine or

any other facility to run without much of routine attention, till it actually breaks down

to be then put back into commission.

Scheduled maintenance: Scheduled maintenance system provides for inspection,

overhaul lubrication, and servicing of certain machines at predetermined dates. Over-



hauling of machines, cleaning of tanks and white washing of buildings is normally

done in this manner.

Planned maintenance: Planned maintenance visualise the work contained in a

future job determines the best method to be adopted and skills required for its

execution; estimates the time, material and costs involved assigning jobs to

individuals; programmes the work to specific time periods on the basis of priority

and after ascertaining production requirements; arranges for availability of material

tools and man-power and for release of machines in time.

Preventive maintenance: It consists of routine actions taken in a planned manner to

prevent breakdowns and to ensure operational accuracy to the extent it is

economically and practically possible to do so.

MAINTENANCE TOOLS & THEIR FUNCTIONS

Tools Nos. Specifications UsesMeasuring Tape 02 Both British and Metric system

measurement.Mostly used for linear measurement

Hammer 01 It is just a weighted head and a handle that directs its course.

The Hammer is very simple striking tool.

Screw Driver (flat type)

02 10” steel shank, with flat blade and plastic handle.

To loosen or tighten screws.

Screw Driver (Phillips head)

01 8” steel shank, with star blade and plastic handle.

To loosen or tighten screws

Pliers 01Nose Pliers 01

Wrench (Locking adjustable)

02 For exerting a twisting strain in turning bolt & nuts

Wrench (Pipe) 03Wrench (Double head open end)

06

Wrench Hacksaw Adjustable frame Used to saw metalChisels (cold, flat point)

01 Made of good grade tool steel Used for cutting or chipping metals.

Table vice 01FileMobil Gun 01Wielding Machine 01Hand Grinding Machine

01

Fixed Grinder 01



Hand drill 01

Chapter-8



U t i l i t y S e r v i c e s

Man, Machine and Material, the three main things that can accelerate the production,

if it is used in proper and organized way. In the Industry, UTILITY plays an important role

in case of production. Production and profit are closely related. In order to get a quality-

finished product, it needs fresh raw materials as well as effective manpower and machinery

in good working condition. Utility is closely related to the three M's plays a vital role to

maximize the production as well as profit.

FUNCTIONS OF UTILITY

Utility ensures power supply by generator.

Utility ensures water supply by pump.

It ensures steam by boiler.

It ensures compressed air handling by vacuum planning system.

It provides fuel and gas supply.

It provides workshop facilities.

AVAILABLE UTILITIES

The following utility facilities are available at HAMS WASHING & DYEING LTD.

Water.

Steam.

Electricity.

Gas.

Compressed air.

Covered Van for Transportation.



SOURCES OF UTILITIES

Water: Own Supply (Pump)

Steam: Own supply (Boiler)

Electricity: Generator & PDB

Gas: Titas Gas Transmission & Distribution Co. Ltd.

Compressed Air: Own supply (Air compressor)

CAPACITY & OTHER TECHNICAL DETAILS

WATER: Water is supplied by pump. Pump supplies water on the basis of pressure.

Pump pressure ranges 0-10 bar. The pump is operated at 2-4-bar pressure. 3 motors

are used for uniform water supply. These are automatic on-off system motor. When

the pressure is reduced to the desired level (2 bars) then the motor is turned on.

Similarly when the pressure is above the desired level (4 bars) then the motor is

turned off. So, it has variable water supply capacity & supplies water as required.

The water, which is used for cooling, is brought to a tank & again supply by a pump.

There are 3 deep tube wells used in this project. Water is directly used in washing &

dyeing & other subsequent process.

02 PCs. Deep Tube wells are submersible, Made in ITALY, BG brand with 30 Horse

Power.

01 PC. Deep Tube well is submersible, Sigma branded, Made in ITALY with 42

Horse Power.

STEAM: Heat generation is a very important factor for washing and dyeing process.

Steam is a very efficient & easy way to transfer heat. There is a boiler to generate

steam. By pipe line the generated steam is supplied to the washing and dyeing



machines & where it is necessary. The boiler has the capacity to generate steam 1.5

Tons/Hr.

Technical details about the boiler:

Boilers function is to transfer the heat produced by the combustion of fuel (gas) to

water and ultimately to generate steam.

Brand name: Sacca

Manufacturer: Made in ITALY

Production capacity: 1.5 Tons/Hr.

Pressure: 7.5 Jules Bar (5.0 Bar used)

Supply system: Automatic Pressure control.

Chimney: 50 Feet with 12-inch diameter.

ELECTRICITY: It is totally impossible to continue the production without

electricity. A frequent supply of electricity is very essential for soundless production.

Here all the machines in washing and dyeing section are provided electricity by the

govt. electricity with own standby generator of the industry.

Technical Details about the Generator:-

Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"

production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA),

"SINCRO"(SI) alternators. All alternators are three phase, four pole, single bearing,

synchronous type, cosj=0.8, 50Hz.

Model Rated power Voltage Alter-nator

Diesel enginespecification

Dimensions Weight

KVA KW V LxWxH cm KgE275VM 275 220 400/230 MA "VOLVO" TWD1210G,

6 cyl., turbocharg300x110x192

2400

Electric Substation:

o 500 KVA Transformer (11 KV to 440 KV)

Brand: Power man

Three phase

Rated power: 500 KVA



Standard: Bs-171

Class: A

Rated Frequency: 50 Hz

Type of cooling: ONAN

AMBIENT Temperature: 50°C

Duty: Continuous.

Voltage: 11000 Volt (HT) 415 (LT)

Rated Current: [HT - 26] [LT - 695] AMP

Vector group Dyn – 11

Impedance Voltage: 0.5%

Total Weight: 179 Kg

Lift able Weight: 990 Kg

Oil Weight: 610 Kg

Winding Temperature: 55°C

Manufacturing Year: 2003

Made in Bangladesh.

o High Tension Switch.

o Switch Gear

Brand: Power Man

Voltage: 415 Volt, 50 Hz

Phase: 3 Phase, 1 Neutral

Incoming: 800 AMP

MCCB/ACB

Made in Bangladesh

o ACB (Air-Circuit-Breaker)

Brand: SPARK Energy

Model: OSLO 6E

o MCCB (Magnetic Contact Current Circuit Breaker)

o PFI (Power Factor Improvement Plant, 6 step auto control)

Brand: Power man

Rating: 200 KV

Voltage: 415V, 50 Hz

o Change Over



o Bash Bar Panel Board.

Compressor: Two compressors with same following specifications.

o Brand: ELGI


o Made in INDIA

One compressor with following specifications:

o Brand: OSD

o Made in ITALY

o Includes Change Over

o MCCB


Air Condition:

o Exhaust Fan: 03 Nos.

o Air Cooler: 02 Nos.

Fire Fighting Tools:

o Washing section: 10 Nos. Fire Extinguisher

Air Dryer:

o For Compressor: 3 Nos.

Cover Van:

o 3 Cover Van used to carry garments.

Gas: The company gets natural gas from Titas Gas Transmission & Distribution Co.

Ltd. Capacity of gas line is variable ie. line able to supply gas according to the

requirements.

COST OF UTILITIES

Water: Own supply (Pump)

Electricity Required- 46 KW/Hr. Cost 5 TK/KW.

Steam: Own Supply (Boiler)

Gas required: 670 Meter3/Hr. Cost 5.60 TK/ Meter3 (Aprox.)

Compressed Air: Own Supply (Air compressor)



REMARKS

There is problem with water supply in the company. The supply of water is not

sufficient, which create problem in washing and dyeing. The quality of water is not up to the

level. The hardness & presence of iron in water is high. A water treatment plant is very

essential to continue the production without disturb & to increase the production.

The generator of the industry is too old to supply the electricity fluently. Sometimes

it trip without any warning. So, it’s necessary to have a new generator for the industry.

The boiler also very old to maintain it high bar pressure. It should be replaced

with modern boiler for better service.



Chapter-9



S t o r e & I n v e n t o r y C o n t r o l

In HAMS WASHING & DYEING LTD. there are different inventory systems for

different raw materials and finished materials.

DYE & CHEMICAL STORE

There is a different store for dyes & chemicals. Various types of dyes & chemicals

are stored here according to the dyes & chemical company.

Different types of dyes & chemicals are listed in a sheet. In the sheet the stored

quantity of dyes & chemicals are also included. Everyday the sheet is updated & a copy of

this sheet is supplied to the GM (production), Dye house & lab section.

SPARE STORE

In HAMS WASHING AND DYEING LTD. required amount of spears of different

machines are stored in the mechanical storeroom. All the spears are listed in a sheet, which

is controlled by the mechanical & maintenance personnel. Spares are arranged in the

storeroom according to their size, quantity & requirements. There are shelves in the

storeroom to keep the small spare parts.

FINISHED PRODUCT STORE

HAMS WASHING AND DYEING LTD. supplies its finished dyed fabrics to its

garments section. So, dyed finished fabrics are stored for short time in the finishing section.

All the delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics

diameter, buyer’s name, colour& considering other technical parameters.



OTHERS STORE

There is a central store at HAMS WASHING AND DYEING LTD. In that store the various

types of forms, papers, stationary & other necessary goods are kept.

Chapter -10



Cost analysis is a crucial step for any business organization, specially if it is a manufacturing company. Here cost analysis is done in conventional method. SAMPLE COST ANALYSIS

Issue Date: 10-07-2004 Buyer: Nassa – Pinacle Po-Style-Ref. : 21051 Type of Garments: Denim Long Pant Type of Wash: Enzyme/ Bleach/ Tint Quantity/ Machine: 60 PCs. Weight of Total Garments: 62 Kg.

Process Chemicals Quantity Temp Time Total

Desizing Caustic Soda 500 gm 12 /=Soda Ash 500 gm 60°C 15 min 7 /=Bio. D 400 gm 25 /=

Enzyme Wash Enzyme Powder 400 gm 152 /=Enzyme Liquid 200 gm 48 /=Anti Back Staining 200 gm 40°C 55-60 min 25 /=Acetic Acid 100 gm 7 /=Stone ½ bag 212 /=

Bleaching Bleaching (Japan) 500 gm 50°C 6-8 min 46 /=Neutral Wash Hypo Sulphide 500 gm Cold 5 min 9 /=

Peroxide H2O2 500 gm 50°C 10 min 18 /=Bio. D 100 gm 12 /=

Tinting Dir Brown GTL 20gm 14 /=Dir Yellow 2 gm 50°C 20 min 2 /=Salt 4 Kg 28 /=

Total Chemical Cost= 617/=Add 10% Wastage = 678/=

Per Dozen = 135.6/=Chemical Cost in USD/Doz = 2.47/=

Overhead Cost USD/Doz = 1.5/=Total Cost USD/Doz = 3.97/= ~ 4.00/=


C o s t a n a l y s i s


Profit USD/ Doz = 0.75/=

Final Cost USD/Doz = 4.75/=



Chapter -11



M a r k e t i n g A c t i v i t i e s

MARKETING:

Marketing plays a vital role in the field of displaying/showing the good criteria

of the products to the buyer & to communicate with the buyer .there about 30 people in the

marketing section of the industry .

Marketing Strategy :Marketing strategy is a very important factors to sale the products to the

buyers If the marketing strategy Is not so developed it will be very hard to reach the goal In

case of garments marketing the dealings with the buyer is a very important factor.In one

Washing & Dyeing Mainly senior marketing officers ,merchandisers & higher officials deal

with the buyer There are some fixed buyers of the industry. The buyers give their orders

continuously all over the year. The marketing officers & by both side understanding The rate

& the order quantity are fixed.

DUTIES & RESPONSIBILITIES OF MARKETING OFFICERS

Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A

marketing officer has some also other duties The main duties & responsibilities of a

marketing officer are given below :

• To prepare cost sheet by dealing with buyer .

• To take different steps by discussing with the high officials & merchandisers .

• To maintain a regular & good relationship between commercial officers &

merchandisers

• To maintain a regular communication with the buyers & buying houses .

• Communicate with the new buyers .

• Display the better criteria of the products .

Actually the responsibilities & duties of marketing officer begins from getting order of

buyer & ends after receiving goods by the buyer So he should be always smart energetic

& sincere.



CONSUMER OF THE PRODUCT

HAMS Washing & Dyeing Ltd. is a 100% export oriented industry. All the goods

produce in this industry are exported to various country .

Product Label:

Product label differs from fabric to fabric. The product labels are prepared according to

the quality & the buyer requirements .

LOCAL MARKET

HAMS Washing & Dyeing Ltd is a 100% export oriented industry. All the goods

produced in this industry are exported into various foreign countries . So, goods are not

supplied into local market.

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 of garments marketing the dealings with the buyer is a very important

factor .

In HAMS Washing & Dyeing Ltd. mainly senior marketing officers ,

merchandiser & higher officials deal with the buyer . There are some fixed buyers of

the industry. The buyers give their orders continuously all over the year . The

marketing officers & the merchandisers communicate with the buying houses to

collect the orders .

By both side understanding the rate & the order quantity are fixed .

REMARKS

HAMS Washing & Dyeing Ltd has a well learned marketing & merchandising team. They always communicate with the buyers HAMS Washing & Dyeing Ltd has some fixed buyers The marketing section also looks for the quality & quantity of buyers .



Chapter-12



Compliance

Compliance:Compliance is undertaking activities or establishing practices or policies in accordance with the requirements or expectations of an external body such as ILO,ISO,WARP,ETI etc and international buyer.

Benefits for business:

Putting company values into action. Enhancing company reputation. Improve company requirement. Better supply chain management and performance.

Benefits for workers

Educating the worker to avail a better life style. More awareness about quality Better job satisfaction will be developing.

Benefits for investor and customer: Identification of product made ethically Clear and credible assurance for ethical purchasing.

The return will be greater on less investmentCompliance with the law.

1. Fire Training:• At least 20 percent of factory personnel are trained in fire safety

and emergency evacuation.• Certificates and pictures of fire safety and emergency evacuation

training are maintained.• Factory holds fire emergency drills regularly.• For factories with high turnover, fire drills are held more frequently.• Factory trains new employees in fire drill procedures.

2. Fire alarm:• Factory has fire alarm system that is audible throughout entire facility.• Fire alarm has a distinct sound from other notice systems.• Alarm is tested regularly in coordination with fire drills.• Factory trains all new employees about alarm system sound

and procedures.

3. Emergency Exits:• Factory has at least two emergency exits per floor in buildings

with less than 1000 workers.• At least three exits exist per floor in buildings with more than 1,000 workers.



• Factory ensures that the maximum travel distance to an emergency exit is200 feet or 60 meters for unsprinklered industrial buildings.

• Exit doors are at least 28 inches, 71 cm or 2.3 feet and have a width adequate for the number of persons it must accommodate.

• Exit doors are not unlocked and do not have locks that require special operation.• Door should open outwards.• Emergency signs are visible for 30m and use letters at least 18cm high.

Also, signs have bright colors are illuminated or have a photo luminescent front panel.

• Battery operated exit signs are checked regularly and batteries are replaced.

4. Emergency exit routes:

• As referenced above, factory posts diagrams/maps of emergency exit routes at various locations throughout the factory.

• All exit routes are at leastl 12cm wide.• Exit routes are not obstructed by equipment, materials, product,

etc. and are regularly checked.• Two exit routes exist on opposite sides of the factory.

5. Emergency lighting:• Factory has emergency lighting for all stair ways and where

needed on exit routes.• Lighting will last for at least 90 minutes.• Factory regularity checks test-button and replace batteries immediately if

needed on emergency lighting systems.

6. Electrical Wiring:• Electrical cords in the factory and dormitories are in good

condition and properlyencased to prevent shorting or fire.

• Electrical equipment is grounded to prevent injury and or fire.

• Electrical cords are not found in damp areas of in standing water. • Electrical wiring does not obstruct aisles unless they are securely taped to the

floor in a manner that does not create additional hazard

7. Lighting:• Factory uses a light meter to take periodic measurements of light

levels in the factory and keeps a record of light levels in various work areas.

• Factory has minimum illumination of 30 foot-candles (300 Lux) in work areas.• Factory has minimum illumination of 5 foot-candles (50 Lux) in corridors utilized as emergency routes.



8. Ventilation:• Factory has adequate ventilation system in work areas where

chemicals are handled and where there are significant dusts or metal particles.

• Factory has ventilation system present in enclosed spaces where heat-generating equipment is operated.

9. Hazardous Chemicals or Materials:• Factory stores chemicals in separate area, which is equipped with

appropriate fire extinguishers, safety signs, and ventilation, instructions on handling or disposal, and personal protective equipment for personnel.

• Factory is familiar with all chemicals on site and the potential health effects.• Explore opportunities for hazardous chemical/material

minimization and document changes made

10. Medical Care:• Factory has a medical clinic available on-site or in close

proximity to address basic health and injury needs.• Factory has a system in place to address severe injuries.• Factory maintains copies of licenses for all applicable medical personnel.• A record of injuries is maintained at the factory to focus on how

injuries can be reduced.

11. First Aid:• Factory has one properly stocked first aid kit available for every 100 employees.• Factory maintain standard first aid kits that includes basic supplies, a

kit for blood borne pathogens protections, an emergency log, and a first aid guide in the local language.

• First aid stations are posted with a first aid sign.• The first aid kit is inspected regularly and restocked when needed.• Factory trains at least 10 percent of personnel in basic first aid.• Records are maintained for employees seeking first aid to

track injury/illness as well as remedy.



Responsibilities & Duties Of Compliance Team of “ HAMS Washing and Dyeing Ltd ”

1. To floor visit at least thrice a day.2. To ensure workers fire safety, fire prevention, fire equipment, health & safety &

comfortable environment at work place.

3. To aware the workers about personal protective equipment.

4. To receive grievance, complain, demand & suggestion from the workers & after

receiving the issue discuss with related persons & local management immediately.

5. Try to find out emotional problem of an employee. The problem may be work

related or personal or family which affects his/her work performance.

6. To provided supportive counseling the sick worker for medicinal support on the

worker’s requests, complain or situational demand.

7. Try to make aware the existing workers about by company provided all facilities

8. Necessity of compliance.

9. To perform when social compliance audit.

10. To follow up aisle mark free, fire extinguisher no blocked, emergency exit free, fire

equipment free, stair free from carton in the floor

11. To check all production related register if any date mentioned of holiday or not.

12. To conduct orientation program for newly appointed worker.

13. Try to motivate & make them conversant with the company objective, rules &

regulations, buyer code of conduct & local laws.

14. To briefing the employees about all facilities of company, mandatory safety

instruction including all “do’s & Don’ts”.

15. To make aware the employees about leave procedure, maternity benefits, working

hour & over time system according to local laws.

16. To make aware the employees about personal health & hygiene, HIV/ AIDS/STD.

17. To conduct awareness programs the pregnant workers about safe motherhood

18. To ensure that no employee each maltreated mentally or physically abused & they

should be treated with respect & dignity.

19. And any other work assigned by the Management.



Chapter-13



ETP (EFFLUENT TREATMENT PLANT)

E T P - E ff l u e nt T r e a t m e nt p l ant

Capacity of ETP : 30,000 Litres

W o r k i ng P r o c e du r e :

We use different type of chemical, detergent, which is mixed with water & also mixed different types of fiber, that pollute our environment.

Wastewater contains both organic & inorganic chemical. The inorganic constituents are present in the carriage water & increase because of water use. In the case of industrial wastewater, inorganic are highly present & physio-chemical treatment has to be employed to maintain desirable water quantity.

We treatment the wastewater by using modern technology & decontaminate water & the drag out which is not harmful for our environment. The process by which wastewater treatment is occurred to obtain pure water to kept our environment free from pollution that process is known as ETP (Effluent Treatment Plant).

By using ETP we are getting the result of distillation water is 6”-8”.

W a s t e w a t er c ha m b e r : Firstly the waste water which is mixed with different types of chemical& detergent used for washing in the factory is stored in the waste water chamber.

E ff l u e n t Tran s f er P u mp : There is a Effluent transfer pump connected with this chamber for the treatment of waste water which is connected with three other chambers. Two of them are chemicals & another one is lime. Chemical pumps are called Alum pump & Poly Electrolyte pump & the Lime is called the waste water pump.

P l o y - E l ec t ro l y t e C h e m i c a l pu m p : The chemical pump which is poly electrolyte, in this chamber250gm poly electrolyte is mixed with 1000 litter of pure water.

Al u m C h e m i c a l pu m p : In the Alum chemical pump 5kg Alum is mixed with 1000 litter of pure water.

L i m e w a s t e w a t er pu m p : And in the Lime waste water pump 1kg lime is mixed with 100 litter of pure water.

After mixing with Alum & poly electrolyte & also mixing with lime the waste water is

purified. By flowing through these three pumps like Alum, Poly electrolyte & lime waste

water becomespurified, then this purified water is preserved in the preserver.

P r ese r v e r : the treated water which is preserved in the preserver pass through the treated water drain outline & the sediment is stored in the lower portion of the preserver.



B l o w do w n c ha m b e r : There is a blow down line connected with the lower portion of the preserver 7 sediment pass through this blow down line to the blow down chamber. This blow down chamber is connected with the suction chamber with three valves.

S u c ti o n c ha m b e r : Sediment water from the blow down chamber comes to the suction chamber. After purifying in this chamber the purifying water flows to the drain out chamber & then discharge to the sewer





Chapter-14



C o n c l u s i o n

As a ready made garments washing and dyeing sector, HAMS WASHING &

DYEING LTD. is excellent among the industries of Bangladesh. Garments washing and

dyeing sector comprise varieties of machineries. It is still completely running position.

The Management system of the factory is quite well too. All the personnel of the

factory are co-operative and friendly with us. The security system is very good too.

In the training period, we were introduced as a member of the factory. For that, they

gave us all kind of facilities and scope for learning about washing and dyeing production and

machineries.

Above all the industrial attachment has given us new ideas for practical life.


Documents

Industrial Attachment on Hams Washing & Dyeing Ltd