Factory Information Report On

Noman Textile Mills Ltd. (A concern of Noman Group)

Submitted to

Jahidul Hoque Majumder Asst. General Manager

Noman Textile Mills Ltd.

Prepared by

Sohel Rana Production Officer

Weaving Shed-1

Abstract Noman Textile Mills Limited is a modern textile industry based on woven garments production.

My approach was to know and work with all the parameters of each section and practice with

technical experts.

I have the opportunity to work with Noman Textile Mills Limited. I studied the man, machine,

material and planning, grey fabric inspection, finished fabric inspection.

According to the studies in the whole factory i have prepared the following reportand would like

to present as the factory information based on combination of theoretical knowledge and the

practical experiences. The main objective of this is to comprehend the situation and condition of

the factory.

It also enabled me to orient myself with the practical environment which is my place of work.

Contents Project location: ...................................................................................................................................... 4

Organogram: ........................................................................................................................................... 5

Sections:.................................................................................................................................................. 7

Raw Materials: ........................................................................................................................................ 7

Product Range: ........................................................................................................................................ 8

Production & Sequence of Operation ....................................................................................................... 8

Warping Department ............................................................................................................................... 9

Direct Warping Section: The Machines description are given in below................................................. 9

Sectional Warping Section ................................................................................................................. 10

Sizing Department ................................................................................................................................. 11

Machine-1, 3, 4.................................................................................................................................. 11

Machine-2 ......................................................................................................................................... 12

Sizing Chemical Use ......................................................................................................................... 13

Weaving Process ................................................................................................................................... 14

Drawing-in, Denting & Knotting Department .................................................................................... 14

Weaving department: ......................................................................................................................... 14

Loom Specifications: ......................................................................................................................... 14

Shed 01: Tsudacoma: ..................................................................................................................... 14

Toyota: .......................................................................................................................................... 16

Shed 02:Dornier Looms ................................................................................................................. 17

Picanol .......................................................................................................................................... 18

Inspection and Mending Department ..................................................................................................... 19

Maintenance .......................................................................................................................................... 20

Discussion ............................................................................................................................................. 21

Project location: Noman Textile Mills Ltd. is a 100% weaving fabric company. This is also a company of Noman

Group. This is the 28th number factory or project of Noman Group. The project is located in

Maouna, Shreepur under the District of Gazipur, about 40 kilometers distance from the

International Airport of Dhaka & about 10 kilometers distance from Gazipur Chowrasta. The

factors of project establishment is given in below:

Transportation system is good.

Energy source is available i.e. Gas, Electricity etc.

Skilled labor is available.

Land is available.

Environment is friendly for textile production.

Buyer is available.

Communication process is good i.e. Mobile, telephone, internet etc.

Fig: Map of location. Fig: Satellite view of project.

5

Organogram:

1. Production (weaving) Manager Sr PO/PO Asst. Production officer

Supervisor

Weaver

Cone boy

2. Sizing and warping Sr PO/PO

Assistant PO

Supervisor

Sizer/ back sizer

Warper

Cooker

3. Quality

In charge

Quality officer

Asst Q.O.

MachSupervisor

4. Electrical Section

Manager

In charge

Asst. Engg./ Sub A.E

Foreman

Electrician

Helper

5. Mechanical

Manager/ Assistant Manager

Engg/ AE/ SAE

Beam fitter in charge

Beam fitter

Asst. B.F.

6

6. Mending:

In charge PO/APO Supervisor

Shift Change:

There are two types of shift system, one type is for the workers and executives and the other shift

system is followed by the managers.

Shift Duration

A 06:00 am to 02:00 pm

B 02:00 pm to 10:00 pm

C 10:00 pm to 06:00 am

General Shift 09:00 am to 06:00 pm

7

Sections: NTML has different sections. These are following:

Warping

Sizing

Weaving

Inspection and Mending

R&D

Electrical

Mechanical

Generator

Boiler

Administration

Accounts

Store

Warehouse

Security

Raw Materials: Source of Raw material of yarn for Weaving

Talha Spinning Ltd.

Yesmin Spinning Ltd.

Zubai Spinning Mills Ltd.

Zaber Spinning Mills Ltd.

Salek Textile Ltd.

Ashik Composite Textile Mills Ltd.

8

Product Range: Plain

Ribstop

Oxford

Bedford cord

Twill

Dobby

Satin

Matt etc.

Production & Sequence of Operation The fabric production process involves following operations:

Flowchart:

Raw materials: Yarn

Warping

Sizing

Drawing and Denting

Knotting

Weaving

Grey Fabric Inspection and mending

9

Warping Department There are two types of warping is running here. These are given in below.

1. Direct Warping. 2. Sectional Warping.

Types Of Creel:

1. Horizontal Creel 2. V Creel

Direct Warping Section: The Machines description are given in below. Machine Name: Benninger

Model: BenDirect 1000

Year: 1999

Machine Type: Direct warping m/c

No. of m/c: 04

Country Origin: Switzerland

M/C RPM: 600-1000

Machine width: Max 1800 mm

Creel Capacity: Mc 01: 728, Mc 02: 728, Mc 03: 770, Mc 04: 840

Creel Type: V and H

Fig: Direct warping machine.

10

Sectional Warping Section M/C Name: Benninger

Model: CH-9240

M/C Type: Sectional Warping m/c

No. of m/c: 02

Country Origin: Swizerland

RPM: 800-1000

Drum width: 2600 mm

Year: 1999

Creel Capacity: Mc 01: 800, Mc 02: 672

Creel Type: H

Fig: Sectional Warping machine

Fig: Creel

11

Sizing Department Noman Textile Mills Ltd. has has 04 sizing machines. Here in this industry use 02 types of sizing

machines. All the sizing machine details & its machines specification are given in below.

Machine-1, 3, 4 Brand: Sucker Muller

No. of M/C: 03

Country Origin: Switzerland

Year: 1996

Total Drying Cylinder: 12

Total Size Box: 02

Total Beam Creel: Mc. 01 & 03: 24, Mc 04: 10

Speed: 80 to 100 m/min

Yarn tension: 150 N

Fig: Sucker Muller Sizing Machine

12

Machine-2 Brand: West Point

No. of m/c: 01

Country Origin: USA

Year: 1997

Speed: 80 – 100 m/min

Total Dryer Cylinder: 12

Total Size Box: 02

Yarn tension: 150 N

Beam creel: 24

Fig: West point sizing machine

13

Sizing Chemical Use Starch:

*Natural Starch – Tapioca Starch

Use: For Coarser type yarn.

*Modified Starch – Penetrose-50 (Maize [Corn] Starch)

Use: For Finer type yarn.

*Jetsize 105

*Jetsize 210

Softener:

*Artificial Waxes (Pinitex-K300)

Use: Make yarn surface smooth.

Bonding Agent:

*Polyvinyl Alcohol Resin (PVA-217PK)

Use: Increase starch stability with yarn.

*Elastex-3040

Use: Increase starch stability with yarn.

*Size CA

Use: Increase starch stability with yarn.

14

Weaving Process Drawing-in, Denting & Knotting Department After finishing the sizing process, when the weaver beam is completely ready, it is necessary to

mount this beam on the loom machine for weaving. There are two processes which are done

before mounting the beam.

These are:

Drawing-in & Denting.

Warping tying or knotting.

Weaving department: Weaving Shed Loom No.

Shed 01 142

Shed 02 96

Loom Specifications: Shed 01: Tsudacoma:

Machine Brand: Tsudacoma

No of Machines: 132

Model: 205 and 205i, Zax 205i

Width: 190 cm, 280 cm, 330 cm

RPM: 400 to 480

Selvedge: Tuck In and Leno

Picking: Airjet

Shedding: Zax: Dobby shedding, Others: Positive cam shedding

Heal frame capacity: 6

IRO capacity: 2

Reed space: 75, 110, 130 cm

15

Fig: Tsudacoma Loom.

Fig: Tsudacoma Zax loom.

16

Fig: Toyota loom.

Toyota: Machine Brand: Toyota

No of Machines: 10

Model: 500

Width: 280 cm

RPM: 400

Selvedge: Leno

Picking: Airjet

Shedding: Positive cam shedding

Heal frame capacity: 6

IRO capacity: 1

Reed space: 110 cm

17

Shed 02:Dornier Looms Machine Brand: Dornier

No of Machines: 49

Model: 96, 97, 98

Width: 210 cm

RPM: 560

Selvedge: Leno

Picking: Airjet

Shedding: Dobby shedding

Heal frame capacity: max 16

IRO capacity: 6

Fig: Dornier loom.

18

Picanol Machine Brand: picanol

No of Machines: 47

Model: Optimax

Width: 190 cm

RPM: 600

Selvedge: Leno

Picking: Rapier

Shedding: Dobby shedding

Heal frame capacity: 6-8

IRO capacity: 2

Fig: Picanol loom.

19

Inspection and Mending Department Fabric batcher is set at the back side of machine equipped with rollers which provides fabric

unwinding. Inspection table is laminated white to enhance the defect identification. Four tube

lights are provided to optimize the lighting. Measuring counter is provided in front of the

inspection table for controlling length. It has forward, reverse, start and stop button controls.

Inspection is carried out on slanting glass plate table. The cloth is pulled over the glass plate by a

variable speed motor. After that the fabric is mended as much as possible.

Inspection Machines: Conventional : 07 ; Modern: 02

Mending Station: 29 tables

Folding Machine: 03

Fig: Inspection.

Fig: Folding machine.

20

Maintenance Electrical Maintenance – preventive and corrective.

Mechanical Maintenance – preventive and corrective.

Tools & equipments:

1. Screw Driver.

2. Mechanical tool box.

3. Cutter.

4. Digital Multi Meter

5. Heating Shoulder

6. Hammer

Preventive Maintenance

Preventive Maintenance is a predetermined routine activity to ensure on time inspection or

checking of facilities to uncover conditions that may lead to production break downs or harmful

depreciation.

Corrective Maintenance or Break down Maintenance

In this case, repairs are made after the equipment is out of order it cannot perform its normal

function.

21

Discussion Noman textile mills ltd lack modern machines. Most of the machines in this factory are decades

old which are to be maintained very very carefully during production otherwise there is a tend to

rise in faulty products.

With the building of new shed it is hoped that the production of this factory will increase in a

greater scale and raise the goodwill of this factory among buyers.

The overall environment of the factory is satisfactory, in terms of administrative and project

related personnel.

The R&D department are working with significant responsibility to looking after the

development of new products demanded. Quality department are also working their best to check

the quality of fabrics and find any faults to make it possible to deliver maximum fault free

problems.

The organizational system must be through continuous development to meet the current class of

international quality textile production facility.