Padma PolyCotton Knit Fabrics Ltd, Dhaka

Ahsanullah University of science and

Technology

4th year 2nd semester

Department of Textile Engineering

Course No: Tex- 500

Course Title: Industrial Training

Padma PolyCOtton Knit fabrics limited

SUBMITTED BY:

NAME ID

Arif Rahman 08.02.06.022

SUBMITTED TO

MD. Ruhul Amin

Assistant Professor

Department of Textile Engineering

1

CHAPTER NAME CHAPTER CONTENT PAGE NO

CHAPTER 1 INTRODUCTION 1.1 MILL LOCATION

1.2 GENERAL INFORMATION ABOUT THE MILL

1.3 BOARD OF DIRECTOR

6

8

10

CHAPTER 2

MANPOWER

MANAGEMENT

2.1 MANAGEMENT SYSTEM

2.2 SHIFT CHANGE

2.3 RESPONSIBILITIES OF HR

2.4 JOB DESCRIPTION AND RESPONSIBILITIES

12

12

12

13

CHAPTER 3 RAW MATERIALS 3.1 TYPES OF RAW MATERIALS

3.2 YARN

3.3 SOURCES OF RAW MATERIALS

3.4 REMARKS

15

15

16

16

CHAPTER 4 MACHINE DESCRIPTIONS 4.1 MACHINE AT A GLANCE

4.2 MACHINE DESCRIPTION OF KNITTING SECTION

4.3 MACHINE SPECIFICATION OF 1ST FLOOR

4.4 LAY OUT OF THE 2ND FLOOR OF KNITTING SECTION

4.5 MACHINE SPECIFICATION OF 2ND FLOOR

4.6 LAY OUT OF COLLAR AND CUFF SECTION

4.7 MACHINE SPECIFICAITON OF COLLAR AND CUFF

SECTION

18

19

20

21

23

24

25

CHAPTER 5 PROCESS PLANNING AND

OPERATION

5.1 CLASSIFICAITON OF KNITTING

5.2 PROCESS FLOW CHART OF KNITTING

5.3 DESCRIPTION OF PRODUCTION PROCESS

5.4 PROCESS REQUIREMENT

5.5 MINIMUM REQUIRMENT OF PRODUCTION

PARAMETERS

5.6 CONSIDERABLE POINTS TO PRODUCE KNIT FABRICS

5.7 PASSES OF YARN IN CIRCULAR KNITTING MACHINE

27

28

29

29

30

30

31

INDEX

2

5.8 DIFFERENT PARTS OF CIRCULAR KNITTING MACHINE

5.9 FUNCTION OF KNITTING ELEMENTS

5.10 PRODUCTION CALCULATION

5.11 COMMENTS

32

32

37

40

CHAPTER 6 QUALITY ASSURANCE

SYSTEM

6.1 QUALITY ASSURANCE

6.2 OBJECTIVE OF QUALITY CONTROL

6.3 QUALITY ASSURANCE SYSTEM

6.4 YARN QUALITY

6.5 KNITTING QUALITY

6.6 RESPONSE TO FAULT

6.7 LIST OF QUIPMENT OF QUALITY CONTROL

6.8 QUALITY ASSURANCE SYSTEM

6.9 SOME COMMON KNITTING FAULT

42

42

42

42

42

44

44

45

46

CHAPTER 7 SAMPLE ANALYSIS DIFFERENT SAMPLE ANALYSIS 48

CHAPTER 8 MAINTENANCE

MANAGEMENT

8.1 OBJECTIVE OF MAINTANANCE

8.2 TYPES OF MAINTENANCE

8.3 PREVENTING MAINTENANCE

8.4 ROUTINE MAINTENANCE

8.5 MAINTENANCE TOOLS AND EQUIPMENTS

55

55

55

55

56

INDEX

3

CHAPTER 9 UTILITY SERVICES 9.1 UTILITY REQUIRED IN TEXTILE INDUSTRY

9.2 SOURCE OF UTILITY

9.3 MACHINES FOR UTILITY SERVICES

9.4 AIR COMPRESSOR

60

60

60

61

CHAPTER 10 CONCLUSION 10.1 CONCLUSION 63

INDEX

4

Industrial training summery

Textile engineering education is based on industrial ground. Theoretical background is not

sufficient so, industrial training is an essential part of study to make a technologist technically

sound in this field. Industrial training provides us that opportunity to gather practical

knowledge.

Padma PolyCotton Knit Fabrics Limited is a truly integrated undertaking. The textile

division has the capability to offer a complete product range for the export & domestic textile

markets. The goal of the textile division is to become the preferred partner for sourcing high

quality fabrics & clothing from Bangladesh. With high advanced technology & an emphasis

on developing local human resources, the textile division has the potential to make an important

contribution to the nation’s growing readymade garments export sector.

The rationale behind the existing structure & future expansion of the textile division is to

capture value added at each stage of the textile manufacturing process. Despite Bangladesh’s

lack of indigenous cotton production capability, Padma PolyCotton Knit Fabrics Limited has

leveraged Bangladesh’s labor cost advantage & export competitiveness to maximum level.

5

CHAPTER 1 INTRODUCTION

6

1.1 Mill Location:

7

Padma PolyCotton Knit Fabrics Ltd. is a 100% export oriented composite plant for knit

fabrics and garments. Padma PolyCotton Knit Fabrics Ltd. is well equipped with most

modern & sophisticated European state of the art textile finishing equipment & Japanese

made sewing machineries operated by highly skilled 4,500 technicians & managed by a

vastly experienced management. Padma PolyCotton kint Fabrics Limited committed to

render best services on timely shipment of garments to the valued customers all over the

world.

Padma PolyCotton Knit Fabrics Limited is knit composite mill consists of fabric manufacturing

(knitting), Knit dyeing, Printing & Garments manufacturing departments. With an area of

300,000 square feet Padma PolyCotton kint Fabrics Limited is located in Tejgaon, Industrial Area,

Dhaka.

Padma PolyCotton kint Fabrics Limited is very much distinctive about the quality of the

product as in the knitting & dyeing section varieties of product is produced. All of the

machineries used in this company are branded, modern & sophisticated machineries. All of the

manpower of this company are highly trained and consists of skillful knowledge.

This company deals with various foreign buyers those are very much renowned worldwide for

their supremacy. Among these buyers I may include S.Oliver, Tom Tailor, Esprit, C & A, Defacto,

New Look etc

8

1.2 General Information about the Mill:

Name of the mill : Padma PolyCotton Knit Fabrics Limited

Status : Private Limited Company

Type : 100% Export oriented industry knit composite mill.

Year of establishment : 1995 Year

Year of starting production : 1995 Year

Location: 131 Tejgaon Industrial Area,Dhaka.

Address: Factory: 131 Tejgaon Industrial Area,Dhaka.

Head Office: 5, Rajuk Avenue,Dhaka-1000

Tel: 9460917-20. Fax: 880956204

Email: [email protected]

Raw Materials: 100% cotton 100% polyester

a) Spun

b) Filament

100% Viscose

95% cotton 5% lycra

95% polyester 5% lycra

95% viscose 5% lycra

60% cotton 40% polyester

50% polyester 50% sulcool

48% cotton 48% modal 4% lycra

Production Capacity:

a) Knitting Section

b) Dying Section

c) Cutting Section

d) Sewing Section

e) Printing Section

f) Embroidery Section

g) Garment Washing

Capacity

a) 8 Ton/Day

b) 25 Ton/day

c) 65000 Pcs/day

d) 60000 Pcs/day

e) 60000 Pcs/Day

f) 35000 Pcs/Day

g) 15000 Pcs/Day

9

Yearly Turnover: 2 Million US dollar per year(approx.)

Different Departments:

a) Knitting Section

b) Dyeing Section

c) Garments Section

d) Merchandising & Marketing

e) Maintenance Section

f) Store Section

2 Knitting section

Inspection

Batch section

Dyeing lab.

Dyeing section

Quality control

Finishing

Cutting

Sewing

R.N.D. / Sample

Finishing & packing

Quality Control

I.E.N. & planning

Store

Electrical

Mechanical

Supporting Departments Security department

HRD

10

Marketing

Procurement

Finance and accounting

Personnel administration

Total Manpower: Over 4000

Major Customers: S.Oliver, Tom Tailor, Esprit, C&A ,New

Look, TEMA, Defacto

1.3 Board of Directors:

Khan Mohammed Ameer

CEO

Padma Group

Mrs. Parveen Sultana Khan

Managing Director

Padma Group

Mrs. Rukshana Ameer

Director

Padma Group

11

CHAPTER 2 Manpower management

12

2.1 Management System:

Buyer sample is send to G.M.

Matching is done by lab in charge.

Sample is prepared by asst. dyeing master.

Sample is send to the buyer for approval.

Approved sample is returned and taken as std. Sample for bulk production.

Asst. dyeing master gives responsibilities to production officer

Then production officer, with the supervisors start bulk production

On line and off line quality check is done by lab in charge and asst. dyeing master.

After dyeing finishing in charge controls the finishing process with the supervision of

production officer

After finishing, the material is checked by asst. dyeing master

Finally G.M. checks the result with asst. dyeing master and decision is taken for

delivery

2.2 Shift Change:

Three shifts (A, B, C): each of 8 hrs

A Shift: 6 A.M to 2 P.M.

B Shift: 2 P.M. to 10 P.M

C Shift: 10 P.M. to 6 A.M

General Shift: 9 A.M to 8 P.M.

Office Time : 9 AM to 5 PM

2.3 Responsibilities of HR:

1. Man Power Planning.

2. Man Power recruitment.

3. Man Power Selection.

4. To monitor Performance of Management.

5. To Observe Disciplinary cases.

6. To look after the welfare of worker.

7. To handle Grievances of worker

13

2.4 Job description and Responsibilities:

Title : Supervisor

Dept. /Section : knitting

Report to : Shift Incharge

Job summary: To guide the operator and helpers working at the production unit, motivation the

workers when necessary, Check the materials list whether they are at the right quantity or not.

Title : Shift Incharge

Dept. /Section : knitting

Report to : Production Officer

Job summary: To follow the workers movement, To maintenance the production sequence,to

check the sample at certain time interval, To set programs for the supervisions.

Title : Production Officer

Dept/Section : knitting

Report to : Manager

Job summary: To plan, execute & follows up the production activities & control the quality

Production with related activities.

Title : Manager


Report to : General Manager

Job summary: To plan for the sequence of production, To arrange necessary raw material for

the production, to follow up the production and give solution to the production problems, To

supervise the personal working under him.

Title : General Manager


Report to : Director and Chairmen

Job summary: To plan,apply and administrative function, To set up the price for the product,

To deal with the buyer and merchandiser .

14

CHAPTER 3 Raw materials

15

Raw material is a unique substance in any production oriented textile industry. It plays a vital

role in continuous production and for high quality fabric. Padma PolyCotton Knit Fabrics

Limited Takes yarn as its raw materials for its initial production of knitted fabrics to make

garments. It is dependent on different spinning mills of home and abroad to collect different

types of yarn as it requires.

3.1 Types of raw material:

Natural and synthetic, cellulosic, non-cellulosic all kind of yarn are used as raw materials in this

mill. Generally cotton, polyester, viscose, nylon is most widely used.

3.2 Yarn

Cotton yarn used in the Padma PolyCotton knit Fabrics Limited according to yarn count.

Serial No: Yarn Count Brand Name

1 18CD ARIF

2 20CD AMAN

3 20CB MOTIN

4 22CD NRG

5 22CB NRG

6 24CD SQR

7 24CB PRIME

8 26CD VIYELLA

9 26CB AMAN

10 28CD MALAK

11 28CB MALAK

12 30CD MSA

13 30CB MSA

14 32CD DELTA

16 32CB DELTA

17 34CD BEXTEX

18 34CB BEXTEX

19 36CD AKBAR

20 36CB AKBAR

21 40CD KADER

22 40CB KADER

*CB= Combed, CD=Carded

16

3.3 Sources of raw materials:

Square spinning mills ltd.

ARIF KNITSPIN LTD.

N.R.G Spinning mills ltd.

Akbar composite ltd.

The delta spinning ltd.

BEXTEX LTD.

TRIDENT LTD.

MSA spinning limited.

MATIN SPINNING MILL’S LTD.

THERMAX SPINNING LTD.

SQUARE TEXTILE LTD.

PRIME COMPOSITE MILLS LTD.

Aman cotton fibrous ltd.

Kader compact Spinning

VIYELLATEX

3.4 Remarks:

Padma PolyCotton Knit Fabrics Limited uses the best quality raw materials, maximum

amount for raw materials are collected from home and rest of amount is collected from India,

Korea, and Vietnam etc. Raw materials are tested before going for production.

17

CHAPTER 3 Machine description

18

Knitted structures are progressively built up from row of intermeshed loops. The newly feed

yarn converted into a new loop in each needle hook. The needle then draws a new loop head

first through the old loop, which remains from previous knitted cycle. The needles at the

same time release the old loop so that they hang suspended by their heads from the feet of

the new loops whose heads are still held in the hook of the needles.

A cohesive knitted loop structure is thus produced by a combination of the intermeshed

needle loops and yarn that passes from needle loop to needle loop.

Padma PolyCotton Knit Fabrics Limited is well equipped modern export oriented industry. It

has high quality machinery with large production. There are 2 types of machine in this

industry.

These are:-

Circular knitting machine

Single jersey machine

Double jersey machine

Flatbed machine (cuff & collar).

4.1 Machine at a glance:

Machine type Machine name Total no

Circular knitting machine Single jersey 28

Double jersey 14

Flat knitting machine Collar , cuff 33

19

4.2 Machine Description of knitting section:

Circular Knitting machines:

In total there are 42 knitting machine are present in Padma PolyCotton Knit Fabrics Limited

and which are divided in to two floor. First floor contain 30 circular knitting machine.

FIGURE: LAYOUT OF FIRST FLOOR (KNITTING SECTION)

20

4.3 Machine Specification of 1st floor:

Serial

No:

Machine

Name

Machine Type Origin Machine

Diameter

Machine

Gauge

No of

Feeder

1. Origio -1 Single Jersey Italy 26” 24G 84





6. Origio -6 Lycra Rib Italy 30” 18G 60

7. Origio -7 Lycra Interlock Italy :30” 18G 60

8. Origio -8 Fleece Italy 20” 20G 96

9. Origio -9 Single jersey Italy 30” 20G 96



12. Origio -12 P/Interlock Italy 30” 22G 96



15. Origio -16 Rib Italy 36” 18G 72

16. Origio -17 Lycra Rib Italy 36” 18G 72

17. Baso - 6 Fleece China 32” 20G 102

18. Baso - 7 Fleece China 35” 24G 108

19. Mayer - 1 Fleece Germany 30” 20G 96

21

20. Mayer – 2 Fleece Germany 30” 20G 96

21. Mayer - 7 Rib Germany

36” 18G 62

22. TERROT-17

Single jersey Germany

22” 24G 70

23. TERROT-25

Single jersey /

Heavy jersey

Germany 24” 20G 70

24. Terrot -26 Single jersey Germany 34” 24G 108

25. Terrot -27 Lycra Rib Germany 34” 18G 60

26. Terrot -28 Rib Germany 36” 18G 64

27. Terrot -29 Lycra Rib Germany 30” 18G 54

22

4.4 Layout of the 2nd floor of knitting section:

Second floor contain total 12 circular knitting machine.

FIGURE: LAYOUT OF SECOND FLOOR (KNITTING SECTION)

23

4.5 Machine Specification of 2nd floor:

Serial

No:

Machine

Name

Machine Type Origin Machine

Diameter

Machine

Gauge

No of Feeder

28. Pailung - 1 Single jersey Taiwan 34” 24G 102

29. Pailung -2 Fleece /terry Taiwan 36” 24G 108



32. Pailung - 5 D/Interlock Taiwan 40” 24G 80

33. Lisky – 1 Fleece Taiwan 32” 20G 102

34. Lisky - 2 Fleece Taiwan 32” 20G 102

35. Baso - 1 Single jersey Taiwan 28” 24G 84


37. Baso - 3 P/Interlock Taiwan 38” 24G 76



24

4.6 LAYOUT OF COLLAR AND CUFF SECTION:

Collar-cuff section contain 19 semi-automatic and 12 automatic flatbed machine.

FIGURE: LAYOUT OF COLLAR AND CUFF SECTION

25

4.7 Machine Specification of Collar and cuff section:

Machine Type Company Name Brand name Gauge Origin Total no of

machine

Fully Automatic

Flat bed knitting

machine

Matsuya Corporation - G 14 Japan 19

Computerized

Flat Bed knitting

machine

Sheng Meel machine

manufacturing limited

Flying Tiger G 14 Taiwan 6

Computerized

Flatbed knitting

machine

Shima Seiki

manufacturing limited

- G 14 Japan 7

Tape Making

Machine

Saehwa Precision

Machine Company

Saehwa loom - Korea 1

26

CHAPTER 5 Process planning & operation

operation

27

5.1 Classification of Knitting

Classification of knitting can be prevented as below:

Weft knitting:

A method of making a fabric by normal knitting means in which the loops made by each weft

thread are formed substantially across the width of the fabric, characterized by the fact that

each weft thread is fed more of less at right angle to the direction in which the fabric is

produced.

Single jersey:

A fabric in which all the loops of the Wales are intermeshed in one direction is called single

jersey only cylinder to make single jersey fabric.

Knitting

Weft knitting Warp knitting

Flat knitting Circular knitting

Double jersey Single jersey

28

Double jersey:

A fabric in which all loops of the alternate Wales are intermeshed in one direction and all the

loops of the other Wales knitted at the same course intermeshed in the other direction is called

double jersey Dial and cylinder is used to make this type of fabric.

5.2 Process Flow Chart Of Knitting:

Yarn in cone form

↓

Feeding the yarn cone in the creel

↓

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

↓

Knitting

↓

Withdraw the rolled fabric and weighting

↓

Inspection

↓

Numbering

29

5.3 Description of Production Process:

In every mill, there maintains a sequences in production processing. It is also followed in this

mill where we were in industrial attachment. The process sequences are in list below:

1) Firstly, knitting manager gets a production shit from the merchandiser as accordance as

consumer requirements then he informs or orders production officer about it.

2) Production officer informs technical in charge and knows about machine in which the

production will be running.

3) Technical in charge calls for leader of mechanical fitter troops, they two take decision

about machine for production considering machine condition, production capacity,

maintenance complexity, etc.

4) Production officer with experienced mechanical fitter adjusts required stitch length and

grey GSM for required final GSM.

5) Supervisor checks daily production regularity and make operator conscious about finishing

tin due time.

6) Operators operate machine in high attention as if there were no faults in the fabrics. If he

thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty.

Mechanical fitter then fixes it if he can or he informs technical in charge. Then he comes in

spot.

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

section.

5.4 Process Requirements:

We have already discussed there are basically three kinds of machine which is used to

Produce knit fabric and these are:

1. Circular knitting machine (Single Jersey Machines).

2. Circular knitting machine (Double Jersey Machines).

3. Flat knitting machine.

30

5.5 Minimum Requirement of Production Parameters:

For Machine:

1. Machine Diameter

2. Machine rpm (revolution per minute)

3. No of feeds or feeders in use

4. Machine Gauge

5. Counter setup

6. Required time (M/C running time)

7. Machine running efficiency.

For Lycra:

1. Should be good elasticity

2. Yarn should be uniform

3. Elastic recovery 100%

Other:

1. Needle oil; should be water soluble

2. Belt

3. Grease

4. Kerosene: etc.

5.6 Considerable Points to Produce Knit Fabrics:

When a buyer orders for fabric then they mention some points related to production and

quality. Before production of knitted fabric, these factors are needed to consider. Those are as

follows-

- Type of Fabric or design of Fabric.

- Finished G.S.M.

- Yarn count

- Types of yarn (combed or carded)

- Diameter of the fabric.

- Stitch length

- Color depth.

31

5.7 Passes of Yarn in Circular knitting Machine

Creel

Cone

Tube

Knot Catcher

Magnet Pressure

Sensor

Ceramic Eye Pot

Yarn Wheel

Guide

Sensor

Guide

Ceramic eye pot (Feeder Ring)

Feeder

32

5.8 Different parts of circular knitting machine:

1. Creel 26. Cylinder Balancer

2. Pipe 27. ON/OFF Switch

3. VDQ Pulley 28. Power Switch

4. Pulley belt 29. Automatic oiler

5. Brush 30. Motor

6. Knot Cather 31. Machine motherboard

7. Tension Disk 32. Manual drive

8. Inlet top motion

9. Yarn guide

10. MPF Wheel

11. MPF

12. Outlet stop motion

13. Feeder ring

14. Feeder

15. Needle

16. Needle track

17. Sinker

18. Sinker ring

19. Cam box

20. Cam

21. Lycra Attachment

22. Lycra stop motion

23. Inverter

24. Cylinder/dial

25. Screen

5.19 Function of knitting elements

Name: Needle

The needle is the primary knitting element. Needle is a thin metal bar.

Function:

It is used to produce a loop

33

Name: Sinker

The sinker is the second primary knitting element. It is a thin metal plate.

Function:

Holding down

Knocking over

Loop formation

Name: Knitting Cam

Cam is the devices which convert rotary machine drive in to a suitable reciprocation action

for the needle.

Knit cam

Function:

To produce knit loop

Tuck cam

Function:

To produce Tuck loop.

Miss cam

Function:

To produce miss loop.

Name: Cam Box

Function:

To set cam on the slider.

34

Name: Oiling Point

Function:

To pass oil into the needle.

Name: Air Pipe

Function:

To flow air into the cam and needle.

Name: Quality Adjustments Pulleys

Function:

It is used to control GSM

Name: Hemminge Positive Feeder

Function:

It is use to apply positive Feed of the yarn.

Name: Lycra Feeding Device

Function:

It is use to apply positive Feed of the spandex.

35

Name: Needle Detector

Function:

It is used to detect faulty Needle in the machine.

Stop the machine when it finds out faulty needle.

Name: Creel

Function:

Creel is a part of a knitting machine.

Hear yarn package are store and

Ready to feed in the machine .

Name: Pulley Belt

Function:

It controls the rotation of the MPF wheel.

Name: Yarn Guide

Function:

Help the yarn to feed the feeder. .

Name: Feeder

Function:

Feeder is help yarn to feed in to the machine. .

36

Name: Needle Trick

Function:

Where all needle is placed together in a decent design.

Name: Stop Sensor

Function:

Indicates when yarn becomes worn out.

Name: Screen and On Off Switch

Function:

Indicates the all information of the machine switch use to

Start or stop the machine.

37

5.10 Production Calculation:

A. Production / shift in Kg at 100% efficiency

=𝑅𝑃𝑀 × 𝑁𝑜. 𝑂𝑓 𝑓𝑒𝑒𝑑𝑒𝑟 × 𝑁𝑜 𝑜𝑓 𝑛𝑒𝑒𝑑𝑙𝑒 × 𝑆𝐿 × 60 × 12

10 × 25.4 × 36 × 840 × 2.2046 × 𝑌𝑎𝑟𝑛 𝐶𝑜𝑢𝑛𝑡

B. Production/shift in meter

= 𝐶𝑜𝑢𝑟𝑠𝑒/ 𝑚𝑖𝑛

𝐶𝑜𝑢𝑟𝑠𝑒/𝑐𝑚

= 𝑅𝑃𝑀×𝑁𝑜.𝑜𝑓 𝑓𝑒𝑒𝑑𝑒𝑟×60×12×𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

𝑐𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×100

C. Fabric width in meter

= 𝑇𝑜𝑡𝑎𝑙 𝑛𝑜.𝑜𝑓 𝑤𝑎𝑙𝑒𝑠

𝑊𝑎𝑙𝑒𝑠/𝑐𝑚×100

= 𝑇𝑜𝑡𝑎𝑙 𝑛𝑜.𝑜𝑓 𝑛𝑒𝑒𝑑𝑙𝑒𝑠 𝑖𝑛 𝑘𝑛𝑖𝑡𝑡𝑖𝑛𝑔

𝑤𝑎𝑙𝑒𝑠/𝑐𝑚×100

D. GSM Calculation

1.

= 𝑆𝑡𝑖𝑡𝑐ℎ 𝑑𝑒𝑛𝑠𝑖𝑡𝑦×𝑆𝑡𝑖𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚)×59

𝑌𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡(𝑖𝑛 𝑁𝑒)

= 𝐶𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×𝑤𝑎𝑙𝑒𝑠/𝑐𝑚×𝑠𝑡𝑖𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚) ×59

𝑌𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡(𝑖𝑛 𝑁𝑒)

2.

= 𝑆𝑡𝑖𝑡𝑐ℎ 𝑑𝑒𝑛𝑠𝑖𝑡𝑦×𝑆𝑡𝑖𝑡𝑐ℎ 𝐿𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚)×𝑌𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡 ( 𝑖𝑛 𝑡𝑒𝑥)

10

= 𝐶𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×𝑤𝑎𝑙𝑒𝑠/𝑐𝑚×𝑠𝑡𝑖𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚) ×𝑦𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡(𝑖𝑛 𝑡𝑒𝑥)

10

38

E. Length calculation

= 𝑊𝑒𝑖𝑔ℎ𝑡 (𝑖𝑛 𝑔𝑚) ×39.37𝑊𝑖𝑑𝑡ℎ (𝑖𝑛 𝑖𝑛𝑐ℎ) ×𝐺𝑆𝑀

Fabric Type: Single Jersey Plain

Number of Feeder : 90 R.P.M. of Machine: 30

Machine Dia : 30 Machine Gauge : 24

Count of Yarn : 24/1 Ne Stitch Length : 2.74

Efficiency : 85 %

Production/8 hours shift = 90 x 30 x 60 x 8 x 0.85 x 3.14 x 30 x 24 x 2.74 Kg

10 x 2.54 x 36 x 840 x 24 x 2.2046

= 168 Kg

Actual production

Efficiency = × 100%

Calculated production

=138/168×100

= 82%

39

Fabric Type: 1 X 1 RIB

No of Feeder: 60 R.P.M. of Machine: 25

Machine Dia: 30 Machine Gauge : 20

Yarn Count : 34/1 Stitch length : 2.54

Efficiency : 80 %

Production/ 8 hours shift = 60 x 25 x 60 x 8 x 0.8 x 3.14 x 30 x 20 x 2.54 Kg

10 x 2.54 x 36 x 840 x 34 x 2.2046

= 96 Kg

Actual production



= 83 %

40

Fabric Type: Plain Interlock

No of Feeder: 108 R.P.M. of Machine: 26

Machine Dia: 34 Machine Gauge : 24

Yarn Count : 34/1 Stitch Length : 1.54

Efficiency : 80 %

Production/day = 108 x 26 x 60 x 8 x 0.8 x 3.14 x 34 x 24 x 1.54 Kg

10 x 2.54 x 36 x 840 x 34 x 2.2046

= 147 Kg

Actual production



= 74 %

5.11 Comments:

Actual production is less because of lower efficiency.

Machine is stopped after complesion of each roll. This is a reason for less actual

production.

Machine stops during shift change Which results less actual production.

Order sortage & Yarn sortage also responsible for less actual production.

41

CHAPTER 6 Quality assurance system

42

6.1 Quality Assurance:

Quality assurance is defined as all those possible planned and

systematic actions necessary to provide adequate confidence than a product or service will

satisfy given requirements for quality. The Quality Assurance Department is assigned to

maintain consistently uniform quality of the material in process and various stages of

manufacturing.

6.2 Object of Quality Control:

Specification test

Raw materials control

Process control

Process development

Product testing

Research

6.3 Quality Assurance System:-

Quality assurance procedure may be divided into two major parts:

1) Online quality control

2) Offline quality control

6.4 Yarn quality:

check the quality by yarn test method( suitable for white color or dark color)

check the yarn count( thick/thin, slub,neps,contamination, patta,hariness)

6.5 Knitting quality:

Working Area of ON Line Quality Control:

At the knitting production stage check the every fabric quality by online quality person. Also

check the program sheet with the knit card (like buyer, order, yarn count, machine diameter,

gauge, stitch length, yarn lot etc.)

43

a) On line circular knit:

Function:

1. Design & shade approval.

2. Yarn & m/c evaluation.

3. QC parameter checking.

4. Body& Rib Inspection.

b) On line flat knit:

Function:

1. Design & shade approval.

2. Yarn & m/c evaluation.

3. QC parameter checking.

4. Collar & cuff. Inspection.

a) Grey inspection:

Function:

1. 100% Fabric Inspection.

2. Fabric transfer to store.

3. Area cleaning.

4. Co-ordination & reporting.

b) On line finishing:

Function:

1. 100% Fabric Inspection.

2. Problem Identification.

3. Problem Rectification.

4. Fabric Transfer for reprocesses.

44

6.6 Response to Faults:

Following response is to be taken:

Faults Response

Grey inspection Inform yarn supplier & knitting department.

Knitting fault Inform knitting Department

Finishing fault Inform Finishing Department

Working Area of OFF Line Quality Control:

After knitting, check the grey fabric by inspection machine .find out the knitting fault & mark

by marker pen. Make a report sheet (on 4 point system).

6.7 List of equipment for quality control:

The list of equipment’s to assure quality:-

1) Inspection m/c.

2) Electronic balance

3) GSM cutter.

4) Measuring tape.

5) Scissors.

6) Indication sticker.

Following faults are detected & identified in final inspection for body:

A) Penalty points legends: B) Faulty appearance:

H= Hole US= Uneven shade

OS= Oil Stain N= Neps

CS= Chemical stain CR= Crease Mark

RS= Rust Stain HR= Hairy

GS= Grease Stain MS= Machine stoppage

MS= Missing Yarn NL= Needle Line

DS= Drop Stitch BR= Barre mark

D= Dirt Stain CM= Crumple MarkUT= Uneven

Tension DC= Dead Cotton

45

S= Stripe BW= Bowing

OL= Oil Line

TT= Thick & Thin Yarn

S= Slubs

SM= Sinker Mark

FL= Fly Contamination

MY= Mixed Yarn

YC= Yarn Contamination

BE= Birds Eye

WD= Wrong Design

BR= Barre Mark

PH= Pin Holes

Besides roll to roll and meter to meter variation is checked.

6.8 Quality Assurance System

Padma PolyCotton Knit Fabrics Limited maintains the ISO: 9002 standard in case of quality.

Therefore, the four points system is followed to inspect fabric. The defects found and points

given against are recorded in the inspection sheet. Following table shows the four point grading

system followed by inspection at the Padma PolyCotton Knit Fabrics Limited.

Length of defects Penalty point

3 inches or less 1

Over 3 inch but not over 6 inch 2

Over 6 inch but not over 9 inch 3

Over 9 inch 4

Total defect points per 100 square yards are calculated

Hole Penalty Point

1 inch or less 2

Over 1 inch 4

46

6.9 Some Common Knitting Faults:

NAME: CAUSES : FIGURE

Hole

1. Due to tide knots.

2. Needle break due to slub.

3. Defective needle on yarn.

Set

up o

r pre

ss o

ff

1. Due to drop stitch and empty

needle running into the yarn feeder.

2. If an empty needle (generally

after drop stitch) with a close latch

runs into the yarn feeders and

remove the yarn out

from the hook of the following

needles.

Sin

ker

Lin

e

1.Due to uneven movement of

sinker

47

Nee

dle

Lin

e 1. Due to defective needle.

2. Dirty needle slot.

3. Needle is too tight or loose in the

slot.

T

hic

k a

nd T

hin

pla

ces

1. Uneven tension.

2. Uneven courses.

3. Count mix, lot mix.

Oil

Lin

e

1. Over flow of oil

Mis

sing Y

arn

1. Faulty positive feed system

2. Wrong feeder setting.

3. Due to missing of cotton or

spandex yarn

48

CHAPTER 7 Sample analysis

49

Single Jersey Plain

Structure

Sample

Needle and cam arrangement

Polo Pique

Structure

Sample


50

Back Pique Or Double Lacoste

Structure

Sample


Two Yarns Fleece (In-Lay)

Structure

Sample


51

Three-Thread Fleece

Structure

Sample


1×1 Rib

Structure

Dial

Cylinder

Sample

52

2×2 Rib

Structure

Dial

Cylinder

Sample

Terry

Structure cam arrangement

1 2 3 4

Needle arrangement

K T K M

K M K M

K M K T

K M K M

53

Plain Interlock

Structure

Sample

54

CHAPTER 8 Maintenance management

55

Maintenance is a process by which equipment is looked after in such a way that trouble

free. Services and increased machine life can be ensured and specific product quality

required by the customers is sustained.

8.1 Objective of Maintenance:-

To keep the factory plants, equipment’s, machine, tools in an optimum working

condition.

To ensure specified accuracy to product & time schedule of delivery to customer.

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

production program.

To keep the production cycle within the stipulated range.

To modify the machine tools to meet the need for production

8.2 Types of Maintenance:-

8.3 Preventive Maintenance

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

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

harmful depreciation.

8.4 ROUTINE MAINTENANCE

Routine maintenance usually denotes those activities of maintenance which are bare minimum to

ensure efficient working of machines. These activities have to be performed according to

predetermined frequencies which are based on technical and quality considerations.

Maintenance

Preventive Maintenance Break Down Maintenance

Electrical

Maintenance

Mechanical

Maintenance

Electrical

maintenance

Mechanical

Maintenance

56

Routine maintenance tasks followed in the factory

Daily work

Motor sound checking

Auto line checking

Positive feeder checking

Oil line checking

Airline checking

Take up roller checking

Every 15 days

Gear box checking

All bearing checking

All bearing greasing

Panel board cleaning

Fan filter cleaning

Checking all control panels

Lubrication of all motor bearing

All cable terminal tighten

8.5 Maintenance tools & equipment’s

Adjustable Wrench

Use :

To set different type of nuts And bolts

Tightening & loosening of nuts & bolts.

Double Head Spanner

Use :

To set nuts and bolts.


57

Single Head Spanner

Use :

To set nuts and bolts.


T-Type L-Key

Use :

Use to fitting cam box And other m/c parts.


Allen-Key

Use :

Use to fitting cam box And other m/c parts.


Pin setter

Use :

To hold small m/c parts.

T-Type L-Key

Use :

To fitting cam box And other m/c parts.

Tightening & loosening Of nuts & bolts.

Flat Screw Driver

Use :

To fitting varies type screw.


58

I- Type L-Key

Use :

To fitting cam box And other m/c parts.


Hammer

Use :

To beat metal parts.

Multi-Pliers

Use :

To hold m/c parts,

Cut metal wire,

Set nuts and bolts.

Cutting-Pliers

Use :

To cut metal wire.

Long Nose-Pliers

Use :

To hold and set m/c parts In thin or narrow space.

59

CHAPTER 9 Utility services

60

Utility is a very big factor in case of any industry. In textile industry there are various types of

utility has to be present for the smooth running of the operations. In case of any textile

processing industry following types of utility are very much necessary like;

9.1 Utility required in Padma PolyCotton Knit Fabrics Limited Textile

industry:

1. Electricity

2. Water

3. Steam

4. Compressed air

9.2 Sources of utility:

Electricity : Government supply and Factory own generator.

Steam : Boiler

Water : Pump

Compressed air : Compressor

Gas : TITAS GAS LTD.

9.3 Machines for utility services:

Power generator:

In Padma PolyCotton Knit Fabrics Limited There are four power generator present and three

of them run by diesel fuel and the remaining one run with gas fuel.

Name ENGINATOR

MODEL: VHP-7100-GSID

MODEL: 1000

RPM: 415/240

VOLTS: 410/24 hours

61

9.4 Air Compressor:

In order to compress the air and to raise its pressure Air compressor is used. The air compressor

sucks air from the atmosphere, compress it and then deliver the same under a high pressure to

a storage vessel. From the storage vessel it may be conveyed by the pipeline to a place where

the supply of compressed air is required. Padma PolyCotton Knit Fabrics limited does have

five compressors

Machine no 1 2 3 4 5

BRAND KEISER KEISER LG KEISER -

ORIGIN Germany Germany - Germany UK

SERIAL 4511922 4511922 6M37021558H 1824 SSRML50

POWER 30KW 30KW - 55KW -

CAPACITY 3bar 3bar 5m3/min 11bar 8bar

62

CHAPTER 10 conclusion

63

10.1 Conclusion:

For every person who is fresher in the field of textile, industrial training works like learning

route. This course has given the opportunity to learn the industrial work & follow the process

sequence virtually. From our two month observation of the industry along with research &

development and knitting section specially, we can say that in the knitting sector, this industry

has strong possibility because the industry is running with all modern machineries & very

knowledgeable persons are working all the time. In the production floor the commanding

power of the officers, compliance, administration rules, everything is appealing. We hope that

this industrial training will help us a lot in the future period where ever we want to develop our

career. Finally wishing the best prospect for both the industry & praying for a good future for

us that we want to conclude.