Industrial attachment of urmi garments ltd

Over the last Two Decades, by offering the best blend of quality, efficiency and productivity to their valued customers, they have been able to grow up from a 50 machines stitching unit

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

URMI GROUP

CHAPTER – 1

COMPANY PROFILE

Name of Company : Fakhruddin Textile Mills Ltd

(Concern of Urmi Group)

Concern of URMI Group:

 Fakhruddin Textile Mills Ltd

 Urmi Garments Ltd

 Attires Manufacturing Co Ltd

Inception of Urmi Group Dates back to n1984 when Urmi Garments Ltd was set up Today

they are one of the leading manufacturers & exporters of knit garments in Bangladesh Over

the last Two Decades, by offering the best blend of quality, efficiency and productivity to

their valued customers, they have been able to grow up from a 50 machines stitching unit to a

composite textile having knitting, dyeing and finishing facilities of about 20 tons fabric and

70,000 pcs garments per day

Strength of Fakhruddin Textile Mills Ltd.:

Their Goal is to achieve zero tolerance in production by upgrading total quality

management and proper production management

FTML srength

Proffessional Management Team

Latest Machinery &

Technology

Proactive Planning

Competetive Pricing

Focus on Continuous Improvement

Dedicated &

Competent Workforce

Annual Turnover : About Tk 50, 00, 00,000 to 55, 00, 00,000

Certification & Awards : ISO 9001: 2000, WRAP,OekoTex&

GOTS(Global Organic Textile Standard)

Bank Name & Address:

Islami Bank Bangladesh Ltd

75, Motijheel C/A, Dhaka-1000, Bangladesh

Telex:642525 IBANK BJ

S.W.I.F.T –IBBLBDDH102

Contact Person:

Mr Hafizur Rahman –Sr General Manager, Cell no - 01711-560980

Mr RuhulKuddus –Deputy General Manager, Dyeing, Cell no.- 01713-013028

Mr Moniruzzaman –Asst General Manager, Knitting, Cell no - 01712-106405

Capacity & Machineries

Floor space: 320,000 Square Feet

Knitting machine : 82 nos

Knitting per day : 15,000 Kgs

Dyeing machine : 27 nos

Dyeing per day : 20,000 Kgs

Finishing Per Day : 20,000 Kgs

Stenter machine : 02 nos

Open width compactor : 02 nos

Tension free dryer : 01 nos

Tubular compactor : 01 nos

Slitting & squeezing machine: 03 nos

Brushing machine : 02 nos

Tumble dryer : 02 nos

Fabric inspection machine : 06 nos

Printing Unit

Floor space : 26,000 square feet

Carosol print machine : 04 nos

Glass table : 16 nos with 400 feet

Capacity : 25,000 pcs per day with multi color average size printing

Embroidery Unit

Machines : 20 Head 04 nos,06 Head 01 nos

Capacity : 3000 million stitches per day

Main Production : Men’s, Ladies, Boy’s, Girls & Infant -Polo Shirt,

T-Shirt, Tank Tops, Shorts, Trouser, Fleece Jacket, Vest etc

Compliance & Certificates:

Fakhruddin Textile Mills Ltd is extremely particular to meet all levels of compliances at

national and international levels

Fakhruddin Textile Mills Ltd use AZO free dyes and chemicals and are certified by

OekoTex, WRAP GOLD Certificate, GOTS(Global Organic Textile Standard

In Fakhruddin Textile MillsLtd all personnel are equipped with the necessary safety gear and

trained to combat any accidents that may take place

As they are ISO 9001:2000 for its QMS certificate for manufacturing responsible textile

manufacturing process

Their Sporting skill in Textile production includes:

All Kinds of S/J, Rib, Interlock, Pique, French Terry,

Brushed Fleece, Drop Needle,different type of design etc on :

100% Polyester,100% Cotton & Different blend of Cotton and Polyester

Lab QC Physical Inspection

to wash, perspiration, pilling etc

Stentering/Drying

CHAPTER-2

MAN-POWER MANAGEMENT

Manpower of Fakhruddin Textile Mills ltd.:

Unit Officer & Staff worker Total

Professionals Working For:

MD/Director

AGM Work Study

AGM Commercial

Chief Operating Officer

AGM Accounts &

Finance

AGM Admin.HR &

Comp

DGM Commercial

DGM

Dyeing

DGM Project Implementation

AGM Cutting

AGM

Knitting

Sr AGM Accounts

& Finance

AGM Production

AGM Merchandising

AGM Quality

DGM Merchandising

DGM Production [Factory Manager]

Merchandising Project Commercial Accounts

CHAPTER-3

RAW MATERIALS

Raw Material

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

Some Factory Name of Yarn Suppliers,

 Square Textile Mills

 Padma Textile Mills

 Mosharaf Textile Mills ltd

 Prime Composite Mills

 Israq Textile Mills ltd

 Badsha Textile Mills ltd

 Shamsuddin Spinning

 Tara Textile Mills ltd

 PHP Textile Mills ltd

 Numan Spinning Mills ltd

Different Yarn And Count for Knitting:

01 Carded Yarn 100% Cotton 10s, 12s, 16s, 20s, 20/2, 22s, 24s, 26s,28s, 30,

32s, 34s,

02 Combed Yarn 100% Cotton 20s, 22s, 24s, 26s, 28s, 30s, 32s, 34s, 36s, 40s,

50s, 60s

 1 x 1 rib & others

 Collar & cuff

01 Soda ash light 24 Mcropan DPE

02 Caustic Soda 25 Cibapon R

03 Common salt 26 Ctobalance NSR

04 Glauber Salt 27 Rucozen RES

05 H2O2 28 TinofixFRd

06 Acetic Acid 29 Lily XXL powder

07 Oxalic Acid 30 RewanAcp

08 Bleaching Powder 31 Cibatex ECO

09 Hydrose 32 Invatex CRA

10 Leuphore BMB 33 Heptole EMG

11 Uvtex BHT 34 Cibafluide C

12 Uvtex BHV 35 Biovin 109

13 Uvtex BAM 36 Tinozym 44L

14 Syno White 4BK 37 Beizym ULBD

15 Uvtex BFE 38 Invatex PC

01 Solazol Black sp GRI 21 Cibacron Blue FNR

02 Reactofix Red ME4BL 22 Cibacron Blue FGFN

03 Cottofix Red ME4BL 23 Cibacron Navy WB

04 Reactofix Orange ME2RL 24 Drimarin Yellow CL2RL

05 Reactofix N.ME2GL 25 Drimarin Red CL5B

06 Reactive Yellow H4GL 26 Drimarin Violet K2RL

07 Reactive Deep Black N 27 Drimarin Navy CLB

08 Cottofix Black B 28 Drimarin Blue CT2R

09 Reactive Blue R(SP) 29 Bezaktrive Yellow S3R

10 Remazol Red RR 30 Bezaktrive Yellow SLF

11 Remazol Yellow RR 31 Bezaktrive Yellow V GL

12 Remazol Blue RR 32 Diss Yellow F5GL

13 Remazol Blue BB NEW 33 Diss Red BF

14 Remazol T Blue G 34 Diss Blue FRL

15 Remazol B Yellow 3GL 35 Diss Navy 2GL

16 Remazol Red RGD 36 Diss Black EXNSF

17 Cibacron Red FN2BL 37 Terasil Black WNS

18 Cibacron Red FB 38 Terasil Red FB

19 Cibacron Red FN3G 39 Terasil Red WFS

20 Cibacron Red WB 40 Terasil Red W4BS

Remarks:

Fakhruddin Textile Mills Limited uses best quality raw materials It produces fabrics from

best quality yarn They uses the best quality dyes like REMAZOL, REACTRON,

REACTIVE,TERACIL etc During the time of using dyestuff they give importance upon the

quality of dyes than the price of the dyes and chemicals

CHAPTER-04

INVENTORY CONTROL

AND UTILITY

Store & inventory control:

Frequency of Inventory Control:

 Monthly inventory control

 Annual inventory control

Scope of Inventory Control:

 Raw materials

 Dyes store

Inventory system for raw materials:

 Raw materials partially received from production planning & directly from head

office

 Material Receiving & Inspection Report (MRIR) is prepared Received quantity is

mentioned & noted down

 Submitted to QC department Some are OK & few rejected

 Entry of data of goods in DATATEX

 Goods are arranged according to OK or rejected group

 Department gives store requisition to warehouse

 As per requisition materials supplied & this record is noted down

Stages of grey fabric inventory control:

 After knitting production

Moreover Urmi Group have the following facilities for smooth operation:

• Stand by Generator to run the full factory

• Fire protection system

• Sufficient volume of water reservoir at underground & overhead

• Quality electrical cable with circuit breakers

• Separate toilets for male & female workers

• Sufficient ventilation is provided by installing ceiling fans, exhaust fans, large

windows

• Factory premises is always kept neat & clean

• We do not have any child labor

• Doctor & Nurse are provided to take care of workers health

• Canteen for workers

• Day care center

• Work study center

CHAPTER-05

MARKETING STRATEGY

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 Fakhruddin Textile Mills 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

Fakhruddin Textile Mills Ltd is a 100% export oriented industry All the goods produce in

this industry are exported to various country

Clients of Fakhruddin Textile Mills Ltd.:

Ernesting’s Family Germany

Main Products:

Polo Shirt, Sweat Shirt, Ladies rib tops, basic and fancy polo, T-Shirt,Tank-Tops, Sweat

Tops and bottoms for all age range of male and female

CHAPTER-06

KNITTING SECTION

Knitting:

Knitting is a process of manufacturing a fabric by inters looping of

yarns Knitting is the second most important method of fabric formation It can be defined as

a needle technique of fabric formation, in which, with the help of knitting needles, loops are

formed to make a fabric or garment Fabric can be formed by hand or machine knitting, but

the basic principle remains exactly the same i.e pulling a new loop through the old loop

In other words, Knitting is a method by which thread or yarn may be turned into

cloth or other fine crafts It is a fabrication process i.e intermeshing series of loops of one or

more yarns or from a set of yarns Knitted fabric consists of consecutive rows of loops, called

stitches As each row progresses, a new loop is pulled through an existing loop The active

stitches are held on a needle until another loop can be passed through them This process

eventually results in a final product, a garment Knitting may be done by hand or by machine

.Different yarns and knitting needles may be used to achieve different end products by giving

the final piece a different color, texture, weight, and/or integrity Using needles of varying

sharpness and thickness as well as different varieties of yarn can also change the effect A

knitted fabric is the third major class of fabric, after woven and nonwoven fabrics.

In knitting, the inter-lopping is carried out by needles (may be Latch or beard or

compound needle etc), the needles are equipped on a cylinder and Needle butt moves

between the grooves of cams to accomplish knitting cycle and producing the fabric The

shape of the needle cam grooves depends on the required knitting pattern

All over the world, the majority of knit fabrics are manufactured on circular knitting

machines The high performance level of these machines, the different materials and the

range of yarn counts that they are able to process, the wide variety of designs and stitches are

some of the reasons which have granted circular machines the market leadership in the

knitting sector

Layout Of Knitting Section:

Knitting Machine Specification:

No Brand Name of Origin of

TAIWAN 2009 Double Jersey 40*18 80 2262

20 PAOLO ORIZIO ITALIA 2002 Double Jersey 30*18 60 1697

TAIWAN Single Jersey 30*24 90 2262

40 PAOLO ORIZIO ITALIA 2002 Single Jersey 30*24 90 2262

TAIWAN Single Jersey 28*28 84 2464

71 FUKAHARA CHINA Auto Stripe

(Double Jersey)

72 FUKAHARA CHINA Auto Stripe (D/J)

Process flow chart of knitting:

Cone from spinning

Creeling the cone

Yarn feed by different tensioner

Adjust S/L, GSM, etc by V.D.Q pulley

Produce 0.5 m fabric, if fault found, it adjust

After bulk production, cut the role

Marking the role such as S/L, Diameter, GSM etc

Different Parts of Circular Knitting Machine:

1 Creel:Creel is a part of a knitting machine Here yarn package are store and ready to feed

Creel Yarn Tube/Pipe Wheel

Yarn Sensor Knot Catcher Positive Feeder Feeder

Final Yarn Guide

Needle

2 Positive Feeders:Here number of yarn wounded on two positive feeder for smooth

feeding of two yarn in the machine

3 Feed Sensor:It is used in positive feeder to help the little display at the time of yarn

breakage At that time machine is stopped

4 Final Yarn Guide:It controls the path of the yarn

5 Needle:Hooked metal part which is used to formation of loops

6 Indicators:In any yarn breakage or any fault in the machine Indicators are used to

identify them

7 Lubricants:The lubricator provides lubrication to needle, cam tracks, lifters and other

knitting machine components

8 Fluff Blower:It removes the fiber, dust particle on the machine

9 VDQ Pulley:It controls the stitch length as well as GSM of knit fabric

10 Cam: Cams are knitting elements which cover rotary machine drive into a suitable

reciprocating action for the needles and other elements

11 Cam Box:Where the cams are set horizontally

12 Cylinder:Needles are situated here

13 Dial:Needles are situated here It is used in double jersey knitting machine

16 Needle Detector:This part detects the any type of faults of needles

17 Spreader:To control the width of the knitted fabric

18 Taker-in:It is takedown the fabric in suitable tension

19 Cloth Roller:Numbers of fabric layers are wound evenly

Other parts,

 Positive Feeder Belt

 Knot Catcher

 Top Gear Oil D/J

 Yarn Tube/Pipe

 Rotating Fan

 Yarn Feeder Ring Ceramic

 Yarn Feeder Ceramic

 Lycra Guide/Wheel

 Fabric Detector

 Needle detector

 Machine Gate

 Take Down Side Gears

 Fabric Roller Lock

 Rubber Belt (Curling)

 All Gear Greasing

 All Type of Nut & Bolt

Terms of Knitting:

Course:

Horizontal row of loops produced by adjacent needles in knitting cycle is called the course of

the fabric A course is a predominantly horizontal raw of needle loops produced by adjacent

needles during the same knitting cycle called course (Loop length * No of loop)

Wales:

Vertical column of loops produced by same needle in knitting cycle is called the Wales of the

fabric

A wale is a predominantly vertical column of intermeshed needle loops generally produced

by the same needle knitting cycles i.e The number of vertical columns of loop of knitted

fabrics is called wale

The term stitch density is frequently used in knitting instead of a linear measurement of

courses or Wales; it is the total number of needles loops in a square area measurement such

as a square inch or three square centimeters

The needle gauge of a knitting machine is a measure expressed the no of needle per unit of

the needle bed or needle bar As for example:

1 In case of circular weft knitting machine & Tricot warp knitting machine [Gauge,

N= Number of needle per inch.]

2 In case of Raschel warp knitting machine [Gauge, N= Number of needle per two

inch.]

 One butt needle

 Two butt needle

 Three butt needle

 Four butt needle

The most widely used needle is latch needle

Fig: Main parts of latch needle

Cam:

Cam is called the specific path of the needles to produce a specific type of fabric