INDUSTRIAL ATTACHMENT OF BISWAS GROUP LTD

1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF BISWAS GROUP LTD. 2 TABLE OF CONTENTS Serial No. Topic Page No. 01 Introduction 05 02 Company Profile 06 03 Knitting Section 12 04 Quality Control 30 05 Batch Section 33 06 Dyeing Lab 35 07 Dyeing 39 08 Finishing Section 68 09 Fabric Inspection 75 10 Quality Assurance system 77 11 Maintenance 79 12 Utility 85 13 Effluent Treatment Plant 89 14 Conclusion 91 3 INTRODUCTION By means of practical knowledge its not possible to apply the theoretical knowledge in thepractical field. For any technical education, practical experience is almost equal importance in association with the theoretical knowledge. The industrial attachment is the process, which builds understanding skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provide us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skillness about various processing stages. It is also provide us sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. Textile education cannot be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. We got an opportunity to complete our industrial training at BISWAS SYNTHETIC LTD. It has well planned & equipped fabric dyeing-finishing and printing unit in addition to facilitate knitting and knitwear manufacturing. 4 COMPANY PROFILE GENERAL INFORMATION ABOUT THE COMPANY:  Biswas Group was established in 1985  Biswas Group deals in Apparels, Textile and Accessories.  Biswas Group have 9 fully automated garments factories in Dhaka.  7 associate factories in Dhaka. Product Range- Men's Women's Boys, Girls, Kids and Toddlers, T-Shirts, Polo Shirts, Woven Women's Blouses, Men's Shirts, Pants/Shorts Casual/Denim Men's, Women's and kids, Jogging Suits, Swimwear, Nighwear, Winter Wear and All kinds of Accessories. Monthly Capacities : 43000 pcs woven bottoms, 300000 pcs woven tops, 380000 pcs pants, 600000 pcs knit tops, 30000 pcs knit bottoms.  Work force - 9000 employees  Sewing Lines : 100  Sewing Machines : 4567  Knitting Machines : 220  Weaving Machines : 300  Dying Machines : 47 Head office: J.S. Bhaban, 95, BirUttam C.R. Dutta Road (New)299/2A Sonargaon Road (Old), Dhanmondi, Dhaka-1205, Bangladesh Tel: 9668835-7,8611796,8610685,9673065 Fax: 88028613367 Email: babu@biswasgroup.com 5 Web: www.biswasgroup.com Project location: 6 7 Buyer:  Aldi - Germany  C & A - UK  Calvin Klein- USA  Carrera - Italy  Defacto - Turkey  Ecko– USA  H & M - Sweden  Hurley -USA  Inditex - Spain  JC Penney - USA  Kenneth Cole - USA  Kik - Germany  LC Waikiki - Turkey/France  Li & Fung - Internalional  Lidl - Germany  Oshkos -USA  Roca Wear - USA  Sol's - France  Sears/K-Mart - USA  Tema - Turkey  Wal- Mart - Europe  Zara – Spain 8 General Manpower Organogram: Chairman Director Executive Director Production QualityAdminAccounts MarketingMaintenance Utility store security Production QualityAdmin Accounts Marketing Maintenance Utility store security ManagerManagerManagerManagerManagerManager Mngr. Mngr.officer Assistant Senior AdminAccountsMarketingMaintenanceUtilitystore Assist Manager Officer OfficerOfficerOfficer Engineer Engineer Officer Officer Senior Assistant Cashier Fore man Assistant Helper security Production Officer Admin Engineer Guard Officer Officer Fitter man Worker Production Lab Helper Worker officer Assistant Assistant Lab Worker Production Boy officer Machine Operator Helper Worker 9 Shifting: In Biswas Synthetic Ltd. the whole day production time is divided into 2shift. Per shift 12 hours. Shift Duration Shift A 8:00 am- 8:00 pm Shift B 8:00pm – 8:00 am Responsibility of Production officers: 1. To give dyeing program slip. 2. To match production sample with target shade. 3. To collect production sample lot sample matching next production, 4. To observe dyed fabric during finishing running & also after finishing. 5. To identity disputed fabrics & report to P.M/G.M. for necessary actions. 6. To discuss with P.M about overall production if necessary. 7. To sign the store requisition & delivery challan in the absence of P.M. 8. Also to execute overall floor works. 9. To maintain loading'/unloading khata. 10. Any other assignment given by higher authority. Title :Production Office Report To : Sr. Production Officer. Job Summary: To plan, execute & follows up the production activities &. control the quality … production with related activities. Duties & Responsibilities:  Overall supervision of dyeing, finishing production.  Batch preparation & p H I chock.  Dyes & chemical requisition issue & check.  Write Fabrics loading & unloading time from m/c  Program making, sample checking, colour measurement  Control the supervisors,operator, ass. operator and helper of 10  Dyeing m/c.  And also any other over work as & when required by the management. Title : Sr. Production Office Report To :Manager Job Summary: To plan.execute& follows up the production activities & control the quality production with related activities. Duties & Responsibilities:  Overall supervision of dyeing, finishing production.  Checks the sensitive parameters of different machine for smooth dyeing  Checks the different log books of different areas & report to management  Checks out the plan to control the best output from supervisors & workers.  To trained up& motive the subordinates how to improve the quality production.  Control the supervisor, operator, Asstt. Operator & helper of dyeing. [...]... Knitting is the method of creating fabric by transforming continuous strands of yarn into a series of interlocking loops, each raw of such loops hanging from the one immediately preceding it The fundamental structure unit of a knitted fabric is the loop Any circular knitted fabric is composed of row after row of intermeshed loops Different types of fabric are made of different method of intermeshing the... exceed 3.7, whereas in case of carded yams, a twist factor up to 3.9 is tolerated of yarns for knitted fabrics In case of knitting yams a part of the yarn strength has to be sacrificed for a better and softer handle Yarns with low twist are used for knitted fabrics, yarns with high twist are used for crepe yarns Yarnswith average twist are used for regular woven fabrics 24 Effect of stitch length on color...      Yarn count Yarn twist Spinning system No of ply of the yarn Stitch length Yarn tension Required time (M/C running time); Take down tension Yarn quality Machine gauge Machine Diameter Machine rpm No of feeds or feeders in use Machine running efficiency Machine pitch (t) : Is defined as the distance between the centers of two adjacent Needle of the same needle row indicated in mm 25.4 Pitch... (E) : Machine gauge denotes the number of needles per inch , arranged On the needle carrier and based on the nominal machine diameter 25.4 Gauge (E) = mm Pitch Loops : It is a basic unit consisting of a loop of yarn meshed previously Basic unit at its base with Stitch : The smallest dimensionally stable unit of all knitted fabrics is the stitch It consists of a yarn loop which is held together by... method of intermeshing the loop The gross dimension of knitted fabric is simply a relation of average shape and size of individual loop There are several key variables in the production which affect the average shape and size of the loop After knitting the grease fabric is dyed to required shade and finished to required weight and width  Classification of knitting: Knitting Warp knitting Weft knitting... inspection of grey and finished fabric In this system, we count penalty point for different kind of defect as well as according to the defect size Different types of defect may come from yarn fault, manufacturing fault, transportation fault Parameter of penalty point:      Hole-H Rus Stain-RS Oil Stain-OS Missing Yarn-MY Fly/Contamination-F/c  Slubs-S  Needle drop-ND Four point grading system Size of. .. chart of Batch preparation: Receive the order sheet from in-charge Make the batch card on the priority of shipment date Take the Batch card which order have to deliver first Check the availability of the fabric Take require quantity of body fabric from the store Take collar/cuff as per size and keep the total weight Distribute the collar/cuff or Rib in each rope equally ensuring equal length Turn off... Quality assurance system of knitting division: The quality assurance department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing After collecting fabric rolls from different machines, these fabrics need to inspect thoroughly by the quality inspectors to assure required quality before dying Quality assurance of knitted grey fabric... knitted grey fabric is described here Quality control On-lineOff-line Quality control equipment: Following equipment are used to ensure proper quality of the produced fabric     Yarn tension meter Stitch length meter Magnifying glass GSM cutter etc On- line: 1 2 3 4 Grey GSM of the fabric Grey inspection Stitch length In coming good quality check Off- line: 1 Check diameter, GSM, unevenness, dead fiber,... loops of the other wales knitted t the same course are intermeshed in the other direction is called the double jersey Dial and cylinder are used to make this type of fabric Primary knitting elements: Needle: The needles are the most important stitch forming elements They are displaced vertically up and down and are mounted into the tricks or cuts of the knitting cylinder There are three types of needles . 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF BISWAS GROUP LTD. 2 TABLE OF CONTENTS Serial No COMPANY PROFILE GENERAL INFORMATION ABOUT THE COMPANY:  Biswas Group was established in 1985  Biswas Group deals in Apparels, Textile and Accessories.  Biswas Group have 9 fully. ManagerManagerManagerManagerManagerManager Mngr. Mngr.officer Assistant Senior AdminAccountsMarketingMaintenanceUtilitystore Assist Manager Officer OfficerOfficerOfficer Engineer Engineer Officer Officer Senior Assistant