Industrial attachment of newtex composite textiles ltd.

Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF Newtex Composite Textiles Ltd. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 2 ABSTRACT: By means of the practical knowledge it’s possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge. In this report describe about our entire internship period. By this industrial attachment we can know about Impress-Newtex composite Textiles Ltd basic information. The internship paper provides knowledge about Knitting, planning, wet processing lab, dyeing, finishing, quality & dry lab. It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management, production planning and control, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on industrial attachment makes us reliable to accustomed with the industrial atmosphere & improve courage & inspiration to take self-responsibility. Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 3 CONTENT Topics name Page No. 1.CHAPTER -I 7-9 COMPANY PROFILE 1.1 General information About the Mill 1.2 Buyers of Impress-Newtex Composites Textile Ltd. 1.3 Site Location 2.CHAPTER -II 10-11 STRUCTURE OF THE ORGANIZATION 2.1 Organ gram of Impress-Newtex Composite Textiles Ltd 2.2 Shift Classification 2.3 Responsibilities of the officer 3.CHAPTER -III……………………………………………………………… 12-26 KNITTING DEPARTMENT 3.1 Knitting 3.2 Raw materials 3.3 Lay-out of knitting section 3.4 Specification of knitting department 3.5 Production flow chart of knitting section 3.6 Description of production process in Impress-newtex composite textiles ltd 3.7 Production parameter 3.8 DESCRIPTION OF IMPORTANT MACHINE PARTS 3.9 Types of fabrics produce in Impress-Newtex Composite Textiles Ltd. 3.10 Production Calculation 3.11 Knitting faults, causes & their remedies Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 4 4.CHAPTER -IV……………………………………………………………… 27-29 PLANNING DEPARTMENT 4.1 Planning department 4.2 Batch section 4.3 machines used in batch section 5.CHAPTER -V……………………………………………………………… 30-31 WET PROCESSING LAB 5.1 Dyeing laboratory 5.2 Lab Dip 6.CHAPTER -VI…………………………………………………………… 32-47 Dyeing 6.1 Raw-materials 6.2 Production planning, sequence & operations 6.3 sequence of operation for knit dyeing 6.4 Dyeing process 6.5 Process sequence of stripping 6.6 Lay out plan of Dyeing Shed 6.7 Specification 7.CHAPTER -VII……………………………………………………………….48-54 FINISHING 7.1Finishing 7.2Process flow chart of knitting finishing 7.3 Lay out Plan of Finishing Shed 7.4Specification of Finishing Section 7.5Objects of finishing machine used in Impress-Newtex composite Textiles Ltd. 7.6Data for Tumble machine 8.CHAPTER -VIII…………………………………………………………… 55-58 QUALITY CONTROL 8.1 Quality Management System 8.2 Objectives of quality control 8.3 Quality Management system in Impress-Newtex Composite Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 5 Textiles Ltd. 8.4 Analysis of different types of faults 8.5 Four (4) point system 9.CHAPTER -IX…………………………………………………………………59-63 DRY LAB 9.1 Different types of machine used in finishing lab 9.2 Short note on some tests 10.CHAPTER -X………………………………………………………………64-69 WTP & ETP 10.1 Water treatment plant 10.2 Standard water quality for dye house 10.3 Flow chart of ETP 10.4 Step wise function of different unit of E.T.P 11.CHAPTER -XI……………………………………………………………….70-73 MAINTENACE & UTILITY SERVICES 11.1 Maintenance 11.2 Utility servicess 12.CHAPTER -XII…………………………………………………………… 74 CONCLUSION 12.1Comments 12.2Some suggestions Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 6 CHAPTER-I COMPANY PROFILE 1.1 General information About the Mill Name of the Company : Impress-Newtex Composite Textiles Ltd. Type : 100% Export oriented Knit Dyeing Factory. Year of Establishment : 1996. Location : Gorai, Mirzapur, Tangail. Address: Factory : Gorai industrial area, Mirzapur, Tangail. Head Office : “Evergreen Plaza”(6 th Floor) 260/B, Tejgaon Industrial Area, Dhaka-1208 Project Cost : 100crores taka. Capacity : Knit Dyeing 22-24 tons per day Annual Turnover :Around 10 Lac U.S Dollar/year. Physical Infrastructure: Physical infrastructure of Impress-Newtex Composite Textiles Ltd. is simple one. It is constructed by steel structure; outside is brick wall, somewhere it is R.C.C. & brick wall structure. Vision: 1. To be one of the best leading composite mill in Bangladesh 2. To build a true marketing led enterprise with motivated workforce, innovative vision & more value added product portfolio, customer satisfaction & understanding of global market. Mission: Each of our activities must benefit and add value to the common wealth of our society. We firmly believe that, in the final analysis we are accountable to each of the Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 7 constituents with whom we interact; namely, our employees, our customers, our business associates, our fellow, citizens. Medical facility: Trained team of medical are formed in case of any emergency. Working environment: An excellent working environment exits in the factory with proper ventilation & light. No child labor work in the factory Certification & Award: ISO 9001:2008 certified Company. 1.2 Buyers of Impress-Newtex Composites Textile Ltd. Name/logo Country SWEDEN NETHERLAND Germany AUSTRALIA Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 8 1.3 Site Location Mirzapur Cadet College Impress- Newtex Group Karnafully Knit-Industries Ltd. Nabinagor Chandra West South North East Dhaka-M anikgonjRoad Dhaka- Tangail Road Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 9 CHAPTER-II STRUCTURE OF THE ORGANIZATION 2.1 Organ gram of Impress-Newtex Composite Textiles Ltd. Impress-Newtex Composite Textiles Ltd. is well equipped with highly efficient team of management, which is very essential for smooth running of a factory. Chairman Managing Director Director Executive Director Senior General Manager General Manager Deputy General Manager Manager Deputy Manager Assistant Manager Senior Executive Executive Junior Executive Supervisor Operator Assistant operator Helper Industrial attachment on Impress-Newtex Composite Textiles Ltd. Page 10 2.2 Shift Classification There are three shifts per day in Impress-Newtex Composite Textiles Ltd. So each shift contain eight hour. Shift Start End A 6:00 A.M. 2.00 P.M. B 2.00 P.M. 10:00 P.M. C 10:00 P.M. 6:00 A.M. General 9.00 AM 5.00 PM The factory runs 24 hours a day & 365 days a year. It maintains a strong working schedule which is shown in the chart below- Section No. of shift Duration Dyeing 3 shifts 8 hours each Knitting 3 shifts 8 hours each Finishing 3 shifts 8 hours each Inspection 3 shifts 8 hours each Staff & Commercial General shift(9am to 5pm) 8 hours Top management General shift(9am to 5pm) 8 hours 2.3 Responsibilities of the officer  General Manager (G.M):  Deals with the buyers & merchandiser.  Setting up price for the product  Planning, applying & controlling all administrative functions.  Following up the instructions of the Managing Direction & Chairman.  Arranging necessary facilities for the buyer’s demand.  Manager:  Planning for the sequence of operation.  Organizing necessary raw materials for the production  To follow the production & provide solution to the production problems.  Indicating reasons which are liable for less production.  Executive:  Follows the worker’s movement  Discuss with the manager what is going on the floor  Maintain production sequence  Check the sample at a certain time interval.  Setting program for the supervisor [...]... 70D, 75D, 100D, 120D, 150D Fig: Yarn Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 12 3.3 Lay out of knitting section Fig: Lay out of knitting section 3.4 Specification of knitting department 1  Machine no:  Brand: 1 PRECISION FUKUHARA WORKS LTD  Origin:  Model:  Size: Japan DXC-35 20 Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 13 2  Machine no: ... of the circular knitting machine Its control the speed of the machine Power Switch: To give the power to the machine Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 20 ON/OFF Switch: It help the m/c to start and stop Manual drive: To drive the machine manually Machine motherboard: All the Electronic parts are placed hear 3.9 Types of fabrics produce in Impress -Newtex Composite Textiles. .. cm RPM  No of Feeder  60  12  Efficiency  Course / cm  100 C Fabric width in meter: (formula)  Total no of wales Wales / cm  100 Total no of Needles used in knitting  Wales / cm  100  D Let, Fabric Type: Single Jersey Plain Number of Feeder: 90 R.P.M of Machine: 30 Machine Diameter: 30 Machine Gauge: 24 Count of Yarn: 24/1 Ne Industrial attachment on Impress -Newtex Composite Textiles Ltd.. . no Roll no Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 27 4.3 machines used in batch section 1   Machine name: Fabric inspection machine Brand: Uzu Fig: Fabric inspection machine 2     Machine name: Air turning machine Model no: DNAT-400 Brand: DONG NAM INDUSTRIAL CO., LTD Origin: Korea Fig: Air turning machine Industrial attachment on Impress -Newtex Composite Textiles Ltd.. . very important part of the machine It controls the quality of the product Altering the position of the tension pulley changes the G.S.M of the fabric If pulley moves towards the positive directive then the G.S.M is decrease And in the reverse direction G.S.M will increase Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 17 Pulley belt: It controls the rotation of the MPF wheel Brush:... Page 29 ↓ Second correction ↓ Grading of sample (A, B, C, D) ↓ Yarn and knit sample send to buyer ↓ Approved by buyer ↓ Order for bulk production ↓ Production card with approved sample and recipe send to production section Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 30 CHAPTER -VI DYEING 6.1 Raw-materials: In impress -Newtex Composite Textiles Ltd., the raw materials used for production... loop is formed in front of the old loop The old loop is then brought over the new loop to form the knitted fabric Knitting is different from weaving in the sense that a single piece of yarn can be used to create fabric The knitted fabric consists of horizontal rows known as courses and vertical columns of loops known as wales Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 11 3.2... availability of fabric Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 26 Take require quantity of the body fabric from ware house Make required no of rape maintaining equal length Take collar as per size, keep the total weight Distribute the collar/ cuff or rib in each rope equally ensure equal length Stitch the fabric Write down the weight against roll no in the back side of the batch... method of fabric construction, after weaving It is one of the several ways to turn thread or yarn into cloth It is similar to crochet in the sense that it consists of loops pulled through other loops In other words, knitting is the process of construction of a fabric made of interlocking loops of yarn by means of needles The loops may be either loosely or closely constructed, according to the purpose of. .. Baby Tery Industrial attachment on Impress -Newtex Composite Textiles Ltd Page 21  Fleece fabric  Terry Fleece     Pique Lycra single jersey Stripe fabric Grey Mélange (5%,10%,15% viscose) 3.10 Production Calculation: A Production/shift in kg at 100% efficiency :( formula) RPM  No of Feeder No of Needle SL( mm)  60  12 10  2.54  36  840  2.2046 Yarn count RPM  No of Feeder No of Needle . Industrial attachment on Impress -Newtex Composite Textiles Ltd. Page 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF Newtex Composite Textiles Ltd. . Industrial attachment on Impress -Newtex Composite Textiles Ltd. Page 9 CHAPTER-II STRUCTURE OF THE ORGANIZATION 2.1 Organ gram of Impress -Newtex Composite Textiles Ltd. Impress -Newtex. Objectives of quality control 8.3 Quality Management system in Impress -Newtex Composite Industrial attachment on Impress -Newtex Composite Textiles Ltd. Page 5 Textiles Ltd. 8.4 Analysis of