INDUSTRIAL ATTACHMENT OF rupa fabrics ltd.

INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF RUPA GROUP LTD. Page 2 of 121 Report On INDUSTRIAL INTERNSHIP Course Code: Tex -4036 Duration: 6 weeks RUPA FABRICS LTD. Kunia, Barobari, Gazipur. Page 3 of 121 Objective The main object of our training is to gather the practical knowledge on various textile processes related with the industry. During the training period we have tried to meet the gap between theoretical and practical knowledge. As we are the students of wet processing technology so our main concern was about knitting, knit dyeing, knit finishing & quality control of knitted fabrics?. We have also tried to gather knowledge about machine maintenance and various utility services. Page 4 of 121 TABLE OF CONTENT Chapter No. Title page no. Chapter- 1 Introduction 6-8 Chapter- 2 Project Description 9 Chapter-3 Management System 10-12 Chapter-4 Raw materials 12-15 Chapter-5 Production Planning & Sequence of operation: 16-112 1.Knitting 16-34 2. Batching 35-36 3. Laboratory 37-541 4. Dyeing Section (Knit Dyeing) 42-57 5. Finishing Section 58-71 6. Garments 72-80 Chapter-6 Quality Assurance System 81-86 Chapter-7 Maintenances 87-90 Chapter-8 Utility Services 91-93 Chapter-9 Safety Management 94 Chapter-10 Store & Inventory Control 94 Chapter-11 Cost Analysis 95 Merchandising &marketing 96 Chapter-12 Social & Environment Information 96-106 .Chapter-113 Conclusion 107-109 Page 5 of 121 Page 6 of 121 INTRODUCTION By means of practical knowledge it’s not possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equaled important 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 provides 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, stillness about various processing stages. It also provides us sufficient practical knowledge about production management, work study, efficiency, industrial management, 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 be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at RUPA FABRICS LTD , which is a 100% export-oriented composite Knit Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing. Page 7 of 121 COMPANY PROFILE Name : Rupa Fabrics Ltd. Type : 100% Export Oriented Composite Knit Industry. Year of establishment : 2010(Dyeing Section) Investor : Md. Shahidul Islam Location : Kunia, Barobari, Gazipur. Certification & awards : ISO 9001:2000. Production capacity : Knitting: 4 tons/day Dyeing: 13 ton/day Sewing: 50,000 pcs/day Main Production : Basic T-Shirt, Long Sleeve, Sweater, T-Shirt, Polo Shirt, Pajama, Ladies, Kids Knitwear& all kinds of knit Garments & Knit fabrics. E–mail Address :rupa@citechco.net rupafash@bol-online.com Website : www.rupagroup.net Phone : 9292997, 9291704 Page 8 of 121 Page 9 of 121 History of the project: After successful operation in Rupa fabrics Ltd, the owner had decided to start a fully information & technology based along with the social accountability and quality controlled modern readymade composite knit garments industry in large scale. In this connection Shahidul Islam had decided in a resolution to start a company in Kunia, Barobari, Gazipur. Right from inception the policy of the company has been to provide total customer satisfaction by offering quality knitwear in time. To meet the commitments of quality and prompt delivery, Rupa fabrics Ltd Decided to integrate the manufacturing process in a planned manner. Over the years the entire process has been integrated by importing sophisticated machinery from world-renowned manufacturers. Vision & mission of the project The mission and vision of Rupa fabrics Ltd. is to manufacture and deliver high quality readymade garments (RMG) to its customers. The core objective is to attain and enhance customer satisfaction by providing on time delivery of desired quality readymade garments and also to increase efficiency of workforce. To attain these objectives, the management of Rupa fabrics Ltd. has decided to adopt the following- To increase awareness regarding customers requirements throughout the organization. By providing training to develop efficiency of the employee. To collect customer’s feedback regularly to know about their conception about their company and to take timely appropriate action. To reduce the percentage of wastage / rejection minimum by 2% per annum’s implement and monitor ISO 9001:2000 quality management system within the organization. Page 10 of 121 [...]... of 121 Production Planning & Sequence of Operation Production of the industry describe to the below sequentially given which may expresses the working principle of every operation: KNITTING SECTION Knitting: Knitting is the method of making fabric by transforming continuous strands of yarn into a series of interloping loops, each row of such loops forms the one immediately preceding it Flow chart of. .. Singapore, Indonesia, Korea, Japan Fabric : 01 RUPA Fabrics Ltd 02 Cotton Club (BD) Ltd Types of fabrics:               Single jersey Single jersey with lycra pique Polo pique Single lacoste Double Lacoste Fleece Rib Rib with lycra 1×1 Rib 2×1 Rib CVC Polyester PC Different Types of Dyes Used In RUPA FABRICS LTD with Their Brand Name: Page 15 of 121 Reactive Dye BRAND NAME COUNTRY NAME DY-STAR... ∆ ∆ ∆ ∆ Page 30 of 121 ∆ Image of Knitting M/c By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed A By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses will... depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop length is less compact In dark shade dye take up% is high so GSM is adjusted then Similarly in case of light shade loop length should be relatively smaller Factors that should be change in case of fabric design on quality change: a) Cam setting b) Set of needle c) Size of loop shape Methods of. .. production of knitted fabric can be increased – A By increasing m/c speed: Page 34 of 121 Higher the m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed B By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses... Page 23 of 121 Image of Grey GSM setting cylinder Rib M/C: a) 1*1 Rib fabric b) 2*2 Rib fabric Considerable points to produce knitted 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... to produce knitted 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 Effect of stitch length on... Production/shift in kg at 100% efficiency:  RPM  No of Feeder No of Needle SL( mm) 3527.80  Yarn count  Production/shift in meter: Course / min Course / cm RPM  No of Feeder  60  12  Efficiency  Course / cm  100  Fabric width in meter: Total no of wales Wales / cm  100 Total no of Needles used in knitting  Wales / cm  100  Page 32 of 121 Some points are needed to maintain for high quality... Salt Glubar Salt Marla OLS Detergent KRCP Rukozen-NZA Soaping agent Dekol ISN Erapon R Nerosoft-JS(an-ionic) Softener Nerosoft-NI(non-ionic) Kappa Soft BD Sandofix-EC Stabilizer Marla PS 100 Disperse Dye Black EX SF Yellow K 4GB Blue KFBL Crimson-XFT D-Red-XFT Orange-HWT Blue BBL Orange F-3R Red KRB Page 17 of 121 COUNTRY NAME Germany Switzerland Germany Germany China Chaina Chaina+Korea Switzerland...  ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ CAM SETTING ARRANGEMENT Page 27 of 121 Image of Cam with Cam box CAM SETTING ARRANGEMENT ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ D ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ Page 28 of 121 C Image of Cam box NEEDLE ARRANGMENT HL HL L 11 LS 11 22 N.B: ∆ = Knit cam H =High butt needle L = Low butt needle 1 = One butt needle 2 = Two butt needle Page 29 of 121 22 Image of Cam setting to the Cylinder Fabric: 2  2 Rib CAM . INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF RUPA GROUP LTD. Page 2 of 121 . Page 7 of 121 COMPANY PROFILE Name : Rupa Fabrics Ltd. Type : 100% Export Oriented Composite Knit Industry. Year of establishment : 2010(Dyeing Section). all kinds of knit Garments & Knit fabrics. E–mail Address :rupa@ citechco.net rupafash@bol-online.com Website : www.rupagroup.net Phone : 9292997, 9291704 Page 8 of 121