Liberty Textile (Project Proposal)

INDUS INSTITUTE OF HIGHER EDUCATION.

M.B.A – IV (EVENING)

• SUBJECT : BUSINESS RESEARCH

SUBMITTED TO: MR.

PROJECT:

RESEARCH PROPOSAL Proposal to study on Steam consumption

• SUBMITTED BY:

ZAHOOR AHMAD.

TABLE OF CONTENTS

Acknowledgment .............................................................................. .1Executive summary................................................................................2Problem statement ...................................................... 3Project goals.....................................................................................4Project time line.............................................................................5Motivation....................................................................5Back ground..............................................................................................6Introduction of Liberty Textile mills...........................................................................................6Types of energy used in textile industry..............................................................................................8Progress in relative field...............................................................................................10Importance of Boiler.......................................................................................13Identification of problems and its justification...........................................................................14Research method.....................................................................................15

INDUS INSTITUTE OF HIGHER EDUCATION

PROJECT PROPOSAL

ACKNOWLEDGEMENT:

“The hardest steel goes through the hottest furnace”

The same was the case with us. We faced many problems when we started the work

on Report. There was no any information about our research. But, we are greatly

thankful to Al Mighty Allah for enable us to get successfully through our

Responsibilities.

Very warm and special tanks to our respected teacher “Mr.Rana Tariq”

We also thank to

DYEING HOUSE MANAGER “BABAR KHAN”

ALL DYEING MANAGERS

ALL SENIOR MACHINE CHEMIST

And all whole technician of “LIBERTY TEXTILE MILLS”.

Who gives us a lot of information and pay full attention? And give real dedication

and devotion kindly for us.

Sir we thank full yours ability of extracting the very best out of us. For your

Patience and perseverance, and also for acknowledgement the efforts made by us

during the whole semester.

Thank you sir, God Bless You


PROJECT PROPOSAL

EXECUTIVE SUMMARY


PROJECT PROPOSAL

Problem Statement

The purpose of this proposal is to outline the need for a project that analyze the

Use of steam in textile industry. This project will seek answer the following

Question.

What is the use of steam in textile?

How can we reduce the steam consumption during process?

Is this step can able to cut down the cost of production?


PROJECT PROPOSAL

PROJECT GOALS

The result of this project will be suggest to reduce the production cost by reducing

Consumption of steam by use of better steam management and technology.


PROJECT PROPOSAL

PROJECT TIME LINE

The project will be completed according following schedule,

Initial research complete 2nd Class

Follow up research 3rd Class

Interviews/Questioner Completed 4th To 8th Class

Analysis of date completed 9th and 10th Class

Final report draft 11t Class

Final presentation submit 12th Class


PROJECT PROPOSAL

MOTIVATION:

Textile industry has a lion share in export of Pakistan, and these days in industry in

Troubles Because of high energy charges, in addition shortage of electricity , gas,

and water have depend the problem. Exports are also suffering due to high

Production cost then other competitor’s countries.

As we know that steam is one of the main source of dyeing and printing process and

Generate by gas and water through boiler.


PROJECT PROPOSAL

BACK GROUND:

This conservation of energy is an essential step we can all take towards overcoming

the mounting problem of the world wide energy crises and environment

degradation.

In particular, developing countries are interested to increase their awareness on the

inefficient power generation and energy usage in their countries. However, usually

only limited information sources on the rational use of energy are available,\.The

know-how on modern energy saving and conservation technologies should ,

therefore , be disseminated to governments and industrial managers, as well as to

Engineers and operators at the plant level in developing countries. It is particularly

important that they acquire practical knowledge of the currently available energy

conservation technologies and techniques.


PROJECT PROPOSAL

INTRODUCTION OF LIBERTY TEXTILE MILLS

Liberty Mills Limited, located in the industrial heart of Karachi, Pakistan,

was established in 1964. From humble beginning it is today one of the

largest textile processing and production unit in Karachi, Pakistan with a

production capacity of about 500,000 square meters of fabric per day. The

whole production is exported directly and indirectly to customers which

include vendors of internationally recognized brands, departmental stores

and mail order firms.

Liberty Mills Limited is an ISO 9001:2000, OE 100 and OEKO TEX Standard

100 Certified companies. Upgrading the quality of our products and

services, personnel, equipment and infrastructure is an ongoing feature of

our operation.


PROJECT PROPOSAL

TYPES OF ENERGY USED IN THE TEXTILE INDUSTRY

In general , energy in the textile industry is mostly used in the forms of

electricity, as a common power source for machinery, cooling and

temperature control system , lighting office equipment , etc; oil as a fuel for

boilers which generate steam; liquefied petroleum gas; coal ; and city gas.

Table 1 compares the energy consumption shares of various specialized

technical fields and it can be seen that energy consumption is relatively

high in the fields of dyeing and finishing ,fiber production , spinning,

weaving and clothing manufacturing.


PROJECT PROPOSAL

Specialized Technical Field

Fuel Electricity Total Share

Fiber production 32,551 21,498 54,049 21.0%

Spinning 3,224 44,262 47,480 18.4

Twisting 219 1,660 1,879 0.7

Textured-yam production 120 1,543 1,663 0.6

Weaving 4,467 24,848 29,315 11.4

Knitting 4,059 11,709 15,858 6.1

Dyeing 37,661 28,412 66,073 25.0

Clothing manufacturing 8,240 15,420 23,660 9.2

Others 5,959 12,000 17,959 7.0

Total 96,500 161,442 257,942 100.0

Note: Calculated from the Tabulated Industrial Statistics (Industry Volume)


PROJECT PROPOSAL

In 90’s UNIDO organized a Regional Meeting on Energy

Consumption as well as an Export Group Meeting on Energy Conservation in small

and medium scale industries for Asian countries. During these meetings , it was

Brought out that, for some energy intensive industries , saving up to 10% could be

Achieved through basic housekeeping improvements,

Such as auditing and energy management. The rational use energy calls for a broad

Application of energy conservation technologies in the various industrial sector

Where energy is wasted. One of these energy intensive industrial sectors to be

Consider to improve efficiency through the introduction of modern energy

Conservation technologies is the textile industry.

“In the textile industry, appreciable amount of energy could be saved or conserved

By regulating the temperature in the steam pipes , adjusting the air/fuel ratio in the

boilers, and installing heat exchangers using warm waste water.”

Currently, UNIDO, with the financial support of Japanese Government, is carrying

out a regional programmed on the promotion and application of energy saving

Technologies in selected Asian developing countries. This program aims at

adopting

these innovative energy conservation technologies, to the conditions of develop

countries. In this programmed, we are considering that the transfer of these

technologies could be achieved throgh


PROJECT PROPOSAL

A: Conducting surveys of energy usage and efficiency at the plant level.

B: Preparing manual on energy management and energy conservation / saving

Technologies, based on the findings of the above surveys;

C: Presenting and discussing the manual at seminars held for government

officials, Representatives of industries, plant managers and engineers;

D: Disseminating the manuals to other developing countries for their proper

utilization and application by the industrial sector.

INDUS INSTITUTE OF HIGHER EDUCATION PROJECT PROPOSAL

IMPORTANCE OF BOILER

As we know steam generate by boiler. Water, gas and electricity are the main raw

material of steam. If boiler is working efficiently there raw material use in very

Uncomely than generation of steam and if boiler is not work effecienlly their steam

Generation process become costly because heavy amount of gas and electricity use

During this process and amount of steam generate very pour. So, role of boiler and

Selection of boiler play a very important role in conservation of energy.


PROJECT PROPOSAL

PROBLEM IDENTIFICATION

During visit of “LIBERTY TEXTILE MILL” we discover that steam waist on

Following ways;

PROBLEM:

1: Steam lines are not in proper ways.

JUSTIFICATION:

If we re-arrange the steam lines we can reduce the wastage of steam.

PROBLEM:

2: High neglected attitude of machine staff concern steam line leakage.

JUSTIFICATION:

If machine staff inform about leakages it will be control.

PROBLEM:

3: Mechanical and electrical staff attitude also seems be very negative.

JUSTIFICATION: Maintenance staff works with loyalty. It can be helpful to minimize the leakage.


PROJECT PROPOSAL

PROBLEM:

4: Sensor and actuating valve often not working properly.

JUSTIFICATION: Sensor and actuating valve should be monitor because it control over all steam

consumption.

PROBLEM:

5: Fabric moisture is less than required moisture.

JUSTIFICATION: We can reduce steam consumption, if we put dryer temperature according

fabric.

PROBLEM:

6: Water chamber temperature also more than required temperature.

JUSTIFICATION:

We can also reduce steam consumption by putting water chamber temperature

according manually.


PROJECT PROPOSAL

RESEARCH METHOD

We did our research by filling questionnaire to the employees of “LIBERTY

TEXTILES MILLS” (Dyeing unit) .We categories our questionnaire sample in 3

Categories. The Question mode of questionnaire is investigative.

1: TOP LEVEL MANAGEMENT

We get filled 7 questionnaire sample by dyeing house manager , dyeing manager,

And assistant dyeing managers.

2: MIDDLE LEVEL MANAGEMENT

We get filled 17 questionnaire sample by supervisor and senior machine chemist.

3: LOWER LEVEL MANAGEMENT

We get filled 16 questionnaire sample by machine chemist and assistant machine

Chemist.

Question -1

Ever the company study on the wastage of steam

Management Level All the Time

Some Time

Never No Idea

Top Management 7

Middle Management 13 4

Lower Management 4 8 1 3

Total 24 12 1 3

Conclusion : 60% All the time agreed that management study on wastage of steam while 30%

some time 2.5% never and 7.5% have no idea.

Question -3

Management is satisfied with the design of steam consumption system


Some Time

Never No Idea

Top Management 1 5 1

Middle Management 4 12 1

Lower Management 2 9 5

Total 7 26 7

Conclusion : 65% employee believe that management some time satisfied with design of steam

consumption while 17.5 with all the time and 17.5 have no idea

Question - 4

Ever you realized that company need to redesign the system of streamlines or other areas where steam is in use


Some Time

Never No Idea

Top Management 5 2



Total 19 14 1 5

Conclusuin : 47.5% employees belive that company realised to redesign the steam system while

35% belive with some time 2.5 realised never and 12.5% have no idea

Question -5

If company studded on it so, management introduced any system to reduce the consumption of system


Some Time

Never No Idea

Top Management 5 2



Total 20 19 1

Conclusion : 50% belive that company improved system to reduce the consumption while 47.5

believe on some time 2.5 think never.

Question - 6

Have the system is implemented


Some Time

Never No Idea

Top Management 5 2



Total 24 14 1 1

Conclusion : 60% employees believes that system have been implemented 35% says some time

2.5% think never and 2.5 have no idea

Question - 7

Interest of company to improve boiler efficiency in consultation with the consultants


Some Time

Never No Idea

Top Management 7


Lower Management 3 13

Total 12 8 20

Conclusion : 50% have no idea about boiler efficiency while 30% believe all the time 20% believe

with some time.

Question - 8

Trend of management about training and development


Some Time

Never No Idea

Top Management 4 3


Lower Management 16

Total 4 6 30

Conclusion : 10% says all the time 15% think some time75% have no idea

Question - 9

Management supplies of related material/literature to the machine staff about the use of new technology on steam


Some Time

Never No Idea

Top Management 7

Middle Management 17

Lower Management 16

Total 30

Conclusion : 100% employees says no literature is being provided to machine staff

Question - 10

Machine staff is informed about less or excess stem consumption than production


Some Time

Never No Idea

Top Management 7


Lower Management 16

Total 30

Conclusion : 100% employees believed never

Question -11

Logbook/history data is maintaining for individual machine on daily basis and it is shared with all concerned.

CONCLUSION: 45% says all the time, while 53% says some time

Question -12

Management LevelAll the Time

Some Time

Never No Idea

Top Management 7



Total 18 22

Appraisal or punishment system to staff is existing and implementing

CONCLUSION:97% employees says never know while only 2.5% says all the time.


Some Time

Never No Idea

Top Management 7


Lower Management 16

Total 1 39

Question -13Company staff having technical skills

CONCLUSION: 72.5% all the time while 22.5% are some times.


Some Time

Never No Idea

Top Management 7



Total 29 9 1

Question -14Machine staffs are aware about the moisture required for different fabric on different process.

CONCLUSION:40% says all the time,47.5% says some time,7.5%says never and 5%don’t know.


Some Time

Never No Idea

Top Management 5 2



Total 16 19 3 2

Question -15

Machine staffs are aware about the temperature of different areas of machine required for different process.

CONCLUSION:97.5%employees agree to alla the time while 2.5% say never

Question -16


Some Time

Never No Idea

Top Management 7



Total 39 1

Existing staff is capable to handle the issues and complaints about the steam leakages.

CONCLUSION: 97.5% employees agree to all the time and 2.5% says never.


Some Time

Never No Idea

Top Management 7



Total 39 1

Question -17

Response of machine staff if any error is formed in parameters.

CONCLUSION:25% employee agree to all the time , while 75% says some time.

Question -18


Some Time

Never No Idea

Top Management 7



Total 10 30

Yours efforts are apprized by the management for the process

CONCLUSION:12.5% says all the time , 25% says some time while 62.5% agree to never.

Question -19


Some Time

Never No Idea




Total 5 10 25

Supervisor’s trend for feed book of employee/machine staff how they are performing towards achieving the result expected

CONCLUSION:15%employee agree all the time , 65% say to some time while 20% says to never.

Question -20


Some Time

Never No Idea




Total 6 26 8 3

They monitor the safety valves

CONCLUSION: 47.5% employee agree to all the time 50% don’t know while 2.5% says never.


Some Time

Never No Idea

Top Management 7



Total 19 1 20

Documents

Liberty Textile (Project Proposal)