54

Knitting Parameter

Machine diameter.

Machine gauge.

Number of feeds or feeder in use.

Machine RPM.

Count of yarn.

M/C running time.

Running efficiency

.

Calculation of the Production

Production/Shift in Kg

( )

( )

Production/Shift in m

Fabric Width in m

55

56

Production calculation for fleece fabric and fleece yarn %

Count S. L

Surface 30 Ne 4.30

Binder 75D 2.80

Loop 20/2 1.60 No of the feeder = 108

Production for the surface:

Production for the binder:

Production for the loop:

Total = (43.84+12.08+48.94) = 104.86 kg/shift % for the surface yarn = 41.80 % % for the binder yarn= 11.52 %

for the loop yarn= 46.67

57

Chapter 6

Quality Assurance Systems

58

Quality Assurance System All rolls are kept in front of the inspection m/c time to time and are inspected over the grey inspection

m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, bare marks,

fall out, contamination, fly, holes, oil lines, needle lines, slubs etc are recorded in grey inspection

report to classify the fabric based on the four point system.

Collar & cuff are inspected visually under light box, any major & minor faulty collar/cuff like having

wrong ply, hole, needle lines, slubs, wrong design, first line problem etc properly counted and

recorded.

Quality Assurance Procedure

Based on the sequence of grey inspection, the inspector serially numbers each roll ensuring that all

rolls having the knit card with complete details of the roll.

a) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from the cloth or batch

roller and they are carried to inspection section by the helpers.

b) Almost four inspection workers are for every shift to check the fabric rolls. For any kind of

fault they are checked thoroughly. Skilled inspectors find them and indicate them by the

scissors in some cases.

c) Quality is specified on the basis of 4-points system. Here is the point distribution for different

kinds fault in this system:-

List of Quality Assurance Equipments Inspection m/c

Scissors

Weight balance & Micro balance

GSM cutter

Four Point Grading System

Size of defects Penalty

3 inches or less 1 point

Over three inch but not 6 inch 2 point

Over 6 inch but not 9 inch 3 point

Over 9 inch 4 point

59

Rejection Criteria for Body & Rib

Rejection Criteria for Collar &Cuff

Faults Response

Wrong ply Reject

Hole Reject

Needle line Reject

Slubs Reject

Wrong design Reject

Wrong tripping Reject

Fly & contamination Acceptable for color but not for white

First round problem Reject

Uneven tension Discuss with manager

Missing yarn Reject

Crease line Reject

Rust line Reject

Oil stripe Reject

Thick-thin Reject

Wrong tube Reject

Faults Response

Needle marks Major needle line is rejected.

Stripe Major needle line is rejected.

Bare marks Rejected

Slubs 1 point

Wrong design Rejected

Pin holes 1 point

Fly & contamination Acceptable for color but not for white

Sinker marks Do

Uneven tension Discuss with manager

Missing yarn Use 4 point

Crease line Do

Uneven tension Discuss with manager

Oil stripe/line Do

Thick-thin place Rejected

Mixed yarn Discuss with manager

60

KNITTED FABRIC FAULT AND REMEDIES

1. HOLE:

Causes: • Excessive dirt on feeder • Take up in improper tension • Improper match of count and stitch length

Remedies: • Keeping the feeder clean as well as m/c should also be

cleansed • Adjusting proper take up tension • Adjusting count and stitch length

2. KNOT:

Causes: • After thread breakage or bobbin end, Twisting to join thread ends; therefore Hand

dust get incorporated with yarn.

Remedies:

Knotting should be done in proper way.

Need skill full worker.

3. DIRTY SPOT

Causes: • Externally incorporated dirt, lint, grease etc . • Dead insect.

Remedies: • By keeping the work place and m/c clean.

Using cleaning precautions and material like poly bags to store.

Hole

Knot

Dirty spot

61

4. SINKER MARK:

Vertical line is found at Wales’s direction. (Back side)

Causes: Due to sinker decayed.

Due to faulty adjustment of sinker with sinker cam.

Remedies: Change the sinker.

Make necessary adjustments of sinker with sinker cam

as required.

Don’t use sinker for long time.

5. LYCRA OUT :

A lycra yarn missing at horizontal direction.

Causes: If lycra yarn missed or breakage happened.

Remedies: Operator should be more cautious to make

necessary adjustment or replacement or joining the lycra yarn.

6.OIL SPOT :

Oil spot on fabric surface. It may be created both Wales and coarse wise.

Causes: Excessive supply of oil at different friction point.

If there is any type of problem in needle and sinker, oil can be bleeded on the fabric.

Remedies:

Proper lubrication system is must.

Change the faulty needle and sinker.

Machine should be cleaned time to time.

Sinker Mark

Lycra out

Oil Spot

62

7. Set Up/Press off:

Found loop gape on knit fabric.

Causes: Press off occurred when needle and sinker both

inactive simultaneously in the process of knitting.

Remedies: Machine should be stopped as early as possible.

8. FLY YARN CONTAMINATION:

Causes: For proper m/c settings and management problem.

Less care of worker.

Remedies: Use separator from one m/c to another.

By cleaning the floor continuously.

Worker must be careful.

Set Up

Fly Yarn Contamination.

63

Lab & QC

Introduction

The Quality assurance Department is assigned to maintain consistently uniform quality of the

material in process and various stages of its manufacturing. SKFL is more about concern about

quality. In this factory quality assurance is more preferred than quality control, but both are in

advancement. After collecting fabric rolls from different M/Cs, they are needed to be inspected or

assured required quality by the quality inspectors as if there were no big production hampered and no

complain from the buyers. Here are the details about it.

Objects of Quality Control

1. Research.

2. Selection of raw materials.

3. Process control.

4. Process development.

5. Product testing.

6. Specification test

Scope of Quality Control

1. Testing lab

2. Machine auditing system

3. A good training system

4. Excellent analytical back up

5. Technical expertise

64

Quality Control Flow Chart

Yarn receiving

Sample Knitting

Batching

Dyeing (Check shade & Faults of dyeing)

Dewatering or slitting

Drying (Check diameter, Pretreatment, Shrinkage Spirality

and GSM)

Compacting

Final inspection

If sample OK go for bulk production

65

Quality Control in Grey Fabric Inspection

Some Points Are Needed To Maintain For High Quality Fabric

a) Brought good quality yarn.

b) Machines are oiled and greased accordingly.

c) G.S.M, Stitch length, Tensions are controlled accurately.

d) Machines are cleaned every shift and servicing is done after a month.

e) Grey Fabrics are checked by 4 point grading system.

Quality Control in Dyeing and Finishing

The SKFL assures the quality of the products of dyeing section in the following three steps:

1. In laboratory

2. In Dyeing section &

3. In Finishing Section

Procedures are described below:

In laboratory

Swatch card from buyer according to their requirement

Recipe prediction for sample dyeing

Sample dyeing until matching with swatch card

Fastness & other tests of the fabric or yarn are done here.

In dyeing section

According to the buyer’s sample, sample dyeing is done in sample dyeing

machine in dyeing shed & again matched with the approved sample.

If result is OK, then bulk production.

During dyeing, samples are taken until accurate shade matching. The interval may

be 30-40 minutes.

After dyeing sample is collected after softening matching is done.

Last of all, sample is collected after fixation & matched.

Then allowed the fabrics to be finished.

In finishing section

By using a series of finishing machines correct width, softness & appearance are

maintained according to requirements.

Then sampling is done for several times to test GSM, Shrinkage & fastness

properties. Finally fabric is inspected & prepared for delivery.

66

Physical Lab

Dimensional stability test:

Working Procedure:

R&D garments

After finishing sample receive

Conditioning

(4hrs,temp-20 degree,flat,R.H-65)

Template (50cm*50cm/35cm*35cm)

Sewing

(3 sides sewing, length side open)

Washing

(60 degree,time-65min,m/c rpm-1105,m/c load- min 2kg)

Drying (Line/flat/tumble)

Measurement

67

Measurement:

Shrinkage

* 100%

Shrinkage calculation (for S/J fabric):

Lengthwise

= 34.33 ; Shrinkage% =

*100 = -1.9

Widthwise

=33.57 ; Shrinkage% =

*100 = -4.095

Spirality calculation:

Distortion

Spirality

* 100%

For 1*1 Rib:

Distortion

= 3.05

After length

= 48.05

Spirality

* 100%

*100%

= 6.34%

For S/J:

Distortion

= 2.25

After length

= 46.75

Spirality

* 100%

*100%

=4.81%

68

GSM TEST

Specification of GSM cutter:

Name: G.S.M CUTTER

Manufacturer: James H.Heal & Company limited.

Origin : England

GSM Test

Procedure of GSM measurement by GSM cutter :

1. Cut the fabric with the G.S.M cutter.

2. Weight the fabric with the electric balance .

3. The cut sample is 100 sq.cm. The weight of the cut sample is multiplied by 100.

4. The result is the G.S.M of that particular fabric .

Suppose ,

The weight of the fabric is 2.51 gm. That means the G.S.M of the fabric is 251 gm.

69

Chapter 7

Maintenance

70

Maintenance:

Maintenance of machineries is very important for any type of industries and it is a must for a knit

composite mill. All machines and machines parts of knitting, dyeing and garments are maintained

with extreme care. Because production quality and quantity, both depends on the maintenance

with regularity. Square knit fabric Ltd. ( SKFL) leads maintenance with a troop of skilled mechanical

fitters.

Maintenance of machinery:

In the knitting floor of SKFL all circular and flat knitting m/cs are maintained regularly and as

necessity requirements. Here, different type of maintenance of machinery, which is taken, different

time on the machineries.

Routine:

Maintenance of circular knitting machine:

Lubrication:

Since the life of the m/c and its correct working depend to a large extend adequate and

proper lubrication. It is recommended that the instructions given in the lubrication charts be

followed conscientiously. The Company can not be need responsible for faults that arise from

wrong or inadequate lubrication.

Routine of maintenance

71

Oiling Needles & Jacks:

Too much oil is preferable to too little. Dark vertical lines in the fabric originate not from

excessive oiling but from too much friction between needle and jacks and the trick walls on account

of lack of oil. Should dark vertical lines makes their appearance is recommended that the

appropriates m/c parts be flooded with oil. This will cause heavy soiling or ht fabrics but the trouble

will disappear quickly correct quantity of oil then can be applied. The supply of oil should be

reduced if light oil striper appears on the fabric.

The Cleaning of Needle & Jacks:

Thin oil is most suitable for this work, about one point heated to a temperature not exceeding

160ºF poured into the oiling position of the cylinder & dial cam races & in the heads of the needles

while the m/c is running. The fabric will found to be cleaned again after few yards have been

knitted. How often cleaning is necessary will depend upon what kind of yarn is being used.

Synthetic yarn cleaning is taken place at lest monthly, yarn with absorbent properties being knitted

at same time.

72

General Cleaning Schedule:

Long m/c life, maximum output & trouble free running depend upon proper care and

maintenance. A general overhaul should take place annually when single shifts are worked &

correspondingly at more frequent interval. When extra shifts are worked. The overhaul involves

removal of all cam section and removal of needles and jacks from their tricks, so tat the tricks

should be thoroughly the cleaned. Before parts are replaced they should be adequately lubricated.

Maintenance Procedure:

1) For there is any mechanical fault of machine which is responsible for

production hamper, operator informs mechanical fitters in duty. Mechanical fitters come

and observe the problem firstly, and then they begin to fix it.

2) If mechanical fitters be unable to fix it, then they inform technical in-charge, he

then comes in spot and fix it.

3) For there is any electrical problem of machine or serious founding

mechanical problem, mechanical and electrical department are informed, they come and

fix the problem. They commence at work after informing of knitting manager. There are

two mechanical engineers in the department.

4) For restorative maintenance, senior production officer orders mechanical

fitters to fit required machine for cam and needle arrangement and other necessary

requirements in case of new design development.

73

Maintenance sequence of circular knitting machine:

Power on/off

↓

MPF/Positive feeder current line off

↓

MPF belt out/loss

↓

Yarn cut

↓

Fabric out by handle

↓

Cleaning and Oiling

↓

Cam box out

↓

Needle & sinker out

↓

Needle & sinker cleaning by oil

↓

Cam box cleaning by air

After opening & cleaning, m/c is leveled by using leveling meter and follows the reverse process to

ready the m/c.

74

Maintenance tools/equipment & their functions:

Maintenance tools/equipments Functions

1. Adjustable wrench Used for setting nut & bolts

2. Air suctioner For cleaning machine

3.Spanner Fixed Spanner for nut & bolts fitting

4.Socket spanner Handle system for nut & bolt fitting

5. hammer To apply load where required

6. Screw driver To release any screw

7. Punch Used to fit any worn out shaft

8. Lock opener To open the clip of bearing

9. Hack saw To cut any metallic thing

10. Outside calipers To measure outside dia

11. Inside calipers To measure inside dia

12. Cutting pliers To cut thin wires

13. Pulley key To loosen pulleys

14. Chain ton To lift heavy load

15. Welding machine To join metallic parts

16. Grinding machine To make the smooth fabrics

17. Tester To test electric circuit

18. Pliers To grip anything & cut anything

19. Star driver Screw unlocking

20. Steel tape To measure length, width & height

21. Chisel To cut any metal

22. L-key For loosen & tighten the screw

23. File To smooth the rough surface

75

Different types of maintenance tools:

Hammer Double ended wrench

Adjustable wrench One ended wrench

L-key

76

Weekly

Clean the glass electrode of pH meter.

Check the filter net of dosing pump.

Check the current of air pressure.

Clean air filter of blower (monthly).

Every 4 month

Calibrate the PH meter with buffer solution, 7 & 4.

Calibrate the blower meter,

Grease the oxygen meter.

Grease the scraping, bridge, bridge wheel of ball bearing.

EVERY 2 YEAR

Grease the spring ball bearing.

Change the oil of sludge transfer pump.

Change the oil of feed pump.

Change the oil of lifting pump.

Change the oil of sludge blower.

Change the sensor of oxygen blower (if necessary).

Change the electrode of pH meter (if necessary).

Change the oil of dosing pump.

Change the oil of scraping grease motor

Remarks:

This mill has a strong maintenance fitter’s troop to fix up all types problem. Two

groups of two shifts obey their duties responsibly and sincerely. With their different tools

or equipments they perform their duties skillfully.

77

CHAPTER 8

UTILITY SERVICE

78

Description of the Utilities

Utility Facilities Available:

The following utility facilities are available at SKFL Water.

- Steam.

- Electricity.

- Gas.

- Compressed air.

Source of Utility:

1. Water- Own supply (Pump)

2. Steam-Own supply (Boiler)

3. Electricity-Generator & PDB

4. Gas- Titas Gas Transmission & Distribution Co. Ltd.

5. Compressed air- Own supply (Air compressor)

Water Conditioner

Raw water hardness: 18-20 0 (Generally 30 ppm)

Boiler water hardness: 0 0

M/c used: Water conditioner

Submergible pump : 2 (For SKFL) & 1 (For Dormitories)

Process water: 200m3/hr and 150 m3/hr

Domestic use: 150 m3/hr

Company: Cleaver Brooks

Country of origin: USA.

Water consumption: 4500-5000m3/day

Water pressure: 6-6.5 bar

Water conditioner machine

79

Steam:

Fig: Fire tube type gas boiler

Boiler Steam: 10.2 tons/hr. & 2.3 tons/hr.

Steam pressure: 7.5-8 bar

Steam temp: 150-160 0 C

M/c used: Fire tube type Gas Boiler & Exhaust Gas Boiler

Piece: 02 (Fire tube type Gas Boiler) & 01 (Exhaust Gas Boiler).

Capacity: 10.2 tons/hr. & 2.3 tons/hr.

80

Application:

1. The major portion of the steam is supplied to the SKFL. Dyeing section.

To heating the drying Cylinder.

To heating the calendar rollers.

Heating the chemicals liqor.

2. Garments section

For steaming and ironing.

Power Supply:

Fig: Electricity Gas Generator

Supply: Titas Gas Transmission & Distribution Co. Ltd.

M/c used: Electricity Gas Generator

Brand: Cater Pillar

Origin: USA

Piece: 05

Total Capacity: 5.6 MW (1 MW+1 MW+1 MW +1 MW+1.6 M

81

Chiller:

Fig: Chiller

Hot water chiller

Vapour absorbent chiller

Vapour compression chiller (Centrifugal Chiller)

Flue gas with steam absorption Chiller (Dual core chiller)

Brand:

Prochill

Thermax

Brand: Prochill

Thermax

Brand: Mc Quay Brand: Shuang Liang

Capacity:

400 rt/hr.

Capacity: 400

rt/hr.

Capacity: 400 rt/hr Capacity: 661 rt/hr.

Origin:

India

Origin: India Origin: USA Origin: China

Application:

The maintenance of relative humidity and temp is very important for knitting to

reduce yarn breakage and produce quality fabric. The chiller maintain required amount of

relative humidity (80 – 85%) and temp (22 – 26ºC) in all section of SKFL.

82

Air Compressor:

Piece: 07 Brand: BOGE (No. of machine 6) &

ROLL AIR (No. of machine 1).

Country of origin: Germany

Capacity: 6 m3 /hr

To reservoir

Fig: Working principle of air compression

Application:

1. The major consumption of compressed air is in knitting section.

2. To the air gun for yarn insertion

3. To clean different section and machinery

4. To the sensors where pneumatic pressure required (computerized control machines).

5. For the compensator movement.

6. Pneumatically controlled loading and unloading of yarn dyeing machinery

7. Pneumatically controlled loading and unloading of different machinery.

Air filter

Cooler

Screw compressor

Motor

Oil

filter

Oil tank

Separator

BOGE Air compressor

83

Cooling Tower:

Fig: Cooling Tower

Use in: Generator

Country of origin: Thailand

Piece: 12

Fig: Coiling system of Gas Generator

84

Effluent Treatment Plant (ETP)

Square Knit Fabrics Ltd. is very much concern about its effluent, for this reason they

established two effluent treatment plant and they are ETP-I (capacity1200 m3 per day) &

ETP-II (capacity 3000m3 per day). The ETP in SKFL is a biological one. Here bacterial and

protozoa are the catalyst of biochemical reaction to convert the toxic material into

environmental friendly gases and substances. The initial cost of biological ETP is more but it

has a low running cost if control is greater.

Reaction Time:

8-12 hr for secondary treatment

50 m3/ hr for secondary treatment

3-4 ppm/30-35c(for proper bacterial action)

Quantity of micro-organism 1:4

Total capacity of ETP plant: 1200 m3 /day + 3000 m3/day = 4200 m3/day.

Sludge removes level: 800 MI/ 1/2hr f

85

Effluent Analyzing Report:

Parameter Unit Quantity Std. Value

PH 7.5 6-8

COD mg/lt 39 150-200

BOD5 mg/lt 23 29-50

Color APHA/Pt.Co 335 220-250

Phosphate mg/lt 3.2 5-15

Sulphate mg/lt 560 1000

Ammonia mg/lt 2.50 5-10

Chloride mg/lt 120 500-600

Nitrate mg/lt 6.16 08-10

TSS mg/lt 80 60-80

TDS mg/lt 2075 2100

Chlorine mg/lt 0.1 1

Nitrite mg/lt 0.21 >1

Sludge (wet) ml / ½ hr 800-820 700-800

Ref:

USPEA (United States Environment Protection Agencies)

IWRA (International Water Resources Association)

GOB (Government of Bangladesh)

86

Typical flow diagram of a Physical-Chemical and Biological treatment

Plant in Square Knit fabric Ltd (SKFL):

Influent of

Factory effluent

Activated

Sludge

Sludge disposal

Treated effluent

Equipments for ETP Laboratory:

o HACH method (for measuring BOD & COD)

o BOD Incubator

o Electric Shaker

o Reflex Condensat for COD measuring

o PH meter

o TDS meter

o Inhoff con for measuring sludge quantity

o Desiccators

o Separating funnel

o Electric Balance

o COD Reactor

UHRSCC

Equalization Unit Screening Unit Coagulation Unit

PH control Unit

Aeration Unit Primary

Sedimentation(Primary

sludge pit) Flocculation Unit

Sludge dewatering Unit

(Centrifuge) Sludge thickening

(Centrifuge)

Sedimentation Unit

(Lamella)

Chlorination

87

Parameters of ETP:

Waste water outlet 3000 m3/day

Treatment capacity 1500 m3/day

Running cost 2 – 4 Tk./m3

Plant capacity 1200 m3/day

Bacterial: Protozoa 60:1

Sludge collection at 60 – 70 %

Screen allowance 1 in2

PH 6.5 – 8

Dissolved oxygen (DO) 2 – 3 ppm

Outlet water temperature 30 - 35ºC

Dwell time for effluent discharge 48 hrs. (For oxidation tank)

Bacteria in oxidation tank: Protozoa:

Bacilli Paramecium caudatum

Cocehi Euplotes

Beggiatoa Vorticella dutrina

Spirillum Colpidium

88

Biochemical Reaction:

Bacteria decompose the organic matter and other matters are related with oxygen by microbial action i.e.

biochemical reaction and produce gases and free radicals.

Metals are bio-chemically reacting with the enzyme and produces gases.

Mn + O2 Enzyme MnO2

Organic radicals Gases and free radicals

C

+ O2

ORGANISMMICRO

CO2

H H20

N NO3

S SO42-

P PO43-

Process Water Test Report Sl. No. Water quality parameters Unit Dye house standard Test result

1. PH - 6 to 8 6.23

2. Color Pt.Co 5 2.0

3. Turbidity NTU 2 1.0

4. Total Alkalinity as CaCO3 mg/lt 150 46

5. Chloride mg/lt 100 8.7

6. Total Hardness as CaCO3 (TH) mg/lt 2o Gh = (2X17.85) = 35.7 ppm 16.45

7. Manganese (Mn) mg/lt 0.1 Nil

8. Iron (Fe) mg/lt 0.1 0.02

9. Total Dissolved Solid (TDS) mg/lt 100 to 180 145

10. Sulphate mg/lt 100 1

11. Oil & Grease mg/lt Nil -

12. Arsenic (As) ppb 0.005 -

13. Dissolved Silica mg/lt - 42.6

Note: Sample Collection from Hanks Dyeing Area

89

Caustic Recovery Plant (CRP)

Square Knit Fabrics Ltd is very much concern about the environmental issues. Here a large volume of

caustic both liquid and solid used in different wet processes as a basic chemical. In case of Yarn and

Fabric Mercerization most of the liquid caustic produced and effluent containing caustic produced.

The recovery of these caustic of 2º to 5º Be concentration is beneficial for cost minimization and

reduction of effluent which may cause environmental hazard.

Fig: Caustic Recovery plant (CRP)

Few Parameters:

Inlet steam pressure 7 – 8 bar

Vacuum condenser pressure 0.3 – 0.4 bar

Condenser temperature 70ºC - 75ºC, Pressure 2 bar, Flow 60lit/80sec

Weak lye temperature 35 - 37ºC, Concentration 5-6ºBe

Strong lye temperature 75 ºC - 85ºC, concentration 28 - 30ºBe

1st stage:

o Shell side steam pressure 1.2 – 1.6 bar

o Shell side temperature 120 – 130ºC

o Pipe temperature 110 – 115 ºC

2nd stage:

o Shell side temperature 110 ºC

o Pipe temperature 90 – 100 ºC

3rd stage:

Shell side temperature 85 -100ºC

Pipe temperature 70 - 85ºC

90

We

ak ly

e

tan

k

Pre Heater

Pre Heater

Heat Exchanger

Heat Exchanger

Evapura

tor

Evapura

tor

Heat Exchanger

Evapura

tor

Condenser

Se

dim

en

tatio

n

tan

kS

tron

g

lye

tan

k

He

atin

g S

tea

m in

let

Ste

am

inle

t

Fig

: Shhem

atic

dia

gra

m o

f Caustic

Recovery

Pla

nt

91

Recovery Process:

Effluent reached to weak lye tank Concentration is 2º - 5º Be

Pre heating done in pre heater Temperature 60ºC - 65ºC

Boiling occurs in 1st Heat exchanger Temperature 120ºC

Evaporation of water in 1st evaporator Concentration 10ºBe

2nd Heat exchanger Temperature 114ºC

2nd Evaporator Concentration 20º Be

3rd Heat exchanger Temperature 84ºC

3rd Evaporator Concentration 30º Be

Vapor

Condensation at condenser (Condense flow rate)

Strong lye tank / sedimentation tank

Dosing H2O2

Strong lye tank

Mixing tank

Mixing with pre stored caustic (1litre 30o Be Caustic + 25 gm Solid Caustic)

Concentration 40ºBe

92

Rain Water harvesting

Rain water is collected here.

Remarks:

SKFL is using 0-5deg (total) hardness water which is suitable very for dyeing. The underground water is free

from hardness creating metals and eliminates the need for water treatment plant. The electricity supply

system is very good and fluently. It is fully equipped to produce its necessary power. Its capacity of power

generation is increasing with another two generators to be established. The constant pressure of water also

eliminates the need for high rise water tank and maintains flow speed in different machines.

93

Chapter 9

Store & Inventory Control

94

STORE & INVENTORY CONTROL

Inventory is planning and execution involves participation by most of the fundamental segment of business

sales, production, purchase, finance and accounting. Inventory is a wider sense is defined as any idle resource

of an enterprise however it is semi-finished packing spares and other stocked in order to meet an expected

demand or distribution.

Objectives of inventory control:

1) Financial activities:

a) To save amount of investment

b) To know the cash position

2) Property Protection:

a) Preventable waste

b) Insurable damage

c) Unauthorized use

3) Operating:

a) To obtain the best overall balance between production and inventory carrying cost.

b) To minimize losses

c) To avoid stock out and to keep inventory holding costs in costs in balance.

95

Inventory system:

For Raw Materials:

In this factory, Square knit fabric Limited, raw materials are yarn of different type, different count

and of different spinning mills of home and abroad. As according to knitting section demand yarn is

either imported or bought from spinning mills and they are kept in the store for raw materials in

accordance with type and count. As like as polyester, cotton, lycra are kept separately and also to

their count variation. Inventory office

keeps record of this raw materials

amount, their usage and storage.

Central Yarn Store

For Dyes and Chemicals:

There is a different store for dyes and chemicals. Vanes types of dyes and chemicals are stored here

according to dyes and chemicals companies. Different types of dyes and chemicals are listed in a

sheet. In the sheet the stored quantity of dyes and chemicals are also included. Every day the sheet

is updated and a copy of this sheet is supplied to the dyeing manager, dye house and lab sectio

96

For Spares:

Different spares parts of knitting machines and other equipments are kept in store as

inventory so that there are no time and money losses while it is being used. Here is the list of spare

parts as inventory:

1) Needle detector

2) Fan

3) Air gun

4) MPF belt tensioning device

5) Air nozzle

6) Fabric spreader

7) Fabric light

8) Compressor line + pipe

9) Air blower

10) Memminger

11) Oil Tank

12) Fabric roller

13) Inverter

14) Yarn Guide feeder

15) Oil Nozzle

16) Cam box

17) Magnet

18) VDQ pulley

19) Fan broker

20) Oil Meter cover

21) Oil plutonic

22) Air meter cover

23) Knot catcher

24) Feeder ring bolt

97

For Knitted Fabrics:

After knitting the fabrics are collected according to roll form. There is a big store room beside

knitting section in this factory and fabric rolls are stored here according to fabric types and some

specification is given to fabric rolls such as buyer name, yarn count, lot no, fabric type, m/c no, fabric

weight etc. Collars and cuffs are also stored in this room. A store keeper always does this job

successfully.

For Finished Goods:

SKFL supplies its finished dyed fabrics to its garments section. So, dyed finished fabrics are stored for short

time in the finishing section. All the delivered fabrics are noted on the tally khata according to the lot no,

quantity, fabrics diameter, buyer's name, Color & considering other technical parameters.

For Others:

Out of above types there are inventory systems for semi-finished goods like as dyed fabrics,

garments pattern pieces, markers, sewed goods, scrap, surplus, absolute items, garments labels, packages

etc.These goods are maintained by the respective inventory control office different departments this knit-

composite mill.

Remarks:

Proper inventory control of raw materials, semi-finished goods, finished goods and other

miscellaneous goods lead smooth production. As SQUARE KNIT FABRIC LTD. follow the correct way

of inventory control system, it can have a good and huge production as it demands.

98

Chapter10

Cost Analysis

99

COST ANALYSIS

Costing of the Product:

Costing system mainly describe how the cost of the final product is fixed by the company or the

managements. As it is a garments manufacturing factory , so accordind to the buyer or customer

requirements of final garments , merchandiser give the consumption of the fabric with specification . Then it

is calculated how much dyestaffs & chemicals are required for processing. After that, the final cost is fixed

including some profit. Then the unit price is differed to the buyer for their approval.

Costing of the Products is done by the Consideration of the Following Factors:

• Amount raw materials consumed

• Direct Labour

• Indirect Labour

• Factory Cost

• Officer and administrative cost

• Sales and distribution cost

• Profit, etc.

Price of the Product:

Generally price of product is determined by the required profit adding to the total expenses. So,

Price of products^ (Direct expenses + Indirect expenses + Factory verhead) + Required profit

Costing of a Product Includes:

Yarn cost

Knitting cost

Dyes & chemicals cost

Cost of dyeing

Cost of finishing

Cost of cutting, sewing, accessories etc.

Cost printing

Labor cost

Factory cost

Office & administration cost

Sales & caring cost

Others cost

Profit etc.

100

Price of different operations:

Knitting cost:

Fabric name Charge per kg(Tk)

Single Jersey 9

Single Jersey with Lycra 34

Single locoste PK 16

Double lacoste PK 16

Single PK 18

Double PK 18

1X1 rib 18

1X1 rib feeder stripe 30

Design rib 50

Lyc 1X1 rib 35

2X2 rib 30

2X2 rib Lycra 40

Interlock 35

Fedeer stripe 30

Auto stripper 110

Auto striper with Lycra 140

Fleece 30

J/Q 200

101

Dyeing Cost:

SL no Processing type Price per Kg

01 Light shade 75

02 Medium shade 90

03 Dark 95

04 Extra dark 110

05 Royal /Reactive black 130

06 White 30

07 CVC /TC (white) 130

08 CVC/TC (white) 50

09 Exceptional color (more than 8%) 120

10 Normal wash 25

Finishing charge of different fabrics:

Remarks:

The costing of the product is most secret matter of the industry. They were not interested to share

the cost related data with us. So we could not collect detail the price of the product.

Name of fabric process Charge per kg(Tk)

Slitting only 5

Stenter only 25

Compacting only 15

Stenter + Compacting 35

Stenter + Compacting+ wash 50

Tube Compacting 10

102

CHAPTER11

MARKETING ACTIVITY

103

Marketing Activities

Marketing:

The process of advertising, promoting and making a product popular among the masses is called marketing. It

is the sector of ultimate importance of an industry.

Duties of marketing officer:

1) To collect the order from buyer.

2) To determine the price of product.

3) To inform the buyer when the product in process.

4) To ensure fabric quality, product quality.

5) To concern about the product until the shipment.

Order follow up process:

Buyer sends product package

Costing on product package

Price approval

Sampling

Order confirmation (Order sheet)

Fabric booking

Fabric production

Fabric dyeing and finishing

Garments making

Quality check

Packaging

Shipment

104

Price Quotation:

There are some systems for price quotation as given below -

1. FOB (Free on board)

2. C & F (Cost & Freight)

3. CIF (Cost, Insurance & Freight)

List of Some of Buyers:

I) Puma

II) G-Star

III) Espirite

IV) M & S

V) S. Oliver

VI) Mexx

VII) H&M

VIII) Street one

IX) Matalon

X) Kitaro

XI) Tema

XII) Norwest

105

EXPORT VALUE-2011

EXPORT VALUE-2012

PUMA 28%

G-STAR 11%

S. OLIVER 8%

H & M 7%

MEXX 4%

STRAUSS 4%

OTHERS 9%

ESPRIT 29%

0%

PUMA 32%

G-STAR 7%

S. OLIVER 8%

H & M 11%

MEXX 5%

STRAUSS 3%

OTHERS 7%

ESPRIT 27%

0%

106

Remarks

SQUARE KNIT FABRICS LIMITED is a well-planned versatile project. The administrations, management, chain

of command - all are well organized. They are devoted to satisfy the customer by their activities.

However, some of the points we want to mention for the betterment of SQUARE KNIT FABRICS

LIMITED.

We asked the concerned persons to cut some sample pieces for us. The samples were cut

very much more than we required. This is noticeable. A huge amount of fabric goes to

wastage. No doubt, this lessens the overall efficiency.

We found the floor was watery due to overhead sanitary leakage & the problem remains

unsolved due to negligence.

The dyeing floor is watery most of the time; it should be cleaned all the time.

Modern material handling tools are to be utilized.

The machine stoppage time should be analyzed and minimized. Good maintenance practice

is needed.

107

CHAPTER12

Conclusion

108

Conclusion

Two month of industrial attachment at the SQUARE KNIT FABRICS LIMITED (SKFL.) was a part of the

B.Sc. in textile technology course. The eight weeks of the training period were segmented &

scheduled to a systematic routine. We have got the impression that it is one of the most modern

export oriented knit composite factories in Bangladesh. Though it was established only a few years

ago, it has earned very good reputation for its quality products, over many other export oriented

textile mills.

This training gives us actual picture about man, machine, material, methods and market. We have

earned the direct knowledge about the raw materials, actual running condition of the machines,

working technologies, production follow-ups and the administration.

This mill is a well-planned with enough expansion facilities. The working condition & the relation

between employer & worker is wonderful.

We are enough fortunate to get an opportunity of having a training in this factory. During the

training period we received cordial association and co-operation from the authority & found all man,

machines & materials in appreciable working condition. All stuffs & officers were very sincere &

devoted to their duties for achieving the factories goal.

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