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INDUSTRIAL TRAININGCourse Code: Tex -4036
INDUSTRIAL ATTACHMENTAPEX SPINNING AND KNITING MILLS LTD.
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TABLE OF CONTENT
ChapterNo.
Topics Contents Page No.
Chapter-I ProjectDescription
Name, Type, Year of establishment,Location, Address, Sponsors, Productmix, Annual production capacity,Project cost, History of the projectdevelopment, Different Departments,Physical infrastructure, Remarks.
6-10
Chapter-II Man powerManagement
Organ gram of man power-1.Administration2.Production3.MaintenanceManagement system, Shift change,Responsibilities of production officer,Job description of the productionofficer, Job description of the Sr.production officer
11-20
Chapter-III
MachineDescription
No. of the M/C, Make, Brand name,Main specification, Machinery layoutplan, List of machinery, Remarks.
21-26
Chapter-IV
Rawmaterials
Types, Price, Source, Annualrequirement, Remarks.
27
Chapter-V Productionplanningsequence &operation
Production parameters, Description ofthe production process, Dailyproduction report, Monthly avg.production, Production flow chart,Recipe, Monthly efficiency, Remarks.
28-31
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Chapter-VI
Qualityassurance
Quality assurance procedure, List ofequipments, Quality standard, Qualityreport, Remarks
32-38
Chapter No. Topics Contents Page No.Chapter-VII Maintenance Maintenance of machinery,
Routine, Manpower set up formaintenance, Maintenanceprocedure, Maintenancetools/equipments & theirfunction, Remarks,
39-43
Chapter-VIII Utility services Utility facility available,Capacity & other technicaldetails, Source of utility, Costof different utilities, Remarks.
44-49
Chapter-IX Store &inventorycontrol
Inventory system of rawmaterial, Spares, Finishedgoods, others, Remarks.
50
Chapter-X Cost analysis Price of the product, Cost ofthe product, Remarks
51-52
Chapter-XI Marketingactivities
Consumer of the product,product level, package size &level, Local market, Importingcountries, Manpower,Marketing strategy, Duties &responsibilities of marketingofficer, Remarks.
53-55
Chapter-XII Conclusion 56
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CHAPTER-I( PROJECT DESCRIPTION )
NAME: Apex Spinning and Knitting Mills Ltd..TYPE: Composite knit fabrics and garments (with dyeing & finishing) mill(100% Export Oriented Composite Industry)STATUS: Private limited companyYEAR OF ESTABLISHMENT: 1992LOCATION & ADDRESS:Head Office :Apex Spinning and Knitting Mills Ltd.Biman Bhaban ( 5th floor)100,Motijheel C/A, Dhaka-1000Tele : 9562383, 9338867 (F)E-mail : [email protected] :Chandura Kunabari,Gazipur .
LOCATION OF THE MILL:
Apex Spinning and Knitting Mills Ltd.. is situated at Chandura Kunabari,Gazipur. It is located at the west Side of Gazipur Chowrasta-Thangail road and at thepoint of Polli Biddut bus stopageabout 45 km away from Sotheast University,Tejgaon, and Dhaka.
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# SITE LOCATION OF Apex Spinning and Knitting Mills Ltd:
Gazipur
Chowrasta
SotheastUniversity
Air Port
MymensingRoad
ShofeepurBazer
PollyBiddut,Chandura
ApexSpinnningand KnittingMills Ltd
GazipurMain Town
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SPONSOR:OWNSELF
PRODUCT MIX:a) Knitted grey fabrics:Plain single jersey, Heavy jersey, polo pique,1’s Lacoste ,Double Lacoste , Rib &Interlock double jersey, Billister Fabrics, 2/3 threaded fleece (brushed &unbrushed),Lycra Single Jersey, Auto stripper, Feeder Stripper, Jacqured DesignFabrics, Collar & Cuff , Warp knitted Fabrics, Narrow fabrics etc100% cotton, 15% viscose+ 85% cotton, 10% viscose+ 90% cotton, 30% viscose+
70% cotton, 95% Cotton + 5% Lycra, PC , CVC, Millange , 84% Nylon + 16%
Spandex etc
b) Knit garments:
Men polo shirt, Women polo shirt, Men T-shirt, Women T-shirt, Men sweat shirt,
Women sweat shirt, Men fleece shirt, Women fleece shirt, Kids polo shirt, Babies
polo shirt, Kids T-shirt, Babies T- shirt, Jogging Pants, Ladies Under garments ( Bra,
Panty etc )
ANNUAL PRODUCTION CAPACITY:
Knitting: 9125 tons per year
Dyeing: 9125 tons per year
Garments: 3 cores pieces per year
PROJECT COST:
500 cores taka (approx)
HISTORY OF PROJECT DEVELOPMENT:
Starting with 36 knitting machines only in 1990 and dyeing capacity was only 3 tons
per day. Garments section has only two floors with 6 lines.
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DIFFERENT DEPARTMENTS:
1. Admin Section
2. Knitting: circular knitting , Flat knitting and Warp knitting
3. Dyeing & Finishing
. Lingerie Dyeing Section
. Yarn dyeing
. Sewing thread manufacturing section
. Narrow fabric dyeing
. Printing Section
4. Lab department
5. Quality Assurance
6. Garments:
Cutting
Sewing
Finishing
Inspection
Packing
7. Stores & Inventory Section
8. Technical Department (Maintenance)
9. Human & Resource and Administration
10.Account and commercial section
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11.Utility Department
TOTAL AREA OF THE INDUSTRY: 20000 sq. meters
FACTORY LANDS AREA: 8000 sq. meters
FLOOR SPACE OF KNITTING: 17600 sq. feet
FLOOR SPACE OF DYEING: 17600 sq. feet
FLOOR SPACE OF FINISHING: 17600 sq. feet
FLOOR SPACE OF GARMENTS: 9856 sq. feet
PHYSICAL INFRASTRUCTURE:
Physical infrastructure of APEX SPINNING AND KNITTING MILLSLTD. is R.C.C and brick wall structure. There are six big building among these one iseight floored building (1st floor for printing and finishing, 2nd is for laboratory and partof addmin3rd is for knitting and rest of all are for garments section), two is six flooredbuilding (one is Lingerie and warp knitting section and another is for dyeing ,finishing ,Utility dept collar & cuff and garments section), Another two building is foryarn dyeing and head administration section. There is a big mosque and children carecentre as well as medical centre.
REMARKS:
APEX SPINNING AND KNITTING MILLS LTD. is The biggest project I have everseen. In this project combine many and unique department which are really rare inBangladesh. This is also a profitable project and also greatly contributes the economyof our country.
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CHAPTER-II(MAN POWER MANAGEMENT)
(MANAGEMENT SYSTEM):
KNITTING SECTION:Four mechanical fitters for per shift .One skilled operator and one unskilled operatorfor per knitting machine.
SHIFT CHANGE:
Shift of Twelve hours but four hours daily overtime added for the workers. Shiftchanges after a week on Saturday and daily shift changes 8:30 am and 8:30 pm.
RESPONSEBILITIES OF PRODUCTION OFFICER:
From getting an order of upper level all responsibilities are on the production officers.They work with a troop of operators, helpers, fitters etc. to finish the production in duetime. In the meantimeProduction officers bear all hazards, problems. They have to explain to the managerfor any type of production hamper. So all production activities and its success dependon the production officers .Now I can explain the works of the Production Officerfollowing way..
1. Get order sheet and making program sheet send to operator2. Production sample making3. Show this production sample to authority4. Correction of sample making parameters for correct the sample5. Final production sample6. Approved the sample from authority7. M/C selection and Direction to operators for bulk production8. Gray Inspection and Send to Dyeing Department9. Final finished fabric as well as finished garments inspection
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Organ gram of ASKML:
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PRODUCTION CALCULATION
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1. Production/shift in kg at 100% efficiency:
countYarnmmSLNeedleofNoFeederofNoRPM
2046.28403654.210
1260)(..
countYarnmmSLNeedleofNoFeederofNoRPM
80.3527
)(..
2. Production/shift in meter:
100/1260.
/.min/
cmCourseEfficiencyFeederofNoRPM
cmCourseCourse
3. Fabric width in meter:
100/.
100/.
cmWalesknittingNeedlesofnoTotal
cmWaleswalesofnoTotal
(i) RAW MATERIAL USED
Material (Yarn) Count Type ColorCotton (100%) 24/1 Carded GreyCotton (100%) 26/1 Combed PurpleCotton (100%) 26/1 Carded GreyCotton (100%) 30/1 Combed GreyCotton (100%) 34/2 Combed Avg.Cotton (100%) 16/1 Carded GreyCotton (100%) 34/1 Combed GreyLycra (100%) 20D
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(ii) FABRIC WEIGHT (G.S.M.) SETTING
M/c. Gauge Yarn count F/Dia in inch GSM(Grey state)
16 24/1 31 17028 30/1 32 15024 26/1 50 14516 26/1 19 13516 34/2 19 16516 24/1 33.5 18020 26/1 37 22518 24/1 35.5 18220 26/1 35 22022 34/1 31.5 165
G.S.M. CONTROL:1. Major control by quality pulley.2. Minor control by stitch length adjustment.
(b) NECESSARY INFORMATION
1. G.S.M.:
It is technical term that indicates the weight of the fabric per square meter.
2. Changing of G.S.M.:
The GSM of the fabric is change by altering the position of the tension pulley.If pulley move towards the positive direction then the GSM is decrease and in thereverse direction GSM will increase.
3. Points that should consider incase of g.s.m. Changing:
i) Tension pulleyii) Cam positioniii) Take up motion
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4. Factors that should be changed incase of fabric design on quality change:
i) Cam settingii) Tension pulleyiii) Set of needleiv) Size of the loop shape
5. Recommendable points of a buyer:
i) Dia of the fabricii) Design of the fabriciii) GSM of the fabriciv) Total wt. of the fabricv) Yarn countvi) Types of yarnvii) Color of the fabric
6. Gauge number that are usually seen in different m/c:
i) Incase of rib m/c. 16 to 18 G are normally used. But incase ofimproved quality yarn 20G M/cs are used in European country.
ii) Single jersey m/c are normally found 20,24,28etc. Gauges.
7. Relation between yarn count and m/c gauge seen in different m/c.:
We know,G2
Ne =-------------18
Where, Ne = English Cotton CountG = M/c. gauge.
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8. Maximum and minimum g.s.m. Of a fabric for a particular yarn:
Types of m/c Yarn count Maximum GSM Minimum GSMSingle Jersey m/c 20/1 240 120Single Jersey m/c 30/1 165 100
Rib m/c 20/1 380 190Rib m/c 30/1 180 130
9. Chemical that used in needle, sinker or m/c cleaning:
i) Needle and sinker: Petrol + Needle oil mixture.ii) Cylinder: At first wash with petrol and finally wash with needle oil.
10. Oil require per hour for each m/c:
More than one liter.
11. Production per shift for each m/c:
Types offabric
Yarn count Hours M/c. R.P.M. Fabric wt.(kg)
Single Jersey 30 12 30 145Single Jersey 20 12 30 200
Rib 30 12 20-25 180Rib 20 12 20-25 250
12. Weight losses after finish the fabric:
6-7% weight losses on the basis of whole wt.
13. Weight increases per square meter after finish the fabric:
15-16% weight increases per square meter.
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WORKING PARTICULARS
1. Working hours: Two shift each of 12 hours.
# M/c cleaning and maintenance at the time of shift running# M/c cooling at lunch hour
2. Type of fabric produced:
Single Jersey, Single pique polo, lacost, honeycomb, rib, fleece and many othersdesigned fabrics.
3. Needle breaks: 4.5 Nos./day 13 machine.
Needle breakage occurs mainly due to which yarn supply. M/cs automationsystem can minimize the higher breakage rate. Also operator’s negligence, worn m/cset up and wrong handling may cause more needle breakage.
4. Adjusting points of the knitting machine:
a) Feeder to needle (horizontal distance, 1 to 2 sinker thickness)b) Feeder to needle (vertical distance, by feeder adjustment or by dia height
adjustment)c) Dial to Cylinder distance.d) Sinker groove to Cylinder groove.e) Tension and loop length.f) Yarn tension adjustment.g) Adjustable speed in motor driving shaft.h) Change pinion in take up roller to perform tension.
5. Auto stop motion in knitting machine:a) Gate openb) Needle breakagec) Motor drive faultd) Yarn inpute) Yarn outputf) Oil air problemg) Targeth) Photo electric cell
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6. Wastage of the factory:
a) Empty cartoon or yarnb) Yarn and fabric wastage due to packing pin marks, yarn irregularity,
reckoning, knotting, recreeling of new package on the knitting m/c, threading ofknitting elements.
c) Drop out loops, broken needles, stripe effect, lack of supervision and worker’snegligence.
7. Maintenance:
3 to 4 months gap between two maintenance.
(c) METHODS OF INCREASING PRODUCTION
By the following methods the production can be increased –
1. By increasing m/c speed:Higher the m/c speed faster the movement of needle and ultimately production
will be increased.
2. By increasing the number of feeder:If the number of feeder is increased in the circumference of cylinder, then the
number of courses will be increased in one revolution at a time.
3. By increasing cam angle:By increasing cam angle production is increased.
4. By imposing automation in the m/c:a) Quick starting & stopping for efficient driving system.b) Automatic m/c lubrication system for smoother operation.c) Photo electric fabric fault detector.
5. By imposing other developments:a) Using creel-feeding system.b) Applying yarn supply through plastic tube that eliminates the
possibilities of yarn damage.c) Using yarn feed control device.d) Using auto lint removal.
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CAUSES OF LOOP LENGTH VARIATION
1. Fluctuation in yarn variable:
a) Due to count variation.b) Due to twist variation.c) Due to insufficient M.C. or M.R.d) Due to package hardness.e) If frictional property of yarn is not maintained.
2. Fluctuation in m/c variable:a) If temperature of the m/c is not standard.b) If m/c gauge is not accurate.c) If m/c cam setting is not properly maintained.d) If needle timing and knock over is not accurate.e) If take down tension is wrong.f) If sinker timing is not correct.g) Improper yarn tension.
3. Robbing back:Due to 15% of yarn robbed back from old loop to newly formed loop.
JOB DESCRIPTION:
SENIOR PRODUCTION OFFICER:In a knitting factory a senior production officer plays a great role in production andmanpower management. Here we enlist the duties of senior production officers:
1. Follow up knitting production2. Regular observation of the knitting floor.3. Prepare knitting orders regularly4. Maintain the quality of the product
PRODUCTION OFFICER:Production officer is the right hand of senior production officer and he is directlyrelated with production, manpower & informs senior production officer time to time.Here are his listed duties: Follow up overall knitting production
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Decide every machine utilization during production Recruit new labor To inform the authority on the overall knitting production and make it
financially profitable Regular machine Maintenance Maintains subcontract orders Help knitting manager and also guide the junior officers of the section
REMARKS:Production runs with the help of mechanical fitters. For any kind of mechanical faultof any machine they fix and work under knitting manager. Production officer takesaccount of daily production by running after the two supervisors & workers so on.
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CHAPTER-III( MACHINE DESCRIPTION )
Apex Spinning and Knitting Mills Ltd.. (KNITTING SECTION)
FLAT KNITTING SECTION:
No of flat bed knitting m/cs : 7
:
WARP KNITTING SECTION:
No of warp knitting m/cs : 40. Karl Mayer Warp knitting m/c s -5. Rachel Warp knitting m/cs -8. Narrow fabric woven m/cs -27
CIRCULAR KNITTING SECTION:
No of circular knitting m/cs : 104. No of single jersey m/cs- 42. No of rib m/cs – 18. No of Interlock m/cs -21. No of fleece m/cs -14. No of auto stripper m/cs -8. No of jacquard m/cs -1
SL GaugeWidth
Brand Origin
1 14 152 cm SHIEMA SEIKI JAPAN2 14 152cm SHIEMA SEIKI JAPAN3 14 152cm SHIEMA SEIKI JAPAN4 14 152cm SHIEMA SEIKI JAPAN5 14 152cm SHIEMA SEIKI JAPAN6 14 152cm SHIEMA SEIKI JAPAN7 14 152cm SHIEMA SEIKI JAPAN
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1. CIRCULAR KNITTING SECTION:Sl type dia gauge feeder Needle attachement Brand name Origin1 S/j 22 24 69 1656 Lycra Mayer & CIE Germany2 S/j 24 24 78 1800 Lycra Mayer & CIE Germany3 S/j 23 24 69 1728 Lycra FUKAHAMA Taiwan4 S/j 20 24 65 1512 Lycra Mayer & CIE Germany5 S/j 18 24 57 1368 Lycra Mayer & CIE Germany6 S/j 24 24 72 1800 Lycra FUKAHAMA Taiwan7 S/j 26 24 84 1944 Lycra Mayer & CIE Germany8 S/j 30 24 96 2268 Lycra Mayer & CIE Germany9 Rib 30 16 62 3002 Lycra Mayer & CIE Germany10 Rib 34 16 72 3408 Lycra Mayer & CIE Germany11 Rib 34 18 72 3960 Lycra UNITEX Singapore12 Int 32 18 66 3720 Lycra UNITEX Singapore13 S/j 25 24 75 1894 Lycra FUKAHAMA Taiwan14 Rib 38 18 76 4260 Lycra FUKAHAMA Taiwan15 S/j 18 24 54 1332 Lycra UNITEX Singapore16 S/j 19 24 57 1440 Lycra UNITEX Singapore17 S/j 19 24 57 1440 Lycra FUKAHAMA Taiwan18 S/j 21 24 63 1584 Lycra FUKAHAMA Taiwan19 S/j 20 24 60 1488 Lycra UNITEX Singapore20 S/j 19 24 57 1440 Lycra UNITEX Singapore21 S/j 17 24 51 1272 Lycra FUKAHAMA Taiwan22 S/j 16 24 48 1212 Lycra FUKAHAMA Taiwan23 Int 34 24 72 5100 Lycra UNITEX Singapore24 Int 36 24 78 5400 Lycra UNITEX Singapore25 Int 36 18 78 5400 Lycra UNITEX Singapore26 Int 40 24 84 6000 Lycra UNITEX Singapore27 S/j 34 20 102 2520 Lycra UNITEX Singapore28 S/j 36 20 108 2688 Lycra UNITEX Singapore29 S/j 36 20 108 2688 Lycra UNITEX Singapore30 S/j 40 24 120 3000 Lycra UNITEX Singapore31 Rib 40 18 84 4512 Lycra UNITEX Singapore32 Int 40 19 84 6000 Lycra UNITEX Singapore
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CIRCULAR KNITTING MACHINE
Circular knitting m/cs. are widely used through out the knitting industry toproduce fabric. This m/c can be built in almost any reasonable diameter and thesmall diameter of up to five, which are used for wear.
Machine for outerwear and under wear may vary from 12 inch to 60 inch indiameter according to manufactures requirement. This m/c can be used either asfabric or for making garments completely with fancy stitch. Latch needles arecommonly employed in all modern circular m/c because of their simple action andalso their ability to process more types of yarns.
Plain circular m/c uses only one sets of needles, circular rib m/c uses two sets ofneedles i,e, Cylinder needle and Dial needle, the interlock circular knitting m/c alsouses two sets of needles by needles are long and short respectively for both dialand cylinder, that is why multiple design and thick fabric can be produce with thatm/c. That m/c is also called double Jersey m/c.
M/c. Gauge – needle/inch (varies according to diameter) Needle Type – Latch Needle bed type – Single cylinder, Double cylinder, Cylinder &
Dial, long or short needles for cylinder and dial. Two principle operation exist:
1. English system – Where the cams and yarns strands revolve byneedle and fabric take down is stationary.
2 American system – Where the needles and fabric take down revolvesby cams and yarn strands are stationary.
(d) IMOPORTANT EQUIPMENT OF CIRCULAR KNITTING M/C
(e)1. START/STOP/INCH BUTTONS:
Complete set of easily accessible start/stop/inch buttons at top in eachleg.
2. RATCHET LEVER:Permit hand movement of the M/C
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3. AUTO STOP MOTION:
Automatic three stages 24v yarn motion, positive feed tapes & knitting zone. Indicatorlamps are on individual stop motions & on the main control panel. While the yarn isbroken we can find the location which is broken as well as to repair, meanwhile themotor can brake and stop operation at once to keep the security of M/C.
4. FREE STANDING SIDE CREEL:With an active reserve package for each feed.
5. AUTO–COUNTER:Two shift revolution with display counter with predetermined stop, tosettle freely the weight or yardage of fabric.
6. VARIABLE SPEED DRIVE WITH M/C BRAKE:
Transistor inverter provided for free controlled, the process of “V.s. motor-drive”from slow operation to normal operation is quite & fast brake to prevent damages incase of needles or yarn breakage.
7. FABRIC TAKE UP SYSTEM:With variable speed control by a belt drive set can be adjusted the speedfor different course of fabric-constant and uniform fabric tension.
8. SAFETY GUARD SWITCH:Machine cannot be started with guards open; this guards have reinforcedfibreglass window for easy fabric inspection.
9. AUTO LUBRICATION:The automatic central pressurized oil sprayer can be adjusted at cyclingtime and quantity to make cylinder, dial, sinker ring’s cam, needles andsinkers lubricated enough, besides it has the function cooling andclearing.
10. AUTO-LINE REMOVAL SYSTEMS:Three fans on each rotating arm for clearing off any dust of creel andknitting zone.
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OPERATION PROCEDURE OF FLAT MACHINES:
To start operation, depress a green button provided at the letf- handside of the machine. If either of the red buttons fitted at the right and left sides of themachine is pushed, the machine will stop. For manual operaion, first push a blackclutch button at the right hand lower part of the machine to disconnect the clutch.Next, push away and turn right manual operation handle. To reconnect the clutch forautomatic operation, pull the manual operation handle. The clutch lever is of 2-steptype. When it is set to the 1st step, changeover drum will turn lightly, Whenperforming link fitting to the drum or reknitting, the lever should be set at thisposition. the clutch is connected when the clutch lever is raised to the 2nd step.
Note : Before raising the clutch lever don’s fail to push the STARTswitch ( green button). The clutch lever would not be raised unlelss motor is onoperation. Forecible raising of the leer will cause machine trouble on speed changemechanism.
CHANGING OF THE CARRIAGE TRAVEL WIDTH:
Traveling width of the carriage can be changed in the sequencedescribed below. This change work requires five minutes. During the change work theclutch lever should be set at the position where the over durm would not rotate, even ifthe manual handle is turned.
1. Place-u-shape gauge on the right end of the carriage rail.
2. Disconnect the clutch and move the carriage to the right end bymeans of the manual handle.
3. Loosen two carriage position change serews.
4. Shift the crand rod fulcrum of sector wheel in accordance the travelwidth scale.
5. Move the sector wheel to the right end disengaging position bymanual handle and secure the handle with set screws (use carriage rail set screws).
6. Move the carriage rightwards until it contacts with the u-shape gauge.Then, upon making certain that the carriage is in contact with the u-shape gauge,tighten the carriage position change screws.
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7. Fine adjust the carriage position screws to assure reliable contact ofcarriage and u-shape gauge. If the left screw is loosende and the right one is tightened,the carriage can be move rightwards, and on the cantrary, if the right screw isloosened and the left one is tightened, the carriage can move leftwards. At this time,be careful not to stretch the chain too tight. The proper chain tension is such that thechain can teach the upper face of the carriage rail, of picked up at the machine center.
8. Upon cornpletion of the works in steps 1 to 7, unscrew the handle setscrews, tighten the carriage rail, and upon confirming that the carriage travel widthhas been set as required, start operation.
POSITION ADJUSTMENT OF PRECEDING CAM RELEASING DEVICEAFTER WIDTH CHANGE:
After changing travel width, adjust the position of preceeding camreleasing device 3 shown in the illustration below.
1. Loosen 5 and 6 and move 3 left.2. Travel the carring by the manual handle to the left limit position.3. Place bearing 2 located at the right of the carriage in an indent of 1
as show in the illustration.4. Move 3 to provide a clearance of 1mm between 3 and 1. Then
fighten 6 to fix 3.5. Pring 4 in contact with 3 and tighten 5 to secure 4. 4 serves as a
mark in the event when 3 is moved not to hinder the carriage removal.
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Chapter-IV(Raw Materials)
Types of Raw materials : Cotton Polyester CVC Lycra Nylon Melange PC Etc
These above raw material’s price , source , annual requarements are as follows-
Types Price per KG( Approx )
Source Req per Year( Approx)
Cotton 2.7 dollar Square, Hanif,Purbani, BeximcoPadda, and manyothers localspinning Mills
5475 Ton
Polyester 1.8 dollar Pakistan, Taiwan,Indonesia etc
109 Ton
Nylon Indonesia, Taiwan,Chine,
PC 1.8 dollar Both local andAbroad
150 Ton
CVC 2.6 dollar Local spinningMills
547 Ton
Melange 3 dollar Local spinningMills
100 Ton
Lycra 16 dollar Taiwan 164 Ton
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CHAPTER-V(Production Planning, Sequences & Operations)
PRODUCTION PARAMETERS:Buyer RequirementMachine Diameter;Machine rpm (revolution per minute);No. of feeds or feeders in use;Machine Gauge;Count of yarn;Fabric GSM;Fabric Dia or Width;Required time (M/C running time);Machine running efficiency .
DESCRIPTION OF PRODUCTION PROCESS:In every mill, there maintains a sequences in production processing.
It is also followed in this mill where I was in industrial attachment. The processsequences are in list below:
1) Firstly, knitting manager gets a production sheet frommerchandisers as accordance as consumer requirements. Then he informs ororders senior production officer about it.
2) Senior production officer informs technical in charge and knowsabout m/c in which the production will be running.
3) Technical in charge calls for leader of mechanical fitter troops,they two take decision about m/c for production considering m/c condition,production capacity, maintenance complexity etc.
4) Production officer with experienced mechanical fitter adjustsrequired stitch length and grey GSM (gram per square meter) for required finalGSM.
5) Supervisor check daily production regularity and make operatorsconscious about finishing in due time.
6) Operators operate machine in highly attention as if there were nofaults in the fabrics. If he thinks or sure about any fabric fault, then he call formechanical fitter in duty. Mechanical fitter then fixes it if he can or he informstechnical in-charge. He then comes in spot.
7) After required production and final inspection in 4-point system,they are sent in dyeing section.
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Process Flow Chart of ASKML:
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PRODUCTION DAILY REPORT:Here is a daily report of production which is kept in Apex Spinning and
Knitting Mills Ltd..:-
APEX SPINNING AND KNITTIG MILLS LTD.Production Daily Report
PRODUCTION FLOW-CHART Of Knitting Section:
Executive director takes order from Buyer|
Merchandiser estimates total amount of yarn of production|
Knitting manager gets production order sheet|
Senior Production Officer ordered by K.M. and ordersProduction officer and Technical in-charge.
|Production officer fixes up stitch length and GSM
with mechanical fitter.|
Definite operator operates machine in his full conscious andAttention.
|Mechanical fitter fixes machine if there is any m/c fault.
|Supervisors keep daily production report and assure m/c is OK.
|Fabric roll is checked by a troop of inspectors in inspection unit
and weighted.|
Final product to the required amount is delivered to dyeing unit.
Maximum Capacity of knitting section is 25 tons per day but actually maximumproduction is 22 tons but all over average production is 15-18 tons per day due to lackof orders and some other reasons because dyeing section capacity is 25 tons of varioustypes of fabric
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MONTHLY EFFICIENCY:Daily production 15000 kgs. Approx.Daily production capacity 25000 kgs approx.So, monthly production 450000 kgs.Monthly production capacity 75000 kgs.So, Monthly production efficiency= 450000/750000 %
= 60%
REMARKS:As APEX SPINNING AND KNITTING MILLS LTD. is a big project; its
production quantity is huge. Production quantity varies as according as buyersdemand. It gives approximately 450 ton production per month. In Bangladesh, thereare a few mills which can produce such quantity of knitted fabrics.
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CHAPTER-VI(Quality assurance system)
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. Forany major or minor faults like thick-thin, barre marks, fall out, contamination, fly,holes, oil lines, needle lines, slubs, etc are recorded in grey inspection report toclassify the fabric based on the four point system.
Collar & cuff are inspected visually under light box, any major & minorfaulty collar/cuff like having wrong ply, hole, needle lines, slubs, wrong design, firstline problem etc properly counted and recorded.
1) CONTROL OF FABRIC QUALITY
Control of the quality of the cloth being knitted is the knitter mechanic’s majorresponsibility. Fabric set-ups and m/c maintenance, although necessary, must be putinto their proper order of importers. To set-up a fabric and run it on a well-maintainedm/c, when its quality is questionable, is senseless.
The mechanic must be able to diagnose a problem on a m/c and render animmediate cure. To do this, he must have a thorough knowledge of what causes adefect in fabric. When the cause is known, correction will soon follow.
FABRIC DEFECTS:Defects in circular knitted cloth fall into the following major groups: vertical
lines, barre, holes and snags, tuck or double stitches, these will be discussed seriatim.
Vertical lines:This defects can be caused by defective needles or defective trick walls. If the
trick walls are worn or not evenly spaced, the needles will knit at different speed. Thisuneven movement of the needles will cause uneven stitches which is turn can causevertical lines.
If a wall is too big for the needle, the needle will have a sideward motion,which will cause formation of a wide wale in the fabric. When the trick walls are not
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evenly spaced, the needles will knit a certain points wide and narrow stitches in thefabric. These will also cause unsightly lines.
Dirt may often get into the tricks pushing the needles outwards (cylinder) orupward (dial) causing irregular vertical stitches. Bent and worn needles will cause thefabric to have wider Wales in certain places.
Needles with chipped latches, butts, hooks, cheeks, a protruding rivet or brokenspoons will cause fuzzy and irregular vertical lines. Needles with bent latches willcause vertical tears or ladders in the fabric. Too much lubrication or the use ofimproper needle oil often causes oil or dirt strakes.
28
Dark black vertical lines may be caused by dirty tricks, which cause the needlesto run high and rub against the cams. Not enough lubrication may also be the cause ofblack vertical lines.
Barre or uneven courses:
The following may cause these faults :1. Improper cam adjustment,2. Uneven yarn tension,3. Different yarn thickness or shaded yarn dyes,4. Dial not in even relationship to cylinder and5. Defective take down mechanism
With the use of positive feeding devices, the stitch cam adjustment isVery accurate. The most important thing to remember when adjusting stitch cams is tokeep the ratio of the dial stitch to the cylinder stitch the same at all the dial andcylinder feeds.
It must be remember that a positive feed system (tape) will feed the sameamount of yarn to all feeds regardless of stitch adjustment. This stitch adjustmentcontrols the tension only.
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In the case of pique fabric or any similar kind, the odd feeds must be done at thesame tension, but the even form the odd feeds so long as they are all the same. Weknow now that the yarn tension will control the length of stitch.
It is very important that any surfaces that the yarn runs over or through mist beclean of any instruction which will cause irregular tension.
A defective takes down mechanism which pulls tight and then soft will causeare as on the fabric to be loose and tight. The take down mechanism must pull evenlyat all times to maintain a fabric with even courses.
If dial is not in the proper relationship to the cylinder, fabric of uneven stitchlength will produced. The dial and cylinder relationship should be inspective at leastonce a year to maintain proper running conditions.
Uneven thickness of the yarn is one of major causes of barre. The mechanic isreally helpless in the situation. The only thing he can do is to learn to recognize thiscondition and notify the throwster immediately.
Badly wound yarn also will cause uneven tension. In most cases a positive feedsystem will eliminate this defect, but if one used the mechanic should have the yarnrewound. In the case of dyed yarn shaded the mechanic is helpless in such a situation,he must notify the throwster immediately.
Holes and Snags:Holes in most cases are caused by excessive tension of the yarn. If stitch cams
are adjusted too deep and there is excessive tension in the yarn, it wills beak, causing ahole. If the dial height is too high these will also cause a tremendous strain on theyarn.
Other factors that produce excessive tension on the stitch are as follows:1. Too tight a take down pup,2. The positive feed system operating improperly,3. Badly wound yarn,4. Yarn with thin or weak spots.5. Dirty or clogged surface in which the yarn passes through or on,6. Yarn warp around.
Snags in most cases are usually caused by badly wound yarn which at
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a low tensions and then suddenly jerks and runs at a high tension. This high tensionwills usually a line of holes from one to nine inches.
Drop Stitches:
This defect occurs when the needle tails to take new yarn of when the needlefails to take new yarn or when the needle losses its loop.
One of the major causes of this problem is an improperly set yarn carrier. If theyarn is not fed directly into the hook of the needle, there is a good chance that theneedle will not take the new yarn.
If the stitch cam is set too far back there will be too much yarn is the needleloop. Because of this loop will be so loose that it can fall causing a drop stitch.
Other possible causes of droop stitches are: the take down mechanism is tooloose, not enough tension on yarn, dial height too high, needles, yarn in wrong hole ofthe carrier, dial needle latch closing under yarn carrier and dial needle latch closingnear the hole of the carrier.
Tuck Stitches or Double Stitches:This defect occurs when the needle does not cast off its old loop. In most cases
this defect can be traced to an improperly set stitch cam.If the needle is not drown far enough back the old loop will remain on the
needle. On the other hand, if the stitch cam is set too far back, too much yarn will begoing to needle. In this case this needle will be unable to knock over such a large loop.
Other possible causes of Tuck Stitches are as follows:1. Take down mechanism set too loose,2. Needles move too freely in their slots,3. Dial height set too low,4. Defective needles,5. Needle trick walls clogged with dirt etc.
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.
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1) After production of fabric rolls of 8 to 25 kg, m/c operators cut themfrom the cloth or batch roller and they are carried to inspection section by the helpers.
2) Almost four inspection workers are for every shift to check the fabricrolls. For any kind of fault they are checked thoroughly. Skilled inspectors find themand indicate them by the scissors in some cases.
3) Quality is specified on the basis of 4-points system. Here is the pointdistribution for different kinds fault in this system:-
THICK THIN DIRT, OIL SPOT, CONTAMINATION:
Up to 3’’ in length: 1 PtUp to 6’’ in length: 2 “Up to 9’’ in length: 3 “Up to 9’’ in length: 4 “
QUALITY Pts / per 100 square meter= (Total point * GSM)/ (Rollweight*10)
Quality inspectors seal on the fabric rolls as ‘CHECK-1’, ‘OK’ &‘REJECT’ as according as quality classification.
QUALITY CLASSIFICATION1 2 3
<20 20-30 30>OK ASK REJECT
LIST OF EQUIPMENTS:In this factory ‘Apex Spinning and Knitting Mills Ltd.’ this is the
list of equipments to assure quality:-1) Inspection m/c # 1(For plain single jersey)
FOUR POINT GRADING SYSTEMSize of defects Penalty
3 inches or less 1 pointOver three inch but not 6 inch 2 pointOver 6 inch but not 9 inch 3 pointOver 9 inch 4 point
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2) Inspection m/c #2 (For decorative single jersey as like as Lycra,Lacoste, waffle, Fleece and all kind of double jersey as like as Rib, Interlock).
3) Scissors4) Weight balance & Micro balance5) GSM cutter6) Seal (‘CHECK-1’, ‘OK’, ‘REJECT’.).
Rejection criteria for body & Rib: Following table shows common body & ribfaults and response by grey inspection section.Rejection criteria for collar & cuff: Following table shows common collar & cuff
No. Faults Response1. Needle marks Major needle line is rejected.2. Stripe Major needle line is rejected.3. Barre marks Rejected4. Slubs 1 point5. Wrong design Rejected6. Pin holes 1 point7. Fly & contamination Acceptable for color but not for white8. Sinker marks Do9. Uneven tension Discuss with manager10. Missing yarn Use 4 point11. Crease line Do12. Uneven tension Discuss with manager13. Oil stripe/line Do14. Thick-thin place Rejected15. Mixed yarn Discuss with manager
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Faults and response taken by grey inspection section.
No. Faults Response
1. Wrong ply Reject2. Hole Reject3. Needle line Reject4. Slubs Reject5. Wrong design Reject6. Wrong tripping Reject7. Fly & contamination Acceptable for color but not for
white8. First round problem Reject9. Uneven tension Discuss with manager10. Missing yarn Reject11. Crease line Reject12. Rust line Reject13. Oil stripe Reject14. Thick-thin Reject15. Wrong tube Reject
QUALITY STANDARD: VERY HIGH QUALITY STD MAINTAINED
Here is the quality standard:-
1) Fabric width 7) Broken needle /2’’2) Fabric length 8) Thick /thin yarn4) Slub 9) Barre/ Stripe3) Fabric weight 10) Dirt5) Hole 11) Oil6) Needle / Sinker line 12) Press off
REMARKS:There is hardly any chance of any roll to pass through production on to any buyers byto by unchecked or disqualified. The inspections are too much experience and they areaware about their duties and responsibilities. The factory authority and productionrelated personnel are happy and satisfied with their works
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CHAPTER-VII(Maintenance)
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 qualityand quantity, both depends on the maintenance with regularity. Apex Spinning andKnitting Mills Ltd. lead maintenance with a troop of skilled mechanical fitters.MAINTENANCE OF MACHINERY:
In the knitting floor of Apex Spinning and Knitting Mills Ltd. all circularand flat knitting m/cs are maintained regularly and as necessity requirements.Approximately after twenty days all machines go under regular maintenance and perday three machine can be completed . Here different type of maintenance ofmachinery, which is taken, different time on the machineries.
ROUTINE:1) Daily Maintenance: Every machine is taken maintenance daily by the
operators during production. When a production is started by the operator afterhanding over from previous shift operator, he takes a routine maintenance on themachine. He cleans the machine, assures yarn is fed to all needles, cleans the eye potof feeder, memminger, signal lamp sensor etc. Before a while of a roll cut from batchor cloth roller, operator cleans needles, cylinder base plate etc. All around of themachine are kept neat and clean as if there is no dirt with yarn in the fabric.
2) Schedule/Routine Maintenance: Every machine has a schedule ofmaintenance of 10 or 15 days. According to date, schedule maintenance is taken onthe machines. Operators are informed about the time of maintenance. After pre-estimated production, they hand over the machine to the fitters. Thus, fitters assure allmachines are OK. for any time.
3) Break down maintenance: When product quality hampered and tocomplete production in due time break down maintenance is taken. There are manyfaults seen in the fabric during production due to needle, sinker, take down roller etc.Then operators inform the mechanical fitters and they fix it.
4) Restorative maintenance: Restorative maintenance is taken for designchange or new design development. According to advice or order of productionofficer, a machine is fixed for new design and mechanical fitters rearrange cam andneedle system.Planned and preventive maintenance are not taken on the machineries in this mill.MAINTENANCE OF ‘CIRCULAR KNITTING M/C’:
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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 thelubrication charts be followed conscientiously. The Company can not be needresponsible for faults that arise from wrong or inadequate lubrication.Oiling Needles & Jacks:
Too much oil is preferable to too little. Dark vertical lines in the fabricoriginate not from excessive oiling b but from too mach friction between needle andjacks and the trick walls on account of lack of oil. Should dark vertical lines makestheir 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 quicklycorrect quantity of oil then can be applied. The supply of oil should be reduced if lightoil striper appears on the fabric.The Cleaning of Needle & Jacks:
Thin oil is most suitable for this work, about one point heated to atemperature not exceeding 160ºF poured into the oiling position of the cylinder & dialcam races & in the heads of the needles while the m/c is running. The fabric willfound to be cleaned again after few yards have been knitted. How often cleaning isnecessary will depend upon what kind of yarn is being used. Synthetic yarn cleaningis taken place at lest monthly, yarn with absorbent properties being knitted at sametime.General Cleaning Schedule:
Long m/c life, maximum output & trouble free running depend upon propercare and maintenance. A general overhaul should take place annually when singleshifts are worked & correspondingly at more frequent interval. When extra shifts areworked. The overhaul involves removal of all cam section and removal of needles andjacks from their tricks, so tat the tricks should be thoroughly the cleaned. Before partsare replaced they should be adequately lubricated.
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MANPOWER SET-UP FOR MAINTENANCE:
APEX SPINNING AND KNITTING MILLS LTD..SARDAGONJ, KASHIMPUR, GAZIPUR
DEPT-TECHNICAL
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MAINTENANCE PROCEDURE:
1) For there is any mechanical fault of machine which is responsible forproduction hamper, operator informs mechanical fitters in duty. Mechanical fitterscome 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 foundingmechanical problem, mechanical and electrical department are informed, they comeand 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 ordersmechanical fitters to fit required machine for cam and needle arrangement and othernecessary requirements in case of new design development.
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 thereverse process to ready the m/c.
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MAINTENANCE TOOLS/EQUIPMENTS & THEIR FUNCTIONS:
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 theirdifferent tools or equipments they perform their duties skillfully.
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. Welding machine To join metallic parts
15. Grinding machine To make the smooth fabrics
16. Tester To test electric circuit
17. Pliers To grip anything & cut anything
18. Star driver Screw unlocking
19. Steel tape To measure length, width & height
20. L-key For loosen & tighten the screw
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CHAPTER-VIII( UTILITY SERVICES )
UTILITY FACILITIES AVAILABLE:For smooth functioning of any production unit,
uninterrupted and required utility services are indispensable. Success of anyindustry largely depends on this factor. Any irregularity or lack in the requiredutility services immediately results in unexpected halt of the productionprocess. An Industry needs various utilities depending on its manufacturingprocess.
In APEX SPINNING AND KNITTING MILLS LTD.., themajor utilities are available-
- Power (Electricity)- Water- Natural gas- Compressed air- Steam- ETP
SOURCES OF UTILITIES:The main utility which is used by APEX SPINNING AND
KNITTING MILLS LTD. is natural gas. From natural gas generator produceelectricity. From natural gas and electricity in association with mechanical andelectrical apparatus, APEX SPINNING AND KNITTING MILLS LTD.produces other utilities like water, steam, compressed air, ETP etc.
CAPACITY AND OTHER TECHNICAL DETAILS:Power (Electricity):
Generator house is the main power producing plant ofAPEX SPINNING AND KNITTING MILLS LTD.. There are six generatorsin generator house. All are gas generator . Description of six generators aregiven below :
Generator no.: 01Type : gas generatorBrand name : CaterpillarOrigin : USAModel no. : G-3412Rated power : 437 kva
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Maximum current : 350 kwFrequency : 50 HzEngine RPM : 1500Voltage : 400Power factor : 0.8Water temp. : 92°CMobil pressure : 58 PSIGas pressure : 10 PSIGenerator no. : 02Type : gas generatorBrand name : CaterpillarOrigin : USAModel no. : G-3408Rated power : 287 kvaMaximum current : 230 kwFrequency : 50 HzEngine RPM : 1500Volt : 400Power factor : 0.8Water temp. : 92°CMobil pressure : 58 PSIGas pressure : 10 PSI
Generator no. : 03Type : Diesel generatorBrand name : PerkinsOrigin : EnglandModel no. : P-330ERated power : 330 kvaMaximum current : 264 kwFrequency : 50 HzEngine RPM : 1500Volt : 400Power factor : 0.8
STEAM:The required steam is produced by boiler .There is one boiler in
Apex Spinning And Knitting Mills Ltd.
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Boiler specification:Brand name: cleaver brooksOrigin: AmericaType: Fire tube boilerCapacity: 5.5 ton / hrModel no.: CBW 200350150Maximum pressure: 150 psiYear of built: 2000Minimum circuit capacity: 37 ampMaximum rating of circuit protection: 120 ampBlower motor: 15 HPAir compressor motor: 3 HPControl circuit: 120 volts 1 PH 50 HZ 7 AMPOil pump motor: 220 volts 3 PH
50 HZ 609 AMP
Water supply for the boiler:Water required for steam production is supplied by deep
tube well.
Pretreatment of the boiler water:Boiler feed water needs special standard. Any deviation from the
required standard may result in scale formation, which eventually reduces theefficiency of the boiler. This ultimately affects the cost of steam generationand makes the production cost high. To maintain the required standard of thewater, there should be some means to pretreat the boiler feed water. To protectscale formation of boiler, NELCO is used as chemical in water feed tank. 200gm NELCO is injected per 12 hrs. In APEX SPINNING AND KNITTINGMILLS LTD.., there are water softeners that act before the water enters theboiler.
Manufacture of the softener:The manufacturer of the softener is also cleaver brooks®, USA.
No. of the softener:There are two water softener to pretreated the boiler feed water.
Softener specification:Brand name: Cleaver brooks®
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Model no. : ACC-SMR-150-1- ½ TSerial no.: CS-0000235Capacity: 150000 GRS / tankUnit no.: HS008891Pipe size: 1 ½ inchSalt capacity brine marker: 575 lbs
COMPRESSED AIR:The compressed air is supplied from air compressor. There are
two air compressors in APEX SPINNING AND KNITTING MILLS LTD.Compressor no.: 01Brand name: Atlas cop coOrigin: BelgiumModel no. : GA 22FFSerial no.: AII 254060Maximum working pressure: 10 barAverage working pressure: 6-7.5 barFree air delivery: 52 liter / secondNominal shaft power: 22 kwRotational shaft speed: 3000 r / minGross weight: 480 kgYear of construction: 2000Compressor no.: 02Brand name: BOGEOrigin: JapanModel no. : S361694Serial no.: 546206Year of establishment: 2003Volt: 400Frequency: 50 HZMaximum working pressure: 10 barAverage working pressure: 6-7.5 bar
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WATER:The water source of APEX SPINNING AND KNITTING MILLS
LTD. is deep tube well. The deep tube well is about 260 ft deep. The averagewater consumption is 40-50 m³ / hr.
Water treatment plant: There is a eater treatment plant in APEX SPINNINGAND KNITTING MILLS LTD.
GAS:The source of gas is government agency. Gas is required mainly for
generation of electricity, boiler to produce steam, the burners of heat setting m/ c. As APEX SPINNING AND KNITTING MILLS LTD. generates theirown electricity, the gas consumption is quite high. The gas consumption is350-400 m³ / hr.
ETP:This is the latest utility facilities of APEX SPINNING AND KNITTINGMILLS LTD. Which is running before few day. This plant is urgent forevery mill to protect our environment.
Steps of ETP:1. At first Equalization tank is used for collecting raw effluent2.Then in HRSCC tank or mixing tank raw effluent is collected
by pumping Blower is used for proper mixing.3In HRSCC tank-lime, polymer, FeSO4 are used.4In HRSCC tank solution is drained .Then sludge is divided &
placed in the sludge pump.5. The solution is brought to PH Control tank where acid is used to
control PH. 6. Thesolution is led to the Biological reaction tank .In this tank BACTERIAMEDIA is used to absorb the harmful insects in effluent by using Urea asfood of bacteria. 7. Then water is againdrained .The sludge is divided here too & placed in sludge sump & madeit cake form to remove. 8. To remove color, smell &others chlorine is used in Treated Water tank Atlas the treated water isdrained out in the pond.
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Chemical used in ETP:
-Lime-FeSO4-HCl-Polymer-Chlorine-Colfoc RD-NaOCl-Urea-Chita gur-Dewatering Polymer-cow dung
COST OF DIFFERENT UTILITIES:
Electricity cost :REB =3.8 TK / KW-HRGas generator = 2.70 TK / KW-HRDiesel generator = 6.50 TK / KW-HR
Gas cost :4.94 Tk/m³ for boiler3.66 Tk/m³ for generator4.5 Tk/m³ for domestic purpose
Steam cost: 4.30Tk per kg fabric.
ETP cost: 2300.00Tk per hour
.REMARKS:
For smooth running of a factory main utilities like gas, electricityor steam is very essential. Sometimes gas pressure is low than requiredpressure. When the gas pressure is low, then diesel generator run. Governmentshould have to ensure proper gas supply for Industrial purpose.
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CHAPTER-IX(STORE & INVENTORY CONTROL)
INVENTORY SYSTEM OF RAW MATERIAL:
It is previously speak that APEX SPINNING AND KNITTINGMILLS LTD.. is a knit composite industry. The main raw material of APEXSPINNING AND KNITTING MILLS LTD.. is gray fabric . Grey fabric firstproduce in knitting department of this company . Knitting section of APEXSPINNING AND KNITTING MILLS LTD.. produces grey fabric as perbuyers order. Dyeing section get grey fabric from knitting section . Greyfabric store officer receive the grey fabric and store the grey fabric in storeroom. Then he delivers the grey fabric to batch preparation section accordingto shipment date or according to production manager of dyeing sectioninstruction.
Other raw materials of APEX SPINNING AND KNITTINGMILLS LTD. are dyes and chemicals. Dyes and chemicals store officeralways keep stock report of dyes and chemicals and also know the daily ormonthly requirements of each dyes or chemicals. If the stock is bellowing 45days then he gives requisition to head office for each product. Head officeindent dyes and chemicals.
SPARES:Spare store officer keep the spare part in store & make a list of spare
parts. If the spare parts are little in stock he gives requisition to maintenancemanager. Technical manager give requisition to Head office. Head officeindent spare parts or buy local market as per requirements.
FINISHED GOODS INVENTORY:Finish fabrics from the compactor go to inspection team. From the
inspection table the fabric weighted in weight meter & go to finish fabric storeroom. Here finished fabric store officer make a list of total finished products.He sends the finished fabric to APEX GARMENTS SECTION as pershipment date or requirements of production manager of APEXGARMENTS SECTION. He also keeps the delivery list.
REMARKS: Inventory control system and storing system of APEXSPINNING AND KNITTING MILLS LTD. is over all good.
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CHAPTER -X(COST ANALYSIS)
INTRODUCTION:Costing is a process by which the setting price of a product is calculated. It
is a very important task for a factory which runs for business purposes.And it is also strictly followed in the APEX SPINNING AND KNITTING MILLSLTD. Costing of the products considering the raw materials expenditure, salary andwages of officers and workers, distributions and advertisement expenses etc. all directand indirect expenses is done in this factory. It is determined by a troop of accountantswith advice and consultancy of executive director.
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
Overhead) + Required profit
PRICE RANGE OF DIFFERENT PRODUCTS:
T-Shirt = $0.75 - $4.50 /PcsPolo Shirt =$2.00 - $6.50 /Pcs
Kids Wear ==$0.75- $2.15 /Pcs
KNITTING CHARGE OF DIFFERENT FABRICS:
Fabric name Charge per kg(Tk)Single Jersey 8-9
Single Jersey with Lycra 30-35Single locust PK 16
Double locust PK 16Single PK 16
Double PK 16Rib 12-17
Rib with Lycra 30Interlock 18-22
Auto striper 80Auto striper with Lycra 100
Fleece 22-25
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COSTING OF THE PRODUCT:
Let price of yarn is $ 3.00/ kg.Process loss of yarn for knitting (10%) = $0.30Knitting fabric cost = $3.30
Cost of dyes & chemicals = $2.50Process loss for dyeing (12%) = $0.30Dyed fabric cost = $ 6.10Packing cost = $0.05Production cost of fabric=$6.15Fabric price (with 25% margin) =$7.79
Fabric consumption/ doz. = (Body length + Sleeve length +10) x Chest length x 2 xGSM x12 /10000000
Garments specification:Body length=78 cmSleeve length=33 cm
Chest length=62 cmGSM=210
Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000= 3.469 kg
Fabric consumption/doze (with 10% wastage) = 3.816 kg
Body fabric cost / doz. =$(7.79x 3.816)= $29.73
Cost of collar& cuff/doz.= $ 4.00Cost of Trims=$ 2.25Cost of Trims (with 5% Process loss) = $2.36Production Cost of Garments/ doz=$36.09Garments Price/doz (with 25% Profit) =$45.12
REMARKS:Costing is very important for a productive factory. Without proper costing all
production curriculums will go to vain. Because a factory cannot reach to its goalwithout achieving good profit and good profit is not possible without skillful costing.In Apex Spinning and Knitting Mills Ltd. There are some skillful personnel to do thisjob.
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CHAPTER-XI(MARKETING ACTIVITIES)
INTRODUCTION:Marketing activities are done in this mill, APEX SPINNING AND
KNITTING MILLS LTD. by a skillful team of marketing officers under the ExecutiveDirector. Here are the details of marketing activities.
CONSUMER OF THE PRODUCTS:The mill has a great number of renowned and international consumers.
Following are some regular consumers:
- Fruit of the loom- Charter house- Sinnl effers- WHG- Signum- Supersports- Primkie- Diadora- Western store- Woolworth- Sport-soccer- Gebel- Rex & holm- Ballward- ETEC- TEXEBO
PRODUCT LEBEL:There are following labels used by this mill:
1) Care Label: It contains washing in hot or cold water, chemicalcleaning, drying conditions etc.
2) Size Label: It contains size of garments.3) Composition Label: It contains the fabric composition of different
fiber type.4) Decorative Label: Decoration is as buyer or consumer choice wise.
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PACKAGE SIZE & LEBEL:Most common sizes are
S - SmallM - MediumL - LargeXL - Extra largeXLL - Very very large
LOCAL MARKET:APEX SPINNING AND KNITTING MILLS LTD. is 100% export
oriented mill. So there is no local market involved in it.
IMPORTING COUNTRIES:This mill relates to the countries for yarn importing, they are
1) India2) Korea3) Pakistan4) Taiwan5) Indonesia
This mill also related to countries for machineries, spares and chemicalimporting. They are
1) USA2) Canada3) China4) Japan5) Korea6) EUROP
MANPOWER:Almost ten marketing officers and ten others workers act under the
Executive Director.
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DUTIES & RESPONSIBILITES OF MARKETING OFFICERS:
1) Executive director takes order from the buyer and gives order themarketing officer’s troops to produce a cost sheet.
2) Marketing officers are known the amount and design of product.3) They collect the sample from the buyers and send to knitting and dyeing
section.4) Knitting section adjusts the amount of total yarn and knitting conditions
and dyeing sections adjust the amount of dyes and chemicals. They send a roughcalculation to the marketing section.
5) Marketing officers adjust the amount of garments accessories with thehelp of their own experiences and their knowledge. They also take help of garments incharge.
6) Finally, they adjust their cost sheet after consulting with the ExecutiveDirector and copy several pieces of the cost sheet.
REMARKS:Marketing activities are very important tasks for a productive factory. In
this mill having highly qualified marketing officers. As a result, the mill rises up dayby day.
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CHAPTER-XII(CONCLUSION)
CONCLUSION:At a juncture of time, when the development of the country
was at a stand still position due to the legacy of shattered economy and theindustrialization was stagnant, the export oriented textile and RMG sector hadshown the ray of hope by its all-pervasive positive impact on the nationaleconomy. At the fag end of the eighty, this sector started expanding andwithin a short period of its existence, this nascent industry became the largestforeign exchange earner.
Standing at the verge of a new millennium, Textile andRMG sector is now the heart of our national economy. Even after all thisachievements, this industry faces the major challenge of global adjustment inthe coming years when it has to respond the new trading arrangement after2004.
APEX SPINNING AND KNITTING MILLS LTD. being apart of this decisive sector will have to take necessary measure to cope withthe change of globalization. Modification of the technical arrangement withthe advancement of technologies and good positive approach will help tosurvive in this ever-changing global economy.
Hopefully, the confidence and foresight of the entrepreneursand the enthusiastic teamwork of the professionals will take APEXSPINNING AND KNITTING MILLS LTD. to an even better position.
