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Industrial attachment of urmi garments ltd

Industrial attachment of urmi garments ltd

sheshir
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Industrial attachment of urmi garments ltd

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  1. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF URMI GROUP URMI Group 1

  2. INDUSTRIAL INTERNSHIP REPORT CHAPTER – 1 COMPANY PROFILE SOUTHEAST UNIVERSITY Name of Company : Fakhruddin Textile Mills Ltd. (Concern of Urmi Group) Address : GhargariaMasterBari,Kewa,sreepur,Gazipur,Bangladesh Head Office : 235/B,Tejgaon Industrial Area,Dhaka-1208,Bangladesh Phone : +88 02 8878584 Fax Number : +88 02 8878587 Website : www.urmigroup.net Concern of URMI Group: Fakhruddin Textile Mills Ltd. Urmi Garments Ltd. Attires Manufacturing Co. Ltd. URMI Group 2

  3. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Inception of Urmi Group Dates back to n1984 when Urmi Garments Ltd. was set up. Today they are one of the leading manufacturers & exporters of knit garments in Bangladesh. Over the last Two Decades, by offering the best blend of quality, efficiency and productivity to their valued customers, they have been able to grow up from a 50 machines stitching unit to a composite textile having knitting, dyeing and finishing facilities of about 20 tons fabric and 70,000 pcs garments per day. URMI Group 3

  4. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Strength of Fakhruddin Textile Mills Ltd.: Proffessional Management Team Dedicated & Competent Workforce Latest Machinery & Technology FTML srength Focus on Continuous Improvement Proactive Planning Competetive Pricing Their Goal is to achieve zero tolerance in production by upgrading total quality management and proper production management. URMI Group 4

  5. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY FACTORY INFORMATION: Factory Type : 100% Export Oriented Knit Composite Industry. Year of Establishment : 2004 Investor : Asif Ashraf Cell No. :0171-521090 Location : Gargaria Master Bari, Kewa, Sreepur, Gazipur Telephone : 9289539, 0171684935 E-mail:ftml@urmigroup.net, Annual Turnover : About Tk. 50, 00, 00,000 to 55, 00, 00,000 : ISO 9001: 2000, WRAP,OekoTex& Certification & Awards GOTS(Global Organic Textile Standard) Bank Name & Address: Islami Bank Bangladesh Ltd. 75, Motijheel C/A, Dhaka-1000, Bangladesh. Telex:642525 IBANK BJ S.W.I.F.T. –IBBLBDDH102 Contact Person: Mr. Hafizur Rahman –Sr. General Manager, Cell no. - 01711-560980 Mr. RuhulKuddus –Deputy General Manager, Dyeing, Cell no.- 01713-013028 Mr. Moniruzzaman –Asst. General Manager, Knitting, Cell no. - 01712-106405 URMI Group 5

  6. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Capacity & Machineries Floor space: 320,000 Square Feet Knitting machine : 82 nos Knitting per day : 15,000 Kgs Dyeing machine : 27 nos Dyeing per day : 20,000 Kgs Finishing Per Day : 20,000 Kgs Stenter machine : 02 nos Open width compactor : 02 nos Tension free dryer : 01 nos Tubular compactor : 01 nos Slitting & squeezing machine: 03 nos Brushing machine : 02 nos Tumble dryer : 02 nos Fabric inspection machine : 06 nos Printing Unit Floor space : 26,000 square feet Carosol print machine : 04 nos Glass table : 16 nos with 400 feet Capacity : 25,000 pcs per day with multi color average size printing URMI Group 6

  7. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Embroidery Unit Machines : 20 Head 04 nos,06 Head 01 nos Capacity : 3000 million stitches per day : Men’s, Ladies, Boy’s, Girls & Infant -Polo Shirt, Main Production T-Shirt, Tank Tops, Shorts, Trouser, Fleece Jacket, Vest etc Compliance & Certificates: Fakhruddin Textile Mills Ltd. is extremely particular to meet all levels of compliances at national and international levels Fakhruddin Textile Mills Ltd. use AZO free dyes and chemicals and are certified by OekoTex, WRAP GOLD Certificate, GOTS(Global Organic Textile Standard. In Fakhruddin Textile MillsLtd..all personnel are equipped with the necessary safety gear and trained to combat any accidents that may take place. As they are ISO 9001:2000 for its QMS certificate for manufacturing responsible textile manufacturing process. URMI Group 7

  8. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Their Sporting skill in Textile production includes: All Kinds of S/J, Rib, Interlock, Pique, French Terry, Brushed Fleece, Drop Needle,different type of design etc. on : 100% Polyester,100% Cotton & Different blend of Cotton and Polyester. Cotton –Elastane. 100% Organic Cotton. Blend of Organic and normal Cotton. 100% Modal. 100% Viscos Viscos- Elastane Cotton-Modal Polyamide- Elastane We are Impregnable in producing Special Fabrics like : Coolmax . Soil / Stain Release. Water Repellent Silpur Finish ( Anti Bacterial) UV Finish. 3X dry finish URMI Group 8

  9. INDUSTRIAL INTERNSHIP REPORT Process Flowchart: SOUTHEAST UNIVERSITY Check point: Yarn count Slub / Strength / evenness Quality Check Yarn In line inspection Knitting Greige Quality Check Quality Check Heat Setting Batch preparation Turning/reversing As per confirmation of lab dip Dyeing Slitting/Dewateri In line QC Stentering/Drying Shrinkage, Rubbing, Bursting, spirality, Fastness to wash, perspiration, pilling etc. Stentering/Drying Special finish/ Brushing/Sueding / Print Compacting Finished Goods Physical Inspection Lab QC 4-Point System URMI Group 9

  10. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY CHAPTER-2 MAN-POWER MANAGEMENT Manpower of Fakhruddin Textile Mills ltd.: URMI Group 10

  11. INDUSTRIAL INTERNSHIP REPORT Unit Officer & Staff SOUTHEAST UNIVERSITY worker Total FTML Textile 260 940 1200 FTML Garments 575 3248 3823 Total 835 4188 5023 Professionals Working For: SL.no. Name of Education Persons 01 Masters 106 02 BBA/MBA 29 03 Industrial Engineering 06 04 B.Sc. In Textile Engineering 42 05 B.Sc. In Mechanical Engineering 02 06 B.Sc. In Electrical Engineering 03 07 B.Sc. In Computer Science and Engineering 03 08 CA (CC) 03 09 MBBS 02 10 PGDHRM 02 11 L.L.B 02 12 Diploma In Engineering 60 Total 260 ORGANOGRAM: URMI Group 11

  12. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY MD/Director Chief Operating Officer Textile Garments Sr. GM Sr. GM Store HR, Admin & Compliance Planning & Work study Company Secretary Merchandising Accounts & Finance Commercial Project Sr. AGM Accounts & Finance DGM DGM Project Implementation DGM DGM Dyeing DGM Production [Factory Manager] Merchandising Commercial AGM Knitting AGM Accounts & Finance AGM Cutting AGM Production AGM AGM Quality AGM Work Study AGM AGM Commercial Admin.HR & Comp. Merchandising URMI Group 12

  13. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY CHAPTER-3 RAW MATERIALS Raw Material Raw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production and for high quality fabric. Types of Raw Materials: URMI Group 13

  14. INDUSTRIAL INTERNSHIP REPORT 1. Yarn SOUTHEAST UNIVERSITY 2. Grey Fabric 3. Dyes 4. Chemical Raw Materials Sources: Yarn: Some Factory Name of Yarn Suppliers, Square Textile Mills Padma Textile Mills Mosharaf Textile Mills ltd. Prime Composite Mills Israq Textile Mills ltd. Badsha Textile Mills ltd. Shamsuddin Spinning Tara Textile Mills ltd. PHP Textile Mills ltd. Numan Spinning Mills ltd. Different Yarn And Count for Knitting: SL/No Yarn Type Composition Yarn Count 01 Carded Yarn 100% Cotton 10s, 12s, 16s, 20s, 20/2, 22s, 24s, 26s,28s, 30, 32s, 34s, 02 Combed Yarn 100% Cotton 20s, 22s, 24s, 26s, 28s, 30s, 32s, 34s, 36s, 40s, 50s, 60s. URMI Group 14

  15. INDUSTRIAL INTERNSHIP REPORT 03 G/M SOUTHEAST UNIVERSITY (Viscose %) 1%, 2%, 5%, 10%, 15%, 20%, 30%, 40% 04 Spun Yarn 100% Polyester 36D, 70D, 72D, 75D, 05 PC Polyester + Cotton 24s, 26s, 28s,30s, 32s, 34s, 06 CVC Cotton + Polyester 24s, 26s, 28s, 30s, 34s, 36s, 40s 07 C/M Cotton 50% + Polyester 50% 26s, 28s, 30s, 08 Lycra Synthetic 20D, 40D, 70D, Grey Fabrics: Following types of grey fabrics are dyed- Single jersey Double jersey Single jersey with lycra Interlock Single Lacoste Double Lacoste Rib Lycra rib 1 x 1 rib & others Collar & cuff Polyester fabrics Single Pique Double Pique Terry Fleece Fleece Sources: The required grey fabric is produce in the industry. Chemicals: 01. Soda ash light 24. Mcropan DPE 02. Caustic Soda 25. Cibapon R 03. Common salt 26. Ctobalance NSR 04. Glauber Salt 27. Rucozen RES URMI Group 15

  16. INDUSTRIAL INTERNSHIP REPORT 05. H2O2 SOUTHEAST UNIVERSITY 28. TinofixFRd 06. Acetic Acid 29. Lily XXL powder 07. Oxalic Acid 30. RewanAcp 08. Bleaching Powder 31. Cibatex ECO 09. Hydrose 32. Invatex CRA 10. Leuphore BMB 33. Heptole EMG 11. Uvtex BHT 34. Cibafluide C 12. Uvtex BHV 35. Biovin 109 13. Uvtex BAM 36. Tinozym 44L 14. Syno White 4BK 37. Beizym ULBD 15. Uvtex BFE 38. Invatex PC 16. Albatex FFC 39. Invatex AC 17. CHTE nt. K50 40. Catalar BF 18. InvadineLun 19. Feloson NOF 20. Invadine DA Dyes: 01. Solazol Black sp GRI 21. Cibacron Blue FNR 02. Reactofix Red ME4BL 22. Cibacron Blue FGFN 03. Cottofix Red ME4BL 23. Cibacron Navy WB 04. Reactofix Orange ME2RL 24. Drimarin Yellow CL2RL 05. Reactofix N.ME2GL 25. Drimarin Red CL5B 06. Reactive Yellow H4GL 26. Drimarin Violet K2RL URMI Group 16

  17. INDUSTRIAL INTERNSHIP REPORT 07. Reactive Deep Black N SOUTHEAST UNIVERSITY 27. Drimarin Navy CLB 08. Cottofix Black B 28. Drimarin Blue CT2R 09. Reactive Blue R(SP) 29. Bezaktrive Yellow S3R 10. Remazol Red RR 30. Bezaktrive Yellow SLF 11. Remazol Yellow RR 31. Bezaktrive Yellow V GL 12. Remazol Blue RR 32. Diss Yellow F5GL 13. Remazol Blue BB NEW 33. Diss Red BF 14. Remazol T. Blue G 34. Diss Blue FRL 15. Remazol B Yellow 3GL 35. Diss Navy 2GL 16. Remazol Red RGD 36. Diss Black EXNSF 17. Cibacron Red FN2BL 37. Terasil Black WNS 18. Cibacron Red FB 38. Terasil Red FB 19. Cibacron Red FN3G 39. Terasil Red WFS 20. Cibacron Red WB 40. Terasil Red W4BS Remarks: Fakhruddin Textile Mills Limited. uses best quality raw materials. It produces fabrics from best quality yarn. They uses the best quality dyes like REMAZOL, REACTRON, REACTIVE,TERACIL etc. During the time of using dyestuff they give importance upon the quality of dyes than the price of the dyes and chemicals. URMI Group 17

  18. INDUSTRIAL INTERNSHIP REPORT CHAPTER-04 INVENTORY CONTROL AND UTILITY SOUTHEAST UNIVERSITY Store & inventory control: Frequency of Inventory Control: Monthly inventory control Annual inventory control Scope of Inventory Control: Raw materials Dyes store Others chemicals store URMI Group 18

  19. INDUSTRIAL INTERNSHIP REPORT Grey fabrics SOUTHEAST UNIVERSITY Finishing fabric spare parts General store Capital equipment Accessories Stationary Maintenance parts. Inventory system for raw materials: Raw materials partially received from production planning & directly from head office. Material Receiving & Inspection Report (MRIR) is prepared. Received quantity is mentioned & noted down. Submitted to QC department. Some are OK & few rejected. Entry of data of goods in DATATEX. Goods are arranged according to OK or rejected group. Department gives store requisition to warehouse. As per requisition materials supplied & this record is noted down. Stages of grey fabric inventory control: After knitting production Grey inspection Warehouse Batch preparation Dye house. Stages of finished fabric inventory control: Finishing section After final inspection Warehouse. URMI Group 19

  20. INDUSTRIAL INTERNSHIP REPORT Utility: SOUTHEAST UNIVERSITY SL MACHINE NAME BRAND ORIGIN QUANTITY (Nos) CAPACITY 01 GAS WAUKESHA U.S.A 02 750 KW GENERATOR 02 BOILER COCKRAN U.K 03 4500 KG 03 DIESEL GENERATOR DAIHATSU JAPAN 01 550 KW 04 COMPRESSOR COMP AIR GERMANY 01 5.5 m3/MIN 05 PUMP KSB INDIA 01 80-120 m3/Hr 06 BOOSTING PUMP KSB DPVF-65- 30 INDIA 06 65 m3/Hr Moreover Urmi Group have the following facilities for smooth operation: •Stand by Generator to run the full factory •Fire protection system •Sufficient volume of water reservoir at underground & overhead. •Quality electrical cable with circuit breakers •Separate toilets for male & female workers •Sufficient ventilation is provided by installing ceiling fans, exhaust fans, large windows •Factory premises is always kept neat & clean •We do not have any child labor •Doctor & Nurse are provided to take care of workers health •Canteen for workers •Day care center •Work study center URMI Group 20

  21. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY CHAPTER-05 URMI Group 21

  22. INDUSTRIAL INTERNSHIP REPORT MARKETING STRATEGY SOUTHEAST UNIVERSITY Marketing Strategy: Marketing strategy is a very important factors to sale the products to the buyer . If the marketing strategy is not so developed , it will be very hard to reach the goal . In case of garments marketing the dealings with the buyer is a very important factor. In Fakhruddin Textile Mills Ltd. mainly senior marketing officers , merchandiser & higher officials deal with the buyer . There are some fixed buyers of the industry. The buyers give their orders continuously all over the year . The marketing officers & the merchandisers communicate with the buying houses to collect the orders . Fakhruddin Textile Mills Ltd. is a 100% export oriented industry. All the goods produce in this industry are exported to various country . Clients of Fakhruddin Textile Mills Ltd.: Buyer Country Lidl Germany S.Oliver Germany URMI Group 22

  23. INDUSTRIAL INTERNSHIP REPORT Tchibo SOUTHEAST UNIVERSITY Germany Puma Germany Marks & Spencer UK H&M Sweden Ellos Sweden LaRedoute France Litex UK Vertbaudet France Auchen France Decathlon France Brylane USA Toray Japan Meters Bonwe China Ernesting’s Family Germany URMI Group 23

  24. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Main Products: Polo Shirt, Sweat Shirt, Ladies rib tops, basic and fancy polo, T-Shirt,Tank-Tops, Sweat Tops and bottoms for all age range of male and female. CHAPTER-06 KNITTING SECTION URMI Group 24

  25. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Knitting: Knitting is a process of manufacturing a fabric by inters looping of yarns. Knitting is the second most important method of fabric formation. It can be defined as a needle technique of fabric formation, in which, with the help of knitting needles, loops are formed to make a fabric or garment. Fabric can be formed by hand or machine knitting, but the basic principle remains exactly the same i.e. pulling a new loop through the old loop. In other words, Knitting is a method by which thread or yarn may be turned into cloth or other fine crafts. It is a fabrication process i.e. intermeshing series of loops of one or more yarns or from a set of yarns. Knitted fabric consists of consecutive rows of loops, called stitches. As each row progresses, a new loop is pulled through an existing loop. The active stitches are held on a needle until another loop can be passed through them. This process eventually results in a final product, a garment. Knitting may be done by hand or by machine .Different yarns and knitting needles may be used to achieve different end products by giving the final piece a different color, texture, weight, and/or integrity. Using needles of varying sharpness and thickness as well as different varieties of yarn can also change the effect. A URMI Group 25

  26. INDUSTRIAL INTERNSHIP REPORT knitted fabric is the SOUTHEAST UNIVERSITY third major class of fabric, after woven and nonwoven fabrics. In knitting, the inter-lopping is carried out by needles (may be Latch or beard or compound needle etc), the needles are equipped on a cylinder and Needle butt moves between the grooves of cams to accomplish knitting cycle and producing the fabric. The shape of the needle cam grooves depends on the required knitting pattern. All over the world, the majority of knit fabrics are manufactured on circular knitting machines. The high performance level of these machines, the different materials and the range of yarn counts that they are able to process, the wide variety of designs and stitches are some of the reasons which have granted circular machines the market leadership in the knitting sector. Layout Of Knitting Section: URMI Group 26

  27. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Knitting Machine Specification: M/C M/C Name or Country Year M/C Type Dia& No. of No. of URMI Group 27

  28. INDUSTRIAL INTERNSHIP REPORT No. Brand Name SOUTHEAST UNIVERSITY of Origin of Gauge Feeder Needle Manu. 01 JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. JIUNN LONG M/C CO.LTD. PAI LUNG M/C CO. LTD. PAI LUNG M/C CO. LTD. PAI LUNG M/C CO. LTD. PAI LUNG M/C CO. LTD. KEUMYONG M/C CO. LTD. PAI LUNG M/C CO. LTD. PAOLO ORIZIO PAI LUNG M/C CO. LTD. KEUMYONG M/C CO. LTD. PAI LUNG M/C CO. LTD. PAI LUNG M/C CO. LTD. PAI LUNG M/C TAIWAN Single Jersey 28*28 84 2464 02 TAIWAN Single Jersey 28*24 84 2464 03 TAIWAN Single Jersey 28*24 84 2464 04 TAIWAN Single Jersey 30*28 90 2639 05 TAIWAN Single Jersey 30*28 90 2639 06 TAIWAN Single Jersey 30*28 90 2639 07 TAIWAN Single Jersey 32*28 96 2815 08 TAIWAN Single Jersey 32*28 96 2815 09 TAIWAN Single Jersey 32*28 96 2815 10 TAIWAN Single Jersey 34*28 102 2991 11 TAIWAN Single Jersey 34*28 102 2991 12 TAIWAN Single Jersey 34*28 102 2991 13 TAIWAN Single Jersey 36*24 108 2715 14 TAIWAN 2009 Double Jersey 36*24 72 2715 15 TAIWAN 2004 Double Jersey 36*18 72 2036 16 TAIWAN 2009 Double Jersey 36*18 72 2036 17 TAIWAN 2004 Double Jersey 36*18 72 2036 18 KOREA 2007 Double Jersey 38*18 90 2149 19 TAIWAN 2009 Double Jersey 40*18 80 2262 20 21 ITALIA TAIWAN 2002 2009 Double Jersey Double Jersey 30*18 42*18 60 84 1697 2376 22 KOREA 2007 Double Jersey 42*18 84 2376 23 TAIWAN 2009 Single Jersey 24*24 72 1810 24 TAIWAN 2009 Single Jersey 24*24 72 1810 25 TAIWAN 2004 Single Jersey 26*24 78 1961 URMI Group 28

  29. INDUSTRIAL INTERNSHIP REPORT CO. LTD. 26 PAI LUNG M/C CO. LTD. 27 JIUNN LONG M/C CO.LTD. 28 JIUNN LONG M/C CO.LTD. 29 PAI LUNG M/C CO. LTD. 30 PAI LUNG M/C CO. LTD. 31 PAI LUNG M/C CO. LTD. 32 PAI LUNG M/C CO. LTD. 33 PAI LUNG M/C CO. LTD. 34 KEUMYONG M/C CO. LTD. 35 KEUMYONG M/C CO. LTD. 36 KEUMYONG M/C CO. LTD. 37 PAI LUNG M/C CO. LTD. 38 PAI LUNG M/C CO. LTD. 39 JIUNN LONG M/C CO.LTD. 40 PAOLO ORIZIO 41 PAI LUNG M/C CO. LTD. 42 PAI LUNG M/C CO. LTD. 43 PAI LUNG M/C CO. LTD. 44 PAI LUNG M/C CO. LTD. 45 JIUNN LONG M/C CO.LTD. 46 PAI LUNG M/C CO.LTD. 47 PAI LUNG M/C CO.LTD. 48 KEUMYONG M/C CO. LTD. 49 JIUNN LONG M/C CO.LTD. 51 JIUNN LONG M/C CO.LTD. SOUTHEAST UNIVERSITY TAIWAN 2009 Single Jersey 26*24 78 1961 TAIWAN Single Jersey 28*24 84 2112 TAIWAN Single Jersey 28*24 84 2112 TAIWAN 2003 Double Jersey 40*18 80 2262 TAIWAN 2003 Double Jersey 36*18 72 2036 TAIWAN 2004 Double Jersey 32*18 64 1810 TAIWAN 2009 Double Jersey 32*18 64 1810 TAIWAN 2009 Double Jersey 30*18 60 1697 KOREA 2007 Single Jersey 40*24 120 3016 KOREA 2007 Single Jersey 40*24 120 3016 KOREA 2007 Single Jersey 36*24 120 2715 TAIWAN 2009 Single Jersey 36*24 108 2715 TAIWAN 2009 Single Jersey 34*24 102 2564 TAIWAN Single Jersey 30*24 90 2262 ITALIA TAIWAN 2002 2004 Single Jersey Single Jersey 30*24 30*24 90 90 2262 2262 TAIWAN 2004 Single Jersey 26*24 78 1961 TAIWAN 2004 Single Jersey 30*24 90 2262 TAIWAN 2004 Single Jersey 30*24 90 2262 TAIWAN Single Jersey 32*24 96 2413 TAIWAN 2004 Single Jersey 32*24 96 2413 TAIWAN 2004 Single Jersey 32*24 96 2413 KOREA 2007 Single Jersey 34*24 102 2564 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 URMI Group 29

  30. INDUSTRIAL INTERNSHIP REPORT 52 JIUNN LONG M/C CO.LTD. 53 JIUNN LONG M/C CO.LTD. 54 JIUNN LONG M/C CO.LTD. 55 JIUNN LONG M/C CO.LTD. 56 JIUNN LONG M/C CO.LTD. 57 JIUNN LONG M/C CO.LTD. 58 JIUNN LONG M/C CO.LTD. 59 JIUNN LONG M/C CO.LTD. 60 JIUNN LONG M/C CO.LTD. 61 JIUNN LONG M/C CO.LTD. 62 JIUNN LONG M/C CO.LTD. 63 JIUNN LONG M/C CO.LTD. 64 JIUNN LONG M/C CO.LTD. 65 JIUNN LONG M/C CO.LTD. 66 JIUNN LONG M/C CO.LTD. 67 JIUNN LONG M/C CO.LTD. 68 JIUNN LONG M/C CO.LTD. 69 JIUNN LONG M/C CO.LTD. 70 JIUNN LONG M/C CO.LTD. 71 FUKAHARA SOUTHEAST UNIVERSITY TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 TAIWAN Single Jersey 28*28 84 2464 CHINA Auto Stripe (Double Jersey) Auto Stripe (D/J) 72 FUKAHARA CHINA Process flow chart of knitting: Cone from spinning Creeling the cone URMI Group 30

  31. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Yarn feed by different tensioner Adjust S/L, GSM, etc. by V.D.Q pulley Produce 0.5 m fabric, if fault found, it adjust After bulk production, cut the role Marking the role such as S/L, Diameter, GSM etc. Role inspection Gray Store Finishing/Dyeing Sequence of Yarn Feeding: URMI Group 31

  32. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Creel Yarn Tube/Pipe Wheel Yarn Sensor Knot Catcher Positive Feeder Feeder Final Yarn Guide Needle Different Parts of Circular Knitting Machine: 1. Creel:Creel is a part of a knitting machine. Here yarn package are store and ready to feed in the machine. URMI Group 32

  33. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY 2. Positive Feeders:Here number of yarn wounded on two positive feeder for smooth feeding of two yarn in the machine. 3. Feed Sensor:It is used in positive feeder to help the little display at the time of yarn breakage. At that time machine is stopped. 4. Final Yarn Guide:It controls the path of the yarn. URMI Group 33

  34. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY 5. Needle:Hooked metal part which is used to formation of loops. 6. Indicators:In any yarn breakage or any fault in the machine. Indicators are used to identify them. 7. Lubricants:The lubricator provides lubrication to needle, cam tracks, lifters and other knitting machine components. URMI Group 34

  35. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY 8. Fluff Blower:It removes the fiber, dust particle on the machine. 9. VDQ Pulley:It controls the stitch length as well as GSM of knit fabric. 10. Cam: Cams are knitting elements which cover rotary machine drive into a suitable reciprocating action for the needles and other elements. 11. Cam Box:Where the cams are set horizontally. URMI Group 35

  36. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY 12. Cylinder:Needles are situated here. 13. Dial:Needles are situated here. It is used in double jersey knitting machine. 16. Needle Detector:This part detects the any type of faults of needles. URMI Group 36

  37. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY 17. Spreader:To control the width of the knitted fabric. 18. Taker-in:It is takedown the fabric in suitable tension. 19. Cloth Roller:Numbers of fabric layers are wound evenly. Other parts, URMI Group 37

  38. INDUSTRIAL INTERNSHIP REPORT Positive Feeder Belt Knot Catcher Top Gear Oil D/J Yarn Tube/Pipe Rotating Fan Yarn Feeder Ring Ceramic Yarn Feeder Ceramic Lycra Guide/Wheel Fabric Detector Needle detector Machine Gate Take Down Side Gears Fabric Roller Lock Rubber Belt (Curling) All Gear Greasing All Type of Nut & Bolt SOUTHEAST UNIVERSITY Terms of Knitting: Course: Horizontal row of loops produced by adjacent needles in knitting cycle is called the course of the fabric. A course is a predominantly horizontal raw of needle loops produced by adjacent needles during the same knitting cycle called course. (Loop length * No of loop). Wales: Vertical column of loops produced by same needle in knitting cycle is called the Wales of the fabric. URMI Group 38

  39. INDUSTRIAL INTERNSHIP REPORT A wale is a predominantly vertical column of intermeshed needle loops generally produced by the same needle knitting cycles. i.e. The number of vertical columns of loop of knitted fabrics is called wale. SOUTHEAST UNIVERSITY Face loop: If the legs of new loop is passes over the old loop is called face loop. Back loop: If the legs of new loop is passes under the old loop is called face loop. Stitch density: The term stitch density is frequently used in knitting instead of a linear measurement of courses or Wales; it is the total number of needles loops in a square area measurement such as a square inch or three square centimeters. It is expressed as, Course per inch × Wales per inch. Stitch length: Length of one loop in the course direction express in mm. Number of needle: Machine diameter × Machine gauge × 3.1416. GSM: The weight of one square meter of fabric express in gram is known as GSM. Needle gauge: The needle gauge of a knitting machine is a measure expressed the no. of needle per unit of the needle bed or needle bar. As for example: 1.In case of circular weft knitting machine & Tricot warp knitting machine. [Gauge, N= Number of needle per inch.] 2.In case of Raschel warp knitting machine. [Gauge, N= Number of needle per two inch.] URMI Group 39

  40. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Needle: There are three types of needle- 1.Bearded needle 2.Compound needle 3.Latch needle- One butt needle. Two butt needle. Three butt needle. Four butt needle. The most widely used needle is latch needle. Fig: Main parts of latch needle. Cam: Cam is called the specific path of the needles to produce a specific type of fabric. URMI Group 40

  41. INDUSTRIAL INTERNSHIP REPORT There are three types of cam used in circular knitting machine: SOUTHEAST UNIVERSITY 1.Knit Cam. 2.Tuck Cam. 3.Miss Cam. Knit Cam: It moves the needle upward enough to clear the old loop and receive the new yarn. Tuck Cam: It moves the needle upward not enough to clear. The old loop but receive the new yarn. Miss cam: It does not move the needle upward. The needles neither clear the old loop nor receive the new yarn. Sinker: It is a thin metal plate with an individual or collective operation approximately at right angles at the hook side between adjacent needles. URMI Group 41

  42. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Function of sinker: In circular knitting m/c sinker helps to form the loop by holding down the yarn Loop forming sequence of latch needle: Latch Opening: The needle goes upward and the sinker comes in action to hold down the loop. Then the old loop press down the latch and it gets open. Yarn Receiving: URMI Group 42

  43. INDUSTRIAL INTERNSHIP REPORT The needle iscontinuous moving upward enough to receive the new yarn. The old loop remains on the open latch that is called tucking on the latch position. SOUTHEAST UNIVERSITY Clearing: The needle goes to its ultimate height to clear the old loop and the new yarn still within the reach of the needle. Landing: According to the path of cam, the needle starts moving downward. Being pushed by the old loop the latch gets closed and the new yarn is entrapped within the closed hook. Knock off: The needle continues moving downward. When it reaches at the down position, the old loop slides off from the back of the latch over the tip of the needle.This old loop then taken by the take up roller hangs from the new loop. Fabric Types: Single Jersey Rib Interlock URMI Group 43

  44. INDUSTRIAL INTERNSHIP REPORT Normal S/J Fancy Diagonal Fleece Polar Fleece Single Lacoste Double Lacoste High S/J French Terry Single Pique Double Pique SOUTHEAST UNIVERSITY (1*1) Rib (1*2) Rib Needle Drop Rib Milano Rib Flat back Rib B-Waffle FFL-Rib Plain Interlock Mesh Net Mesh Considerable points to produce knitted fabrics: When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows- Type of Fabric or design of Fabric. Finished G.S.M. Yarn count Types of yarn (combed or carded) Diameter of the fabric. Stitch length Color depth Relationship between knitting parameter: 1. Stitch length increase with decrease of GSM. 2. If stitch length increase then fabric width increase and Wales per inch decrease. 3. If machine gauge increase then fabric width decrease. 4. If yarn count increase (courser) then fabric width increase. 5. If shrinkage increases then fabric width decrease but GSM and Wales per inch increase. 6. For finer gauge, finer count yarn should use. 7. Gray GSM should be less than finish GSM Production Parameter: Machine Diameter; Machine rpm (revolution per minute); No. of feeds or feeders in use; URMI Group 44

  45. INDUSTRIAL INTERNSHIP REPORT Machine Gauge; Count of yarn. SOUTHEAST UNIVERSITY Responsibilities of a Production Officer : Monitor and control shift wise production, plant utilization, waste generation etc. implement correct work methods and maintain all records related to production.  Responsible for systematic planning and execution of production programs. Adequate control over process in order to achieve quality of product & better waste management.  Monitor shift wise production, utilization etc. and take corrective action for any shortfall. Maintain all the procedure of his department and shall incorporate amendments as and when required in procedure. Responsibilities for monitoring the performance of manpower under him and identification of training needs. Methods of increasing production: By the following methods the production of knitted fabric can be increased – By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately production will be increased but it has to make sure that excess tension is not imposed on yarn because of this high speed. 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. By using machine of higher gauge: URMI Group 45

  46. INDUSTRIAL INTERNSHIP REPORT The more the machine gauge, the more the production is. So by using machine of higher gauge production can be increased. SOUTHEAST UNIVERSITY By imposing other developments: Using creel-feeding system Applying yarn supply through plastic tube that eliminates the possibilities of yarn damage Using yarn feed control device Using auto lint removal. Factors that should be change in case of fabric design on quality change: a)Cam setting b)Set of needle c)Size of loop shape If shrinkage increases then fabric width decrease but GSM and Wales per inch increase. For finer gauge, finer count yarn should use. Effect of stitch length on color depth: If the depth of color of the fabric is high loop length should be higher because in case of fabric with higher loop length is less compact. In dark shade dye take up% is high so GSM is adjusted then. Similarly in case of light shade loop length should be relatively smaller Some points are needed to maintain for high quality fabric: URMI Group 46

  47. INDUSTRIAL INTERNSHIP REPORT Brought good quality yarn Machines are oiled and greased accordingly G.S.M, Stitch length, Tensions are controlled accurately Machines are cleaned every shift and servicing is done after a month Grey Fabrics are checked by 4 point grading system SOUTHEAST UNIVERSITY Changing of GSM: Major control by VDQ pulley Minor control by stitch length adjustment Altering the position of the tension pulley changes the G.S.M. of the fabric. If pulley moves towards the positive direction then the G.S.M. is decrease. And in the reverse direction G.S.M will increase Tension: Tension should be control for different yarns, because for tension variation yarns may be broke. Tension measured by Tension Meter. Yarn Tension (CN) Cotton (S/J) 4-5 Polyester (Single Jersey) 3.5-4 Double Jersey 2-2.5 CVC/Viscose 6-7 For Fleece Yarn: Yarn Tension (CN) Binding Cotton Polyester 3-4 1 Knit 4-5 Tuck 8-10 URMI Group 47

  48. INDUSTRIAL INTERNSHIP REPORT SOUTHEAST UNIVERSITY Production Calculation: We took all the necessary data which is related to calculating production (kg/hr) while machine running. And here we show how to calculate different types of fabric production. Machine No-46: Single jersey (Plain): = 16.34 kg/hr = 130.73 kg/hr = 392.2 kg/day = 11765 kg/month or, 11.765 ton/month = 141.18 ton/year Machine No-20: (Double Jersey Rib) URMI Group 48

  49. INDUSTRIAL INTERNSHIP REPORT = 7.12 kg/hr SOUTHEAST UNIVERSITY = 56.96 kg/shift = 5126.4 kg/month or, 5.13 ton/month = 61.52 ton/year Machine No-14: (Double Jersey Interlock) = 9.14 kg/hr = 73.13 kg/shift = 219.38 kg/day = 6.58 ton/month Relationship Between G.S.M, S/L & Count for different fabric: Single Jersey (Plain): G.S.M 120 130 140 150 160 170 Count 36/1 32/1 30/1 28/1 26/1 24/1 S/L (mm) 2.80 2.80 2.85 2.85 2.85/2.90 2.95 URMI Group 49

  50. INDUSTRIAL INTERNSHIP REPORT 175 180 200 210 220 SOUTHEAST UNIVERSITY 24/1 24/1 20/1 20/1 20/1 2.90 2.85 3.10 3.05 3.00 Rib: G.S.M 200 210 200 200 200/210 280 Count 34/1, 20D 30/1 28/1 34/1, 75D 26/1 27/1 (CB) S/L (mm) 2.90/1.30 2.76 2.80 2.85/2.30 2.90 2.90/1.18 Interlock: G.S.M 190 Count 36/1, 70D S/L (mm) 1.65/1.15 Analysis of the Fabric: Design analysis: URMI Group 50

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