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Industrial Attachment of Beximco textiles limited (btl)

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Industrial Attachment of Beximco textiles limited (btl)

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  1. 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Beximco Textiles limited (BTL)

  2. 2 Chapter I Project Description

  3. 3 BEXIMCO TEXTILES LTD (BTL) AT A GLANCE Beximco Textiles limited (BTL) 1. Name of the project :Beximco Textiles limited (BKL.) 2. Project proponent :Beximco group of companies 3. Location :Sarabo, Kashimpur, Gazipur. About 25 kms north of Dhaka city and 10 kms from Savar. 4 Address : Factory & head Office: Beximco Industrial Park, Saraboo,Kashimpur, Gazipur, Bangladesh. 5. Board of directors : A.S.F. Rahman, Chairman& Managing Director. Salman F Rahman, vice – Chairman. 7. Communication 8. Product name fabric. 9. Product Mix : A) Gray fabric: 1. Solid dyed 2. yarn dyed. :The project is easily accessible by road. :Woven yarn dyed ,solid dyed and shabrey , bleached a. Stripe. b. Check. 3. Shambrey fabric. 4. Canvas. B) Design. a. In Tappet loom. i. Plain. ii. Twill. iii. Sateen. iv. Some combination weave which are posible in tappet. v. Oxford. (Warp rib and weft rib). vi. Queen’s Oxford. vii. Matt. b. In Dobby loom: i. Various types of weave.

  4. 4 ii. Diamond. iii. Diaper. iv. Herring bone. v. Honey comb. vi. The design which are possible in 16 heald frames. 10. Annual production capacity 11. Factory area 12. Type of the factory 13. No. of employees 14. Project cost 15. Different Departments : 3,65,00,000 per year. :Approx. 30acres. :Horizontally integrated. :Approx. 300. :Approx. 17000 million taka : a) Adminstration. b) Human Resource and Develoment Dept. c) Weaving. d) Woven Dyeing e) Woven finishing. f) Spinning. g) Knitting Dept h) Knit dyeing Dept. i) Yarn dyeing Dept. j) Woven Garments Dept. k) Knit Garments Dept. l) Denim weaving. m) Denim finishing. n) Garments washing plant. o) Planning Dept. p) Utility Dept. q) Research & development Dept. r) Product development. s) Design Studio. Site Location: Location description: Beximco Industrial park is near about 1 kilometre from Chakraborti Bus stop. Chakra borti bus stop is in the way of Dhaka Tangail High way. There are two easy way to go from Dhaka. 1. Motijheel → Sat rasta → Mohakhali → Uttara→ Abdullahpur→ Ashulia → Bipile → DEPZ → Chakraborti → Beximco Industrial Park. 2. Motijheel → Farmgate→ Mirpur Road → Gabtoli → Savar → Nobinagar → Bipile → DEPZ → Chakraborti → Beximco Industrial Park.

  5. 5 DEPZ Chakraborti Bipile Nobinagar DEPZ J. U. Beximco Industrial Park Dhaka Mymensing Road Savar Ashulia Tongi Gabtoli Abdullahpur Mirpur Uttara Mirpur Road New Air port Mohakhali Prime Minister’s House Old Air port National Assembly College of Textile Technology Asad gate Farmgate Sat Rasta Location diagram is not to scale. It is only a scematic diagram.

  6. 6 Transport: For the Beximco employee there are 7 large bus to transport. Bus’s are Air conditioned and comfortable. These bus’s are up and down from beximco industrial park to Dhaka metropolitan city to 7 Route. Without these bus’s there are some micro bus’s to lift the Shift executives. For the general people there are two bus service available: 1. Hanif Metro Service. 2. Super bus Service. These bus’s are start from Motijheel to Nandan Park. Cost of Transport: About 30 Taka per head from Motijheel. HISTORY OF BEXIMCO GROUP: 1965-1975 1965 New Dacca Industries Ltd Beximco is born. 1973 Beximco UK branch. 1976-1989: Beximco diversifies 1978 Beximco foods Ltd. 1979 Beximco pharmaceuticals ltd. 1982 Shinepukur Jute Spinners Ltd. 1985 Beximco apparels Ltd. 1987 Recognised as export house for contribution to country’s export. 1990-1995: Beximco expands 1990 Padma Textile Mills Ltd.(plant -1) 1992 Beximco Synthetics Ltd. 1996-1999: Beximco preparing for the new millennium. 1996 Beximco Textiles Ltd (Phase 1). Beximco Knitting Ltd. Beximco Denims Ltd .

  7. 7 1997 Padma Textiles Mills Ltd (Plant-2). 1998 Beximco Textiles Mills Ltd (Phase 2). Beximco Fashions Ltd .  Physical Infrastructure: - Single storied building (only dye warehouse is double storied ) - Concrete structure (about 25 ft high)

  8. 8 Chapter II Manpower Management

  9. 9 Oragan gram : Chairman (A. S. F. Rahman) ↓ Vice Chairman (Salman F. Rahman) ↓ C. E. O. ↓ C. O. O. ↓ ↓ ↓ ↓ ↓ ↓ ↓ D.G.M Weaving D.G.M Dye house D.G.M Yarn dyeing D.G.M knitting D.G.M spinning D.G.M Garments Winding Mr. Jamil Warping Mr. Ahad. Sizing Mr. Monir Loom 1, 2 Mr. Saleh Mechanical + Label Mr. Nazir Drawing Denting Mr. Aman Design Cell Mr. Rana + Loom 3, 4 Mr. kabir Man power in Different section of BTL (Weaving): Section Man power Winding 329 Warping 83 Sizing 50 Drawing, Denting 135 Weaving 269 Design cell 10 Label 30 Maintenance 50 Others 40 Utility 50 Total 1046

  10. 10  SHIFT CHANGE: There are three shifts per day in B.K.L. So each shift contain eight hour. Shift A B C General shift Duration 06.00 AM – 02.00 PM 02.00 PM – 10.00 PM 10.00 PM – 06.00 AM 09.00 AM – 05.00 PM General shift, which is applicable for some officers.  Function area: Setting the different parameters of machines, using correct yarn for order, controlling machine stare, controlling process quality system.  Remarks: The organization and management system are good for mill environment and as the job description is classified, so duties are done honestly and sincerely.

  11. 11 Chapter III Machine Description

  12. 12

  13. 13 Chapter VI Raw Materials

  14. 14 Main raw Materials are yarn.size materials such as starch anti bacterial agent. Yarn used mainly 100% cotton, PC, CVC, 100% Polyester, Lurax, lycra core spun yarn. Spinning section of Beximco supply maximum variety of yarn. Theyt can supply 100% cotton, PC, CVC. Beximco synthetic supply 100% polyester. Lurax, lycra core spun yarn import from other countries of the world. Size material purchase by tender.

  15. 15 Chapter V Production planning Sequences and Operation

  16. 16 Process Flow: There are two ways Woven fabric produced: 1. Solid dyed. 2. Yarn dyed. Generally yarn dyed fabrics are costly item. Because dyed yarn are costly and, In case of yarn dyed fabric Sectional warping is necessary which is also costly and time consuming process. Weaving Yarn Dyed Solid dyed ↓ ↓ Store ↓ Store ↓ Soft Winding ↓ Yarn dyeing ↓ Hard winding ↓ Sectional Warping ↓ Sizing ↓ Drawing, Denting ↓ Weaving Direct Warping ↓ Sizing ↓ Drawing, Denting ↓ Weaving

  17. 17 When Order Comes to the Marketing Section, then they contact with the Product development (in case of new product) or Design cell (in case of available product) that, is it possible or not possible in beximco. They Send a Article Request paper. After reaching the Article Request paper Design cell produce Article Code and send mail to the planning and marketing section. Planning print a Dispo paper and send to 11 sections with related production of that fabric. Buyer Merchandiser Marketing Planning Design Cell Send Dispo Paper 1. Design Cell 2. Yarn Requisition 3. yarn store 4. winding 5. yarn dyeing 6. warping 7. Sizing 8. Drawing, denting 9. Weaving 10. M.I.S. 11. Finishing. Dispo Paper: Dispo Paper is a paper which contain All necessary information for the production of a specific item of fabric. Dispo paper contains: ------next page --------------------------------Fill up

  18. 18 Design Cell: Design Cell is one of the most important department of BTL (weaving). When a order comes to the marketing or merchandizing officer he/she send the fabric to the design cell that is it possible or not possible in beximco. They send a Article request paper. Design cell analyze the fabric design and test the feasibility of produciton and create a Article code and send this article code the marketing or marchandizing officer and input data to the Data tex which is a software used in beximco for all types of information by networking. After getting Article code planning discuss with marketing officer about costing. Then marketing officer send mail or discuss directly to the buyer about pricing of the product. If buyer agree with the price then marketing officer send mail to the central planning section with Article code. Planning take a print of dispo paper for the article code from the system data tex. After printing dispo paper they send it to the design cell to check or varify. Design cell check and give drawing and denting plan and send it to the planning section again. Planning then send it to the various section where these information required and at a time requisition all necessary raw materials or other materials. Article Code: Article code is a gathering of All informations which are need to produce that fabric in terms of code. Article code is form by three codes: 1. 2. 3. Fabric code. Pattern / variant. Finish type. 7 digit. 6 digit. 4 digit. Example of Fabric Code: C CD LK C A Design Width Warp count and weft count EPI x PPI Composition Cotton/ CVC/PC Example of pattern / variant ( 7 digit):

  19. 19 T T D D 36 10 Crimp % Cover factor Drawing Direct Warping Tappet Loom Tappet design Organ gram of Design cell: Assistant Manager ( Md. Masud Akhter Rana) ↓ Data Entry + Design Analyzer (2+6 person) ↓ Peon (1 person) Dispo paper goes to the following sections: 1. Design cell. 2. Store. 3. Winding. 4. yarn dyeing. 5. warping. 6. sizing. 7. Drawing and denting. 8. Loom. 9. Finishing 10. M.S.I. Dispo paper contains following types of informations: 1. Fabric Specification. 2. Yarn composition 3. Finished type. 4. Finished fabric’s EPI x PPI 5. Finished fabric’s width. 6. Required length. 7. Reed count. 8. Grey EPI and PPI. 9. Greige width. 10. Reed width. 11. Reed EPI 12. Required greige length. 13. Required warp length.

  20. 20 14. Ground Ends. 15. Selvedge Ends. 16. Cover Factor. 17. Numerical Plan (Warp & Weft) 18. Drawing & Denting Plan. Typical Sample Analysis:

  21. 21 Possible Ends per inch by using Available Reed in Inventory in Beximco by denting 2,3 and 4 in a dent For yarn dyed fabric. Finished Epi Reed Epi Reed count 30 Denting 2 in dent Available no. Reed 1 33.33 30 30 3 in dent 1 50 45 46 2 in dent 20 51.11 46 47 2 in dent 1 52.22 47 49 2 in dent 25 54.44 49 50 2 in dent 8 55.56 50 52 2 in dent 10 57.78 52 58 2 in dent 81 64.44 58 30 4 in dent 1 66.67 60 62 2 in dent 11 68.89 62 66 2 in dent 6 73.33 66 46 3 in dent 20 76.67 69 70 2 in dent 12 77.78 70 47 3 in dent 1 78.33 70.5 72 2 in dent 26 80 72 49 3 in dent 25 81.67 73.5 50 3 in dent 8 83.33 75 75 2 in dent 20 83.33 75 76 2 in dent 22 84.44 76 52 3 in dent 10 86.67 78 78 2 in dent 23 86.67 78 84 2 in dent 6 93.33 84 86 2 in dent 11 95.56 86 58 3 in dent 81 96.67 87 46 4 in dent 20 102.2 92 92 2 in dent 20 102.2 92 62 3 in dent 11 103.3 93 47 4 in dent 1 104.4 94 94 2 in dent 10 104.4 94 96 2 in dent 62 106.7 96 49 4 in dent 25 108.9 98 66 3 in dent 6 110 99 99 2 in dent 144 110 99 50 4 in dent 8 111.1 100 103 2 in dent 6 114.4 103 52 4 in dent 10 115.6 104

  22. 22 Finished Epi Reed Epi Reed count 70 Denting 3 in dent Available no. Reed 12 116.7 105 106 2 in dent 73 117.8 106 72 3 in dent 26 120 108 112 2 in dent 10 124.4 112 75 3 in dent 20 125 112.5 76 3 in dent 22 126.7 114 58 4 in dent 81 128.9 116 116 2 in dent 16 128.9 116 78 3 in dent 23 130 117 121 2 in dent 50 134.4 121 62 4 in dent 11 137.8 124 84 3 in dent 6 140 126 86 3 in dent 11 143.3 129 129 2 in dent 40 143.3 129 66 4 in dent 6 146.7 132 92 3 in dent 20 153.3 138 70 4 in dent 12 155.6 140 94 3 in dent 10 156.7 141 72 4 in dent 26 160 144 96 3 in dent 62 160 144 99 3 in dent 144 165 148.5 75 4 in dent 20 166.7 150 76 4 in dent 22 168.9 152 103 3 in dent 6 171.7 154.5 78 4 in dent 23 173.3 156 106 3 in dent 73 176.7 159 84 4 in dent 6 186.7 168 112 3 in dent 10 186.7 168 86 4 in dent 11 191.1 172 116 3 in dent 16 193.3 174 121 3 in dent 50 201.7 181.5 92 4 in dent 20 204.4 184 94 4 in dent 10 208.9 188 96 4 in dent 62 213.3 192 129 3 in dent 40 215 193.5 99 4 in dent 144 220 198 103 4 in dent 6 228.9 206 106 4 in dent 73 235.6 212

  23. 23 Finished Epi Reed Epi Reed count 112 Denting 4 in dent Available no. Reed 10 248.9 224 116 4 in dent 16 257.8 232 121 4 in dent 50 268.9 242 129 4 in dent 40 286.7 258 Proposed Process Allowances For the different process: Yarn Dyeing Section Warp% Weft% Section 2.00 0.50 3.00 0.50 8.00 1.00 1.50 2.00 2.00 Cumulative 23.32 20.86 20.25 16.64 16.06 6.78 5.71 4.12 2.04 Section 2.00 0.50 Cumulative 26.59 24.06 23.44 23.44 23.44 Yarn Dyeing Winding Warping Sizing Weaving (Crimp) Greige (Reject) Process Loss Shrinkage Inspection (Rejection 13.5 1.00 1.50 2.00 2.00 5.71 4.12 2.04 Total 23.32% 26.59% Yarn Dyeing(pc/cvc) Section Warp% Weft% Section 2.50 1.00 3.50 0.50 8.00 1.00 1.50 1.5 2.00 Cumulative 24.59 21.48 20.26 16.05 15.47 6.23 5.17 3.59 2.04 Section 2.50 1.00 - - 13.50 1.00 1.50 1.50 2.00 Cumulative 27.24 24.06 22.81 22.81 22.81 6.23 5.17 3.59 2.04 Yarn Dyeing Winding Warping Sizing Weaving (Crimp) Greige (Reject) Process Loss Shrinkage Inspection (Rejection Total 24.59% 27.24% There are major departments are : 1. Winding. 2. Warping. 3. Sizing.

  24. 24 4. Drawing, Denting. 5. Weaving. 6. Inspection. These departments are described below: Winding Section Definition: In fabric manufacturing (weaving) process this is the first stage where rewinding of supplied yarn is done on to a desired package suitable for use in the next process. Organogram: The organogram of this section is given below: Section in charge Assist Manager [Jamilur Rahman (Jamil) ] ↓ Quality Control Officer ↓ Supervising Officer ↓ Senior Operator ↓ Operator ↓ Helper ↓

  25. 25 Cleaner Skill Level Man power Assist Manager 1 Quality Control Officer 3 Super vising Officer 27 Senior Operator. 259 Operator Helper 27 Cleaner. 12 Total 329 Winding Section: Types of Winding: 1. Soft Winding. 2. Hard widing.

  26. 26 Soft Winding: Where the grey yarn is wound on to special “Dye Spring” and the package (Spool) is made softer and bulkier to make it suitable for dye liquour penetration in the (package) dyeing machine. Hard Winding: Where the grey yarn dyeing machine is converted from spool to paper cone, to make the yarn easily be fed to the sectional warping machine. Branch of Winding Section: 1. Soft Winding. 2. Hard Winding. 3. Left Over Cone Winding. 4. Sewing Thread Winding. M/c used for Soft winding:

  27. 27 Name of the machine Machine no. 1. FADIS Winder 1 2. RJK Winder. 4 3. HARISH Winder. 3 4. METTLER Winder. 2 FADIS is 10 times more expensive m/c than RJK . In this m/c every drum is controlled by individual motor. So, if the yarn breaks that drum will be stopped . but in RJK and HARRIS there is a common motor. Traversing motion is controlled by grooved drum. The drum width is equal to package width. If we want to change the package width then we have to change the drum width. But in FADIS Traversing motion is controlled by traversing rod. So, package width can be changed easily. During Soft winding Special type of package is used, which is called spring type package. This package is made of metal and has special type of structure for yarn dying. This structure protects any kinds of deformation during yarn dying. After dyeing the package is checked by quality assurance dept. If every thing is OK then it goes to the winding sec. Otherwise it will be rejected. During winding we can not wound hard package in soft winding m/c. because, hard package in soft winding m/c because, hard package has a conical shape and soft package forms a parallel package. This package is of two types. 1. Full cone. 2. Dia cone. If full cone, there are about 5000 m yarn in a cone. But in dia yarn is consumed according to the requirements. For dia every package should be checked and measured for completion of winding. Generally 2 workers are required for every head and 4 workers needs for every m/c. Details information of winding machineries:

  28. 28 M/c Name : FADIS Winder. Manufacturer : FADIS Italy. Manuf. Year : 1995 M.P.M. : 650 No. of Head : 2 No. of Drum /head : 42 Traversing system : By Traverse guide. Motor : Individual Stop motion : Mechanical No. of m/c : 1 Production per head : 748.8 km /day [Assuming 80% efficiency] Production per m/c : 62899.2 km /day [Assuming 80% efficiency] If all head active M/c Name : HARRISH Winder. Manufacturer : HARRISH Textile Engineers Ltd. Gujrat, India. Manuf. Year : 1998 R.P.M. of Motor : 1430 M.P.M. : 650 No. of Head : 2 No. of Drum /head : 60 Traversing system : Grooved drum Motor : Common Stop motion : Mechanical No. of m/c : 3 Production per head : 748.8 km /day [Assuming 80% efficiency]

  29. 29 Production per m/c : 89856 km /day [Assuming 80% efficiency] M/c Name : RJK Winder. Manufacturer : Kinarivala RJK Industries, Ahmadabad, India. Manuf. Year : 1998 R.P.M. of Motor : 1440 M.P.M. : 750 No. of Head : 2 No. of Drum /head : 60 Traversing system : Grooved drum Motor : Common Stop motion : Mechanical No. of m/c : 4 Production per head : 864 km /day [Assuming 80% efficiency] Production per m/c : 103680 km /day [Assuming 80% efficiency] M/c Name : METTLER Manufacturer : FR Mettler’s Sons Ltd. Switzerland. Manuf. Year : 1998 R.P.M. of Motor : 1745 M.P.M. : No. of Head : 2 No. of Drum /head : 48 Traversing system : Grooved drum Motor : Common Stop motion : Mechanical No. of m/c : 4 Production per head : km /day [Assuming 80% efficiency]

  30. 30 Production per m/c : km /day [Assuming 80% efficiency] Speciality : Lycra winding M/c used for Hard winding: Name of the machine Machine no. 1. Textool winder. 6 2. KAMITSU 2 3. Harrish 1 Details information of Hard winding machineries: M/c Name : Textool Winder. Manufacturer : Textool Company Ltd. Coimbatore, India. Manuf. Year : 1996 M.P.M. : 650 No. of Head : 2 No. of Drum /head : 60 Traversing system : By Grooved drum Motor : Common Stop motion : Mechanical No. of m/c : 6 Production per head : km /day [Assuming 80% efficiency] Production per m/c : km /day [Assuming 80% efficiency] If all head active M/c Name : KAMITSU Winder.

  31. 31 Manufacturer : Harrish Textile Engineers Ltd. Gujrat, India. Manuf. Year : 1998 R.P.M. of Motor : 1440 M.P.M. : No. of Head : 1 No. of Drum /head : 40 Traversing system : Grooved drum Motor : Individual Stop motion : Mechanical No. of m/c : 1 Production per head : km /day [Assuming 80% efficiency] Production per m/c : km /day [Assuming 80% efficiency] M/c Name : Harrish Winder. Manufacturer : Harrish Textile Engineers Ltd. Gujrat, India. Manuf. Year : 1998 R.P.M. of Motor : 1430 M.P.M. : 650 No. of Head : 2 No. of Drum /head : 60 Traversing system : Grooved drum Motor : Common Stop motion : Mechanical No. of m/c : 1 Production per head : 748.8 km /day [Assuming 80% efficiency] Production per m/c : 89856 km /day [Assuming 80% efficiency]

  32. 32 Yarn path tensioner and guide: Grooved drum: Key Accessories: Cone Diameter gauge. Materials or Chemicals used: Parafin wax is rarely used in this process. Machine speed: 650 m /min.

  33. 33 Operation Procedure: Soft Winding: Flow Chart: DISPO ↓ Store Requisition. ↓ Receive the yarn. ↓ Setting & Running. ↓ Winding ↓ Checking. (Dia) ↓ Stop Winding. ↓ Quality assurance. ↓ Root card making. ↓ Delivery for dyeing. Dispo: Dispo is a planning sheet that comes from Design cell, it mention type of yarn, count, amount, color, shed and other information required from yarn preparation to finished fabric state.

  34. 34 Requisition: According to Dispo yarn preparatory section wanted sheet send to general ware house (store) for giving yarn. Receiving: When yarn come from the store winding department receive yarn in pounds by checking the required quality. Checking: After a certain time the worker checks the package diameter by diameter gauge, so that required amount of yarn is wound on the package. When the desired amount is wound the worker stops the winding. Quality Assurance: The Quality assurance officer checks the desired softness of package and fault. If it is OK then the package is poly packed to keep it from dust. Root card: The yarn preparatory section Fill – up a sheet with the whole information about preparatory yarn and with yarn send to the yarn dyeing section. After dyeing receiving Root card: After dyeing related person of preparatory section receive the yarn by checking all mentioning quality at root card the yarn again to the sub store section. Procedure: 1. Marketing order is sent to weaving department through planning cell. 2. Design cell plan the amount of yarn, color and some other important parameters. 3. Design cell prepare a dispo paper and sent to related 11 departments. 4. Winding department sent requisition to Store section according to dispo requirement.

  35. 35 5. Store department write down in register book the amount of yarn. 6. Worker of winding department open/ break the cartoon and put it under the soft winding machine. 7. Then set dye spring on holder and manually wind some turn for the better building the package. 8. After the required shape of spool has been achieved, the operator manually put the spool on the salve. 9. Now the helper collects the package and put them in a trolley and sent to the yarn dyeing section. Storage area on the floor and cover with cloth giving lot no. , etc. in a board.

  36. 36 Fig: Batch Hard Winding: The Scoured, bleached or dyed yarn transfer from dye spring to paper cone where comparatively high tension according to desired size. There are two types of hard winding. 1. From spring package: After yarn dyeing. 2. From hard package: After warping extra yarn left in the packages are re wind in the hard package. Flow Chart: Root Card ↓ Checking ↓ Receiving ↓ Prepare batch card ↓ Start hard winding ↓ Measuring weight Root card: The document sheet of material flow comes to the hard winding section to the related person. Checking: Check the mentioned quality of yarn. Receiving: If all qualities are OK then yarn is received by the winding section. Otherwise back to the dyeing sec. Prepare batch card:

  37. 37 BEXIMCO TEXTILES LTD. Order No: Customer: Batch No: Count: Shade: Pcs & Qty: Recones: Remarks: Date: Procedure: 1. Dyed soft spools are received from dyeing section with specification, (Lot number, order number, counts, shade etc.) 2. Q.C. Officer check the shade of yarn and other necessary parameters. 3. Amount of yarn received from the dyeing department is written in the register book. 4. Supervisor checks the actual order number and order for preparations of warping batch. 5. Yarn of same color & count are kept in a cartoon. 6. After preparation for warping batch, excess yarn is rewound to produce weft package. Left Over cone winding Section: The Cone Containing excess yarn after warping are sent in the left over section. Here rewinding is done from several left over cone. These cone are used as weft yarn. As a result the wastage of costly yarn is minimized. Machine Available for this section:

  38. 38 Name of the machine Machine no. 1. Textool winder 4 2. METTLER 1 3. CIMMCO 1 Details of those m/c: M/c Name : Textool Winder. Manufacturer : Textool Company Ltd. Coimbatore, India. Manuf. Year : 1996 M.P.M. : 650 No. of Head : 2 No. of Drum /head : 60 Traversing system : By Grooved drum No. of Traverse : ½ Motor : Common Stop motion : Mechanical No. of m/c : 4 Production per head : km /day [Assuming 80% efficiency] Production per m/c : km /day [Assuming 80% efficiency] If all head active M/c Name : METTLER Manufacturer : FR Mettler’s Sons Ltd. Switzerland. Manuf. Year : 1998 R.P.M. of Motor : 1745 M.P.M. : No. of Head : 2 No. of Drum /head : 45

  39. 39 Traversing system : Grooved drum No. of traverse : 2/3 Motor : Common Stop motion : Mechanical No. of m/c : 1 Production per head : km /day [Assuming 80% efficiency] Production per m/c : km /day [Assuming 80% efficiency] Speciality : Lycra M/c Name : CIMMCO Manufacturer : CIMMCO Ltd. Manuf. Year : 1998 R.P.M. of Motor : 1745 M.P.M. : No. of Head : 2 No. of Drum /head : 45 Traversing system : Grooved drum No. of Traverse : Motor : Common Stop motion : Mechanical No. of m/c : 1 Production per head : km /day [Assuming 80% efficiency] Production per m/c : km /day [Assuming 80% efficiency] Speciality : Lycra Note: This left over cone winding section also used for normal hard cone winding when necessary.

  40. 40 Sewing thread cone winding Section: Here the the dyed ply yarn is wound in to a small plastic cone. These cones are supplied from different garments factory of BEXICO group. Here lubrication is done during winding. Each cone contain 2000 meter yarn. Machine available for this section: Name of the machine Machine no. 1. CHENGFENG 10 M/c Name : CL – PAGODA Thread winding machine Manufacturer : CHENGFENG Ltd. Origing : China Driving system : Direct Driving No. of Motor/mc 6 No. of spindle/ motor : 2 R.P.M. of Motor : M.P.M. : Traversing system : Traversing rod No. of Traverse : Motor : Individual Stop motion : No. of m/c : 10 Production per head : km /day [Assuming 80% efficiency] Production per m/c : km /day [Assuming 80% efficiency] Faults in winding section:

  41. 41 Faults Causes 1. Excessive Hard package Excess tension 2. Excessive Loose package Less tension 3. Ring Faulty drum 4. Stitching Vibration of Package 5. Ribbon Ribbon breaker problem. 6. Bulging Improper alignment of Package 7. Entanglement Jerking package 8. Bunch Improper store and handling 9. Cut cone Package drop 10. Reverse winding Low pressure Swing Thread winding Machine: Types of Maintenance:

  42. 42 1. Schedule maintenance 2. Break down maintenance. Spare item types: 1. Readymade / purchase: 2. Fabrication tool in work shop / other side 3. Import item. Quality Control in winding Section: The following quality is maintained in preparatory stage. Shade matching: The dyed yarn compared with lab drip sample or swatch card. Level Checking: During package dyeing dyes chemical enter in to package by pressure. So there is a possibility to differ level in inner and outer side. It is checked and allow up to (5 -6)% Fastness: Water and color fastness is checked. Strength: CSP, tenacity, CV% of tenacity, elongation are tested. Package hardness: Soft wound package is checked by hand if it is hard improper dyeing will occur, the hard wound package also checked if it is less hard or too hard it will create problem in subsequent process. Material Handling Equipment For Winding Section: 1. Creel.

  43. 43 2. Trolley. 1. Creel: 2. Trolley. Trolley:

  44. 44 Weft yarn package traveller:

  45. 45 Warping:

  46. 46 Operational Staff: Section in – Charge Senior Executive (Abdul Ahad) ↓ Quality Control Officer ↓ Supervising officer ↓ Senior Operator ↓ Creel man ↓ Helper Direct Warping Process Flow: Dispo ↓ Yarn from store ↓ Creeling ↓ Warping High Speed Warping m/c Setting: Set up parameters Range Set value Cone no. of Creel 400-600 As required

  47. 47 Warping Speed 1-1200 m/min Warping length 1-999999 m Shift selection 1-5 3 Beaming drum pressure 1-11 mm scale 5 mm scale Stop drop wire 1, 2, 3. 1 higher Tensioner A, B, C. C higher Depth of penetration 1-40 mm As required Beam barrel dia 315 mm Fixed Beam flange dia. 987 mm Fixed Beam width 1800 mm As required Depth of travel must be same in both the sizes of creel. Yarn ;tension can be increased or decreased by changing depth of travel. Higher the setting values higher the tension applied, but high tension may be needed fore lower bearing speed, lower end breaks in comb, lower clinging ends. # The sequences of operation of the pretension is controlled through the following 2 programs 1. program A = Ease program ( For trouble free program) 2. Program B = Anti snarl program ( For lively, high twist or OE yarn. # Pressure setting of stop motion & tensioner: (Off Creel) Setting is adjustable by rotary button, which activate stop motion drop wire & pressure. Stop motion Tension Setting range Yarn Count (Ne) 3 C Coarse 4-30S 2 B` Medium 4-60S 1 A Fine 15-120s

  48. 48 Operation Procedure Direct Warping: 1. As per production program given by assistant manager, preparation through the yarn warp record register, the supervising officer collects griege yarn from store as per required count, lot number and quantity. 2. The machine operates and helpers open / break the yarn cartoon and place the cones in the creel head as per program and draw the head end of the cone through pretension rods, feeler guides, yarn guides and then through expanded comb of beaming unit. 3. The basic creel data setting and machine data setting are done according to the requirement as per m/c manufacturer operating instruction. 4. An empty beam is set in between driving clutch and engaged by means of electric switch. 5. All the ends from the creel is wrapped around the beam manually one round. 6. The press roller is moved towards the beam by means of electric switch. 7. The m/c is then run slowly and checked for yarn alignment with beam flange on both sides. To ensure alignment the expanded comb may be moved either to the right or left as required by switch. 8. Thus the m/c is ready and the operational switch is to be turned on. 9. As the present length is achieved the m/c will stop automatically. The beam is doffed by switch and another beam is mounted. 10. In this way a set of beams are made to feed the subsequent sizing process. 11. Production is recorded in the yarn wrap record register; each beam is set with warping data sticker for identification in the next process. Sectional Warping

  49. 49 Process Flow: Dispo Yarn from store Creeling (According to warp plan) Machine setup Section wise warping Beaming Warp width: Total Ends Warp Width Below 7200 1800 mm 7200 2000 mm Above 7200 2100 mm Control Data Parameter Evaluation:   Decitex Total Ends 0.5 Feed- 1 =  Density Total Warp width Feed 2= Measured feed X 0.85 ( For Cotton) = Measured feed X 0.95 (For Synthetic) Feed -1= Drum Movement with revolution per minute. Feed -2= Actual movement of Drum. Measured feed=> It find out the variation between Feed -1 to Feed -2 Variation +/- 15% Piece length= Machine stop before wound 10 -15 meter of required length.

  50. 50 Fig: Sectional Warping m/c. Head stock of sectional warping machine: Causes of yarn breakage in warping: 1. Weak yarn. 2. Sloughing off. 3. Over lapping. 4. Knots/ bad splice.

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