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Industrial attachment of fakir knitwears ltd

Presentation about 'Industrial attachment of fakir knitwears ltd'

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Industrial attachment of fakir knitwears ltd

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 Course Code: Tex -4036 Course Code: Tex -4036 INDUSTRIAL TRAINING INDUSTRIAL TRAINING INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT FAKIR KNITWEARS LTD FAKIR KNITWEARS LTD FAKIR KNITWEARS LTD

  2. Acknowledgement At first I would like to thank almighty Allah for giving me the opportunity to complete my internship. I have taken an opportunity to express my deepest since of gratitude and sincere thanks to my reverend teacher Prof. Syed FakhrulHasan,Chairman, Department of Textile Engineering, Southeast University, Banani, Dhaka.I also thank toA.N. M. Ahmad Ullah , Co-ordinator, Departmentof Textile Engineering, Southeast University, Banani, Dhaka,for giving me the chance internship in Fakir Knitwears Ltd. It is an auspicious for me a student of Department of Textile Engineering. One of the prestigious academic center of the Southeast University to express my deep feeling of gratitude to the department and especially to my supervisor S.M.MasumAlam, Department of Textile Engineering. Special thanks to go Mr.FakirAkhteruzzaman, Managing Director of Fakir Knitwears Ltd. For kind help extend to me. I also thank to Mr.FakirMashriquzzaman, Director of Fakir Knitwears Ltd. I also thank to Mr.SyedImtiajRajib of Fakir Knitwears Ltd. I would like to thank Mr.S.M.Md. Fakhruzzaman,GM (Dyeing) of Fakir Knitwears Ltd. I would like to thank Mr.Sultan Mahmud Hosseinee,GM (HR & Compliance) of Fakir Knitwears Ltd. 1 would like to thank Mr. MdMojiburRahman, GM(Production) of Fakir Knitwears Ltd. I would like to thank Mr. Md. Kashem Ali Khan, Manager (IE & Planning) of Fakir Knitwears Ltd. for his valuable direction and special attention. I would like to thank Mr. Md. Toriqul Islam, Manager (Dyeing) of Fakir Knitwears Ltd. I also thank to Mr. Mohammad Din Islam, Asst. Manager (IE & Planning) of Fakir Knitwears Ltd. for his real advice. I am also grateful to Mr. Abul Basher Muhammad Suhas, Management Trainee & Mr. Md. TanvirHossainMazumdar ,PO (Knitting) of Fakir Knitwears Ltd. for giving me their proper guideline and continuous support. I want to offer my deepest thanks and complements to my parents and brother for their unselfish and stimulating influence in my any education life. Finally my cordial gratitude to almighty Allah to successfully completed my industrial attachment. May-2012 SAIDUL ISLAM

  3. FAKIR KNITWEARS LTD Introduction Industrial attachment is an essential part of 4 years B. Sc in Textile Engineering course of Southeast University, Banani, Dhaka. As a Textile graduate should have an experience in the study of Wet Processing Technology, machineries products and over all situation of the Factory before work in the industries. I have the opportunity to perform the industrial attachment on Fakir Knitwears Ltd. Fakir Knitwears Ltd, is a renowned and modern technology integrated industry. Fakir KnitwearsLtd, started in the year 1988 in knit garment exporter, Fakir Knitwears Ltd. Crossed over a long way and found us as one of the best knitwear manufacturer-exporter of Bangladesh. Fakir Knitwears Ltd. certified with OKEO-TEX, ISO 9001-2000 &SRM and also getting by WRAP and ISO-14001 Fakir Knitwears Ltd. strive to provide the best quality garment to the buyers. Factory provided advanced technology in all aspects of operation to attain excellence concerning quality, dependability and commitment for apparel industry and society. Product quality is ensured with the practice of advanced technology and our inclination toward meeting with the buyer's satisfaction with competitive price.

  4. Fig: Location map of the FKL

  5. Chapter One: Project Description COMPANY PROFILE Factory :FakirKnitwears Ltd. Factory & Head Office :Kyempur, Fatullah, Narayangonj-1400 Phone:88-02-7641379-80 7643242,7643271 Fax:88-02-7634611 :89 Lucky chamber,1stFloor,Motijheel Commercial Office Dhaka-1000,Bangladesh. Managing Director :Fakir Akhtaruzzaman (C.I.P) Year of Establishment :1988 Area of Premises :550000 sqft Number of Employee :8500 Yearly turnover :$120 million Production Capacity : Knitting- 40 tons/day Dyeing-42 tons/day Dyeing Finishing-42tons/day Garments-200000 pcs/day Garments Washing-20000pcs/day Printing-100000 pcs/day Embroidery-200 Head

  6. Contact(Marketing) : 1)F.A.Zaman(neaz),(Director) Email: neaz@fakirgroup.com 2)Mr.MahmudulHasan, DGM (Merchandising & Marketing) Email: hasan@fakirgroup.com 3)Mr.BiswajitSaha,AGM (Merchandising & marketing) Email: biswajit@fakirgroup.com Bank:1) National Bank of Pakistan 2)One Bank Limited 3)Datch Bangla Bank Limited Buyers : H & M TEMA PRIMARK PEACOCKS PENNYES BERSHKA ZERA

  7. Type of Factory& Concern Department The factory is a Knit composite industry. The factory has the following departments- Knitting: o Knitting o Inspection o Quality control Dyeing: o Batch section o Dye house o Dyeing laboratory o Quality control o Finishing Garments: o Merchandising o Sample o Cutting Section o Sewing Section o Finishing Section Maintenance: o Electrical o Mechanical Administration Security Marketing Production Planning & Control Human Resource & Development Remarks The factory has outstanding quality of producing and exporting goods. The infrastructure is the fabric is well enough to be a very good composite factory in Bangladesh. The information’s are given according to source of Management department.

  8. Organogram

  9. Chapter Two: Management System FAKIR KNITWEARS LTD

  10. Managing Director • Reporting to Chairperson • Responsible to board of director/s • Having total charge of the operation • Directly responsible to overlook marketing department and fulfill marketing requirements • Monitor factory operation and make sure orders are delivered on time, with customer's required quality at a minimum cost • Take the total charge of all human resource activities and make sure FKL. To have professional and cheerful work force Director • Reporting to Managing Director • Direct co-ordination with Production Manager / Sample Room In-Charge / Quality Manager / Lab In-Charge. • Product analyzing and providing technical guidance for optimum benefit of the company. • Monitor productivity and take necessary actions and give advises. • Take charge of all pre production activities. • Take charge of all new developments. • Identify tanning needs. • Maintain safety system and procedures. • Introduce cost effective management methods.

  11. General Manager (Operation) • Report directly to Managing Director & Director. • Take total charge of the factory activities. • Take charge of administration / fund management / cost control/ purchasing / production planning / store and stock control / delivery schedules and compliance. • Directly control all the system maintenance and upgrading. • Take responsibility of all information flow to / from head office with the help of coordinator • Take charge of all recruitments and terminations with the guidance of Director. General Manager (Production) • Report directly to Managing Director. • Negociate with the Merchandising DGM • Co-ordinate with the Merchandising department about costing & Consumption. • Directly Report to the Director about the Garments Unit. • Over all monitoring the productivity and take necessary actions. • Responsible to Production Manager. Merchandising (DGM) • Report directly to Managing Director. • Co-ordinate with Marketing officer, Director Operations and Sample Room In- Charge. • Upgrade Managing Director on the progress. Follow-up on new order confirmations and transfer information to subordinates • Make contribution to production planning and make sure that the production plan is up to date. • Monitoring maintained and processed order information, which transferred between head office and the factory • Execute raw materials bookings and follow-ups.

  12. • coordinator. Follow up and get it done samples from sample room with the help of the • Understand the general / technical problems in the factory, customer requirements and get buyer's approvals where ever possible. Finance and Accounts (DGM) • Directly report to the Director. • Close co-ordination with Managing Director. • Responsible for execution funds and maintain relevant documentation. • Maintain salary sheets and follow up cash requirements and organize funds for company needs. • Handle all kind of banking affairs. • Produce Management reports with regards to company finance General Manager (Purchase & Inventory) • Report directly to Managing Director. • Co-ordinate with Merchandising Manager. • Responsible for business development / develop new supplier sources and cost control. • Frequent market research and up date management and related departments on the current trends in the market. • Generate innovation to the organization. • Follow up current customers and ongoing orders. • Co-operate with customers and make their requirements understand to the subordinates and related departments. • Understand the general / technical problems in the factory; convince customers and get customers approvals where ever is possible on company interest. • Find business for surplus goods. • Prepare and maintain management reports.

  13. General Manager (HR & Compliance) • Directly reporting to Director. • Co-ordinate with the entire departmental in charges and all the workers in the factory • Responsible to monitor, o Factory timing o Discipline and cleanliness o Attendance, leave and holydays o Security and maintenance of the factory o Transportation and its maintenance o Wagers, over time pay, allowances and other payments. o Do necessary formalities during new recruitment or terminations. Manager (IE & Planning) • Directly reporting to the Director. • Directly reporting to the MD Sir about the over all situation of the factory • Sample break down and SMV establish. • Discussion with GM (Production) about lost time and bottle neck. • Co-ordination with HR department about the workers recruitment. Senior Merchandiser • Report directly to Manager Merchandising. • Maintain and process information received from buyers and buying offices and process and transfers them between head office and factory. • Follow up on new order confirmations and book raw materials accordingly. • Help to up date the production plan. Production Manager • Directly reporting to General Manager. • Responsible to GM, Operations. • Co-ordinate with Quality Manager, Cutting manager, Finishing & Store

  14. Inventory Manager • Directly reporting to General Manager. • Responsible to Merchandising Manager. • Co-ordinate with production Co-coordinator. • Responsible to follow up production planning and all the raw material requirements. • Maintain inventory / storing system / documentation and provide information to prepare statistics • Stock controlling and keep management inform as and when required. Quality Control In-charge • Reporting to Quality Manager • Responsible to Director Operations • Co-ordinate with production, knitting, linking, trimming, mending and finishing In-Charges and Supervisors • Responsible to follow up instructions given by Quality Manager and Director Operations. • Monitor the work done by Quality Checkers. • Make sure the quality is maintained at buyer's required standard and maintained company quality system. • Maintain relevant paper work. Human Resources &Welfare Officer • Reporting to General Manager • Co-ordinate with all department heads in the organization. • Responsible to monitor training, cleanliness, health and safety, meals, picnics, welfare fund and all other welfare affairs

  15. Compliance Officer • Reporting to HR & Welfare Officer • Responsible to General Manager • Co-ordinate with all department heads in the organization. • Responsible to monitor system management, health & safety and all other compliance affairs. HROfficer • Directly reporting to Administration Manager • Responsible to General Manager • Co-ordinate with the entire department in charges and all the workers in the factory. • Responsible to monitor, o Factory timing. o Discipline and cleanliness. o holydays. o Security and maintenance of the factory. o Transportation and its maintenance. o Wagers, over time pay, allowances and other payments. o Do necessary formalities during new recruitment or terminations. Accounts Executive Attendance, leave and • Reporting to Finance & Accounts Manager. • Responsible to maintain all the books and paperwork with regards to company accounts. • Prepare and maintain salary sheets. • Follow up day-to-day cash requirement and handled funds. • Prepare management reports.

  16. Security In-charge • Reporting to Dept. General Manager • Responsible to monitor all the activities of security officers, conduct security activities and make sure the total premises are completely safe and secured. • Should conduct regular security inspections in the premises both day and night • Maintain records of all incomings and out going goods, personal and vehicles. • Provide training to security staff. Security Guard • Reporting to Security In-charge. • Responsible to Security Manager. • Conduct security activities and make sure the total premise is completely safe and secured. • Should be conduct regular security inspections in both day and night. • Maintain all security records. Time Keeper • Reporting to Administration Manager • Responsible to maintain the time record of all the employees. • Maintain timecard in order. Sewing Supervisor • Directly reporting to Finishing In-Charge. • Responsible to Assistant Production Manager. • Co-ordinate with finishing Supervisor. • Responsible for all labeling. • Monitoring work of all the workers. • Maintain needle policy and safety.

  17. Sewing Operators • Reporting to Sewing Supervisor. • Responsible to Finishing In-Charge. • Duties to do sewing with optimum quality. • Maintain cleanliness and safety. Ironing Supervisor • Directly reporting to Finishing In-Charge • Responsible to Assistant Production Manager • Co-ordinate with Washing In-Charge • Responsible for all finishing activities • Motivate subordinates. Iron man • Reporting to Ironing Supervisor • Responsible to Finishing In-charge • Duties to do ironing with optimum quality. • Maintain cleanliness and safety. Packing Supervisor • Reporting to Finishing In-Charge • Responsible for Assistant Production Manager • Co-ordinate with Ironing Supervisor and Sewing Supervisor. • Responsible for best quality goods. • Monitoring work of all the workers. • Motivate subordinates.

  18. Chapter Three: Machineries Garments Machineries SI no. Name of the m/c No of m/c Brand /Origin 01 Straight Knife m/c 30 Mack- Japan 02 Band Knife m/c 02 OSHMAKK, Taiwan 03 Lay spreading m/c 04 Eastman 04 Sample print heating m/c 02 Speed cutter, Japan 05 Single Needle Lock Stitch 591 Brother , Japan 06 Over lock m/c 512 Pegasus, Japan 07 Flat Lock m/c 156 Pegasus, Japan 08 Feed of the arm 02 Japan 09 Snp button m/c 16 Prime 10 Button hole m/c 20 Brother, Japan 11 Button attaching m/c 17 Brother, Japan 12 Back tape m/c 22 Pegasus, Japan 13 One stop Zik m/c 22 Brother, Japan 14 Thread sucking m/c 20 OSHIMA 15 Thread Re-Con m/c 08 OSHIMA 16 Spot Removing m/c 16 OSHIMA 17 Metal Detector 07 Hasima 18 Iron Vacuum table 150 Hasima 19 Bar take M/c 32 Brother, Japan 20 Rib Cutter 30 OSHMAKK, Taiwan

  19. 21 Cylinder bed m/c 177 Brother, Japan 22 Lock stitch two needle 05 Brother, Japan 23 Iron m/c 150 OSHIMA 24 Hand tag m/c 60 Japan 25 Hand dry m/c 120 Brother, Japan

  20. Knitting Machineries Machine Type: Single Jersey SL MC NO. DIA-GG-F BRAND TYPE A-1 Open Width 1 36"24-108 Jiunn Long 2 A-2 Open Width 36"24-108 Jiunn Long 3 A-3 Open Width 36"24-108 Masa 4 A-4 Open Width 36"24-108 Masa 5 A-5 Open Width 36"24-108 Masa A-6 Open Width 6 40"24-120 Masa 7 A-7 Open Width 40"24-120 Jiunn Long 8 A-8 Open Width 40"24-120 Jiunn Long 9 A-9 Open Width 40"24-120 Jiunn Long 10 Open Width A-10 42"24-126 Jiunn Long 11 Open Width A-11 42"24-126 Jiunn Long 12 Open Width A-1 2 42"24-126 Masa Machine Type:Single Jersey B-1 Open Width 1 34"24-102 Jiunn Long B-2 Open Width 2 34"24-102 Jiunn Long 3 B-3 Open Width 34"24-102 Jiunn Long 4 B-4 Open Width 34"24-102 Masa 5 B-5 Open Width 34"24-102 Masa 6 B-6 Open Width 34"24-102 Masa 7 B-7 Jiunn Long Open Width 38"24-114 8 B-8 Jiunn Long Open Width 38"24-114 9 B-9 Open Width 38"24-114 Masa 10 Open Width B-10 38"24-114 Masa 11 Open Width B-11 38"24-114 Masa

  21. 12 Open Width B-1 2 44"24-132 Masa

  22. Machine Type: Single Jersey MC NO. SL DIA-GG-F BRAND TYPE D-1 1 26"24-104 King Knit Tube D-2 2 26"24-104 Quan Tex Tube D-3 3 26"24-78 Masa Tube D-4 4 28"24-84 Masa Tube D-5 5 28"24-84 Masa Tube D-6 Jiunn Long 6 28"24-112 Tube 7 D-7 30'24-72 Santec Tube 8 D-8 30"24-90 Masa Tube 9 D-9 30"20-90 Masa Tube 10 D-10 30"24-90 Masa Tube 11 Jiunn Long D-11 34"24-102 Tube 12 Jiunn Long D-1 2 32"24-102 Tube Machine Type: Single Jersey E-1 1 21"24-84 Quan Tex Tube 2 E-2 22"24-88 Quan Tex Tube E-3 3 22"24-66 Masa Tube 4 E-4 22"24-66 Masa Tube 5 E-5 23"24-69 Masa Tube 6 E-6 23"24-69 Masa Tube 7 E-7 23"24-92 Quan Tex Tube 8 E-8 24"24-72 Masa Tube 9 E-9 24"24-96 Quan Tex Tube 10 E-10 24"24-96 Quan Tex Tube 11 E-11 25"24-100 Quan Tex Tube 12 E-12 25"24-100 Quan Tex Tube

  23. FAKIR KNITWEARS LTD Machine Type: Single Jersey Jiunn Long Open Width 1 C-1 32"24-96 2 Jiunn Long Open Width C-2 32"24-96 Open Width 3 C-3 32"24-96 Masa Open Width 4 C-4 32"24-96 Masa C-5 5 36"24-108 Masa Tube C-6 6 36"24-108 Quan Tex Tube 7 C-7 Jiunn Long 36-24-72 Jaquard 8 C-8 Jiunn Long 38"24-114 Tube 9 C-9 38"24-114 Masa Tube 10 C-10 40"24-120 Masa Tube 11 C-11 40-24-120 Masa Tube 12 C-1 2 42"24-126 Masa Tube Machine Type: Rib & Inter Lock (Double Jersey) G-1 Jiunn Long 1 34"24-102 Tube G-2 Jiunn Long 2 34"24-102 Tube G-3 Jiunn Long 3 34"24-102 Tube G-4 Jiunn Long 4 36"24-108 Tube 5 G-5 Jiunn Long 36"24-108 Tube 6 G-6 Jiunn Long 36"24-108 Tube 7 G-7 Jiunn Long Tube 38"24/22/18-72 8 G-8 Jiunn Long 38"24-114 Tube 9 G-9 Jiunn Long 38"24-114 Tube 10 Jiunn Long G-10 40"24-120 Tube 11 Jiunn Long G-11 40"24-120 Tube 12 Jiunn Long G-12 Tube 40"24/22/18-84

  24. Machine Type: Rib Jersey (Double Jersey) F-1 Jiunn Long 1 20"24-80 Tube F-2 Jiunn Long 2 30"18-72 Tube 3 F-3 Terrot 30"18-54 Tube F-4 4 32"18-66 Masa Tube 5 F-5 Jiunn Long 32"18-72 Tube 6 F-6 Jiunn Long 32" 18-72 Tube 7 F-7 Jiunn Long 34"18-72 Tube F-8 Jiunn Long 8 34"18-72 Tube F-9 Jiunn Long 9 36"18-72 Tube Jiunn Long ~10 F-10 36"18-72 Tube Jiunn Long 11 F-11 38"18-72 Tube Jiunn Long 12 F-1 2 40"18-84 Tube Machine Type: Rib & Inter Lock & S/J H-1 1 42"24-252 Masa Tube H-2 Jiunn Long 2 36"20/18-84 Tube H-3 Jiunn Long 3 38"16-72 Tube 4 H-4 Jiunn Long 34"18-72 Tube 36"18/16-72 Tube 5 H-5 Jiunn Long 6 H-6 Jiunn Long 36"22-72 Tube 7 H-7 Jiunn Long 34"22-72 Tube 8 H-8 Jiunn Long 34"24-102 Tube 9 H-9 Jiunn Long 32"24-96 Tube 10 Jiunn Long H-10 36"16-66 Tube 11 Fukuhara H-11 38"24-48 Tube 12 Fukuhara H-12 38"24-48 Tube H-1 3 33-18/24-48 Tube 13 Fukuhara

  25. FAKIR KNITWEARS LTD Machine Type: Single Jersey (Relaknit:4.0/3.2ll) 1 R-1 38"24-123 Mayer &Cie Tube 2 R-2 38"24-123 Mayer &Cie Tube 3 R-3 34"24-108 Mayer &Cie Tube 4 R-4 34"24-135 Mayer &Cie Tube 5 R-5 34"24-135 Mayer &Cie Tube € R-6 36"24-144 Mayer &Cie Tube 7 R-7 36"24-144 Mayer &Cie Tube 8 R-8 36"24-116 Mayer &Cie Tube Machine Type: Plain S/J & Fleece 1 P-1 30"24-60 Sanda Tube 2 P-2 30"24-60 Sanda Tube 3 P-3 30"24-60 Sanda Tube 4 P-4 30"24-60 Sanda Tube 5 P-5 30"24-60 Sanda Tube Total = 102 PCS

  26. Laboratory Machineries SI no. Name of the m/c No of m/c Origin Brand 01 Spectro Photo Meter 01 U.S.A Gretag M/C 02 Lab Dyeing M/C 01 Taiwan Irdyer Rapid 03 Lab Dyeing M/C 01 Hong Kong Tung Shing 04 Gray Scale 01 Japan Shinko 05 Light Box 01 England Verivide 06 Washing Machine 06 Sweden TMS-900 07 Tumbling Machine 01 Sweden TK-111S 08 Rubbing Machine 02 U.S.A 09 Auto dispensing Machine 01 Italy Lawer Dyeing Machineries (Sample) SI no. Name of the m/c No of m/c No of Nozzle Origin Brand Capacity 01 Sample Machine 04 01 Taiwan Fong's 40kg 02 Sample Machine 04 01 Taiwan Fong's 40kg 03 Sample Machine 01 01 Taiwan Fong's 160kg 04 Sample Machine 01 01 Taiwan Fong's 120kg 05 Sample Machine 01 01 Taiwan Fong's 120kg 06 Sample Machine 01 01 Taiwan Fong's 25kg 07 Sample Machine 01 01 Taiwan Fong's 30kg 08 Sample Machine 01 01 Taiwan Fong's 30kg

  27. FAKIR KNITWEARS LTD Dyeing Machineries (Bulk Production) SI no. Name of the m/c No of m/c No of Nozz le Origin Brand Capacity 01 Low Temperature & Atmosphere 01 02 Taiwan Fong's 400kg 02 Low Temperature & Atmosphere 01 03 Taiwan Fong's 600kg 03 Low Temperature & Atmosphere 01 04 Taiwan Fong's 800kg 04 Low Temperature & Atmosphere 01 04 Taiwan Fong's 800kg 05 Low Temperature & Atmosphere 01 06 Taiwan Fong's 1200kg 06 Low Temperature & Atmosphere 01 06 Taiwan Fong's 1200kg 07 Low Temperature & Atmosphere 01 01 Taiwan Fong's 200kg 08 Low Temperature & Atmosphere 01 01 Taiwan Fong's 200kg 09 Low Temperature & Atmosphere 01 06 Taiwan Fong's 1500kg 10 Low Temperature & Atmosphere 01 05 Taiwan Fong's 1000kg 11 Low Temperature & Atmosphere 01 05 Taiwan Fong's 1000kg 12 Low Temperature & Atmosphere 01 04 Taiwan Fong's 800kg 13 Low Temperature & Atmosphere 01 04 Taiwan Fong's 500kg 14 Low Temperature & Atmosphere 01 02 Taiwan Fong's 500kg 15 Low Temperature & Atmosphere 01 02 Taiwan Fong's 500kg 16 Low Temperature & Atmosphere 01 02 Taiwan Fong's 500kg 17 High Temperature & Pressure 01 02 Taiwan Fong's 400kg 18 High Temperature & Pressure 01 05 Taiwan Fong's 1500kg 19 High Temperature & Pressure 01 01 Taiwan Fong's 500kg 20 High Temperature & Pressure 01 03 Taiwan Fong's 1500kg

  28. 21 High Temperature & Pressure 01 03 Taiwan Fong's 1500kg 22 High Temperature & Pressure 01 03 Taiwan Fong's 1500kg 23 High Temperature & Pressure 01 3 Greece Sclavos 750kg 24 High Temperature & Pressure 02 4 Greece Sclavos 1000kg 25 High Temperature & Pressure 02 6 Greece Sclavos 1500kg Dyeing Finishing Machineries SI no. Name of the m/c No of m/c Brand Origin 01 Stenter 03 Bruckner Germany 02 Stenter 01 ACC Turkey 03 Stenter 01 Chengfu Taiwan 04 Open Compactor 03 Lafer Italy 05 Open Compactor 01 Ferraro Italy 06 Slating 02 Bianco Italy 07 Slating 02 EL Italy 08 Bag Sewing 03 MTG Italy 09 Singing 01 Osthoff Germany 10 Sueded M/C 01 Lafu (Has) Turkey 11 Combing 01 I kuang Taiwan 12 Shewing 01 I kuang Taiwan 13 Squeezer 02 AB Calator Sweden 14 Squeezer 01 AKAB Sweden 15 Squeezer 01 Kromson Turkey 16 Tube Compactor 01 Fab-Con U.S.A 17 Tube Compactor 01 Specttorimar Italy 18 Calender 01 Ferraro Italy 19 Dryer 01 AMS Turkey

  29. 20 Dryer 01 Obermaier France 21 Tube Compactor 01 Lafer (Has) Turkey 22 Dryer 01 Dilmiler Turkey Boiler Machineries SI no. Model No of m/c Origin Brand 01 DDHI 5.0-10 02 Germany Omnica 02 UL-S-1000 02 Germany Loos Manpower FAKIR KNITWEARS LTD Total Manpower and Section Wise Manpower: Administration Department: SL.No Designation No of Manpower 01 General Manager (Operation) 01 02 General Manager (Admin, RH & Com) 01 03 Admin Officer 01 04 IT Manager 01 05 IT Officer 04 06 Welfare Officer 02 07 Software Engineer 02 08 Doctor 01

  30. 09 Nurse 01 10 Day Care Governess 02 11 Time Keeper 02 12 Painter 02 13 Peon 13 14 Cleaning Supervisor 08 15 Cleaner & Sweeper 240 16 Cook 07 17 Medical Assistant 02 Total = 310 Accounts Department SL.No Designation No of Manpower 01 Deputy General Manager 01 02 Sr. Accounts Officer (Tax) 01 03 Accounts Officer 09 04 Cash Officer 02 05 Asst. Manager 02 06 Junior Officer 02 Total = 17 IE & Planning Department SL.NO Designation No of Manpower 01 Manager 01 02 Asst. Manager 01 03 IE Officer 20 04 Work study officer 20 Total = 42

  31. Merchandising Department SL.NO Designation No of Manpower 01 Deputy General Manager 01 02 Asst. General Manager 01 03 Manager 03 04 Sr. Merchandising 01 05 Merchandising 12 06 Asst. Merchandising 06 07 Trainee Merchandising 02 Total=1 26 Maintenance Department SL.No Designation No of Manpower 01 Deputy General Manager 01 02 Mechanical In-Charge 01 03 Mechanic 08 04 Electrician 03 05 Mechanics Helper 11 Total = 24 Sample Department SL.NO Designation No of Manpower 01 Manager 01 02 Pattern Master 04 03 Sample Cutter 08 04 Sample Man 06

  32. 05 CAD Manager 01 06 CAD Designer 09 07 Q.C (Sewing) 06 08 Operator (Sewing) 27 Total = 61 Security Department SL.No Designation No of Manpower 01 Deputy General Manager 01 02 Manager 01 03 Security Officer 02 04 Security Supervisor 04 05 Fire Man 08 06 Security Guard 87 07 Driver 20 Total = 123 Inventory Department SL.NO Designation No of Manpower 01 General Manager 01 02 Asst. Store Manager 03 03 Inventory Officer 02 04 Asst. Inventory Officer 05 05 Sr. Store Keeper 05 06 Store Officer 11 07 Store Keeper 21 08 Store Assistant 19 09 Tally Man Incharge 01 10 Tally Man 14

  33. Total = 82 Cutting Department SL.No Designation No of Manpower 01 Cutting Manager 01 02 Cutting In-charge 09 03 Cutting Supervisor 10 04 Cutting Man 65 05 Sticker Man 11 06 Cutting Inspection 96 07 Marker Man 10 08 Lay Man 230 09 Loader 51 Total = 483 Production Department SL.NO Designation No of Manpower 01 General Manager 01 02 Production Manager 05 03 Floor In-charge 15 04 Production Co-ordinator 02 05 Supervisor 48 06 Input Man 15 07 Operator 1056 08 Helper 864

  34. 09 Count Man 48 10 Quality Control Man 336 Total = 2390 Printing Department SL.No Designation No of Manpower 01 Printing Manager 01 02 In-charge 02 03 Color Muster 01 04 Invigilator 08 05 Supervisor 04 06 QC 21 07 Check Man 73 08 Printer 74 09 Bundle Count Man 24 10 Cleaner 22 11 Helper 428 12 Expose Man 2 13 Loader 11 Total = 671 Quality Department SL.NO Designation No of Manpower 01 Deputy Manager 01 02 Manager 01 03 Asst. manager 01 04 In-charge 04 05 Quality Controller 26

  35. 06 Check Supervisor 39 Total = 72 Finishing Department SL.No Designation No of Manpower 01 Finishing Manager 01 02 Finishing In-charge 06 03 Finishing Supervisor 34 04 Iron Man 150 05 Folding man 120 06 Poly man 110 07 Packer man 40 08 Helper 60 Total = 527

  36. Chapter Four: Raw Materials Yarn The raw material for knitting is the yarn. Different types of yarn of wide range of different count areused. Both carded and combed yarn is used for knitting. Generally used yarn and their count: Yarn Type Count Cotton 24S, 26S, 28S, 30S, 32S, 34S, 40S Polyester 75D, 100D Spandex yarn 20D,40D, 70D Grey Mélange 24S, 26S PC (65%Polyester & 35% cotton) 24S, 26S, 28S, 30S CVC 24S, 26S, 28S, 30S Fabric: Fakir Knitwears Ltd.is a knit composite textile industry. In the industry fabric is used as raw material in dyeing- Grey Fabrics: Following types of gray fabrics are dyed:     Single jersey Single jersey with lycra Polo pique Single lacoste

  37.            Fleece Interlock Interlock with lycra Rib Rib with lycra 1Χ1 rib 2Χ2 rib 6X2 rib Sugar rib Regular drop needle Irregular drop needle Different types of collar & cuff Chemicals: List of Chemicals used in Cotton Club (BD) Ltd. is as follows- Basic Chemicals: 1. Acetic Acid 2. Hydrochloric Acid 3. Sulphuric Acid 4. Caustic soda 5. Formic acid 6. Bleaching powder Detergent & Scouring agent: 1. SUNMORL CK-2 2. AssistB26f/SL2F(CK) Levelling Agent 1. Neocrystal-200BF 2. LevagalDLP Sequestering Agent 1. Neocristal 150 2. Neocristal-DMBF 3. NOBLEACH N(Multi-function)

  38. Salt 1. Glauber Salt 2. Common Salt Whitening Agent 1. Syno White BYB 2. Syno White 4BK Softener 1. Sapamine FPG 2. Aleamine-CWS 3. Necipole PR 99 4. Gramazin-E2R Fixing Agent 1. NeofixRP70 2. Neofix-R-250 3. Albafix ECO Reducing Agent 1. Hydrose 2. Caustic 3. Visco Color 4. ViscoBleah Bleaching Agent 1. (50%)H2O2 Enzyme 1. Retrocell PLX 2. BIO-C35 Stabilizer 1. Nobleach N(Multi-function) 2. Neorate PH 55 NF 3. Neorate PH 150 Anticreasing Agent 1. Texport GL 500 2. Texport D-600 3. AC-200

  39. PHController 1. Acetic Acid 2. Formic Acid 3. Soda Ash 4. Caustic 5. Invatex AC Per-oxide Killer 1.Croaks NF Antifoaming agent 1. Albatex FFC Dyes Fakir Knitwars ltd uses the following dyes- 1.Sumifix 2.Boductive 3.Ciba 4.Livafix 5.Terafix Remarks As quality is the prime concern of the factory, qualitative raw materials are always bought by the management of the factory. Besides, there is enough space to keep those raw materials in the factory.

  40. Chapter Five: Knitting section Process Flow chart of Knitting: Yarn in cone form Feeding the yarn cone in the creel Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Tension device. Knitting Withdraw the rolled fabric and weighting Inspection Numbering Parts of knitting Machines: Creel: Creel is used to place the cone of yarn. Feeder: Feeder is used to feed the yarn to make a fabric. Tensioning device: Tensioning device is used to give proper tension to the yarn. VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length. Guide: Guide is used to guide the yarn. Sensor: Sensor is used to seen & the machine stops when any problem occurs. Spreader: Spreader is used to spread the knitted fabric before take up roller. Take up roller: Take up roller is used to take up the fabric Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at specific finger.

  41. Rethom: These devise are used in Electrical Auto Striper Knitting machine Design Development by using CAM: The type of fabric to produce depends on the setting of the Cam of Knitting machine. The different types of fabric can be produced by only changing the cam setting. The cam settings to produce different fabric are given below: Single jersey: Only knit cams are used to produce single jersey fabric. So the setting would be- K K K K K K K K K Inter lock: Inter lock fabric is produced by using knit and miss cam. So the setting would be- K M K M K M Lacost: Lacost uses knit and tuck cam like- K K T K K T K K K T French terry: The cam setting is as follows- K M K M K M K T K M K T K M K T K M

  42. Considered pointof Knitting: 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-        Finished G.S.M. Type of Fabric or design of Fabric. Yarn count Types of yarn (combed or carded) Diameter of the fabric. Stitch length Color depth. End products of circular knitting machine: Single Jersey M/C: a) S/J Plain b) Single lacoste c) Double lacoste d) Single pique e) Double pique f) Terry Rib M/C: a) 1*1 Rib fabric b) 2*2 Rib fabric c) Honeycomb End product of Flat bed knitting machine: a) Collar b) Cuff

  43. Production Calculation: A. Production/shift in kg at 100% efficiency    RPM No . of Feeder 3527 No . of Needle SL ( mm )   . 80 Yarn count B. Production/shift in meter Course / min cm .  Course /   cm   RPM No . of Feeder 60  12 Efficiency  Course / 100 C. Fabric width in meter: Total no . cm of wales   Wales / 100 Needles Total no . of used in knitting   Wales / cm 100 D. Needle calculation For Circular knitting machine: Diameter of the Machine X Gauge of the Machine X 3.14 For example: Diameter of the machine is 18” and Gauge of the machine is 24. Then the number of Needles on the machine would be- 18 X 24 X 3.14 = 1356 For Flat Bed knitting machine: Length of the Machine needle bed X Gauge of the Machine For example: Length of the machine needle bed is 56” and Gauge of the machine is 14. Then the number of Needles on the machine would be- 56 X 14 = 1568

  44. Faults of Knitting: 1. Hole Mark Causes:  Holes are the results of yarn breakage or yarn cracks.  During loop formation the yarn breaks in the rejoin of the needle hook.  If the yarn count is not correct on regarding structure, gauge, course and density.  Badly knot or splicing.  Yarn feeder badly set. Remedies:  Yarn strength must be sufficient to withstand the stretch as well as uniform.  Use proper count of yarn.  Correctly set of yarn feeder.  Knot should be given properly. 2. Needle Mark Causes:  When a needle breaks down then needle mark comes along the fabrics.  If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies:  Needle should be straight as well as from broken latch. 3. Sinker Mark Causes:  When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes.  If sinker head bend then sinker mark comes. Remedies:  Sinker should be changed.

  45. 4. Star Causes:  Yarn tension variation during production.  Buckling of the needle latch.  Low G.S.M fabric production. Remedies:  Maintain same Yarn tension during production.  Use good conditioned needles. 5. Drop Stitches Causes:  Defective needle.  If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.  Take-down mechanism too loose.  Insufficient yarn tension.  Badly set yarn feeder. Remedies:  Needle should be straight & well.  Proper feeding of yarn during loop formation.  Correct take up of the fabric & correct fabric tension.  Yarn tension should be properly. 6. Oil stain Causes:  When oil lick through the needle trick then it pass on the fabrics and make a line. Remedies:  Ensure that oil does not pass on the fabrics.  Well maintenance as well as proper oiling. 7. Rust stain Causes:  If any rust on the machine parts. Remedies:

  46.  If any rust on the machine parts then clean it.  Proper maintenance as well as proper oiling. 8. Pin hole Causes:  Due to break down or bend of the latch, pin hole may come in the fabric. Remedies:  Change the needle 9. Grease stain Causes:  Improper greasing  Excess greasing Remedies:  Proper greasing as well as proper maintenance 10. Causes: Cloth fall- out  Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles. Remedies:  Make sure all the latches of needle are closed with feeding yarn after a drop stitch. 11. Barre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) Stripe. Causes:  This fault comes from yarn fault.  If different micro near value of fiber content in yarn.  Different lusture, dye affinity of fiber content in yarn.  During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics.

  47.  In draw fame different similar classes sliver is mixed and make one sliver. Remedies:  We can use this fabric in white color. 12. Causes: Fly dust:  In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. Remedies:  Blowing air for cleaning and different parts after a certain period of time.  By cleaning the floor continuously.  By using ducting system for cleaning too much lint in the floor.  Over all ensure that lint does not attach to the fabric. 13. Yarn contamination Causes:  If yarn contains foreign fiber then it remains in the fabric even after finishing,  If lot, count mixing occurs. Remedies:  By avoiding lot, count mixing.  Fault less spinning. 13. Yarn Faults:  Neps.  Slubs.  Yarn count variations.  Thick/Thin place in yarn.  Hairiness

  48. Flat Knitting Machines Fault: 1. Holes: Causes:  Needle Break,  High Tension on Tensioner,  Excess cotton with yarn on needle. 2. Missing Needle: Causes:  Faulty Needle,  Faulty Cam setting. 3. Oil mark: Causes:  Improper Oiling on Machine.  Inexperienced Operator 4. Loop Miss: Causes:  Tension on take up roller,  Needle miss.

  49. Chapter Six: Batching section Batch process flow chart : Flow process chart of Batching Section of Fakir KnitwearsLtd. Fabric Received ↓ Inspection ↓ Fabric Divided according to Diameter ↓ Supervisor batches the fabric according to quantity by Calculation ↓ Sent for Dyeing Grey fabric inspection The batch section of the Fakir KnitwearsLtd. inspects the following parameters of the received fabric-  Knitting Hole  Oil Spot  Tara  Shade UP  Star Mark  Patta  Lack out Batch Calculation: = Batch Quantity (M/C Quantity) / Total Quantity X Diameter quantity Equation for Rope Length =Diameter Quantity (Weight of Fabric in a roll) X 39.37 X1000 / Finished GSM / Finished open Diameter

  50. Batch management: Primarily batching is done by dyeing manager taking the above criteria under consideration. Batch section in charge receives this primary batch plan from dyeing manager. Some time planning is adjusted according to m/c condition or emergency. Machines in batch section : No of Machine Machine Name Origin : 06 Air Turning Machine KOREA : : Remarks: The batch section of the factory is well equipped but it lacks in a quality controller. Chapter Seven: Lab section Lab dip: Lab dip is a process by which buyers supplied swatch is matched with the varying dyes percentage in the laboratory with or without help of “DATA COLOR” Lab dip plays an important role in shade matching & and detaching the characteristics of the dyes and chemicals are to be used in the large scale of production so this is an important task before bulk production.

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