Industrial attachment of givensee group of industries ltd.

1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF Givensee Group of Industries Ltd. 1

2. INTRODUCTION By achieving practical knowledge it is possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equality necessary in association with the theoretical knowledge. The industrial attachment is the most effective process of achieving practical experience. University education provides us vast theoretical knowledge as well more practical knowledge, despite of all these Industrial Attachment helps us to be familiar with technical support of modern technology, suitability about various processing/operation stages. It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management, production planning and control, production cost analysis, inventory management, purchasing, utility and maintenance of machinery and their operation technique etc. The above mentioned cannot be achieved successfully by means of theoretical knowledge only. Industrial attachment makes us reliable and improves courage and inspiration to take self-responsibility. We had the opportunity to perform the industrial attachment with Givensee Group of Industries Ltd. During 42days (6-Weaks) long attachment, We studies the man, Machine, material expects of the Batching, Dyeing section (Knit fabric), Finishing section, Quality Control, Lab, Knitting section, store & inventory control of the mill. According to my studies there we have prepared the following report and would like to present. We have prepared this report according to the guideline given by the University authority, which will lead to a strong guideline and milestone for our future career. 2

3. Object of Industrial Attachment B. Sc. in Textile Technology is the combination of Theoretical knowledge along with the practical experience. We as the Graduates of Textile Technology must acquire adequate practical knowledge to combat with the challenge that we will face in future. This is why 'the mid-course' industrial training has been included in our academic curriculum. The main objective of this training is to comprehend our theoretical knowledge along with the practical knowledge. It also enables us to orient ourselves with the practical environment that we will work in future. We systematically learned about various steps of wet processing. Moreover we know about the man management technique. We also learned about dyeing techniques and quality assurance system. 3

4. CHAPTER-1 PROJECT DESCRIPTION 4

5. Company Profile Introduction: Hotapara Garments LTD.was established in late 2005 and is currently one of the largest knitwear manufacturing factories in Bangladesh. It has been exporting automatic circular knitted items to North American and European retailers. Its operations are spread over a floor space of more than 180000 sq. Ft. With a net export of over USD 12 Million in 2011, we are ready to support our customer with their new knitwear collections for the upcoming seasons. Hotapara Garments LTD. can produce various types of fabrication such as Single Jersey, Rib, Interlock, Pique, and Drop Needle, 2-Thread / 3-Thread Fleece and feeder stripe repeats. Ourdyeing section has capabilities of dyeing under atmospheric pressure in case of cotton fabric andalso it can dye viscose, nylon and polyester fabrics under pressure dyeing conditions. Some ofour common product lines are T-shirt, Polo shirt, Knitted Jackets and bottoms. 5

6. Hotapara Garments LTD. has a successful record of customer satisfaction. It is also a highly Compliant unit in terms of social standard. It has a very strong quality management team, whoare continually reporting their finding to the board of directors. This ensures our commitment tothe customers on their quality requirement. Hotapara Garments LTD. has a daily production capacity of 40,000 pieces of T-shirts, Polo shirts and other knitted items and its major raw materials such as yarn and accessories are sourced fromother group sister concerns such as Givensee Spinning Mills LTD. and GivenseeGarment, Accessories LTD. Our Spirit: Our Market base experience, research techniques and razor- sharp analytical skills have enabled us to leverage opportunities in our existing and emerging markets. Our Vision: To become the largest multinational embellishment corporate in garments Industry 6

7. COMPANY NAME Factory Address Head Office HOTAPARA GARMENTS LTD. BOKRAN, MONIPUR GAZIPUR. Givensee Group of Industries House # 06, Road # 13 Sector # 03, Uttara Model Town Uttara, Dhaka, Bangladesh. Tel: 8932813, 8913802 8961936jkj Mail: rubel@givenseegroup.com 2005 MERCHANTILE BANK LTD 1.2 MILLIONE PER MONTH 12000KGS PER DAY 8000KGS PER DAY 40000 32000 25000 120000 SFT. US$14.50 MILLIONE PER ANNUM(APRX) 1850 Establishment Year Banker Production Capacity Dyeing capacity Knitting Capacity Sewing Capacity Basic T- Shirt Polo shirt Fancy Item Floor space Yearly Turnover Total Workers 5000 PCS Minimum Order Quantity 60 DAYS Shipment lead time associated with Infrastructure: Being one of the earliest composite units in Bangladesh, HGL has a very robust infrastructure in Terms of machinery, floor layout and space distribution. The factory is well equipped with top of.The line machinery along with adequate a pares in order to ensure smooth operation and efficient performance 7

8. Single Jersey(S/J) S/J with Lycra Alt/Full Feeder Heavy Jersey Honeycomb Pique Diamond Pique Lycra Pique Single Lacoste Double Lacoste Interlock 1x1 Rib 2x2 Rib 1x1 Rib 2x2 Rib with Lycra with Lycra French Terry Yarn Dyed Polo Shirt (Basic/Fancy) T-Shirt(Basic/Fancy) Sweat Shirt Tank- tops Skirts & Dresses Ladies Wear Children’s Wear Sports Wear Under Garments Different Departments: To ensuring smooth running of various activities, some departments are available they are given below: Knitting Section: Knitting Grey Fabric Inspection Batch Section Knit Dyeing Section: Store house for Dyeing & Chemicals Dyeing Section Lab & QC Finishing 8

9. Garments Section: Merchandising Sample Production Packaging Maintenance Electrical Mechanical Utility Section Accounts & Commercial Departments Planning Department HR Section Admin Section Product Mix: YARN- 100% Carded; count 20, 22 24, 26, 28, 30, 32, 34, and 40 100% Combed: count 2-. 22, 24, 24, 28, 30, 32, 34, 40 100% O.E Yarn: count 10, 12, 14, 16, 18, and 20 CVC (65% Cotton + 25% Polyester) Lycra (40d, 80d) 9

10. FABRIC: 1.Single jersey with or without Lycra 2.Ribs -1x1; 2x1; 2x2; plain or with Lycra 3.Polo Pique with or without Lycra 4.Interlock- plain or with needle drop 5.Single or Double Lacoste with or 6.Waffle or Thermal Fabric without Lycra 7.Terry Fabrics - blended or 100% 8.Four track fancy design fabric Cotton Strip fabric 9.Three thread fleece 10.Heavy Jersey Annual Raw Materials Requirement: Dyes chemical Yarn Fabric 69600 kg 100000 kg 2640000 kg 2400000 kg Production Capacity: GARMENTS TEXTILE Woven Items : 300,000 pcs per month Yarn : 900,000 lbs. Knit Items : 800.000 pcs per month Knitting : 240,000 kg Sweaters : 1,400,000 pcs permonth Dyeing : 300,000 kg 10

11. Joint Venture: ZAHINTEX INDUSTRIES 1 Soydana, Board Bazar Gazipur. 3. ZAHINTEX INDUSTRIES 3 ZAHINTEX INDUSTRIES 4 Bokran, Monipur, Gazipur. 5. ZAHINTEX INDUSTRIES 7 ZAHINTEX INDUSTRIES 8 Araishaprashad, Kaultia, Gazipur. 7. MASUMA KHATUN TEXTILE Bokran, Monipur,Gazipur. 9. GIVENSEE GARMENTS LIMITED Hotapara,Gazipur. 11. GIVENSEE GARMENTS ACCESSORIES LTD Araishaprshad, Kaualtia, Vaoul, Mirzapur,Gazipur. 2. ZAHINTEX INDUSTRIES 2 74/A ,Konabari, Gazipur. 4. ZAHINTEX INDUSTRIES 5 ZAHINTEX INDUSTRIES 6 Araishaprashad, Kaultia, Gazipur. 6. ZAHINTEX INDUSTRIES 9 Bishia, Kuribari, Gazipur. 8. HOTAPARA GARMENTS LIMITED Bokran, Monipur, Gazipur. 10. GIVENSEE WASHING LIMITED Bokran, Monipur, Gazipur. 11

12. CHAPTER-2 MANPOWER MANAGEMENT 12

13. MANPOWER MANAGEMENT Management System: Buyer sample is send to Responsible Management. Matching is done by lab in charge. Sample is prepared by Ass. Dyeing Manager. Sample is send to the buyer for approval. Approved sample is returned and taken as std. Sampleforbulk production. Asst. Dyeing Manager gives responsibilities to production officer. Then production officer, with the supervisors start bulk production. On line and off line quality check is dome by Lab in charge and A. D.M. After dyeing finishing in charge controls the finishing process with the supervision of production officer. After finishing the material is checked by Ass. Dyeing Manager. Finally D.M checks the results with A.D.M and decision is taken for delivery. Shift Schedule: Per shift is 12 hrs. 1st shifts 8 am -8 pm 2nd shifts 8pm -8am 13

14. NO.OF EMPLOYEE DEPERTMENT G.M (PRODUCTION) 01 P.M 01 QC. Manager 02 H.R officer 01 Trainer 10 Senior H.R officer 01 Mercendiser 03 Well fair officer 01 Flore in charge 01 Line chef 05 Production reporter 01 pion 01 supervisor 15 input man 18 Line quality 08 Sewing operator 490 cutting 06 Sewing helper 320 Sewing mechanical 10 14

15. security 13 Office stuff 02 Line quality 10 sample 15 Finishing 260 Quality 63 utility 28 Designation No of employee director 01 Group fire officer 01 Side engineer 01 Assistant officer 01 Mechanical engineer/dyeing 01 Store assistant 04 15

16. DYEING SECTION No of employee Dyeing manager 01 Dyeing assistant manager 01 Assistant production officer 04 Shift in charge 03 supervisor 02 Assistant supervisor 04 Dyeing operator 52 Dyeing helper 21 fitter 01 total 88 16

17. LAB SECTION : LAB in charge 01 Assistant in charge 01 LAB technician 04 LAB assistant 03 TOTAL 09 BATCH SECTION Batch in charge 01 Batch supervisor 02 Batch supervisor 13 TOTAL 16 Finishing manager 01 Q.C. in charge 01 Assistant q.c. in charge 01 Compactor technician 01 supervisor 08 Q.C. 07 Q.I. 05 17

18. Operator 20 helper 47 Sample man 05 Total 96 18

19. KNITTING SECTION: Knitting manager 01 Mechanical engineer 01 Shift in charge 02 Q.C. in charge 01 Filter 05 mechanics 03 Q.C. 06 Operator 40 Helper 12 TOTAL 78 OTHERS WORKSHOP 01 Ometer 01 Leath supervisor 01 Security guard 10 Drive 06 Office pion 12 loader 14 Stuff 08 19

20. CHAPTER-3 LAY OUT PLAN 20

21. 21

22. CHAPTER-4 MACHINE DESCRIPTION 22

23. DYEING SECTION •Total Dyeing Machine: 27 •No. of sample Dyeing Machine: 12 •No. of Bulk Production Dyeing Machine: 15 Dyeing Machine: Machine Name Brand Model Origin Capacity / M/c kg No.of M/C ED-8-250 2000 1 ED-4-250 ED-8-250 1000 600 1 4 Overflow winch Tungshing Honkong (Soft Flow) ED-2-250 ED-1-250 400 200 5 2 ED-5-100 ERD-2-250 70 400 2 1 High Pressure Tungshing Honkong Sample (High Pressure) Tungshing ERD-5-15 Honkong 15 1 30 2 Sample Local Banglade sh 50 1 20 2 10 5 Total M/C 27 :02 : AIR TURNING MACHINE : DONG NUM INDUSTRIAL CO.LTD. :KOREA : DNAT-400 : DONG NUM : 20000 : To reverse the fabric front side to back side. AIR TURNING MACHINE No. of machine Machine Name (Functional) Manufacturer Manufacturing Country Model Brand Capacity Function 23

24. Benefits of overflow winch machine: 1.Efficient washing effect. 2.Less water consumption. 3.Less temperature shocks when filling with cold water. 4.Precise calculation of water consumption. Fully automatic function: 1.Automatic salt & soda dosing system 2.Automatic chemical injection system 3.Automatic heat exchanging process Components of M/c: 1. Mixing tank:There is a tank in this machine. Every chemical are used to put here. Here all the chemicals, dyes & salt are mixing for delivery into machine. 2. Unloading reel: The fabric is used to unload from the machine by this part. The number of unloading reel is equal to the number of nozzle in the machine. It is rubber coated which helps to unload fabric easily. 3.Monitor:It is situated at the right side of the machine. The commands are shown in the monitor & the operators can work from these commands. There are also some buttons for working properly & to obey these commands. 4. Alarm Box:There is an alarm box on the upper side of the machine. There are also some buttons to operate the machine & to stop the alarm. 24

25. 5. Three detectors:There are 3 detectors on the above of the nozzle are as follows: a. Temperature detector: It is at the left side between these 3 detectors which can detect the temperature of the main tank. b. Fabric turning pressure detector: It is at the middle of these 3 detectors. It can detect the pressure at which the fabric turning. c. Atmospheric pressure detector: It can detect the atmospheric pressure of the main tank. 6. Plain board:It is situated at the right side of the machine. 7. Waterlevel:There is a water level to know the amount of water in the main tank. It does not give correct result but it can give an approximate result. Process Requirement: Software used: In this factory for total dyeing management usedSETEX – GERMANY. Key accessories used in this factory for pretreatment to complete dyeing are: -Salt tank. -Mixing tank. -Machine tank. -PH meter. -Eye protecting glass. -Hand gloves. -Sewing machine. -Gum boot. -Hand lifter for carrying the batch. 25

26. N.B:Fixing process is done during dark or deep shade. N.B: SAS: If shade% is more than salt is added before dyes add. Sometimes salt is adding two times in deep shade. DAS:If shade% is less then salt is added after dyes adding Work instruction of Bulk dyeing Machine: At first should to clean the machine. Should to check electrical connection of the machine. Should to take the working description of daily work from shift operator, Senior production officer or production officer. To take the fabric from supervisor of batch section according to Production plan +Batch lot No. for coloration. By observing the indicated program of the machine described abovethe fabric dyeing program sheet, should to set the program no. kept @ computer memory attached with the dyeing machine. Should to be kept/write down the batch no./program no./party Name/order ref./color name/into dyeing m/c/ comp memory. Should to use the color into m/c. M/c should to run /set by program no. Dyes/chemical should to mix from the given chart /chart got from m/c During the running of program. Coloration running according to the computer program of m/c. Sample should to collect from the coloring processed fabric into m/c When computer panel program show sample. To check shade, collected sample is sent to the lab, Water inside m/c is drained out if the sample is "ok" by lab. Hot wash is done by filling the water inside m/c of the colored fabric. After the drain out of water soft wash of the fabric is done using soft Wash chemical by filling water into m/c. Then dyed /colored fabric is dropped from the m/c if s sent to the Dewatering section with batch card by trolley. 26

27. Checklist before operation: Checking the program Machine set-up. Fabric weight. Fabric quality. Yarn quality. Collar design (Tipping/ solid). Rib designs (Normal/Lycra). Chemical availability, Power availability. Steam availability. Water availability. Compressed air. Manpower availability. Fabric stitch is done properly. 27

28. Finishing Section Finishing Machine: Brand Model Origin Machine Serial No. Machine Name No. of Capacity (kg) M/C Ball Corino Italy 1 7000 owningSqueeze r Ball Dongnam DNBS-1600 Korea DN-053, DN- 2 8000 owningSqueeze 054 r Tensionless Dongnam DNTD-2400 Korea 0527, 0653 2 1200 Dryer 0 Soft Setting Dongnam 1400 Korea 0553, 0830 2 1200 0 Tube Tex Tube Tex BM- USA 10043, 10187 2 1400 Compactor 10043(SP) 0 Tumble Dryer GuangzhouPa China 3 30 yne Air Turning Dongnam DNAT-400 Korea DN-0829, 2 2400 DN-0532 0 Wet Calendar Dongnam DNW - 1400 Korea DN - 0531 1 6000 Fabric SAFOT JD 6A- 40S China JD 1 A - 40 1 Inspection Total = 16 28

29. Lab Section Wet Lab Machine Capacity Qty Machine name Brand OriginModelSerial no. Test Name (pot) . DATA Spectrophotometer COLOR USA 600TM Recipe Analysis 1 Light Box VERIVIDE UK CAC-120 Lab Dip Shade Check 1 Electronic Balance Meter SHIMADZUJAPANAUY-120 Weight Measuring 1 Lab Dip Dyeing M/C-1 Taiwan IR 12SM 8102 12 1 Lab Dip Dyeing M/C-2 IRDYER IR 12SM 8085 12 1 Lab Dip Dyeing M/C-3 IR 24SM 6337 Lab Dip Dyeing 24 1 Lab Dip Dyeing M/C-4 China HB-12SF 11163 12 1 Lab Dip Dyeing M/C-5 RAPID L-24C 5620 24 1 Dryer Taiwan R-3 92706 Lab Dip Drying 1 Total= 9 29

30. Physical & Chemical Lab Machine Machine Test Qty name Brand Origin Model Serial no. Test Name method . CROCK 67 ISO 105- Crock meter MASTER UK 0 670/07/2060 Color Fastness to Rubbing X12 1 0SU11B0 09.3815.32. ISO 105- Q-SUN XENON USA 2 B02 Color Fastness to Light B05 1 FOM71- 98670116 Wascator ELETROLUXSweden CLS 3 Dimensional Stability ISO 6330 1 Tumble Dryer SIEMENSPoland WDT 2 Shrinkage Test 1 Tumble Dryer WDT 45 1 ISO 105- Rotter wash RAPID China HB 125F Dimensional wash C06 1 YG511- Pilling Test M/C FYICHINA IV ..0106 Pilling Test ISO 12945-1 1 Color Fastness to ISO 105- Precision Woven Y902 ..0906 Perspiration E04 1 HI.98129, pH meter HANNA 30 pH & EC/TDS test ISO-3071 2 Total = 10 30

31. Knitting Machine Profile S/L No. Brand Origin M/C Grade Dia. Gauge CapacityQty. 1 17 24 250 1 2 18 24 250 1 3 19 24 250 2 4 20 24 250 2 5 21 24 250 2 6 22 24 250 3 7 23 24 250 4 8 FUKAHAMA TIWAN S/J-SH-2BFA 24 24 250 4 9 25 24 250 3 10 26 24 250 3 11 27 24 250 1 12 S/J-SH-2XFA 28 24 250 2 13 30 24 233 1 14 RIB-SH-2BIR-2 30 18 233 1 15 32 18 200 1 16 34 18 200 2 17 36 18 235235 22 18 30 24 200 1 19 Interlock SH-BIR-2 32 24 200 1 20 34 24 233 1 SHIMA FLAT KNIT SFF- 21 SEIKI GERMANY 152T 60 14 1200 PCS 2 BANGLADES FABRIC 22 LOCAL H INSPECTION M/C 2 Total = 42 31

32. Utility Section Utilities & Supporting Equipment Machine Name Origin Capacity Unit Gas generator Austria 1064 Kw 3 Diesel generator UK 400 Kw 3 8.4 Ton 4 Gas boiler LC - 11 Taiwan Air compressor USA 13 m3/hrs 11 Air dryer USA 13 m3/hrs 15 32

33. CHAPTER- 5 RAW MATERIALS 33

34. RAW MATERIAL Raw material is a unique substance in any production oriented textile industry. It plays a vital role in case of continuous production & for high quality fabric. The EKCL always try to use high quality raw material to export high quality and world class product. 34

35. Types of Raw material: 1.Yarn 2.Fabric 3.Dyes 4.Chemical & Auxiliaries 1. Yarn: •Cotton •Polyester •Lycra •Viscose 2. Fabric: •Single Jersey(S/J) •Heavy Jersey •Honeycomb Pique •Diamond Pique •Single Lacoste •Double Lacoste •Interlock •1x1 Rib •2x2 Rib •2x2 Rib with Lycra with Lycra •French Terry •Terry Fleece 35

36. 3.Dyes: Serial No. Trade Name Type of Dyestuffs Origin 1 COLVAZOL YELLOW-3RS Reactive China 2 COLVAZOL YELLOW 4GL (150%) 3 COLVAZOL.RED 3BSN 4 COLVAZOL BLACK-B 5 COLVAZOL YELLOW-4GL 6 COLVAZOLYELLOW-RR 7 8 COLVAZOL RED-RR COLVAZOL BLUE-RR 1 Shulofix Yellow 3RS(Y 145) Reactive China 2 Shulofix Red 3BS (R 195) 3 Shulofix Black B 1 Sumifix Brilliant Blue R special gran. Reactive Singapore 2 Sumifix Supra Blue BRF 150% gran. 1 STARFIX YELLOW 3RFN 150% 2 STARFIX YELLOW 4GL 150% 3 STARFIX RED 3BFN 150% 4 STARFIX BLACK B 150% 5 STARFIX BRILL BLUE R(SPL) 150% 36

37. 6 STARFIX T.BLUE G 150% 7 STARFIX BLUE BRN 150% 1 NOVACRON® YELLOW FN-2R Reactive Switzerland 2 NOVACRON® BRILLIANT RED FN-3GL 3 NOVACRON® YELLOW S-3R 4 NOVACRON® RED FN-R 5 NOVACRON® BLUE FN-R 6 NOVACRON® TURQUISE H-GN 7 NOVACRON® SUPER BLACK G 8 NOVACRON® BRILLIANT BLUE FN-G 1 TERASIL® GOLDEN YELLOW W-3R Disperse Switzerland 2 TERASIL® YELLOW W-6GS 3 TERASIL® RED FBN CONC 4 TERASIL® RED WW-FS 5 TERASIL® RED W-RS 6 TERASIL® RED W-4BS/W-4BS-01 150% 7 TERASIL® NAVY W-RS 8 TERASIL® BLUE W-BLS 9 TERASIL® BLACK W-NS 37

38. Chemicals& Auxiliaries S/L 1 2 3 4 5 6 7 8 9 10 Trade Name CETATEX PC Avosperse AD STABILISER A pdr CETALUBE NFL CETAFIX R Texsanscour CS Texsantifoam AF ALBAFIX® ECO ERIOPON® R LIQ. UNIVADINE® DP Technical Name H2O2 killer Sequestering Agent Stabilizer for H2O2 Anti-creasing Agent Fixing Agent Detergent Antifoaming Agent Fixing Agent Washing Agent Leveling& Dispersing Agent pH-Regulating Agent Fixing Agent Detergent Optical Brightening Agent Optical Brightening Agent Softener Levelling Agent Optical Brightening Agent Acid Bleaching agent Origin England Korea Switzerland 11 12 13 14 15 ALBATEX® AB-45 Alba fixFRD Optifix EC Liq HostapalDTC Leucophor BBU 300 powder Ultrafab ARW Plus Thailand 16 Thailand 17 18 19 Flake Super TLF ASTROLEVEL CO Sunhite - 4 B K Italy Taiwan 20 21 Rossacid N liquid Hydrogen Per-Oxide (H2O2)50% IogenFibrilase® HDL 350 IogenFibrilase® GXM Ultra KAPPATEX R 98 India Bangladesh 22 Enzyme 23 Enzyme Canada 24 Strong Reducing Agent Alkali 25 HK J218 China 26 Acetic Acid Acid Taiwan 27 Caustic Soda Strong Alkali China 28 Soda ASH Light Mild Alkali China 38

39. 29 Glauber Salt Electrolytes Singapore 30 Bleaching Powder Reducing Agent 31 Hydrose Reducing Agent 39

40. CHAPTER-6 PRODUCTION PLANNING & SEQUENCE & OPERATION 40

41. PRODUCTION PLANNING, SEQUENCES & OPERATION Introduction and Basic Procedure of Planning and Control: A planned work brings success. Without planning nothing is completed within the required time. So planning has its own importance which is intolerable. "Planning" gives a scheduled task and 'control' completes it successfully. But production planning and control is not an easy task. So Esquire Knit Composite Limited’s has a high-performance department called "Production Planning & Control". Its Basic working procedure is as follows – Taking orders from marketing division. Analyzing the orders. Planning for knitting the fabric. Planning for dyeing the fabric. Planning for finishing the fabric. It is only a basic procedure. It may change according to the type of order. Sometimes, order is places only for finishing the material or only for dyeing the white goods. Then some steps are omitted for planning procedure. Taking orders from marketing division: EKCL marking division supplies Fabric Orders to the EKCL Planning and control division by a special format. Analyzing the orders: This section analyzes the orders according to buyers, Order Quantity, type of orders (i.e. type of fabric, color to be dyed etc.), delivery date etc. Then it selects which M/C. to use, no of M/C. to use, time required for production etc. This section plans for required quantity of fabric to be knitted 41

42. (Order quantity + 6% of Order Quantity), knitting balance, fabric need to be dyed. Dyeing balance, RFD (Ready for delivery), RFD balance, delivered fabric and delivery balance. Planning for knitting: This section plans for knitting production. It selects machine for knit the fabric for specific type of fabric, type of yarn used, required GSM, width etc. It also gives delivery data for knitted fabric. It also places orders for buying of yarn from spinning mills by a specific schedule. Planning for dyeing the fabric: Production planning for dyeing is called 'Batch Plan'. According to the batch no. And color, width, style and construction the batch plan is made. For easy understand this section gives some 'ROUTE CARD.' cards. "ROUTE CARD' cards are serialized according to the priority of delivery. The batches and "ROUTE CARD ' cards also serialized as to dye light shade at first and lastly the dark shades, since faulty shades can be converted to dark color later. Planning for finishing the fabric: Finishing schedule is same as the dyeing. After dyeing the material goes to the finishing section with the batch plan. Finished data is written to the batch card and is informed to the planning section. However, this section always enforces to all the departments to finish all the works within the delivery time given by the buyers. This section delivers materials by truck, micro, air etc to the customer within the meantime. Thus it plays a very important role in the success of the company. 42

43. 43

44. KNITTING SECTION 44

45. PROCESS FLOW CHART OF KNITTING Knitting Tension devices Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Feeding the yarn cone in the creel Yarn in cone form 45

46. PRODUCTION FLOW CHART OF KNITTING SECTION Sample fabric Design analysis Machine selection Setting the Machine forthe Specific Design Sample Knitting Sample approval Bulk Production Grey fabric inspection 46

47. DESCRIPTION OF PRODUCTION PROCESS: 1. Firstly, knitting manager gets a production shit from the merchandiser as accordance as consumer requirements then he informs or orders production officer about it. Production officer informs technical in charge and knows about machine in which the production will be running. Technical in charge calls for leader of mechanical fitter troops, they two take decision about machine for production considering machine condition, production capacity, maintenance complexity, etc. Production officer with experienced mechanical fitter adjusts required stitch length and grey GSM for required final GSM. Supervisor checks daily production regularity and make operator conscious about finishing tin due time. Operators operate machine in high attention as if there were no faults in the fabrics. If he thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty. Mechanical fitter then fixes it if he can or he informs technical in charge. Then he comes in spot. After required production and final inspection in 4-point system, they sent in dyeing section. 2. 3. 4. 5. 6. 7. PRODUCTION PARAMETER: Machine Diameter; Machine rpm (revolution per minute); No. of feeds or feeders in use; Machine Gauge; Count of yarn; Required time (M/C running time); Machine running efficiency 47

48. YARN PATH OF CIRCULAR KNITTING M/C Ceramic Eye pot (Feeder Ring) Creel Guide Tube Senser Feeder Needle Knot Catcher Guide Tension Disc Yarn Wheel Ceramic Eye pot Senser 48

49. Method of Increasing Production 1. By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately production will be increased. 2. By increasing the number of feeder: If the number of feeder is increased in the circumference of cylinder, then the number of courses will be increased in one revolution at a time. 3. By using machine of higher gauge: The more the machine gauge, the more the production is. So by using machine of higher gauge production can be increased. 4. By imposing automation in the m/c: a) Quick starting & stopping for efficient driving system. b) Automatic m/c lubrication system for smoother operation. c) Photo electric fabric fault detector. 5. By imposing other developments: •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. 49

50. Description of Knitting Parts With Figure: Name of the parts Picture Function Creel Creel is a part of knitting machine. Here yarn packages are stored for yarn feeding in the machine. MPF Wheel Its control the speed of the MPF. Pulley belt gives motion to the wheel. MPF It’s mean Mamminger positive feed. It gives equal length yarn distribution in the knitting cycle. VDQ Pulley It is a very important part of the machine. It controls the quality of the product. Altering the position of the tension pulley changes the G.S.M of the fabric. If pulley moves towards the positive directive then G.S.M decreases and reverse direction G.S.M will increase Pulley belt It controls the rotation of the MPF wheel. 50