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Industrial attachment of hams washing & dyeing ltd.

Presentation about 'Industrial attachment of hams washing & dyeing ltd.'

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Industrial attachment of hams washing & dyeing ltd.

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT HAMS WASHING & DYEING LTD. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 1 of 56

  2. Chapter 1 Introduction As a part of course curriculum of Bangladesh College of Textile Engineering & Technology we were send for industrial attachment for two months starting from 17thJune 2006 to 17thAugust 2006 to HAMS Washing & Dyeing Ltd. During the attachment we worked as a trainee textile engineer and had to attend the official working days in general working times i.e. 9 am to 5 pm. AIM AND OBJECTIVES OF INDUSTRIAL ATTACHMENT  To enhance our University learning experience through involvement in industrial and commercial field, thus enabling us to relate theoretical concepts with practical situations;  To develop our ability to evaluate issues and situations critically and propose well considered options and solutions;  To develop and enhance our professional awareness and communication skills;  To provide experiences that will enable us to achieve a breadth of understanding that will form a framework or agenda for our final year of study. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 2 of 56

  3. The experience offered by industrial training varies. However, by the end of the placement we were expected to have substantially met most or all of the following objectives:  Undertaken problem solving activities in the workplace;  Further developed my communication skills;  Shown the ability to accept responsibility, work independently, manage my own time and schedule my work;  Understood the constraints of a formal working environment and the benefits of team work;  Appreciated the relevance of my academic work and have applied this to new situations;  Used new tools and techniques to supplement those covered on my scheme of study;  Acquired the experience to understand, discuss and evaluate the professional issues relating to textile engineering.  Gained an understanding of which final year courses will provide the best foundation for my int ended career. SUPERVISION DURING THE INDUSTRIAL ATTACHMENT During our industrial attachment we were overseen by our industrial tutor. We kept a log of our activities during my industrial attachment in a diary supplied from our institute, which was re-checked and signed by our industrial tutor. We were also visited by our academic professionals of different departments whom discussed about our progress with our industrial tutor. Thus we had the opportunity to learn from our academic tutors in a practical field. A routine was maintained to meet with our head of department. Once in every 15 days we met with our head of department and discussed about solutions of some problems that we had in the industry. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 3 of 56

  4. Chapter 2 Overview of the Industry This chapter contains general overview of the industry where we have carried out the industrial attachment. OVERVIEW  Company Name: M/S HAMS WASHING & DYEING LTD.  Company Nature: Privet Limited Company  Established Date: September, 1998  Location: Tejgaon Industrial Area, Dhaka  Project Cost: 57.04 Cror Tk.  Total area: 20,000 Square Feet (approx.)  Man-power: 200  Business field: Readymade Garments Washing & Dyeing  Main product: Denim long pant, short pant, overall skirt, cotton sweater .  Manufacturing capacity: 2000 Dozens/Day  Types of wash: o Garments Wash o Acid Wash o Heavy Garments Wash o Bio Wash o Pigment Wash o Bleach Wash o Sand Blasting / Spray Blasting o Stone Wash o Tinting Wash o Deep Dye o Stone Enzyme Wash o Tie Dye o Sand Wash o Silicon Wash o Enzyme-Silicon Wash o Whickering Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 4 of 56

  5. Local Buying House: o Li & Fung (BD Ltd.) o Linmark o Nor Wester o ABA Group o Pelican Resources inc. o Auchan o Lindex o Texel Ltd. o NASSA o Jecepenny o DAC Pacific o Tex-EBO o Epic Designers  Washing Capacity: o Dye & Tint 12000 PCs/day o Enzyme Wash 15000 PCs/day o Bleach Wash 20000 PCs/day o Enzyme Stone Wash 16000 PCs/day o Pigment Wash 25000 PCs/day o Garments Wash 40000 PCs/day o Enzyme Silicon Wash 25000 PCs/day o Avg. All type of Wash 22000-23000 PCs/day  Major customers: o Jc-penny o Primark o Vermukt o Walmart o K-Mart o Route-66 Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 5 of 56

  6. o Fashion Traders o Auchan  Sales & Marketing policy: Improvement through Research and development for better marketing.  Banks: Premier Bank Ltd. Gulshan Branch National bank.  Address: 190, Tejgaon I/A, Dhaka-1208, Bangladesh  Telephone: 9885674, 9886406(off.) 8814365, 8814923(fac.)  Fax: 880-2-9881067  e-mail: hfl@bdcom.com  Web: www.hamsgroup.com  Different departments: Sample section, Washing & Dyeing section, Drying section, Sand Blasting section, Quality assurance section, Laboratory, Storage section.  Sister Concern: HAMS Fashion Bijoy (Pvt.) Ltd. HAMS Fashions Ltd. Fashion-2000 Ltd. Pacific Label Ltd. HISTORY Md. Shafiqur Rahman, founder & managing director of this company, is a textile engineer himself who provided service for five year in garments washing and dyeing sector. In September 1998 with five local made garments washing and dyeing machine he launched M/S HAMS WASHING & DYEING LTD. The commitment was “TO MAINTAIN QUALITY AND TO DELIVER TIMELY” and still strongly believes it. Within five years the industry earned good reputation in garments washing & dyeing sector. Now HAMS WASHING & DYEING LTD. is one of the leading garments washing & Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 6 of 56

  7. dyeing industry in Bangladesh. The industry is now equipped with modern washing & dyeing machines. The total numbers of machine are three times than the initial set up. Chapter 3 Man power Management The company includes over 150 employees with some highly skilled personnel. Most of the staffs are self-motivated and hard working. ORGANOGRAM MAN POWER-ADMINISTRATION: No . of Po st SL. No. Foreign expert Designation Gender Qualification Local B.Sc. in Textile Technology Bachelor B.Sc. in Textile Technology Bachelor     1 Managing Director 1 Male  2 Director(admin) 1 Male  3 Director(production) 1 Male  4 Director(marketing) 1 Male  ORGANOGRAM-ADMINISTRATION: Managing Director  Director (Admin.)    Manager (Account) Manager (Admin.) Manager (Compliance) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 7 of 56

  8. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 8 of 56

  9. ORGANOGRAM-PRODUCTION: Managing Director  Director (Production)  Production Manager  Asst. production manager      Supervisor Supervisor Supervisor Supervisor (Sand (Washing) (Dyeing) (Drying) Blasting)     Machine Machine Machine Machine Operator Operator  Operator  Operator   Assistant Assistant Assistant Assistant Operator Operator Operator Operator Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 9 of 56

  10. ORGANOGRAM-QUALITY CONTROL: Production Manager  Super Visor (Quality)  Assistant (Quality) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 10 of 56

  11. ORGANOGRAM LABORATORY: Production Manager    Machine Operator Assistant Machine Operator (Sample washing machine)  (Laboratory) (Sample drying machine)  Assistant Operator Assistant Operator ORGANOGRAM MAINTENANCE: Production manager  Supervisor (Maintenance)  Technician  Assistant ORGANOGRAM FINANCE: Director (Finance)  Accountant  Asst. Accountant Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 11 of 56

  12. MANAGEMENT Management system: Vertical type    Figure: Symbolic representation of vertical type management system. Shift Change: 12 hours shift (two shifts per day). Responsibilities of Production Manager:  To give washing & dyeing slip.  To match production sample with target sample.  To collect production sample for sample matching for next production.  To identify disputed garments & report to director.  Also execute overall floor works.  To maintain loading & unloading record.  Any other assignment given by higher authority. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 12 of 56

  13. Chapter 4 Machine Description There are three (3) sample washing machines and fifteen (15) industrial machines in washing section, seven (7) guns in sand blasting section, one (1) sample drying and twelve (12) industrial drying machines in drying section, four (4) hydro extractors in hydro extraction section. There is a modern sample washing machine, a modern industrial washing machine in washing section and a modern hydro extractor in hydro extraction section. The industry is in the process of upgrading it’s existing machines. Specifications of some incoming machines are also given in this chapter. GARMENTS WASHING & DYEING MACHINES SAMPLE WASHING MACHINES  No. of machines: 03  Manufacturing company: Bengal Heavy Electric Engineering.  Manufacturing country: Bangladesh.  Features: ° Single door design for general washing, sample washing. ° Machine body and essential parts are made of stainless steel. ° Preset front and backward rotation. ° Conventional machine.  Specifications: ° Capacity: 30 kg ° Inner Cylinder: 28”X34” ° Thickness of inner drum: 3mm ° Outer Cylinder: 34”X40” ° Motor (HP): 1HP, 0.75KW ° Power Consumption: 2.3 Amp ° Steam Consumption: 2 HP, 31 Kg ° Water Inlet: 2”, 1 way in. ° Steam Inlet: 1”, 1 way in. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 13 of 56

  14. ° Water Discharge: 3”, 1 way out. INDUSTRIAL WASHING MACHINES  No. of machines: 10  Manufacturing company: Bengal Heavy Electric Engineering.  Manufacturing country: Bangladesh.  Features: ° Single door design for general washing, sample washing. ° Machine body and essential parts are made of stainless steel. ° Preset front and backward rotation.  Specifications: ° Capacity: 200 kg ° Inner Cylinder: 42”X88” ° Thickness of inner drum: 3mm ° Outer Cylinder: 54”X960” ° Motor (HP): 10HP, 7.5KW ° Power Consumption: 17 Amp ° Steam Consumption: 15 HP, 230 Kg ° Water Inlet: 2”, 2 ways in. ° Steam Inlet: 1”, 2 ways in. ° Water Discharge: 3”, 2 ways out MORDERN SAMPLE WASHING MACHINES  No. of machines: 01  Manufacturing company: STEFAB INDIA LIMITED  Model no: LXS 35.  Manufacturing country: India.  Features: ° Single door, front-loading, open pocket. ° Machine body and essential parts are made of stainless steel. ° Automatic timed. Auto reverse. Automatic 5 water level & auto digital temperature control. ° Electric solenoid water & steam valves. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 14 of 56

  15. ° Non-clog motorised drain valve. ° Full electric protection.  Specifications: ° Capacity: 35 kg (Dry: Wet =1:10) ° Inner cylinder: 950 mm dial X 500mm ° Wash motor: 0.75 KW ° Extract speed: 200 RPM ° Main door opening: 500 mm dial ° Water connection consumption: 25 mm dial, 120 litres. ° Drain: 75 mm dial, 1 way out ° Steam connection consumption: 15 mm dial, 25 Kg/hr. ° Electric heating: 12 KW ° Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H) MORDERN INDUSTRIAL WASHING MACHINES  No. of machines: 01  Manufacturing company: STEFAB INDIA LIMITED,  Model no: LXS 280.  Manufacturing country: India.  Features: ° Single door, front-loading, open pocket. ° Machine body and essential parts are made of stainless steel. ° Automatic timed. Auto reverse. Automatic 5 water level & auto digital temperature control. ° Electric solenoid water & steam valves. ° Non-clog motorised drain valve. ° Full electric protection.  Specifications: ° Capacity: 280 kg (1:10) ° Inner cylinder: 1750 mm dial X 1180mm ° Wash motor: 7.5 KW Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 15 of 56

  16. ° Extract speed: 130 RPM ° Main door opening: 1000 mm dial ° Inspection door opening: 300 mm dial ° Water connection consumption: 50 mm dial, 960 litres. ° Drain: 115 mm dial, 2 ways out ° Steam connection consumption: 25 mm dial, 200 Kg/hr. ° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr. ° Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H) HYDRO EXTRACTORS  No. of machines: 03  Manufacturing company: Tongxin Ltd.  Manufacturing country: China.  Features: ° Due to its solid constructions it can be positioned onto firm floorings to operate. ° It has excellent electrical layout in prevention of electricity leakage, shock, which is important in wet conditions in the operations. ° Machine operations are made easy, with convenient start-stop operations for maximum efficiency. ° The inner stainless steel is well balanced, thus achieving longer life span and assuming energy efficiency of machine. ° Shock absorbers are well paced in the three suspension points to reduce vibrations. ° Stainless steel constructions in major parts ensure durability.  Specifications: ° ° ° ° ° ° Model no: SHE-42 Capacity: 280 LBS Inner cylinder: 1067dial X 419mm Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H). Wash motor: 7.5 KW Extract speed: 860 RPM Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 16 of 56

  17. MODERN HYDRO EXTRACTORS  No. of machines: 01  Manufacturing company: STEFAB INDIA LIMITED,  Manufacturing country: India.  Features: ° Full stainless steel outer drum and inner basket. Strong welded construction. Basket can be dismantled without dismantling outer casing. Electrically interlocked top lid stops the machine when opened. Three position drain connection. Outer casing mounted on heavy galvanised plate base frame. Long rust free life and strength. ° Direct drive. Basket is directly mounted on to a specially designed high torque heavy-duty motor resting on spigot of the base frame with built-in rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick self-balancing. Noiseless & vibration less operation. ° Automatic timed. Automatic DC injection for braking. Safety devices against single phasing reverse phasing & motor overload. Great convenience & safety. No foot pedals, no levers, no brake liners, no maintenance.  Specifications: ° Model no: HX 50 ° Capacity: 80 Kg ° Inner cylinder: 1000dial X 300mm ° Volume: 235 Litres ° Basket speed: 750 R.P.M. ° Wash motor: 7.5 KW ° Drain: 75 mm dial ° Overall dimension: 1250mm(W) X 1550mm(D) X 1150mm(H) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 17 of 56

  18. SAMPLE DRYING MACHINES  No. of machines: 01  Manufacturing company: STEFAB INDIA LIMITED,  Manufacturing country: India.  Features: ° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body not painted. Long rust free life and sheen. ° Built in solvent filter housed in the top tank receives soiled from the base tank through a powerful centrifugal pump which pushes the soiled solvent through several fine mesh cylindrical filters for reuse. Maximum recovery of clean solvent. ° Low spin extract. Separate motors for dryclean & extract. Vibrationless during extraction. Low spin extract makes articles lighter to unload. No solvent dripping. No wastage of solvent. ° Automatic timed. Auto reverse. Full electrical protection against single phasing & motor overload. Operator’s convenience & machine safety. Efficient cleaning.  Specifications: ° Capacity: 18 Kg ° Basket size: 700 mm (dial) X 470 mm ° Volume: 180 Litres ° Dry clean motor: 0.37 KW ° Extract motor: 1.5 KW ° Extract speed: 220 rpm ° Loading door opening: 400 mm (dial) ° Base tank capacity: 250 Litres ° Filter tank capacity: 250 Litres ° Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 18 of 56

  19. INDUSTRIAL DRYING MACHINES  No. of machines: 11  Manufacturing company: Bengal Heavy Electric Engineering.  Manufacturing country: Bangladesh.  Features: ° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body painted. ° Low spin extract. Vibration less during extraction. Low spin extract makes articles lighter to unload. ° Automatic timed. Full electrical protection against single phasing & motor overload. Operator’s convenience & machine safety. Efficient cleaning.  Specifications: ° Capacity: 35 Kg ° Basket size: 950 mm (dial) X 500mm ° Volume: 350 Litres ° Dry clean motor: 0.75 KW ° Extract speed: 200 rpm ° Loading door opening: 500mm (dial) ° Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 19 of 56

  20. INCOMING MACHINES INDUSTRIAL WASHING PROCESSING & DYEING MACHINES  No. of machines: 06  Manufacturing company: STEFAB INDIAL LIMITED,  Manufacturing country: India.  Features: ° Single door, front-loading, open pocket. ° Machine body and essential parts are made of stainless steel. ° Automatic timed. Auto reverse. Automatic 5 water level & auto digital temperature control. ° Electric solenoid water & steam valves. ° Non-clog motorised drain valve. ° Full electric protection.  Specifications: ° Capacity: 280 kg (1:10) ° Inner cylinder: 1750 mm dial X 1180mm ° Wash motor: 7.5 KW ° Extract speed: 130 RPM ° Main door opening: 1000 mm dial ° Inspection door opening: 300 mm dial ° Water connection consumption: 50 mm dial, 960 litres. ° Drain: 115 mm dial, 2 ways out ° Steam connection consumption: 25 mm dial, 200 Kg/hr. ° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr. ° Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 20 of 56

  21. HYDRO EXTRACTOR MACHINE:  No. of machines: 01  Manufacturing company: STEFAB INDIA LIMITED,  Manufacturing country: India.  Features: ° Full stainless steel outer drum and inner basket. Strong welded construction. Basket can be dismantled without dismantling outer casing. Electrically interlocked top lid stops the machine when opened. Three position drain connection. Outer casing mounted on heavy galvanised plate base frame. Long rust free life and strength. ° Direct drive. Basket is directly mounted on to a specially designed high torque heavy-duty motor resting on spigot of the base frame with built-in rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick self-balancing. Noiseless & vibration less operation. ° Automatic timed. Automatic DC injection for braking. Safety devices against single phasing reverse phasing & motor overload. Great convenience & safety. No foot pedals, no levers, no brake liners, no maintenance.  Specifications: ° Model no: HX 50 ° Capacity: 80 Kg ° Inner cylinder: 1000dial X 300mm ° Volume: 235 Litres ° Basket speed: 750 R.P.M. ° Wash motor: 7.5 KW ° Drain: 75 mm dial ° Overall dimension: 1250mm(W) X 1550mm(D) X 1150mm(H) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 21 of 56

  22. GARMENTS SAND-BLASTING MACHINES INDUSTRIAL SAND-BLASTIG GUNS  No. of machines: 07  Manufacturing company: Made in China  Features: ° Single door design for general washing, sample washing. ° Machine body and essential parts are made of stainless steel. ° Preset front and backward rotation.  Specifications: ° Model: SBT-650 ° Capacity: 200 Litres ° Dimension: 800mm X 1000mm X 1250mm ° Sand contains: 200 Kg OTHER COMPONENTS/ACCESSORIES  No. of cabinets: 07  Hopper (for controlling dust in cabinets): 02  Helmet: 07 Pcs  Musk: 07 Pcs  Gloves: 07 pairs.  Air preserver-1, capacity of 2000 c.c.  Air preserver-2, capacity of 900 c.c. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 22 of 56

  23. OTHER MACHINES  Spray machines: 03 Nos. Manufacturing country: Hong Kong  Compressor: 03 Nos. Two compressors with same following specifications. o Brand: ELGI o Capacity: 10 Jule/Bar o Made in INDIA One compressor with following specifications: o Brand: OSD o Made in ITALY o Includes Change Over o MCCB o Capacity: 10 Jule/Bar  Boiler: Brand name: Sacca Manufacturer: Made in ITALY Production capacity: 1.5 Tons/Hr. Pressure: 7.5 Jule Bar (5.0 Bar used) Supply system: Automatic Pressure control. Chimney: 50 Feet with 12-inch diameter.  Generator Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta" production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI) alternators. All alternators are three phase, four pole, single bearing, synchronous type, cosj=0.8, 50Hz.  Water supply pump: 03 Nos. 02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse Power. 01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power. REMARKS Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 23 of 56

  24. No live industry can keep place with the advance of technology without continuous renewal & transformation of its production facilities. Existing equipments must be kept on the defensive, compelled always to justify its tenure against the challenge of new & more modern machines. If any piece of existing equipment fails to meet this challenge, it must be displaced, regardless of its age or condition & regardless of whether it is physically “worn out”. Keeping the above in view, this industry is always replacing its existing machines in order to increase productivity & improve quality. Chapter 5 Raw materials Different sections of the industry require raw materials i.e. chemicals of various types in different quantity. Most of the chemicals are purchased locally. A few are imported directly. RAW MATERIALS USED IN GARMENTS WASHING  Caustic Soda (NaOH) ° Type : Alkali ° Unit price : Taka 24 per Kg ° Source : Bangladesh ° Uses : Neutralize acidic materials, saponify glycerides (waxes and oils), solubilize silicate ° Monthly requirements: 4050 kg (approximately)  Soda Ash (Na2CO3) ° Type : Alkali ° Unit price : Taka 14 per kg ° Source : China : Used to alkaline the solution/medium. Control PH ° Uses Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 24 of 56

  25. ° Monthly requirements: 2000 kg (approximately)  Wetting agent: ° Type : Combination of Detergent & Surfactant ° Unit price : Taka 150 per kg ° Source : Bangladesh ° Uses : Emulsify oils, fats and waxes; remove oil-stains; suspend materials after they have been removed. Reduce surface tension & minimize inter facial tensions. ° Monthly requirements: 2000 kg (approximately) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 25 of 56

  26. Anti-back ° Type : Anti back staining agent ° Unit price : Taka 175 per kg ° Source : India, China ° Uses : Prevent back staining ° Monthly requirements: 2000 kg (approximately)  Acetic Acid ° Type : Organic acid ° Unit price : Taka 70 per kg ° Source : Korea : Used to make solution/medium acidic. Control PH ° Uses ° Monthly requirements: 1000 kg (approximately)  Sodium Hypo Chloride (NaOCl) ° Type : Oxidizing agent ° Unit price : Taka 18 per kg ° Source : India, China ° Uses : Used to uniform lightening of the colour of the indigo or sulphur dyed garments in bleach wash. ° Monthly requirements: 1500 kg (approximately)  Bleaching Powder [Ca (OCl)Cl] ° Type : Oxidizing agent ° Unit price : Taka 21 per kg (KCI, 33% Chlorine), Taka 105 per kg (Japan, 65% Chlorine) ° Source : India ° Uses : Used to decolouration of fabric ° Monthly requirements: 3590 kg (KCI), 142 (Japan) (approximately)  Enzyme ° Type : Enzyme ° Unit price : Taka 300 per kg (liquid), Taka 400 per kg (powder) ° Source : China ° Uses : Used to breaks down the long starch molecular chain into smaller sections, that can be easily washed from the Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 26 of 56

  27. garments. ° Monthly requirements: 1500 kg (liquid), 1000 kg (powder) (approximately)  Peumic Stone ° Type : Washing stone ° Unit price : Taka 280 per bag (25 kg) ° Source : China ° Uses : It is used to have an abrasion/irregular-fading effect of stone on garment. ° Monthly requirements: 200 bags (approximately)  Silicon ° Type : Softener ° Unit price : Taka 130 per kg ° Source : Korea ° Uses : Creates the fabric surface oily/ used for lubrication ° Monthly requirements: 500 kg (approximately)  Softener Flax ° Type : Softener ° Unit price : Taka 105 per kg ° Source : Korea ° Uses : Soften fabric handling ° Monthly requirements: 500 kg (approximately)  Potassium Permanganate ° Type : Decolouration agent ° Unit price : Taka 80 to 370 per kg ° Source : India, Bangladesh ° Uses : Used to decolouration of fabric ° Monthly requirements: Locally purchased when required.  Sodium Meta bi Sulphate ° Type : De-chlorination agent ° Unit price : Taka 28 per kg ° Source : China ° Uses : Used to neutralize activity of chlorine on fabric/solution Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 27 of 56

  28. ° Monthly requirements: 475 kg (approximately) Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 28 of 56

  29. Peroxide (H2O2) ° Type : Oxidising agent ° Unit price : Taka 35 per kg ° Source : Korea : OH-ions destroy the colouring material and improve ° Uses whiteness ° Monthly requirements: 1000 kg (approximately)  Common Salt ° Type : Salt ° Unit price : Taka12 per kg ° Source : Bangladesh ° Uses : Used as electrolyte for solution, improves shining of fabric. ° Monthly requirements: 2200 kg (approximately) RAW MATERIALS USED IN GARMENTS DYEING The following raw materials are used in garments dyeing in addition to some of the raw materials already listed above.  Dyestuff o Type : Direct dye o Unit price: Taka 300-1200 per Kg o Source: China, Switzerland. o Use: Cotton & Viscose garments dyeing. o Monthly requirements: Depends on ordered quantity. o Type: Reactive dye o Unit price: Taka 275-850 per Kg. o Source: China, Switzerland. o Use : Cotton & Viscose garments dyeing. o Monthly requirements: Depends on ordered quantity. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 29 of 56

  30. o Type : Pigment dye o Unit price: Taka 300-500 per Kg o Source: Switzerland. o Use: Cotton & Viscose garments dyeing. o Monthly requirements: Depends on ordered quantity.  Glauber salt o Type : Salt o Unit price: Taka 14 per Kg o Source: China. o Use: Levelling agent. o Monthly requirements: Depends on ordered quantity.  Fixing Agent o Unit price: Taka 500 per Kg o Source: Switzerland. o Use: Colour fixation. o Monthly requirements: Depends on ordered quantity.  Dispersing agent o Unit price: Taka 500 per Kg o Source: Switzerland. o Use: Assists in the process of particle size reduction of dye. o Monthly requirements: Depends on ordered quantity. REMARKS The monthly requirements of raw materials vary depending on the type of washing & ordered quantity. Sometimes the price of the materials also varies due to the availability of the materials in the market. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 30 of 56

  31. Chapter 6 Production Planning, Sequences & Operations Production process consist of different types of washing methods such as normal wash, bleach wash, stone wash, acid wash, enzyme wash, super white wash, dirty wash etc and dyeing methods with reactive, direct, sulphur etc dyes are done. Recently sandblast and chemical sprayer added to the production process. PRODUCTION FLOW CHART OF GARMENTS WASHING Batching  Pre-treatment  Washing  Hydro Extraction  Drying  Quality Control  Storage Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 31 of 56

  32. PRODUCTION FLOW CHART OF GARMENTS DYEING Batching  Pre-treatment  Dyeing  Sample Check  Hydro Extraction  Drying  Quality Control  Storage Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 32 of 56

  33. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 33 of 56

  34. PROCESS TECHNIQUE OF SOME WASHING & GARMENTS DYEING METHODS  ENZYME-BLEACH WASH WITH TINTING: Batch 60 PCs. Liquor 400 Litre Step 01 Water is added (400 Lt)  Desizing Garments are added  Machine started running  500 gm Soda Ash added  500 gm Caustic Soda added  200 gm Bio. D added  Steam to raise temp 60°C  Process time 25 minutes  Drop liquor  Wash down twice Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 34 of 56

  35. Step 02 Water is added (400 Lt)  Enzyme Wash Machine started running  200 ml liquid, 400 gm powder type Enzyme added  150 ml Acetic Acid Added  200 gm Anti back added  10 Kg Peumic Stone added  Steam to raise temp 50°C  Process time 60 minutes  Drop liquor Step 03 Water is added (400 Lt)  Bleaching Machine started running  4 Kg KCI (35% Cl2) added  Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 35 of 56

  36. 500 gm Soda Ash added  Steam to raise temp 60°C  Process time 10 minutes  Drop liquor Step 04 Water is added (400 Lt)  Neutral Wash Machine started running  500 gm Hypo sulphide added  Steam to raise temp 45°C  Process time 10 minutes  Drop liquor Step 05 Water is added (400 Lt)  Tinting Machine started running  Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 36 of 56

  37. 0.02% Direct Brown GTL & 0.01% Direct Black V-200 added  4 Kg Salt added  Steam to raise temp 70°C  Process time 20 minutes  Check Shade  Drop the liquor Step 06 Garments are then taken out  Drying Hydro extracted  Send to dryer for drying of garments.  ACID WASH Liquor 500 Batch 100 PCs. Litre Step 01 Water is added (500 Lt)  Desizing Garments are added Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 37 of 56

  38. Machine started running  400 gm Soda Ash added  400 gm Caustic Soda added  200 gm Bio. D added  Steam to raise temp 60°C  Process time 20 minutes  Drop liquor  Wash down twice Step 02 Water is added (500 Lt) Normal  Wash Machine started running  Steam to raise temperature 40°C  Process time 5 minutes  Drop liquor Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 38 of 56

  39. Take out the garments  Hydro extract the garments  Dry the garments Load the pre-treated & dried Step 03 garments in another washing machine  Acid Wash Machine started running  Add stones soaked with potassium per magnate double the volume of garments  Continue machine running for 7 minutes  Unload the garments from the machine Load the garments into another washing Step 04 machine Neutral  Wash Water is added (500 Lt)  Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 39 of 56

  40. Machine started running  1.5 Kg detergent is added  Steam to raise temp 50°C  Process time 15 minutes  Drop liquor Step 05 Water is added (500 Lt) Neutral  Wash Machine started running  500 ml Auxalic Acid added  Process time 5 minutes  Check Shade  Drop the liquor  Garments are then taken out  Hydro extracted  Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 40 of 56

  41. Send to dryer for drying of garments.  COTTON GARMENTS DYEING PROCESS (Sample Dyeing) Liquor Batch 1.4 Kg 14 Litre Step 01 Water is added (14 Lt)  Desizing Garments are added  Machine started running  500 gm Soda Ash added  500 gm Caustic Soda added  100 gm Bio. D added  Steam to raise temp 80°C  Process time 45~60 minutes  Drop liquor Step 02 Water is added (14 Lt)  Hot Wash Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 41 of 56

  42. Machine started running  Steam to raise temperature 50°C  Process time 5 minutes  Drop liquor Step 03 Scouring & Water is added 14 litre Bleaching  Start machine running  Added 1 litre H2O2  50 gm Stabiliser added  150 gm Soda Ash added  250 gm Caustic Soda added  100 gm Bio-D added  Process temp 80° C  Process time 90 minutes Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 42 of 56

  43. Drop the liquor Step 04 Water is added (14 Lt)  Hot Wash Machine started running  Steam to raise temperature 50°C  Process time 5 minutes  Drop liquor Step 05 Water is added (14 Lt)  Neutral Wash Machine started running  200 ml Acetic Acid added  Process time 5 minutes  Drop the liquor Step 06 Water is added (14 Lt)  Dyeing Start machine running Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 43 of 56

  44. 560 gm Salt is added  Reactive dye (T. Blue. G) - 0.2% & Drimerine – Blue K2RL-0.03% is added  20% Soda Ash is added  Processing temp 80° C  Processing time 60 minutes  Drop the liquor Step 07 Water is added (14 Lt)  Washing Machine started running  1 % Detergent is added  Steam to raise temperature 50°C  Process time 10 minutes  Drop liquor  Again Add water of 14 litre Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 44 of 56

  45. Process time 5 minutes  Drop liquor  Unload the Garments  Hydro extractor  Drying Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 45 of 56

  46. PRODUCTION REPORTS Date: 08.11.2004 Sl. No. Name of Buyer Name of Garments Order/ Style no. Types of Process Total Delivery Amount (pcs) Balance (pcs) received (pcs) 1 Snoopy Utah Washing Sand Blast 17745 14899 2846 2 Snoopy Yoke Design G-21 Sand Blast + Bleach 4129 778 3351 3 Caree Four Tusuka Fashion 100341/2 Rewash 5100 3576 1524 4 Etam Aba Fashion Enzyme Silicon 18935 15127 3808 5 Caree Four Aba Fashion Enzyme Silicon 19576 15679 3897 6 Etam Export Knit 6094619 Enzyme Silicon 8696 8124 572 7 Texel Sportx Gmts. 100093 Enzyme + Dyed 7990 7191 99 8 Texel Sportx Gmts. 100093 Enzyme Wash 7628 5500 2128 9 Primark Universal 52510 Sand Blast + Dyed 1200 1200 10 RN Sha Sha Gmts. 1161R Sand Blast + Dyed 5793 3767 2029 11 RN Sha Sha Gmts. 8488 Sand Blast + Enzyme 2934 798 2136 12 Nor Wester Leader Gmts. 25021X Z Sand Blast + Enzyme 7404 2932 3122 13 Nor Wester Leader Gmts. 25027X Z Sand Blast + Enzyme 5903 1500 4633 14 Nor Wester Fasnoor Gmts. 25069X Z Enzyme Silicon 5155 4506 649 15 Nor Wester Grand Tamanna Ltd. 25074/75 Silicon Wash 4527 3769 758 3275 Total Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 46 of 56

  47. Chapter 7 Maintenance Maintenance is considered as important as other engineering functions. It makes responsible for provision of a condition of machines, buildings and services that will permit uninterrupted implementation of plans requiring their use. OBJECTIVES OF MAINTENANCE:  To keep the factory-plants, equipments, machine tools etc. in an optimum working conditions.  To ensure specified accuracy to products and time schedule of delivery to customers.  To keep the down time of machines to the minimum thus to have control over the production program.  To keep the production cycle with in the stipulated range.  To modify the machine tools to meet the augmented need for production. Total cost Labour & Overhead Cost of spares & maintenance Cost of down time Cost of down in efficient operation > Degree of maintenance effort.  To improve productivity of existing machine tools and to avoid sinking of additional capital.  To reduce the maintenance costs as for as possible thereby leading to a reduction in factory overheads.  To prolong the useful life of the factory, plant and machinery, while retaining their acceptable level of accuracy of performance thus avoiding or prosponding incurring of heavy capital expenditure involved in their replacement. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 47 of 56

  48. ECONOMIC CONSIDERATION OF MAINTENANCE  It is very profitable activity & ensures maximum productivity at minimum costing.  It improves product quality.  It ensures less time to produce a specific product.  It improves machine accuracy.  It maintains a long life of the machine.  No chance of back order. MAINTENANCE FLOW CHART Head of Maintenance  Technician  Assistant FUNCTIONS OF MAINTENANCE PERSONNEL  Inspection or Check-Ups: ° External inspections: Watching and detecting defects form abnormal sound, vibration, heat, smoke etc when machine is in operation. ° Internal inspections: Inspection of parts such as gears, bushes, bearings, tolerances in the parts etc. when machine is under pre-planned shutdowns. ° Inspections of important machines: Machines, which can disrupt whole of the production, are delicate and require much time for the repair. Attentions are given for inspection of these machines and schedule for inspection, cleaning lubrication are done rigidly. ° Inspections of ordinary machines: Frequency of inspection of ordinary machines is kept as low as they do not affect the production. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 48 of 56

  49. Lubrication: Mechanical components like gears, bearings, bushes and other friction surfaces etc. give good performance for long periods when they are systematically lubricated. Systematic lubrication means the application of right type of lubricants at the right time, at right place and in right quantity. For lubrication, a lubrication schedule should be prepared and that should be followed strictly. Here lubrication is done whenever is needed.  Planning and scheduling: Every preventive maintenance work should be pre-planned in detail on the basis of the analysis done on the past records. A scheduled programme thus prepared should be followed strictly. Thus programme should be in detail specifying the point-requiring daily, weekly, monthly, half yearly or yearly attention.  Records and analysis: Good record keeping is essential for good maintenance, as it helps in for casting maintenance. For this purpose following records are generally maintained: ° Operation manual ° Maintenance and instruction manual ° History Cards and History Registers ° Spares Procurement Registers ° Spare Procurement Register ° Inspection Register ° Log books ° Defect Register etc.  Training of Maintenance personnel: For the success of maintenance a sound training is essential for the maintenance personnel. Hence the technicians and supervisors are trained to carry out maintenance, inspection and repaired in a systematic way.  Storage of Spare Parts: Sometimes machine remains idle for want of spare parts for considerable time and thus it affects considerable loss of production. Hence it is essential to keep the spare parts so as to avoid loss of production. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 49 of 56

  50. Maintenance practices are made from the following ways:  Capital replacement: capital replacement is undertaken if analysis reveals that the retention of equipment no more remains an economical proposition.  Provision of stand-by-capacity: Stand by capacity is often provided for items of equipment that we are critical to production. It is sometimes an economical maintenance practice to install such spare capacity to be put into operation while the original unit is under repair or is over-hauled.  Break-down maintenance: Break-down maintenance practice allows a machine or any other facility to run without much of routine attention, till it actually breaks down to be then put back into commission.  Scheduled maintenance: Scheduled maintenance system provides for inspection, overhaul lubrication, and servicing of certain machines at predetermined dates. Over- hauling of machines, cleaning of tanks and white washing of buildings is normally done in this manner.  Planned maintenance: Planned maintenance visualise the work contained in a future job determines the best method to be adopted and skills required for its execution; estimates the time, material and costs involved assigning jobs to individuals; programmes the work to specific time periods on the basis of priority and after ascertaining production requirements; arranges for availability of material tools and man- power and for release of machines in time.  Preventive maintenance: It consists of routine actions taken in a planned manner to prevent breakdowns and to ensure operational accuracy to the extent it is economically and practically possible to do so. Industrial Attachment Report HAMS WASHING & DYEING LTD. Page 50 of 56

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