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Industrial attachment of opex group

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Industrial attachment of opex group

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  1. Industrial Attachment Report 2013 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OPEX GROUP 1 OPEX GROUP OPEX GROUP

  2. Industrial Attachment Report 2013 Industrial Attachment Report At 2 OPEX GROUP OPEX GROUP

  3. Industrial Attachment Report 2013 OBJECTIVE 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 cope up with the challenge that we will face in future. This is the why the 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 garment manufacturing. Moreover we knew about the man management technique. We also learned about merchandising and buyer co-ordination. 3 OPEX GROUP OPEX GROUP

  4. Industrial Attachment Report 2013 INTRODUCTION By achieving practical knowledge it is possible to apply the theoretical knowledge in the technical field. For any technical education, practical experience is almost equally necessary in association with the theoretical knowledge. The industrial attachment is the most effective process of achieving the practical experience. It provides us sufficient practical knowledge about production management, productivity, evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory control, purchasing, utilities and Maintenance of machinery and their operation technique etc. Industrial attachment is an essential part of four years B.Sc. in Textile technology course of College Of Textile Technology under University of Dhaka. We had the opportunity to perform the industrial attachment with OPEX GROUP LTD. During 60 days long attachment, we studied the man, machine, material, quality control section, planning section, grey fabric inspection, finished fabric inspection, dyeing & finishing section, merchandising section of the mill. We also had a short visit in the garments section of the factory. 4 OPEX GROUP OPEX GROUP

  5. Industrial Attachment Report 2013 Table of Content Chapter Contents Page no. 6-12 13-18 19-25 26-27 28-33 Chapter-i Chapter-ii Chapter-iii Chapter-iv Chapter-v Project description Manpower management Machine description Raw materials Production planning, sequences & operations Quality assurance system Maintenance Utility services Store & inventory control Cost analysis Marketing activities Garments washing Merchandising Conclusion Chapter-vi Chapter-vii Chapter-viii Chapter-ix Chapter-x Chapter-xi Chapter-xii Chapter-xiii Chapter-xiv 34-37 38-44 45-48 49-50 51-52 53-57 58-70 71-70 73-77 5 OPEX GROUP OPEX GROUP

  6. Industrial Attachment Report 2013 CHAPTER- I (PROJECT DESCRIPTION) 6 OPEX GROUP OPEX GROUP

  7. Industrial Attachment Report 2013 Name: OPEX FASHION LTD. (a sister concern of OPEX & SINHA TEXTILE GROUP) Type: Ready made garments(100% Export oriented Woven& knit garments Industry). Status: Private limited company Location: Mirpur-13 , Dhaka. Year of establishment: 1984 Anisur Rahman Sinha Sponsors: Address: a. Dhaka office: 56/1,Block#C,Section-13,Mirpur, Dhaka-1216 Bangladesh. Tel: 8015446 8015241 8023726-7 Fax: 880-2-8013522 b. Head Office: House # 368, Road # 28, New DOHS, Mohakhali Dhaka-1206, Bangladesh. Tel: 88-02-8828860-4, 9891390-1 Fax: 880-2-8828856-7 c. Kanchpur Office: Sinha Textile Complex,Kanchpur , Sonargaon,Narayanganj Tel:7618066,7618055,7617788. d. Hongkong Office: Joyful Miles Ltd. 16B Alpha House Tel: 2721-1950(5 lines), Fax: 2721-1967 E-mail: mhkhan@opexhkg.com.hk 7 OPEX GROUP OPEX GROUP

  8. Industrial Attachment Report 2013 Factory Location: Cantonment Banani Kachu Khet Mirpur-10 Mirpur-14 OPEX 8 OPEX GROUP OPEX GROUP

  9. Industrial Attachment Report 2013 PRODUCT MIX: a) Woven Garments: Shirt,Jacket,Pant/Trousers,Shorts Jeans item,Ladies & Children item. b) Knit garments: T-shirt, polo shirt, Short / trouser, Knitted pant, Vests DAILY PRODUCTION CAPACITY: Garments: 40000 pcs (Dhaka Zone) No. of line: 32(Dhaka zone) &100 (Kanchpur zone) MONTHLY EFFICIENCY: Daily production: 40000 pcs Approx. Daily production capacity: 45,000 pcs So, monthly production: 1040000 pcs Monthly production capacity: 1170000 pcs So, Monthly production efficiency= 88% PROJECT COST: US$1,0000000per year (approx) in 2007 US$1,5000000Projection for 2008. DIFFERENT DEPARTMENTS: 1. Marketing and Merchandizing 2. Lab department 9 OPEX GROUP OPEX GROUP

  10. Industrial Attachment Report 2013 3. Quality Assurance 4. Garments& GGT Lab . Cutting  Sewing  Finishing  Inspection  Packing 5. Stores 6. Technical Department (Maintenance) 7. Human & Resource and Administration 8. Account and commercial section 9. Batching section TOTAL AREA OF THE INDUSTRY: 15000 sq. feet & 4 building, OPEX FASHIONS LTD : 10 Storeyed OPEX STYLE WEAR LTD: 8STOREYED SINHA STYLE WEAR LTD : 12 Storeyed 10 OPEX GROUP OPEX GROUP

  11. Industrial Attachment Report 2013 COMPANY PROFILE: OPEX Opex is one of the largest garment manufacturing conglomerates in Asia and has a complete vertical integrated setup in woven, knit and sweater with most modern and state of the art machineries from USA, Europe and Japan. It is a private owned company with an annual turn over of US $ 350 million and annual export is about US $ 250 million. Garments Division Opex has over 18000 sewing machines distributed to 300 production lines including 40 Knit garment lines and 2000 Sweater machinery. It produces over 220,000 pieces of garment every day. The production lines are broadly earmarked as Bottom lines, Shirt lines and Knit lines. Bottom Factories Opex has about 210 bottom production lines and they produce over 140,000 pieces of garments daily. These are organized into dress pant lines, casual pant lines, cargo short/ pants lines and denim production lines. Dress and casual pant lines have some specialized sewing machines like pocket welting machines, zigzag operations machines, blind stitch machines, front fly J-stitch machines, etc. Finishing of casual and dress pant is done with lager and topper press machines, seam opening and pressing machines, curing oven etc. Other than standard denim production line Opex has 16 dedicated specialized denim production lines, equipped with fully automated computerized sewing and finishing range machines from Italy. Each line produces 230-250 pieces of 5-pocket jeans in one hour, totaling to 34000-37000 pieces daily. Shirt factories Opex has 48 dedicated shirt lines which produces 35,000 to 40,000 pieces of casual, sports and formal dress shirts daily. The formal and dress shirt lines are equipped with Droukoff Adler sewing machines of Germany fitted with servo motors and trimmers which ensures consistency in sewing and eliminates puckering effects. Collar & cuff making and setting, placket making, pocket making & setting and arm hole fusing are all done with computer controlled automatic machines. The finishing units have automatic collar, cuff, arm hole and body pressing machines for perfect finish. Knit Garment Factories Opex’s 40 Knit garment lines have over 2000 sewing machines and it produces about 60,000 pieces of T-Shirt, Polo Shirts daily. These lines can also be converted to produce shirts or ladies dresses by changing and adding few machines. Sweater Factory 11 OPEX GROUP OPEX GROUP

  12. Industrial Attachment Report 2013 Our major production is on 12 gauge. However we have production facilities in 10 gauge, 7 gauge, 5 and 3 gauge. Presently we have about one hundred thousand production capacity per month but recently have gone into expansion this will have capacities from Dec ’08 about two hundred per month. Dry and Wet Processing Facilities The in house dry and wet processing units of Opex includes sand blasting, brushing, chemical spraying, laser blasting, heavy, medium and light wash facilities and post cure wrinkle free processing facilities. Opex has one of the most modern denim washing facilities in the country equipped with computer controlled European machines. Denim wash capacity is about 1,00,000 pieces daily. It also has 55 belly type Chinese machines to take care of other washes. It has two modern dry finish units with modern equipment with curing oven. Backward Linkage and Vertical Setup of Opex Customer’s increasing need of varied range of fabric, shorter lead time, sharper price and consistent quality, led Opex to set up its own vertical set up in 1995, named as Sinha Textile Group. The objectives of these facilities are; attaining consistency in fabric quality, developing specialized fabric & offering competitive price and shorter lead time. Opex today has the entire chain of backward linkage facilities of spinning, weaving, yarn dyeing, fabric dyeing & finishing, knitting, knit dyeing and finishing. State of the art machines, Textile experts from home & abroad have been combined together to make wide range of high quality woven fabric for bottom, shirt & Knit fabric. Supporting Establishments To support garments manufacturing, Opex has its own button factory, label factory, Sewing Thread manufacturing unit and Embroidery unit. It also has its own Carton and Poly manufacturing factory. We have also joint venture with IDEAL Zipper factory in Bangladesh. Opex has done massive expansion in increasing its garments production, washing and finishing capacities as well as increasing capacity and adding new technology in its backwards integration units like compact yarn, producing high density fabric, wet sueding and different types of fabric finishing etc. Denim Village. Recently, we have established a massive project named denim village where we are producing, Denim fabric, Denim garments, Denim Washing, and different types of finishing in one complex. Opex can convert all its fabric into Garments and will produce about 65000 pcs Denim Jeans and Jacket per day. Conclusion. Opex with over 45,000 work forces is in business for more than two decades. It always tries and maintains its commitment of on time delivery, quality and competitive price. Over the years, the business relations with all customers and partners have grown stronger based on mutual trust and commitment. Opex is an ethical and compliant company, putting in maximum emphasize on developing human values, qualities of human life and comfort of work environment. It is committed to ensure ethical source place for the customer. 12 OPEX GROUP OPEX GROUP

  13. Industrial Attachment Report 2013 CHAPTER- II (MANPOWER MANAGEMENT) 13 OPEX GROUP OPEX GROUP

  14. Industrial Attachment Report 2013 ORGANOGRAM MANPOWER: Chairman Executive Director General Manager Deputy General Manager Asst. General Manager Merchandising Manager Sinior Merchandiser Merchandiser Production Manager Sample incharge Cutting incharge Sewing incharge Quality inchare Cutting executive Line supervisor Operator Operator Cutting supervisor Operator Helper Helper Marker man Helper 14 OPEX GROUP OPEX GROUP

  15. Industrial Attachment Report 2013 Cutterman MANAGEMENT SYSTEM: GARMENTS SECTION: 8 hours per day.8 AM-5 PM. Overtime: 2hours. Offday: Thursday in a week. RESPONSIBILITIES OF PRODUCTION MANAGER: RESPONSIBILITIES OF SAMPLE ROOM INCHARGE: To make pattrn from specification sheet. When there is no measurement chart then he make specification chart by his own idea, then send to buyer,if it is ok then he make pattern. After making sample he check the sample if it is ok , then he order to make 4 pcs of the sample. RESPONSIBILITIES OF CUTTING INCHARGE: Check the relaxation of fabric,order wise quantity measure, patterncutting with signature,befor sewing to communicate the print embroidery. To ensure equal input & output. To check fabric shrinkage, twisting repair. To make the cutting plan according to operation breakdown. To give target and style devide in every table. RESPONSIBILITIES OF QUALITY INCHARGE: To control the overall quality of the garments. To brief the incharge about tentative problem of quality. To make size set of the garments. To check the measurement of the garments, if required increase or decrease RESPONSEBILITIES OF PRODUCTION OFFICER: From getting an order of upper level all responsibilities are on the production officers. They work with a troop of operators, helpers, fitters etc. to finish the production in due time. In the meantime 15 OPEX GROUP OPEX GROUP

  16. Industrial Attachment Report 2013 Production officers bear all hazards, problems. They have to explain to the manager for any type of production hamper. So all production activities and its success depend on the production office. MANPOWER MANAGEMENT ADMINISTRATIVE STRUCTURE OF OPEX GROUP: CHAIRMAN EXECUTIVE DIRECTOR COMPUT ER ADMIN ACCOUNT S STORE COMPLINCE DGM D.G.M. GM UNIT-IN- CHARGE UNIT-IN- CHARGE UNIT-IN- CHARGE UNIT-IN- CHARGE AGM AGM INTERNAL & EXTERNAL ADMIN & DAY CLEANER & SANITER TRAINING INSTITUTE MEDICAL OFFICER TECHNIC DGM PERSON AL SECURITY INCHARG PRINCIPAL MECHANICAL ELECTRICAL AGM SECURITY SUPERVIS AGM 16 OPEX GROUP OPEX GROUP

  17. Industrial Attachment Report 2013 ORGANOGRAM OF QUALITY CONTROL DEPARTMENT: GENERAL MANAGER (QUALITY ) ↓ ASST. GENERAL MANAGER ↓ MANAGER ↓ ASST. MANAGER ↓ QUALITY- IN-CHARGE ↓ QUALITY CONTROLLER ↓ LINE Q.C. ORGANOGRAM OF WASHING DEPARTMENT: OFFICER-IN-CHARGE (O.I.C.) ↓ ASST. OFFICER-IN-CHARGE ↓ MANAGER ↓ FLOOR-IN- CHARGE ↓ ASST. MANAGER ↓ QUALITY INSPECTION CONTROLLER ↓ QUALITY CONTROLLER 17 OPEX GROUP OPEX GROUP

  18. Industrial Attachment Report 2013 ↓ SUPERVISOR DESCRIPTION MERCHANDISING STUFF IT STUFF SAMLE MAN Q.A-RAW MAT. INSPECTOR Q.A-IN-LINE INSPECTOR FLOOR Q.C Q.A AUDITORS CUTTING SECTION SEWING SECTION TRIMMING/ FINISHING PRESSING & PACKING PACKING ELECTRICIAN/MECHANICS WASHING,SAND BLASTING & SAND BRUSHING PRINTING PACKAGING POLY QUILTING EMBROIDERY OFFICE STUFF & OTHERS NO OF EMPLOYEES 40 04 150 10 TOTAL EMPLOYEES 250 50 30 200 3200 500 600 250 150 200 5976 12 50 30 30 20 200 ↓ OPERATOR TOTAL EMPLOYEES: 18 OPEX GROUP OPEX GROUP

  19. Industrial Attachment Report 2013 REMARKS: Production runs with the help of mechanical fitters. For any kind of mechanical fault of any machine they fix and work under knitting manager. Production officer takes account of daily production by running after the two supervisors & workers so on. CHAPTER-III (MACHINE DESCRIPTION) 19 OPEX GROUP OPEX GROUP

  20. Industrial Attachment Report 2013 LOCK STITCH M/C LOCK STITCHM/C H/S D/N LOCKSTITCH 4-holed button sewing 20 OPEX GROUP OPEX GROUP

  21. Industrial Attachment Report 2013 CHAIN STITCH BUTTON SEWER 4 NEEDLE DOUBLE CHAINSTITCH MULTI-NEEDLE DOUBLE CHAIN STITCH MAIER BLIND STITCH MACHINE 21 OPEX GROUP OPEX GROUP

  22. Industrial Attachment Report 2013 SIMPLE PUSH-BUTTON TYPE STITCH FLAT-LOCK SEWING MACHINERY OVERLOCK MACHINES STRAIGHT KNIFE CUTTING M/C 22 OPEX GROUP OPEX GROUP

  23. Industrial Attachment Report 2013 MACHINE DESCRIPTION MACHINE DESCRIPTION Type of Machine A. General Sewing Machine Quantity(Sets) Sewing Capacity Single Needle Double Needle Over lock Kansai Bar Tack Button Stitch Button Hole Eyelet Button Hole Bottom Hem Flat Lock Snap Button Blind Stitch Feed of the Arm Cutter m\c Heat Cutter Fusing m\c Over lock Elastic Attaching m\c Arm Hole Sewing m\c Total 1000 421 320 50 200 150 100 25 50 65 30 25 150 100 15 15 6 40,000 pieces per day 15 2737 23 OPEX GROUP OPEX GROUP

  24. Industrial Attachment Report 2013 B. Specialized Sewing Machine Auto Patch Pocket Setting Auto Welt Pocket Setting Waist Belt Setting Seam Sealing Zigzag Elastic Attaching Pattern Sewing Auto Loop Attaching Snap Testing m\c Pattern(Collar& Cuff) m\c Pocket Facing Picoting Velcro Cutter Feather Filling Total 2 10 15 15 10 12 10 5 5 5 10 2 10 4 115 Cutting Capacity Cutting Room Fabric Inspection m\c Light Box Gerber Cam Gerber Auto Spreader Manual Cutting Table Manual Cutter Finishing Room Needle Detector Hang Tagger Attaching 05 02 50,000 yards/day 2 5 20 100 Finishing Capacity 5 20 20,000 pieces per day m\c Steam Iron Thread Sucking m/c CAD Room Gerber CAD Gerber Plotter Gerber Digitizer Support Steam Boiler Generator Other Projects Poly Bag Making Project Carton Making Project Printing Project Quilting Embroidery 150 15 2 1 1 Capacity 1.5 MW 02 02 20 heads on each end and up 24 OPEX GROUP OPEX GROUP

  25. Industrial Attachment Report 2013 to 15 colors Pin Point Stitch m/c Vacuum Iron Table Lay End Cutting m/c Washing Plant Type of Machine Sample Washing m/c Washing m/c Washing m/c(Tonello+Yilmak) Hydro Extractor Dryer Sand Blast m/c Laser Blasting Sand Brush m/c E.T.P Quantity (Sets) Capacity 500 lbs 40,760 lbs 12600 lbs 05 14 5 8 12 02 2 10 1 2,610 lbs 32,600 lbs 1000 pcs per day 500 pcs per day 3000 pcs per day 80 cubic meter per hour 30,000 pieces of gt per day Average Production Capacity 25 OPEX GROUP OPEX GROUP

  26. Industrial Attachment Report 2013 CHAPTER-IV RAW MATERIALS 26 OPEX GROUP OPEX GROUP

  27. Industrial Attachment Report 2013 RAW MATERIALS OF OPEX FASHIONS LTD Garments Section:  Soucing tag  Price ticket  Fabric woven  Hanger  Button  Sizer  Zipper  Size sticker  Sewing thread  Poly bag  Main label  Cartoon  Care label  Tag pin SOURCES OF RAW MATERIALS Required raw materials are purchased from following countries through agent : a. Taiwan b. Philippines c. India d. Germany e. Brazil f. Pakistan g. South China 27 OPEX GROUP OPEX GROUP

  28. Industrial Attachment Report 2013 CHAPTER-V (Production Planning, Sequences & Operations) 28 OPEX GROUP OPEX GROUP

  29. Industrial Attachment Report 2013 DESCRIPTION OF PRODUCTION PROCESS(GARMENTS SECTION): ] Squence Operation for Sample Section: Product Package Make Pattern If not OK Make Sample Send to Buyer through Merchandiser If OK Collect the approved Sanple Sequence Operation for Cutting Section: Fabric Inspection & relaxation Fabrid spreading Fabic cutting Parts numbering Part inspection 29 OPEX GROUP OPEX GROUP

  30. Industrial Attachment Report 2013 If any defect is found then make this part Sequence Operation for Sewing Section: Front Yoke joining Elastic join Topstich Sleeve join Front Yoke join Sleeve join Elastic tuck Elastic tuck Elastic join Back part piping Front Yoke+Sleeve+Back Yoke Joining Elastic ¼ Stiching Vertical tuck Sleeve opening tuck 30 OPEX GROUP OPEX GROUP

  31. Industrial Attachment Report 2013 Side seam Chup tuck Sleeve opening chup tuck Hem Inspection OPERATION BREAKDOWN : FIVE POCKET JEANS (JC PENNEY) BACK PART MAKING Serial No 1 Back Pocket Rolling 2 Marking Table 3 Back Yoke Joining in Folder System 4 Back Rise Joining 5 Back Rise Top 6 Back Pocket Positioning on Marker Table 7 Back Pocket Joining 8 ¼” Stitch on Pocket Joining Name of Operation Machine used No of Machine 2 Needle Machine 1 Feed of the Arm m/c Plain Stitch m/c Feed of the Arm m/c 1 1 1 Plain Stitch m/c Plain Stitch m/c 1 1 FRONT PART MAKING Serial No 1 Pocket Matching 2 Ironing 3 Coin Pocket Attaching 4 Label Joining 5 Coin Pocket Attaching with Front Facing Name of Operation Machine used No of Machine 2 Needle m/c Plain Stitch m/c Plain Stitch m/c 1 1 1 31 OPEX GROUP OPEX GROUP

  32. Industrial Attachment Report 2013 6 7 8 9 10 11 12 13 14 15 16 17 Number Match with Front Part Coin Pocket Joining with Front Part Front Pocket Rolling Pocket Tuck Pocketing Over Lock Single Fly Join with Top Stitch Pocket ¼” Top Stitch Front Pocket with Front Tucking Zipper Joining J - Stitch Double Fly Joining Front Rise Stitch Plain Stitch m/c 2 Needle m/c Plain Stitch m/c Over Lock m/c Plain Stitch m/c Plain Stitch m/c Plain Stitch m/c 2 Needle m/c 2 Needle m/c Plain Stitch m/c 2 Needle m/c 2 1 1 1 1 1 1 1 1 1 1 BODY SECTION Serial No 1 Name of Operation Back & Front Part Match on Table In Seam Top Seam on In Seam Side Seam Hemming Waist Belt Matching by Number Waist Belt Sewing Edge Neatening of Down Part of the Waist Waist Top Part Making Waist Top Part Edge Neatening Checking by LQC Belt Loop Matching Loop Tuck on Down Side of Waist Loop Joining with Top Side of Waist Final Inspection Loop & Back Part Bar Tacking Side Pocket Tucking Machine used No of Machine 2 3 Plain Stitch m/c Feed of the Arm m/c Over Lock m/c Plain Stitch m/c 1 1 2 4 5 6 1 7 8 KANSAI 2 2 Plain Stitch m/c 9 10 Plain Stitch m/c 2 11 12 13 Plain Stitch m/c 2 14 Plain Stitch m/c 2 15 16 17 Bar Tack m/c Plain Stitch m/c 2 1 32 OPEX GROUP OPEX GROUP

  33. Industrial Attachment Report 2013 SUMMERY Plain Stitch Machine - 36 2 Needle Machine Over Lock Machine Bar Tack Machine KANSAI Feed of Arm Machine – 04 Production Manpower - 07 - 04 - 02 - 02 - 1000 pieces per day - 94 persons REMARKS: As OPEX FASHION LTD a big project; its production quantity is huge. Production quantity varies as according as buyers demand. It gives approximately 500-ton and 1000000 pcs production per month. In Bangladesh, there are a few mills, which can produce such quantity of garments. 33 OPEX GROUP OPEX GROUP

  34. Industrial Attachment Report 2013 CHAPTER-VI (Quality assurance system) 34 OPEX GROUP OPEX GROUP

  35. Industrial Attachment Report 2013 QUALITY ASSURANCE SYSTEM: All rolls are kept in front of the inspection m/c time to time and are inspected over the grey inspection m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre marks, fall out, contamination, fly, holes, oil lines, needle lines, slubs, etc are recorded in grey inspection report to classify the fabric based on the four point system. Collar & cuff are inspected visually under light box, any major & minor faulty collar/cuff like having wrong ply, hole, needle lines, slubs, wrong design, first line problem etc properly counted and recorded. QUALITY ASSURANCE PROCEDURE: Based on the sequence of grey inspection, the inspector serially numbers each roll ensuring that all rolls having complete details of the roll. 1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from the cloth or batch roller and they are carried to inspection section by the helpers. 2) Almost four inspection workers are for every shift to check the fabric rolls. For any kind of fault they are checked thoroughly. Skilled inspectors find them and indicate them by the scissors in some cases. 3) Quality is specified on the basis of 4-points system. Here is the point distribution for different kinds fault in this system: - FOUR POINT GRADING SYSTEM Size of defects 3 inches or less Over three inch but not 6 inch Over 6 inch but not 9 inch Over 9 inch Penalty 1 point 2 point 3 point 4 point QUALITY CLASSIFICATION 1 2 3 <20 20-30 30> OK ASK REJECT 35 OPEX GROUP OPEX GROUP

  36. Industrial Attachment Report 2013 LIST OF EQUIPMENTS: In this factory OFL the list of equipments to assure quality: - 1) Inspection machine 2) Scissors 3) Weight balance & Microbalance 4) GSM cutter 5) Seal (‘CHECK-1’, ‘OK’, ‘REJECT’.). Rejection criteria for Fabrics: No. Faults Response 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Needle marks Stripe Barre marks Slubs Wrong design Pin holes Fly & contamination Sinker marks Uneven tension Missing yarn Crease line Uneven tension Oil stripe/line Thick-thin place Mixed yarn Major needle line is rejected. Major needle line is rejected. Rejected 1 point Rejected 1 point Acceptable for color but not for white Do Discuss with manager Use 4 point Do Discuss with manager Do Rejected Discuss with manager 36 OPEX GROUP OPEX GROUP

  37. Industrial Attachment Report 2013 Rejection criteria for collar & cuff: Following table shows common collar & cuff faults and response taken by grey inspection section. No. Faults Response 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Wrong ply Hole Needle line Slubs Wrong design Wrong tripping Fly & contamination First round problem Uneven tension Missing yarn Crease line Rust line Oil stripe Thick-thin Wrong tube Reject Reject Reject Reject Reject Reject Acceptable for color but not for white Reject Discuss with manager Reject Reject Reject Reject Reject Reject QUALITY STANDARD: Here is the quality standard:- 1) Fabric width 2) Fabric length 8) Thick /thin yarn 4) Slub 9) Barre/ Stripe 3) Fabric weight 5) Hole 11) Oil 6) Needle / Sinker line 12) Press off 7) Broken needle /2’’ 10) Dirt REMARKS: There is hardly any chance of any roll to pass through production on to any buyers by to by unchecked or disqualified. The inspections are too much experience and they are aware about their duties and responsibilities. The factory authority and production related personnel are happy and satisfied with their works 37 OPEX GROUP OPEX GROUP

  38. Industrial Attachment Report 2013 CHAPTER-VII (Maintenance) 38 OPEX GROUP OPEX GROUP

  39. Industrial Attachment Report 2013 MAINTENANCE: Maintenance of machineries is very important for any type of industries and it is a must for a knit composite mill. All machines and machines parts of Washing, dyeing and garments are maintained with extreme care. Because production quality and quantity, both depends on the maintenance with regularity. OPEX FASHIONLTD lead maintenance with a troop of skilled mechanical fitters. MAINTENANCE OF MACHINERY: In the knitting floor of OFL all machine are maintained regularly and as necessity requirements. Here, different type of maintenance of machinery, which is taken, different time on the machineries. ROUTINE: 1) Daily Maintenance: Every machine is taken maintenance daily by the operators during production. When the operator starts a production after handing over from previous shift operator, he takes a routine maintenance on the machine. He cleans the machine, assures yarn is fed to all needles, cleans the eye pot of feeder, memminger, signal lamp sensor etc. Before a while of a roll cut from batch or cloth roller, operator cleans needles, cylinder base plate etc. All around of the machine are kept neat and clean as if there is no dirt with yarn in the fabric. 2) Schedule/Routine Maintenance: Every machine has a schedule of maintenance of 10 or 15 days. According to date, schedule maintenance is taken on the machines. Operators are informed about the time of maintenance. After pre-estimated production, they hand over the machine to the fitters. Thus, fitters assure all machines are OK. For any time. 3) Break down maintenance: When product quality hampered and to complete production in due time break down maintenance is taken. There are many faults seen in the fabric during production due to needle, sinker, take down roller etc. Then operators inform the mechanical fitters and they fix it. 4) Restorative maintenance: Restorative maintenance is taken for design change or new design development. According to advice or order of production officer, a machine is fixed for new design and mechanical fitters rearrange cam and needle system. Planned and preventive maintenance are not taken on the machineries in this mill. 39 OPEX GROUP OPEX GROUP

  40. Industrial Attachment Report 2013 MAINTENANCE OF ‘SEWING M/C: Lubrication: Since the life of the m/c and its correct working depend to a large extend adequate and proper lubrication. It is recommended that the instructions given in the lubrication charts be followed conscientiously. The Company can not be need responsible for faults that arise from wrong or inadequate lubrication. Oiling Needles: Too much oil is preferable to too little. Dark vertical lines in the fabric originate not from excessive oiling . The Cleaning of Needle: Thin oil is most suitable for this work, about one point heated to a temperature not exceeding 160ºF poured into the oiling position of the m/c. General Cleaning Schedule: Long m/c life, maximum output & trouble free running depend upon proper care and maintenance. A general overhaul should take place annually when single shifts are worked & correspondingly at more frequent interval. MAINTENANCE PROCEDURE: 1) For there is any mechanical fault of machine, which is responsible for production hamper, operator informs mechanical fitters in duty. Mechanical fitters come and observe the problem firstly, and then they begin to fix it. 2) If mechanical fitters were unable to fix it, then they inform technical in-charge, he then comes in spot and fixes it. 3) For there is any electrical problem of machine or serious founding mechanical problem, mechanical and electrical department are informed, they come and fix the problem. 4) For restorative maintenance, senior production officer orders mechanical fitters to fit required machine for cam and needle arrangement and other necessary requirements in case of new design development. 40 OPEX GROUP OPEX GROUP

  41. Industrial Attachment Report 2013 MAINTENANCE TOOLS/EQUIPMENTS & THEIR FUNCTIONS: Maintenance tools/equipments Functions 1. Adjustable wrench Used for setting nut & bolts 2. Air suctioner For cleaning machine 3.Spanner Fixed Spanner for nut & bolts fitting 4.Socket spanner Handle system for nut & bolt fitting 5. Hammer To apply load where required 6. Screw driver To release any screw 7. Punch Used to fit any worn out shaft 8. Lock opener To open the clip of bearing 9. Hack saw To cut any metallic thing 10. Outside calipers To measure outside dia 11. Inside calipers To measure inside dia 12. Cutting pliers To cut thin wires 13. Pulley key To loosen pulleys 14. Chain ton To lift heavy load 15. Welding machine To join metallic parts 16. Grinding machine To make the smooth fabrics 17. Tester To test electric circuit 18. Pliers To grip anything & cut anything 19. Star driver Screw unlocking 20. Steel tape To measure length, width & height 21. Chisel To cut any metal 22. L-key For loosen & tighten the screw 23. File To smooth the rough surface 41 OPEX GROUP OPEX GROUP

  42. Industrial Attachment Report 2013 Repair, maintenance and setting and replacement of different parts of lockstitch machine: Apparatus: 1. Flat screw driver 2. Star screw driver 3. Hammer 4. Pliers 5. Lubricating oil 6. Grease Standard atmospheric condition: Temperature………………28c Relative humidity………..62% Procedure: The repair, maintenance, setting and replacement procedure are described below:- 1. Repair: Repair work is carried out when a component requires slight modification. To carry out such job the machine needs to be switched off first. The component under repair is then screwed off by suitable apparatus. After repairing, the part is fixed to its designated place and hence its correctness is measured by running the machine. In a lockstitch machine bobbin case, bobbin, check spring, feed dog. Motor belt etc can undergo repair job. a. Maintenance: Maintenance can be of different types. But following types are important in this aspect. b. Routine maintenance: lubrication and regular inspection are the constituent of routine maintenance. Lubrication ensures long life and safe working of all the equipment. Inspection tries to detect faults in equipment so that repairs and replacement may be under taken at the right time. c. Scheduled maintenance: this type of maintenance provides for inspection, overhaul lubrication and servicing of the machine, cleaning of all components is normally done in this manner. It involves opening of the machine into its smallest component and carry out lubrication. 2. Setting: the setting of the lockstitch machine is of immense importance. Following setting points need to be ensured before running the machine. 42 OPEX GROUP OPEX GROUP

  43. Industrial Attachment Report 2013 a. Stitch density controller: It controls the no of stitch per inch. Before starting the machine, stitch per inch is determined by rotating the knob and fixing it at the desired position. b. Motor: Motor rpm depicts the speed of the machine. The rpm is controlled by tightening or looseness the belt over machine & motor pulley. c. Needle: needle undergoes accurate setting to ensure proper sewing. Needle is attached by means of a screw which needs to be tightened enough to produce easy sewing. Again the needle size is also important from fabric point of view. d. Pressure foot: The type of pressure foot to be used & its proper setting is important which is ensured by proper attachment with the motor through machine pulley. e. Feed dog: It is often found that due to random working the feed dog is subjected to be loose which may cause accident also. Thus the feed dog must be set properly with the screw. 3. Replacement: The replacement is revealed when the retention of equipment is no more remain an economical proposition. A replacement is affected when the equipment is subjected to complete breakage which cannot be used even after repair or the component has become so obsolete that affects production or it has crossed its expire date. Replacement can be affected to any components of the machine at any time. In lockstitch machine components like needle, pressure foot, feed dog etc undergo frequent replacement. Precaution: Following precautions must be taken when repair, setting maintenance is carried out in the lockstitch machine. 1. All repair & maintenance work must be carried out by switching off the machine. 2. Right tools should be used at right place. 3. Skilled personnel should be involved for specialized job. 4. Careful handling of all the components is necessary. 5. The components should not be too tight or too loose. 43 OPEX GROUP OPEX GROUP

  44. Industrial Attachment Report 2013 Remarks: The experiment has provided us wide idea regarding the repair, maintenance, setting & replacement of different components of lockstitch machine .It has given us a basic knowledge on machine maintenance as a whole. It has also oriented us with different machine tools & their use those are required for the said job. The gathered knowledge will indeed help us in our practical life. We hope to important our learning in the days to come. This mill has a strong maintenance fitter’s troop to fix up all types problem. Two groups of two shifts obey their duties responsibly and sincerely. With their different tools or equipments they perform their duties skillfully 44 OPEX GROUP OPEX GROUP

  45. Industrial Attachment Report 2013 CHAPTER-VIII (UTILITY SERVICES) 45 OPEX GROUP OPEX GROUP

  46. Industrial Attachment Report 2013 UTILITY FACILITIES AVAILABLE: For smooth functioning of any production unit, uninterrupted and required utility services are indispensable. Success of any industry largely depends on this factor. Any irregularity or lack in the required utility services immediately results in unexpected halt of the production process. An Industry needs various utilities depending on its manufacturing process. In OFL the major utilities are available- - Power (Electricity) - Water - Natural gas - Compressed air - Steam - ETP SOURCES OF UTILITIES: The main utility, which is used by OFL, is natural gas. From natural gas generator produce electricity. From natural gas and electricity in association with mechanical and electrical apparatus, OFL produce other utilities like water, steam, compressed air etc. CAPACITY AND OTHER TECHNICAL DETAILS: Power (Electricity): Generator house is the main power producing plants of NCL There are two generator in generator house. Generator - Type: gas generator Brand name: Caterpillar Origin: USA Frequency: 100 Hz Voltage: 400 V STEAM: Boiler produces the required steam. There is two boiler in OFL Boiler specification: Brand name: Industrial boiler Ltd 46 OPEX GROUP OPEX GROUP

  47. Industrial Attachment Report 2013 Capacity: 8ton / hr Blower motor: 25 HP Water supply for the boiler: Water required for steam production is supplied by deep tube well. Pretreatment of the boiler water: Boiler feed water needs special standard. Any deviation from the required standard may result in scale formation, which eventually reduces the efficiency of the boiler. This ultimately affects the cost of steam generation and makes the production cost high. To maintain the required standard of the water, there should be some means to pretreat the boiler feed water. To protect scale formation of boiler, NELCO is used as chemical in water feed tank. 200 gm NELCO is injected per 12 hrs. In OFL there are water softeners that act before the water enters the boiler. . No. Of the softener : There is one water softener to pretreat the boiler feed water. COMPRESSED AIR: The compressed air is supplied from air compressor. There two -air compressors in OFL. Compressor - Brand name Hitachi Screw Compressor Origin: Japan Model no. OSP-55S5 ARI Maximum working pressure: 15 bar Average working pressure: 6.5-7.5 bar Year of construction: 2004 WATER: The water source OFL is deep tube well. Water treatment plant: There is no Water treatment plant in Mirpur but one in Kanchpur. GAS: The source of gas is government agency. Gas is required mainly for generation of electricity, boiler to produce steam, the burners of heat setting m / c. 47 OPEX GROUP OPEX GROUP

  48. Industrial Attachment Report 2013 As OFL generates their own electricity, the gas consumption is quite high. The gas consumption is 250-350 m³ / hr. COST OF DIFFERENT UTILITIES: Electricity cost: REB =3.8 TK / KW-HR Gas generator = 2.70 TK / KW-HR Diesel generator = 6.50 TK / KW-HR Gas cost: 4.94 Tk/m³ for boiler 3.66 Tk/m³ for generator 4.5 Tk/m³ for domestic purpose Steam cost: 4.30 Tk per kg fabric. REMARKS: For smooth running of factory main utilities like gas, electricity or steam is very essential. Sometimes gas pressure is low than required pressure. When the gas pressure is low, then diesel generator run. Government should have to ensure proper gas supply for Industrial purpose. 48 OPEX GROUP OPEX GROUP

  49. Industrial Attachment Report 2013 (CHAPTER-IX) STORE & INVENTORY CONTROL 49 OPEX GROUP OPEX GROUP

  50. Industrial Attachment Report 2013 INVENTORY SYSTEM OF RAW MATERIAL: It is previously speak that OFL. is a Woven composite industry. The main raw material of OFL is grey fabric. Grey fabric first produce in knitting department of this company. Weaving section of OPEX GROUP Produces grey fabric as per buyers order. Dyeing section get grey fabric from Weaving section. Grey fabric store officer receive the grey fabric and store the grey fabric in storeroom. Then he delivers the grey fabric to batch preparation section according to shipment date or according to production manager of dyeing section instruction. Other raw materials of OFL are dyes and chemicals. Dyes and chemicals store officer always keep stock report of dyes and chemicals and also know the daily or monthly requirements of each dyes or chemicals. If the stock is bellowing30days then he gives requisition to head office for each product. Head office indent dyes and chemicals. SPARES: Spare store officer keep the spare part in store & make a list of spare parts. If the spare parts are little in stock he gives requisition to maintenance manager. Technical manager give requisition to Head office. Head office indent spare parts or buy local market as per requirements. FINISHED GOODS INVENTORY: Finish fabrics from the compactor go to inspection team. From the inspection table the fabric weighted in weight meter & go to finish fabric storeroom. Here finished fabric store officer make a list of total finished products. He sends the finished fabric to OPEX FASHION LTD as per shipment date or requirements of production manager of OPEX FASHION LTD. He also keeps the delivery list. REMARKS: Inventory control system and storing system of OFL. is over all good. 50 OPEX GROUP OPEX GROUP

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