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Industrial attachment of paramount textile ltd

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Industrial attachment of paramount textile ltd

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  1. 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT PARAMOUNT TEXTILE LIMITED

  2. 2 Project Description

  3. 3 PARAMOUNT TEXTILE LIMITED AT A GLANCE PARAMOUNT TEXTILE LIMITED 1. Name of the project : Paramount Textile Limited 2.Location : Gilar Chala,Sreepur, Gazipur. 3. Address : About 60 kms north of Dhaka city. Factory : Village:Gilar Chala, P.O: 1 No C&B Bazar Thana:Sreepur,Dist:Gazipur, Bangladesh. Tele-Fax: 880-6825 52555

  4. 4 Office: Chaklader House (Level-6), House # 22,Road #113/A, Gulshan-2,Dhaka-1212,Banladesh Ph:(+8802) +8809890618,9890467 Fax:(8802)9890783 E-mail:ptexltd@gmail.com Web;www.paramountgroupbd.com 5. Board of directors : Chairman& Managing Director. Md. Shakhawat Hossain 7. Communication :The project is easily accessible by road. 8. Product name :Woven yarn dyed ,solid dyed . 100% Cotton & TC 9. Product Mix : A)Gray fabric: 1. Solid dyed 2. yarn dyed. a. Stripe. b. Check.

  5. 5 B) Design. a. In Tappet loom. i. Plain. ii. Twill. iii. Sateen. iv. Some combination weave which are posible in tappet. v. Oxford. (Warp rib and weft rib). vi. Queen’s Oxford. vii. Matt. b. In Dobby loom: i. Various types of weave. ii. Diamond. iii. Diaper. iv. Herring bone. v. Honey comb. vi. The design which are possible in 16 heald frames. 10.Annual production capacity : 18millions per year. 11.Factory area :Approx. 180acres.(including ETP) 12.Type of the factory :Horizontally integrated 13.No. of employees :Approx. 100. 14.Project cost :Approx. 2000million taka 15.Different Departments : a) Adminstration.

  6. 6 b) Human Resource and Develoment Dept. c) Weaving Preperatory d) Weaving. e) Woven finishing. f) Yarn dyeing Dept. g) Store. h) Planning Dept. i) Utility Dept. j) Procurement k) Merketing Location description: Paramount Textile Limited is located in Sreepur, Gazipur about 60 kms North from Dhaka while it takes about 90 minutes by bus.There are available bus services from Mohakhali Bus Terminal and also from Gulistan Bus Terminal. Transport: For the Paramount officer’s there are two micro bus and one private car which carry them on to the factory from Dhaka. Cost of Transport: About 100Taka per head from Gulistan HISTORY OF PARAMOUNT TEXTILE LIMITED: Paramount Textile limited was incorporated under the companies Act(Act-8) of 1994 in june 12, 2006 and went into commercial production in November 2008

  7. 7 Man Power Management

  8. 8 Oraganogram Chariman Deputy Managing Director Executive Director (Operation) Executive Director (Finance & Accounts) G. M. (Admin, H. R., Compliance) DGM (A/F) Manager (Admin / HR) Manager (Compliance) Manager (Purchase) Executive Executive Executive Jr. Executive Jr. Executive Jr. Executive Officer - 1 Officer - 1 Officer - 1 Peon Peon Peon SHIFT CHANGE: There are three shifts per day in P.T.L. So each shift contain eight hour. Shift Duration A 06.00 AM – 02.00 PM B 02.00 PM – 10.00 PM C 10.00 PM – 06.00 AM General shift 09.00 AM – 05.00 PM

  9. 9 General shift, which is applicable for some officers. Man power in different section (weaving) of PTL

  10. 10 JOB DESCRIPTION: SENIOR PRODUCTION OFFICER: In a weaving factory a senior production officer plays a great role in production and man power management who are production related. Here we enlist the duties of senior production officer: 1) Follow up weaving production, 2) Regular observation of weaving floor, 3) Prepare weaving order status regularly, 4) Maintain the quality of the product, 5) To help the senior prod. Officer & co-operate with others for fulfilling the required destination. PRODUCTION OFFICER:

  11. 11 Production officer is the right hand of senior production officer and he is directly related with production manpower and informs senior production officer time to time. Here are his listed duties:- 1) Follow up overall weaving production, 2) Decide every m/c utilization during production, 3) Recruit new labor, 4) To inform the authority on the overall weaving prod. and make it financial profitable, 5) Regular m/c maintenance, 6) Maintain sub-contract orders, 7) Help weaving manager & also guide the junior officers of the section, etc.  Function area: Setting the different parameters of machines, using correct yarn for order, controlling machine store, controlling process quality system. Remarks: The organization and management system are good for mill environment and as the job description is classified, so duties are done honestly and sincerely.

  12. 12

  13. 13 Machine Description There are two ways woven fabric produced: 1. Solid dyed 2. Yarn dyed Generally yarn dyed fabrics are costly item. Because dyed yarn are costly and in case of yarn dyed fabric Sectional warping is necessary which is also costly and time consuming process. Weaving Solid dyed Yarn dyed

  14. 14 ↓ ↓ Store Store ↓ ↓ Direct Winding Soft Winding ↓ ↓ Sizing Yarn Dyeing ↓ ↓ Drawing & Denting Hard Winding ↓ ↓ Weaving Sectional Waarping ↓ Sizing ↓ Drawing & Denting ↓ Weaving Now the machines used in every stage are described below- Soft winding: Machine Type: A (HS 101C) No. of M/cs:07 Name Of m/cs: Soft winding machine Brand name: CORAL TEXTILE Origin: China

  15. 15 No of head: (54×2)/machine M/c rpm:2800 Machine Type: B (TH-8A) No. of M/cs:06 Name of M/ca: Soft winding machine Brand Name: TAIZHOU JINWEL TEXTILE Origin: China No. of head: (54x2)/mahine M/cs rpm: 2800 YARN DYEING A Dyeing machine M/c model No. of Capacity Power Kw Steam Water m / 3 hr m/c Kg Kg/hr Labwin-3 1 4 2.1 2 .12 Labwin-6 2 8 3.5 34 .40 Labwin-12 4 12 8.5 62 .80 Allwin-53 3 48 11.5 214 1.9

  16. 16 Allwin-70 1 81 15 382 3.2 Allwin-85 6 108 27 638 6.5 Allwin-105 3 288 39.9 1233 11.5 Allwin-120 2 432 47 1808 17.31 Allwin-145 1 648 76 2609 25.9 Allwin-166 1 828 94.8 3633 33.1 GF24INT-21 1 12 2.1 9 .12 GF24INT-42 1 12 5.5 47 .20 GF24INT-50 1 48 7 118 .70 GF24INT-187 1 140 58 3165 36.5 GF24INT-21 1 12 2.1 13 .20 GF24IHLC- 1 288 11.4 1105 15 140 30 B.Hydro-extractor No. of machine:6 Brand Name:STALAM(Shanghai) DYET Origin:China Rotation speed:1530rpm Capacity:32pkg Power consumtion:11kw/machine

  17. 17 C.RF DRYER No. of machine:2 Brand Name:STALAM(Shanghai) DYET Origin:China Capacity:12tons Power consumtion:170kw/machine Steam Consumtion:450kg Hard Winding M/c Type:A(HS 101C) No. of machine:7 Name of m/c: Hard winding machine Brand Name:CORAL TEXTILE Origin:China No of head: (54×2)/machine M/c rpm:2800 M/c Type:B(TH-8A) No. of machine:3 Name of m/c: Hard winding machine Brand Name:TAIZHOU JINWEL TEXTILE Origin:China No of head: (54×2)/machine M/c rpm:2800

  18. 18 M/c Type: C (SHA) No. of machine: 1 Name of m/c: Hard winding machine Brand Name: STLM (shanghai) DYET Origin: China No. of head: 108 Installed Power: 14kW WARPING A.High Speed Warping m/c No. of machine: 1 Brand Name:TSUDAKOMA Origin:JAPAN Creel capacity:644 Creel Type: V type Max beam width: 1780mm B. Sectional warping m/c Type 1 No. of machine: 2 Brand Name: UKIL MACHINARY Origin: KOREA Creel capacity: 720 Creel Type: V type Max beam width: 1780mm

  19. 19 Type 2 No. of machine: 2 Brand Name: RABATEX Origin: INDIA Creel capacity:800 Creel Type: V type Max beam width: 1780mm Sizing: Type 1 No. of machine:1 Brand Name: Tsudakoma Origin: Japan Back beam capacity: 16 No of drying cylinder: 12 No of size box: 02 No of wax box: 01 Power consumption: 76kw Type 2 No. of machine: 1 Brand Name: JUPITAR Origin: INDIA Back beam capacity: 1 No of drying cylinder: 8

  20. 20 No of size box: 02 No of wax box: 01 Power consumption: 76kw Loom Total no of looms: 218 Brand name Shedding Weft RPM No. of of the Loom Device Insertion Looms Picanol Tappet 06 700-850 10 omniplus 800 Picanol Tappet 04 650-900 52 omniplus Dobby Toyota JAT Cam 06 725-950 15 710 Toyota JAT Dobby 06 600-700 01 710 Toyota JA Tappet 2+4+6 525-650 34 600/610 Dobby Tsudakoma Cam 06 750-850 12 ZAX 9100 Tsudakoma Dobby 04 500-650 13 ZAX Tappet Tsudakom Cam 02,06 450-600 81 ZAX 205,205i

  21. 21 Total 218 Finishing machines 1. Singeing and Desizing m/c No. of m/c: 01 Company Name: Jaingsu Redflag Printing & Dyeing machinery Co. Ltd. Origin: China Speed: 80-85 m/min (Standard: 70 m/min) Power Consumption: 60-70 kW 2. Scouring & Bleaching m/c No. of m/c: 01 Origin: China 3 baths for hot wash (90 -100 degree celcius) where the first 2 are chemical bath. One steamer (Steaming temperature: 100 degree celcius) Again 4 baths for hot wash Drying cylinder No. 24 Power Consumption: 70 kW 3. Stentering m/c: Company name: HUNAN VIROCK TEXTILE PRINTING AND DYEING MACHINERY CO. LTD.

  22. 22 No. of m/c: 01 Origin: China Model: LVK4000 – 200X8 Drying chamber: 08 Temperature: 120- 170 degree celcius Fan Speed: 1480 rpm Fabric dry: 43 m/min Power Consumption: 140 kW 4. Peach Finishing M/c: Company name: Xetma Vollenweider GmbH No. of m/c: 01 Origin: Germany Model: DE- 08280 Number: 160.008/NW 2200 Year of manufacturing : 2008 Power Consumption: 76 kW 5. Sanforizing m/c: Company name: WuXi Dakai Printing and dyeing machinery Co. LTD. No. of m/c: 01 Origin: China Model: LMH 4P2 – 200 Number: 0804 Year of manufacturing : 2008

  23. 23 Power Consumption: 70 kW Remarks: Maximum m/cs are made of China& Japan. Looms are of old model. If technology would have better and new version m/cs been used productivity would have been greatly increased.

  24. 24 Raw Materials

  25. 25 Main raw Material is yarn. Yarn used mainly 100% cotton, PC, CVC, 100% Polyester, Lurax, lycra core spun yarn. Some common type of yarns are tabulated below with local price Count Type 10/1 Autocone 16/1 Autocone 16/1 Comb 20/1 Autocone 20/1 Comb 20/1 Kard 20/1 Open end 30/1 Comb 40/1 Comb 50/1 Comb 60/1 Comb 40/2 Comb 80/2 Comb 100/2 Comb 24/1 Slub 30/1 Slub 16/1 Kard

  26. 26 Some of the manufacturing companies from where Paramount procure there yarn are 1 Zaber Spinning Mill 2.GTN (India)

  27. 27 Production Planning, Sequences &Operations

  28. 28 There are two ways Woven fabric produced: 1. Solid dyed. 2. Yarn dyed. Generally yarn dyed fabrics are costly item. Because dyed yarn are costly and, In case of yarn dyed fabric Sectional warping is necessary which is also costly and time consuming process. Weaving Solid dyed Yarn dyed ↓ ↓ Store Store ↓ ↓ Direct Winding Soft Winding ↓ ↓ Sizing Yarn Dyeing ↓ ↓ Drawing & Denting Hard Winding ↓ ↓ Weaving Sectional Waarping ↓ Sizing ↓ Drawing & Denting ↓ Weaving

  29. 29 When Order Comes to the Marketing Section, then they contact with the Product development (in case of new product) or Design cell (in case of available product) that, is it possible or not possible in PARAMOUNT. They Send a Article Request paper. After reaching the Article Request paper Design cell produce Article Code and send mail to the planning and marketing section. Planning print a Dispo paper and send to 10 sections with related production of that fabric. Marketing Buyer Merchandiser Planning Design Cell Send Dispo Paper 1. Design Cell 2. Yarn Requisition 3. yarn store 4. winding 5. yarn dyeing 6. warping 7. Sizing 8. Drawing, denting 9. Weaving 10. Finishing. Dispo Paper: Dispo Paper is a paper which contain All necessary information for the production of a specific item of fabric. A typical Dispo Paper is attached below:

  30. 30 Paramount Textiles Ltd. Y/D GREIGE FABRIC SPECIFICATION. PI No: T40824 Line No : 01 Conut ( Warp x Weft) 40X40 Costomer :Paramoun Textiles ………..C & A Yarn Composition (Warp x Weft) 100 % Cotton FINISHED FABRIC DETAILS Dispo No : F90001 Ends x Picks ( Finished ) 120X90 Fabrice Code : Blue Stripe Finished Fabric width ( inch 58/59" Required Finished Length ( Mater Design : Plain 9,076.00 Finish SOFT Delivery Date ( Finished 27/02/2009 GREIGE FABRIC DETAILS Dispo Req No : Ends x Picks ( Greige ) 112X90 No:W90001 Article Code Greige Width ( Inch 63" Reed No 108/2 Required Greige ( Mater ) 9,711.32 Reed Width ( Inch Required Loom Production ( Mtr) 65.55 9809.41 Flow R.P.M : 525 Required Warp Length ( Mtr) 11,630.04 Code:TYD0412 Delivery Date 20/02/2009 Ground Ends 7080 D:4, D.C Comments Selvedge Ends 120 G:1234,S:1234

  31. 31 Color Breakdown Quantity ( kg) Length (Mtr) Count Shade Color Code 40/1 White 797 94874.90 Warp 40/1 Blue 443 47477.95 1240 Warp Total 40/1 White 920 Weft 920 Weft Total DYED YARN DETAILS Dispo No : W90001 Delivery Date : 28/02/2009 BREAKDOWN OF YARN FOR DYEING Dispo Line Greige Yarn ( kg) Dyed Yarn ( kg) Yarn Type Count Shade ALD NO 1 40/1 White 1850 1805 2 40/1 Blue 478 466 Total 2328 2271 Design Cell: Design Cell is one of the most important department of PARAMOUNT TEXTILE LTD.(weaving). When a order comes to the marketing or merchandizing officer he/she send the fabric to the design cell that is it possible or not possible in PARAMOUNT. They send a Article request paper. Design cell analyze the fabric design and test the feasibility of

  32. 32 produciton and create a Article code and send this article code the marketing or marchandizing officer and input data to the Data tex which is a software used in PARAMOUNT for all types of information by networking. PARAMOUNT’s Design department is equipped with hand loom and sophisticated software”TEX-DESIGN CLASSIC” by KOPPERMANN of GERMANY. After getting Article code planning discuss with marketing officer about costing. Then marketing officer send mail or discuss directly to the buyer about pricing of the product. If buyer agree with the price then marketing officer send mail to the central planning section with Article code. Planning take a print of dispo paper for the article code from the system data tex. After printing dispo paper they send it to the design cell to check or verify. Design cell check and give drawing and denting plan and send it to the planning section again. Planning then send it to the various section where these information required and at a time requisition all necessary raw materials or other materials. Organ gram of Design cell: Assistant Manager ↓ Data Entry + Design Analyzer (3 person) ↓ Peon (1 person)

  33. 33 Dispo paper goes to the following sections: 1. Design cell. 2. Store. 3. Winding. 4. yarn dyeing. 5. warping. 6. sizing. 7. Drawing and denting. 8. Loom. 9. Finishing Dispo paper contains following types of informations: 1. Fabric Specification. 2. Yarn composition 3. Finished type. 4. Finished fabric’s EPI x PPI 5. Finished fabric’s width. 6. Required length. 7. Reed count. 8. Grey EPI and PPI. 9. Greige width.

  34. 34 10.Reed width. 11.Reed EPI 12.Required greige length. 13.Required warp length. 14.Ground Ends. 15.Selvedge Ends. 16.Cover Factor. 17.Numerical Plan (Warp & Weft) 18.Drawing & Denting Plan. Possible Ends per inch by using Available Reed in Inventory in PARAMOUNT by denting 2,3 and 4 in a dent For yarn dyed fabric. a) Read available for air jet Looms Jat-600-ZAX(Tsudakoma) Si Read 1/1-2 2/1-3 3/1-4 Present Required Short Remark No No Ends/EPI Ends/EPI Ends/EPI 1 144 160 4 15 -11 2 131 146 218 291 3 3 0 Local 3 130 144 217 289 66 66 0 New 25 4 128 142 213 284 1 0 1 5 126 140 210 280 23 25 -2 10 New 6 122 136 203 271 41 41 0 7 120 133 200 267 36 36 0 37 Available 8 118 131 197 162 36 30 0 36

  35. 35 9 116 129 193 258 2 10 -6 10 112 124 187 249 0 6 -6 11 108 120 180 240 89 90 -1 5 recount count 12 99 110 165 220 58 60 -2 New 1 + 25 13 98 109 163 218 2 10 -8 2 local 14 96 107 160 213 25 25 0 New 19 15 94 104 157 209 2 4 -2 16 92 102 153 204 3 10 -7 20indnt 17 90 100 150 200 42 42 0 40 New 18 86 96 143 191 3 8 -5 19 84 93 140 187 6 8 -2 20 82 91 137 182 1 10 -9 21 78 87 130 173 41 30 11 New 12+15+18 22 75 83 125 167 3 12 -9 23 72 80 120 160 3 12 -9 24 70 78 117 156 31 31 25 68 76 113 151 3 10 -7 26 66 73 110 147 3 3 0 27 65 72 5+6 12 -6 28 62 69 103 138 4 8 -4

  36. 36 29 60 67 100 133 7 7 0 30 58 64 97 129 22 22 0 New20 31 54 60 90 120 5 5 0 32 52 58 87 116 5 5 0 33 50 56 83 111 6 6 0 34 48.5 54 81 108 9 9 0 35 46.25 51 77 103 10 10 0 36 41.5 46 69 92 8 8 0 37 38.5 43 64 56 6 6 0 38 37 41 62 82 2 2 0 39 35.75 40 60 79 5 5 0 Total 609 682 -73 b)Reed for picanol looms (10+7) Si No Reed No Present Required Short Remark 1 130 7 7 2 108 10 10 Came with loom 3 99 10 10 Indnted 4 65 4 10 -6

  37. 37 b) Requirements of cut reed of picanol 45 loom Si No Reed No Present Require Short 1 130 4 4 0 2 108 35 36 -1 3 99 32 30 2 4 96 8 10 -2 5 90 32 32 6 87 4 7 86 2 8 78 8 9 72 1 10 71 1 11 58 1 12 65 5 10 5 Proposed Process Allowances For the different process:

  38. 38 Yarn Dyeing Section Warp% Weft% Section Cumulative Section Cumulative Yarn Dyeing 2.00 23.32 2.00 26.59 Winding 0.50 20.86 0.50 24.06 Warping 3.00 20.25 23.44 Sizing 0.50 16.64 23.44 Weaving (Crimp) 8.00 16.06 13.5 23.44 Greige (Reject) 1.00 6.78 1.00 Process Loss 1.50 5.71 1.50 5.71 Shrinkage 2.00 4.12 2.00 4.12 Inspection (Rejection 2.00 2.04 2.00 2.04 Total 23.32% 26.59% Yarn Dyeing(pc/cvc) Section Warp% Weft%

  39. 39 Section Cumulative Section Cumulative Yarn Dyeing 2.50 24.59 2.50 27.24 Winding 1.00 21.48 1.00 24.06 Warping 3.50 20.26 - 22.81 Sizing 0.50 16.05 - 22.81 Weaving (Crimp) 8.00 15.47 13.50 22.81 Greige (Reject) 1.00 6.23 1.00 6.23 Process Loss 1.50 5.17 1.50 5.17 Shrinkage 1.5 3.59 1.50 3.59 Inspection (Rejection 2.00 2.04 2.00 2.04 Total 24.59% 27.24% There are major departments are : 2. Winding.

  40. 40 3. Warping. 4. Sizing. 5. Drawing, Denting. 6. Weaving. 7. Inspection. These departments are described below: Winding Section Definition: In fabric manufacturing (weaving) process this is the first stage where rewinding of supplied yarn is done on to a desired package suitable for use in the next process. Types of Winding: 1. Soft Winding. 2. Hard widing

  41. 41 Soft Winding Section Soft Winding: where the grey yarn is wond on to a special dye spring or plastic bobbin and the package(spool) is made softer and bulkier to make it suitable for dye penetration in the(package) dyeing machine.

  42. 42 Dye Spring Plastic bobbin Organogram: The organogram of this section is given below: Section in charge ↓ Senior Operator ↓ Operator ↓ Helper ↓ Cleaner Skill Level Man power Section-in charge 3 Senior Operator. 36 Operator Helper 27 Cleaner. 12 Total 72

  43. 43 M/c Name : CORAL TEXTILE Manufacturer : Shanghai Coral Textile machinery Co. Ltd Manuf. Year : 2008 R.P.M. of Motor : 1430 No. of Head : 2 No. of Drum /head : 54 Traversing system : Grooved drum Motor : Individual Stop motion : Automatic No. of m/c : 07 Production per m/c : 86867 km /day [Assuming 80% efficiency]

  44. 44 Flow Chart: DISPO ↓ Store Requisition ↓ Recieve the yarn ↓ Setting & Running ↓ Winding ↓ Checking(dia) ↓ Stop winding ↓ Quality assurance ↓ Root card making Delivery for dyeing Assignment in soft winding : 1. Finding out package density 2. Production calculation

  45. 45 1.Finding out package density We know package density ρ =mass(m)/volume(v) gm/cc Volume= π( R2-r2)h R= outer radius of package R= inner radius of pkg h= height of pkg Now we consider a sample of 40/1 cotton yarn whose R=4.138 r= 1.59 h=15.24 mass m=1000gm So package density ρ=1000/π(4.1382-1.592)15.24 gm/cc =1.433 gm/cc 2.Production calculation We know production= speed(m/min)×60×24 ×1.09/(840×40×2.2045) kg/day/head When speed is 800m/min at 80% efficiency Production=800×60×24×1.09/(840×40×2.2045)kg/day/head =10.5976kg/day/head Total production=10.5976×54×12kg/day =6867.2448kg/day

  46. 46 YARN DYEING

  47. 47 OBJECT: To dye grey yarn to produce check and stripe fabric. Dyeing procedure: Deminerelization ↓ Bleaching ↓ Hot wash ↓ Dye run ↓ Neutralization ↓ Finishing ↓ Hydro extracting ↓ Drying Dyeing process: Process Recipies

  48. 48 Demineralization Ladiquest 0.5g/l Acetic acid 0.1g/l 70°-15min Bleaching Caustic 1g/l Per- oxide 4g/l 115°-20min Dyeing Ladiquest 0.80g/l Salt 40g/l Suffix Yellow SPD 4% Suffix Red SPD 0.2325% Suffix Nevy Blue 0.5663% Soda ash 10g/l Washing off Ladiphore RSK 0.4g/l Finishing Permafix RDX 0.7% Acetic acid 0.2g/l Assignments 1.Observing Hydro Extracting Cycle & production calculation 2.Production calculation 2.Observing Hydro Extracting Cycle & production calculation

  49. 49 Hydro extracting cycle is with time required Lowering(30sec) ↓ Circulation( 12 sec) ↓ Operation(5min,40sec) ↓ Lifting(21sec) Water removing Efficiency: Weight of cone after dyeing: 2.38kg Weight of cone after drying: 1.11kg Water removing Efficiency=(2.38-1.11)/2.38% = 53.36% 3.Production calculation of RF Dryer Length of RF Dryer=13m At 28rpm it takes 21 min 9 sec to pass this length Along this length it can accommodate 416 pkgs i.e 416kgs So at 21 min9sec or 1269sec it can dry 416kgs So in 1hr or 3600sec it can dry=416×3600/1269 kg/hr =1180.14 kg/hr so Production per day=1180.14×24kg =22658.688 kg =22.66 tons Hard Winding Section

  50. 50

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