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Industrial attacthment of masco industries ltd.

Presentation about 'Industrial attacthment of masco industries ltd.'

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Industrial attacthment of masco industries ltd.

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  1. INTERNY PAPER ON MASCO GROUP INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT MASCO INDUSTRIES LTD. 1

  2. INTERNY PAPER ON MASCO GROUP Chapter: 1 INTRODUCTION INTRODUCTION 2

  3. INTERNY PAPER ON MASCO GROUP Textile and garments sector is the biggest and fastest growing sector in Bangladesh. It is also the highest foreign currency earning sector in Bangladesh. Among this sector, Knit garment is growing very rapidly due to smaller investment requirement, greater backward linkage facility & higher profit than woven garments. That’s why export of knit garments is increasing steadily for last few years and up to now. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-months long industrial training at MASCO INDUSTRIES LIMITED, which is a 100% export-oriented composite Knit Dyeing Industry. It has well planned & equipped fabric dyeing-finishing and garments units in addition to facilitate knitting and knitwear manufacturing. Introduction By means of practical knowledge it’s possible to apply the theoretical knowledge in the practical field. For any technical education, practical experience is almost equal important in association with the theoretical knowledge. The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skill ness about various processing stages. 3

  4. INTERNY PAPER ON MASCO GROUP It also provides me sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned can not be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on. Industrial attachment makes us reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self responsibility. I have prepared this report as required on completion of my attachment of my attachment course in regarding guideline given by the university authority. 4

  5. INTERNY PAPER ON MASCO GROUP Chapter: 2 INFORMATION ABUOT FACTORY 5

  6. INTERNY PAPER ON MASCO GROUP GENERAL INFORMATION ABOUT THE FACTORY: Name of Company : MASCO INDUSTRIES LTD. Factory : MASCO INDUSTRIES LTD. 297 Khortoil, Tongi, Gazipur-1712.,Dhaka Bangladesh. 6

  7. INTERNY PAPER ON MASCO GROUP LAYOUT FOR GOING TO THE MASCO GROUP FROM DHAKA: KAI Alluminim Co.Ltd. MASCO GROUP Viyellatex Group MASCO GROUP Oishi Fashion Pvt. SMP Design Pvt. Ltd. Gajipur Dhaka Board Bazar Tongi DHAKA-MAYMANSHING HIGHWAY WEST NORTH SOUTH EAST Different Sections of MASCO Knit-Dyeing Composite Unit: 7

  8. INTERNY PAPER ON MASCO GROUP a) knitting Section:  Knitting  Inspection b) Dyeing section:  Batch section  Dye house  Dyeing lab.  Quality control  Finishing Different Sections c) Garments section:  Merchandising  Sample  Cutting Section  Sewing Section  Finishing Section d) Maintenance section:  Electrical  Mechanical e) Store Section f) Administration Section g) Security Section h) Marketing Section i) Production Planning & Control j) Human Resource & Development Section 8

  9. INTERNY PAPER ON MASCO GROUP MASCO GROUP INFORMATION Capacity: Production Capacity : 650 tons per months KNITTING No. of Machines : Circular 74, Auto Striper : 8, Flat bed : 20 : Single Jersy : 18”-48”,Rib : 30”-40”, Interlock : 30”-38” Available Dia Gauges Converter : Single Jersy -16,20,24,28,32, Rib- 16,18, Interlock-24. : Single Jersey Rib, Interlock, lacoast, Polo Pique,Drop needle, Fleece, Terry, stripe, Auto stripe 100 of Designs in different gauges. Fabric Type: DYEING & FINISHING Production Capacity : 650 tons per month No. of Machine : Bulk Dyeing – 44, Sample Dyeing- 11 Machine Capacity : 20kg to 1500kg Types of Machine : Atmospheric & High Temperature . Special Fabric Type : Viscose, Lycra-viscose, Modal, Bamboo, Polyester etc. Special Fabric Type : Carbon/Moss/Sueding, Both side brush, Antibacterial, Moisture Management Water/Soil repellent, Anti UV, Scotch guard, Teflon finish etc Finishing Facility: Both Open & Tubular Line 9

  10. INTERNY PAPER ON MASCO GROUP Garments Unit Total Machines : SAMPLE UNIT 75 Sample Capacity: 300 pcs /day (depending on styling) Dummy: Both for Children & Ladies Software Facility: Garber, Euro Cad, Winda, Photo digitizer CAD UNIT Plotter: Garber, Winda, Morgan, Kama Tech Pattern Maker & Cutter: Winda. Spreader: 5 machine from Morgan. SEWING UNIT Area: 5,56,300 Sft. Man Power: 9,200 Production Capacity: 3.5 Million pcs per month. No. of Machines: 3010 Sewing lines: 96 sewing lines Cutting: Marker from CAD & Auto spreader facility. All Kinds of baby items. Men’s & Ladie’s Light & medium wears. Product Mix: Special Machines: Pneumatic Button attaching machine from Prym. 10

  11. INTERNY PAPER ON MASCO GROUP Special Sewing m/c: 4 smoking machine, pneumatic button attaching & Button pull test machine at sewing facility Special Facilities: Quarantines area for metal free zone. All garments pass through metal detector & Finishing is done in quarantine zone. Finishing: LAUNDRY UNIT Number of Machine: 4 washing m/c, 1 sample m/c,7 tumble dryer. Washing Capacity: 80,000pcs/day Garments wash, Silicon wash , Enzyme wash, Pigment Dyeing. Acid wash, Enzyme Stone wash, Spray wash etc. Wash Facility: Printing & Embroidery Ltd Area : 139,322 square feet. Printing Unit : Worker – (Male- , Female-), Stuff – (Male- , Female - ). Man Power Production capacity : 80,000 – 100,000 pcs/day (considering 3-4 color print), : 77 regular, 17 glass of 8500 running feet with 3 sample tables (200 running feet). Number of Tables Auto Circular Machine Machine Facility : Pannon, Spain 11

  12. INTERNY PAPER ON MASCO GROUP Voltage/ Tension : 220 || 50/60 Horse Colors (Heads) : 6 Palate : 12 Dryers : 4 Capacity of one Machine : 300 pcs per hr (Two Colors) : Four employees act as designers in design section Design Section Manpower : 1 color: 50 designs , 2 Color: 25 designs , 3 Color : 10 designs, 4 Color: 8 designs Capacity Positive section Machine : Katana, China Productivity : 100.000 square inch per day Name of Exposing Machine Screen preparation : Atma, Taiwan Capacity : 180-200 pcs per day Name of Dryer : Atma Auto Exposing Dryer Capacity : 1000 pcs Stretching Machine : Atma Capacity : 180- 200 pcs of Frames 12

  13. INTERNY PAPER ON MASCO GROUP Name of Machine : Jet- Force, UK. Curing Type of Machine : High temperature. Number of Chamber : 3 Type of Belts : Duel Number of Machines : 2 pcs Auto mixing machine : 3 Pcs Color kitchen Digital Balance : 12 Pcs Recipe Maintenance : By register Printing Technique : Screen print (major), Heat transfer, Spray, Stencil etc.. In Lab all types of styles are cleaned up with a view to checking the printing color, rubbing fastness in order to ensure whether colors clear away or not at five times daily. Lab Section: Storage Area belongs to 2400 square feet (3 floor). Storage Masco Printing & Embroidery Ltd. Abounds with incoming goods, storage and checking area. Inventory Facility CHT (Germany) – Pigment paste, Fixer, Binder, Flock paste, Glitter paste, Bezama (Switzerland) – Pigment color, Dyestuff & Auxiliaries 13

  14. INTERNY PAPER ON MASCO GROUP Kukyoto (Japan)- Pigment Fixer, Magna (UK) – Discharge ink, Silkflex (Malaysia) Rubber, Zhong Dic Color (China) Rubber, Changzhu (China) Flock, Asuluck (Spain) Pigment ready paste, Pearl, Embroidery Facility Area : 10,500 square feet. Manpower : Stuff – 34, Worker -96. Production Capacity : 120 million stitches per day. Design Section : Two dedicated designers. Software : Wilcom ES45, DGML by Pules. Embroidery technique : Regular stitch, 3D embroidery, Sequin, Boring. Name of Machines Machine Facility : Tajima, Japan and SWF,Korea Number of Machines : 12 ( 20 head of each) Heads : 20 Colors : Maximum 9, Name of Appliqué cutting Machine : Yueming Laser Number of Machines Applique cutting M/C : 3 14

  15. INTERNY PAPER ON MASCO GROUP Capacity : 10200- 10800 nm Sequin source : Wonil (Korea). : Regular yarn : Well Thread (Bangladesh), Innova Textile (Bangladesh), Air plane (Korea), Yarn source Lurex : Marthon (Korea). Embroidery Category : Regular stitch (run, satin, tatami), motif, Cross stitch, Chain, Boarder do, Aplique (felt, twill, jersey), Sequin, boring. : Regular shiny yarn, matt yarn, Acrylic, Thicker yarn, Filament, Lurex, Multiclolor Yarn category Buyer: Buyers Name Country H&M Sweden C&A Belgium Tchibo Germany Zare Spain Pull & Bear Spain Bon Prix Germany Mayoral Spain United colors of benetton Italy Lemoir Japan Target Australia Kappahl Sweden New Yorker Germany 15

  16. INTERNY PAPER ON MASCO GROUP Production Capacity • WEAVING : 36, 000, 00 LBS/YEAR • DYEING : 37, 50,000 LBS/YEAR • SEWING AND FINISHING : 38, 30,000 LBS/YEAR CSRP: Run ETP to treat dyeing water before release to environment Donate Blood transfusion Thalassaemia Hospital Donated Kidney Dialysis Machine by Rotary Club Dhaka North-West Scholarship to meritorious students A Local school runs by Masco group Welfare Trust Projected 80 bedded general Hospital Carbon Footprint Project by BASF Reuse of Generator exhaust to run chiller & Boiler Preserve Rain water Free Eye Camp & health Campaigns for local community Take part on others social & national activates, disaster etc. 16

  17. INTERNY PAPER ON MASCO GROUP Name Function Address Masco Center House -06, Road -01, Sector -03 Jashimuddin Avenue, Uttara Dhaka-1230, Bangladesh Phone: +88 02 8918082, 8914130 Fax: +88 02 8923126 Masco Center Corporate Office 221-223, Shataish Road, Gazipura, Tongi, Gazipur - 1712, Bangladesh. Phone: +88 02 9813362-63, 9815041-42 Fax: +88 02 9810790 Composite Knit Garments Masco Industries Ltd. Garments Manufacturing 31-32 Mannan Mension, Shataish, Tongi, Gazipur-1712. Mascotex Limited Garments Manufacturing 44, Redwan Complex, Gazipura, Tongi, Gazipur-1712, Bangladesh. Masco Cottons Limited Garments Manufacturing Tasniah Fabrics Limited Nayapara, Kashempur, Gazipur. Garments Manufacturing 44, Redwan Complex, Gazipura, Tongi, Gazipur-1712, Bangladesh. MPL Wear Limited Concept Knitting Limited Composite Knit Garments Tilargati, Sataish Bazar, Tongi, Gazipur- 1712. Masco Printing & Embroidery Ltd 15/4 M. I. Khan Bhaban, Shataish Maddhapara, Tongi, Gazipur-1712. Printing & Embroidery Terry Towels manufacturring Masco Exports Limited Baghata, Palbari, Norshindi. HR (Human Resources) 17

  18. INTERNY PAPER ON MASCO GROUP Group HR Support Service C&B and ES Compliance T&D ER & TM BU HR, Garments, BU HR, Fabrics, GDL & FPPL, 18

  19. INTERNY PAPER ON MASCO GROUP Chapter: 3 RAW MATERIALS 19

  20. INTERNY PAPER ON MASCO GROUP Raw Materials Raw material is a unique substance in any production oriented textile industry. It plays a vital role in continuous production and for high quality fabric. Types of raw material: 1. 2. 3. 4. Yarn Fabric Dye stuff Chemical and auxiliaries Name and source: Yarn: The raw material (cotton yarn) used in Knitting are the product of another spinning Mill. They produce carded and also combed yarn according to their buyer requirement. The yarn count range vary for carded yarn from(34/1) to (7/1) Ne. The yarn count range vary for combed yarn from(40/1) to (20/1) Ne. Mellange: Mellange is produced by blending different amount of top dyed fibre with grey fibre. Different types of mellange used in knitting are: Mellange White/Ecru mellange Grey mellange Anthra mellange (dyed fibre 0.2-5%) (dyed fibre 5-15%) (dyed fibre 15-30%) Sources of mellange:  Patartoli  Prime  Shohag pur  Thermax Sources of polyester:  Kader Synthetic.  China.  Count: 75den, 100den, 150den. 20

  21. INTERNY PAPER ON MASCO GROUP Sources of Lycra: * Brand : Roica Country : Taiwan. * Brand : Texlon Country : Korea. *Brand : Acelen Country: China *Brand : Creora Country: Japan *Brand : Lioli (In Masco used mostly) Country: China  Count: 20 den, 40 den, 70 den. Price list of different types of yarn: Cotton: Yarn Count Combed Yarn 3.65 $/Kg 3.00 $/Kg 2.90 $/Kg 2.70 $/Kg 2.70 $/Kg 2.65 $/kg 2.60 $/Kg 2.55 $/Kg 2.50 $/Kg Carded Yarn 2.65-2.7 $/Kg 2.5-2.6 $/Kg 2.30 $/Kg 2.30 $/Kg 2.25 $/Kg 2.25 $/Kg 2.25 $/Kg 2.20 $/Kg 2.15-2.2 $/Kg 40/1 34/1 32/1 30/1 28/1 26/1 24/1 22/1 20/1 Polyester Yarn: Kader Synthetic - 2.40 $/Kg China - 1.60 $/Kg Lycra Yarn: 20 den - 12.70 $/Kg 40 den - 8.40 $/Kg 70 den - 7.50 21

  22. INTERNY PAPER ON MASCO GROUP Chapter: 4 KNITTING SECTION 22

  23. INTERNY PAPER ON MASCO GROUP KNITTING SECTION Organogram of Knitting Section (Consider-68 m/c): DGM / AGM Manager /Asst. Manager (Production & Plan)(02) Manager/ (Technical) Asst. Manager(01) Sr. Executive (Production, Plan & Sample)(02) Prduction officer (01) Executive / Jr. Executive (Prod. & Sample)(05) Asst. Feeder(04) Sr. Supervisor/Supervisor(06) Sample Supervisor(02) Needle Man(03) Sr. Operator/Operator(135) Sample Asst.(05) Servicing Man(06) Asst. Operator(33) Servicing Helper(06) Production Helper(21) Manager / Asst. Manager (Store)(01) Sr. Executive / Executive (02) Jr. Executive (Yarn)(02) Jr. Executive (Grey Fabric)(03) Store Asst.(Yarn)(03) Store Asst.(Grey Fabric)(07) Loader (Yarn)(26) Batch Helper/Loader (35) S 23

  24. INTERNY PAPER ON MASCO GROUP YARN STORE FABRIC STORE E X I T E IHSFHFYFHIZFYHqwwwIFU8DUH RERR1 S N WWWW XHDH1253453653533666666 w 17 32 1 16 48 33 2 15 18 34 31 47 3 30 14 19 35 46 4 13 20 29 36 45 5 12 21 44 37 28 6 11 22 43 27 38 7 23 10 26 39 42 8 24 25 9 40 41 ENTER 24

  25. INTERNY PAPER ON MASCO GROUP Machine List of Knitting Section in Masco Group : Machine name Circular Knitting(Single jersey) m/c Circular Knitting(Rib) m/c Circular Knitting(Interlock) m/c Engineering Stripe m/c V-bed Knitting m/c Grey Fabric Inspection m/c Machine Quantity 38 05 05 05 18 03 Specification of Circular Knitting Machine: Machine no-01 M/c type: Single jersey Model: KM-3SF Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 30 Gauge: 24G Cylinder: 1 Needle: 2256 Feeder: 90F Safety rpm: 25 Date of manufacturing: 2009,9 Machine no-02 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 26 Gauge: 24G Cylinder: 1 Needle: 1968 Feeder: 78F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-04 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 30 Gauge: 24G Cylinder: 1 Needle: 2256 Feeder: 90F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-03 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 30 Gauge: 24G Cylinder: 1 Needle: 2256 Feeder: 90F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-06 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 26 Gauge: 24G Machine no-05 25

  26. INTERNY PAPER ON MASCO GROUP M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 32 Gauge: 24G Cylinder: 1 Needle: 2400 Feeder: 96F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-08 M/c type: Interlock Model: KRB-2TIV Brand name: Keum Yong Origin: Korea Cylinder Dia: 38 Gauge: 24G Cylinder: 1 Needle: 2856 Feeder: 73F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-07 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 26 Gauge: 24G Cylinder: 1 Needle: 1968 Feeder: 78F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-10 M/c type: Single jersey Model: : KM-3SF Brand name: Keum Yong Origin: Korea Cylinder Dia: 34 Gauge: 24G Cylinder: 1 Needle: 2568 Feeder: 102F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-09 M/c type: Single jersey Model: : KRB-2TIV Brand name: Keum Yong Origin: Korea Cylinder Dia: 36 Gauge: 24G Cylinder: 1 Needle: 2712 Feeder: 72F Safety rpm: 28 Date of manufacturing: 2009,9 26

  27. INTERNY PAPER ON MASCO GROUP Machine no-12 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 36 Gauge: 24G Cylinder: 1 Needle: 2712 Feeder: 144F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-11 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 34 Gauge: 24G Cylinder: 1 Needle: 2568 Feeder: 72F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-14 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 36 Gauge: 24G Cylinder: 1 Needle: 2712 Feeder: 144F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-13 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 36 Gauge: 24G Cylinder: 1 Needle: 2712 Feeder: 108F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-16 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 38 Gauge: 24G Cylinder: 1 Needle: 2856 Feeder: 114F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-15 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 38 Gauge: 24G Cylinder: 1 Needle: 2856 Feeder: 114F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-18 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 42 27

  28. INTERNY PAPER ON MASCO GROUP Machine no-17 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 40 Gauge: 24G Cylinder: 1 Needle: 3000 Feeder: 160F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-20 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 46 Gauge: 24G Cylinder: 1 Needle: 3456 Feeder: 138F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-19 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 44 Gauge: 24G Cylinder: 1 Needle: 3312 Feeder: 132F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-22 M/c type: Single jersey Model: KRB-2TIV Brand name: Keum Yong Origin: Korea Cylinder Dia: 34 Gauge: 24G Cylinder: 1 Needle: 2568 Feeder: 68F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-21 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 44 Gauge: 24G Cylinder: 1 Needle: 3312 Feeder: 132F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-24 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 34 28

  29. INTERNY PAPER ON MASCO GROUP Machine no-23 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 34 Gauge: 24G Cylinder: 1 Needle: 2568 Feeder: 102F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-26 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 28 Gauge: 24G Cylinder: 1 Needle: 2111 Feeder: 84F Net wt: 2310kg Safety rpm: 37 Date of manufacturing: 2006-11 Machine no-25 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 34 Gauge: 24G Cylinder: 1 Needle: 2568 Feeder: 96F Safety rpm: 28 Date of manufacturing: 2009,9 Machine no-28 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 25 Gauge: 24G Cylinder: 1 Needle: 1872 Feeder: 74F Net wt: 2310kg Safety rpm: 42 Date of manufacturing: 2007.03 Machine no-27 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 28 Gauge: 24G Cylinder: 1 Needle: 2111 Feeder: 84F Net wt: 2310kg Safety rpm: 37 Date of manufacturing: 2006-11 Machine no-30 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 21 29

  30. INTERNY PAPER ON MASCO GROUP Machine no-29 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 23 Gauge: 24G Cylinder: 1 Needle: 1728 Feeder: 68F Net wt: 1800kg Safety rpm: 40 Date of manufacturing: 2006-11 Machine no-32 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 19 Gauge: 24G Cylinder: 1 Needle: 1428 Feeder: 56F Net wt: 1550kg Safety rpm: 55 Date of manufacturing: 2006-11 Machine no-31 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 19 Gauge: 24G Cylinder: 1 Needle: 1428 Feeder: 56F Net wt: 1550kg Safety rpm: 55 Date of manufacturing: 2006-11 Machine no-34 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 34 Gauge: 24G Cylinder: 1 Needle: 2544 Feeder: 102F Net wt: 2450kg Safety rpm: 30 Date of manufacturing: 2006-11 Machine no-33 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 33 Gauge: 24G Cylinder: 1 Needle: 2256 Feeder: 90F Net wt: 2310kg Safety rpm: 37 Date of manufacturing: 2006-11 30

  31. INTERNY PAPER ON MASCO GROUP Machine no-35 M/c type: Single jersey Model: PL/XSB3/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 36 Gauge: 24G Cylinder: 1 Needle: 2712 Feeder: 108F Net wt: 2850kg Safety rpm: 29 Date of manufacturing: 2006-11 Machine no-36 TYPE OV3, 20 NENNDURCHMESSR 762MM 30 INCH MASCHINE-NR 51557 TEILANG FEINEIT 106M 24E BAUJAHR 2001 MODELAR ZAHL 2×2268 Machine no-37 TYPE OV3, 20 NENNDURCHMESSR 762MM 30 INCH MASCHINE-NR 51556 TEILANG FEINEIT 106M 24E BAUJAHR 2001 MODELAR ZAHL 2×2268 Machine no-38 TYPE FV2,0 NENNDURCHMESSR 672MM 30 INCH MASCHINE-NR 51554 TEILANG FEINEIT 1.59M 16E BAUJAHR 2001 MODELAR ZAHL 2×1512 Machine no-39 TYPE FV2,0 NENNDURCHMESSR 864MM 34 INCH MASCHINE-NR 51555 TEILANG FEINEIT 1.59M 16E BAUJAHR 2001 MODELAR ZAHL 2×1704 Machine no-41 M/c type: Single jersey Model: PL-XR2B/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 36 Machine no-40 31

  32. INTERNY PAPER ON MASCO GROUP M/c type: Single jersey Model: PL-XRA/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 40 Gauge: 18G Cylinder: 1 Needle: 2256 Feeder: 40F Net wt: 3200kg Safety rpm: 22 Date of manufacturing: 2007.03 Machine no-42 M/c type: Single jersey Model: PL-XR2B/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 34 Gauge: 18G Cylinder: 1 Needle: 1920 Feeder: 60F Net wt: 2450kg Safety rpm: 25 Date of manufacturing: 2002.12 Machine no-43 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 36 Gauge: 24G Cylinder: 1 Needle: 2712 Feeder: 108F Safety rpm: 28 Date of manufacturing: 2010.06 Machine no-41 M/c type: Single jersey Model: PL-XR2B/C Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 36 Gauge: 18G Cylinder: 1 Needle: 2040 Feeder: 72F Net wt: 2450kg Safety rpm: 25 Date of manufacturing: 2002.12 Machine no-44 M/c type: Single jersey Model: KM-3WV4T Brand name: Keum Yong Origin: Korea Cylinder Dia: 34 Gauge: 24G Cylinder: 1 Needle: 2568 Feeder: 102F Safety rpm: 28 Date of manufacturing: 2010.06 Machine no-45 32

  33. INTERNY PAPER ON MASCO GROUP TYPE MV4-3,2 NENNDURCHMESSR 610MM 24 INCH MASCHINE-NR 52580 TEILANG FEINEIT 1,06M 24E BAUJAHR 2001 MODELAR ZAHL 1800 Machine no-46 TYPE MV4-3,2 NENNDURCHMESSR 559MM 22 INCH MASCHINE-NR 52581 TEILANG FEINEIT 1,06M 24E BAUJAHR 2001 MODELAR ZAHL 1656 Machine no-47 TYPE MV4-3,2 NENNDURCHMESSR 508MM 20 INCH MASCHINE-NR 52579 TEILANG FEINEIT 1,06M 24E BAUJAHR 2001 MODELAR ZAHL 1512 Machine no-48 TYPE MV4-3,2 NENNDURCHMESSR 457MM 18 INCH MASCHINE-NR 52578 TEILANG FEINEIT 1,06M BAUJAHR 2001 MODELAR ZAHL 1368 24E Machine no-50 M/c type: Auto Striper(S/j) Model: PL-XSC/6 Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 32 Gauge: 24G Needle: 2400 Feeder: 44F Net wt: 2850kg Safety rpm: 20 Date of manufacturing: 2007.10 Machine no-49 M/c type: Auto Striper(S/j) Model: PL-XSC/6 Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 30 Gauge: 24G Needle: 2256 Feeder: 42F Net wt: 2650kg Safety rpm: 22 Date of manufacturing: 2007.10 Machine no-52 M/c type: Auto Striper(S/j) Model: PL-XSC/6 Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 30 33

  34. INTERNY PAPER ON MASCO GROUP Machine no-51 M/c type: Auto Striper(S/j) Model: PL-XSC/6 Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 31 Gauge: 24G Needle: 2544 Feeder: 18F Net wt: 2850kg Safety rpm: 20 Date of manufacturing: 2007.10 Machine no-53 M/c type: Auto Striper(S/j) Model: PL-XSC/6 Brand name: Pai Lung Origin: Taiwan Cylinder Dia: 30 Gauge: 24G Needle: 2256 Feeder: 42F × 6 Net wt: 2650kg Safety rpm: 23 Date of manufacturing: 2007.03 Specification of V-Bed Knitting Machine : No. of V-Bed Knitting m/c: 18 Machine no: 01 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7695 Date : 6.2001 Machine no: 02 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7694 Date :6.2001 Machine no: 04 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7691 Date : 6.2001 34

  35. INTERNY PAPER ON MASCO GROUP Machine no: 03 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7690 Date :6.2001 Machine no: 06 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7809 Date : 1.2002 Machine no: 05 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7692 Date : 6.2001 Machine no: 08 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7804 Date : 1.2002 Machine no: 07 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7693 Date : 6.2001 Machine no: 10 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7806 Date : 1.2002 Machine no: 09 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7807 Date : 1.2002 Machine no: 12 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7805 Date : 1.2002 Machine no: 11 M/c type: Rib (collar) Model: M-100 Gauge: 14 G Manufacturing no: 7808 Date : 1.2002 Machine no: 13 35

  36. INTERNY PAPER ON MASCO GROUP AROUND STAR INTERNATIONAL CO. LTD S/N: 37045 Date: 2007 #7#31 Model: AS-318, 14G , 40“ Power: AC 220V,-Hz, 1Ơ Machine no: 14 AROUND STAR INTERNATIONAL CO. LTD S/N: 37046 Date: 2007 #7#31 Model: AS-318, 14G , 40“ Power:Ơ: AC 220V,-Hz, 1Ơ Machine no: 15 AROUND STAR INTERNATIONAL CO. LTD S/N: 37048 Date: 2007 #7#31 Model: AS-318, 14G , 40“ Power: AC 220V,-Hz, 1Ơ Machine no: 16 AROUND STAR INTERNATIONAL CO. LTD S/N: 37047 Date: 2007 #7#31 Model: AS-318, 14G , 40“ Power: AC 220V,-Hz, 1Ơ Machine no: 18 KAVO HENG CO.LTD Model: KH-313J, 14G S/N: 412454 Date: 2006 12 Power: 220V, 50Hz 1 Ơ Made in TAIWAN Machine no: 17 KAVO HENG CO.LTD Model: KH-313J, 14G S/N: 412455 Date: 2006 12 Power: 220V, 50Hz 1 Ơ Made in TAIWAN 36

  37. INTERNY PAPER ON MASCO GROUP Pictures of Knitting Machine of MASCO GROUP: Single Jersey Circular Knitting m/c V-Bed Knitting m/c DIFFERENT PARTS OF KNITTING MACHINE 37

  38. INTERNY PAPER ON MASCO GROUP Creel: Creel is used to place the cone. Feeder: Feeder is used to feed the yarn. Tensioning device: Tensioning device is used to give proper tension to the yarn. VDQ pulley: VDQ pulley is used to control the GSM by controlling the stitch length. Guide: Guide is used to guide the yarn. Sensor: Sensor is used to seen & the machine stops when any problem occurs. Spreader: Spreader is used to spread the knitted fabric before take up roller. Take up roller: Take up roller is used to take up the fabric Fixation feeder: These types of feeder are used in Electrical Auto Striper Knitting Machine to feed the yarn at specific finger. Rethom: These devise are used in Electrical Auto Striper Knitting machine PROCESS FLOW CHART OF KNITTING: Yarn in cone form Feeding the yarn cone in the creel Feeding the yarn in the feeder via trip-tape positive feeding arrangement and Tension device. Knitting Withdraw the rolled fabric and weighting Inspection Numbering 38

  39. INTERNY PAPER ON MASCO GROUP RAW MATERIALS USE FOR KNITTING: Type of yarn Count 16s,20s, 22s, 24s, 26S, 28S, 30S, 34S, 40S 75D, 100D,150D Cotton Yarn Polyester Yarn Spandex yarn 20D,40D,70D 20S,22S,24S, 26S,30S,34S 24S, 26S, 28S, 30S 24S, 26S, 28S, 30S Grey Mellange (C-90% V-10%) PC (65%Polyester & 35% cotton) CVC CONSIDERABLE POINTS TO PRODUCE KNITTED FABRICS When a buyer orders for fabric then they mention some points related to production and quality. Before production of knitted fabric, these factors are needed to consider. Those are as follows-        Finished G.S.M. Type of Fabric or design of Fabric. Yarn count Types of yarn (combed or carded) Diameter of the fabric. Stitch length Color depth. 39

  40. INTERNY PAPER ON MASCO GROUP Fabric Type Plain Single Jersey GSM 115 135 150 160 Yarn Count 40/1 CB 30/1 CD 28/1 CB 26/1 CD Color Black Anthracite Black Ribbon red Stitch Length M/c dia x gauge Finished Width 2.54 30 x 28 2.68 36 x 24 2.75 36 x 24 2.7 30 x 24 33" Tube 72" Open 74" Open 62" Open Lycra Single Jersey H.F.L-190 F.F.L-250 190 32/1+20DL 30/1CB+40DL 32/1+20DL Wash Black Wash 2.85 2.98 2.85 30 x 28 30 x 28 30 x 28 64" Open 64" Open 64" Open 160/65 210/20 210/20 220 220 215/20 32/1CD 22/1CD 22/1CD 22/1CD 22/1CD 24/1CB Blue White White White White Light 2.7 2.72 2.75 2.75 2.75 2.64 30 x 24 28 x 24 25 x 24 24 x 24 25 x 24 32 x 24 43" Tube 76" Open 35.5" Tube 66" Open 66" Open 46" Tube Single Lacost Lycra S/Lacost 210 28/1+40DL Average 2.85 26 x 24 66" Open 160/65 160/65 160/65 160/65 30/1CD 30/1CD 32/1CD 32/1CD White White Blue White 2.65 2.65 2.58 2.52 30 x 24 28 x 24 30 x 24 30 x 24 43" Tube 41" Tube 43" Tube 43" Tube Double Lacost 175 200 200 200 200 200 220 34/1 CB 30/1 CB 30/1 CB 30/1 CB 32/1 CB 28/1 CB 28/1 CB Light 2.54 2.52 2.64 2.54 2.54 2.58 2.52 40 x 18 38 x 18 38 x 18 38 x 18 38 x 20 38 x 18 36 x 18 37" Tube 74" Open 37" Tube 68" Open 41" Tube 74" Open 68" Open Light Violet Medium Light Black White Red/Green 1x1 Rib 1x1 Lycra Rib 280 380 28/1CB+70DL 34/2CB+70DL Average Average 2.85 3.1 34 x 18 36 x 16 32" Tube 34" Tube 2x2 Rib 300 380 24/1 CB 20/1 CB Average Average 3.3 3.42 40 x 18 40 x 18 24" Tube 24" Tube 2x2 Lycra Rib 340 24/1CB+70DL Average 3.45 36 x 18 22" Tube Pique 220 20/1CD Average 2.78 26 x 24 37" Tube Fleece 260 280 270 300 30/1CD+75DP+26/2CB 34/1GM+75DP+20/2CB 32/1CD+12/1CD 32/1CD+12/1CD Medium Anthalatic Grey Dark Dark P-4,B-3,L-1.5 P-3.5,B-3.25,L-1.6 P-4.3,B-3.3,L-1.6 P-4.1,B-3.3,L-1.6 30 x 20 30 x 20 30 x 20 30 x 20 68" Open 68" Open 74" Open 74" Open B/B B/B Lycra Fleece 260 260 30/1CD+70DP+26/1CB+20DL 30/1CD+75DP+26/1CB+20DL Medium Dark P-4,B-3.1,L-1.5 P-4,B-3,L-1.5 30 x 20 30 x 20 68" Open 64" Open Engineering 165 26/1Dyed Wash 2.75 30 x 24 64" Open Stripe(S/j) 190 Wash 3 36 x 24 76" Open 200 Wash 2.85 30 x 24 64" Open 40

  41. INTERNY PAPER ON MASCO GROUP END PRODUCTS OF CIRCULAR KNITTING MACHINE: Single Jersey M/C: a) S/J Plain b) Single lacoste c) Double lacoste d) Single pique e) Double pique f) Terry Rib M/C: a) 1*1 Rib fabric b) 2*2 Rib fabric END PRODUCTS OF FLAT BED KNITTING MACHINE: a) Collar b) Cuff c) Emboss PRODUCTION CALCULATION: A. Production/shift in kg at 100% efficiency    RPM No . of Feeder 3527 No . of Needle SL ( mm )   . 80 Yarn count B. Production/shift in meter Course / min cm .  Course /   cm   RPM No . of Feeder 60  12 Efficiency  Course / 100 C. Fabric width in meter: Total no . cm of wales   Wales / 100 Needles Total no . of used in knitting   Wales / cm 100 41

  42. INTERNY PAPER ON MASCO GROUP PRODUCTION PARAMETER: 1. Machine Diameter 2. Machine rpm (revolution per minute) 3. No. of feeds or feeders in use 4. Machine Gauge 5. Count of yarn 6. Required time (M/C running time) 7. Machine running efficiency SAMPLE OF VARIOUS TYPE OF KNITTED FABRIC: Fabric Type Sample Single jersey Lycra Single jersey Single Lacost Double Lacost 42

  43. INTERNY PAPER ON MASCO GROUP Fleece Grey Mellange (1*1) Rib (2*2) Rib Lycra Rib Stripe Single jersey 43

  44. INTERNY PAPER ON MASCO GROUP FAULTS, CAUSES & THEIR REMEDIES IN KNITTING: 1. Hole Mark Causes:  Holes are the results of yarn breakage or yarn cracks.  During loop formation the yarn breaks in the rejoin of the needle hook.  If the yarn count is not correct on regarding structure, gauge, course and density.  Badly knot or splicing.  Yarn feeder badly set. Remedies:  Yarn strength must be sufficient to withstand the stretch as well as uniform.  Use proper count of yarn.  Correctly set of yarn feeder.  Knot should be given properly. 2. Needle Mark Causes:  When a needle breaks down then needle mark comes along the fabrics.  If a needle or needle hook is slightly bends then needle mark comes on the fabrics. Remedies:  Needle should be straight as well as from broken latch. 3. Sinker Mark Causes:  When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker mark comes.  If sinker head bend then sinker mark comes. Remedies:  Sinker should be changed. 4. Star Causes:  Yarn tension variation during production.  Buckling of the needle latch.  Low G.S.M fabric production. Remedies: 44

  45. INTERNY PAPER ON MASCO GROUP  Maintain same Yarn tension during production.  Use good conditioned needles. 5. Drop Stitches Causes:  Defective needle.  If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.  Take-down mechanism too loose.  Insufficient yarn tension.  Badly set yarn feeder. Remedies:  Needle should be straight & well.  Proper feeding of yarn during loop formation.  Correct take up of the fabric & correct fabric tension.  Yarn tension should be properly. 6. Oil stain Causes:  When oil lick through the needle trick then it pass on the fabrics and make a line. Remedies:  Ensure that oil does not pass on the fabrics.  Well maintenance as well as proper oiling. 7. Rust stain Causes:  If any rust on the machine parts. Remedies:  If any rust on the machine parts then clean it.  Proper maintenance as well as proper oiling. 8. Pin hole Causes:  Due to break down or bend of the latch, pin hole may come in the fabric. Remedies:  Change the needle 45

  46. INTERNY PAPER ON MASCO GROUP 9. Grease stain Causes:  Improper greasing  Excess greasing Remedies:  Proper greasing as well as proper maintenance 10. Cloth fall- out Causes:  Cloth fall- out can occur after a drop stitch especially when an empty needle with an empty needle with closed latch runs into the yarn feeder and remove the yarn out of the hook of the following needles. Remedies:  Make sure all the latches of needle are closed with feeding yarn after a drop stitch. 11. Barre: A fault in weft knitted fabric appearing as light or dark course wise (width wise) Stripe. Causes:  This fault comes from yarn fault.  If different micro near value of fiber content in yarn.  Different lusture, dye affinity of fiber content in yarn.  During spinning different similar classes of fiber is mixed specially in carded yarn & these fibers have similar characteristics.  In draw fame different similar classes sliver is mixed and make one sliver. Remedies:  We can use this fabric in white color. 12. Fly dust: Causes:  In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production. 46

  47. INTERNY PAPER ON MASCO GROUP Remedies:  Blowing air for cleaning and different parts after a certain period of time.  By cleaning the floor continuously.  By using ducting system for cleaning too much lint in the floor.  Over all ensure that lint does not attach to the fabric. 13. Yarn contamination Causes:  If yarn contains foreign fiber then it remains in the fabric even after finishing,  If lot, count mixing occurs. Remedies:  By avoiding lot, count mixing.  Fault less spinning. 14. Yarn Faults:  Neps.  Slubs.  Yarn count variations.  Thick/Thin place in yarn.  Hairiness. 47

  48. INTERNY PAPER ON MASCO GROUP DIFFERENT TYPES OF KNITTING FAULTS: Fault Name Sample Hole Pin Hole Slab Yarn contamination Barre mark 48

  49. INTERNY PAPER ON MASCO GROUP Drop Stitch Lycra Out Dust Sport Needle mark Fly 49

  50. INTERNY PAPER ON MASCO GROUP Chapter: 5 LABORATORY 50

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