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Industrial Attachment of aboni textiles ltd

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Industrial Attachment of aboni textiles ltd

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT ABONI TEXTILES LIMITED 1

  2. 2

  3. Chapter - I PROJECT DESCRIPTION 3

  4. ABONI TEXTILES LIMITED TYPE ABONI TEXTILES LTD. is a joint venture knit composite mill with Denmark integrated vertically with knitting & dyeing section set up in the same shed side by side with garments section established in just outside of the shed. lt is equipped with circular and flat knitting dyeing, and finishing. It produces fine quality cotton and blended knit fabrics in a variety of styles. Jerseys, ribs, piques and other single knit textures are all available current production in tabular exceeds 3 tons per day. Fabric weights range from 130 GSM to 260 GSM in styles. Which include jersey, piques, needle out textures and fabrics with Lycra. Aboni Textiles Ltd. lt was established through a technology partnership with TPM of U.K. The Aboni Textiles Ltd. was the most advanced and high-the equipment from the world’s leading manufacturers. These machines have been coupled with the best skilled technological support-expatriate staff and local experts trained at the suppliers plants. Year Of Establishment The Aboni Textiles Ltd. was established on April , 2001. Location Aboni Textiles Ltd. is situated at Tetuljhora Union, Hemayetpur, Savar, Dhaka.. It is located at the southest corner of savar road and about 20 k.m. away from college of Textile Technology, Tejgaon, Dhaka. Address Of Mill Address of Head office Plot# 169-171, 2-B/1, Darus Salam Road, Tetuljhora Union, Mirpur, Dhaka-1216, Hemyaetpur, Bangladesh. Savar, Dhaka. SITE LOCATION OF ABONI TEXTILE LTD. 4

  5. GAVTOLI BUS STAND Aboni Textile Ltd. MIRPUR ROAD HEMAYETPUR DHAKA AMIN BAZAR SAVAR DARUS SALAM ROAD SPONSORS Aboni textiles ltd. is an industry of “Babylon group”. It works in join venture with a company come from Denmark. The Danish company send their Representative in the factory location. PRODUCT MIX Aboni Textiles Ltd. works as per demand order of the Aboni Knitwear Ltd.. Also it produces a fraction of its total production by the order of subcontract of other mill both knitted fabrics & finished fabrics (dyed fabrics) . ANNUAL PRODUCTION CAPACITY The circular knitting m/c’s has able to fulfill the fabric requirement for Aboni Knitwear ltd. The mill works in two shifts- (a) Shift-A & (b) Shift –B. The annual production capacity of grey fabric is about 1300 ton collar & cuff is about 3285000pcs. & finished fabric with dyeing is about 2500 ton . PROJECT COST 5

  6. The project cost of Aboni textiles Ltd. is near about 300 million of Bangladeshi taka DIFFERENT DEPERTMENTS The mill has different departments working in co-ordination with each other under the production manager of dyeing. The Aboni textile mill consists of several depertments.1) The knitting dept.2) Grey inspection dept.3) The dyeing lab4) Dyeing dept.5) Finishing dept.6) Quality assurance dept.7) Maintenance dept.8) Utility dept.9) Store & Inventory dept.& 10) Administration dept. With all these departments working in a sequence from beginning department to end. The garments section also be added by all those section & considered as a potential department of the mill. PHYSICAL INRASTRACTURE The mill is built in such a way that there is possibility for further expansion of the mill. The structure such as mill, office buildings, record rooms, guardrooms & dining room etc. are made of solid hard concrete & brick mtls. . The whole area is surrounded by safety brick wall .The main set up for m/c’s are built of corrugated iron & iron sheet, transparent hard plastics with enough ventilation & scope for passing light & air. REMARKS Aboni Textiles Ltd. is going to prove its own standard about product quality in world market as they know that their reputation depends on its quality. They have applied for ISO9001 to exert its standard .They expect they shall achieve the ISO9001. ABONI TEXTILES LTD. AT A GLANCE 6

  7. Aboni Textiles Limited 1. Name of the project : Aboni Textiles Limited . 2. Project Proponent : Babylon Group of Companies. 3. Location : Tetuljhara Union, Hemayetpur Savar,Dhaka About 2o kms west of Dhaka City and 5 km from Savar. 4. Communication : The project is easily accessible by road. 5. Product Name : Knitted, bleached and dyed fabric. 6. Plant Capacity : 2500 ton. 7. Factory Area : Approx. 25000 sq. feet 8. Major Chemicals Used : Various Chemicals including dyes, hydrogen peroxide. Sodium, Hydroxide etc. 9. Type of the factory : Vertically integrated. 10. No. of employees : Approx. 200 7

  8. Chapter - II MANPOWER MANAGEMENT ORGANOGRAM: NESAR AHMED (MANGING DIRECTOR) 8

  9. JESPER GROS (FACTORY MANAGER) KAMAL UDDIN AHMED (EXECUTIVE DIRECTOR) MR. HUMAYAN MANAGER (MARKETING) ARUN KUMAR MONDAL MANAGER (PRODUCTION) SENIOR MERCHANDISER G.M. REZAUL HAQUE DEPUTY MANAGER (KNITTING) SYED MD. AZIZUR RAHMANM DEPUTY MANAGER (DYEING) JUNIOR MERCHANDISER Md. MAHBUBUL ALAM (LAB IN CHARGE) SUPERVISER PRODUCTION OFFICER (DYEING) Organ gram of maintenance: 1. Maintenance manager 2. Forman 9

  10. Organ gram of administration section: 1) Admin officer. 2) Account officer 3) Account officer Organ gram of store: 1. Store in-charge. 2. Asst. Store in-charge SHIFT CHANGE: The mill is running on two shift a) Day shift (8 a.m. to 8 p.m.) b) Night shift (8 p.m. to 8a.m) Besides the general shift is also available there which duration is 8 p.m. to 6 p.m through the whole week. RESPONSIBILITIES OF PRODUCTION OFFICER: - To ensure the production process control. - To check the production sequence. - To assure the quality. - To control the worker. 10

  11. Chapter - III MACHINE DESCRIPTION NO. OF MACHINE Circular knitting m/c = 11 Flat knitting m/c = 9 11

  12. Dyeing m/c = 6 (with sample dyeing m/c) Squeezing m/c = 1 Dryer = 1 Calendering & Compacting m/c = 1 Cloth inspection m/c = 5 BRAND NAME Type of m/c Brand Name Orgin Total no. m/c of Circular knitting m/c Circular knitting m/c Flat knitting m/c Dyeing m/c Dyeing m/c Dyeing m/c Squeezing m/c Drying m/c Calendering & Compacting m/c Cloth Inspection m/c 8 Mayer & Cie Germany 3 Fukahama Taiwan Kauo Heng Co. Ltd. Sclavos 9 Taiwan 4 Greece 1 Longclose England 1 Dilmenler Turkey 1 Santa stress Switzerland 1 Santa shrink Switzerland 1 Santex.Group.com Switzerland 5 UZU Thailand 12

  13. LAYOUT OF KNITTING SECTION W S N E 11 10 9 8 7 6 1 5 2 3 4 SPECIFICATION OF CIRCULAR KNITTING M/C S/l no. of m/c 1 2 3 4 5 6 7 8 9 10 11 FUKA Mayer Mayer Mayer Mayer Mayer Mayer Mayer Mayer FUKA FUKA- 13

  14. - & Cie & Cie & Cie & Cie & Cie & Cie & Cie & Cie - HAMA Brand HAM A HAM A SHBI R-2 FV 2.0 RELA -NIT 3.2 II MVA- 3.2 RELA -NIT 3.2 II MVA- 3.2 MVA- 3.2 RELA -NIT 3.2 II OV- 3.2QC SH- IAG24 SH- IAG24 Type 18 18 24 24 24 24 24 24 24 24 18 Gauge Cyl. Dia. 38” 34” 30” 24” 26” 20” 24” 30” 30” 34” 36” 76 72 96 78 84 63 78 96 96 96 76 Feeder 2x214 9 2X192 0 2268 1800 1944 1512 1800 2268 2x226 8 2X256 4 2x2036 Needle Drving Power Motor Work- ing Volt. Freq- uency 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 4 K/W 415 VOLT 415 VOLT 415 VOLT 415 VOLT 415 VOLT 415 VOLT 415 VOLT 415 VOLT 415 VOLT 415 VOLT 415 VOLT 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. 50 Hz. Nomi- nal Speed Air Conn- ection Year 33 33 33 33 33 33 33 33 35 33 35 M/MI N M/MI N M/MI N M/MI N M/MI N M/MI N M/MI N M/MI N M/MI N M/MI N M/MIN 6 6 6 6 6 6 6 6 6 6 6 BAR BAR BAR BAR BAR BAR BAR BAR BAR BAR BAR 2003 2001 2001 2001 2001 2001 2001 2001 2001 2003 2003 M/C Type Rib Rib S/J S/J S/J S/J S/J S/J Inter- lock Inter- lock Rib CIRCULAR KNITTING MACHINE: 14

  15. Circular Machine is widely used throughout the knitting industry to produce fabric. This machine can be built in almost any reasonable diameter and the small diameter of unto 5 which are used for wear. M/C’s for outerwear and under wear may vary from 12” to 60” in diameter according to requirement. This m/c. can be used either as fabric or for making Garments section completely with fancy stitch. Latch needles are commonly employed in all modern circular m/c. Because of their simple action and also their ability to process various types of yarn. Plain circular m/c. uses only one sets of needles, circular Rib m/c uses two sets of needle i.e. cylinder needle and dial needle, the inter lock circular knitting m/c also uses two sets of needle by needles are long and short respectively for both dial and cylinder, that is why multiple design and thick fabric can be produce with that m/c. that m/c is also called double jersey m/c. Some Terms of Knitting M/C M/c Gauge - needle/inch (Varies according to diameter) Needle Type - Latch Needle bed type - single cylinder, double cylinder, Cylinder and dial, long short needles far cylinder and long short needle for dial. Two principle operations exist: - English system- where the cams and yarns stands revolve by needle and fabric take down is stationary. American system- where the needles & fabric take down revolves by cams and yarn stands are stationary. #Main Parts Of Knitting M/C 1) Latch needle 15

  16. 2) Cylinder 3) Dial (In case of double jersey m/c) 4) Cylinder driving gear. 5) Sinker 6) Sinker operating cam. 7) Cam box for needle. 8) Cam plate for needle. 9) Take up roller. 10) Stop motion. 11) Yarn feeding guide. 12) Tension adjustable screw. 11) Cone strand. 12) Positive feed system. 13) Tension pulley. # Important Parts Of Machine: Name of parts MPF Magnet/Air Nozzle Knot Catcher Function To deliver the yarn in proper place To hold knot, slub and after holding stop the machine To pass the yarn smoothly To clean dust To detect the needle from break To flow oil into needle, sinker To pass oil To flow air into needle, sinker To pass air To detect the fabric fault To start or off the m/c To visualize the fabric while take off Eye pot Hose pipe Needle fault detector Oil Nozzle Oil Pipe Air flashing Nozzle Air flashing pipe Fabric detector Main Switch Take down light Important Equipment Of Circular Knitting Machine: 1. START / STOP / INCH BUTTONS: 16

  17. Complete set of easily accessible START / STOP / INCH buttons at top lf each leg. 2. RATCHET LEVER: Permits hand movement of the machine. 3. AUTO-STOP MOTIONS: Automatic three (3) stage 24v. Yarn motion, positive feed tapes and knitting zone. Indicator lamps are on individual stop motions and on the main control panel. While the yarn is broken or too tight that we can find the location, which is broken as wall as to repair, meanwhile the motor can break and stop operation at once to keep the security of machine. 4. FREE STANDING SIDE CREEL: With an active and reserve package for each feed. 5. AUTO-COUNTER: Three- (3) shifts revolution with digital display counter with predetermined stop, to settle freely the weight or yard of fabrics. 6. VARIABLE SPEED DRIVE WITH MACHINE BRAKE: Transistor inverter provided for free controlled, the process of “V.S. MOTOR- DRIVE” from slow operation to normal operation is quite and fast brake to prevent damages in case of needles or yarn breakage. 7. FABRIC TAKE-UP SYSTEM: With variable speed control by a belt drive set can be adjusted the speed for different course of fabric-constant and uniform fabric tension. 8. SAFELY GUARD SWITCH: Machine cannot be started or run with guards open, this guard have reinforced fiberglass window for easy fabric inspection. 9. AUTO-LUBRICATION: The automatic central pressurized oil sprayer can be adjusted at cycling time and quantity to make cylinder, dial, sinker ring’s cams, needles and sinkers lubricated enough, besides it has the function cooling and clearing and clearing. 10. AUTO-LINE REMOVAL SYSTEMS: 17

  18. Three fans on each rotating arm for clearing off any dust of creel and knitting zone. LAYOUT OF FLAT KNITTING SECTION 9 7 5 1 3 8 6 2 4 FLAT KNITTING MACHINE: 18

  19. Flat m/C’s are the most important industrial knitting m/C’s. The needles are mounted in beds opposite in an inverted V. formation, are operated by cams in a reciprocating carriage. Two sets of needles normally position at right angle to cach other, Latch needles are Commonly used. Because of the almost unlimited popular in western countries. Their main disadvantages low productivity compare to other weft Knitting m/c. SPECIFICATION OF FLAT KNITTING M/C # Brand name: - KAUO HENG KH-313 # Model: - KH-313 # Gauge: - 14G # Knitting Width: - 54” # Knitting Speed: - 1.2 m/sec (Varies according to gauge & knitting speed.) # Yarn Carrier: - 12 Yarn. Carries on 3 double rails. # Cam System: - Single system (Tuck on front bed & near bed. High butt & Low butt system.) # Stitch Density: - Electrical control with stopping motion 00-99 levels. # Racking: - 6 levels to left on right each per time. # Fabric Take Down: - Compound main roller, torque motor control, high Speed & low speed adjustable. # Stop motion: - Yarn break, knot, needle break, shock, and fabric drop out, wrap Around check, price count, motor overload etc. # Drive: - Timing belt, no oil speed programming speed. # Top Tension: - Electronic top tension, easy to thread the yarn through. # Operation Lamp: - Green-Normal operation. Yellow- Abnormal stop. # Power: -220v, 1/3 HP motor. # Control System: - Computer controlling system & L.C.D display. # Wooden Case: - 2250X700X1790 mm.; N/G weight 550-1700 kgs. 19

  20. Chapter - IV RAW MATERIALS TYPES 20

  21. Yarn Types Composition % Count Dyed / Undyed Undyed Cotton 100% 24,26,30,34,40 Ne (Both card & comb) 26, 28 Ne. Polyester Cotton (PC) P-65%, C-35% Undyed Grey mélange 100% 24 ,26 Ne Dyed Lycra (Spandex) 100% 40, 20 Denier Undyed YARN SOURCE Yarn Types Source Price Prime Spinning Mills. Youth Spinning Mills. Utah Spinning Mills. Square Spinning Mills. Hanif Spinning Mills. India Combed- 3$(approx.) Carded- 2.85$(approx.) Cotton 2.16$(approx.) Polyester Cotton Shamim Spinning Mills. 2.75$(approx.) Grey Mélange Local Market (Made In Korea) 900 tk./kg Lycra (Spandex) 21

  22. ANNUALYARN REQUIREMENTS Monthly yarn consumption is approximately 225 ton/month. So the annual requirement of yarn is approximately 2700 ton/month. REMARKS As the yarn consumption totally depends on production & production depends on order of buyer, so recommendation of yarn type, source, price, reuirements may vary 22

  23. Chapter - V PRODUCTION PLANNING, SEQUENCE &OPERATIONS 23

  24. PROCESS FLOW CHART OF ABONI TEXTILES LTD. Yarn in cone form Feeding the yarn cone in the creel Feeding the yarn in the feeder via trip-tap positive feeding arrangement and tension devidce Knitting With draw the rolled fabric & weighting Numbering Grey inspection Dyeing & Finishing Final inspection Packing Delivery 24

  25. PROCESS DEFINITION Knitting is the interlocking of one or more yarns through a series of loops. The length wise columns of stitches, corresponding to the warp in woven cloth, are called WALES; the cross wise rows of stitches, corresponding to the filling in woven cloth, are known as COURSES, FILLING KNITS (WEFT KNITS) are those fabrics in which the courses are composed of a single strand of yarn, while warp knits are those in which the Wales are composed of single strands of yarn. GAUGE Corresponds to the yarn count in a woven fabric, and is defined as the number of needles or yarns in ½ inches of cloth. The higher the gauge, the more compact and finer the cloth. PROCESS REQUIREMENTS In Aboni Textiles Ltd. 3 types of machines are used for producing knitted fabric. These are: - 1. Circular knitting Machine (Single Jersey Machines) 2. Circular knitting Machine (Double Jersey Machine) 3. Flat knitting Machine. CONSIDERABLE POINTS TO PRODUCE KNITTED FABRIC. 1. G.S.M. It is technical term that indicates the weight of the fabric per square meter. 2. CHANGING OF G.S.M: (I) (ii) Major control by quality pulley. Minor control by stitch length adjustment. 25

  26. Altering the position of the tension pulley changes the G.S.M. of the fabric. If pulley moves towards the positive directive then the G.S.M. is decrease. And in the reverse direction G.S.M will increase. 3. POINTS THAT SHOULD CONSIDER IN CASE OF G.S.M. CHANGING: 1. Tension pulley 2. Cam position 3. Take up motion 4. FACTORS THAT SHOULD BE CHANGE IN CASE OF FABRIC DESIGN ON QUALITY CHANGE: 1. Cam setting 2. Tension pulley 3. Set of needle 4. Size of the loop shape 5. RECOMMENDABLE POINTS OF A BUYER: 1. Diameter of the fabric 2. Design of the fabric 3. G.S.M. of the fabric 4. Total weight of the fabric 5. Yarn count 6. Types of yarn (combed or carded) 7. Color of the fabric. PRODUCTION CALCULATION: 1. Production /kg/shift at 100% efficiency: =RPM of m/c X NO. of Needle X no of feeder X SL(mm) X60X8 10X2.54X36X840X2.2046XYarn Count 2. Production in Length/Shift in meter: 26

  27. =No. of Course Course/cm =M/C RPM XNO of Feeder X60X8 X Efficiency Course/cmX100 3. Fabrics width in meter: =Total no of wales Wales/cm X100 =Total no of needles Knitting wales/cmX100 R.P.M. USED IN CIRCULAR KNITTING MACHINE: M/C Type 24G S/J 24G S/J 24G S/J 24 G S/J 24G S/J 24G S/J 18 G Rib 18G Rib 18 G Rib 24 G Int 24 G Int R.P.M. Use 30 37 39 48 48 41 20 21 20 30 30 27

  28. RELATION AMONG YARN COUNT, GAUGE, S.L., GREY GSM, FINISHED GSM & M/C DIA. (ACCORDING TO EXPERMENT): M/C No. 1 M/C GAUGE 18 G Fabric Type 1x1 Rib Yarn count. 30/1 CC Grey GSM 147-148 S.L. (mm) 2.74 Finished G.S.M 200 Grey Dia 45" M/C Dia. 38" 2 18 G 1x1 Rib 26/1 CC 170-172 2.74 200 42" 34" 3 24 G S/J- Lycra S/J 30/1 CC ______ 2.80 220-230 35" 30" 4 24 G 26/1 CC 126-127 2.90 160 30" 24" 5 24 G P.PK 26/1GM 160-165 2.65 205-210 32" 26" 6 24G S/J 24/1 KC 140-142 2.86 180 26" 20" 7 24 G S/J 26/1 CC 126-127 2.90 160 30" 24" 8 24 G Double Lacoste P/Int 26/1 PC 158-160 2.80 200 56" 30" 9 24 G 40/1CC 145 1.65 190 30" 30" 10 24 G P/Int 34/1 CC 162 1.70 220 34" 34" 11 18 G 1x1 Rib 26/1 CC 168 2.74 240 44" 36" 28

  29. FLAT KNITTING PROCESS DEFINATION Flat m/C’s are the most important industrial knitting m/C’s. The needles are mounted in beds opposite in an inverted V. formation, are operated by cams in a reciprocating carriage. Two sets of needles normally position at right angle to cach other, Latch needles are Commonly used. Because of the almost unlimited popular in western countries. Their main disadvantages low productivity compare to other weft Knitting m/c. OPERATION PROCEDURE OF FLAT MACHINES: To start operation, depress a green button provided at the letf- hand side of the machine. If either of the red buttons fitted at the right and left sides of the machine is pushed, the machine will stop. For manual operaion, first push a black clutch button at the right hand lower part of the machine to disconnect the clutch. Next, push away and turn right manual operation handle. To reconnect the clutch for automatic operation, pull the manual operation handle. The clutch lever is of 2-step type. When it is set to the 1ststep, changeover drum will turn lightly, When performing link fitting to the drum or reknitting, the lever should be set at this position. the clutch is connected when the clutch lever is raised to the 2ndstep. Note : Before raising the clutch lever don’s fail to push the START switch ( green button). The clutch lever would not be raised unlelss motor is on operation. Forecible raising of the leer will cause machine trouble on speed change mechanism 29

  30. PROGRAM SET ON M/C TO PRODUCE PLAIN COLLAR 001 3 000 1 45 45 7 _1_ 000__000__ 000 1 002 0 000 0 45 45 7 _1_ 000__000__ 000 1 003 0 000 1 45 00 7 _1_ 000__000__ 000 0 004 3 000 1 45 45 7 _0_ 001__003__ 004 1 005 0 000 1 45 45 8 _1_ 000__000__ 000 1 006 0 000 1 45 00 8 _1_ 000__000__ 000 1 007 0 000 1 00 45 0 _0_ 000__000__ 000 0 008 0 000 1 00 45 0 _0_ 000__000__ 000 0 009 1 000 1 22 22 9 _1_ 000__000__ 000 1 010 2 000 0 60 00 9 _1_ 000__000__ 000 0 011 0 000 0 00 65 9 _0_ 000__000__ 000 1 30

  31. 012 0 000 0 60 00 9 _1_ 004__011__ 012 0 013 0 000 0 45 45 7 _1_ 000__000__ 000 1 014 3 000 2 45 45 7 _1_ 045__000__ 000 1 31

  32. FABRIC ANALYSIS: 1)FABRIC NAME : POLO PIQUE (P.PK) S W A TC H  NOTATION DIAGRAM: ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙  CAM ARRANGEMENT ^ ∏ ^ ∏ NEEDLE REPEAT 1 ^ ∏ ^ ∏ ∏ ^ ∏ ^ ∏ ^ ∏ ^ 2 3 4 LEGENDS: 1 = 1 Butt Needle 2 = 2 Butt Needle 3 = 3 Butt Needle 4 = 4 Butt Needle ^ = Knit cam ∏ = Tuck cam 32

  33. 2)FABRIC NAME : DOUBLE LACOST S W A TC H  NOTATION DIAGRAM: ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙  CAM ARRANGEMENT ^ ^ ^ ^ ∏ ∏ ^ ^ ^ ^ ∏ ∏ NEEDLE REPEAT ^ ^ ^ ^ ∏ ^ ∏ ^ ∏ ^ ∏ ^ 1 2 3 4 33

  34. 3)FABRIC NAME : (1X1) RIB S W A TC H  NOTATION DIAGRAM: ∙ ∙ ∙ ∙ . ∙ ∙ ∙ ∙  CAM ARRANGEMENT NEEDLE REPEAT For dial: ^ ^ ─ ─ 1 2 For cylinder : ^ ^ ─ ─ 1 2 34

  35. 3)FABRIC NAME : (2X2) RIB S W A TC H  NOTATION DIAGRAM: ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ .  CAM ARRANGEMENT NEEDLE REPEAT For dial: ^ ^ ─ ─ 1 2 For cylinder: 1 ^ ^ ─ ─ 2 35

  36. 4)FABRIC NAME : SINGLE JERSY S W A TC H  NOTATION DIAGRAM: ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ . CAM ARRANGEMENT NEEDLE REPEAT 1 ^ ^ ^ ^ ^ ^ ^ ^ 2 3 4 36

  37. 5)FABRIC NAME : (1X1) INTERLOCK S W A TC H  NOTATION DIAGRAM: ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙  CAM ARRANGEMENT NEEDLE REPEAT For dial: 1 ^ ─ ─ ^ 2 For cylinder: 2 ─ ^ ^ ─ 1 37

  38. Chapter - VI QUALITY ASSURENCE SYSTEM 38

  39. QUALITY ASSURANCE PROCEDURE #1)Body & Rib Inspection: All rolls are kept in front of the inspection m/c time to time and are inspected over the greige inspection m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, slubs etc are recorded in greige inspection report to classify the fabric based on the four point system. #2)Collar & Cuff Inspection : Collar& cuff are inspected visually under the light box, any major or minor faulty collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly counted and recorded. #3)Fabric Roll Identification: Based on the sequence of greige inspection, the inspector serially numbers each roll ensuring that all rolls having the knit card with complete details of the roll. PROCESS REQUIREMENT #Cloth Inspection M/C: Name of the m/c: UZU M/c for Garment Model : UZ 900.31 Voltage : 220v Freq.-50/60 Hz. Current : 3 amp. Orgin : Thailand. Serial : 0092522 Date : 01/11/2001 #Key Accessories : Key accessories used for greige inspection process are:-  Cutter/scissor  Nipper  Pointer  Weighting balance  Inch tape. 39

  40. QUALITY STANDARD Aboni Textile Ltd. maintains the ISO standard in case of quality. Therefore, the four point system is followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by greige inspection at Aboni. Four point grading system Size of defects 3 inches or less Over 3 inch but not over 6 inch Over 6 inch but not over 9 inch Over 9 inch Penalty 1 point 2 point 3 point 4 point Following table shows common body and rib faults and response by greige inspection section at Aboni Textile Ltd.:- Rejection criteria for body & ribs Faults Needle mark Stripe Barre mark Contamination & fly No. Response 1. 2. 3. 4. Major needle line is rejected Major needle line is rejected Rejected Approved for color but for white shed 1 point is assigned 1 point Reject 1 point 1 point Reject Discuss with manager Major sinker mark is rejected. Use 4 point Do Do Do Do Do Discuss with manager 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Slubs Thick thin place Birds eye Pin holes Wrong design Mixed yarn Sinker mark Missing yarn Holes Oil line/stain Chemical Dirt stain Crease line Uneven tension 40

  41. Following table shows common collar and cuff fault and response taken by greige inspection section at Aboni Textile Ltd.:- Rejection criteria for collar & cuff Faults 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 No. Response 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Reject Reject Reject Reject Reject Reject Acceptable for color but not for white Reject Discuss with manager Reject Reject Reject Reject Reject Reject Following theory is used to calculation of Acceptance Quality Level: A.Q.L= Points Counted X 36" X 100 Roll Length X Fabric Width Following table shows the acceptance calculation followed by the greige inspection section at Aboni Textile Ltd.:- Acceptance calculation Factory: Roll yardage (A) Total points founds(B) Formula :B AX100 =points per 100 yard Classification : <= 40 points = A type 41-60 61-80 above 80poin = Reject = B type = C type 41

  42. RESPONSE OF Q.C OFFICER Response To Q.C Faults :- Faults Yarn fault Knit fault Response Inform yarn supplier Inform knitting department Response To Machine Fault :- Faults Response Any electrical fault Any mechanical fault Inform electrical maintenance Inform mechanical maintenance 42

  43. Chapter - VII MAINTENANCE 43

  44. MAINTENANCE: It is required for proper functioning of knitting machines. TYPES OF MAINTENANCE: 1. Routine maintenance. 2. Unscheduled major maintenance. 3. Scheduled minor maintenance. (1) Routine maintenance:  During this maintenance production should be off.  During this maintenance cleaning should be done  During this maintenance setting should be checked & adjusted if necessary.  During this maintenance oiling should be done  It takes approximately 5-6 hrs. (2) Unscheduled major maintenance:  It is done suddenly.  During this maintenance production should be temporary off.  It takes one day (minm) but it depends on availability of parts. (3) Scheduled minor maintenance:  During this maintenance production should be temporary off  It takes half a day. (4) Preventive maintenance:  It is done regularly.  During this maintenance production should be temporary off.  It is one kind of rectifying system.. 44

  45. MAINTENANCE PROCEDURE: 1. Cleaning procedure of the machine: Machine generally cleaned during running by the operator. He uses the air gun to remove dust, hairy fiber, and other foreign matter deposited on the machine. Major cleaning operation is done when machine breaks down. i. Type of cleaning:  Manual cleaning by compressed air with the air gun. ii. Cleaning points:  Needle  Sinker  Creel tube  Feeder  Yarn  Body of the machine iii. Cleaning frequency:  Daily per shift 2. Oiling procedure of the machine: Nowadays all knitting machinery has automation. Lubricating system in the machine is automatic. When machine’s different zone feels the requirement of oil then oil circulates to that zone in correct proportion from the oil tank by pumping. Operator just check the oil tank either it is full or empty. When the tank is going to be empty then operator fill the oil tank by the recommanded oil. If the machine were inactive in auto lubrication then there is a push button, which circulates oil to different zone. i. Type of oil:  Gear oil 630 (Mobil)  Textile oil light (Mobil) 45

  46. ii. Type of grease:  EP3  XHP – 222 iii. Name of the greasing points:  Dial gear  Cylinder gear  Roller gear  Chain  Sprocket iv. Greasing frequency:  Not frequently used. v. Name of the oiling points:  Needle butt  Cam  Trick  Sinker vi. Oiling frequency:  Daily per shift in running machine  Changing of gear oil in dial after 2000 hours. 46

  47. 3. Setting points and their effect of changing: Setting points  Quality adjustment pulley (QAP)  Gauge meter Effects  Yarn tension & stitch length  Cylinder movement (Up & Down),  Control yarn tension and stitch length.  Cam box movement (Up & Down),  Control yarn tension and stitch length.  Grey fabric diameter control,  Stitch length control  In clockwise rotation of button fabric takedown tension increases & vice-versa  Selection of rib or interlock gaiting  Fabric takedown tension control  Tension bolt on cam box  Spreader bar  Fabric takedown tension pulley  Centering bolt  Takedown roller/change wheel 4. Maintenance schedule of the machine:  Use 15-20 drops of oil per day in each machine dial.  Give needle oil daily while the machine is running.  Further oil change will be carried out after every 3 months.  Grease to be given to all movable parts. 5-6 drops oil to be given in handle of bearing. Additionally it is necessary to clean the ball bearings of the electric motor after2000 running hours and to refill them with grease. 5. Preventive maintenance of the machine:  All persons do the maintenance work in the knitting machine should have adequate knowledge about maintenance of knitting machine.  They will cutoff the electric line, airline, and make them safe before maintenance of machine.  Checked that auto circuit breakers are fitted in the machine.  Use dust mask.  Keep all fire fighting equipment, first aid box ready. Routine maintenance: 6.  In this factory having no routine maintenance of machinery. But generally each three months maintenance is done for each machine randomly. Besides when 47

  48. any machine doesn’t run properly then call the maintenance stuffs from the maintenance department. They will solve the problem either mechanical or electrical. MANPOWER SETUP FOR MAINTENANCE:  Generally 1 or 2 persons from maintenance department come to solve the problem of a single machine. MAINTENANCE OPREATION:  Any problem of machinery in the knitting department shall report to knitting section and maintenance department.  Knitting technician and maintenance assigned person will thoroughly investigate the problem. Find out the causes of problem determines the degree of service requires. Estimate spare requirement place requisition for spare to the store and service the machinery to bring it back to running condition.  All breaks down maintenance works will be recorded in the breakdown maintenance register. SERVICING OF CIRCULAR KNITTING MACHINE: When a machine is selected for production after a long time break then servicing of that machine is being essential. Besides due to long running machine sometimes jammed. So it is required to clean that machine thoroughly. No machine is kept under rest after servicing. At the start of servicing the machine is run for 30 minutes in empty condition with adding oil. In this time the feeder, holder is parted then they are cleaned by compressed air. Then cam boxes are separated from the machine. After that sinker and needle are removed from the machine. Cam boxes and sinker cam bed are cleaned by compressed air. After removing needles the tricks are petrol washed then adding lubricant. During petrol wash the maximum dust is cleaned. The remaining dust is removed manually with care. During servicing the damaged needle or sinker are replaced by the new one. 48

  49. MAINTEANANCE TOOLS WITH THEIR FUNCTIONS: Tools & Equipments  Adjustable wrench  Spanner  Star screw driver  Flat screw driver  Hex screw driver  Cutter pliers  Combined Pliers  Lock pliers  Pulley key  Handle  Scissors  Plastic hammer  Iron hammer  Shouldering iron  Allan key  Nut driver Functions  Loosening/tightening bolts  Loosening/tightening bolts  Loosening/tightening star screw  Loosening/tightening flat screw  Loosening/tightening hex screw  Cable cutting  Multi purpose  Lock setting  Loosening/tightening Q. pulley  To run machine manually  Cutting purpose  Thrusting on rubber coated surface  Thrusting on hard surface  Joining circuit  Loosening/tightening Allan nut  Loosening/tightening nut YEARLY PREVENTIVE MAINTENANCE SCHEDULE FOR FLAT KNITTING M/C Frequency: Weekly: - Check each connection of torque control unit. - Check main switch. - Check main switch. Frequency: Monthly: - Check & clean dirt at main motor fan cover. - Check safety measure switch. - Check motor terminal. Frequency: Two months: - Cleaning the all m/c & equipments. - Check on/off switch. - Check all indicator lamps. - Check temperature sensors. 49

  50. Frequency: Six Months: - Check motor v-belt alignment & tension. - Check all feeders & spring. - Check main drive chain alignment & tension. - Lubrication of all chain , gears & moving parts. Frequency: Yearly: - Check belt tension in the main motor tension. - Clean & check bearing in the m/c. - Checking m/c lubricating system. - Greasing of all takedown grease points please. 50

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