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Industrial attachment of epyllion knitex ltd

Presentation about 'Industrial attachment of epyllion knitex ltd'

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Industrial attachment of epyllion knitex ltd

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  1. SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering INDUSTRIAL TRAINING Course Code: Tex -4036 Course Code: Tex -4036 Course Code: Tex -4036 INDUSTRIAL TRAINING INDUSTRIAL TRAINING INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT Epyllion Knitex Ltd Epyllion Knitex Ltd Epyllion Knitex Ltd 1 | P a g e

  2. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering ACKNOWLEDGEMENT A number of people have made significant contributions on preparing this report. Their advice and suggestions helped us a lot. During the attachment with Epyllion Group(Textile Division). We worked in all the departments related with the Wet Processing section. We are not only give priority to the Wet Processing but also worked sincerely in the Knitting Section, Maintenance and Finished Fabric Inspection Section, warehouse & Store & Inventory, finishing & specially dyeing. I would like to pay special thanks to Professor Syed Fakhrul Hassan Chairman, Department of Textile Engineering, Southeast University, for continuously guiding us about the development and preparation of the report. He has enriched me with necessary ideas and concepts for incessant improvement of the report. I would like to express our sincere gratitude to, Managing Director of Epyllion Group who has allowed us to work in his organization. I recognize Mr. Syed Sayeed Munir G.M. Epyllion Fabrics & Knitex Ltd, Mr. Md. Sadrul Amin Bhuiyan AGM Pocurement, Mr. Engr. Rothin Pallab Chakraborty, (DGM, Maintenance), Mr. Khairul Islam (Sr. Manager, Knitting), Mr. Najmul(Asst. Manager, Knitting), Mr. Sumon( Managaer, Dyeing),Mr. M. Aminul Islam GM HR & administration & Mr. M.A Hashem DGM HR, admin & CSR for providing sincere help in all administrative & technical matter while working in the organization. My heart fell thanks to Mr. Hasan and Mr Samsujjan (Executive, Dyeing)Mr. Tanbir (Executive, knitting), Mr. Robiul (Executive. Finishing), Mr. Robiul and Mr. Talha (Executive, Finishing QC) Mr. Sayed (Executive, Lab), We also grateful to all other Sr. Executives & Executives for assisting us to gather information about various processes. However, we have prepared our industrial Training report overcoming all the difficulties & also the shortage of time. Here I would like to present the report. 1 | P a g e

  3. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering SPECIAL THANKS TO & 2 | P a g e

  4. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Location for going to the Epyllion Knitex Ltd and Epyllion fabrics Ltd BANANI GAZIPUR CHOWRASTA RAJANDROPUR CHOWRASTA BANGLABAZAR (EPYLLION FACTORY) 3 | P a g e

  5. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Table of Contents INTRODUCTION ................................................................................................5 PROJECT DESCRIPTION...................................................................................6 INTRODUCTION TO EKL & EFL...................................................................12 KNITTING DEPARTMENT..............................................................................14 QUALITY ASSURANCE SYSTEM.................................................................35 LAB & TESTING DEPARTMENT...................................................................49 DYEING DEPARTMENT OF EKL & EFL......................................................58 FINISHING.........................................................................................................80 STORE & INVENTORY CONTROL ...............................................................91 MAINTENANCE ...............................................................................................95 UTILITYIES.....................................................................................................104 EFFLUENT TREATMENT PLANT ...............................................................112 BUYER COMPLAIANCE...............................................................................122 CONCLUSION.................................................................................................123 4 | P a g e

  6. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering INTRODUCTION By means of practical knowledge it is possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge. The industrial attachment is the process which builds understanding skill and attitude of the performer, which improves his/her knowledge in boosting productivity and services. Academic education provides us vast theoretical knowledge as well as more practical attachment, despite all these industrial attachment help us to be familiar with the technical support of modern machinery, skill ness about various operation stages. It also provides us sufficient practical knowledge about production management, Productivity evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory management, purchasing, utility & maintenance of machinery and their operation techniques etc. The above mentioned cannot 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 & improve courage & inspiration to take self- responsibility. From fiber to fabric, the TEXTILE division of Epyllion group is a truly integrated undertaking. The Textile Division has the capability to offer a complete product range for the export textile markets. The goal of Textile Division is to become the preferred partner for sourcing high quality fabrics and clothing from Bangladesh. With this goal Epyllion Fabrics Ltd. is advancement of this journey. With highly advanced technology and an emphasis on developing local human resources, the Textile Division has the potential to make an important contribution to the nation's growing readymade garments export sector keeping green environment into close consideration.The rationale behind the existing structure and future expansion of the Textile Division is to pure value-added at each stage of the textile manufacturing process. 5 | P a g e

  7. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering PROJECT DESCRIPTION  Company Name:  Epyllion Fabrics Ltd.  Epyllion Knitex Ltd.  Status: Private Ltd. Company  Type: 100% Export oriented composite knit Dyeing Industry.  Product Mix:  100% cotton  100% polyester a) Spun b) Filament  Nylon   Polyester Cotton blend  (15% Viscose 85% cotton 10% Viscose 90% cotton 30% Viscose 70% cotton)  Year of establishment: 2003, Commencement of Production in month 2004.  Address: It is situated in Banglabazar, Joydebpur, Gazipur. Bangladesh. 6 | P a g e

  8. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering  Website: www.epylliongroup.com Vision: To establish as a one stop source for the Global knit Apparel market and to satisfy and meet customer's expectation by developing and providing products and services on time, which offer value in terms of Quality, Price, Safety & Environmental impact. Assuring complete compliance with the international quality standards and also providing the employees internationally acceptable working condition and standards. To promote the development and to use human talent & equal opportunity of employment. They procure the most advanced & sophisticated technology suitable for producing desired product and attain highest level of competence through continuous development of the professional, management system and to ensure complete transparency in an aspects of business. Mission: 'Epyllion realizes the need to stake out a competitive segment in the changing global market of today through technological excellence and human expertise. Epyllion is committed to transpose its local success to the world scene. 7 | P a g e

  9. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering History of project development: Epyllion Group started with first venture DEKKO KNIT WEARS Ltd (DKL) in 1993 with 2 sewing lines and total of 200 work forces at Mirpur area. Now it has 7000 wprk force with 36 sewing lines in several areas of Dhaka and Gazipur. Combining modern technology with skilled manpower under Epyllion's unique inspiring, atmosphere, this new Epypllion venture soon rose to the top of the local textile industry. Today it has one of the most sophisticated vertically integrated set-ups. Concern of Epyllion group:  Textile Industries  Garments Industries  Garments Accessories.  Real Estate. Group Members:  Textile Industries 1. Epyllion Fabrics Ltd. 2. Epyllion Knittex Ltd.  Garments Industries 1. Epyllion Style Ltd. 2. Epyllion Knitwears Ltd. 3. Dekko Knitweaers Ltd. 4. Dekko Knitweaers Ltd. Unit-2 8 | P a g e

  10. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 5. Mirabella Dresses Ltd. 6. Epyllion Jeans Ltd.  Garment accessories 1. Epyllion Limited. 2. Epyllion Washing Ltd.  Real Estate: 1. Nima Holdings Ltd. Other facilities are  Own network Server.  Own power management,  Own utility management.  Transport facilities.  Medical centre.  Fire service facility.  Effluent Treatment Plan. Shiftchange shift is 8 hrs : 6:00 A.M-2:00P.M : 2:00 P.M- 10:00 P.M : 10.00 P.M-6:00 A.M General shift : 9:00 A.M - 5:00 P.M 9 | P a g e

  11. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Product: Single Jersey Heavy Jersey Pique Lacoste Interlock Rib French Terry        Cotton Fleece /Cvc Fleece Flat Knit Auto man Cotton Viscose Polyester Cotton polyester CVC Organic Cotton         Clients: CELLIO G-STAR 10 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  12. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Certificate & Achievement:  BGMEA  BKMEA  BTMA  SEDEX  Oeko-Tex  C&A Best Supplier Award 2004 Capacity:  Production capacity in knitting: 27175 Kg of knitted fabrics per day  Production capacity in knit dyeing: 32500 Kg per day Cost: Investment 500 Core (Approximately) Remarks: Epyllion Fabrics Ltd. is greatest concerned with the quality of its product. Better quality has come buyers to pay more. The infrastructure and land asset has the greatest possibility to extension Contact Information: Corporate Office: Plot # I/1, Road # 06, Section # 07, Mirpur I/A, Dhaka-1216. Bangladesh Tel:+880-2-9006028, 9006747, 8013883, 9013897, Fax # 880-2-9007978, 9016994, Web: www.epylliongroup.com Factory: Banglabazar, Joydebpur, Gazipur. 11 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  13. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering INTRODUCTION TO EKL & EFL Front view of Epyllion Knitex Ltd 12 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  14. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering ORGANOGRAM OF EPYLLION GROUP HR & Administration Operation & Planning Knitting Production Grey Inspection Batch Preparation Wet Processing Dyeing Section Finishing Section Quality Assurance R & D Laboratory Fabric Inspection Maintenance Electrical Mechanical Utility Compressed Air Water Electricity Steam ETP 13 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  15. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering KNITTING DEPARTMENT 14 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  16. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering LAYOUT OF KNITTING DEPARTMENT OF EKL & EFL 15 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  17. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Types of Fabric Produced by EKL & EFL: Epyllion Knitex Ltd. is able to produce high quality circular weft knitted fabric with great flexibility to produce a wide range of fabrics. The main products are : Plain Jersey Polo Pique Single Lacoste /Single tuck back pique Double Lacoste / Double tuck back pique Herringbone Creap Twill pique Lapique Fred Perry Two thread fleece Rib Yarn dyed feeder stripe Waffle Two tone pique Pop Corn Bubble Knit Mini box design fabric Vertical design Drop needle Honey Comb 16 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  18. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering CAPACITY OF KNITTING SECTION: FABRIC TYPE EKL EFL MONTHLY CAPACITY DAILY CAPACITY JERSEY 11 36 16,500 KGS 4,95,000 KGS INTERLOCK 05 05 3,500 KGS 1,05,000 KGS RIB 05 05 3,500 KGS 1,05,000 KGS FLEECE - 10 3,500 KGS 1,05,000 KGS AUTO-STRIPE 01 - 175 KGS 5,250 KGS 27175 KGS 815250 KGS TOTAL 17 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  19. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Knitting machine details of EKL: m/c no m/c type Dia*gauge No of feeder No of needle Brand origin 01 S/J 30*28 90 2580 Orizio paolo Italy 02 S/J 30*28 90 2580 Orizio paolo Italy 03 S/J 30*28 90 2580 Orizio paolo Italy 04 Interlock 30*24 72 2220 Orizio paolo Italy 05 S/J 32*24 90 2412 Well knit China 06 S/J 32*24 90 2412 Well knit China 07 S/J 32*24 96 2412 Well knit China 08 S/J 30*28 90 2580 Orizio paolo Italy 09 S/J 30*28 90 2580 Orizio paolo Italy 10 P/L 30*24 72 2220 Orizio paolo Italy 11 P/L 30*24 72 2220 Orizio paolo Italy 12 P/L 34*24 120 2562 Terrot Germany 13 P/L 34*24 120 2562 Terrot Germany 14 S/J 32*24 96 2410 Terrot Germany 15 S/J 30*28 90 2580 Orizio paolo Italy 16 S/J 30*28 90 2580 Orizio paolo Italy 17 1*1Rib 30*18 60 1680 Orizio paolo Italy 18 1*1Rib 30*18 60 1680 Orizio paolo Italy 19 1*1Rib 30*18 60 1680 Orizio paolo Italy 20 Rib 36*18 64 2040 Terrot Germany 18 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  20. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 21 Rib 36*18 64 2040 Terrot Germany Circular Knitting machine details of EFL: m/c no m/c type Dia*gauge No of feeder No of needle 2640 Brand Origin 01 S/L 30*28 90 Well knit China 02 S/L 30*28 90 2640 Well knit China 03 S/L 30*28 90 2640 Well knit China 04 S/L 30*28 90 2640 Well knit China 05 S/L 30*28 90 2640 Well knit China 06 S/L 30*28 90 2640 Well knit China 07 S/L 30*28 90 2640 Well knit China 08 S/L 30*28 90 2640 Well knit China 09 S/L 30*28 90 2640 Well knit China 10 S/L 30*28 90 2640 Well knit China 11 S/L 30*28 90 2640 Well knit China 12 S/L 30*28 90 2640 Well knit China 13 S/L 30*28 90 2640 Well knit China 14 S/L 30*28 90 2640 Well knit China 15 S/L 30*28 90 2640 Well knit China 16 S/L 30*28 90 2640 Well knit China 17 S/L 30*28 90 2640 Well knit China 18 S/L 30*28 90 2640 Well knit China 19 S/L 30*28 90 2640 Well knit China 20 S/L 30*28 90 2640 Well knit China 21 S/L 30*28 90 2640 Well knit China 22 S/L 30*28 90 2640 Well knit China 23 Rib 30*24 60 2256 Well knit China 24 Rib 30*24 60 2256 Well knit China 19 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  21. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 25 Rib 34*24 68 2544 Well knit China 26 Rib 34*24 68 2544 Well knit China 27 Rib 34*24 68 2544 Well knit China 28 S/L 30*28 90 2640 Well knit China 29 S/L 30*28 90 2640 Well knit China 30 S/L 30*28 90 2640 Well knit China 31 S/L 32*28 96 2812 Well knit China 32 S/L 30*28 90 2640 Well knit China 33 S/L 30*24 90 2640 Well knit China 34 S/L 28*24 84 2112 Well knit China 35 S/L 30*28 90 2640 Well knit China 36 S/L 30*20 90 1896 Well knit China 37 Interlock 36*24 64 2712 Well knit China 38 Interlock 36*24 64 2712 Well knit China 39 Interlock 36*24 64 2712 Well knit China 40 Rib 36*24 64 2712 Well knit China 41 Rib 30*18 54 2256 Well knit China 42 Rib 30*18 54 2256 Well knit China 43 S/J 28*24 84 2112 Well knit China 44 S/J 28*24 84 2112 Well knit China 45 2T Flece 28*24 84 2112 Well knit China 46 3T Flece 30*20 90 1896 Well knit China 47 3T Flece 30*20 90 1896 Well knit China 48 3T Flece 30*20 90 1896 Well knit China 49 3T Flece 30*20 90 1896 Well knit China 50 S/J 30*28 90 2640 Well knit China 51 S/J 30*28 90 2640 Well knit China 52 S/J 30*28 90 2640 Well knit China 53 3T Fleece 30*20 90 1896 Well knit China 20 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  22. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 54 3T Fleece 30*20 90 1896 Well knit China 55 3T Flece 30*20 90 1896 Well knit China 56 3T Flece 30*20 90 1896 Well knit China 57 Rib 32*18 64 2712 SSANGYONG Korea 58 Rib 44*18 88 2812 SSANGYONG Korea Auto striper machine details: m/c no m/c type Dia*gauge No of feeder No of needle Brand origin 01 Auto striper 30*24 48 2268. Mayer & Cie Taiwan 02 Auto striper 30*24 48 2268 Mayer & Cie Taiwan 03 Auto striper 30*24 48 2268 Mayer & Cie Taiwan 04 Auto striper 30*24 48 2268 Mayer & Cie Taiwan 05 Auto striper 30*24 48 2268 Terrot Germany 06 Auto striper 30*24 48 2268 Terrot Germany 07 Auto striper 30*24 48 2268 Terrot Germany 08 Auto striper 30*24 48 2268 Terrot Germany 09 Auto striper 30*24 48 2268 Well knit china 21 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  23. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering RAW MATERIALS: Raw material used in EKL & EFL: SL no. Yarn Type Yam count 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Hi 17 18 19 20 21 22 23 Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Combed Yarn Carded Yarn Carded Yarn Carded Yarn Carded Yarn Carded Yarn Carded Yarn Carded Yarn Carded Yarn Girded Yam 16CC 18CC 20CC 22CC 21CC 26CC 2BCC 30CC 32CC 36CC 36CC 40CC 50CC 60CC 16KC 1SKC 20KC 22KC 21KC 26KC 28KC 30KC 32KC 24 25 26 27 Carded Yarn Carded Yarn Carded Yarn Carded Yarn 34KC 36KC 40KC 50KC 22 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  24. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 28 29 30 31 Carded Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn CVC Yarn G.M. Yarn G.M. Yarn G.M. Yarn 60KC 16CVC 18CVC 20CVC 22CVC 24CVC 26CVC 28CVC 30CVC 32CVC 34CVC 36CVC 40CVC 50CVC 60CVC 20GM 5V 20GM 10V 20GM 1.5V 32 33 34 35 86 37 38 39 40 41 42 43 44 45 Knitted fabrics specifications: Knitting Parameters consists of- 1. G.S.M. 2. Yarn count. 3. Stitch length. 4. Fabric width. 5. Fabric thickness. 23 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  25. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 1. G.S.M: The weight of fabric in gram per square meter is called G.S.M. 2. Yarn count: It is a numerical expression of coarseness or fineness of yarn which can be measured in two systems. One is direct system and another one is indirect system. For direct system: × Count = For Indirect System: × Count = × 3. Stitch length: The length of yarn knitted into one stitch in a weft knitted fabric. Stitch length is theoretically a single length of yarn which includes on needle loop & half the length of yarn (Half a sinker loop) between that needle loop & the adjacent needle loops on either side of it. Generally, the larger the stitch length the more elastic & lighter the fabric, & the poorer its cover capacity & bursting strength. 4. Fabric Width: Along the fabric width there presents the Wales. The total no. of needle is fixed for the same cylinder having the equal gauge as well as diameter. Fabric width = No. of Wales X Wales space. = No. of needle X Wales space. = Πdg X Wales's space. d = Cylinder diameter, 24 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  26. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering g = Gauge. The above concept clarifies that Fabric width closely depends on total no. of needle not directly related to machine diameter machine gauge. 5. Fabric Thickness: In the dry and wet relaxed states fabric thickness (t) is depends upon fabric tightness, but in the fully relaxed state, it is more or less dependent of the fabric tightness factor. In the fully relaxed state t= 4d. Where d is the yarn diameter For single jersey, t = 2d Technical Specification: 1. Machine gauge: No. of needles per inch present in a needle bed of a knitting machine is called machine gauge for that knitting machine. A term giving a notational indication of the no. of needles per unit length along a needle bed or needle bar of a knitting machine in current practice, a common unit length of one English inch (25.4mm) is used for all types of warp and weft knitting machine. Selection of machine gauge depends upon yam diameter. Yam diameter depends upon the following: 1. Yarn count. 2. Yarn type. 25 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  27. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 3. Yarn twist. 4. Yarn finished. Generally practiced in different industries in Bangladesh given below: yarn count used Machine gauge 16 18 18 20 20 20 20 24 24 22 24 24 26 20 26 22 26 24 26 28 28 22 28 25 28 28 30 22 30 24 30 28 30 34 34 28 34 28 26 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  28. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 2. V.D.Q Pulley (Variable Dia Quality): In a knitting m/c to supply the specific length of yarn, there are two or more adjustable pulleys which are known as V.D.Q. Pulley. By adjusting the V.D.Q. pulley we can control the speed of accumulator which supplies the required amount of yarn. V.D.Q. pulley is very important to set up the correct loop length. The amount of yarn wound on accumulator by one revolution of cylinder is called the course length of fabric VDQ Pully Measurement: For Orizio machine, . × VDQ = – 2 For an Exp: S.L = 2.90 No of needle = 2580 27 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  29. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering . × VDQ = -2 = 187-2 = 185 For well knit m/c 140 for S.L 2.62 EXP: For S.L 3.10 2.62----------------140 1 ----------------140/2.62 3.10----------------140*3.10/2.62 =165.65≈166 For Terrot m/c For Mayer m/c for each S.L 0.10 VDQ will increase 1mm. for each S.L 0.10 VDQ will increase 10mm. Some VDQ measurement of Different Brand m/c: NO BRAND 01 Orizio 02 Orizio 03 Orizio 04 Orizio 05 Orizio 06 Well knit 07 Well knit 08 Well knit 09 Terrot 10 Terrot 11 Terrot S.L 2.85 3.10 2.76 2.72 2.10 2.70 2.65 2.74 3.25 2.30 2.70 VDQ 181 197 175 147 118 145 140 149 192 158 144 3. Machine Diameter: Machine diameter is mainly diameter of cylinder. It is important for fabric width. Only diameter does not determine the fabric width. It need helps machine gauge and Wales space which is depend upon yarn count and loop length. 28 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  30. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 4. Needle gauge: Thickness of needle express by the needle gauge. It is important for selection of machine gauge. Needle gauge is different for the different gauge and different Brand. Some needle gauges found in industries are given below: Machine gauge Needle thickness in mm 24 0.52 28 0.41 PRODUCTION PLANNING, SEQUENCE AND OPERATIONS Production Equipment EPYLLION FABRICS LTD (EFL) & EPYLLION KNITEX LTD are capable to knit Weft Knitted fabrics only. Machine description is given before. Quality Control Equipment Following equipment are used to ensure proper quality of the produced fabric:  Starfish Computer Programme  Yarn Tension Metre  Stitch Length Metre  Magnifying glass (to check Wales or Course/Unit)  GSM Cutter etc. Key Accessories: Key accessories used for circular knitting process are: 29 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  31. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering  Needle: The commonly used needle types are Vo 154.41 G001-4, Vo 154.50 G001-4, VoTA 60.58 G01, and Vo 92.62 G01.  CAM : KNIT, TUCK and MISS  Sinker: Commonly used types are 0.250 mm and 0.200 mm.  MPF  Positive feeder  Dial  Cylinder  Manager tooth belt  Timing belt for motor and take down. Minimum requirement of other parameters are: For Yarn :  Yarn strength 13 gm/Tex (minimum)  Should be waxed 0.1 % - 0.3% (on the weight of the material)  Yarn should not be dried.  Cone angle should be accurate.  A tail should be kept during winding.  Packing density must be maintained. For Sewing Thread  Sewing thread should be bleach proof. 30 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  32. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering For Spandex  Should have good elasticity.  Yarn should be uniform.  Elastic recovery 100%.  Elongation 500%.  Should be Acid, Alkali and temperature stable  Should be moisture free (i.e. without containing water). Other Materials  Needle Oil: Should be water soluble.  Belt,  Grease,  Kerosene oil, etc. The acceptable limits for Mellange and Polyester depend on customer's specification. These yarns are rarely used (based on buyer's demand) at EKL. The international standards for these yarns are mentioned Operation Staff Operation stuffs of Circular Knitting Process include: 1. Manager 2. Sr. Production Executive / Production Executive 3. Operator 4. Assistant Operator 5. Helper 31 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  33. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Machine Set-up: Operator sets the following parameters prior to operation: Parameters Range Speed 26 ~ 28 RPM (for Solid dyed) 20 ~ 25 RPM (for Yarn dyed & designed) Yarn Tension 4-5 gm/tex. Stitch Length 2.60 -3.00 mm Weight 100 - 240 GSM (as required) Yarn (Cotton) 16~40Ne Yarn (Polyester) 75 - 300 Denier Checklist Before Operation Operator checks the following points prior to operation: 1. Machine condition. 2. Power supply and air availability. 3. Yarn availability. 4. Buyer's specification. 5. Yarn quality. 6. Machine adjusted with given parameter (Yarn count, Stitch length/GSM). 7. Oil inlet clean or not. 8. Oil drip metre should be adjusted. 9. Door should be close. 10. PC controller is set for record keeping. 32 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  34. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Factors to Be Considered during sample analysis Before Producing a Fabric: Before production few factors but be considered: 1. Design of the fabric( expressed by notation diagram), 2. Needle arrangement according to Notation diagram, 3. Cam arrangement according to Notation diagram, 4. Feeding, 5. Drive & 6. Stitch length. 7. Machine gauge & dia Design of the fabric; We have analyzed a fabric, the drew notation diagram which is attached in following page. Needle arrangement & Cam arrangement: Needle arrangement & Cam arrangement for the design is shown following page. Feeding: Well-knit brand has Single jersey machines with positive feed system. We fed yarn in following sequence: Type of yarn Count No. of yarn Color of yarn Cotton 30 cc 14 Orange Polyester 175 den 3 White Cotton 30 cc 8 Orange Polyester 175 den 3 White Cotton 30 cc 14 Orange Cotton 30 cc 48 Orange 33 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  35. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Drive: Today the belt system has by far become most common positive feed system. The belt makes the spool rotate and the no of rotating spools corresponds to the no of feed systems. By adjusting the belt RPM, the quantity of yarn per loop can be increased or reduced. This system grants an accurate control of the yarn tension. We know knit loops more yarn than tuck loops. To produce this fabric we use 3 belt drive. Two drive for knit loops & one drive for tuck loops. Stitch length: Stitch length of each loop is controlled by VDQ pully . VDQ pully was adjusted to give 3.1 mm length for knit loops & 2.65 mm for tuck loops. Thus we produced the fabric. Lycra attachment: There are several methods to calculate lycra percentage in fabric sample. Some of them are described below- Manual method: 5 gm sample fabric is taken & withdrawn the lycra yarn from sample fabric Then the sample fabric is weighted. From difference weight, we calculate the lycra percentage of the sample fabric % ℎ ℎ − ℎ = ℎ ∗ 100% 34 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  36. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering QUALITY ASSURANCE SYSTEM ORGANOGRAM BODY PART Tube & Collar Cuff Quality Manager Executive Sr.Executive (2) Supervisor Executive (3) Helper Supervisor Sr. Inspector Inspector Helper 35 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  37. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering The Quality assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. Epyllion Fabrics Ltd. is more about concern about quality. In this factory quality assurance is more preferred than quality control, but both are in advancement. After collecting fabric rolls from different m/cs, they are needed to be inspected or assured required quality by the quality inspectors as if there were no big production hampered and no complain from the buyers. Here are the details about it. Objects of Quality Control: 1. Research. 2. Selection of raw materials. 3. Process control. 4. Process development. 5. Product testing. 6. Specification test Scope for quality control, quality assurance and testing: 1. Testing lab 2. Machine auditing system 3. A good training system 4. Excellent analytical back up 5. Technical expertise 36 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  38. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Quality Control in Grey Fabric Inspection: Some Points Are Needed To Maintain For High Quality Fabric: a) Brought good quality yarn. b) Machines are oiled and greased accordingly. c) G.S.M, Stitch length, Tensions are controlled accurately. d) Machines are cleaned every shift and servicing is done after a month. e) Grey Fabrics are checked by 4 point grading system. List of Equipments: In this factory this is the list of equipments to assure quality:- 1) Inspection m/c# 1 2) Inspection m/c #2 3) Scissors 4) Electronic balance 5) GSM cutter 6) Indication sticker 7) Measuring tape 1) Body & Rib Inspection: All rolls are kept in front of the inspection m/c time to time and are inspected over the 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 inspection report to classify the fabric which is based on the four point system. 37 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  39. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 2) Collar & Cuff Inspection: Collars 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. Quality Standard: Epyllion Fabrics Ltd. maintains the ISO: 9002 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 inspection at Epyllion Fabrics Ltd. Four point grading system Size of defects Penalty 3 inches or less 1 point Over 3 inch but not over 6 inch 2 point Over 6 inch but not over 9 inch 3 point Over 9 inch 4 point 38 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  40. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Following table shows common body and rib faults and response by inspection section at Epyllion Fabrics Ltd: Rejection criteria for body & ribs No Faults Response 1. Needle mark Major needle line is rejected 2. Stripe Major needle line is rejected 3. Barre mark Rejected 4. Contamination & fly Approved for color but for white shed 1 point is assigned 1 point 5- Slubs 6. Thick thin place Reject 7. Birds eye 1 point 8. Pin holes 1 point 9. Wrong design Reject "10. Mixed yarn Discuss with manager 11. Sinker mark Major sinker mark is rejected. 12. Missing yarn Use 4 point 13. Holes Do 14. Oil line/stain Do 15. Chemical Do 16. Dirt stain Do 17. Crease line Do 39 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  41. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 18. Uneven tension Discuss with manager Following table shows common collar and cuff fault and response taken by inspection section at Epyllion Fabrics Ltd.:- Rejection criteria for collar & cuff Response No. Faults 1. Wrong ply Reject 2. Hole Reject 3. Needle line Reject 4. Slubs Reject 5. Wrong design Reject 6. Wrong tripping Reject 7. Fly & contamination Acceptable for color but not for white Reject 8. First round problem 9. Uneven tension Discuss with manager 10. Missing yarn Reject 11. Crease line Reject 12. Rust line Reject 13. Oil stripe Reject 14. Thick-thin Reject 40 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  42. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering 15 Wrong tube Reject Following table shows the acceptance calculation followed by the inspection section at Epyllion Fabrics Ltd.: Acceptance calculation Factory: Roll yardage (A) & Total point’s pounds (B) Formula: B/A X100 =points per 100 yard Classification: 40 points = A type 41-60 = B Type 61-80 = C type Above 80point = Reject Quality Standard: Epyllion Fabrics Ltd follows the quality standard: ISO-9002:2000. List of Equipments: - In the lab Department the followings equipments are used –  Yarn Grade Tester  78-1 Magnetic Stirrer  KERN Electronic Balance 41 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  43. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering  Spray Rating Tester  Incubator  Iron  Button Tester  Ahiba Nuance Lab. Dip Dyeing Machine  Thermostatic Water Bath  Digital Pipette  Creda Dryer  Rota Wash  Electrolux Washcator  Orbitor Pilling & Snaging Tester  Marks & Spencer Holoscope  True Burst  Crock Meter  Push - pull tester  Megasol (Light fastness tester)  Spectra Photometer with software (Data Color)  Thermo hygrograph  PHmeter 42 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  44. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering PRODUCTION SUMMARY SERVICE PRODUCTION (TON) COLLAR & CUFF (TON) TOTAL PRODUCTION (TON) UNIT PRODUCTION (TON) 20 (285715 Sets) EFL 713 57 791 8 (112680 Sets) EKL 317 39 364 1 (14285 Sets) Subcontract 451 0 452 29 (412680 Sets) Grand Total 1482 97 1607 OVERALL SUMMARY Particulars INHOUSE SERVICE SUBCONTRACT TOTAL Qty (Ton) 1058 96 452 1606 % 66% 6% 28% 100% 43 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  45. SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering 1058 1200 1000 800 452 600 400 96 200 0 IN HOUSE SERVICE SUBCONTRACT FABRIC TYPE WISE PRODUCTION FABRIC TYPE WISE PRODUCTION FABRIC TYPE WISE PRODUCTION F. Type Pro. Qty Fab. % SJ 714,815 47.33 3TFL 318,818 21.11 LSJ 137,467 9.10 SP2RIB 70,061 4.64 1RIB 56,069 3.71 IRRGDNI 47,179 3.12 IN 46,483 3.08 IN Ply 32,842 2.17 SPRIB 31,188 2.07 44 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3 44 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3 44 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  46. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Collar & Cuff 28,127 1.86 STBPQ 14,287 0.95 2TFL 6,913 0.46 LSTBPQ 2,186 0.14 WFL 2,130 0.14 DNI 566 0.04 2TBPQ 559 0.04 2RIB 322 0.02 L2TFL 90 0.01 Mesh 54 0.00 Grand Total 1,510,153 100.00 INHOUSE PRODUCTION ANALYSIS CAPACITY (TON) PRODUCTION (TON) CAPACITY UTILIZATION MCS REJECT (TON) FLOOR REJECT% UTILIZATION EFL 1539 770 50% 54% 0.95 0.12% EKL 521 356 68% 72% 0.38 0.11% TOTAL 2060 1126 55% 58% 1.33 0.12% 45 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  47. SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering Total (KG) 560,000 540,000 520,000 Total (KG) 500,000 480,000 460,000 440,000 Jan’11 Feb’11 Mar’11 46 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3 46 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3 46 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  48. SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering School of Science and Engineering, Department of Textile Engineering Total Target Total Delivered Delivered Total Floor wise average % Month Unit Performance % Quarterly perfm % Quarterly perfm % 89% Jan ' 11 EFL 385250 341714 341714 87% Feb ' 11 EFL 357000 342924 342924 96% Mar ' 11 EFL 374000 289626 289626 77% 96% 96% Jan ' 11 EKL 189750 171582 171582 90% 105% Feb ' 11 EKL 168000 197828 197828 118% Mar ' 11 EKL 176000 185750 185750 106% 47 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3 47 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3 47 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  49. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering Rejects EFL EKL Delivery Qty (Kg) Reject Qty (Kg) Delivery Qty (Kg) Reject Qty (Kg) Month Reject In % Reject In % 259355.2 Kg 604.0 Kg 0.23% 171582 Kg 924.4 Kg 0.53% January February 286267.4 Kg 376.0 Kg 0.13% 197828 Kg 679.1Kg 0.34% 268178.0 kg 611.0 Kg 0.22% 185750 kg 364.9 Kg 0.19% March 1968.4 Kg Avg 0.19% Avg 0.35% Total 813809.6 Kg 1591.0 Kg 555160Kg 48 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

  50. SOUTHEAST UNIVERSITY School of Science and Engineering, Department of Textile Engineering LAB & TESTING DEPARTMENT 49 | P a g e S u b m i t t e d b y : M d . K a m r u l H a s a n I D : 2 0 0 8 0 0 0 4 0 0 0 9 3

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