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Industrial attachment of uttara knitting & dyeing ltd.

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Industrial attachment of uttara knitting & dyeing ltd.

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  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Uttara Knitting & Dyeing Ltd. Page no: 1

  2. CHAPTER – I PROJECT DESCRIPTION PROJECT DESCRIPTION Page no: 2

  3. CHAPTER – I 1. Name of the company: Uttara Knitting & Dyeing Ltd. 2. Status : Private Ltd. company 3. Type : 100% Export oriented composite knit dyeing industry 4. Year of establishment : 1997 5. Location : South Pansail, Zirani bazaar, Gazipur Sadar, Gazipur 6. Address : Factory : South Pansail, Zirani bazaar, Gazipur Sadar, Gazipur Head Office : 39, Dilkusha C/A, Dhaka - 1000 7. Sponsor : Late. Md. Moklesur Rahman 8. Product mix : value 100% cotton, 100% polyester, Chief cotton, P/C 9. Annual production capacity 1800 tons 10. Project cost 22 crs (Initial), 50 crs (Present) 11. History of the project development 1994 – Establishment of the industry at Tongi with 8 Knitting m/c. 1997 – Shifted in Zirany, Gazipur Sadar, BKSP with 24 knitting m/c (rib – 3, S/J - 21) 1997 – Installment of 7 Dyeing m/c 1997 – Installment of 6 Flat Collar m/c 2000 – Installment of 3 rib m/c 2003 – Installment of 4 Dyeing m/c (Bangla) 2004 – Installment of the 2 Sample Dyeing m/c (5 kg, 25 kg) 2004 – Installment of 3 Pai Lung m/c Page no: 3

  4. 12. Different departments : To run the factory smoothly, there are some department in the factory . They are given bellow:- KNITTING SECTION:  Knitting  Inspection DYEING SECTION  Batch section  Dye house  Dyeing lab.  Quality control  Finishing MAINTENANCE  Electrical  Mechanical ACCOUNTS & COMMERCIAL SECTION ADMIN SECTION  Time section  Cleaning  Security  Store 13. Total area of the industry : 30 acres 14. Area of the plant : 20 acres REMARKS: Uttara Knitting & Dyeing Ltd. is a well established Knit Composite Industry. The industry stands by the side of BKSP. The area is sufficient for the industry. But its drainage system is not very good. There is no system for effluent treatment. Page no: 4

  5. LAYOUT OF UKDL Mixing Room Drain Dye Store Steam Water Chemical Store Dyeing manag er Produc tion Officer Q.C. & Lab Dyeing m/c (1 – 15) Finished fabric store Softene r Calator Hydroextractor Office DYEING FLOOR N FINISHING SECTION compacto r W E Batch Section Store Batch Turner Soft set - 1 Steam Set m/c 1 S Tensionless dryer Soft set - 2 Steam Set m/c 2 Tumble Dryer Delivery Fabric Store Page no: 5

  6. CTET MOHAKHALI AIRPORT UTTARA ASHULIA BAZAR EPZ - II UKDL BAIPAIL BKSP EPZ - I FIG: LOCATION OF UKDL Page no: 6

  7. CHAPTER – II MANPOWER MANAGEMENT MANPOWER MANAGEMENT Page no: 7

  8. UTTARA KNITTING & DYEING LTD. JIRANI BAZAR, GAZIPUR SADAR, GAZIPUR ORGANOGRAM A/C & store Dyeing Sl. No. 01 02 03 04 Marketing Commercial Production Production Knit Quality Utility Administrati on General Manager DGM AGM (Factory) Manager (Dyeing) Assistant Manager Sr. Prod. Engineer DGM AGM Manager DGM AGM Manager DGM AGM Manager Manager (Knit) Assistant Manager Sr. Prod. Officer Manager Manager Manager (Admin) Administrati on Officer Sr. Executive Admin Executive Admin 05 Assist manager Sr. Executive Assist manager Sr. Executive Cost Assistant Manager QC officer Electrical Engineer Mechanical Engineer Accountant Sr. Executive 06 07 Executive Executive Executive Production Engineer Asst. Assistant QC Officer Sub. Production Engineer Shift In- charge Production Clark Sr. Supervisor Supervisor Assistant Engineer Forman 08 Jr. Jr. Jr. Asst. Prod. Officer Lab. Chemist QC In- charge Sr. QC Supervisor QC Supervisor Assistant QC Supervisor QC Asst. Officer Admin Security Officer Computer Operator Office Assistant/Ti me Keeper Assistant Time Keeper Typist Executive Assistant Executive Assistant Executive Accounts Assistant Cashier 09 Supervisor 10 Sr. Lab. Assistant Lab. Assistant Assistant Supervisor Sr. Fitter 11 Purchase officer 12 Sr. Store officer Report Clerk Assistant Supervisor Fitter 13 Store officer Asst. Store Officer St. Store Keeper Store Keeper Asst Store Keeper Store Assistant Helper Store Batch Incharge Finish Incharge Froman Tr. Assistant QC Tr. QC Assistant Fitter Electrician Supervisor Fitter 14 Telephone Operator Delivery Supervisor Peon 15 Assistant Fitter Operator Tr. Assistant QC QC Man Assistant Electrician Boiler Operator Boiler Assistant Generator Operator Compressor Operator Asst. Operator W.T.P. Attendant Tr. Operator Helper 16 Sr. Supervisor 17 Supervisor Assistant Operator Tr. Operator Driver 18 Assistant Supervisor Tr. Supervisor Gardener 19 Tr. Assistant Operator Helper Loader 20 Tr. Asst. Supervisor Sr. Operator Cleaner 21 Painter 22 23 24 25 Operator Asst. Operator Tr. Operator Assistant Tr. Operator Helper Sweeper 26 Page no: 8

  9. MANAGEMENT SYSTEM:    Intercom telephone Fax Written letters & Oral  SHIFT CHANGE: There are two shifts in this industry. So the shifts are changed at every 12 hours RESPONSIBILITIES OF PRODUCTION OFFICER: I. To give dyeing program slip. 2. To match production sample with target shade. 3. To collect production sample lot sample matching next production, 4. To observe dyed fabric during finishing running & also after finishing. 5. To identity disputed fabrics & report to P.M/G.M. for necessary actions. 6. To discuss with P.M about overall production if necessary. 7. To sign the store requisition & delivery challan in the absence of P.M. 8. Also to execute overall floor works. 9. To maintain loading'/unloading khata. 10. Any other assignment given by higher authority. Page no: 9

  10. JOB DESCRIPTION OF PRODUCTION OFFICER: REPORT TO: Sr. Production Officer JOB SUMMARY: To plan, execute & follows up the production activities &. control the quality production with related activities. DUTIES & RESPONSIBILITIES:       Overall supervision of dyeing, finishing production. Batch preparation & pHI chock. Dyes & chemical requisition issue & check. Write Fabrics loading & unloading time from m/c Program making, sample checking, colour measurement Control the supervisors, operator, ass. operator and helper of dyeing m/c. And also any other over work as & when required by the management.  JOB DESCRIPTION OF Sr. PRODUCTION OFFICER: REPORT TO: A.G.M. (production) JOB SUMMARY: To plan. execute & follows up the production activities & control the quality production with related activities. DUTIES & RESPONSIBILITIES:  Overall supervision of dyeing, finishing production.  Checks the sensitive parameters of different machine for smooth dyeing  Checks the different log books of different areas & report to management  Checks out the plan to control the best output from supervisors & workers.  To trained up& motive the subordinates how to improve the quality production.  Control the supervisor, operator, Asstt. Operator & helper of dyeing.  Maintenance of machine & equipment Any other works & when required by the management REMARKS: The man power management system of Uttara Knitting & Dyeing Ltd. is well arranged. Every officer & stuff are responsible for their duty. But there are only five textile engineers in the industry. Page no: 10

  11. CHAPTER – IIII MACHINE MACHINEDESCRIPTION DESCRIPTION Page no: 11

  12. DYEING FLOOR DYEING MACHINES: In Uttara Knit Dyeing Ltd.. There are 14 dyeing machines. Among them 9 machines are winch dyeing machines, 3 are H.T. dyeing machines and 4 sample dyeing machines. All the machines are from same company and country. The description and specifications of the machine are given below- Name of the machine : Brand Name Manufacturing country: Capacity Year of manufacturing: Specification Jet Dyeing Machine Fukuoka Japan 400 Kg 1995 : : : No of nozzle: Pressure/nozzle: Motor : Winch motor – 2 Pump motor – 1 Stirring motor – None 2 0.5 bar OPERATION PROCESS: a. Preparation: 1. Turn on power on main panel 2. Open valve for cooling water of main pump 3. Check stream, water & air + Steam pressure : + Water pressure : + Air pressure : 4. Adjustment of feeding valve as per production item & capacity 5 – 6 1.2 – 2 kg/cm2 G 5 – 7 kg/cm2 G kg/cm2 G b. Putting fabric into the machine: 1. Select water supply level 2. Supply water automatically by pushing ‘turn on’ button and stop by ‘turn off’ button. 3. Take up edge of fabric to fabric gate through guide of the reel 4. Put edge of fabric to nozzle 5. Start main pump and put whole fabric with adjusting feeding by valve upto remaining 2 -3 meters fabric end 6. Stop main pump and pull up 2 -3 meters of fabric edge by stick 7. Joint both ends of fabric 8. Start main pump & reel to circulate whole fabric and adjust torque of speed 9. Make sure if fabric circulation is normal, then close the door of the gate, (Check again reel speed) Page no: 12

  13. C. Operation: 1. Close the door 2. In-put the pattern on programme controller 3. Mix dyeing stuff & chemical in dyeing-mixing tank and pour it with using pouring pump by adjusting feeding valve, after poring, feeding valve shall be closed 4. Switch ‘run’ on programme setting device 5. Automatic operation 1) Select the switch of water supply to ‘automatic’ on main panel 2) Push the button of automatic operation, then automatically operation will go through heating, holding, cooling, washing as per programming. Put ‘stop’ button when finishing buzzer will ring 3) Open the door and take out fabric Caution: 1. Before operation: (1) Check the power (Voltage/hz) wrong Voltage / Hz will cause to brake motor, meter etc (2) Check air pressure (3) Clean inside of tube before dyeing (4) Set the meter correctly as per dyeing method (5) Check every valves 2. Starting operation: (1) Check closing the door perfectly (2) Set pressure below 1 kg / cm3by watching pressure meter (3) When temperature will be over more than 800C, do not forget item (1) & (2) (4) Do not start pump when tube is empty (5) Put definitely cooling water before starting operation because pump & reel is made for cool water 3. During operation (1) Check if meter is working correctly during operation (2) Check if any strange vibration (3) Check if any strange sound of pumping (4) Check if pressure in the tube is too high (5) Check if temperature in the tube meet programming (6) Start pump when feeding steam & cooling water (7) Check if reel is working correct under high temperature & high pressure 4. Nozzle installation Set nozzle base into nozzle-casing and install nozzle by turning it clock wise. After install nozzle, turn it one round by anti-clock wise to make 2 mm gap. The gap on nozzle shall be adjusted by kind of fabric 5. After operation: (1) Before opening the door, check if air pressure of inside the tube is 0 kg/cm2 and temperature of inside the tube is between 800-900C if the pressure is still remained or temperature is more than 800C, it is very dangerous to open the door (2) Temperature inside the tube shall be under 800C for manual draining Page no: 13

  14. (3) Turn off the power after operation and close the valve Maintenance: (1) Keep cleaning seal packing of the door and surface to touch the packing to be prevented from dust and hurting (2) Keep electric portion, pump and control panel not to be wet by water (3) Keep tight valve shaft seal ground packing of each valve by tightening sometime (4) Check valve seat part of air valve & drain valve sometime (5) Keep tight each volt (6) Make often oiling rotating part (7) Inspect mechanical seal according to manual of pump (8) Keep adding grease & oil in pump bearing part according to manual of pump (9) Inspect sometime if safety valve is working correctly (10) Inspect sometime if steam trap is working correctly (11) Inspect meters of pressure and temperature 6. Page no: 14

  15. Jet mechanism Soft water pipe Winch Steam pipe Led filter Water pipe motor pump drain pump motor Automatic High Pressure Dyeing Machine Page no: 15

  16. TOTAL MACHINE CAPACITY CATALOGUE CAPACITY IN (KG) NO. OF MACHINE ACTUAL CAPACITY ORIGIN OF MACHINE SL NO M/C TYPE FUKUOKA IRON WORKS, JAPAN HIGH TEMPERATURE SAMPLE DYEING M/C (JET DYEING) 01 01 20 20 HIGH TEMPERATURE (JET) SAMPLE DYEING M/C 02 01 20 20 JAPAN 03 H/T (JET) DYEING M/C 01 60 60 JAPAN 04 H/T (JET) DYEING M/C 01 150 150 JAPAN 05 H/T (JET) DYEING M/C 01 150 150 JAPAN 06 H/T (JET) DYEING M/C 01 150 150 JAPAN 07 H/T (JET) DYEING M/C 01 300 260 JAPAN 08 H/T (JET) DYEING M/C 01 300 280 JAPAN 09 H/T (JET) DYEING M/C 01 300 280 JAPAN 10 H/T (JET) DYEING M/C 01 400 320 JAPAN 11 ATMOSPHERIC DYEING M/C 01 400 310 JAPAN 12 ATMOSPHERIC DYEING M/C 01 150 120 JAPAN 13 ATMOSPHERIC DYEING M/C 01 150 120 JAPAN 14 ATMOSPHERIC DYEING M/C 01 300 260 JAPAN 15 ATMOSPHERIC DYEING M/C 01 300 260 JAPAN 16 ATMOSPHERIC DYEING M/C 01 300 260 JAPAN BANGLADES H 17 SAMPLE DYEING M/C 01 10 10 BANGLADES H 18 SAMPLE DYEING M/C 01 15 15 Page no: 16

  17. MACHINERIES OF THE DYEING LAB: The dyeing lap of the UKDL is not so developed. The description of the machineries of the dyeing lab are given bellow- Laboratory facilities & equipments:  Light box  Electric balance  Iron  Sample dyeing m/c  Lab dip m/c  GSM tester  Washing m/c  PHtester  Dryer Light box:  Visual assessment of color by reflectance & transmission  Mainly used for shade matching  Four types of light source are used  Sometime it may be more such as TL84, CWD etc  Metamerism of the fabric is checked Brand Name Model VITIVIDE CAC-60 Manufacturing country U.K. Types of light source which is used in the m/c is given below- Symbol Full meaning UV Ultra violet Functions Used for white color matching Check the metamerism of the fabric Do Used for color matching F Fluorescent light TL84 L D65 Tube light Artificial day light Crock meter: Feature:  Mainly used for rubbing fastness  Rub may be wet and dry Brand name Model GUVEN SURTME Mgf. Country Turkey Serial no. S-9011 Page no: 17

  18. Electric balance: Features:  Weight of the fabric and dyes and chemical is measured digitally which give good result in weighting  Used for accurate measurement  Maximum weight that can be perfectly measured is 121 gm and minimum weight which can be measured perfectly is 1.001 gm  Accuracy 0.001 gm Brand Name Company Model Sartorius James H. Heal & Co. Ltd Country UK BL310 IRON: Feature:   Wet sample is placed between the two white fabric and temperature and pressure is given  A dial is provided indication the different temperature marked on tits upper surface and gives accurate temperature for cootn, silk, wool etc. which is adjusted manually. Used for drying the sample SAMPLE DYEING MACHINE: There are three sample dyeing m/c in the laboratory, which features are described below in brief Solvent – Glycerin Model – HR No: 3800 M/c type Brand name RAPID Company LABROTEX.CO Country TAIPE (TAIWAN) Sample dyeing m/c: Feature:  Sample can be dyed above 1000C, 1300C or more  Glycerin bath is used  18 holders are providing in this machine Main parts of the machine:  Program set panel  Glycerin bath  Holder  Holder carrier Controlling point:  Time  Temperature  Rotation speed  Auto stop Page no: 18

  19. Type of fabric processed: COTTON AND POLYESTER GSM Tester: Feature:  Used to measure GSM for gray, dyed and finished fabric  One GSM tester is in finishing section and another GSM tester is in Knitting Section  100 Cm2cut sample is weighted by electric balance 3 and given value of in gm. Multiplied by 100 is the GSM of fabric, Say, 100 cm2sample weight in 1.9 gm that means its GSM is 180 Washing machine:  All the washing condition and parameter can be controlled  Model – RS-12MS  Temp 1200C  Solvent – water + glycerin m/c no 1. Brand name INDESIT Company INDESIT Country Italy Wash fastness machine: It also used as a dyeing machine. Specification is unknown Hot air rapid drying oven: Country – Taiwan Component – Timer, Temperature indication meter MACHINARIES OF THE FINISHING SECTION: Dewatering machine: Feature:  Used to remove excess water after pretreatment and dyeing  Delivered fabric is crease free state  Before squeezing ballon is formed with the help of compressed air passing by a nozzle  It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism  To impart soft finish to the fabric m/c no Brand name Country 1 (modern) ABcalator Sweden Production Company Airtex Main parts of the machine: - Sqeeze roller (to remove water) - Stretcher (to control width) - Over feeding wheels (to control GSM) - De-twisting device (To delivery the fabric roll in untwisted form) - Folding device (to delivery the fabric in folded form) Page no: 19

  20. Utilities: 1. Electricity 2. Processed air (to form the tube fabric into ballon with a view to remove crease) Control system: 1. Overfeed control 2. Pressure 3. Speed control 4. Width control CALENDER M/C: Name : Speed : Softset 100 m /min 20-30 m / min Korea Origin : Functions: 1. To calendar fabric 2. To reduce G.S.M. STREAM SETTING M/C: Name : Origin : Speed : KY0D0 DENKI U.S.A 60 m / min Functions: 1. To remove crease mark 2. To reduce G.S.M of fabric HYDROEXTRACTOR M/C: Name : NGAISHING Model : NS 2542 Serial : 158 Company : NGAISHING Development Origin : Hongkong Function: 1. To extract water from fabric DRYER: Tension less dryer Model Company Origin Speed : : : : MFG NO-0445 LK & LH CO. LTD Taiwan 10 – 20 m/min Functions: 1. To dry the fabric with help of steam Page no: 20

  21. COMPECTOR M/C: Brand M/c number Company Origin : : : : Parnit – II Delta Plus Compactor BM-9529 Tubular Textile Ltd/ U.S.A. Page no: 21

  22. Control Point : - - - Function: 1. To compact the fabric 2. To control the shrinkage 3. To maintain proper width and G.S.M Water pressure Air pressure Steam pressure 2.5 4 6 lb lb lb Main parts of the machine: 1. Heating chamber 2. Blower (8) 3. Synthetic blanket as a conveyor, 4. Folder 5. Exhaust fan Heating system: Steam Utility: 1. Steam 2. Electricity (to run the m/c) 3. Compressed air (to spread the fire) REMARKS: The average machineries in this factory are more or less same compared to the other knit dyeing factories but the dyeing machineries are very much different from the other factories. Page no: 22

  23. CHAPTER – IV RAW MATERIALS RAW MATERIALS Page no: 23

  24. RAW MATERIALS: In Uttara Knitting & Dyeing Ltd., the raw materials used for production are – 1. Grey 2. Dyes 3. Chemicals 1. Grey fabrics: Following types of grey fabrics are dyed- a. Single jersey b. Single jersey with lycra c. Interlock d. Lacoste e. Yarn dyed fabrics f. Rib g. Lycra rib h. 1 x 1 rib & others i. Collar & cuff j. Polyester fabrics Sources: The required grey fabric is produce in the industry Chemicals 01. Hostapol JU 02. Rocowet RDA 03. NaOH 04. Na2CO3 05. Defoamer SF 06. Stab SML 07. H2O2 08. Cibafluid-C 09. A. Acid 10. Ladiquest – 1097 11. Drimazin- E2R 12. Rlf - 349 13. Glanber salt 14. NaCl 15. Decol – SN RFL 16. VNF ECO 17. Softerer [NI catalyst] 18. Enzyme Country Thailand Germany China, India China Taiwan Thailand Belgium Singapore Taiwan, India Thailand Thailand Germany India / China Bangladesh Germany Singapore Singapore Thailand Taiwan Germany Page no: 24

  25. Dyes Solazol Remazol Reactron Reactive Terasil Country Taiwan Germany India India Switzerland Materials consumed: ADD: MANUFACTURING EXPENSES Knitting Dyeing Compacting WT. KGS 610.0 610.0 610.0 @BDT. 13.49 33.55 2.12 UTTARA KNITTING DYEING LTD. IMPORTED YARN PRICING THROUGH L/C: PARTY NAME YARN CATEGORY (KG) Shameem Spinning 20s/1 CVC 2.70 Shameem Spinning 30s/1 CVC 2.80 Padma Textile Mills 30s/1 CVC 3.00 Square Textile Mills 24s/1 Comd 2.95 Square Textile Mills 12s/1 Kard 2.05 Square Textile Mills 10s/1 Kard 1.65 Prime Composite Mills 32s/1 Comd 2.95 Arief Knitspin Ltd 20s/1 Kard 2.58 Arief Knitspin Ltd 26s/1 Kard 2.62 Arief Knitspin Ltd 30s/1 Kard 2.62 Prime Composite Mills 32S/1 Comd 2.95 Arief Knitspin Ltd 24S/1 Comd 3.02 Arief Knitspin Ltd 34S/1 Comd 3.25 Shamsuddin Spinning 24S/1 Comd 3.00 Shamsuddin Spinning 26S/1 Comd 3.00 Arief Knitspin Ltd 20S/1 Comd 3.00 Saiham Textile Mills ltd. Shamsuddin Spinning 30s/1 Comd 3.05 Shamsuddin Spinning 26s/1 Comd 3.00 Prime Composite mills 20s/1 Kard 2.40 Prime Composite mills 24s/1 Comd 2.85 Prime Composite mills 26s/1 Kard 2.82 Prime Composite mills 30s/1 Kard 2.82 Hanif Spinning Mills 28s/1 Comd 3.05 Square Textile Mills 26s/1 Comd 2.95 Square Textile Mills 24s/1 Kard 2.50 Square Textile Mills 10s/1 Kard 1.65 Shameem Spinning 30s/1 CVC 2.80 Square Textile Mills 30s/1 Comd 3.00 RATE $ RATE (Tk. / KG) 158 163 175 172 120 96 172 151 153 153 172 176 190 175 175 175 149 QUANTITY (KGS) 400.00 500.00 3628.80 850.00 500.00 1850.00 2550.00 2000.00 2000.00 3250.00 22500.00 10000.00 20000.00 6700.00 4350.00 1500.00 661.84 30s/1 Kard 2.55 178 175 140 166 165 165 178 172 146 96 163 175 1150.00 1800.00 1400.00 1900.00 650.00 350.00 3800.00 500.00 500.00 600.00 1600.00 1000.00 Page no: 25

  26. CHEMICALS ACETIC ACID DEFORMER SF/ALVATEX FFC BLUTON BVB BLUTON K2 BLEACHING POWDER CAUSTIC SODA COMMON SALT GLOBER SALT H2O2(50%) GEIZYME PR SODIUM HYDROSULPHITE SODA ASH SODIUM SULPHITE SODIUM CHLORIDE CIVAFLUIDE C HOSTAPOL – J – U LADIQUEST – 1097 STABILIZER SF SOFTNER CS DEKOL SN AVERAGE RATE (Tk / KG) 69.33 161.86 238.00 236.00 109.00 17.00 6.45 8.00 20.35 140.79 39.06 11.00 22.00 60.00 99.00 96.00 129.03 86.05 118.22 132.00 DYES REACTIVE BLACK-5 SULPHER BLACK REMA BLUE - BB REACTIVE ORANGE – 16 REMA YELLOW RR-GR REMA RED –RR – GR REMA RED H-38 SOLO TURQUISE –BRIE 400% REACTIVE YELLOW 160 TERASIL BLUE 3RL-02 TERASIL BLUE BGE -01 TERASIL RED F –B REACTIVE BLUE BB REACTIVE BLUE GG AVERAGE RATE 129.29 90.61 2245.89 459.50 757.83 757.01 780.00 525.50 428.83 1774.00 1370.00 3916.00 1319.00 688.50 REMARKS: UKDL uses best quality raw materials. It produces fabrics from best quality yarn. They uses the best quality dyes like REMAZOL, REACTRON, REACTIVE , TERACIL etc. During the time of using dyestuff they give importance upon the quality of dyes than the price of the dyes and chemicals. Page no: 26

  27. CHAPTER – V PRODUCTION PLANNING PRODUCTION PLANNING SEQUENCE SEQUENCE & & OPERATIONS OPERATIONS Page no: 27

  28. PRODUCTION PLANNING, SEQUENCE AND OPERATIONS: PRODUCTION PARAMETERS: a. pH: - During H2O2bleaching pH 9.2 – 12 - During reactive dyeing pH 10.5 – 12.5 - During disperse dyeing pH 4.5 – 6.0 b. Temperature: For cotton scouring 900-950C For cotton cold wash 300– 400C For cotton hot wash 700-800C For cotton acid wash 600-700C For cotton dyeing - - - - - 800-900C (For hot brand) 600C (For cold brand) Polyester dyeing: 1000-1300C - c. Time: - - - For scouring 60-90 mins For reactive dyeing 60-90 mins For disperse dyeing 60-90 mins d. M:L ratio: - For reactive dyeing M:L ration maintained beween 1 : 7.5 to 1 : 10 DESCRIPTION OF PRODUCTION PROCESS: Washing for colored fabrics: - - - - The colored fabrics to be washed is loaded in the machine Required amount of water is taken PCLF (detergents) added & washing continued at 800C for 20 mins Cold washing Scouring-bleaching: - - - - Fabric to be scoured is loaded in the machine Required amount of water is loaded Washing agent/ detergent is added Steam pipes are on & scouring agents (i.e. Caustic soda/ Soda ash) added when the temperature reaches at 500C When the temperature reaches at 600C then stabilizer is added Then H2O2is added Temperature is then raised to 900C and the process is then carried out for 60-90 mins depending on the requirements - - - Page no: 28

  29. - - The liquors are then drained Then cold wash at 300-400C, hot wash at 700-800C and acid wash at 600-700C is done Dyeing: - - - After acid wash all liquors are drained out Required amount of water is taken Then leveling agents, anti-creasing agents, de-foaming agents are added according to the requirement Steam pipes are on & after 10-15 mins dyes are added Salts are added after another 30 mins Then soda ash after another 30 mins Then the temperature is raised slowly up to the mark The process is carried on and samples are taken after every 30-40 mins to match with the target shade. It continues until shade matching. If the sample is matched, then the liquors drained out Then cold wash at 300-400C, hot wash at 700-800C, acid wash at 600-700C is done Then softener is added at 400C for 20-30 mins Fixer is applied for deep shade only before adding softener - - - - - - - - - Re-dyeing: When shade is not matched then fabric is treated again in dyeing machine for shade matching is known as re-dyeing. Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur when the fabrics absorb one or two colors more or less. One re-dyeing process is described below. - - - - - - - - - Drain the let off solution Hot wash at 700-800C Acid wash at 600-700C(600for light shade & 700for deep shade). Soda ash washes at 900-1000C for 60mins to reduce the depth of shade. Acid wash at 600C. Addition to required dyestuffs. Salt addition. Soda ash addition. Other operations are same as previous described dyeing operations. Page no: 29

  30. PRODUCTION FLOW CHART: Production flow chart for 100% cotton ↓ Grey fabric loading ↓ Scouring & Bleaching at 95oC for 1 hour ↓ Scou g HO + (95oC x 15’) ↓ H2O2killer [invotex PC or gazyme PC] ↓ A.Acid ↓ Enzyme [pH 4 – 4.5, temp 60oC for 40’-60’] ↓ Hot wash ↓ Levelling [Ladiquest 1097] ↓ Dyeing Salt Color Soda ↓ A. Acid ↓ Hot wash [Decol SN, RSK, RFL] ↓ Fixing [VNF, ECO] ↓ Softener [LCF, Non ionic] ↓ Unload Scouring & bleaching 950C 1 hr Scouring H2O2 hot killer A. acid 15 m salt dye soda leveling 700C 600C enzyme Hot wash agent 45 – 60 min 40 min matl cold wash 400C Dyeing curve of 100% cotton fabric with reactive dye Page no: 30

  31. CVC DYEING SEQUENCE: Perergent + Artioreasomg agent at 800C for 20' ↓ cad wash ↓ A.Acid [pH 4-4.5] ↓ Levelling agent + Antioreasomg agent ↓ Buffering agent [jinlab RFL] ↓ Color at 130o 50' ↓ ↓ If OK ↓ Bath Drain ↓ ½ scouring ↓ Cotton dyeing sequence ↓ If not oK ↓ temp 1300 ↓ If OK ↓ Bath drain ↓ ½ scouring ↓ Cotton dyeing sequence dye Detergent + Anticreasing agent ½ scourig 1300C 50’ 800C salt 950C Soda R. dye 20’ Leveling & buffering agent A. Acid Cold wash 600C 50’ material 600C 400C Cold wash & unload DYEING CURVE OF PC / CVC FABRIC WITH REACTIVE / DISPERSE DYES Page no: 31

  32. DYEING SEQUENCE FOR WHITE: Scouring + bleaching, 950 ↓ Blutton´ 50' ↓ 15' Sample test ↓ Water drain ↓ Hot (without chem.: at 800C for 20') ↓ A.cAcid ↓ ↓ If OK ↓ Sequester ↓ Softner ↓ Unload ↓ If not oK ↓ Softener ↓ Unload Page no: 32

  33. STANDARD RECIPE OF SCOURING & BLEACHING OF UKDL SCOURING & BLEACHING: DEEP SHADE LIGHT SHADE 01. ALBATEX FFC : 0.15 G/L : 0.15 G/L 02. LADIQUEST 1097 : 0.25 G/L : 0.25 G/L 03. CIBAFUUIDE C : 0.50 G/L : 0.50 G/L 04. HOSTAPOL JU : 2.00 G/L : 2.00 G/L 05. CAUSTIC SODA : 2.50 G/L : 2.00 G/L 06. SODA ASH : 2.50 G/L : 2.00 G/L 07. STABILIZER SF. : 0.35 G/L : 0.30 G/L 08. H2O2(50%) : 3.50 G/L : 3.00 G/L 09. ACETIC ACID : 1.00 G/L : 1.00 G/L 10. INVATEX PC : 0.30 G/L : 0.25 G/L LEVELLING: 01. CIVAFLUDIE c : 0.50 G/L : 0.50 G/L 02. LADIQUEST 1097 : 0.80 G/L : 0.60 G/L (FOR LYCRA S/J CIBAFLUIDE C : 0.70 G/L) LEVELLING: FOR TURQUISE BLUE, R-BLACK, ROYEL COLOUR 01. CIBAFLUIDE C : 0.70 G/L 02. LADIQUEST 1097 : 1.00 G/L 03. E2R : 0.50 G/L [ FOR WHITE SHADE ] H2O2 ( 50% ) : ( 4.00 G/L - 7.00 G/L) Page no: 33

  34. White Dyeing Recipe For (100% Cotton) Buyer Name : Farnoorr Order No : Cross line Batch No : 19100 Fabric Type : (1 * 1) Rib G. S. M. : 200 – 210 M : L = 1 : 8 Mtl wt. = 100 kg Water = 800 Liter Fab dia. = 42 inch Colour = White Serial No Name Dosing (g/l) Quantity Remarks 01 Hostapol JU 0.20 160 gm 02 Cibafluide-C 0.20 160 gm 03 Albatex – FFC 0.20 160 gm 04 Cibafluide – C 0.73 584 gm 05 Hostapol JU 1.20 960 gm 06 Sequester – K 1.00 800 gm 07 Caustec Soada 2.25 1.80 Kg 08 Soda Ash 1.00 800 gm 09 Stabilizer SF .30 240 gm 10 H2O2 4.00 3.20 Kg 950C , 60 min 11 BLUETONE – BVB 0.21 % 210 gm 12 Acetic Acid 0.60 480 gm 13 Sequester – K 0.40 320 gm 14 Softener (Non - Ionic) 1.50 1.20 Kg Prepared by : ………………… Dyeing Incharge : ……………. Checked by : ………………………….. Production Manager : ………………….. Page no: 34

  35. Colour Dyeing Recipe (100% Cotton) With Reactive Dye Buyer Name : D. S. L Order No : Cross line Batch No : 19100 Fabric Type : S / J G. S. M. : 160 – 170 M : L = 1 : 8 Mtl wt. = 100 kg Water = 800 Liter Fab dia. = 42 inch Colour = Navy Serial No 01 02 03 04 05 06 07 08 09 10 Name Hostapol JU Ladiquest 1097 Albatex – FFC Cibafluide – C Stabilizer SF Soda Ash Caustec Soada H2O2 Acetic Acid Invatex PC Dosing (g/l) 2.00 0.40 0.15 0.50 0.50 2.50 3.00 4.00 1.00 0.15 Quantity 1.60 kg 320 gm 120 gm 400 gm 400 gm 3.60 kg 2.40 Kg 3.20 Kg 800 gm 120 gm Remarks 11 12 Cibafluider – C Ladiquest 1097 0.50 0.80 400 gm 640 gm 13 14 15 Reactive S Yellow F3R Reactive S Red F3B Reactive Black – 5 0.33 % 0.79 % 4.20 % 330 gm 790 gm 4.20 kg 16 17 18 19 20 Salt Soda Ash RFL A. Acid Softner (Non Ionic) 62.00 20.00 0.80 1.00 1.00 49.60 kg 16 kg 640 gm 800 gm 800 gm Scouring & bleaching 950C 1 hr Scouring H2O2 hot killer A. acid 15 m salt dye soda 700C leveling 600C enzyme Hot wash agent 45 – 60 min 40 min matl cold wash 400C Dyeing curve of 100% cotton fabric with reactive dye Page no: 35

  36. REMARKS: UKDL strictly follow the production parameters like the time, temperature, M:L ratio pH etc. As they do some difficult shade, it takes more time for the production of the batch. Because of the trolley shortage and generator failure, the production process is sometime hampered. Considering these limitations, the production officer and the Sr. Production Officer try their best to reduce the production time. Page no: 36

  37. CHAPTER – VI QUALITY ASSU QUALITY ASSURANCE RANCE Page no: 37

  38. Q. C. DEPARTMENT QUALITY POLICY: It is the policy of UKDL to produce quality dyed knit fabrics that meet or exceed customers expectations & needs. To implement this policy the top management of UKDL is committed to provide adequate resources in terms of good raw materials and trained personnel & continually improve / upgrade its processes and systems. QUALITY OBJECTIVES:  Overall material/product loss (Level of rejection) for the company during the production process (in a year) shall not exceed 1.5 %  Defects during dyeing & knitting operations to reduced by 10% by the Jan ‘03  Process capability shall be maximized by maximizing the m/c breakdown time. M/c breakdown time should be reduced to 20 % form its current status/position by the mid 2003.  A quality procedure manual in line with the requirement of ISO9001 shall be developed and implemented by August 2002.  To ensure better work environment for the personnel working in the organization. MACHINES:  Wash Fastness Tester  Light fastness tester  Rubbing fastness tester  Electronic balance  G.S.M. cutter  Fabric inspection table  Light box  Shrinkage (%) meter INSPECTION AREA:  Shade match of fabric  G.S.M.  Fabric diameter  Shrinkage (%)  Length wise  Width wise  Fiber type  Wash fastness  Light fastness  Rubbing fastness  Faults  Dyeing faults  Knitting faults Page no: 38

  39. FAULTS ARE FOUND IN QC DEPERTMENT: Knitting faults:  Hole  Slub  Thick place  Thin place  Neps  Stripe  Missing yarn  Contamination  Light  Medium  Deep Dyeing faults:  Uneven shade  Running shade  In fastness property Finishing faults:  GSM variation  Spirality  Shrinkage control  Length wise Page no: 39

  40. QUALITY ASSURANCE SYSTEM QUALITY ASSURANCE PROCEDURE:  Uttara Knitting & Dyeing Ltd. assures the quality of their products in the following three steps:  In laboratory  In Dyeing section &  In finishing section  Procedures are described below: In laboratory:  Swatch card from buyer according to their requirement  Recipe prediction for sample dyeing  Sample dyeing until matching with swatch card  If matching is OK, then it is sent to the buyer for approval.  If buyer approves the sample then bulk production. In dyeing section:  After approval form the buyer, sample dyeing is done in dyeing m/c in dyeing shed & again matched with the approved sample  If result is OK. then balk production,  During dyeing, samples are taken until accurate shade matching. The interval may be 30-40 minutes  After dyeing sample is collected after softening matching is done  Last of all, sample is collected after fixation & matched  Then allowed the fabrics to be finished In finishing section:  Correctly dyed, after treated & matched fabrics are allowed for finishing  By using a series of finishing machines correct width, softness & appearance are maintained according to requirements  Then sampling is done for several times to test GSM, Shrinkage & fastness properties.  Finally fabric is inspected & prepared for delivery Page no: 40

  41. List of Equipments: Machineries & equipment used :           Spectrophotometer with software (Datacolor) Colour light box Sample dyeing machine (2) Lab. Dip Iron Electric Balance Crock meter Washing m/c GSM Tester PHmeter Quality standard: Uttara Knitting & Dyeing Ltd. follows the quality standard: ISO-9001.2000, REMARKS: Uttara Knitting & Dyeing Ltd. always aware about the quality of the product. The quality of the product is always approved by the buyer. They follows the quality standard: ISO 9001: 2000, Uttara Knitting & Dyeing Ltd. is well equipped for checking the quality of the ptoduct.. They report to the buyer time to time/ batch to batch. sent the quality Page no: 41

  42. CHAPTER – VII MAINTENANCE MAINTENANCE Page no: 42

  43. MAINTENANCE Maintenanace of Machinery: Maintenance of machinery is very essential mechanical effort for achieving smooth running of different machines. Maintenance is a process by which equipment is looked afterin such a way that trouble free. Services and increased machine life can be ensured and specific product quality required by the customers is sustained. On time maintenance increase m/c lifetime & ensures tuouble free services. In Uttra Knitting & Dyeing Ltd. 2 types of maintenance are done: 1. Break down maintenance 2. Routine maintenance Maintenance Routine Maintenance Break Down Maintenance Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance 1. Break down Maintenance: Break down maintenance is done instantly when problem arises in machine. In this case, repairs are made after the equipment is out of order and it cannot perform its normal functions. 2. Routine Maintenance: After a particular little the machines are cleaned & reordered, that is routine or schedule maintenance. PPC does it once in a month. Schedule maintenance varies, time in time & also depends on situation according to types of machines, because maintenance is directly related to production. Most of the time, all the screws, nuts, bolts & levers are checked, lubrication is also done. Workers inform about the problem areas of the machines. Depending on their information. maintenance is done, Maintainers analyses the machine records & take steps according to requirements. Page no: 43

  44. MAINTENANCE PROCEDURE: Duringmaintenance procedure following points should be checked. Checklist of different parts: Maintenance: Mechanical Machine: Dyeing Machines Sl. No. Item need to be checked & Serviced 1 Crease the winch bearing. 2 Complete cleaning of machine 3 Cleaning of drain valves, replace seals if required 4 Check air supply filter, regulators, and auto drain seals 5 Clean filters element and blow out 6 Greasing of Unloading Roller Bearings. 7 Checking of oil level and bolts of Unloading Roller Gearbox. 8 Checking of unloading roller coupling and packing. 9 Checking and cleaning (if required) of Min Vessel Level Indicator 10 Check the oil level of pump bearing and refill if requird. 11 Check the function of heat and cool modulating valves 12 Check all belts and belt tension 13 Check all door seals Maintenance: Machine: Mechanical Lab dyeing m/c. Sl. No. Item need to be checked & Serviced 1 Check rotating main shaft bearing. 2 Check cooling water inlet and outlet nose and nose clips. 3 Check cooling fans 4 Check driving bells and pulleys. Page no: 44

  45. Maintenance Machine : Mechanical : Lab dyeing m/c. Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Items need to be checked & Serviced Check & clean fluff and dirt at all motor fan covers Check all motors terminals Check min panels (by using compressed air) Check panel cooling fan & clean it filter Clean main pump inverter and its cooling fan Check all circuit breaker, magnetic contractors and relays Check current setting of all circuit breaker & motor over loads. Visual checking of all power & control cables Check DC drive of reel motors Check all pressure switches Check calibration of main vessel & all additional tank Check all pneumatic solenoids Check calibration of heating/cooling. Modulating value Check setting of tangle sensor. Check setting & operation of lid safety switches Check all emergency Switches Check all indicating lamps Check all on/off switches Check all signal isolators Check key pad & display of controller Check proximity switches The following tasks are generally done during maintenance:       Inspections & check ups Lubrications Planning & scheduling Record analysis Training of the maintenance crew Collection or purchase of spares Page no: 45

  46. Maintenance work to the different machines: BOILER MAINTENANCE SCHEDULE: Daily:  Check gas pressure  Maintain log sheet  Chemical dosing Weekly:   Check all steam line Fire quality of boiler Monthly:     Check all steam line Fire quality of boiler Gas consumption report Burner clean Quarterly:      Burner clean Economizer clean Feed tank clean Chemical tank clean Sight glass clean Half yearly:        Burner clean Feed tank clean Chemical tank clean Economizer clean Replace gasket Replace valve Check gas line & filter & pressure Yearly:           Overhauling of boiler Chemical cleaning of boiler Safety valve test Economizer clean Feed tank clean Chemical tank clean Burner clean Check safety valve setting Replace valve & gasket Boiler inspection by authority Page no: 46

  47. Dyeing m/c maintenance Schedule Daily:     Check belt tension Check steam or water system & air supply Check chemical pump Machine clean Weekly:      Bearing & belt check Check leakage of air, steam & Water line Greasing bearing points Add gland packing at pump Monthly:      Greasing bearing points Replace bearing points (if required) Gaskrt check Clean steam trap Lubricating all chemical pump Quarterly:       Replace belts Repairing of pulley, shaft & bearing housing Painting m/c & pipe line Clean steam trap Replace seals (if leakage) Change gasket of steam of water lines Half yearly:      Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing Half yearly:      Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing Yearly:  Machine overhauling Page no: 47

  48. Hydro extractor Maintenance Daily:   Machine clean Belt checking Weekly:    M/c clean Belt clean Greasing & lubricating of all points Monthly:   M/c clean Check gear oil quality Quaterly:   Change of gear oil Belt change Half yearly:   Change of gear oil Belt change (if required) Yearly:  Machine overhauling Page no: 48

  49. TENSIONLESS DRYER MAINTENANCE Daily:    Check belt tension Check steam supply & air system Machine clean Weekly:    Check fabric drying quality Greasing bearing points Clean airfilter & regulator Monthly:    Clean radiator & m/c cabinet Greasing bearing points Clean air filter and regulator Quarterly:    Replace belt Replace gear oil Duct clean Half yearly:   Check roller condition Greasing & lubricating all points Yearly:  Machine overhauling Page no: 49

  50. TUMBLER DRYER MAINTENANCE: Daily:  Check belt  Steam leakage area  M/c clean Weekly:     Heat exchange clean Greasing & lubricating of all points Belt check M/c clean Monthly:   Filter clean Steam trap clean Quarterly:     Replace belt Replace gear oil Duct clean Gasket & valve change Half yearly:  Gasket & valve change   Yearly: Machine overhauling Page no: 50

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