1 / 131

Industrial attachment of evince textiles limited

Presentation about 'Industrial attachment of evince textiles limited'

sheshir
Download Presentation

Industrial attachment of evince textiles limited

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Evince Textiles Limited

  2. CONTENTS CHAPTER - 1 PROJECTDESCRIPTION CHAPTER - 2 MAN POWER MANAGEMENT CHAPTER - 3 MACHINEDESCRIPTION CHAPTER - 4 RAW MATERIALS CHAPTER - 5 PRODUCTIONPLANNING,SEQUENCE& OPERATION CHAPTER - 6 SOFT WINDINGSECTION CHAPTER - 7 YARN DYEINGSECTION CHAPTER - 8 HARD WINDINGSECTION CHAPTER - 9 WARPINGSECTION CHAPTER - 10 SIZING SECTION CHAPTER - 11 DRAWING,DENTING SECTION CHAPTER - 12 WEAVINGSECTION CHAPTER - 13 SAMPLEDEVELOPMENT CHAPTER - 14 FINISHINGSECTION CHAPTER - 15 QUALITYASSURANCESYSTEM CHAPTER - 16 MAINTENANCE CHAPTER - 17 UTILITYSERVICES CHAPTER - 18 STORE& INVENTORYCONTROL CHAPTER - 19 COST ANALYSIS CHAPTER - 20 MARKETINGACTIVITIES CHAPTER - 21 CONCLUSION

  3. CHAPTER - 1 PROJECT DESCRIPTION EVINCE TEXTILES LTD

  4. EVINCE TEXTILES LIMITED AT A GLANCE 1. Name of the project : Evince Textiles Limited 2. Location : Shirir Chala, Bhabanipur, Gazipur. 3. Address : About 55 km north of Dhaka city. Factory: Village: Shirir Chala, P.O: Bhabanipur Thana: Joydevpur, Dist.: Gazipur, Bangladesh. Fax: 04494415800. Tel: 88-02-8050349, 8059017. Office: Plot-33, Section-07, Mirpur, Dhaka -1216, Bangladesh. Phone: (88-02) 8011227, 8013356, 8021710. Fax: 88-02-8013504 E-mail: evince@evincebd.com 5. Board of directors: Managing Director: Anwar-ul Alam Chowdhury Deputy Managing Director: Shobnom Shehnaj.

  5. 7. Communication : The project is easily accessible by road. 8. Product name : Woven yarn dyed, 100% Cotton. 9. Product Mix : Yarn dyed: a. Stripe. b. Check. Designs - In Dobby loom: i. Plain. ii. Twill. iii. Sateen. iv. Some combination weaves which are possible in tappet. v. Oxford. (Warp rib and weft rib). vi. Queen’s Oxford. vii. Matt. viii. Diamond. ix. Diaper. x. Herring bone. xi. Honey comb. xii. The design which are possible in 20 heald frames. 10. Annual production capacity: 10 million yards per year.

  6. 11. Factory area : Approx. 135094 Sq. Feet. (Including ETP) 12. Type of the factory : Horizontally integrated 13. No. of employees : Approx. 120(Officer), 1200(Worker) 14. Project cost : Approx. 3000million taka 15. Different Departments : (a) Administration. (b) Human Resource and Development Dept. (c) Weaving Preparatory (d) Weaving. (e) Woven finishing. (f) Yarn dyeing Dept. (g) Store. (h) Planning Dept. (i) Utility Dept. (j) Procurement (k) Marketing HISTORY OF EVINCE TEXTILES LIMITED Evince Textiles limited was incorporated under the companies Act (Act-8) of 1994 in June 12, 2002 and went into commercial production in December 2002.

  7. CHAPTER - 2 MAN POWER MANAGEMENT EVINCE TEXTILES LTD

  8. ORGANOGRAM: ADMINISTRATION Managing Director ↓ Deputy Managing Director ↓ Executive Director ↓ Deputy General Manager ↓ Assistant General Manager ↓ Manager ↓ Deputy Manager ↓ Assistant Manager ↓ Senior executive ↓ Executive ↓ Junior Executive

  9. OPERATION Supervisor/Inspector ↓ Line Man ↓ Operator ↓ Asst. Operator ↓ Helper/carrier/cleaner SHIFT CHANGE There are three shifts per day in EVINCE TEXTILES LTD. So each shift contains eight hours. Shift Duration A 06.00 AM – 02.00 PM B 02.00 PM – 10.00 PM C 10.00 PM – 06.00 AM General shift 09.00 AM – 05.00 PM General shift is applicable for some officers only.

  10. MAN POWER IN DIFFERENT SECTION (WEAVING) OF EVINCE TEXTILE LTD Name of Machine/Job No of Machine Man Coverage for off day (leave & absentism) Section Description Total Required Per Shift Production officer 2 0 6 Asst. Production officer Q.C incharge 1 G shift 2 5 1 0 3 Rapier Loom (148 Loom) On line Q.C 2 2 8 Loom Weaving Off Line Q.C 2 2 8 Line Man 4 0 12 Operator 48 5 150 Helper 20 5 25 Floor Cleaner 6 0 6 Yarn Supervisor 4 1 5 Weft yarn helper 6 1 7 Leno Bobbin winder Total 2 1 3 248 Name of Machine/Job No of Machine Man Coverage for off day (leave & absentism) 0 Section Description Total Required Per Shift 1 Fitter In charge 3 Beam Gaiter 6 6 24 Knotting & Gaiting Weaving 148 Loom Knotting In charge Knotting Operator 0 0 1 2 2 8 Knotting Helper 3 3 12 Total 48

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

  12. CHAPTER - 3 MACHINE DESCRIPTION EVINCE TEXTILES LTD

  13. OPERATION PROCEDURE There are two ways by which woven fabrics are produced. They are: 1. Solid dyed 2. Yarn dyed In EVINCE only yarn dyed fabric are produced. Generally yarn dyed fabrics are costly item. Because dyed yarn are costly and in case of yarn dyed fabric sectional warping is necessary which is also costly and time consuming process. The operation procedures maintained in EVINCE TEXTILES are the following – Raw Materials ↓ Soft Winding ↓ Yarn Dyeing ↓ Hard Winding ↓ Sectional Warping ↓ Sizing ↓ Drawing & Denting ↓ Weaving ↓ Finishing

  14. DESCRIPTION OF THE MACHINE USED IN EVERY STAGE SOFT WINDING Name of machine: Soft Winding Machine Machine Type: (HS-101 C) No. of machine: 3 No of head: (54×2)/machine Machine rpm: 1000 Brand Name: CORAL TEXTILE Origin: Taiwan YARN DYEING Dyeing machine No. of Capacity (Kg) Power (KW) Water Capacity (Liter) machine 01 400 59 3200 02 400 59 3200 03 200 32 1600 04 200 32 1600 05 100 21 800 06 100 21 800 07 50 13 400

  15. 08 30 9 240 09 30 9 240 10 12 7 96 11 12 7 96 12 12 7 96 Rapid dryer No. of machine: 1 Brand Name: Tong Geng Origin: Taiwan Capacity: 400 Kg Power consumptions: 180 kw/machine Time: 80-110 min. Temperature: 110-115° C. HARD WINDING Name of machine: Hard Winding Machine Machine Type: (HS-101 CH) No. of machine: 4 No of head: (42×2)/machine Machine rpm: 1000

  16. Brand Name: CORAL TEXTILE Origin: Taiwan SECTIONAL WARPING MACHINE No. of machine: 3 Brand Name: BENNINGER Origin: SWITZERLAND Creel capacity: 560(1) & 720(2&3) Creel type: H type Max beam width: 2200mm SIZING MACHINE No. of machine: 2[BENNINGER (1) & JUPITER (1)] Brand Name: BENNINGER & JUPITER Origin: SWITZERLAND & INDIA Back beam capacity: 1 & 1 No of drying cylinder: 6 & 8 No of size box: 1 & 1 Capacity of size box: 125 Liter (For both machines) No of wax box: 1 & 1 Voltage/Frequency: 400v/50Hz

  17. LOOM Total no of looms: 156 Name of the Loom Model Shedding Device R.P.M (Avg) No. of Looms SOMMET 450 40 Rapier Loom Dobby SMIT TEXTILE 450 21 VAMATEX 465 95 FINISHING MACHINES 1. Singeing & Desizing machine 2. Washing machine 3. Stenter machine 4. Sanforizing machine

  18. CHAPTER - 4 RAW MATERIALS EVINCE TEXTILES LTD

  19. RAW MATERIAL Main Raw Material is yarn. Yarn used is 100% cotton. Some common types of yarns are tabulated below with local price: Count Type Price$ 20/1 Comb 2.25 30/1 Comb 2.37 40/1 Comb 3.67 50/1 Compact 3.88 60/1 Comb 4.72 40/2 Comb 3.25 80/2 Comb 6.83 100/2 Comb 7.35 Some of the manufacturing companies from where EVINCE procure there yarn are: 1. Akij Spinning Mill. 2. Nahar Spinning Mill. 3. Boshonta Spinning Mill. 4. Aroti International Limited. 5. GTN (India) Limited

  20. CHAPTER - 5 PRODUCTION PLANNING, SEQUENCE & OPERATION EVINCE TEXTILES LTD

  21. OPERATION PROCEDURE There are two ways by which woven fabrics are produced. They are: 1. Solid dyed 2. Yarn dyed In EVINCE only yarn dyed fabric are produced. Generally yarn dyed fabrics are costly item. Because dyed yarn are costly and in case of yarn dyed fabric sectional warping is necessary which is also costly and time consuming process. The operation procedures maintained in EVINCE TEXTILES are the following – Raw Materials ↓ Soft Winding ↓ Yarn Dyeing ↓ Hard Winding ↓ Sectional Warping ↓ Sizing ↓ Drawing & Denting ↓ Weaving ↓ Finishing

  22. DESIGN CELL Design Cell is one of the most important departments of EVINCE TEXTILES LTD. When an order comes to the marketing or merchandising officer he/she send the fabric to the design cell that is it possible or not possible in EVINCE. They send an Article request paper. Design cell analyze the fabric design and test the feasibility of production and create an Article code and send this article code to the marketing or merchandising officer and input data to the Design Deskpo (TEXTRONIC) which is a software used in EVINCE for all types of information by networking. EVINCE’s Design department is equipped with CCI, a sample developing m/c of TAIWAN. After getting the Article code planning department discuss with marketing officer about costing. Then marketing officer send mail or discuss directly with the buyer about pricing of the product. If buyer is agreed with the price then marketing officer sends mail to the central planning section with Article code. Planning department take a print of Dispo paper for the article code from the system Textronic Deskpo. After printing Dispo paper they send it to the design cell to check or verify. Design cell check and give drawing and denting plan and send it to the planning section again. Planning then send it to the various section where these information required and at a time requisition all necessary raw materials or other materials. ORGANOGRAM OF DESIGN CELL Deputy General Manager ↓ Senior Executive (3 person) ↓ CCI Machine (14 person)

  23. DISPO PAPER GOES TO THE FOLLOWING SECTION 1. Design cell. 2. Store. 3. Winding. 4. Yarn dyeing. 5. Warping. 6. Sizing. 7. Drawing and denting. 8. Loom. 9. Quality Control Department. 10. Commercial Department. 11. Costing Department. DISPO PAPER CONTAINS FOLLOWING INFORMATIONS 1. Fabric Specification. 2. Yarn composition 3. Finished type. 4. Finished fabric’s EPI x PPI 5. Finished fabric’s width. 6. Required length.

  24. 7. Reed count. 8. Grey EPI and PPI. 9. Greige width. 10. Reed width. 11. Reed EPI 12. Required greige length. 13. Required warp length. 14. Ground Ends. 15. Selvedge Ends. 16. Cover Factor. 17. Numerical Plan (Warp & Weft) 18. Drawing & Denting Plan. PROPOSED PROCESS ALLOWANCE FOR COTTON YARN Section Yarn Dyeing Winding Warping Sizing Weaving(crimp) Greige(reject) Process Loss Shrinkage Inspection(rejection) Warp % 3% 1% 1-2% 2% 6-15% 1% 7-9% 3% 1% Weft %     3-4% 1% 5-6% 3% 1%

  25. AVAILABLE REED IN EVINCE Reed Count Blue Red Local China Total 49 12 12 51 10 10 53 7 7 56 6 6 60 2 2 63 4 4 66 1 1 74 3 3 80 2 2 84 15 31 46 88 10 4 14 90 22 19 41 94 1 1 96 10 10 98 10 8 18 100 17 23 40 102 11 11 108 19 54 39 112 110 14 14 112 10 10 116 14 14 118 40 30 70 120 7 17 24 130 81 7 16 104 136 10 10 144 38 38 624

  26. MAJOR DEPARTMENTS IN EVINCE 1. Winding. 2. Warping. 3. Sizing. 4. Drawing, Denting. 5. Weaving. 6. Inspection. 7. Finishing. WINDING SECTION In fabric manufacturing (weaving) process this is the first stage where rewinding of supplied yarn is done on to a desired package suitable for the use in the next process. Types of Winding: 1. Soft Winding. 2. Hard winding

  27. CHAPTER - 6 SOFT WINDING SECTION EVINCE TEXTILES LTD

  28. SOFT WINDING Where the grey yarn is wound on to a special type of metallic bobbin and the package (spool) is made softer and bulkier to make it suitable for dye penetration in the (package) dyeing machine. Paper Cone Metallic Bobbin ORGANOGRAM The organogram of this section is given below: Section in charge ↓ Supervisor ↓ Operator ↓ Assistant Operator

  29.    Helper ↓ Cleaner MAN POWER Skill Level Section in charge Man Power 4 Supervisor 3 Operator 3 Assistant Operator Helper 2 8 Cleaner 4 MACHINE DESCRIPTION Manufacturer : Shanghai CORAL TEXTILE Machinery Co. Ltd. Origin : TAIWAN R.P.M. of Motor : 1000 No. of Head : 2 No. of Drum /head : 54 Traversing system : Grooved drum Motor : Individual Stop motion : Automatic No. of m/c : 3 Production per day : 3707.308 kg /day [Assuming 80% efficiency]

  30. OPERATION FLOW CHART Yarn received by store for a specific order ↓ Requisition given from soft winding section ↓ Received the yarn ↓ Winding ↓ Checking (Dia & per package weight) ↓ Stop winding ↓ Quality assurance ↓ Route card making Delivery for Dyeing ASSIGNMENT: FINDING OUT PACKAGE DENSITY For 40/1: Package wt. from spinning mill= 1.96 Kg Only paper cone wt. = 0.05035 Kg

  31. So, only wt. of yarn on package = (1.96 – 0.05035) = 1.90968 Kg = 1909.68 gm Now, Package wt. after S/W = 1.30 Kg Only steel bobbin wt. = 0.24 Kg So, only wt. of yarn on steel bobbin = (1.30 – 0.24) Kg = 1.06 Kg = 1060 gm Package dia = 17.7+ 17.6 /2 = 17.65 cm So, radius, r = 17.65/2 = 8.825 cm Height, h = (14.2+14.3)/2 = 14.25 cm Volume, v = πr2h = 3.14 × (8.825)2× 14.25 =3486.544 cc So, package density = 1060/3486.544 gm/cc =0.304 gm/cc For 50/1: Package wt. from spinning mill = 1.94 Kg Only paper cone wt. = 0.05032 Kg So, only wt. of yarn on package = (1.94 – 0.05032) Kg = 1.88968 Kg =1889.68 gm

  32. Now, Package wt. after S/W = 1.36 Kg Only steel bobbin wt. = 0.24 Kg So, only wt. of yarn on steel bobbin = (1.36 – 0.24) Kg = 1.12 Kg = 1120 gm Package dia = 17.9+ 17.8/2 = 17.85 cm So, radius, r = 17.85/2 = 8.925 cm Height, h = (14.2+14.2)/2 = 14.2 cm Volume, v = πr2h = 3.14 × (8.925)2× 14.2 =3553.495 cc So, package density = 1120/3553.495 gm/cc =0.315 gm/cc For 60/1: Package wt. from spinning mill = 1.94 Kg Only paper cone wt. = 0.05032 Kg So, only wt. of yarn on package = (1.94 – 0.05032) Kg = 1.88968 Kg =1889.68 gm Now, Package wt. after S/W = 1.266 Kg Only steel bobbin wt. = 0.23 Kg So, only wt. of yarn on steel bobbin = (1.266 – 0.23) Kg

  33. = 1.036 Kg = 1036 gm Package dia = 17.4+ 17.7/2 = 17.55 cm So, radius, r = 17.55/2 = 8.775 cm Height, h = (14.1+14.2)/2 = 14.15 cm Volume, v = πr2h = 3.14 × (8.775)2× 14.15 =3422.96 cc So, package density = 1036/3422.96 gm/cc = 0.302 gm/cc So, we can conclude that Soft Winding package density varies between 0.300.35. PRODUCTION CALCULATION Delivery Speed = 600 m/min Total no. of head = 324 Efficiency = 90% Time = 1 day For 40/1: Production/day = (600×324×60×24×0.9×1.09)/(840×40×2.2046) Kg/day = 3707.308 Kg/day. For 50/1: Production/day = (600×324×60×24×0.9×1.09)/(840×50×2.2046) Kg/day = 2965.85 Kg/day. For 60/1: Production/day = (600×324×60×24×0.9×1.09)/(840×60×2.2046) Kg/day = 2471.55 Kg/day.

  34. CHAPTER - 7 YARN DYEING SECTION EVINCE TEXTILES LTD

  35. OBJECTIVE To dye grey yarn & to produce check and stripe fabric. DYEING PROCEDURE Scouring & Bleaching ↓ Dyeing ↓ Wash-off ↓ Finishing BASIC YARN DYEING SEQUENCE Soft Winding   Batching   Dyeing   Hydro extractor   Dryer (R.F. Dryer)   Hard Winding

  36. YARN DYEING SEQUENCE FOLLOWED BY EVINCE Soft Winding   Batching   Dyeing   Drying (Rapid Dryer)   Hard Winding

  37. CHAPTER - 8 HARD WINDING SECTION EVINCE TEXTILES LTD

  38. HARD WINDING Where the dyed yarn from dyeing machine is converted into spool to paper cone, to make the yarn easily be fed to the sectional warping machine. ORGANOGRAM Section in charge ↓ Assistant operator ↓ Helper ↓ Cleaner MAN POWER Skill Level Man Power Section in charge 3 Assistant operator 5 Helper 10 Cleaner 4

  39. MACHINE DESCRIPTION Manufacturer : Shanghai CORAL TEXTILE Machinery Co. Ltd. Origin : TAIWAN R.P.M. of Motor : 1000 No. of Head : 2 No. of Drum /head : 42 Traversing system : Grooved drum Motor : Individual Stop motion : Automatic No. of m/c : 4 Production per day : 3707.308 kg /day [Assuming 80% efficiency] FLOW CHART Route card “ok” by Quality Control Department ↓ Checking by winding supervisor    Start Hard Winding ↓ Measuring weight

  40. ASSIGNMENT: FINDING OUT PACKAGE DENSITY For 40/1: Package wt. after H/W = 1176 gm Empty paper cone wt. = 35gm So, only wt. of yarn on paper cone = (1176 – 35) gm = 1141 gm Package dia = 15.3 + 17.1/2 = 16.2 cm So, radius, r = 16.2/2 = 8.1 cm Height, h = (15.1+15.2)/2 = 15.15 cm Volume, v = πr2h = 3.14 × (8.1)2× 15.15 = 3122.72 cc So, package density = 1141/3122.72 gm/cc =0.365 gm/cc For 50/1: Package wt. after H/W = 1156 gm Empty paper cone wt. = 35gm So, only wt. of yarn on paper cone = (1156 – 35) gm = 1121 gm Package dia = 15.7+ 18.4/2 = 17.05 cm

  41. So, radius, r = 17.05/2 = 8.525 cm Height, h = (14.5+14.6)/2 = 14.55cm Volume, v = πr2h = 3.14 × (8.525)2× 14.55 = 3322.022 cc So, package density = 1121/3322.022 gm/cc = 0.337 gm/cc So, we can conclude that Hard Winding package density varies between 0.330.36. PRODUCTION CALCULATION Delivery Speed = 600 m/min Total no. of head = 336 Efficiency = 90% Time = 1 day For 40/1: Production/day = (600×336×60×24×0.9×1.09)/(840×40×2.2046) Kg/day = 3841.6862 Kg/day. For 50/1: Production/day = (600×336×60×24×0.9×1.09)/(840×50×2.2046) Kg/day = 3075.64 Kg/day.

  42. For 60/1: Production/day = (600×336×60×24×0.9×1.09)/(840×60×2.2046) Kg/day = 2563.774 Kg/day. So, we can conclude that production is reduced by the increasing of yarn count. FAULTS IN WINDING SECTION Faults Causes 1. Excessive Hard package Excess tension 2. Excessive Loose package Less tension 3. Ring Faulty drum 4. Stitching Vibration of Package 5. Ribbon Ribbon breaker problem. 6. Bulging Improper alignment of Package 7. Entanglement Jerking package 8. Bunch Improper store and handling 9. Cut cone Package drop 10. Reverse winding Low pressure TYPES OF MAINTENANCE 1. Schedule maintenance 2. Break down maintenance.

  43. SPARE ITEM TYPES 1. Readymade / purchase 2. Fabrication tool in work shop / other side 3. Import item QUALITY CONTROL IN WINDING SECTION The following quality is maintained in preparatory stage: Shade matching: The dyed yarn compared with lab drip sample or swatch card. Level Checking: During package dyeing dyes chemical enter in to package by pressure. So there is a possibility to differ level in inner and outer side. It is checked and allow up to (5 -6) % Fastness: Water and color fastness is checked. Strength: CSP, tenacity, CV% of tenacity, elongation are tested. Package hardness: Soft wound package is checked by hand. If it is hard, improper dyeing will occur. The hard wound package also is checked. If it is less hard or too hard it will create problem in the subsequent process.

  44. MATERIAL HANDLING EQUIPMENT FOR WINDING SECTION 1. Creel. 2. Trolley. Creel Trolley

  45. CHAPTER - 9 WARPING SECTION EVINCE TEXTILES LTD

  46. SECTIONAL WARPING OPERATIONAL STAFF Manager ↓ Assistant Manager ↓ Supervisor ↓ Senior Operator ↓ Operator ↓ Assistant Operator ↓ Helper

  47. PROCESS FLOW Dispo ↓ Yarn from store ↓ Creeling (According to warp plan) ↓ Machine setup ↓ Section wise warping ↓ Beaming SECTIONAL WARPING MACHINE No of m/c: 3 Brand name: BENNINGER Origin: SWITZERLAND Creel capacity: 560 & 720 Creel type: H type Maximum beam width: 2200 mm Warp width: Total Ends Warp Width Below 7060 1900 mm Above 7060 2100 mm

More Related