Internship Report

Content
Declaration ............................................................................................................ iv
Acknowledgement .................................................................................................. v
Executive Summary................................................................................................ vi
List of Table and Figure ......................................................................................... vii
Chapter One .......................................................................................................... 1
Introduction ........................................................................................................... 1
1.1 BACKGROUND & ESTABLISHMENT ..................................................................................................... 1
1.1.1 LOCATION..................................................................................................................................... 1
1.1.2 Preparation of technical and commercial specification .............................................................. 1
1.1.3 Construction and completion ...................................................................................................... 1
1.1.4 Man power and training .............................................................................................................. 2
1.1.5 Cooperation and participation ..................................................................................................... 2
1.1.6 Organization, Management & Manpower ................................................................................... 3
1.1.7 TECHNOLOGY ............................................................................................................................... 3
1.1.8 QUALITY POLICY ........................................................................................................................... 4
1.1.9MAJOR EMS ACTIVITIES ................................................................................................................ 4
1.1.10 MAJOR QMS ACHIEVEMENTS .................................................................................................... 5
1.1.11 Site selection .............................................................................................................................. 5
1.1.12 Machine specification of the Kombolcha textile share company .............................................. 6
1.1.13 Kombolcha textile share company Monthly usage of cotton .................................................... 7
1.1.14 OTHER UTILITIES......................................................................................................................... 8
1.1.15 Vision.......................................................................................................................................... 8
1.1.16 Mission ....................................................................................................................................... 8
1.2 The major Raw Materials of the Company ......................................................................................... 9
1.2.1 Raw material quality parameter ................................................................................................ 10
1.3 The overall workflow of the company .............................................................................................. 11
1.4 Over All Organizational Structure of the Company ......................................................................... 13
1.4.1 Responsibilities of function area................................................................................................ 14
1.5 Products of the Company ................................................................................................................. 15

i
 Internship Report

1.6 Main customer of the company ........................................................................................................ 16

CHAPTER TWO ..................................................................................................... 17

Over All Internship Experience ............................................................................. 17
2.1 TITTLE ................................................................................................................................................ 18
2.2 SELECTING SECTION OF THE COMPANY TO WORK SECOND TASK ................................................... 18
2.3 OBJECTIVES ....................................................................................................................................... 18
2.4 WORK FLOW PARTICULAR SECTION ................................................................................................. 19
2.5 DETAILED PROBLEMS AND THE METHODS ....................................................................................... 20
2.5.1 First round observation on the processing area ........................................................................ 20
2.5.2 Second round observation on the processing area ................................................................... 22
2.5.3 Third round observation on the processing area....................................................................... 23
2.6 Discussion and main finding ............................................................................................................. 24
2.6.1 Fiber properties on textile processing performance, quality and the impact of cotton costs .. 24
2.7 Solution to solve the problem........................................................................................................... 27
2.7.1 Laboratory Results ..................................................................................................................... 27
2.8 Performance Procedure of the Work Task ....................................................................................... 28
2.9 Challenges during solving the problem............................................................................................. 29
2.10 Measure to overcame the problem ................................................................................................ 29

Chapter Three ...................................................................................................... 30

Benefits Of Internship Program ........................................................................... 30
3.1 Improvement in Practical Skill .......................................................................................................... 30
3.2 Upgrading Theoretical Knowledge.................................................................................................... 31
3.3 Interpersonal Communication Skill ................................................................................................... 32
3.4 Team Playing Skill .............................................................................................................................. 32
3.5 Leader Ship Skill ................................................................................................................................ 32
3.6 Work Ethics ....................................................................................................................................... 32
3.7 Entrepreneurship skill ....................................................................................................................... 33

Chapter Four ........................................................................................................ 34

Recommendation and Conclusion ....................................................................... 34
4.1 Conclusion ......................................................................................................................................... 34

ii
 Internship Report

4.2 Recommendations ............................................................................................................................ 34

Reference ............................................................................................................ 36
Appendix.............................................................................................................. 37
Bale management in spinning mills ........................................................................................................ 37

iii
 Internship Report

Declaration

I, Mahmud Mohammed a fourth year textile engineering student, have undertaken my

internship experience in Kombolcha textile share company from a period of October 2011 to
January 2012 under the guidance of Ass.Professor Adane Haile (Academic Advisor) and
Berhanu (company advisor).
I certify that my work is original and compiled according to the internship report writing
guideline given by the Institute-Industry Linkage office of the Institute.

As the students academic advisor, I certify that the internship report written by the student is his
original work and compiled according to the guideline provided by the institutes IIL office as
far as my knowledge is concerned.

Ass.Professor Adane Haile

Name of the Academic Advisor Signature Date

Mahmud Mohammed
Name of the student Signature Date

iv
 Internship Report

ACKNOWLEDGEMENT
First of all I thanks to my god for who give me everything to full fill this internship program.
Then secondly I thanks to my parents for their valuable support when I was with them. Then I
also thanks to my advisor in the industry Ato Berhanu B. He clearly shows me what one Textile
Engineer do in the factory with sharing his experience. I enjoyed our discussions and have
learned a great deal from him. I also thanks to my mentor assistant professor Adane Haile for his
valuable advice when I write this report.

And finally, but not the least I thanks to the Kombolcha textile share company workers for
their valuable information. When I was in the factory they give me full information about the
task I do for the factory and the information which used me to write this final intern ship report.

Mahmud Mohammed

February 09/02/2012

v
 Internship Report

Executive Summary
The internship program provides an excellent means for enhancing organizations image and
recruitment activities. Organizations have access to prospective employees, and are given the
opportunity to view the intern for future potential without any commitment to hire.
The internship program helps to keep students informed of new developments, concepts and
methods in the field. Through the classroom, the intern is in touch with the most recent
theoretical and technical innovations. Consequently, the student can often bring new ideas and
skills to the organization, stimulating creative thinking and providing new alternatives to
problem areas.
The internship program permits better utilization of full-time personnel. The student intern can
provide professional staff support on short or long-term projects where it would not be
advantageous to divert other qualified employees from their specialized areas.

In this report the things included are the history of the, Kombolcha textile share company the
work flow of the factory, the tasks that I do for the factory and the benefits I get from this
internship program. The details of them are clearly written in the report.

vi
 Internship Report

List of Table and Figure

List of Tables

Table1 Machine specification of the Kombolcha textile share company 7

Table 2 Kombolcha textile share company Monthly usage of cotton...8

Table 3 Products of the Company.15

Table 4 First round observation on the processing area....20

Table 5 Second round observation on the processing area...21

Table 6 Third round observation on the processing area.22

Table 7 Laboratory test result 1st round ..27

Table 8 Laboratory test result 2nd round ..27

Table 9 Comparison the cotton test result with standard test result 28

List of Figures

Fig 1 overall workflow of the company....12

Fig 2 over All Organizational Structure of the Company ....13

Fig 3 work flow particular section......18

vii
 Internship Report

Chapter One
Introduction
1.1 BACKGROUND & ESTABLISHMENT
KTSC is an integrated Textile Mill established in 1986 as a public enterprise with a design &
attainable capacity of 22 & 18 million square meters of fabric per year respectively. The total
investment was 220 million birr & now it has been reorganized and recognized as a share
company since 1998.

1.1.1 LOCATION
Kombolcha Textile Share Company is located in Amhara National Regional State,
South Wollo, Kombolcha town, 380kms away from the capital, Addis Ababa, Ethiopia.
The factory is located within easy access of the main cotton growing regions of the country. The
town Kombolcha is connected to port of Djibouti Via all-weather road & is 500kms east. This is
particularly

1.1.2 Preparation of technical and commercial specification

In Consultation with several groups of technical exports, the technical aspects of the Kombolcha
textile mills project were developed phase by phase in great detail.

A complete set of tender document for planned integrated textile mill was prepared by the
national textile corporation and based on this document text export ,import of the German
democratic republic, invest of Czechoslovakia and general impianti of Italy submitted their offer.

This was then followed by technical and commercial negotiation, which started in oct.1979. For
the negotiation design and supply of machinery were finally concluded in a contact agreement
signed in March 1980 between the national textile corporation and the respective supplier of the
germen democratic republic, Czechoslovakia and Italy.

1.1.3 Construction and completion

The last phase of the design was completed in June 1982 and the construction of the company
building began in august 1982. The machinery and equipment erection was stated in May 1983.
Consequently the first technological line erection and performance taste was completed. In July
1884 and is thus ready to commence operation.
1
 Internship Report

1.1.4 Man power and training

The Kombolcha textile mill would create employment opportunities for 3400 peoples when
fully operational. In the other words, it would be the largest industry in the region employer.

To overcome the shortage of the skilled personal in textile technology especially of filters and
technicians, total of 184 employers has been trained. Locally and abroad. Appropriate training
would be given to about 2150 workers to ensure that the new plant and machinery are handled
and operate efficiently.

A total nearly of 1400 permanent and temporary workers had been engaged in the erecting of
plant and machinery up to 30 June 1984.

The finance for the Kombolcha textile mill has been obtained from the following sources. Equity
of the Ethiopian government. Loans from local bank. Credit secured from the government of
German democratic republic, Czechoslovakia and Italy. The total investment of the project based
on the contractual agreement sand payments affected up to the end of June 1984 is estimated to
be birr 222 million of which 62 % is raised locally through government equity and bank loans

Kombolcha textile mill was obtained the following benefits:-Extract production of 22 million
square meters of fabrics which will help to reduce the gap between supply and demand of fabric
3400 new job in the region More employment opportunities in the clothing and avid trades and
increased production of garment and apparel due to the multiplier effect Cotton production in the
region would be encouraged much more as a consequence of the demand for the factory Increase
government revenue through taxes Further development of the service sector in Kombolcha
town.

Kombolcha Textile Company was the first company to start export of dye fabrics in the history
of the country textile export .the company is exporting grey fabric and terry towels to European
and American markets even though the volume is very small

1.1.5 Cooperation and participation

A large number of government bodies, public enterprises and private centers have taken part
during the implementation of the Kombolcha textile mills project. the national textile corporation

2
 Internship Report

deeply acknowledges the great cooperation extended and effect exerted by the organizations to
make the project a suckers

Some of the major ones that deserve a special mention. The Ethiopian building construction
authority: for designing and constructing factory premises and buildings Ministry of finance for
providing customers and other related services.The ministry of Housing and Urban Development
for building house for workers. The Wollo region administration for providing the plot of land on
which the factory is built, and also for vigorously soliciting and winning the active support of
other public organization in the region for the project

1.1.6 Organization, Management & Manpower

The overall activities of the company are managed & administrated by the G/Manager, who is
assigned by & accountable to the Board of Directors Board members are appointee of the Public
Enterprise Supervisory Authority with a responsibility of formality & setting policy, resolving
policy issues & follow up of development programs etc.

All functional departments and services are led & supervised by their respective Department
Mangers & Service Managers who are directly reporting & accountable to D/G/Manager. This
doesn't include the Audit Service who is directly reporting to the Board of Directors.

The G/Manager is assisted by the D/G/Manager, the department managers & service manager in
formulating & revision of operational policies, exclusion of day-to-day activities, resolving of
operational problems & preparation of operational plan, budget and establishment of medium &
long term development programs.

The overall workforce engaged in the different activities of the company is more than 2000
(Permanent & Temporary) of which 58% are male & 42% female

In terms of level of education, there are professional, semiprofessionals and vocational &
technical school complete. All employees have basic knowledge, which is sufficient enough to
understand their current job requirement.

1.1.7 TECHNOLOGY
KTSC is an integrated textile mill, consisting machineries. In addition to the production
machineries the company is also equipped with utility & auxiliary tools & equipments.

3
 Internship Report

1.1.8 QUALITY POLICY

KTSC is committed to produce cotton products that meet customers' requirements through
implementation of effective Quality Management System based on ISO 9001:2000. KTSC
strives to meet and exceed the dynamic customers' needs and expectations through continual
improvement of the effectiveness of the Quality Management system on products and service
quality. We value our customers' feedback to continually improve our products and services
quality, competitiveness and reputation.

The top management ensures the involvement of stakeholders at all levels of the organization for
the achievement of this quality policy and excellence in performance to attain the company
objective and hence benefit all company's stakeholders.

1.1.9MAJOR EMS ACTIVITIES

Create environmental awareness across the company and through the public

Identify environmental aspects and modify environmental management programs

Segregated the scraps, chemicals, products and label them as per their categories

Effective control over sewage through waste water treatment plant

Recycling the used water of swimming pool and water discharges from different
machines

Minimized process waste, furnace oil and water consumption

Forestation program and participation on social activities

KTSC is also on the final course to be certified in Quality Management System (ISO
9001:2000). The Quality manual, System level procedures, Operational procedures, Work
instructions and check lists are provided and in use. The internal audit has already been
undertaken, the opportunities for improvement have identified and appropriate actions are
being taken.

4
 Internship Report

1.1.10 MAJOR QMS ACHIEVEMENTS

Internal Benefits

Improved management confidence, communications, and awareness of the

company objectives,

Responsibility and authorities are adequately defined

Improved utilization of resources and increased productivity

External Benefits

Easy access to international markets

Improved customer satisfaction confidence and the company image
Consistency in quality of products and services

Convenient for enterprise engaged in manufacturing & import export activities.

1.1.11 Site selection

The town Kombolcha in Wollo administrative region was selected for the location of the
following reasons:- Proximity of town to source of cotton. Availability of water, electric power
and other infrastructural facilities such as:-Telephone, Posta, Banking, Insurance service and An
air strip.

To enhance the economic development of the region and create employment opportunities, the
best of four possible site in Kombolcha was then selected for building the factory.KTSC has
been awarded for its best performance in direct export its products and as a sole supplier of
inputs for finished product exporters in 2007. KTSC has provided the renovation project
proposal which finds acceptance for implementation. It is supposed to bring a breakthrough in
the history of the company.

5
 Internship Report

1.1.12 Machine specification of the Kombolcha textile share company

name of machine Manufacturer Quantity

Bale opener Textima,(german)&trutzschler 8 (old)&1 (new)
Superior cleaner >> 2 (o)& 4 (o)
Auto mixer >> 2 (o) & 2(n)
Horizontal opener >> 4 (o) & 2(n)
Carding Textima,marzoli&trutzschler 32 (o), 8 & 2(n)
Draw frame 1&2 >> 10 (o), 4 & 2(n)
Roving frame Textima & trutzschler 10 (o) & 2(n)
Ring frame >> 55 (o) & 11 (n)
Open end Trutzschler 2 (n)
Twisting Textima 24 (o)
Reeling >> 3 (o)
Winding Marzoli& auto coner 2 & 4 (n)
Warping Textima & -? 2 (o) & 1 (n)
Sizing Textima &-? 2 (o) & 1 (n)
Weaving Picanol,dornier,versamat,&sulzer 50, 10, 120 & 38
Shearing Textima & local (ktsc) 2
Inspection Textima 11
Folding >> 1
Singing >> 1
Bleaching >> &-? 1 (o) & 1 (n )
Scouring >> 1
Mercerizing >> 1
Dryer >> & -? 2 (o) & 1 (n)
Washing >> & -? 2
Jigger Textima 8
Dyeing >> 2
Stainter Textima & trutzschler 2
Ironing ? 1
Calendaring >> 1
Printing >> 1

Table1 Machine specification of the Kombolcha textile share company

6
 Internship Report

1.1.13 Kombolcha textile share company Monthly usage of cotton

Mohammed
no. Date Middle awash Amiru Abebo Total Bale

Bale No. Kg Bale No. Kg Bale No. Kg Bale No. Kg

1 1/12/2011 22 4095 24 5756 _ _ 49 9851

2 2/12/2011 132 24958 4 852 _ _ 136 25810

3 5/12/2011 37 7384 _ _ _ _ 37 7384

4 6/12/2011 54 10672 _ _ _ _ 54 10672

5 9/12/2011 66 12929 _ _ _ _ 66 12929

6 10/12/2011 62 12656 _ _ _ _ 62 12656

7 12/12/2011 _ _ 44 9243 _ _ 44 9243

8 13/12/2011 _ _ 40 8405 _ _ 40 8405

9 14/12/2011 _ _ 91 19130 _ _ 91 19130

10 16/12/2011 _ _ 64 13457 _ _ 64 13457

11 19/12/2011 _ _ 67 14084 _ _ 67 14087

12 21/12/2011 _ _ 75 15768 _ _ 75 15768

13 23/12/2011 _ _ 54 11345 _ _ 45 11345

14 24/12/2011 _ _ 108 22574 _ _ 108 22578

15 26/12/2011 _ _ 36 7497 _ _ 36 7497

16 28/12/2011 _ _ 74 15415 _ _ 74 15415

17 30/12/2011 _ _ 144 29995 _ _ 144 29995

Table 2 Kombolcha textile share company Monthly usage of cotton

7
 Internship Report

1.1.14 OTHER UTILITIES

In Kombolcha textile share company there are utilities which are:-

Boiler machine; these machine are important for textile machine, because of the purpose of
giving a stem to the machine of weaving and finishing section, these machine actuating its work
by using Furness and water. The Furness is used for boiling the water with electrodes, the water
which is by the machine are soft water

West water treatment; the west water treatment process are the important parts of the
Kombolcha textile share company because of the environmental impact, which makes the
company is committed to minimize its impact on environment through prevention of population
by applying the implementation of cleaner production techniques and effective and efficient use
of natural resources . The west material are from the toilet, finishing chemical, dyeing chemical,
spinning and weaving west particle and printing chemicals. Using transporting pipe transfer to
the area of west water treatment

Engineering department; these section are the back bone of the Kombolcha textile share
company, because of the following reason:-Control the company maintenance lead Different use
spear parts are made.

In this section there are four divisions those are:-

Main work shop (mechanical work shop)

Electrical work shop
Auto motive work shop
Wood shop

1.1.15 Vision
To be export leader of the country by manufacturing 100% cotton products through
environmentally friendly processes which satisfy the customers' needs

1.1.16 Mission
To produce 100% cotton Textile products which can satisfy the customers' need through
environmentally friendly processes and expand the market share, there by generating profit and
benefiting all stake holders and play a vital role in the development of the country's economy.

8
 Internship Report

1.2 The major Raw Materials of the Company

Row material and utilities required by the factory at full capacity would be:-

7000 ton of lint cotton per annum from middle awash, Tendaho ,Abebo ,upper awash,
Lucy and Mohammed Amiru
12,500 KN of installed power from E.E.P.C
3,200 m of water per day theirs wealth
8,580 to of fuel oil for boiler per annum from oil company
411491 kg/year dye stuffs and chemicals from local and export

9
 Internship Report

1.2.1 Raw material quality parameter

Kombolcha textile share company standard cotton test result

Short fiber.....</=12.7mm

Trash content..</=3.7 %

Micronair value....</=3.7 (combed) or </=4.4(carded)

Fiber strength..>/=15 g/tex

Moisture content.....</=7.8 %

color white

Grade..>/= m

Honey dew..</=

10
 Internship Report

1.3 The overall workflow of the company

BAL store section

Old line New line

Blow room
Roving line Open end line
Carding

Draw frame1 Blow room

Draw fram2 Carding (mar) Carding

Roving frame Draw frame 1

Draw frame 1

Ring fram Draw frame 2

Drow frame 2

Roving frame

Ring frame

winding Open end

Cone store

11
 Internship Report

Twisting Market
Reeling Warping

Local market
Market Weaving Local Export

Old sizing New sizing

Beam store

Drawing in

Weaving machine

Inspection (gray fabric)

Finishing Marketing

Singing

Scouring

Bleaching

Mercerizing Dying

Printing
Marketing
Inspection (cloth)
Local Export
Garment
Fig 1 overall workflow of the company

12
 Internship Report

1.4 Over All Organizational Structure of the Company

General Manager

Internal Audit Department

Planning and Service and System

MI service improvement

Quality Assurance
Service Deputy of General
Manager

Marketing & HRD & Procure Finance & Spinning Weaving Processin Engineeri
liaise anning Administrati ment & Cost Departme Departm g& ng
dept ( A.A) on Dept property Manageme nt ent Garment Departm
Control nt Departm ent
Departm Departmen ent
Sales & Personnel ent t
Marketing Administrati Producti Producti Processin
DivisionDivision
A.A on Division on on g Central
Procur
General Division division Division W/S
ement
Sales & Training and Accounts Division
Divisio
Marketing MPD (MDD) Division
n Mainten
Division (k) Division Mainten
Garment Electric
ance ance
al &
Logistic & Division Division Division
General Mecha
Administrati Stores & Account
Service nical
on D. (A.A) property ing
Division Divisio
control Manage Mainten
n
Division ment ance
Health & Division Division Utilities
Safety
Division
Service

Fig 2 over All Organizational Structure of the Company

13
 Internship Report

1.4.1 Responsibilities of function area

board of director is one of the responsibilities area ,which controls all the company
working process with regard to selective personnel
general manager is also the responsibilities are, which control or manage all work
of the company
Internal audit department is control the business of the company
Planning and MI service are responsible for prepare plan of the company
Service and system improvement is responsible to control the working situation
of the company
Quality assurance service is responsible to control the quality of the row material
and the output the company
Deputy G/manager is responsible for controlling the work of the company together
with the general manager
Marketing and liaises anning- is responsible to control the out soling and
marketing of the company and it has Addis Ababa and Kombolcha branch
Logistic and administration- is responsible to work about gallery, car service etc. of
the company
HRD and administration department has four division and control these division
Personnel administration- is responsible to administrate the man power of the
company
Training and MPD division is responsible to give a training for a person, who
coming from different organization or place
General service division is control the workers home, car service, etc.
Health and safety service is responsible to control the health service of the
company
Procurement and property control department is responsible to control related
to finance
Store and property control division is responsible to control the store of the
company
Financial and cost management- is responsible to manage financial of the
company
Spinning department is control the production and maintenance department of the
company
Weaving department is control the production and maintenance division of the
company
Processing and garment department is control pretreatment, finishing, garment
and maintenance division

14
 Internship Report

Engineering department is control the mechanical, electrical, central W/S and

utilities

1.5 Products of the Company

No. 1 2 3 4 5 6 7 8 9 10 11
Product Twill Drill Drill French Curtain Poplin Bed Mulmul Abujedid Cotton Terry
type A B Twill cloth Sheet Plain Towel
Export

Table 3 Products of the Company

15
 Internship Report

1.6 Main customer of the company

Local:-
Kombolcha
Dessie
Addis Ababa etc.

Export:-
USA
Europe

16
 Internship Report

CHAPTER TWO
Overall Internship Experience
When I get to this factory I didnt get such a difficult problem .Because they have experiences
in the summer apparent program. But they didnt have any information about the internship
program due to the lack of information between institute and the company. These things make a
new thing for them. Then we simply told them about the program and then they give us a
welcome feedback. We finish the registration and some forms which must be filled on this day
and then the factory human resource and general service manager assign for us un advisor. On
the next day our advisor shows us the whole company and he told us what we have to do with
him for the future.

In this company I work with my class mate Demeke, Kassa, Tsedey & Nardos. We work in
different section of the production, Maintenance and Technique Department. Our initial task is to
work with our advisor on the identification of the factories machines problems and give
reasonable solution. Let me show the step we follow to identify and solve the problem

First we try to identify the problems by asking the machine operators

After we gather the basic informations we add some problems that we observe in the
factories machine which should require a solution
Then we discuss on the solution of the problem with machine operators and then we start
to write the possible solution of the problems.
After we finish everything, we submit it to our advisor.
Then we discuss on the solution of the problem with him and then he starts to write the
possible solution of the problem for the next work.
Then he orders the section workers to take action on the problems occurred on the
machines.
Finally he reports on the problems found, the action which is taken to solve the problem
and the change that factory gets by solving the problem to the management meeting.

When we identify the problems, we get different problems which require a solution. Thus we get
good factory knowledge in the problem identification and in giving possible solution on the
problem.

17
 Internship Report

2.1 TITTLE
INFLUENCE OF COTTON STORAGE ON PROCESSING PERFORMANCE

Even though there are many problems in the Kombolcha Textile Share Company spinning
department which are common, but my observation based on the cotton property study which are
cotton conditioning are very essential for enhancing the processing performance, quality and cost
of the spinning department as well as the factory.

2.2 SELECTING SECTION OF THE COMPANY TO WORK SECOND

TASK
The section of the company that I have chosen to work my second task is spinning
department (section) on bale store.

2.3 OBJECTIVES
Explain how importance of cotton storage for good processing performance, quality and
cost.
Lucid and explain the manufacturing of cotton fiber in spinning
Understand how to manage the cotton in bale store

18
 Internship Report

2.4 WORK FLOW PARTICULAR SECTION

BAL store section

Old line New line

Blow room
Roving line Open end line
Carding

Draw frame1 Blow room

Draw fram2
Carding (mar) Carding
Roving frame
Draw frame 1 Draw frame 1

Ring frame Draw frame 2

Drow frame 2

Roving frame

Ring frame

winding Open end

Cone store

Fig 3 work flow particular section

19
 Internship Report

2.5 DETAILED PROBLEMS AND THE METHODS

Particularly in Kombolcha Textile Share Company the cotton comes from the source are
coming and, then directly transfer processing without any conditional treatment, this experience
is very difficult to produce good(quality) products as well as processing performance in order to
have good quality product and high processing performance the cotton(material) which is used
for processing should have treated by the condition, which are temperature and humidity, at least
for a minimum of year to have a good property and other parameters. This properties are
makes the processing performance increase and to enhance the quality of the product. The
industry is apparently tradition bound and is apt to follow what is generally doled out from the
manufactures of varies test condition for cotton. Unfortunately the aim has always been to get
only these conditions that are essential from the point of view of quality assessment for export or
the domestic market, the roll of the conditions (storage), which could prove to be extremely
useful in controlling the process is generally over looked.

2.5.1 First round observation on the processing area

In table below the situation of the cotton fiber comes from the ginning and directly uses for
processing, so this material (cotton) makes the performance of the machine and quality of the
production are lowered, because of the material untreated or un conditioning on bale store, this
type of material properties are not suitable for processing of the machine and to operate the
machine for the operator (worker) of the section.

20
 Internship Report

Section Room Observation During Processing

Blow Room High wart with the cotton seed
Efficiency of the machine is decrease
Difficult to transport the cotton from one machine to
other machine
Increase the recycle button in the waste feeder
Carding Room Difficult to transport the material
Increase the number of machine idle
Difficult to operate the machine
Draw Frame 1 & 2 Increase lapping on the roller
Increase the number of machine idle
Decrease the machine efficiency
Difficult to operate the machine
Roving Frame Increase the number of machine idle
Decrease the machine efficiency
Difficult to operate the machine
High fluff(dust),roller lapping, waste
Ring Frame High waste
Produce dirty cops
Decrease the machine efficiency
Increase operate per machine
Decrease the number of machine are working

Table 4First round observation on the processing area

21
 Internship Report

2.5.2 Second round observation on the processing area

Section Room Observation During Processing

Blow Room Efficiency of the machine is better
Waste with the cotton seed is somewhat good(better
from the first round)
Good transport the cotton
Carding Room Good transportation
Better to operate the machine
Somewhat good machine efficiency compare with the first
round
Draw Frame 1 & 2 Somewhat good machine efficiency
Roller lapping decrease
Better to operate the machine
Roving Frame Better machine efficiency
Better to operate the machine
Decrease roller lapping ,fluffs, waste etc.
Ring Frame Decrease waste
Somewhat Produce good cops
Better machine efficiency
Better to operate the machine
Increase the number of machine are working

Table 5 Second round observation on the processing area

22
 Internship Report

2.5.3 Third round observation on the processing area

In table below the situation of the processing performance and quality performance of the
production are good. Which is concerning of the cotton store (conditioning) on the bale store.
About at least three months. This makes the cotton fiber to increase the ability of the
performance of the machine.

Section Room Observation During Processing

Blow Room Good efficiency of the machine
Waste with the cotton seed is almost none
Decrease the recycle cotton on the waste feeder
Avoid transportation problem between the machines
Carding Room Avoid transportation problem
Increase the machine efficiency
Better to operate the machine
Increase the machine working capacity
Draw Frame 1 & 2 Good machine efficiency
Decrease roller lapping
Better to operate the machine
Having better delivery to the next process
Roving Frame Good machine efficiency
Good operation of the machine
Decrease roller lapping ,fluffs, waste etc.
Ring Frame Decrease waste
Produce good cops
Good machine efficiency
Better to operate the machine

Table 6 Third round observation on the processing area

23
 Internship Report

2.6 Discussion and main finding

2.6.1 Fiber properties on textile processing performance, quality and the

impact of cotton costs
Cotton fiber is increasingly facing competition from artificial fibers, notably polyester.
Cotton, being a natural product, varies widely in its fiber characteristics, both physical and
chemical (mainly physical), because of genetic, environmental, harvesting and ginning factors.
There are essentially four commercially grown cotton species: medium staple length and medium
fine Gossypium hirsutum, American Upland (which accounts for over 90% of global cotton
production); long staple and fine Gossypium barbadense; and the short staple coarse Gossypium
arboreum and G. herbaceum (together known as Desi cottons). The physical, chemical and
related characteristics of cotton lint, including the type and amount of non-fibrous matter present
and fiber configuration (preparation, neps etc.), determine its textile processing performance
and behavior, in terms of processing waste and efficiency (including machine stoppages and
spinning breaks) and yarn and fabric quality. Ultimately these characteristics also determine
conversion costs and product end-use, price and quality.

The fiber represents 50%70% of the yarn manufacturing costs. Ideally, therefore, the price
of cotton should be linked to fiber characteristics.
Increasing quality and performance demands are being placed on the entire textile pipeline,
from raw material to end-product. It is known that thin yarn places having extension and strength
below certain minimum limits cause weaving end-breaks, such thin places and other defects in
the yarn being influenced by fiber properties and spinning mill conditions.
In view of this, it is understandable that efforts are continuously being directed towards
improving the desirable properties of cotton and eliminating or minimizing any undesirable
properties. Such efforts are aimed at breeding, farming and ginning practices as well as at textile
processing systems and conditions. Furthermore, it is hardly surprising that for over a century so
much effort has gone into developing instrument methods for accurately measuring cotton fiber
properties (preferably testing each bale of cotton), and quantitatively relating the measured
properties to processing performance and yarn and fabric properties, so as to improve and
optimize quality all-round (see box below). Tremendous progress has been made in this regard, a
very good example being the development of the systems for high volume testing of cotton,

24
 Internship Report

commonly referred to as HVI systems. In 2006 there were some 2,000 such systems in place in
over 70 countries, which, in theory, were capable of annually testing the entire global cotton crop
of some 25 million tons.

25
 Internship Report

In spite of the extensive research (experimental and theoretical) carried out to relate the
measured characteristics of cotton to processing performance and yarn quality, no generic
relationships, or other empirical or theoretical means are as yet available to accurately relate
cotton fiber properties to subsequent textile performance. The reasons for this include the
tremendous variations in cotton fiber properties and their interrelationships, as well as variations
in processing conditions, and the interactions between processing conditions and fiber properties.
The relative importance of the fiber properties also depends on the spinning system, on whether
or not the

This chapter briefly discusses the measurement of fiber properties and the impact of changes in
fiber properties on textile processing performance, quality and costs. Nevertheless, the cost
implications of changes in fiber properties are complex, being not only highly mill and product
dependent but also difficult to isolate and quantify, even within a mill. For example, how does
one calculate the cost implications of deterioration in yarn evenness due to a decrease in cotton
fiber length or an increase in short fiber content? Another example is the cost implications of an
increase in cotton waste due to an increase in short fiber content, taking into consideration the
recycling and/or selling of waste. It has been estimated that an increase of 1% in carding waste
and in blow room waste increases yarn costs by about 1%, while an increase of 1% each in blow
room, carding, combing and spinning waste can increase yarn costs by over 3%. Because of
these complexities, the cost implications of changes in fiber properties will only be touched
upon. The property of cotton fiber effect and measurement.

26
 Internship Report

2.7 Solution to solve the problem

2.7.1 Laboratory Results

Sticky cotton thermo

length

visual
Short fiber (%)
Maturity (%)
detector

Visual color
Date of test
Honey Stickin Total

Elongation
No. of bale

Micronair
Moisture
Strength
dew in ess in
Round

Origin

Sugar
Grade
(g/tex)
lot no.

Staple
Trash
No. No.

color
Date

(%)
middle 3 22 25
1st 5/4/2011 270 121 7/4/2011 white 39.29 4.03 14.2 20.86 10.4 29 Scm/m 1/4 8.83 4.15
awash
middle 4 20 24
1st 16/4/11 276 187 19/4/11 white 46.76 4.12 12.9 21.15 10 28.9 Scm/m 1/4 8.85 4.11
awash
Table 7 Laboratory test result 1st round

Sticky cotton thermo

length

visual
Short fiber (%)
Maturity (%)

detector
Visual color
Date of test

Honey Stickin Total

Elongation
No. of bale

Micronair
Moisture
Strength
dew in ess in
Round

Origin

Sugar
Grade
(g/tex)
lot no.

Staple
Trash

No. No.

color
Date

(%)
middle - 25 25
2nd 01/7/2011 270 121 01/7/11 white 35.53 4.07 14.1 18.47 9.2 28.2 Scm/m 1/4 7.79 3.95
awash
middle 6 36 42
2nd 01/7/2011 276 167 01/7/11 white 42.42 3.1 10.2 18.62 9.2 28.6 m/Sm 1/4 7.10 3.94
awash
Table 8 Laboratory test result 2nd round

27
 Internship Report

Which could to be the presentation here deals essentially with many such conditioning (stored)
materials extremely useful in cotton of spinning processes.

Comparison the cotton test result with standard test result

Material Date of Lot Round Moistur Tras Short Strengt Grade Micronie
source test no. e (%) h fiber h r
(%) (%) (g/tex)
Mohamme 07/04/1 27 First 8.83 4.03 14.2 20.86 Scm/ 4.15
d Amiru 1 0 m
Mohamme 01/07/1 >> Secon 7.7 4.07 14.1 18.47 Scm/ 3.95
d Amiru 1 d m
Mohamme 19/4/11 27 First 8.85 4.12 12.9 21.15 Scm/ 4.11
d Amiru 6 m
Mohamme 01/07/1 >> second 7.10 3.1 10.2 16.62 M 3.94
d Amiru 1
Standard </= 7.8 </= </=12. >/= 15 >/=M </=3.7
cotton test 3.7 2
result

Table 9 Comparison the cotton test result with standard test result

2.8 Performance Procedure of the Work Task

First we try to identify the problems by asking the machine operators
After we gather the basic informations we add some problems that we observe in the
factories machine which should require a solution
Then we discuss on the solution of the problem with machine operators and then we start
to write the possible solution of the problems.
After we finish everything, we submit it to our advisor.
Then we discuss on the solution of the problem with him and then he starts to write the
possible solution of the problem for the next work.
Then he orders the section workers to take action on the problems occurred on the
machines.

28
 Internship Report

Finally he reports on the problems found, the action which is taken to solve the problem
and the change that factory gets by solving the problem to the management meeting.

When we identify the problems, we get different problems which require a solution. Thus we get
good factory knowledge in the problem identification and in giving possible solution on the
problem.

2.9 Challenges during solving the problem

Lack of related information with the problem that I choice
Shortage of time and accessories to detailed with the problem
The situation is not safe to work the problem

2.10 Measure to overcame the problem

Using different library and reading books related to the problem to have enough information
about the problem
In order to prepare the problem in good manner I work day and night including holly day
Having good situation to do the problem, I take the measure by communicating with relative
person working on the company, for gathering information by asking a question like these,
what is the source of the problem, what is the reasonable solution etc .

29
 Internship Report

Chapter Three
Benefits of Internship Program
An internship experience provides employers with a student worker who already has some
employability skills and occupational knowledge. It may provide a pool of technically trained
employees from which to fill future positions and may reduce recruitment problems and costs.

Now let me discuss what I have gained from the internship program. In this program I get
different types of companies knowledge. These knowledges are an improvement on the:-

3.1 Improvement in Practical Skill

The major skill I got from this internship program is the practical skill. I got this skill when I
work in different sections of the company. These divisions (section) are:-

The spinning section

The weaving section
Pretreatment section and
Finishing section

Mainly I work in the all division with the sections worker and with my class mate on the
determination of cotton fiber, yarn, fabric & preparing of chemicals. This determination include:-

In addition to that the manufacturing practice, we hope that through effective communicating
what is gained there with in the company not only workers level of understanding about textile
will be enhanced but also the practical aspects of the company shall be changed in practical
aspect we became familiar with the following:-

The determination of Cotton fiber based on:-

Trash content
Staple length
Color
Maturity
Strength
Honey dew
Micronair
Moisture

The determination of cotton yarn based on:-

Yarn strength
Nippiness
Count variation

30
 Internship Report

Twist per meter

Hairiness (thin & thick place)

The determination of cotton fabric based on:-

Crimp percentage
GSM
Density
Number of end (weft & warp) in a given cm fabric etc.

The determination of west water treatment based on:-

Total hardness test

Turbidity test and chlorine test

The determination of chemicals based on:-

Hydrogen per oxide concentration test

Sodium hydro oxide (caustic soda) concentration test
Starch test

. But I work with them (workers) when there is any work and when I have free time. Thus I get
unfinished practical knowledge from them. And also I get different practical skill from the
operator of the machines like the controlling system of the machine etc.

3.2 Upgrading Theoretical Knowledge

The one I benefitted from the company is that I upgrade my theoretical knowledge by doing
different types assignment which require different types theoretical knowledge. These
assignments are:-

Determination efficiency of the machine

Determination productivity the machine
Function of air condition to production
Properties of cotton fiber

The Detail of each assignment are as I discuss it before. All of the assignment require theoretical
and practical concept. This means that they are already related the one I learned before. For each
assignment tried to combine my theoretical knowledge with the practical one. These give me a
feed back of an improvement on my theoretical knowledge.

31
 Internship Report

3.3 Interpersonal Communication Skill

In this company there are different sections. These sections also have different types of workers
which has different types of behavior and technical skill. But finally we communicate easily just
as a friends who live with each other for a long period of time. The major way for me to
communicate with them is that when I start to do different tasks with them. When I was there I
work in different section of the company. At each section there are different peoples who have
different behavior and different technical skills. Therefore I tried to communicate with them by
asking a questions what I didnt know and I also give them an advise what I know. This makes
us to communicate easily. These communications finally brings a very good result on the
assignment. We have done on the solving of different problems which are looked in the factory.

3.4 Team Playing Skill

This skill is the major skill that one textile engineer must to have. This skill is developed by
doing with different types of workers on the same or related tasks. I get this skill before I go to
the internship program when I done different types of projects like maintenance etc. But when I
was in the company I improve this skill when I do different types of assignment or work with my
classmates, with my advisor Ato Berhanu H. and different workers of the company.

3.5 Leader Ship Skill

Leader ship skill is the skill which must be important for once person who works at every section
of works. Therefore it important for once engineer. From the knowledge I get in the internship
program is that the leader ship skill. When I was in the company I work with my adviser berhanu
who is production manager of spinning section. The full responsibilities of controlling the
productivities of the spinning section are done by you. This develops my leadership skill. The
other one I get this skill is that from weaving production manager. He told us how he lead his
department like the system he use when he order his workers and the system he uses when
control the work on his section. Finally this thing develops my leader ship skill.

3.6 Work Ethics

Work ethics is the ethics that once company requires from its workers. This ethics are:-

Arrive on the work place on time

Use the working time effectively
Working area rules and other regulations that the company require from its workers

Therefore in this internship program I said that I get such a good work ethics which I didnt
know it before.

I also try to obey these rules by keeping the in trance and living hours, by submitting the
assignment on the submission date and we finish the task given by our advisor on time when I
work on the all section the company. Finally I said that the get a good knowledge on the work
ethics.

32
 Internship Report

3.7 Entrepreneurship skill

This skill is the skill that every person must have especially a student like me. I get this skill
from the companys division manager Ato Metalem. He takes different types measures for his
todays success. First he starts his work as formal for the Factory worker. Then the Companys
Shift leader and now division manager. During his work he faced different challenges but this
challenge makes him to develop his potential, from this he write a proposal which is improving
the company work management, ethics and other problem area of the company, and also write
the proposal based on the machine type which is functional for the production and quality
enhancement, Then he gets much amount profit by working very hard. Now days he became
important person on textile works on different jobs in Kombolcha textile Share Company. These
give me good knowledge which supports me for my future.

33
 Internship Report

Chapter Four
Recommendation and Conclusion

4.1 Conclusion
Kombolcha textile share company is one of the famous textile company in Ethiopia, these
company makes itself to competent world market it can be work hard on quality, cost and other
parameter with regard to enhance the productivity of the company.

Now it used traditional experience based on cotton storage these came be difficult it to
competent world market. So these experience should change and increase the productivities,
quality and benefits of the company otherwise if the simply keep the experience like now a day
are make the company get always the same benefits, and also not only loss of quality and
benefits other than may be one time, if other company which is found in Ethiopia buy and store
the cotton found on the market, these company cant get any cotton from the market, so which
makes the company cant produce it production because it hast any material (cotton) in the store
this all things makes the company idle.

From the situational done in the Kombolcha textile share company I can summarize that the
existing cotton storage system of the Factory that can be improved by establishing and
implementing the following:

Effective treatment for cotton uses for processing

Effective air condition equipment uses for the bale store
Effective and efficient bale managing system
Adoption of an appropriate training about cotton storage

As it is the main objective, the production schedule proposes a model for the workflow system
material (cotton) management system, considering the existing problem. For the effectiveness of
the proposed system there should be a common understanding between production and workers.
Misunderstandings between these two are the main reason for the failure of different production
programs.

4.2 Recommendations
both natural and manmade fiber are used for spinning to produce yarn of desired quality, the
influence of row material is important issue both from technological as well as economical point
of view row material accounts for 80-90 % of the yarn quality and 50-70 % of the total
production cost of a short staple yarn. This fact is sufficiently to indicate the significant of row
material for the yarn production for the company

It is very important to have a though understanding of the quality parameter of the fibers and
their influence on the spinning process and quality. Knowledge of fiber properties is also
crucial for setting machine and controlling important process parameter

34
 Internship Report

The inherent variation existing in all these properties among fibers, the spinners therefore should
know these aspects of fiber quality which will enable him to choose the material most suited for
the intended purpose from a wide range of cotton that differ in their physical properties.

Finally I recommend that we have done so many assignments which make the factory profitable,
so that it is better if the maintenance department is implement it.

35
 Internship Report

Reference

Menachem Lewin & Eli.M. pearce, Hand book of Fiber science and technology, volume
(IV) , 1983 New York
J.Go & DON Cook, Hand book of Textile Fibers, Fifth edition, Merrow Rublishing
Co,LTD, 1984 England
STEVEN B. WARNER, Fiber Science, edition I, Prentice-Hall international (UK)
limited, London, 1995, United States of America

36
 Internship Report

Appendix

Bale management in spinning mills

Even if there is only no way to span gold tread out of straw like in the fairytales there are ways to
day to produce homogenizes and cost optimization of raw material mixes, adopted to the
requirement of the end product, which stay nearly constant during the whole production time,
this become possible due to the new generation of fiber tasting instruments and raw material
management software.

Cotton mixing is an ongoing process in the cotton industry judgment based on experience
considering fiber characteristics and cost which are linearly related, is used for cotton mixing the
tendency of textile mill is used to substitute a certain percentage of low cost cotton in cotton
mixing so that quality deterioration is insignificantly effective utilization is made of the available
cotton throughout crop year.

Typical environment in which cotton mixing decision needs to be made Cotton quality varies
with season Cotton cost fluctuation Uncertainty in quality of cotton in stock Variation in demand
for cotton quality by the customer Cotton bales have traditionally been purchased based on the
nominal specifications. Testing of fiber characteristics will produce an accurate evaluation of the
variability of the bale population generated data can then be used for bale management. The fiber
select5ion program should involve four basic steps:-Examine the population, and distributions of
fiber properties of cotton bale, Implementing reliable bale picking schemes based on the
distribution of fiber properties of the bale population, Control average output characteristics by
developing reliable fiber yarn relationship, Verify the effectiveness of the fiber selection
program by monitoring the uniformity of fiber characteristics of bale lay dawns and
corresponding yarn characteristics .

A good bale picking scheme should result in a uniform fiber profile on mix to mix. Basic bale
picking system can be of various types:-

Random picking system

Proportional weight category picking
Optimum category picking

37
 Internship Report

KTSC- Kombolcha textile Share Company

A.A-Addis Ababa
K-Kombolcha
Dept-department

38