Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
INDUSTRIAL ATTACHMENT
APEX SPINNING AND KNITING MILLS LTD.
Page 1 of 55
TABLE OF CONTENT
Page 2 of 55
Chapter- Quality Quality assurance procedure, List of
VI assurance equipments, Quality standard, Quality 32-38
report, Remarks
Page 3 of 55
CHAPTER-I
( PROJECT DESCRIPTION )
Page 4 of 55
# SITE LOCATION OF Apex Spinning and Knitting Mills Ltd:
Mymensing
Apex Road
Spinnning
and Knitting
Mills Ltd
Polly
Biddut,
Chandura
Gazipur
Gazipur
Shofeepur Main Town
Bazer
Chowrasta
Air Port
Sotheast
University
Page 5 of 55
SPONSOR:
OWNSELF
PRODUCT MIX:
a) Knitted grey fabrics:
Plain single jersey, Heavy jersey, polo pique,1’s Lacoste ,Double Lacoste , Rib &
Interlock double jersey, Billister Fabrics, 2/3 threaded fleece (brushed &
unbrushed),Lycra Single Jersey, Auto stripper, Feeder Stripper, Jacqured Design
Fabrics, Collar & Cuff , Warp knitted Fabrics, Narrow fabrics etc
100% cotton, 15% viscose+ 85% cotton, 10% viscose+ 90% cotton, 30% viscose+
70% cotton, 95% Cotton + 5% Lycra, PC , CVC, Millange , 84% Nylon + 16%
Spandex etc
b) Knit garments:
Men polo shirt, Women polo shirt, Men T-shirt, Women T-shirt, Men sweat shirt,
Women sweat shirt, Men fleece shirt, Women fleece shirt, Kids polo shirt, Babies
polo shirt, Kids T-shirt, Babies T- shirt, Jogging Pants, Ladies Under garments ( Bra,
Panty etc )
ANNUAL PRODUCTION CAPACITY:
Knitting: 9125 tons per year
Dyeing: 9125 tons per year
Garments: 3 cores pieces per year
PROJECT COST:
500 cores taka (approx)
HISTORY OF PROJECT DEVELOPMENT:
Starting with 36 knitting machines only in 1990 and dyeing capacity was only 3 tons
per day. Garments section has only two floors with 6 lines.
Page 6 of 55
DIFFERENT DEPARTMENTS:
1. Admin Section
2. Knitting: circular knitting , Flat knitting and Warp knitting
3. Dyeing & Finishing
. Lingerie Dyeing Section
. Yarn dyeing
. Sewing thread manufacturing section
. Narrow fabric dyeing
. Printing Section
4. Lab department
5. Quality Assurance
6. Garments:
Cutting
Sewing
Finishing
Inspection
Packing
Page 7 of 55
11.Utility Department
PHYSICAL INFRASTRUCTURE:
REMARKS:
APEX SPINNING AND KNITTING MILLS LTD. is The biggest project I have ever
seen. In this project combine many and unique department which are really rare in
Bangladesh. This is also a profitable project and also greatly contributes the economy
of our country.
Page 8 of 55
CHAPTER-II
(MAN POWER MANAGEMENT)
(MANAGEMENT SYSTEM):
KNITTING SECTION:
Four mechanical fitters for per shift .One skilled operator and one unskilled operator
for per knitting machine.
SHIFT CHANGE:
Shift of Twelve hours but four hours daily overtime added for the workers. Shift
changes after a week on Saturday and daily shift changes 8:30 am and 8:30 pm.
From getting an order of upper level all responsibilities are on the production officers.
They work with a troop of operators, helpers, fitters etc. to finish the production in due
time. In the meantime
Production officers bear all hazards, problems. They have to explain to the manager
for any type of production hamper. So all production activities and its success depend
on the production officers .Now I can explain the works of the Production Officer
following way..
Page 9 of 55
Organ gram of ASKML:
Page 10 of 55
PRODUCTION CALCULATION
Page 11 of 55
1. Production/shift in kg at 100% efficiency:
2. Production/shift in meter:
Course / min .
Course / cm
RPM No. of Feeder 60 12 Efficiency
Course / cm 100
Page 12 of 55
(ii) FABRIC WEIGHT (G.S.M.) SETTING
G.S.M. CONTROL:
1. Major control by quality pulley.
2. Minor control by stitch length adjustment.
1. G.S.M.:
It is technical term that indicates the weight of the fabric per square meter.
2. Changing of G.S.M.:
The GSM of the fabric is change by altering the position of the tension pulley.
If pulley move towards the positive direction then the GSM is decrease and in the
reverse direction GSM will increase.
i) Tension pulley
ii) Cam position
iii) Take up motion
Page 13 of 55
4. Factors that should be changed incase of fabric design on quality change:
i) Cam setting
ii) Tension pulley
iii) Set of needle
iv) Size of the loop shape
7. Relation between yarn count and m/c gauge seen in different m/c.:
We know,
G2
Ne =-------------
18
Page 14 of 55
8. Maximum and minimum g.s.m. Of a fabric for a particular yarn:
13. Weight increases per square meter after finish the fabric:
Page 15 of 55
WORKING PARTICULARS
1. Working hours: Two shift each of 12 hours.
Single Jersey, Single pique polo, lacost, honeycomb, rib, fleece and many others
designed fabrics.
Needle breakage occurs mainly due to which yarn supply. M/cs automation
system can minimize the higher breakage rate. Also operator’s negligence, worn m/c
set up and wrong handling may cause more needle breakage.
Page 16 of 55
6. Wastage of the factory:
7. Maintenance:
Page 17 of 55
CAUSES OF LOOP LENGTH VARIATION
3. Robbing back:
Due to 15% of yarn robbed back from old loop to newly formed loop.
JOB DESCRIPTION:
PRODUCTION OFFICER:
Production officer is the right hand of senior production officer and he is directly
related with production, manpower & informs senior production officer time to time.
Here are his listed duties:
Follow up overall knitting production
Page 18 of 55
Decide every machine utilization during production
Recruit new labor
To inform the authority on the overall knitting production and make it
financially profitable
Regular machine Maintenance
Maintains subcontract orders
Help knitting manager and also guide the junior officers of the section
REMARKS:
Production runs with the help of mechanical fitters. For any kind of mechanical fault
of any machine they fix and work under knitting manager. Production officer takes
account of daily production by running after the two supervisors & workers so on.
Page 19 of 55
CHAPTER-III
( MACHINE DESCRIPTION )
:
SL Gauge Brand Origin
Width
1 14 152 cm SHIEMA SEIKI JAPAN
2 14 152cm SHIEMA SEIKI JAPAN
3 14 152cm SHIEMA SEIKI JAPAN
4 14 152cm SHIEMA SEIKI JAPAN
5 14 152cm SHIEMA SEIKI JAPAN
6 14 152cm SHIEMA SEIKI JAPAN
7 14 152cm SHIEMA SEIKI JAPAN
Page 20 of 55
1. CIRCULAR KNITTING SECTION:
Sl type dia gauge feeder Needle attachement Brand name Origin
1 S/j 22 24 69 1656 Lycra Mayer & CIE Germany
2 S/j 24 24 78 1800 Lycra Mayer & CIE Germany
3 S/j 23 24 69 1728 Lycra FUKAHAMA Taiwan
4 S/j 20 24 65 1512 Lycra Mayer & CIE Germany
5 S/j 18 24 57 1368 Lycra Mayer & CIE Germany
6 S/j 24 24 72 1800 Lycra FUKAHAMA Taiwan
7 S/j 26 24 84 1944 Lycra Mayer & CIE Germany
8 S/j 30 24 96 2268 Lycra Mayer & CIE Germany
9 Rib 30 16 62 3002 Lycra Mayer & CIE Germany
10 Rib 34 16 72 3408 Lycra Mayer & CIE Germany
11 Rib 34 18 72 3960 Lycra UNITEX Singapore
12 Int 32 18 66 3720 Lycra UNITEX Singapore
13 S/j 25 24 75 1894 Lycra FUKAHAMA Taiwan
14 Rib 38 18 76 4260 Lycra FUKAHAMA Taiwan
15 S/j 18 24 54 1332 Lycra UNITEX Singapore
16 S/j 19 24 57 1440 Lycra UNITEX Singapore
17 S/j 19 24 57 1440 Lycra FUKAHAMA Taiwan
18 S/j 21 24 63 1584 Lycra FUKAHAMA Taiwan
19 S/j 20 24 60 1488 Lycra UNITEX Singapore
20 S/j 19 24 57 1440 Lycra UNITEX Singapore
21 S/j 17 24 51 1272 Lycra FUKAHAMA Taiwan
22 S/j 16 24 48 1212 Lycra FUKAHAMA Taiwan
23 Int 34 24 72 5100 Lycra UNITEX Singapore
24 Int 36 24 78 5400 Lycra UNITEX Singapore
25 Int 36 18 78 5400 Lycra UNITEX Singapore
26 Int 40 24 84 6000 Lycra UNITEX Singapore
27 S/j 34 20 102 2520 Lycra UNITEX Singapore
28 S/j 36 20 108 2688 Lycra UNITEX Singapore
29 S/j 36 20 108 2688 Lycra UNITEX Singapore
30 S/j 40 24 120 3000 Lycra UNITEX Singapore
31 Rib 40 18 84 4512 Lycra UNITEX Singapore
32 Int 40 19 84 6000 Lycra UNITEX Singapore
Page 21 of 55
CIRCULAR KNITTING MACHINE
Circular knitting m/cs. are widely used through out the knitting industry to
produce fabric. This m/c can be built in almost any reasonable diameter and the
small diameter of up to five, which are used for wear.
Machine for outerwear and under wear may vary from 12 inch to 60 inch in
diameter according to manufactures requirement. This m/c can be used either as
fabric or for making garments completely with fancy stitch. Latch needles are
commonly employed in all modern circular m/c because of their simple action and
also their ability to process more types of yarns.
Plain circular m/c uses only one sets of needles, circular rib m/c uses two sets of
needles i,e, Cylinder needle and Dial needle, the interlock circular knitting m/c also
uses two sets of needles by needles are long and short respectively for both dial
and cylinder, that is why multiple design and thick fabric can be produce with that
m/c. That m/c is also called double Jersey m/c.
(e)
1. START/STOP/INCH BUTTONS:
Complete set of easily accessible start/stop/inch buttons at top in each
leg.
2. RATCHET LEVER:
Permit hand movement of the M/C
Page 22 of 55
3. AUTO STOP MOTION:
Automatic three stages 24v yarn motion, positive feed tapes & knitting zone. Indicator
lamps are on individual stop motions & on the main control panel. While the yarn is
broken we can find the location which is broken as well as to repair, meanwhile the
motor can brake and stop operation at once to keep the security of M/C.
5. AUTO–COUNTER:
Two shift revolution with display counter with predetermined stop, to
settle freely the weight or yardage of fabric.
Transistor inverter provided for free controlled, the process of “V.s. motor-drive”
from slow operation to normal operation is quite & fast brake to prevent damages in
case of needles or yarn breakage.
9. AUTO LUBRICATION:
The automatic central pressurized oil sprayer can be adjusted at cycling
time and quantity to make cylinder, dial, sinker ring’s cam, needles and
sinkers lubricated enough, besides it has the function cooling and
clearing.
Page 23 of 55
OPERATION PROCEDURE OF FLAT MACHINES:
2. Disconnect the clutch and move the carriage to the right end by
means of the manual handle.
4. Shift the crand rod fulcrum of sector wheel in accordance the travel
width scale.
6. Move the carriage rightwards until it contacts with the u-shape gauge.
Then, upon making certain that the carriage is in contact with the u-shape gauge,
tighten the carriage position change screws.
Page 24 of 55
7. Fine adjust the carriage position screws to assure reliable contact of
carriage and u-shape gauge. If the left screw is loosende and the right one is tightened,
the carriage can be move rightwards, and on the cantrary, if the right screw is
loosened and the left one is tightened, the carriage can move leftwards. At this time,
be careful not to stretch the chain too tight. The proper chain tension is such that the
chain can teach the upper face of the carriage rail, of picked up at the machine center.
Page 25 of 55
Chapter-IV
(Raw Materials)
These above raw material’s price , source , annual requarements are as follows-
Page 26 of 55
CHAPTER-V
(Production Planning, Sequences & Operations)
PRODUCTION PARAMETERS:
Buyer Requirement
Machine Diameter;
Machine rpm (revolution per minute);
No. of feeds or feeders in use;
Machine Gauge;
Count of yarn;
Fabric GSM;
Fabric Dia or Width;
Required time (M/C running time);
Machine running efficiency .
Page 27 of 55
Process Flow Chart of ASKML:
Page 28 of 55
PRODUCTION DAILY REPORT:
Here is a daily report of production which is kept in Apex Spinning and
Knitting Mills Ltd..:-
Maximum Capacity of knitting section is 25 tons per day but actually maximum
production is 22 tons but all over average production is 15-18 tons per day due to lack
of orders and some other reasons because dyeing section capacity is 25 tons of various
types of fabric
Page 29 of 55
MONTHLY EFFICIENCY:
Daily production 15000 kgs. Approx.
Daily production capacity 25000 kgs approx.
So, monthly production 450000 kgs.
Monthly production capacity 75000 kgs.
So, Monthly production efficiency= 450000/750000 %
= 60%
REMARKS:
As APEX SPINNING AND KNITTING MILLS LTD. is a big project; its
production quantity is huge. Production quantity varies as according as buyers
demand. It gives approximately 450 ton production per month. In Bangladesh, there
are a few mills which can produce such quantity of knitted fabrics.
Page 30 of 55
CHAPTER-VI
(Quality assurance system)
Collar & cuff are inspected visually under light box, any major & minor
faulty collar/cuff like having wrong ply, hole, needle lines, slubs, wrong design, first
line problem etc properly counted and recorded.
Control of the quality of the cloth being knitted is the knitter mechanic’s major
responsibility. Fabric set-ups and m/c maintenance, although necessary, must be put
into their proper order of importers. To set-up a fabric and run it on a well-maintained
m/c, when its quality is questionable, is senseless.
FABRIC DEFECTS:
Defects in circular knitted cloth fall into the following major groups: vertical
lines, barre, holes and snags, tuck or double stitches, these will be discussed seriatim.
Vertical lines:
This defects can be caused by defective needles or defective trick walls. If the
trick walls are worn or not evenly spaced, the needles will knit at different speed. This
uneven movement of the needles will cause uneven stitches which is turn can cause
vertical lines.
If a wall is too big for the needle, the needle will have a sideward motion,
which will cause formation of a wide wale in the fabric. When the trick walls are not
Page 31 of 55
evenly spaced, the needles will knit a certain points wide and narrow stitches in the
fabric. These will also cause unsightly lines.
Dirt may often get into the tricks pushing the needles outwards (cylinder) or
upward (dial) causing irregular vertical stitches. Bent and worn needles will cause the
fabric to have wider Wales in certain places.
Needles with chipped latches, butts, hooks, cheeks, a protruding rivet or broken
spoons will cause fuzzy and irregular vertical lines. Needles with bent latches will
cause vertical tears or ladders in the fabric. Too much lubrication or the use of
improper needle oil often causes oil or dirt strakes.
28
Dark black vertical lines may be caused by dirty tricks, which cause the needles
to run high and rub against the cams. Not enough lubrication may also be the cause of
black vertical lines.
With the use of positive feeding devices, the stitch cam adjustment is
Very accurate. The most important thing to remember when adjusting stitch cams is to
keep the ratio of the dial stitch to the cylinder stitch the same at all the dial and
cylinder feeds.
It must be remember that a positive feed system (tape) will feed the same
amount of yarn to all feeds regardless of stitch adjustment. This stitch adjustment
controls the tension only.
Page 32 of 55
In the case of pique fabric or any similar kind, the odd feeds must be done at the
same tension, but the even form the odd feeds so long as they are all the same. We
know now that the yarn tension will control the length of stitch.
It is very important that any surfaces that the yarn runs over or through mist be
clean of any instruction which will cause irregular tension.
A defective takes down mechanism which pulls tight and then soft will cause
are as on the fabric to be loose and tight. The take down mechanism must pull evenly
at all times to maintain a fabric with even courses.
If dial is not in the proper relationship to the cylinder, fabric of uneven stitch
length will produced. The dial and cylinder relationship should be inspective at least
once a year to maintain proper running conditions.
Uneven thickness of the yarn is one of major causes of barre. The mechanic is
really helpless in the situation. The only thing he can do is to learn to recognize this
condition and notify the throwster immediately.
Badly wound yarn also will cause uneven tension. In most cases a positive feed
system will eliminate this defect, but if one used the mechanic should have the yarn
rewound. In the case of dyed yarn shaded the mechanic is helpless in such a situation,
he must notify the throwster immediately.
Holes and Snags:
Holes in most cases are caused by excessive tension of the yarn. If stitch cams
are adjusted too deep and there is excessive tension in the yarn, it wills beak, causing a
hole. If the dial height is too high these will also cause a tremendous strain on the
yarn.
Other factors that produce excessive tension on the stitch are as follows:
1. Too tight a take down pup,
2. The positive feed system operating improperly,
3. Badly wound yarn,
4. Yarn with thin or weak spots.
5. Dirty or clogged surface in which the yarn passes through or on,
6. Yarn warp around.
Snags in most cases are usually caused by badly wound yarn which at
Page 33 of 55
a low tensions and then suddenly jerks and runs at a high tension. This high tension
wills usually a line of holes from one to nine inches.
Drop Stitches:
This defect occurs when the needle tails to take new yarn of when the needle
fails to take new yarn or when the needle losses its loop.
One of the major causes of this problem is an improperly set yarn carrier. If the
yarn is not fed directly into the hook of the needle, there is a good chance that the
needle will not take the new yarn.
If the stitch cam is set too far back there will be too much yarn is the needle
loop. Because of this loop will be so loose that it can fall causing a drop stitch.
Other possible causes of droop stitches are: the take down mechanism is too
loose, not enough tension on yarn, dial height too high, needles, yarn in wrong hole of
the carrier, dial needle latch closing under yarn carrier and dial needle latch closing
near the hole of the carrier.
Tuck Stitches or Double Stitches:
This defect occurs when the needle does not cast off its old loop. In most cases
this defect can be traced to an improperly set stitch cam.
If the needle is not drown far enough back the old loop will remain on the
needle. On the other hand, if the stitch cam is set too far back, too much yarn will be
going to needle. In this case this needle will be unable to knock over such a large loop.
Other possible causes of Tuck Stitches are as follows:
1. Take down mechanism set too loose,
2. Needles move too freely in their slots,
3. Dial height set too low,
4. Defective needles,
5. Needle trick walls clogged with dirt etc.
Page 34 of 55
1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them
from the cloth or batch roller and they are carried to inspection section by the helpers.
2) Almost four inspection workers are for every shift to check the fabric
rolls. For any kind of fault they are checked thoroughly. Skilled inspectors find them
and indicate them by the scissors in some cases.
3) Quality is specified on the basis of 4-points system. Here is the point
distribution for different kinds fault in this system:-
FOUR POINT GRADING SYSTEM
Size of defects Penalty
3 inches or less 1 point
Over three inch but not 6 inch 2 point
Over 6 inch but not 9 inch 3 point
Over 9 inch 4 point
Up to 3’’ in length: 1 Pt
Up to 6’’ in length: 2 “
Up to 9’’ in length: 3 “
Up to 9’’ in length: 4 “
QUALITY Pts / per 100 square meter= (Total point * GSM)/ (Roll
weight*10)
QUALITY CLASSIFICATION
1 2 3
<20 20-30 30>
OK ASK REJECT
LIST OF EQUIPMENTS:
In this factory ‘Apex Spinning and Knitting Mills Ltd.’ this is the
list of equipments to assure quality:-
1) Inspection m/c # 1(For plain single jersey)
Page 35 of 55
2) Inspection m/c #2 (For decorative single jersey as like as Lycra,
Lacoste, waffle, Fleece and all kind of double jersey as like as Rib, Interlock).
3) Scissors
4) Weight balance & Micro balance
5) GSM cutter
6) Seal (‘CHECK-1’, ‘OK’, ‘REJECT’.).
Rejection criteria for body & Rib: Following table shows common body & rib
faults and response by grey inspection section.
Rejection criteria for collar & cuff: Following table shows common collar & cuff
Page 36 of 55
Faults and response taken by grey inspection section.
REMARKS:
There is hardly any chance of any roll to pass through production on to any buyers by
to by unchecked or disqualified. The inspections are too much experience and they are
aware about their duties and responsibilities. The factory authority and production
related personnel are happy and satisfied with their works
Page 37 of 55
CHAPTER-VII
(Maintenance)
MAINTENANCE:
Maintenance of machineries is very important for any type of industries
and it is a must for a knit composite mill. All machines and machines parts of knitting,
dyeing and garments are maintained with extreme care. Because production quality
and quantity, both depends on the maintenance with regularity. Apex Spinning and
Knitting Mills Ltd. lead maintenance with a troop of skilled mechanical fitters.
MAINTENANCE OF MACHINERY:
In the knitting floor of Apex Spinning and Knitting Mills Ltd. all circular
and flat knitting m/cs are maintained regularly and as necessity requirements.
Approximately after twenty days all machines go under regular maintenance and per
day three machine can be completed . Here different type of maintenance of
machinery, which is taken, different time on the machineries.
ROUTINE:
1) Daily Maintenance: Every machine is taken maintenance daily by the
operators during production. When a production is started by the operator after
handing over from previous shift operator, he takes a routine maintenance on the
machine. He cleans the machine, assures yarn is fed to all needles, cleans the eye pot
of feeder, memminger, signal lamp sensor etc. Before a while of a roll cut from batch
or cloth roller, operator cleans needles, cylinder base plate etc. All around of the
machine are kept neat and clean as if there is no dirt with yarn in the fabric.
2) Schedule/Routine Maintenance: Every machine has a schedule of
maintenance of 10 or 15 days. According to date, schedule maintenance is taken on
the machines. Operators are informed about the time of maintenance. After pre-
estimated production, they hand over the machine to the fitters. Thus, fitters assure all
machines are OK. for any time.
3) Break down maintenance: When product quality hampered and to
complete production in due time break down maintenance is taken. There are many
faults seen in the fabric during production due to needle, sinker, take down roller etc.
Then operators inform the mechanical fitters and they fix it.
4) Restorative maintenance: Restorative maintenance is taken for design
change or new design development. According to advice or order of production
officer, a machine is fixed for new design and mechanical fitters rearrange cam and
needle system.
Planned and preventive maintenance are not taken on the machineries in this mill.
MAINTENANCE OF ‘CIRCULAR KNITTING M/C’:
Page 38 of 55
Lubrication:
Since the life of the m/c and its correct working depend to a large extend
adequate and proper lubrication. It is recommended that the instructions given in the
lubrication charts be followed conscientiously. The Company can not be need
responsible for faults that arise from wrong or inadequate lubrication.
Oiling Needles & Jacks:
Too much oil is preferable to too little. Dark vertical lines in the fabric
originate not from excessive oiling b but from too mach friction between needle and
jacks and the trick walls on account of lack of oil. Should dark vertical lines makes
their appearance is recommended that the appropriates m/c parts be flooded with oil.
This will cause heavy soiling or ht fabrics but the trouble will disappear quickly
correct quantity of oil then can be applied. The supply of oil should be reduced if light
oil striper appears on the fabric.
The Cleaning of Needle & Jacks:
Thin oil is most suitable for this work, about one point heated to a
temperature not exceeding 160ºF poured into the oiling position of the cylinder & dial
cam races & in the heads of the needles while the m/c is running. The fabric will
found to be cleaned again after few yards have been knitted. How often cleaning is
necessary will depend upon what kind of yarn is being used. Synthetic yarn cleaning
is taken place at lest monthly, yarn with absorbent properties being knitted at same
time.
General Cleaning Schedule:
Long m/c life, maximum output & trouble free running depend upon proper
care and maintenance. A general overhaul should take place annually when single
shifts are worked & correspondingly at more frequent interval. When extra shifts are
worked. The overhaul involves removal of all cam section and removal of needles and
jacks from their tricks, so tat the tricks should be thoroughly the cleaned. Before parts
are replaced they should be adequately lubricated.
Page 39 of 55
MANPOWER SET-UP FOR MAINTENANCE:
Page 40 of 55
MAINTENANCE PROCEDURE:
Power on/off
↓
MPF/Positive feeder current line off
↓
MPF belt out/loss
↓
Yarn cut
↓
Fabric out by handle
↓
Cleaning and Oiling
↓
Cam box out
↓
Needle & sinker out
↓
Needle & sinker cleaning by oil
↓
Cam box cleaning by air
After opening & cleaning, m/c is leveled by using leveling meter and follows the
reverse process to ready the m/c.
Page 41 of 55
MAINTENANCE TOOLS/EQUIPMENTS & THEIR FUNCTIONS:
Maintenance tools/equipments Functions
1. Adjustable wrench Used for setting nut & bolts
2. Air suctioner For cleaning machine
3.Spanner Fixed Spanner for nut & bolts fitting
4.Socket spanner Handle system for nut & bolt fitting
5. hammer To apply load where required
6. Screw driver To release any screw
7. Punch Used to fit any worn out shaft
8. Lock opener To open the clip of bearing
9. Hack saw To cut any metallic thing
10. Outside calipers To measure outside dia
11. Inside calipers To measure inside dia
12. Cutting pliers To cut thin wires
13. Pulley key To loosen pulleys
14. Welding machine To join metallic parts
15. Grinding machine To make the smooth fabrics
16. Tester To test electric circuit
17. Pliers To grip anything & cut anything
18. Star driver Screw unlocking
19. Steel tape To measure length, width & height
20. L-key For loosen & tighten the screw
Remarks:
This mill has a strong maintenance fitter’s troop to fix up all types problem.
Two groups of two shifts obey their duties responsibly and sincerely. With their
different tools or equipments they perform their duties skillfully.
Page 42 of 55
CHAPTER-VIII
( UTILITY SERVICES )
SOURCES OF UTILITIES:
The main utility which is used by APEX SPINNING AND
KNITTING MILLS LTD. is natural gas. From natural gas generator produce
electricity. From natural gas and electricity in association with mechanical and
electrical apparatus, APEX SPINNING AND KNITTING MILLS LTD.
produces other utilities like water, steam, compressed air, ETP etc.
Generator no.: 01
Type : gas generator
Brand name : Caterpillar
Origin : USA
Model no. : G-3412
Rated power : 437 kva
Page 43 of 55
Maximum current : 350 kw
Frequency : 50 Hz
Engine RPM : 1500
Voltage : 400
Power factor : 0.8
Water temp. : 92°C
Mobil pressure : 58 PSI
Gas pressure : 10 PSI
Generator no. : 02
Type : gas generator
Brand name : Caterpillar
Origin : USA
Model no. : G-3408
Rated power : 287 kva
Maximum current : 230 kw
Frequency : 50 Hz
Engine RPM : 1500
Volt : 400
Power factor : 0.8
Water temp. : 92°C
Mobil pressure : 58 PSI
Gas pressure : 10 PSI
Generator no. : 03
Type : Diesel generator
Brand name : Perkins
Origin : England
Model no. : P-330E
Rated power : 330 kva
Maximum current : 264 kw
Frequency : 50 Hz
Engine RPM : 1500
Volt : 400
Power factor : 0.8
STEAM:
The required steam is produced by boiler .There is one boiler in
Apex Spinning And Knitting Mills Ltd.
Page 44 of 55
Boiler specification:
Brand name: cleaver brooks
Origin: America
Type: Fire tube boiler
Capacity: 5.5 ton / hr
Model no.: CBW 200350150
Maximum pressure: 150 psi
Year of built: 2000
Minimum circuit capacity: 37 amp
Maximum rating of circuit protection: 120 amp
Blower motor: 15 HP
Air compressor motor: 3 HP
Control circuit: 120 volts 1 PH 50 HZ 7 AMP
Oil pump motor: 220 volts 3 PH
50 HZ 609 AMP
Softener specification:
Brand name: Cleaver brooks®
Page 45 of 55
Model no. : ACC-SMR-150-1- ½ T
Serial no.: CS-0000235
Capacity: 150000 GRS / tank
Unit no.: HS008891
Pipe size: 1 ½ inch
Salt capacity brine marker: 575 lbs
COMPRESSED AIR:
The compressed air is supplied from air compressor. There are
two air compressors in APEX SPINNING AND KNITTING MILLS LTD.
Compressor no.: 01
Brand name: Atlas cop co
Origin: Belgium
Model no. : GA 22FF
Serial no.: AII 254060
Maximum working pressure: 10 bar
Average working pressure: 6-7.5 bar
Free air delivery: 52 liter / second
Nominal shaft power: 22 kw
Rotational shaft speed: 3000 r / min
Gross weight: 480 kg
Year of construction: 2000
Compressor no.: 02
Brand name: BOGE
Origin: Japan
Model no. : S361694
Serial no.: 546206
Year of establishment: 2003
Volt: 400
Frequency: 50 HZ
Maximum working pressure: 10 bar
Average working pressure: 6-7.5 bar
Page 46 of 55
WATER:
The water source of APEX SPINNING AND KNITTING MILLS
LTD. is deep tube well. The deep tube well is about 260 ft deep. The average
water consumption is 40-50 m³ / hr.
GAS:
The source of gas is government agency. Gas is required mainly for
generation of electricity, boiler to produce steam, the burners of heat setting m
/ c. As APEX SPINNING AND KNITTING MILLS LTD. generates their
own electricity, the gas consumption is quite high. The gas consumption is
350-400 m³ / hr.
ETP:
This is the latest utility facilities of APEX SPINNING AND KNITTING
MILLS LTD. Which is running before few day. This plant is urgent for
every mill to protect our environment.
Steps of ETP:
1. At first Equalization tank is used for collecting raw effluent
2.Then in HRSCC tank or mixing tank raw effluent is collected
by pumping Blower is used for proper mixing.
3In HRSCC tank-lime, polymer, FeSO4 are used.
4In HRSCC tank solution is drained .Then sludge is divided &
placed in the sludge pump.
5. The solution is brought to PH Control tank where acid is used to
control PH. 6. The
solution is led to the Biological reaction tank .In this tank BACTERIA
MEDIA is used to absorb the harmful insects in effluent by using Urea as
food of bacteria. 7. Then water is again
drained .The sludge is divided here too & placed in sludge sump & made
it cake form to remove. 8. To remove color, smell &
others chlorine is used in Treated Water tank Atlas the treated water is
drained out in the pond.
Page 47 of 55
Chemical used in ETP:
-Lime
-FeSO4
-HCl
-Polymer
-Chlorine
-Colfoc RD
-NaOCl
-Urea
-Chita gur
-Dewatering Polymer
-cow dung
Electricity cost :
REB =3.8 TK / KW-HR
Gas generator = 2.70 TK / KW-HR
Diesel generator = 6.50 TK / KW-HR
Gas cost :
4.94 Tk/m³ for boiler
3.66 Tk/m³ for generator
4.5 Tk/m³ for domestic purpose
.
REMARKS:
For smooth running of a factory main utilities like gas, electricity
or steam is very essential. Sometimes gas pressure is low than required
pressure. When the gas pressure is low, then diesel generator run. Government
should have to ensure proper gas supply for Industrial purpose.
Page 48 of 55
CHAPTER-IX
(STORE & INVENTORY CONTROL)
SPARES:
Spare store officer keep the spare part in store & make a list of spare
parts. If the spare parts are little in stock he gives requisition to maintenance
manager. Technical manager give requisition to Head office. Head office
indent spare parts or buy local market as per requirements.
Page 49 of 55
CHAPTER -X
(COST ANALYSIS)
INTRODUCTION:
Costing is a process by which the setting price of a product is calculated. It
is a very important task for a factory which runs for business purposes.
And it is also strictly followed in the APEX SPINNING AND KNITTING MILLS
LTD. Costing of the products considering the raw materials expenditure, salary and
wages of officers and workers, distributions and advertisement expenses etc. all direct
and indirect expenses is done in this factory. It is determined by a troop of accountants
with advice and consultancy of executive director.
Page 50 of 55
COSTING OF THE PRODUCT:
Fabric consumption/ doz. = (Body length + Sleeve length +10) x Chest length x 2 x
GSM x12 /10000000
Garments specification:
Body length=78 cm
Sleeve length=33 cm
Chest length=62 cm
GSM=210
Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000
= 3.469 kg
Fabric consumption/doze (with 10% wastage) = 3.816 kg
REMARKS:
Costing is very important for a productive factory. Without proper costing all
production curriculums will go to vain. Because a factory cannot reach to its goal
without achieving good profit and good profit is not possible without skillful costing.
In Apex Spinning and Knitting Mills Ltd. There are some skillful personnel to do this
job.
Page 51 of 55
CHAPTER-XI
(MARKETING ACTIVITIES)
INTRODUCTION:
Marketing activities are done in this mill, APEX SPINNING AND
KNITTING MILLS LTD. by a skillful team of marketing officers under the Executive
Director. Here are the details of marketing activities.
PRODUCT LEBEL:
There are following labels used by this mill:
1) Care Label: It contains washing in hot or cold water, chemical
cleaning, drying conditions etc.
2) Size Label: It contains size of garments.
3) Composition Label: It contains the fabric composition of different
fiber type.
4) Decorative Label: Decoration is as buyer or consumer choice wise.
Page 52 of 55
PACKAGE SIZE & LEBEL:
Most common sizes are
S - Small
M - Medium
L - Large
XL - Extra large
XLL - Very very large
LOCAL MARKET:
APEX SPINNING AND KNITTING MILLS LTD. is 100% export
oriented mill. So there is no local market involved in it.
IMPORTING COUNTRIES:
This mill relates to the countries for yarn importing, they are
1) India
2) Korea
3) Pakistan
4) Taiwan
5) Indonesia
This mill also related to countries for machineries, spares and chemical
importing. They are
1) USA
2) Canada
3) China
4) Japan
5) Korea
6) EUROP
MANPOWER:
Almost ten marketing officers and ten others workers act under the
Executive Director.
Page 53 of 55
DUTIES & RESPONSIBILITES OF MARKETING OFFICERS:
1) Executive director takes order from the buyer and gives order the
marketing officer’s troops to produce a cost sheet.
2) Marketing officers are known the amount and design of product.
3) They collect the sample from the buyers and send to knitting and dyeing
section.
4) Knitting section adjusts the amount of total yarn and knitting conditions
and dyeing sections adjust the amount of dyes and chemicals. They send a rough
calculation to the marketing section.
5) Marketing officers adjust the amount of garments accessories with the
help of their own experiences and their knowledge. They also take help of garments in
charge.
6) Finally, they adjust their cost sheet after consulting with the Executive
Director and copy several pieces of the cost sheet.
REMARKS:
Marketing activities are very important tasks for a productive factory. In
this mill having highly qualified marketing officers. As a result, the mill rises up day
by day.
Page 54 of 55
CHAPTER-XII
(CONCLUSION)
CONCLUSION:
At a juncture of time, when the development of the country
was at a stand still position due to the legacy of shattered economy and the
industrialization was stagnant, the export oriented textile and RMG sector had
shown the ray of hope by its all-pervasive positive impact on the national
economy. At the fag end of the eighty, this sector started expanding and
within a short period of its existence, this nascent industry became the largest
foreign exchange earner.
Page 55 of 55