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Internship Report
YUNUS TEXTILE MILLS LTD.
Muhammad Husnain Siddiqi 1/11/16
INTERNSHIP REPORT
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
SUBMITTED BY:
Students of “DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY”
Department “Industrial Engineering & Management” 3rd year. 13 batch.
GROUP MEMBERS:
Name: Muhammad Husnain Siddiqi
Contact No: 0347-8544650
muhammdhasnain22@yahoo.com
Name: Muhammad Mairaj Saleem Name: Muhammad Ahsan
Contact No: 0322-2833454 Contact No: 0331-2078255
Chand.ahmed59@yahoo.com mohammadahsan207@gmail.com
Name: Muhammad Asim Aslam Name: Muhammad Asad Ayoob
Contact No: 0347-2738816 Contact No: 0312-3017002
Asimaslam70@outlook.com muhammadasadmughal@yahoo.com
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
ACKNOWLEDGMENT
We proudly present our report for this report we are extremely
thankful to the talented people that worked and helped us in sorting out
our circulated questionnaires and confusion throughout the internship
especially we would like to thanks the skillful personalities and worker
whose co-operation was very beneficial & studious for us.
Special thanks to,
G.M Processing Mr. Rizwan Yunus
Manager Q.M.S Mr. Azan Sarwar
Manager Printing Mr. Jawed Afzal
We are also very thankful to Mr. Faisal Tufail (Manager Executive)
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PREFACE
This report documents the work done during the winter internshipat YUNUS
TEXTILES MILLS under the guidance of YTM staff. The report first shall give an
overviewof the learning during the periodof internshipwithtechnical details.
We have triedour best tokeepreport simple yet technically correct. We hope
we succeedinour attempt.
Students of Dawood University
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
Introduction
Yunus Textile Mills Limited (YTM) is a vertically integrated textile mill located in Karachi,
Pakistan. The company, with annual production capacity of 100 Million meters, is the largest
exporter of Home Textile products from Pakistan. In addition to manufacturing, YTM also
provides its customers design and distribution services with offices based in USA, France, Spain,
United Kingdom and Canada.
At present YTM supplies directly to majority of leading retailers of USA and Europe and is
producing products for various private and retail brands.
Companies under Yunus Brothers Group
 Lucky Textile Mills
 Fazal Textile MillsLimited
 GadoonTextile MillsLimited
 Lucky Energy(Private) Limited
 Lucky CementLimited
List of the Awards Won.
 National Excellence Award
 Corporate Community Partnership Award
 Poverty Alleviation Award
 Environment Excellence Award
 Supply Chain Award
 Fire & Safety Award
Compliance Certificates
ISO9000:2008 OEKOTEX100 SA 8000:2008 GOTS GSV (C-TPAT)
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
Products of YTM
Bed and comforters
Curtains and draperies
Cushions and pillows
Kid’s zone
Sheet sets
Duvet cover sets
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENTS
 Spinning
 Weaving
 Processing
 Stitching
SPINNING
Spinning:the action or process ofspinning;the conversion of fibers into yarn.
WEAVING
Weaving is a method of textile production in which two distinctsets ofyarns or threads are interlaced atright angles
to form a fabric or cloth.
WET PROCESSING
Wet processing is the process thatuse in any finishing treatment.Where,this process is applied on textile in form of
liquid with involves some for chemical action on the textile
STITCHING
One complete movementofa threaded needle through a fabric or material such as to leave behind it a single loop or
portion of thread, as in sewing,embroidery,or the surgical closing ofwounds.
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
WEAVING DEPARTMENT
ProcessFlow
WARPING
“Warping is the process of conversion of cones into beam”.
Input:
 cone
Output:
 beam
Plant Capacity:
 3 machines for warping.
 640 cones for 1st machine.
 960 cones for 2nd machine.
 1024 cones for 3rd machine.
 16 lacs meter18lacs meter per day production.
 Time to completion one beam 1 hr.
Production Issues:
 Sometimes empty beam not available.
Quality Issues:
 Polypropylene.
 Cut cone.
 Weak yarn
 Lapeta
Maintenance:
Maintenance perform after every 100 hours.
Warping Sizing
Noting/
article
Looming
InspectionPackaging
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
SIZING
“Sizing is a process to protect, strengthen and lubricate the yarn during weaving”
Input:
Unsized beams.
Output:
Sized beams.
Plant Capacity:
No. of machines =2
Two machines have capacity of 24 and 28 beams.
Production rate is 1.25m lac to 1.5m lac per day.
35 to 40 minutes consume in completion of one beam.
One beam contains 4700 m yarn.
Sizing Agents/Chemicals:
10% chemical of total yarn (One beam) is used which includes:
Water 700 liters
Starch 90 to 110 kg
PVA 4 to 5 kg
Wax 1 kg
Softener 1 kg
Quality Issues:
Issue in percentages of chemicals used for sizing.
Production Issues:
Weak yarn.
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
LOOMING
“Looming is a process of weaving which is used to produce the woven fabric by the intersection
of warp and weft yarn.”
Input:
Sized Yarn.
Output:
Woven Fabric.
Plant Capacity:
No. of looms = 254.
There are three different sizes of looms w.r.t yarn width:
 490 cm (no. of looms = 45)
 280 cm (no. of looms = 35)
 340 cm (Remaining).
Production Rate
 OMNI PLUS:
RPM = 400
Production = 400 m per day.
 OMNI PLUS 800:
RPM = 1000
Production = 1000 m per day.
 OMNI PLUS SUMMUM:
RPM = 1100
Production = 110000 m per day
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
INSPECTION
“Inspection in reference to the apparel industry can be defined as the visual examination or
review of raw materials (like fabric, sewing threads, buttons, trims, etc), partially finished
components of the garments and completely finished garments in relation to some standards.”
Plant capacity
 Total inspection frames = 30
Production Rate
Per day production = 1 lakh 30 thousands meters.
Per month production = 30 – 35 lakhs meters.
PRODUCTION FAULTS:-
Following are the bottlenecks usually occur in the looming process.
 Short end  Weft crack
 Wrong darting  Contamination of fluff
 Crack  Hole
 Hand crack  Black warp
 Selvedge  Loose end
 Warp streaks  Double cone
 Weft bar  Hanging thread
Quality check according to the following table
Penalty points 1 2 3 4
Defects along the
Warp except hole
and turn.
Up to 3” Up to 3”-6” Up to 6”-9” Up to 9”-12”
Percentage of rejection and acceptance can be calculated by the following formula:-
 Points / 100 leaner meters =………………
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
Quality standard:
Plain Twill
A= 20 20
B= 25 25
C= 30 35
WEAVING TESTING LAB:
Following are the apparatus used in the laboratory:
1. Appearance of yarn machine.
Yarn Appearance Board Winder is used to compare the appearance of irregularities
against standard rating photographs which carry out visual determination of unevenness
along the length of a yarn. Tenable yarns of different thickness to be assessed; the
spacing between the wraps is suitably selected so as to clearly give a distinguishable
pattern.
2. Pick Glass
Microscope is use to count the no. of warp and weft of fabric per inch.
3. Tensile strength tester.
It is used to determine the maximum force required to rupture (break) a woven fabric.
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PACKING
“After inspection the looms forward to the packing department.”
Packing of looms comprises into 3 categories which are listed below:
 Rolling
 Pelleting
 Bales
MACHINES CAPACITY
1) Rolling machines = 3
2) Folding machines = 4
3) Bailing machines = 3
PRODUCTION CAPACITY
Per day production = 1 lakh 30 thousands meters.
Per month production = 30 – 35 lakhs meters.
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
FLOW CHART FOR WET PROCESSING
Grey Fabric Inspection
Sewing or Stitching
Singeing
De-sizing
Scouring
Bleaching
Mercerizing
Dyeing
Printing
Finishing
Final Inspection
Delivery
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PRINTING
In YTM there are 3 m/c of REGGIANI having max fabric length 130” and 97” and length is 40
m. on Printing 1 and 2 ,16 colors can be printed and on Printing 3 12 colors can be printed at a
time.
 Production is 1-1.3 lack per day.
CAM CAD
The design given by the customer may be on a paper or directly they given a sample fabric
to the cad cam department they scan the design in the computer.
After the approval of the design by the customer design is sent to the engraving department.
ScreenCoating
The screen is made up of 100% nickel. Screen is coated with coated material SCR 64 or
SCR 61. Screen is coated upside down for 15-30 min at high temp over 180-200c and left for dry
about 10-30 min.
Screenexposing
There are 3 exposing machine in YTM,
 Wax exposing machine.
 Contain black wax which fired on the screen. When light strikes on the screen
wax become hard.
 Ink jet.
 Laser exposing.
Laser light bombarded. SCR 102+101 coat is used only curing, exposing and entering.
Screen Developing:
The screen is developed which means only that parts where patterns are printed on screen
are removed from coating while other remains same
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
Recipe:
 Thickener
 Liquor
 Binder
 Water
 Pigment
For reactive:
 Urea
 Sodium bi carbonate
 Alginate
 Revatol
Process flow:
Entry → Printing → Dryer→ Exit
Components of machine:
• Entry
• Suction
• Flat rollers
• Trolley
• Printing zone
• Sensor
• Conveyor belt washing
• Dryer
The fabric is passes through guide screen rollers to the suction area here the sucker sucks the
fabric fluff and dust particles. Flats are provided when we use knit fabric. The fabric enters into
the trolley where PVA is applied to stick he fabric with the blanket belt. The machine is provided
with an I.R system and cambered plate to give temperature to the thermoplastic glue. Then the
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
fabric enters into the printing zone. The fabric is sandwiched b/w the rollers and the blanket,
magnetic system of printing is used.
Color is dozed into the squeegee through pumps automatically. The first screen roller is to press
the fabric and the second gathers the remaining fluff. The printing starts from the third screen. each
screen prints a single color. the number of the screen depends on the type of design. The sensor is
used to control the speed of the blanket. The fabric than entered into compact HC dryer 160-180
c. the dryer has 5 burners. The dryer has three passages air is blown into the chambers 2 times.
Finally the fabric is collected by a crank gear mechanism to a trolley.
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
Our Task
“To Reduce Downtime During Changeover Activity”
Data collectedduring changeoveractivity
ROTARY 2:
 No. of operator = 04
 NO OF SCREEN IN= 08
S.NO ACTIVITY YES/NO TIME Current
status
proposed Time saved
1. Program give to m/c
operator
yes 15min
before
External External
2. Operator goes to
engraving
yes 1min56sec External External
3. Engraving supervisor
handed over screens to
operator
yes 3min56sec External External
4. Operator collect screens
from engraving
yes 8min External External
5. Arrange squeegee holder
if repeat change
no 5min Internal External 5min
6. Screen sequencing as per
design
no 30sec Internal External 30sec
7. As per program quantity
fabric material availability
to m/c
yes 20min(5min
in internal)
Internal External 5min
8. Squeegee preparation yes 12min38sec Internal External 12min38sec
9. Lead clothes trolley to
fabric
yes 2min3sec External External
10. Fabric stitched to lead
clothes
yes 45sec External External
11. Temperature maintaining yes 8min14sec External External
TOTAL 1hr3min2sec 23min8sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
ROTARY 3:
 NO.OF OPERATOR= 03
 NO OF SCREEN IN= 10
S.NO ACTIVITY YES/
NO
TIME Current
status
proposed Time saved
1. Program Give To M/C Operator yes 24HR
BEFORE
External External
2. Operator Goes To Engraving yes 1min 30sec External External
3. Engraving Supervisor Handed
Over Screens To Operator
yes 4min50sec External External
4. Operator Collect Screens From
Engraving
yes 6min10sec External External
5. Screen Sequencing As Per Design no 1min External External
6. As Per Program Quantity Fabric
Material Availability To M/C
yes 2min22sec External External
7. Squeegee Preparation yes 13min22sec Internal External 13min22sec
8. Lead Clothes Trolley To Fabric yes 1min50sec External External
9. Fabric Stitched To Lead Clothes yes 1min3sec External External
10. Temperature Maintaining yes 3min4sec External External
TOTAL 35min11sec 13min22sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
ROTARY 1:
 NO.OF OPERATOR= 04
 NO OF SCREEN IN= 01
ROTARY 1:
 NO.OF OPERATOR= 04
S.NO ACTIVITY YES/NO TIME Current
status
proposed Time saved
1. Program give to m/c
operator
yes 30 min
before
External External
2. Operator goes to
engraving
yes 1min29sec External External
3. Engraving supervisor
handed over screens to
operator
yes 44sec External External
4. Operator collect screens
from engraving
yes 1min56sec External External
5. Arrange squeegee
holder if repeat change
yes
-
External External
6. Screen sequencing as
per design
yes - External External
7. As per program quantity
fabric material
availability to m/c
yes
Last shift
External External
8. Squeegee preparation no 8min30sec Internal External 8min30sec
9. Lead clothes trolley to
fabric
yes 1min31sec External External
10. Fabric stitched to lead
clothes
yes 58sec External External
11. Temperature
maintaining
yes 5min3sec External External
TOTAL time of activities 20min10sec 8min30sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
 NO OF SCREEN IN= 04
S.NO ACTIVITY YES/NO TIME Current
status
proposed Time saved
1. Program give to m/c
operator
yes urgent External External
2. Operator goes to engraving yes 1min34sec Internal External 1min34sec
3. Engraving supervisor
handed over screens to
operator
yes 1min56sec Internal External 1min56sec
4. Operator collect screens
from engraving
yes 1in35sec Internal External 1min35sec
5. Arrange squeegee holder if
repeat change
no - External External
6. Screen sequencing as per
design
no 25sec Internal External 25sec
7. As per program quantity
fabric material availability
to m/c
yes Last shift External External
8. Squeegee preparation yes 6min4sec Internal External 6min4sec
9. Lead clothes trolley to
fabric
yes 1min25sec Internal External 1min34sec
10. Fabric stitched to lead
clothes
yes 1min2sec Internal External 1min56sec
11. Temperature maintaining yes 5min36sec External External
TOTAL 19min37sec 15min4sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
ROTARY 3:
 NO.OF OPERATOR= 02
 NO OF SCREEN IN= 08
S.NO ACTIVITY YES/NO TIME Current
status
proposed Time saved
1. Program give to m/c
operator
yes 3hr before External External
2. Operator goes to engraving yes 1min29sec External External
3. Engraving supervisor
handed over screens to
operator
yes 6min30sec External External
4. Operator collect screens
from engraving
yes 3min17sec External External
5. Screen sequencing as per
design
no 55sec Internal External 55sec
6. As per program quantity
fabric material availability
to m/c
yes 3min54sec Internal External
7. Squeegee preparation yes 11min40sec Internal External 11min40sec
8. Lead clothes trolley to
fabric
yes 1min40sec External External
9. Fabric stitched to lead
clothes
yes 50sec External External
10. Temperature maintaining yes 2min47sec External External
TOTAL 33min2sec 12min35sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
1) ROTARY MACHINE3
NO. of screen removed: 3
No of screen to be set: 11
No of workers available: 04
 Sensor works starts after 5min of squeeze levelling
 Squeeze plates not ready wait = 33min18sec
 Total changeover time = 1hr 12min27sec
S.NO Activity Time
1. Sensor wireremoved 5sec
2. Sensor removed 15sec
3. screen removed 1min21sec
4. Squeeze removed 1min10sec
5. removed color pump 9sec
6. Clean of head 3min5sec
7. screen took in to machine and fit 10min7sec
8. squeezetook into screen 3min38sec
9. Squeeze levelling 11min4sec
10. cleaning of pump 2min15sec
11. sensor took and sensor wire 9min16sec
12. color pump insert 1min9sec
Total activity time 39min.
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
2) ROTARY MACHINE1
NO.of screen removed: 2
No of screen to be set: 1
No of workers available: 03
 Waiting of color =10min
 Change over time and waiting of color included= 23min56sec
S.NO Activity Time
1. Sensor wireremoved 10sec
2. Sensor removed 7sec
3. screen removed 56sec
4. Squeeze removed 58sec
5. removed color pump 10sec
6. Clean of head 2min3sec
7. screen took in to machine and fit 1min32sec
8. squeezetook into screen 1min31sec
9. Squeeze leveling 1min52sec
10. cleaning of pump 2min5sec
11. sensor took and sensor wire 1min35sec
12. color pump insert 54sec
Total activity time 13min.56sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
3) ROTARY MACHINE2
NO.of screen removed: 3
No of screen to be set: 1
No of workers available: 03
 Batcher not available and waiting =18min 45sec
 Total changeover time =27min24sec
S.NO Activity Time
1. Sensor wireremoved 6sec
2. Sensor removed 8sec
3. screen removed 1min30sec
4. Squeeze removed 1min24sec
5. removed color pump 11sec
6. Clean of head 1min55sec
7. screen took in to machine and fit 28sec
8. squeezetook into screen 29sec
9. Squeeze levelling 1min38sec
10. cleaning of pump 33sec
11. sensor took and sensor wire 10sec
12. color pump insert 7sec
Total activity time 8min.47sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
4) ROTARY MACHINE1
NO.of screen removed: 1
No of screen to be set: 9
No of workers available: 04
 Stopper not joint in external
 Sensor work start after 5 min of sequeeeze
 Total changeover time = 27min53sec
S.NO Activity Time
1. Sensor wireremoved 2sec
2. Sensor removed 6sec
3. screen removed 30sec
4. Squeeze removed 27sec
5. removed color pump 5sec
6. Clean of head 40sec
7. screen took in to machine and fit 8min30sec
8. squeezetook into screen +levelling 13min36sec
9. cleaning of pump 37sec
10. sensor took and sensor wire 8min30sec
11. color pump insert 57sec
Total activity time 27min53sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
5) ROTARY MACHINE1
NO.of screen removed: 1
No of screen to be set: 12
No of workers available: 03
 Squeeze holder not arranged = 10min
 Screen sequencing = 15min5sec
 Rod put in squeeze = 6min
 Sensor and screen not arranged.
 Sensor not arranged that’s why took so much time.
 Total changeover time = 2hr4min56sec
S.NO Activity Time
1. Sensor wireremoved 3sec
2. Sensor removed 7sec
3. screen removed 50sec
4. Squeeze removed 23sec
5. removed color pump 5sec
6. Clean of head 1min2sec
7. screen took in to machine and fit 13min
8. squeezetook into screen 5min36sec
9. Squeeze leveling 25min25sec
10. cleaning of pump 18min
11. sensor took and sensor wire 34min
12. color pump insert 1min20sec
Total activity time 1hr33min51sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
6) ROTARY MACHINE2
NO.of screen removed: 4
No of screen to be set: 3
No of workers available: 04
 Batcher not available so worker do external work of next activity do like
 Washing of squeeze =6min15sec
 Total changeover time = 26min15sec
S.NO Activity Time
1. Sensor wireremoved 9sec
2. Sensor removed 1min5sec
3. screen removed 3min22sec
4. Squeeze removed 1min28sec
5. removed color pump 27sec
6. Clean of head 5min20sec
7. screen took in to machine and fit 1min30sec
8. squeezetook into screen + Squeeze leveling 2min18sec
9. cleaning of pump 1min54sec
10. sensor took and sensor wire 1min28sec
11. color pump insert 59sec
Total activity time 20min
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
7) ROTARY MACHINE3
NO.of screen removed: 3
No of screen to be set: 12
No of workers available: 05
 Color not available this takes too much time.
 Screen not available.
 Total changeover time= 1 hr 43min 26sec.
S.NO Activity Time
1. Sensor wireremoved 9sec
2. Sensor removed 25sec
3. screen removed 30sec
4. Squeeze removed 1min52sec
5. removed color pump 30sec
6. Clean of head 1min
7. screen took in to machine and fit 2min46sec
8. squeezetook into screen 4min24sec
9. Squeeze leveling 15min19sec
10. cleaning of pump 24min55sec
11. sensor took and sensor wire 12min16sec
12. color pump insert 9min2sec
Total activity time 1hr13min8sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
8) ROTARY MACHINE2
NO.of screen removed: 03
No of screen to be set: 02
No of workers available: 04
 Waiting of color = 5min53sec
 Total changover time= 23min49sec
S.NO Activity Time
1. Sensor wireremoved 10sec
2. Sensor removed 30sec
3. screen removed 1min34sec
4. Squeeze removed 1min50sec
5. removed color pump 28sec
6. Clean of head 1min20sec
7. screen took in to machine and fit 2min2sec
8. squeezetook into screen 1min15sec
9. Squeeze leveling 6min21sec
10. cleaning of pump 1min56sec
11. sensor took and sensor wire 22sec
12. color pump insert 8sec
Total activity time 17min56sec
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DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
Average Changeover Time per Screen
 Estimated program given time for onescreen = 25min
S.NO ACTIVITY YES/
NO
TIME Current
status
proposed Time saved
11. Operator Goes To Engraving yes 1min35sec External External
12. Engraving Supervisor Handed Over
Screens To Operator
yes 35sec/screen External External
13. Operator Collect Screens From
Engraving
yes 1min21sec/s
creen
External External
14. Screen Sequencing As Per Design no 10sec/screen External External
15. As Per Program Quantity Fabric
Material Availability To M/C
yes 2min12sec/
batcher
External External
16. Squeegee Preparation yes 1min41sec/
squeegee
Internal External 1min41sec
17. Lead Clothes Trolley To Fabric yes 56sec External External
18. Fabric Stitched To Lead Clothes yes 55sec External External
19. Temperature Maintaining yes 4min54sec External External
20. TOTAL 13min 19sec 1min41sec
INTERNAL ACTIVITY
21. Sensor wire removed 3sec Internal Internal
22. Sensor removed 6sec Internal Internal
23. screen removed 32sec Internal Internal
24. Squeeze removed 25sec Internal Internal
25. removed color pump 4sec Internal Internal
26. Clean of head 1min18sec Internal Internal
27. screen took in to machine and fit 57sec Internal Internal
28. squeeze took into screen 24sec Internal Internal
29. Squeeze levelling 1min17sec Internal Internal
30. cleaning of pump 46sec Internal Parallel to
16,17,18
46sec
31. sensor took and sensor wire 1min12sec Internal Parallel to
18.
1min12sec
32. color pump insert 9sec Internal Internal
TOTAL 7min4sec 1min58sec
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How the time of internal activity canbe reduce.
Our observation:
The most time consuming activity is to level the squeegee in screen. In automatic
rotary the time required to level one squeegee is 1 min. and in manual rotary the
time becomes double.
 Leveling 11 squeegee on automatic rotary takes 11min4s (1min./squeegee )
and on manually leveling 9 squeegee takes 13min36 sec (1.5min. / squeegee)
 Up to 1 min. can be saved on every changeover activity which becomes 3min. per shift
9min. per day and 4.5 hrs. per month and 54hrs per year
Our suggestion
If there is possibility to fixed the leveler in manual machine as in automatic the time of
changeover decrease. It can save 54hrs annually and can increase 129600m production
annually
SUGGESTION:
 Changeover teamshouldbe introduced
 Separate stands for rotary 1 and rotary 2 for squeegee, andsqueegee
holder, sensor andlatto.
 Program delivery Time shouldbe mentionedon programscheme.
 Change over start and endtime should be mentionedon board.
 Check list shouldbe marked.
 Squeegee holder shouldbe fixedon rotary 1and rotary 2
 Make job Descriptionprinting worker.
 Active Trouble Shooting department inMaintenance Departmentfor
Monitoring.
 Competitionbetweenthree rotary machine for changeover activity and
set some kind of incentives. (It helps youto get least changeover time).
INTERNSHIP REPORT
32 | P a g e
DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY
STITCHING
“Stitches means a single complete movement of a threaded needle in sewing.”
Sewing Process
The basic process ofsewing involves fastening of fabrics, leather, furs or similar other flexible materials with the help
of needle and threads. Sewing is mainly used to manufacture clothing and home furnishings.
Pre Sewing Functions:
Before the actual taskof sewing begins,there are certain othertasks that have to be taken care of which can be termed
as fabric handling functions- Ply separation; Placing the fabric on working table; Guiding the fabric towards sewing
Recognizing the fabric's shape: The appropriate tensional force depends on the fabric properties. So the
fabrics have to be identified into categories like knitted fabrics, woven fabrics etc. depending on their physical
properties needle; and tension control of fabric during the sewing process.
Fabric Edges to be sewn:There are two basic types of stitches- one is that are for joining two parts of cloth
together and the second one is done for decorative purposes
Planning OF Sewing Process:Sequence of seams to be stitched is determined before the sewing starts.
Which part will be joined first, what stitches will follow one another, etc. are decided. However, some stitches have
to be necessarily done before or after another stitch. In the example above, the decorative stitches must be done first
followed by the joining stitches.
Sewing Fabrics:
The sewing process consists ofmainly three functions- guiding fabric towards needle; sewing of the fabric edge; and
rotation around the needle. The fabric is guided along the sewing line with a certain speed that is in harmony with the
speed of sewing machine. The orientation error is either manually monitored or if monitored automatically then error
is fed to the machine controller so that the machine corrects the orientation of the fabrics
Fabric receiving Drawing for
cutting
Cutting
StitchingCheckingPacking

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internship report YTM

  • 1. Internship Report YUNUS TEXTILE MILLS LTD. Muhammad Husnain Siddiqi 1/11/16
  • 2. INTERNSHIP REPORT 1 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY SUBMITTED BY: Students of “DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY” Department “Industrial Engineering & Management” 3rd year. 13 batch. GROUP MEMBERS: Name: Muhammad Husnain Siddiqi Contact No: 0347-8544650 muhammdhasnain22@yahoo.com Name: Muhammad Mairaj Saleem Name: Muhammad Ahsan Contact No: 0322-2833454 Contact No: 0331-2078255 Chand.ahmed59@yahoo.com mohammadahsan207@gmail.com Name: Muhammad Asim Aslam Name: Muhammad Asad Ayoob Contact No: 0347-2738816 Contact No: 0312-3017002 Asimaslam70@outlook.com muhammadasadmughal@yahoo.com
  • 3. INTERNSHIP REPORT 2 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY ACKNOWLEDGMENT We proudly present our report for this report we are extremely thankful to the talented people that worked and helped us in sorting out our circulated questionnaires and confusion throughout the internship especially we would like to thanks the skillful personalities and worker whose co-operation was very beneficial & studious for us. Special thanks to, G.M Processing Mr. Rizwan Yunus Manager Q.M.S Mr. Azan Sarwar Manager Printing Mr. Jawed Afzal We are also very thankful to Mr. Faisal Tufail (Manager Executive)
  • 4. INTERNSHIP REPORT 3 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY PREFACE This report documents the work done during the winter internshipat YUNUS TEXTILES MILLS under the guidance of YTM staff. The report first shall give an overviewof the learning during the periodof internshipwithtechnical details. We have triedour best tokeepreport simple yet technically correct. We hope we succeedinour attempt. Students of Dawood University
  • 5. INTERNSHIP REPORT 4 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY Introduction Yunus Textile Mills Limited (YTM) is a vertically integrated textile mill located in Karachi, Pakistan. The company, with annual production capacity of 100 Million meters, is the largest exporter of Home Textile products from Pakistan. In addition to manufacturing, YTM also provides its customers design and distribution services with offices based in USA, France, Spain, United Kingdom and Canada. At present YTM supplies directly to majority of leading retailers of USA and Europe and is producing products for various private and retail brands. Companies under Yunus Brothers Group  Lucky Textile Mills  Fazal Textile MillsLimited  GadoonTextile MillsLimited  Lucky Energy(Private) Limited  Lucky CementLimited List of the Awards Won.  National Excellence Award  Corporate Community Partnership Award  Poverty Alleviation Award  Environment Excellence Award  Supply Chain Award  Fire & Safety Award Compliance Certificates ISO9000:2008 OEKOTEX100 SA 8000:2008 GOTS GSV (C-TPAT)
  • 6. INTERNSHIP REPORT 5 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY Products of YTM Bed and comforters Curtains and draperies Cushions and pillows Kid’s zone Sheet sets Duvet cover sets
  • 7. INTERNSHIP REPORT 6 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY DEPARTMENTS  Spinning  Weaving  Processing  Stitching SPINNING Spinning:the action or process ofspinning;the conversion of fibers into yarn. WEAVING Weaving is a method of textile production in which two distinctsets ofyarns or threads are interlaced atright angles to form a fabric or cloth. WET PROCESSING Wet processing is the process thatuse in any finishing treatment.Where,this process is applied on textile in form of liquid with involves some for chemical action on the textile STITCHING One complete movementofa threaded needle through a fabric or material such as to leave behind it a single loop or portion of thread, as in sewing,embroidery,or the surgical closing ofwounds.
  • 8. INTERNSHIP REPORT 7 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY WEAVING DEPARTMENT ProcessFlow WARPING “Warping is the process of conversion of cones into beam”. Input:  cone Output:  beam Plant Capacity:  3 machines for warping.  640 cones for 1st machine.  960 cones for 2nd machine.  1024 cones for 3rd machine.  16 lacs meter18lacs meter per day production.  Time to completion one beam 1 hr. Production Issues:  Sometimes empty beam not available. Quality Issues:  Polypropylene.  Cut cone.  Weak yarn  Lapeta Maintenance: Maintenance perform after every 100 hours. Warping Sizing Noting/ article Looming InspectionPackaging
  • 9. INTERNSHIP REPORT 8 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY SIZING “Sizing is a process to protect, strengthen and lubricate the yarn during weaving” Input: Unsized beams. Output: Sized beams. Plant Capacity: No. of machines =2 Two machines have capacity of 24 and 28 beams. Production rate is 1.25m lac to 1.5m lac per day. 35 to 40 minutes consume in completion of one beam. One beam contains 4700 m yarn. Sizing Agents/Chemicals: 10% chemical of total yarn (One beam) is used which includes: Water 700 liters Starch 90 to 110 kg PVA 4 to 5 kg Wax 1 kg Softener 1 kg Quality Issues: Issue in percentages of chemicals used for sizing. Production Issues: Weak yarn.
  • 10. INTERNSHIP REPORT 9 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY LOOMING “Looming is a process of weaving which is used to produce the woven fabric by the intersection of warp and weft yarn.” Input: Sized Yarn. Output: Woven Fabric. Plant Capacity: No. of looms = 254. There are three different sizes of looms w.r.t yarn width:  490 cm (no. of looms = 45)  280 cm (no. of looms = 35)  340 cm (Remaining). Production Rate  OMNI PLUS: RPM = 400 Production = 400 m per day.  OMNI PLUS 800: RPM = 1000 Production = 1000 m per day.  OMNI PLUS SUMMUM: RPM = 1100 Production = 110000 m per day
  • 11. INTERNSHIP REPORT 10 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY INSPECTION “Inspection in reference to the apparel industry can be defined as the visual examination or review of raw materials (like fabric, sewing threads, buttons, trims, etc), partially finished components of the garments and completely finished garments in relation to some standards.” Plant capacity  Total inspection frames = 30 Production Rate Per day production = 1 lakh 30 thousands meters. Per month production = 30 – 35 lakhs meters. PRODUCTION FAULTS:- Following are the bottlenecks usually occur in the looming process.  Short end  Weft crack  Wrong darting  Contamination of fluff  Crack  Hole  Hand crack  Black warp  Selvedge  Loose end  Warp streaks  Double cone  Weft bar  Hanging thread Quality check according to the following table Penalty points 1 2 3 4 Defects along the Warp except hole and turn. Up to 3” Up to 3”-6” Up to 6”-9” Up to 9”-12” Percentage of rejection and acceptance can be calculated by the following formula:-  Points / 100 leaner meters =………………
  • 12. INTERNSHIP REPORT 11 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY Quality standard: Plain Twill A= 20 20 B= 25 25 C= 30 35 WEAVING TESTING LAB: Following are the apparatus used in the laboratory: 1. Appearance of yarn machine. Yarn Appearance Board Winder is used to compare the appearance of irregularities against standard rating photographs which carry out visual determination of unevenness along the length of a yarn. Tenable yarns of different thickness to be assessed; the spacing between the wraps is suitably selected so as to clearly give a distinguishable pattern. 2. Pick Glass Microscope is use to count the no. of warp and weft of fabric per inch. 3. Tensile strength tester. It is used to determine the maximum force required to rupture (break) a woven fabric.
  • 13. INTERNSHIP REPORT 12 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY PACKING “After inspection the looms forward to the packing department.” Packing of looms comprises into 3 categories which are listed below:  Rolling  Pelleting  Bales MACHINES CAPACITY 1) Rolling machines = 3 2) Folding machines = 4 3) Bailing machines = 3 PRODUCTION CAPACITY Per day production = 1 lakh 30 thousands meters. Per month production = 30 – 35 lakhs meters.
  • 14. INTERNSHIP REPORT 13 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY FLOW CHART FOR WET PROCESSING Grey Fabric Inspection Sewing or Stitching Singeing De-sizing Scouring Bleaching Mercerizing Dyeing Printing Finishing Final Inspection Delivery
  • 15. INTERNSHIP REPORT 14 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY PRINTING In YTM there are 3 m/c of REGGIANI having max fabric length 130” and 97” and length is 40 m. on Printing 1 and 2 ,16 colors can be printed and on Printing 3 12 colors can be printed at a time.  Production is 1-1.3 lack per day. CAM CAD The design given by the customer may be on a paper or directly they given a sample fabric to the cad cam department they scan the design in the computer. After the approval of the design by the customer design is sent to the engraving department. ScreenCoating The screen is made up of 100% nickel. Screen is coated with coated material SCR 64 or SCR 61. Screen is coated upside down for 15-30 min at high temp over 180-200c and left for dry about 10-30 min. Screenexposing There are 3 exposing machine in YTM,  Wax exposing machine.  Contain black wax which fired on the screen. When light strikes on the screen wax become hard.  Ink jet.  Laser exposing. Laser light bombarded. SCR 102+101 coat is used only curing, exposing and entering. Screen Developing: The screen is developed which means only that parts where patterns are printed on screen are removed from coating while other remains same
  • 16. INTERNSHIP REPORT 15 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY Recipe:  Thickener  Liquor  Binder  Water  Pigment For reactive:  Urea  Sodium bi carbonate  Alginate  Revatol Process flow: Entry → Printing → Dryer→ Exit Components of machine: • Entry • Suction • Flat rollers • Trolley • Printing zone • Sensor • Conveyor belt washing • Dryer The fabric is passes through guide screen rollers to the suction area here the sucker sucks the fabric fluff and dust particles. Flats are provided when we use knit fabric. The fabric enters into the trolley where PVA is applied to stick he fabric with the blanket belt. The machine is provided with an I.R system and cambered plate to give temperature to the thermoplastic glue. Then the
  • 17. INTERNSHIP REPORT 16 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY fabric enters into the printing zone. The fabric is sandwiched b/w the rollers and the blanket, magnetic system of printing is used. Color is dozed into the squeegee through pumps automatically. The first screen roller is to press the fabric and the second gathers the remaining fluff. The printing starts from the third screen. each screen prints a single color. the number of the screen depends on the type of design. The sensor is used to control the speed of the blanket. The fabric than entered into compact HC dryer 160-180 c. the dryer has 5 burners. The dryer has three passages air is blown into the chambers 2 times. Finally the fabric is collected by a crank gear mechanism to a trolley.
  • 18. INTERNSHIP REPORT 17 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY Our Task “To Reduce Downtime During Changeover Activity” Data collectedduring changeoveractivity ROTARY 2:  No. of operator = 04  NO OF SCREEN IN= 08 S.NO ACTIVITY YES/NO TIME Current status proposed Time saved 1. Program give to m/c operator yes 15min before External External 2. Operator goes to engraving yes 1min56sec External External 3. Engraving supervisor handed over screens to operator yes 3min56sec External External 4. Operator collect screens from engraving yes 8min External External 5. Arrange squeegee holder if repeat change no 5min Internal External 5min 6. Screen sequencing as per design no 30sec Internal External 30sec 7. As per program quantity fabric material availability to m/c yes 20min(5min in internal) Internal External 5min 8. Squeegee preparation yes 12min38sec Internal External 12min38sec 9. Lead clothes trolley to fabric yes 2min3sec External External 10. Fabric stitched to lead clothes yes 45sec External External 11. Temperature maintaining yes 8min14sec External External TOTAL 1hr3min2sec 23min8sec
  • 19. INTERNSHIP REPORT 18 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY ROTARY 3:  NO.OF OPERATOR= 03  NO OF SCREEN IN= 10 S.NO ACTIVITY YES/ NO TIME Current status proposed Time saved 1. Program Give To M/C Operator yes 24HR BEFORE External External 2. Operator Goes To Engraving yes 1min 30sec External External 3. Engraving Supervisor Handed Over Screens To Operator yes 4min50sec External External 4. Operator Collect Screens From Engraving yes 6min10sec External External 5. Screen Sequencing As Per Design no 1min External External 6. As Per Program Quantity Fabric Material Availability To M/C yes 2min22sec External External 7. Squeegee Preparation yes 13min22sec Internal External 13min22sec 8. Lead Clothes Trolley To Fabric yes 1min50sec External External 9. Fabric Stitched To Lead Clothes yes 1min3sec External External 10. Temperature Maintaining yes 3min4sec External External TOTAL 35min11sec 13min22sec
  • 20. INTERNSHIP REPORT 19 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY ROTARY 1:  NO.OF OPERATOR= 04  NO OF SCREEN IN= 01 ROTARY 1:  NO.OF OPERATOR= 04 S.NO ACTIVITY YES/NO TIME Current status proposed Time saved 1. Program give to m/c operator yes 30 min before External External 2. Operator goes to engraving yes 1min29sec External External 3. Engraving supervisor handed over screens to operator yes 44sec External External 4. Operator collect screens from engraving yes 1min56sec External External 5. Arrange squeegee holder if repeat change yes - External External 6. Screen sequencing as per design yes - External External 7. As per program quantity fabric material availability to m/c yes Last shift External External 8. Squeegee preparation no 8min30sec Internal External 8min30sec 9. Lead clothes trolley to fabric yes 1min31sec External External 10. Fabric stitched to lead clothes yes 58sec External External 11. Temperature maintaining yes 5min3sec External External TOTAL time of activities 20min10sec 8min30sec
  • 21. INTERNSHIP REPORT 20 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY  NO OF SCREEN IN= 04 S.NO ACTIVITY YES/NO TIME Current status proposed Time saved 1. Program give to m/c operator yes urgent External External 2. Operator goes to engraving yes 1min34sec Internal External 1min34sec 3. Engraving supervisor handed over screens to operator yes 1min56sec Internal External 1min56sec 4. Operator collect screens from engraving yes 1in35sec Internal External 1min35sec 5. Arrange squeegee holder if repeat change no - External External 6. Screen sequencing as per design no 25sec Internal External 25sec 7. As per program quantity fabric material availability to m/c yes Last shift External External 8. Squeegee preparation yes 6min4sec Internal External 6min4sec 9. Lead clothes trolley to fabric yes 1min25sec Internal External 1min34sec 10. Fabric stitched to lead clothes yes 1min2sec Internal External 1min56sec 11. Temperature maintaining yes 5min36sec External External TOTAL 19min37sec 15min4sec
  • 22. INTERNSHIP REPORT 21 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY ROTARY 3:  NO.OF OPERATOR= 02  NO OF SCREEN IN= 08 S.NO ACTIVITY YES/NO TIME Current status proposed Time saved 1. Program give to m/c operator yes 3hr before External External 2. Operator goes to engraving yes 1min29sec External External 3. Engraving supervisor handed over screens to operator yes 6min30sec External External 4. Operator collect screens from engraving yes 3min17sec External External 5. Screen sequencing as per design no 55sec Internal External 55sec 6. As per program quantity fabric material availability to m/c yes 3min54sec Internal External 7. Squeegee preparation yes 11min40sec Internal External 11min40sec 8. Lead clothes trolley to fabric yes 1min40sec External External 9. Fabric stitched to lead clothes yes 50sec External External 10. Temperature maintaining yes 2min47sec External External TOTAL 33min2sec 12min35sec
  • 23. INTERNSHIP REPORT 22 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 1) ROTARY MACHINE3 NO. of screen removed: 3 No of screen to be set: 11 No of workers available: 04  Sensor works starts after 5min of squeeze levelling  Squeeze plates not ready wait = 33min18sec  Total changeover time = 1hr 12min27sec S.NO Activity Time 1. Sensor wireremoved 5sec 2. Sensor removed 15sec 3. screen removed 1min21sec 4. Squeeze removed 1min10sec 5. removed color pump 9sec 6. Clean of head 3min5sec 7. screen took in to machine and fit 10min7sec 8. squeezetook into screen 3min38sec 9. Squeeze levelling 11min4sec 10. cleaning of pump 2min15sec 11. sensor took and sensor wire 9min16sec 12. color pump insert 1min9sec Total activity time 39min.
  • 24. INTERNSHIP REPORT 23 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 2) ROTARY MACHINE1 NO.of screen removed: 2 No of screen to be set: 1 No of workers available: 03  Waiting of color =10min  Change over time and waiting of color included= 23min56sec S.NO Activity Time 1. Sensor wireremoved 10sec 2. Sensor removed 7sec 3. screen removed 56sec 4. Squeeze removed 58sec 5. removed color pump 10sec 6. Clean of head 2min3sec 7. screen took in to machine and fit 1min32sec 8. squeezetook into screen 1min31sec 9. Squeeze leveling 1min52sec 10. cleaning of pump 2min5sec 11. sensor took and sensor wire 1min35sec 12. color pump insert 54sec Total activity time 13min.56sec
  • 25. INTERNSHIP REPORT 24 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 3) ROTARY MACHINE2 NO.of screen removed: 3 No of screen to be set: 1 No of workers available: 03  Batcher not available and waiting =18min 45sec  Total changeover time =27min24sec S.NO Activity Time 1. Sensor wireremoved 6sec 2. Sensor removed 8sec 3. screen removed 1min30sec 4. Squeeze removed 1min24sec 5. removed color pump 11sec 6. Clean of head 1min55sec 7. screen took in to machine and fit 28sec 8. squeezetook into screen 29sec 9. Squeeze levelling 1min38sec 10. cleaning of pump 33sec 11. sensor took and sensor wire 10sec 12. color pump insert 7sec Total activity time 8min.47sec
  • 26. INTERNSHIP REPORT 25 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 4) ROTARY MACHINE1 NO.of screen removed: 1 No of screen to be set: 9 No of workers available: 04  Stopper not joint in external  Sensor work start after 5 min of sequeeeze  Total changeover time = 27min53sec S.NO Activity Time 1. Sensor wireremoved 2sec 2. Sensor removed 6sec 3. screen removed 30sec 4. Squeeze removed 27sec 5. removed color pump 5sec 6. Clean of head 40sec 7. screen took in to machine and fit 8min30sec 8. squeezetook into screen +levelling 13min36sec 9. cleaning of pump 37sec 10. sensor took and sensor wire 8min30sec 11. color pump insert 57sec Total activity time 27min53sec
  • 27. INTERNSHIP REPORT 26 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 5) ROTARY MACHINE1 NO.of screen removed: 1 No of screen to be set: 12 No of workers available: 03  Squeeze holder not arranged = 10min  Screen sequencing = 15min5sec  Rod put in squeeze = 6min  Sensor and screen not arranged.  Sensor not arranged that’s why took so much time.  Total changeover time = 2hr4min56sec S.NO Activity Time 1. Sensor wireremoved 3sec 2. Sensor removed 7sec 3. screen removed 50sec 4. Squeeze removed 23sec 5. removed color pump 5sec 6. Clean of head 1min2sec 7. screen took in to machine and fit 13min 8. squeezetook into screen 5min36sec 9. Squeeze leveling 25min25sec 10. cleaning of pump 18min 11. sensor took and sensor wire 34min 12. color pump insert 1min20sec Total activity time 1hr33min51sec
  • 28. INTERNSHIP REPORT 27 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 6) ROTARY MACHINE2 NO.of screen removed: 4 No of screen to be set: 3 No of workers available: 04  Batcher not available so worker do external work of next activity do like  Washing of squeeze =6min15sec  Total changeover time = 26min15sec S.NO Activity Time 1. Sensor wireremoved 9sec 2. Sensor removed 1min5sec 3. screen removed 3min22sec 4. Squeeze removed 1min28sec 5. removed color pump 27sec 6. Clean of head 5min20sec 7. screen took in to machine and fit 1min30sec 8. squeezetook into screen + Squeeze leveling 2min18sec 9. cleaning of pump 1min54sec 10. sensor took and sensor wire 1min28sec 11. color pump insert 59sec Total activity time 20min
  • 29. INTERNSHIP REPORT 28 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 7) ROTARY MACHINE3 NO.of screen removed: 3 No of screen to be set: 12 No of workers available: 05  Color not available this takes too much time.  Screen not available.  Total changeover time= 1 hr 43min 26sec. S.NO Activity Time 1. Sensor wireremoved 9sec 2. Sensor removed 25sec 3. screen removed 30sec 4. Squeeze removed 1min52sec 5. removed color pump 30sec 6. Clean of head 1min 7. screen took in to machine and fit 2min46sec 8. squeezetook into screen 4min24sec 9. Squeeze leveling 15min19sec 10. cleaning of pump 24min55sec 11. sensor took and sensor wire 12min16sec 12. color pump insert 9min2sec Total activity time 1hr13min8sec
  • 30. INTERNSHIP REPORT 29 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY 8) ROTARY MACHINE2 NO.of screen removed: 03 No of screen to be set: 02 No of workers available: 04  Waiting of color = 5min53sec  Total changover time= 23min49sec S.NO Activity Time 1. Sensor wireremoved 10sec 2. Sensor removed 30sec 3. screen removed 1min34sec 4. Squeeze removed 1min50sec 5. removed color pump 28sec 6. Clean of head 1min20sec 7. screen took in to machine and fit 2min2sec 8. squeezetook into screen 1min15sec 9. Squeeze leveling 6min21sec 10. cleaning of pump 1min56sec 11. sensor took and sensor wire 22sec 12. color pump insert 8sec Total activity time 17min56sec
  • 31. INTERNSHIP REPORT 30 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY Average Changeover Time per Screen  Estimated program given time for onescreen = 25min S.NO ACTIVITY YES/ NO TIME Current status proposed Time saved 11. Operator Goes To Engraving yes 1min35sec External External 12. Engraving Supervisor Handed Over Screens To Operator yes 35sec/screen External External 13. Operator Collect Screens From Engraving yes 1min21sec/s creen External External 14. Screen Sequencing As Per Design no 10sec/screen External External 15. As Per Program Quantity Fabric Material Availability To M/C yes 2min12sec/ batcher External External 16. Squeegee Preparation yes 1min41sec/ squeegee Internal External 1min41sec 17. Lead Clothes Trolley To Fabric yes 56sec External External 18. Fabric Stitched To Lead Clothes yes 55sec External External 19. Temperature Maintaining yes 4min54sec External External 20. TOTAL 13min 19sec 1min41sec INTERNAL ACTIVITY 21. Sensor wire removed 3sec Internal Internal 22. Sensor removed 6sec Internal Internal 23. screen removed 32sec Internal Internal 24. Squeeze removed 25sec Internal Internal 25. removed color pump 4sec Internal Internal 26. Clean of head 1min18sec Internal Internal 27. screen took in to machine and fit 57sec Internal Internal 28. squeeze took into screen 24sec Internal Internal 29. Squeeze levelling 1min17sec Internal Internal 30. cleaning of pump 46sec Internal Parallel to 16,17,18 46sec 31. sensor took and sensor wire 1min12sec Internal Parallel to 18. 1min12sec 32. color pump insert 9sec Internal Internal TOTAL 7min4sec 1min58sec
  • 32. INTERNSHIP REPORT 31 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY How the time of internal activity canbe reduce. Our observation: The most time consuming activity is to level the squeegee in screen. In automatic rotary the time required to level one squeegee is 1 min. and in manual rotary the time becomes double.  Leveling 11 squeegee on automatic rotary takes 11min4s (1min./squeegee ) and on manually leveling 9 squeegee takes 13min36 sec (1.5min. / squeegee)  Up to 1 min. can be saved on every changeover activity which becomes 3min. per shift 9min. per day and 4.5 hrs. per month and 54hrs per year Our suggestion If there is possibility to fixed the leveler in manual machine as in automatic the time of changeover decrease. It can save 54hrs annually and can increase 129600m production annually SUGGESTION:  Changeover teamshouldbe introduced  Separate stands for rotary 1 and rotary 2 for squeegee, andsqueegee holder, sensor andlatto.  Program delivery Time shouldbe mentionedon programscheme.  Change over start and endtime should be mentionedon board.  Check list shouldbe marked.  Squeegee holder shouldbe fixedon rotary 1and rotary 2  Make job Descriptionprinting worker.  Active Trouble Shooting department inMaintenance Departmentfor Monitoring.  Competitionbetweenthree rotary machine for changeover activity and set some kind of incentives. (It helps youto get least changeover time).
  • 33. INTERNSHIP REPORT 32 | P a g e DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY STITCHING “Stitches means a single complete movement of a threaded needle in sewing.” Sewing Process The basic process ofsewing involves fastening of fabrics, leather, furs or similar other flexible materials with the help of needle and threads. Sewing is mainly used to manufacture clothing and home furnishings. Pre Sewing Functions: Before the actual taskof sewing begins,there are certain othertasks that have to be taken care of which can be termed as fabric handling functions- Ply separation; Placing the fabric on working table; Guiding the fabric towards sewing Recognizing the fabric's shape: The appropriate tensional force depends on the fabric properties. So the fabrics have to be identified into categories like knitted fabrics, woven fabrics etc. depending on their physical properties needle; and tension control of fabric during the sewing process. Fabric Edges to be sewn:There are two basic types of stitches- one is that are for joining two parts of cloth together and the second one is done for decorative purposes Planning OF Sewing Process:Sequence of seams to be stitched is determined before the sewing starts. Which part will be joined first, what stitches will follow one another, etc. are decided. However, some stitches have to be necessarily done before or after another stitch. In the example above, the decorative stitches must be done first followed by the joining stitches. Sewing Fabrics: The sewing process consists ofmainly three functions- guiding fabric towards needle; sewing of the fabric edge; and rotation around the needle. The fabric is guided along the sewing line with a certain speed that is in harmony with the speed of sewing machine. The orientation error is either manually monitored or if monitored automatically then error is fed to the machine controller so that the machine corrects the orientation of the fabrics Fabric receiving Drawing for cutting Cutting StitchingCheckingPacking