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    Industrial attachment of noman weaving mills limited Industrial attachment of noman weaving mills limited Document Transcript

    • Noman Weaving Mills Ltd 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Noman Weaving Mills Limited Noman Weaving Mills Ltd 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Noman Weaving Mills Limited Noman Weaving Mills Ltd 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Noman Weaving Mills Limited
    • Noman Weaving Mills Ltd 2 Noman Weaving Mills Ltd 2 Noman Weaving Mills Ltd 2
    • Noman Weaving Mills Ltd 3 Acknowledgment “In the name of Allah, the most merciful and beneficent” All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Sunnah, the everlasting source of guidance and knowledge for humanity. At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his supervision. Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University have made our efforts for training & report writing successful. During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their valuable time on the very busy schedule. Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this training and ultimate success could not come out a good result. Noman Weaving Mills Ltd 3 Acknowledgment “In the name of Allah, the most merciful and beneficent” All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Sunnah, the everlasting source of guidance and knowledge for humanity. At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his supervision. Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University have made our efforts for training & report writing successful. During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their valuable time on the very busy schedule. Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this training and ultimate success could not come out a good result. Noman Weaving Mills Ltd 3 Acknowledgment “In the name of Allah, the most merciful and beneficent” All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Sunnah, the everlasting source of guidance and knowledge for humanity. At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his supervision. Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University have made our efforts for training & report writing successful. During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their valuable time on the very busy schedule. Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this training and ultimate success could not come out a good result.
    • Noman Weaving Mills Ltd 4 TABLE OF CONTENTS Acknowledgement Project Description Introduction Objectives Duration of study Location of factory General information of the factory Units of Noman Group Layout plan Product mix Different departments of factory Manpower Management General organ gram Manpower setup Machine Description Specifications of the machines Layout plan of weaving section Information’s of raw materials Research & Development R & D department Production Planning, Sequences & Operation Sequence of operation Winding Yarn path diagram of winding Noman Weaving Mills Ltd 4 TABLE OF CONTENTS Acknowledgement Project Description Introduction Objectives Duration of study Location of factory General information of the factory Units of Noman Group Layout plan Product mix Different departments of factory Manpower Management General organ gram Manpower setup Machine Description Specifications of the machines Layout plan of weaving section Information’s of raw materials Research & Development R & D department Production Planning, Sequences & Operation Sequence of operation Winding Yarn path diagram of winding Noman Weaving Mills Ltd 4 TABLE OF CONTENTS Acknowledgement Project Description Introduction Objectives Duration of study Location of factory General information of the factory Units of Noman Group Layout plan Product mix Different departments of factory Manpower Management General organ gram Manpower setup Machine Description Specifications of the machines Layout plan of weaving section Information’s of raw materials Research & Development R & D department Production Planning, Sequences & Operation Sequence of operation Winding Yarn path diagram of winding
    • Noman Weaving Mills Ltd 5 Warping Calculations of high speed warping Calculations of sectional warping Sizing Machine specification Control system of sizing Size chemicals & their costing Calculation of sizing Drawing & Denting Loom Basic mechanism of power loom Weft path diagram of air jet loom Machine specification of air jet Compressor air quality Loom piping system General operation of air jet Rapier loom Specification of picanol Basic mechanism of rapier Setting of rapier Projectile loom Machine specification Operation procedure Quality Assurance System Quality assurance system Inspection system Quality standard Noman Weaving Mills Ltd 5 Warping Calculations of high speed warping Calculations of sectional warping Sizing Machine specification Control system of sizing Size chemicals & their costing Calculation of sizing Drawing & Denting Loom Basic mechanism of power loom Weft path diagram of air jet loom Machine specification of air jet Compressor air quality Loom piping system General operation of air jet Rapier loom Specification of picanol Basic mechanism of rapier Setting of rapier Projectile loom Machine specification Operation procedure Quality Assurance System Quality assurance system Inspection system Quality standard Noman Weaving Mills Ltd 5 Warping Calculations of high speed warping Calculations of sectional warping Sizing Machine specification Control system of sizing Size chemicals & their costing Calculation of sizing Drawing & Denting Loom Basic mechanism of power loom Weft path diagram of air jet loom Machine specification of air jet Compressor air quality Loom piping system General operation of air jet Rapier loom Specification of picanol Basic mechanism of rapier Setting of rapier Projectile loom Machine specification Operation procedure Quality Assurance System Quality assurance system Inspection system Quality standard
    • Noman Weaving Mills Ltd 6 Maintenance Maintenance of machine Maintenance procedure Utility Services Utility services Available utility facilities Store & Inventory Inventory Cost Analysis & Marketing Activities Cost analysis Marketing activities Conclusion Conclusion Limitations Suggestions Noman Weaving Mills Ltd 6 Maintenance Maintenance of machine Maintenance procedure Utility Services Utility services Available utility facilities Store & Inventory Inventory Cost Analysis & Marketing Activities Cost analysis Marketing activities Conclusion Conclusion Limitations Suggestions Noman Weaving Mills Ltd 6 Maintenance Maintenance of machine Maintenance procedure Utility Services Utility services Available utility facilities Store & Inventory Inventory Cost Analysis & Marketing Activities Cost analysis Marketing activities Conclusion Conclusion Limitations Suggestions
    • Noman Weaving Mills Ltd 7 Chapter -01 Project description Noman Weaving Mills Ltd 7 Chapter -01 Project description Noman Weaving Mills Ltd 7 Chapter -01 Project description
    • Noman Weaving Mills Ltd 8 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction Noman Weaving Mills Ltd 8 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction Noman Weaving Mills Ltd 8 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction
    • Noman Weaving Mills Ltd 9 Noman Weaving Mills Mawna Bazar Tangail Joydebpur Dhaka Candana Gazipur Maymensing N Noman Weaving Mills Ltd 9 Noman Weaving Mills Mawna Bazar Tangail Joydebpur Dhaka Candana Gazipur Maymensing N Noman Weaving Mills Ltd 9 Noman Weaving Mills Mawna Bazar Tangail Joydebpur Dhaka Candana Gazipur Maymensing N
    • Noman Weaving Mills Ltd 10 GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD  Name of the factory : Noman Weaving Mills Ltd. (An enterprise of Noman Group)  Location : (kewa westside), Mawna, Sreepur, Gazipur.  Business Type : 100%Export Woven Factory  Status : Private Ltd. Company.  Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120, Motijheel C/A, Dhaka-1000.  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282 History of the project development: Land purchase : June 2006 Machine setup : December 2006 Year of production : January 2007 Total area of land : 25 Bigha Production floor: (a) Airjet floor : 47581 sft (b) Sizing shed : 44762 sft (c) Sectional warping : 18036 sft (d) Picanol floor :11620 sft No. of machine: (a) Toyota air jet loom : 128 pcs (b) Picanol loom : 40 pcs Production capacity: (a) Toyota airjet loom : 45000 Mtr (b) Picanol loom : 9000 Mtr Total production : 54000 Mtr Per month production : 1404000 Mtr Noman Weaving Mills Ltd 10 GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD  Name of the factory : Noman Weaving Mills Ltd. (An enterprise of Noman Group)  Location : (kewa westside), Mawna, Sreepur, Gazipur.  Business Type : 100%Export Woven Factory  Status : Private Ltd. Company.  Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120, Motijheel C/A, Dhaka-1000.  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282 History of the project development: Land purchase : June 2006 Machine setup : December 2006 Year of production : January 2007 Total area of land : 25 Bigha Production floor: (a) Airjet floor : 47581 sft (b) Sizing shed : 44762 sft (c) Sectional warping : 18036 sft (d) Picanol floor :11620 sft No. of machine: (a) Toyota air jet loom : 128 pcs (b) Picanol loom : 40 pcs Production capacity: (a) Toyota airjet loom : 45000 Mtr (b) Picanol loom : 9000 Mtr Total production : 54000 Mtr Per month production : 1404000 Mtr Noman Weaving Mills Ltd 10 GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD  Name of the factory : Noman Weaving Mills Ltd. (An enterprise of Noman Group)  Location : (kewa westside), Mawna, Sreepur, Gazipur.  Business Type : 100%Export Woven Factory  Status : Private Ltd. Company.  Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120, Motijheel C/A, Dhaka-1000.  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282 History of the project development: Land purchase : June 2006 Machine setup : December 2006 Year of production : January 2007 Total area of land : 25 Bigha Production floor: (a) Airjet floor : 47581 sft (b) Sizing shed : 44762 sft (c) Sectional warping : 18036 sft (d) Picanol floor :11620 sft No. of machine: (a) Toyota air jet loom : 128 pcs (b) Picanol loom : 40 pcs Production capacity: (a) Toyota airjet loom : 45000 Mtr (b) Picanol loom : 9000 Mtr Total production : 54000 Mtr Per month production : 1404000 Mtr
    • Noman Weaving Mills Ltd 11 Man power: Officer Staff Worker a) Male : 41 Male : 93 Male : 418 b) Female : 01 Female : 02 Female : 144 Total manpower of the factory : 699 people Toilet: a) Officer/staff : 13 pcs b) Male worker : 08 pcs c) Female worker : 05 pcs Fire Extinguisher: a) DCP : 99 pcs b) CO2 : 55 pcs c) Water : 20 pcs d) Foam : 06 pcs Dormitory: a) Officer/staff & F.Q : 01 pcs b) Worker : 01 pcs Emergency gate : 01 pcs Units of Noman Group:  Sufia fabrics ltd.  Talha Tex pro Ltd.  Artex Fabrics Ltd.  Noman Fabrics Ltd.  Nice Denim Mills Ltd.  Marium Textile Mills Ltd.  Zaber Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Noman Weaving Mills Ltd.  Sufia cotton Mills Ltd.  Zarba Textile Mills Ltd. Noman Weaving Mills Ltd 11 Man power: Officer Staff Worker a) Male : 41 Male : 93 Male : 418 b) Female : 01 Female : 02 Female : 144 Total manpower of the factory : 699 people Toilet: a) Officer/staff : 13 pcs b) Male worker : 08 pcs c) Female worker : 05 pcs Fire Extinguisher: a) DCP : 99 pcs b) CO2 : 55 pcs c) Water : 20 pcs d) Foam : 06 pcs Dormitory: a) Officer/staff & F.Q : 01 pcs b) Worker : 01 pcs Emergency gate : 01 pcs Units of Noman Group:  Sufia fabrics ltd.  Talha Tex pro Ltd.  Artex Fabrics Ltd.  Noman Fabrics Ltd.  Nice Denim Mills Ltd.  Marium Textile Mills Ltd.  Zaber Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Noman Weaving Mills Ltd.  Sufia cotton Mills Ltd.  Zarba Textile Mills Ltd. Noman Weaving Mills Ltd 11 Man power: Officer Staff Worker a) Male : 41 Male : 93 Male : 418 b) Female : 01 Female : 02 Female : 144 Total manpower of the factory : 699 people Toilet: a) Officer/staff : 13 pcs b) Male worker : 08 pcs c) Female worker : 05 pcs Fire Extinguisher: a) DCP : 99 pcs b) CO2 : 55 pcs c) Water : 20 pcs d) Foam : 06 pcs Dormitory: a) Officer/staff & F.Q : 01 pcs b) Worker : 01 pcs Emergency gate : 01 pcs Units of Noman Group:  Sufia fabrics ltd.  Talha Tex pro Ltd.  Artex Fabrics Ltd.  Noman Fabrics Ltd.  Nice Denim Mills Ltd.  Marium Textile Mills Ltd.  Zaber Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Noman Weaving Mills Ltd.  Sufia cotton Mills Ltd.  Zarba Textile Mills Ltd.
    • Noman Weaving Mills Ltd 12  Noman Terry Towel Mills Ltd.  Yasmin Textile Mills Ltd.  Talha Fabrics Limited  Ismail Spinning Mills Ltd.  Zubair spinning mills Ltd.  Noman Textile Mills Ltd.  Zaber Zubair Fabrics Ltd.  Noman Spinning Mills Ltd.  Yasmin Spinning Mills Ltd.  Saad Saan Textile Mills Ltd.  Zaber &Zubair Accessories Ltd.  Noman composite Textile Ltd  Ismail Anzuman –Ara Fabrics ltd.  Saad Saan Apparels Ltd.  Noman Fashion Fabrics Ltd.  Zarba Rotor Spinnimg Mills Ltd. Noman Weaving Mills Ltd 12  Noman Terry Towel Mills Ltd.  Yasmin Textile Mills Ltd.  Talha Fabrics Limited  Ismail Spinning Mills Ltd.  Zubair spinning mills Ltd.  Noman Textile Mills Ltd.  Zaber Zubair Fabrics Ltd.  Noman Spinning Mills Ltd.  Yasmin Spinning Mills Ltd.  Saad Saan Textile Mills Ltd.  Zaber &Zubair Accessories Ltd.  Noman composite Textile Ltd  Ismail Anzuman –Ara Fabrics ltd.  Saad Saan Apparels Ltd.  Noman Fashion Fabrics Ltd.  Zarba Rotor Spinnimg Mills Ltd. Noman Weaving Mills Ltd 12  Noman Terry Towel Mills Ltd.  Yasmin Textile Mills Ltd.  Talha Fabrics Limited  Ismail Spinning Mills Ltd.  Zubair spinning mills Ltd.  Noman Textile Mills Ltd.  Zaber Zubair Fabrics Ltd.  Noman Spinning Mills Ltd.  Yasmin Spinning Mills Ltd.  Saad Saan Textile Mills Ltd.  Zaber &Zubair Accessories Ltd.  Noman composite Textile Ltd  Ismail Anzuman –Ara Fabrics ltd.  Saad Saan Apparels Ltd.  Noman Fashion Fabrics Ltd.  Zarba Rotor Spinnimg Mills Ltd.
    • Noman Weaving Mills Ltd 13 WEAVINGSHED SIZINGSHED DIGICLOTH STORE FOLDING&INSPECTIONDEPT GENERATOR CHIILLER W ORK SHOP WARPING OFFICE A/C STATION GATE01 SECURITY SECURITY POST NOMANWEAVING MILLSLTD GATE01 SECURITYAIR VESSEL SECURITY W ASTAGE STORAGE BOILER CANTENE FOR WORKER OFFICE ROOM TOILET MAINGATE SECURITYPERSON20 MAYMENSING DHAKA HIGH WAY N LAY-OUT PLAN OF THE FACTORY Noman Weaving Mills Ltd 13 WEAVINGSHED SIZINGSHED DIGICLOTH STORE FOLDING&INSPECTIONDEPT GENERATOR CHIILLER W ORK SHOP WARPING OFFICE A/C STATION GATE01 SECURITY SECURITY POST NOMANWEAVING MILLSLTD GATE01 SECURITYAIR VESSEL SECURITY W ASTAGE STORAGE BOILER CANTENE FOR WORKER OFFICE ROOM TOILET MAINGATE SECURITYPERSON20 MAYMENSING DHAKA HIGH WAY N LAY-OUT PLAN OF THE FACTORY Noman Weaving Mills Ltd 13 WEAVINGSHED SIZINGSHED DIGICLOTH STORE FOLDING&INSPECTIONDEPT GENERATOR CHIILLER W ORK SHOP WARPING OFFICE A/C STATION GATE01 SECURITY SECURITY POST NOMANWEAVING MILLSLTD GATE01 SECURITYAIR VESSEL SECURITY W ASTAGE STORAGE BOILER CANTENE FOR WORKER OFFICE ROOM TOILET MAINGATE SECURITYPERSON20 MAYMENSING DHAKA HIGH WAY N LAY-OUT PLAN OF THE FACTORY
    • Noman Weaving Mills Ltd 14 Product mix:  Plain  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Twill  2/1s twill, 3/2 S twill  Satin  5 ends satin, stripe satin poplin Voile Matt Canvas Oxford stripe fabric Noman Weaving Mills Ltd 14 Product mix:  Plain  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Twill  2/1s twill, 3/2 S twill  Satin  5 ends satin, stripe satin poplin Voile Matt Canvas Oxford stripe fabric Noman Weaving Mills Ltd 14 Product mix:  Plain  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Twill  2/1s twill, 3/2 S twill  Satin  5 ends satin, stripe satin poplin Voile Matt Canvas Oxford stripe fabric
    • Noman Weaving Mills Ltd 15 Check fabric 2/1s twill 3/2 S twill 5 ends satin Stripe Satin Different Department:  Administration dept.  Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  Production dept. Noman Weaving Mills Ltd 15 Check fabric 2/1s twill 3/2 S twill 5 ends satin Stripe Satin Different Department:  Administration dept.  Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  Production dept. Noman Weaving Mills Ltd 15 Check fabric 2/1s twill 3/2 S twill 5 ends satin Stripe Satin Different Department:  Administration dept.  Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  Production dept.
    • Noman Weaving Mills Ltd 16 Chapter- 02 Manpower Management Noman Weaving Mills Ltd 16 Chapter- 02 Manpower Management Noman Weaving Mills Ltd 16 Chapter- 02 Manpower Management
    • Noman Weaving Mills Ltd 17 D Noman Weaving Mills Ltd 17 D Noman Weaving Mills Ltd 17 D
    • Noman Weaving Mills Ltd 18 Manpower setup in different shift:  Administration dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 26 06 03 01 -04  Accounts dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 03 -02  Store dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 37 01 01 01 -04  Security dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 02 22 22 22 -17  Mechanical dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 18 19 19 19 -34  Electrical dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 09 05 05 05 -15  Quality dept. Shift General Shift “A” Shift “B” Shift “C” Short Noman Weaving Mills Ltd 18 Manpower setup in different shift:  Administration dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 26 06 03 01 -04  Accounts dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 03 -02  Store dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 37 01 01 01 -04  Security dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 02 22 22 22 -17  Mechanical dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 18 19 19 19 -34  Electrical dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 09 05 05 05 -15  Quality dept. Shift General Shift “A” Shift “B” Shift “C” Short Noman Weaving Mills Ltd 18 Manpower setup in different shift:  Administration dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 26 06 03 01 -04  Accounts dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 03 -02  Store dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 37 01 01 01 -04  Security dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 02 22 22 22 -17  Mechanical dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 18 19 19 19 -34  Electrical dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 09 05 05 05 -15  Quality dept. Shift General Shift “A” Shift “B” Shift “C” Short
    • Noman Weaving Mills Ltd 19 Manpower 3 2 2 2 -2  Mending &folding dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 130 16 20 -46  Utility dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 12 9 14 14 -15  Workshop dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 10 2 2 -3  Preparatory dept.(sizing & warping) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 6 27 27 27 -55  Production dept.(loom) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 11 59 59 59 -35 Noman Weaving Mills Ltd 19 Manpower 3 2 2 2 -2  Mending &folding dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 130 16 20 -46  Utility dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 12 9 14 14 -15  Workshop dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 10 2 2 -3  Preparatory dept.(sizing & warping) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 6 27 27 27 -55  Production dept.(loom) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 11 59 59 59 -35 Noman Weaving Mills Ltd 19 Manpower 3 2 2 2 -2  Mending &folding dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 130 16 20 -46  Utility dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 12 9 14 14 -15  Workshop dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 10 2 2 -3  Preparatory dept.(sizing & warping) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 6 27 27 27 -55  Production dept.(loom) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 11 59 59 59 -35
    • Noman Weaving Mills Ltd 20 Specification of machineries: List of the machine: Number of m/c Brand name Origin RPM Winding machine: 3 Tangsi Textile Machinery Co. Chine 1120 Warping machine: 4 Benninger /hacoba Switzerland 1200 Chapter -03 Machine description Noman Weaving Mills Ltd 20 Specification of machineries: List of the machine: Number of m/c Brand name Origin RPM Winding machine: 3 Tangsi Textile Machinery Co. Chine 1120 Warping machine: 4 Benninger /hacoba Switzerland 1200 Chapter -03 Machine description Noman Weaving Mills Ltd 20 Specification of machineries: List of the machine: Number of m/c Brand name Origin RPM Winding machine: 3 Tangsi Textile Machinery Co. Chine 1120 Warping machine: 4 Benninger /hacoba Switzerland 1200 Chapter -03 Machine description
    • Noman Weaving Mills Ltd 21 Sizing machine 2 Benninger sucker muller Switzerland 160 Picanol loom 40 Optimax Gamma Belgium 700/500 Air jet loom 128 Toyota JAT 710 Japan 800 Projectile loom 156 sulzer Switzerland 250 Desk loom 1 Bangladesh Knotting m/c 5 Staubli Switzerland Lay out plan of weaving section: Noman Weaving Mills Ltd 21 Sizing machine 2 Benninger sucker muller Switzerland 160 Picanol loom 40 Optimax Gamma Belgium 700/500 Air jet loom 128 Toyota JAT 710 Japan 800 Projectile loom 156 sulzer Switzerland 250 Desk loom 1 Bangladesh Knotting m/c 5 Staubli Switzerland Lay out plan of weaving section: Noman Weaving Mills Ltd 21 Sizing machine 2 Benninger sucker muller Switzerland 160 Picanol loom 40 Optimax Gamma Belgium 700/500 Air jet loom 128 Toyota JAT 710 Japan 800 Projectile loom 156 sulzer Switzerland 250 Desk loom 1 Bangladesh Knotting m/c 5 Staubli Switzerland Lay out plan of weaving section:
    • Noman Weaving Mills Ltd 22 Noman Weaving Mills Ltd 22 Noman Weaving Mills Ltd 22
    • Noman Weaving Mills Ltd 23 Information about yarn source and product mix: Important Yarn Receive From Count Blend Ratio Chapter -04 Raw Materials Noman Weaving Mills Ltd 23 Information about yarn source and product mix: Important Yarn Receive From Count Blend Ratio Chapter -04 Raw Materials Noman Weaving Mills Ltd 23 Information about yarn source and product mix: Important Yarn Receive From Count Blend Ratio Chapter -04 Raw Materials
    • Noman Weaving Mills Ltd 24 (Name of spinning mills) Nahar (India) 80s/1,60s/1,40s/1 CB/CP 100% Local Yarn Receive From (Name of spinning mills) Count Blend Ratio Zaber 30s/1 BC 100% Zaber 40s/1 CW 100% Zaber 50s/1 Comb 100% Zubair 30s/1,40s/1 CW 100% Zubair 40s/1,50s/1 CB/CP 100% Talha 16s/1,20s/1,24s/1 CTN 100% Talha 30s/1 KW 100% Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50% Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100% Yasmin 45s/1,46s/1 TC 65%+35% Yasmin 40s/1,45s/1,50s/1 CVC 60%+40% Yasmin 49s/1 Comb 100% Sufia 19.5s/1,45.5s/1 CTN 100% Sufia 30s/1 KC 60%+40% Sufia 45s/1 CVC 100% Ashik Comp. 9s/1 CTN 100% Ashik 16s/1 CTN Double Yarn Noman Weaving Mills Ltd 24 (Name of spinning mills) Nahar (India) 80s/1,60s/1,40s/1 CB/CP 100% Local Yarn Receive From (Name of spinning mills) Count Blend Ratio Zaber 30s/1 BC 100% Zaber 40s/1 CW 100% Zaber 50s/1 Comb 100% Zubair 30s/1,40s/1 CW 100% Zubair 40s/1,50s/1 CB/CP 100% Talha 16s/1,20s/1,24s/1 CTN 100% Talha 30s/1 KW 100% Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50% Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100% Yasmin 45s/1,46s/1 TC 65%+35% Yasmin 40s/1,45s/1,50s/1 CVC 60%+40% Yasmin 49s/1 Comb 100% Sufia 19.5s/1,45.5s/1 CTN 100% Sufia 30s/1 KC 60%+40% Sufia 45s/1 CVC 100% Ashik Comp. 9s/1 CTN 100% Ashik 16s/1 CTN Double Yarn Noman Weaving Mills Ltd 24 (Name of spinning mills) Nahar (India) 80s/1,60s/1,40s/1 CB/CP 100% Local Yarn Receive From (Name of spinning mills) Count Blend Ratio Zaber 30s/1 BC 100% Zaber 40s/1 CW 100% Zaber 50s/1 Comb 100% Zubair 30s/1,40s/1 CW 100% Zubair 40s/1,50s/1 CB/CP 100% Talha 16s/1,20s/1,24s/1 CTN 100% Talha 30s/1 KW 100% Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50% Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100% Yasmin 45s/1,46s/1 TC 65%+35% Yasmin 40s/1,45s/1,50s/1 CVC 60%+40% Yasmin 49s/1 Comb 100% Sufia 19.5s/1,45.5s/1 CTN 100% Sufia 30s/1 KC 60%+40% Sufia 45s/1 CVC 100% Ashik Comp. 9s/1 CTN 100% Ashik 16s/1 CTN Double Yarn
    • Noman Weaving Mills Ltd 25 Receive From (Name of spinning mills) Count Blend Ratio Z&Z Fab 10s/2,16s/1 CTN 100% Z&Z Fab 36s/2 CVC 60%+40% Noman Tex 30s/2 CW 100% Noman Tex 40s/2 CB/CP 100% Zaber 32s/2 CW 100% Spuare 20s/2 CTN 100% Mytas 20s/2 CTN 100% R.k. Spg 20s/2 TC 35%+65% R.k. Spg 60s/2 CB/CP 100% R.k. Spg 20s/2 CTN 100% R.k. Spg 39s/2 CW 100% MIMTEX 40s/2 Comb 100% MIMTEX 60s/2 CB/CP 100% TAMIJ 80s/2 CB/CP 100% Dyed Yarn (For sample making) Receive From (Name of spinning mills) Count Blend Ratio Color Paramount 40s/1 CVC 60%+40% Opt.White Paramount 20s/1 CVC 60%+40% Beige Paramount 40s/1 PC 50%+50% Opt.white Paramount 20s/1 CTN 100% Opt.white Paramount 40s/1 CB/CP 100% Navy blue Noman Weaving Mills Ltd 25 Receive From (Name of spinning mills) Count Blend Ratio Z&Z Fab 10s/2,16s/1 CTN 100% Z&Z Fab 36s/2 CVC 60%+40% Noman Tex 30s/2 CW 100% Noman Tex 40s/2 CB/CP 100% Zaber 32s/2 CW 100% Spuare 20s/2 CTN 100% Mytas 20s/2 CTN 100% R.k. Spg 20s/2 TC 35%+65% R.k. Spg 60s/2 CB/CP 100% R.k. Spg 20s/2 CTN 100% R.k. Spg 39s/2 CW 100% MIMTEX 40s/2 Comb 100% MIMTEX 60s/2 CB/CP 100% TAMIJ 80s/2 CB/CP 100% Dyed Yarn (For sample making) Receive From (Name of spinning mills) Count Blend Ratio Color Paramount 40s/1 CVC 60%+40% Opt.White Paramount 20s/1 CVC 60%+40% Beige Paramount 40s/1 PC 50%+50% Opt.white Paramount 20s/1 CTN 100% Opt.white Paramount 40s/1 CB/CP 100% Navy blue Noman Weaving Mills Ltd 25 Receive From (Name of spinning mills) Count Blend Ratio Z&Z Fab 10s/2,16s/1 CTN 100% Z&Z Fab 36s/2 CVC 60%+40% Noman Tex 30s/2 CW 100% Noman Tex 40s/2 CB/CP 100% Zaber 32s/2 CW 100% Spuare 20s/2 CTN 100% Mytas 20s/2 CTN 100% R.k. Spg 20s/2 TC 35%+65% R.k. Spg 60s/2 CB/CP 100% R.k. Spg 20s/2 CTN 100% R.k. Spg 39s/2 CW 100% MIMTEX 40s/2 Comb 100% MIMTEX 60s/2 CB/CP 100% TAMIJ 80s/2 CB/CP 100% Dyed Yarn (For sample making) Receive From (Name of spinning mills) Count Blend Ratio Color Paramount 40s/1 CVC 60%+40% Opt.White Paramount 20s/1 CVC 60%+40% Beige Paramount 40s/1 PC 50%+50% Opt.white Paramount 20s/1 CTN 100% Opt.white Paramount 40s/1 CB/CP 100% Navy blue
    • Noman Weaving Mills Ltd 26 Paramount 40s/1 CVC 60%+40% Sky blue Paramount 20s/1 CVC 60%+40% Black Paramount 40s/1 PC 50%+50% Blue NOOR 30s/1 Comb 100% Black NOOR 30s/1 Comb 100% White Raw material for Sizing: Chemical Name  Kollatex 05  Penetrose 50  Glysofill soft  Elastex  Tape  Pinitex  PVA  Quick solan SPR Noman Weaving Mills Ltd 26 Paramount 40s/1 CVC 60%+40% Sky blue Paramount 20s/1 CVC 60%+40% Black Paramount 40s/1 PC 50%+50% Blue NOOR 30s/1 Comb 100% Black NOOR 30s/1 Comb 100% White Raw material for Sizing: Chemical Name  Kollatex 05  Penetrose 50  Glysofill soft  Elastex  Tape  Pinitex  PVA  Quick solan SPR Noman Weaving Mills Ltd 26 Paramount 40s/1 CVC 60%+40% Sky blue Paramount 20s/1 CVC 60%+40% Black Paramount 40s/1 PC 50%+50% Blue NOOR 30s/1 Comb 100% Black NOOR 30s/1 Comb 100% White Raw material for Sizing: Chemical Name  Kollatex 05  Penetrose 50  Glysofill soft  Elastex  Tape  Pinitex  PVA  Quick solan SPR
    • Noman Weaving Mills Ltd 27 Chapter -05 Research & development Noman Weaving Mills Ltd 27 Chapter -05 Research & development Noman Weaving Mills Ltd 27 Chapter -05 Research & development
    • Noman Weaving Mills Ltd 28 R&D Department: Sample analysis:  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  During sample making some parameters are considered-  Cover factor  Reed selection Cover Factor: Cover factor is important part during production like as loom running. It indicates the fabric consumption. Is it possible or not to go to production. Expressed as British method: EPI PPI C.F count count Germany Method: K1 EPI count K2 PPI count EPI PPI count K1 K2 28 C.F count Noman Weaving Mills Ltd 28 R&D Department: Sample analysis:  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  During sample making some parameters are considered-  Cover factor  Reed selection Cover Factor: Cover factor is important part during production like as loom running. It indicates the fabric consumption. Is it possible or not to go to production. Expressed as British method: EPI PPI C.F count count Germany Method: K1 EPI count K2 PPI count EPI PPI count K1 K2 28 C.F count Noman Weaving Mills Ltd 28 R&D Department: Sample analysis:  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  During sample making some parameters are considered-  Cover factor  Reed selection Cover Factor: Cover factor is important part during production like as loom running. It indicates the fabric consumption. Is it possible or not to go to production. Expressed as British method: EPI PPI C.F count count Germany Method: K1 EPI count K2 PPI count EPI PPI count K1 K2 28 C.F count
    • Noman Weaving Mills Ltd 29 Reed selection: Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric construction & storage of reed. Construction: 124 96 40 40 58 * * Total ends 124 * 58 7192 Reed count EPI * Width of cloth Reed Width Reed Width Fabric With 100 * 100 + % regain 58 ** 100 + 12 100 64.96" Reed Count 124 * 58 64.96 110.7 Or Reed count = Finished EPI × 0 .9 = 124× .9 = 111.6 Noman Weaving Mills Ltd 29 Reed selection: Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric construction & storage of reed. Construction: 124 96 40 40 58 * * Total ends 124 * 58 7192 Reed count EPI * Width of cloth Reed Width Reed Width Fabric With 100 * 100 + % regain 58 ** 100 + 12 100 64.96" Reed Count 124 * 58 64.96 110.7 Or Reed count = Finished EPI × 0 .9 = 124× .9 = 111.6 Noman Weaving Mills Ltd 29 Reed selection: Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric construction & storage of reed. Construction: 124 96 40 40 58 * * Total ends 124 * 58 7192 Reed count EPI * Width of cloth Reed Width Reed Width Fabric With 100 * 100 + % regain 58 ** 100 + 12 100 64.96" Reed Count 124 * 58 64.96 110.7 Or Reed count = Finished EPI × 0 .9 = 124× .9 = 111.6
    • Noman Weaving Mills Ltd 30 Reed Width= Total ends Reed Count 7192 111 = = 64.7 Contraction mesurment: Warp contruiction = EPI * 3 Warp count = 124 * 3 40 Weft contruction= *PPI 3 Weft count = 96 * 3 40 = 9.3 7.2= Total Contruction = (9.3 +7.2) * .85 = 14.02 Suppose, fabric required = 5000mtr Tape Length= Required length + (contruction % * .85) + 30mtr wastage 5000 + (14.02 * .85) + (30= = * 2) [Here, no of beam = 2] 5074 Noman Weaving Mills Ltd 30 Reed Width= Total ends Reed Count 7192 111 = = 64.7 Contraction mesurment: Warp contruiction = EPI * 3 Warp count = 124 * 3 40 Weft contruction= *PPI 3 Weft count = 96 * 3 40 = 9.3 7.2= Total Contruction = (9.3 +7.2) * .85 = 14.02 Suppose, fabric required = 5000mtr Tape Length= Required length + (contruction % * .85) + 30mtr wastage 5000 + (14.02 * .85) + (30= = * 2) [Here, no of beam = 2] 5074 Noman Weaving Mills Ltd 30 Reed Width= Total ends Reed Count 7192 111 = = 64.7 Contraction mesurment: Warp contruiction = EPI * 3 Warp count = 124 * 3 40 Weft contruction= *PPI 3 Weft count = 96 * 3 40 = 9.3 7.2= Total Contruction = (9.3 +7.2) * .85 = 14.02 Suppose, fabric required = 5000mtr Tape Length= Required length + (contruction % * .85) + 30mtr wastage 5000 + (14.02 * .85) + (30= = * 2) [Here, no of beam = 2] 5074
    • Noman Weaving Mills Ltd 31 Fabric wt calculation system: Oz/Yds² = 1.03 1.05 0.685 e e EPI PPI N warp N weft         GSM = 1.03 1.05 23.25 e e EPI PPI N warp N weft         eN = L w W l   Wt calculation = 39.37 1000 width GSM length  Warp wt in lbs (yarn consumption): EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) +20% waste of the total warp weight Ne warp × 840 Weft wt in lbs EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% waste of the total warp weight Ne weft × 840 Noman Weaving Mills Ltd 31 Fabric wt calculation system: Oz/Yds² = 1.03 1.05 0.685 e e EPI PPI N warp N weft         GSM = 1.03 1.05 23.25 e e EPI PPI N warp N weft         eN = L w W l   Wt calculation = 39.37 1000 width GSM length  Warp wt in lbs (yarn consumption): EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) +20% waste of the total warp weight Ne warp × 840 Weft wt in lbs EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% waste of the total warp weight Ne weft × 840 Noman Weaving Mills Ltd 31 Fabric wt calculation system: Oz/Yds² = 1.03 1.05 0.685 e e EPI PPI N warp N weft         GSM = 1.03 1.05 23.25 e e EPI PPI N warp N weft         eN = L w W l   Wt calculation = 39.37 1000 width GSM length  Warp wt in lbs (yarn consumption): EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) +20% waste of the total warp weight Ne warp × 840 Weft wt in lbs EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% waste of the total warp weight Ne weft × 840
    • Noman Weaving Mills Ltd 32 Design identification: Fig: plain weaves (1/1) Fig: 2/1 z twill Fig: 5 end satin Move-3 Fig: 2/2 Matt Fig: Dobby design Noman Weaving Mills Ltd 32 Design identification: Fig: plain weaves (1/1) Fig: 2/1 z twill Fig: 5 end satin Move-3 Fig: 2/2 Matt Fig: Dobby design Noman Weaving Mills Ltd 32 Design identification: Fig: plain weaves (1/1) Fig: 2/1 z twill Fig: 5 end satin Move-3 Fig: 2/2 Matt Fig: Dobby design
    • Noman Weaving Mills Ltd 33 Chapter -06 Operation procedure Noman Weaving Mills Ltd 33 Chapter -06 Operation procedure Noman Weaving Mills Ltd 33 Chapter -06 Operation procedure
    • Noman Weaving Mills Ltd 34 Sequence of operation Yarn from spinning (Cone) Winding Weft (Cone form)Warping Sizing Drawing Knotting And Denting Inspection Mending Folding Packing Unwind the fabric from the cloth roller Looming Weaving warp weft Introduction of winding: Noman Weaving Mills Ltd 34 Sequence of operation Yarn from spinning (Cone) Winding Weft (Cone form)Warping Sizing Drawing Knotting And Denting Inspection Mending Folding Packing Unwind the fabric from the cloth roller Looming Weaving warp weft Introduction of winding: Noman Weaving Mills Ltd 34 Sequence of operation Yarn from spinning (Cone) Winding Weft (Cone form)Warping Sizing Drawing Knotting And Denting Inspection Mending Folding Packing Unwind the fabric from the cloth roller Looming Weaving warp weft Introduction of winding:
    • Noman Weaving Mills Ltd 35 Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be considered. Objectives:  To know about the winding process  To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To acquire perfect knowledge about winding and apply it in future. Purpose of winding:  To remove objectionable faults from the yarns  To produce good package containing long continuous length of yarn.  The winding package should facilitate smooth operation of the subsequent process  To make the suitable package for warping  To control the exact tension of the package Types of winding: Actually winding is divided into three types:  Parallel wound package  Near parallel wound package  Cross wound package Winding faults: Yarn faults  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Adhered loose fiber. Package faults  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls. 1 Machine Specification:  Cone winding machine Model : GA014MD- 120 Origin : China Spindle : 120  High speed cone/ Cheese winding machine M/c serial no : 1817 R. P .M : 1720 Noman Weaving Mills Ltd 35 Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be considered. Objectives:  To know about the winding process  To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To acquire perfect knowledge about winding and apply it in future. Purpose of winding:  To remove objectionable faults from the yarns  To produce good package containing long continuous length of yarn.  The winding package should facilitate smooth operation of the subsequent process  To make the suitable package for warping  To control the exact tension of the package Types of winding: Actually winding is divided into three types:  Parallel wound package  Near parallel wound package  Cross wound package Winding faults: Yarn faults  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Adhered loose fiber. Package faults  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls. 1 Machine Specification:  Cone winding machine Model : GA014MD- 120 Origin : China Spindle : 120  High speed cone/ Cheese winding machine M/c serial no : 1817 R. P .M : 1720 Noman Weaving Mills Ltd 35 Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be considered. Objectives:  To know about the winding process  To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To acquire perfect knowledge about winding and apply it in future. Purpose of winding:  To remove objectionable faults from the yarns  To produce good package containing long continuous length of yarn.  The winding package should facilitate smooth operation of the subsequent process  To make the suitable package for warping  To control the exact tension of the package Types of winding: Actually winding is divided into three types:  Parallel wound package  Near parallel wound package  Cross wound package Winding faults: Yarn faults  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Adhered loose fiber. Package faults  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls. 1 Machine Specification:  Cone winding machine Model : GA014MD- 120 Origin : China Spindle : 120  High speed cone/ Cheese winding machine M/c serial no : 1817 R. P .M : 1720
    • Noman Weaving Mills Ltd 36 Yarn path diagram of winding: Winding package Yarn clearer Traverse Tension device Guide rod Bobbin holder Yarn package Fig:Yarn path in winding 2 Hardness of cone: Hardness = wt. of package/ volume of package D H  Cone winding machine Model : GA014MG Origin : China Tangsi Textile Machinery Co. Ltd Noman Weaving Mills Ltd 36 Yarn path diagram of winding: Winding package Yarn clearer Traverse Tension device Guide rod Bobbin holder Yarn package Fig:Yarn path in winding 2 Hardness of cone: Hardness = wt. of package/ volume of package D H  Cone winding machine Model : GA014MG Origin : China Tangsi Textile Machinery Co. Ltd Noman Weaving Mills Ltd 36 Yarn path diagram of winding: Winding package Yarn clearer Traverse Tension device Guide rod Bobbin holder Yarn package Fig:Yarn path in winding 2 Hardness of cone: Hardness = wt. of package/ volume of package D H  Cone winding machine Model : GA014MG Origin : China Tangsi Textile Machinery Co. Ltd
    • Noman Weaving Mills Ltd 37 We know, Volume of package = πR2 H /4 Where, R2 = D2 -d2 =142 -42 = 180cm So, volume = 3.1416*180*17/4 =2403 cm3 Hardness of cone = 1600/2403 gm/cm3 =0.6658 gm/cm3 Standard range of hardness: For soft cone …………………..0.350--0.500 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 Winding angle and Winding length calculation: Winding angle, Ѳ =2 tan-1 (t / π*d*n) Noman Weaving Mills Ltd 37 We know, Volume of package = πR2 H /4 Where, R2 = D2 -d2 =142 -42 = 180cm So, volume = 3.1416*180*17/4 =2403 cm3 Hardness of cone = 1600/2403 gm/cm3 =0.6658 gm/cm3 Standard range of hardness: For soft cone …………………..0.350--0.500 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 Winding angle and Winding length calculation: Winding angle, Ѳ =2 tan-1 (t / π*d*n) Noman Weaving Mills Ltd 37 We know, Volume of package = πR2 H /4 Where, R2 = D2 -d2 =142 -42 = 180cm So, volume = 3.1416*180*17/4 =2403 cm3 Hardness of cone = 1600/2403 gm/cm3 =0.6658 gm/cm3 Standard range of hardness: For soft cone …………………..0.350--0.500 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 Winding angle and Winding length calculation: Winding angle, Ѳ =2 tan-1 (t / π*d*n)
    • Noman Weaving Mills Ltd 38 Where, Travers length, t= 150 mm Scroll number, n= 2 Bobbin dia, d = 5cm So winding angle, Ѳ=2 tan-1 (150/3.1416*50*2) =51.068 ◦ Winding length = 2t/ sin Ѳ/2 =2*150/sin 51.068/2 = 695.97mm Requirements for winding:  The fault level in the yarn must be reduced to an acceptable level.  The yarn must not be damaged in any way in the winding process.  The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed.  The package size, shape and build must be most technologically suitable for particular end use.  The package size should be controlled to meet the particular economic requirement.  The device must be reliable.  The device must not introduce difference in count.  It must be easily cleaning.  The operating surface must be smooth. Introduction: The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing (slashing). It depends on some aspects as different condition. What is warping? Warping is transferring many yarns from a creel of single end package forming a parallel sheet of yarns wound onto a beam or section beam. Noman Weaving Mills Ltd 38 Where, Travers length, t= 150 mm Scroll number, n= 2 Bobbin dia, d = 5cm So winding angle, Ѳ=2 tan-1 (150/3.1416*50*2) =51.068 ◦ Winding length = 2t/ sin Ѳ/2 =2*150/sin 51.068/2 = 695.97mm Requirements for winding:  The fault level in the yarn must be reduced to an acceptable level.  The yarn must not be damaged in any way in the winding process.  The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed.  The package size, shape and build must be most technologically suitable for particular end use.  The package size should be controlled to meet the particular economic requirement.  The device must be reliable.  The device must not introduce difference in count.  It must be easily cleaning.  The operating surface must be smooth. Introduction: The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing (slashing). It depends on some aspects as different condition. What is warping? Warping is transferring many yarns from a creel of single end package forming a parallel sheet of yarns wound onto a beam or section beam. Noman Weaving Mills Ltd 38 Where, Travers length, t= 150 mm Scroll number, n= 2 Bobbin dia, d = 5cm So winding angle, Ѳ=2 tan-1 (150/3.1416*50*2) =51.068 ◦ Winding length = 2t/ sin Ѳ/2 =2*150/sin 51.068/2 = 695.97mm Requirements for winding:  The fault level in the yarn must be reduced to an acceptable level.  The yarn must not be damaged in any way in the winding process.  The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed.  The package size, shape and build must be most technologically suitable for particular end use.  The package size should be controlled to meet the particular economic requirement.  The device must be reliable.  The device must not introduce difference in count.  It must be easily cleaning.  The operating surface must be smooth. Introduction: The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing (slashing). It depends on some aspects as different condition. What is warping? Warping is transferring many yarns from a creel of single end package forming a parallel sheet of yarns wound onto a beam or section beam.
    • Noman Weaving Mills Ltd 39 Depending on the kind of intermediate carrier used, the industrial warping process can be carried out according to two different technologies:  Sectional warping ( indirect or conical drum or dresser warping)  Beam warping or direct warping (preparatory beam warping) Objectives:  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To minimize the machine breakdown time. Purpose of warping  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To build a suitable package for the perfect sizing and weaving. Direct or high speed warping: Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer, from the wound packages in the creel.  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn this is also called direct beaming.  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends each. Noman Weaving Mills Ltd 39 Depending on the kind of intermediate carrier used, the industrial warping process can be carried out according to two different technologies:  Sectional warping ( indirect or conical drum or dresser warping)  Beam warping or direct warping (preparatory beam warping) Objectives:  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To minimize the machine breakdown time. Purpose of warping  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To build a suitable package for the perfect sizing and weaving. Direct or high speed warping: Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer, from the wound packages in the creel.  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn this is also called direct beaming.  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends each. Noman Weaving Mills Ltd 39 Depending on the kind of intermediate carrier used, the industrial warping process can be carried out according to two different technologies:  Sectional warping ( indirect or conical drum or dresser warping)  Beam warping or direct warping (preparatory beam warping) Objectives:  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To minimize the machine breakdown time. Purpose of warping  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To build a suitable package for the perfect sizing and weaving. Direct or high speed warping: Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer, from the wound packages in the creel.  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn this is also called direct beaming.  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends each.
    • Noman Weaving Mills Ltd 40 Operation procedure of direct warping: The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn parallel. M /C specification: Modern- Conventional- Name of the m/c: Benninger Name of the m/c: hacoba Name of origin: Switzerland Name of origin: China Creel capacity : 1224 Creel capacity : 720 R P M : 1200 R P M : 600 Beam width : 2400 mm Beam width : 2400mm Noman Weaving Mills Ltd 40 Operation procedure of direct warping: The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn parallel. M /C specification: Modern- Conventional- Name of the m/c: Benninger Name of the m/c: hacoba Name of origin: Switzerland Name of origin: China Creel capacity : 1224 Creel capacity : 720 R P M : 1200 R P M : 600 Beam width : 2400 mm Beam width : 2400mm Noman Weaving Mills Ltd 40 Operation procedure of direct warping: The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn parallel. M /C specification: Modern- Conventional- Name of the m/c: Benninger Name of the m/c: hacoba Name of origin: Switzerland Name of origin: China Creel capacity : 1224 Creel capacity : 720 R P M : 1200 R P M : 600 Beam width : 2400 mm Beam width : 2400mm
    • Noman Weaving Mills Ltd 41 Diagram of direct warping: Calculations of high speed warping Noman Weaving Mills Ltd 41 Diagram of direct warping: Calculations of high speed warping Noman Weaving Mills Ltd 41 Diagram of direct warping: Calculations of high speed warping
    • Noman Weaving Mills Ltd 42 Total ends =7000 PPI =70 Warp length =1200 Creel capacity =875 40*40 120*70 Construction:- Beam required =8 solution: Each beaming time at 100% efficiency = 1200 800 = 15 min waste times are --- Creeling =60 min knoting =40 min Beam change =16 min Breakage time =80 min Total = 196 min wastes time for each beam = 196 8 = 24.5 min With waste per beaming time = 15 +24.5 = 39.5 minutes For one shift,/8 hours production = 480 39.5 = 12 beam So efficiency, = 12 39.5 *100 =37.9746 % 58 inch suppose,finish construction Indirect or Sectional warping system: Noman Weaving Mills Ltd 42 Total ends =7000 PPI =70 Warp length =1200 Creel capacity =875 40*40 120*70 Construction:- Beam required =8 solution: Each beaming time at 100% efficiency = 1200 800 = 15 min waste times are --- Creeling =60 min knoting =40 min Beam change =16 min Breakage time =80 min Total = 196 min wastes time for each beam = 196 8 = 24.5 min With waste per beaming time = 15 +24.5 = 39.5 minutes For one shift,/8 hours production = 480 39.5 = 12 beam So efficiency, = 12 39.5 *100 =37.9746 % 58 inch suppose,finish construction Indirect or Sectional warping system: Noman Weaving Mills Ltd 42 Total ends =7000 PPI =70 Warp length =1200 Creel capacity =875 40*40 120*70 Construction:- Beam required =8 solution: Each beaming time at 100% efficiency = 1200 800 = 15 min waste times are --- Creeling =60 min knoting =40 min Beam change =16 min Breakage time =80 min Total = 196 min wastes time for each beam = 196 8 = 24.5 min With waste per beaming time = 15 +24.5 = 39.5 minutes For one shift,/8 hours production = 480 39.5 = 12 beam So efficiency, = 12 39.5 *100 =37.9746 % 58 inch suppose,finish construction Indirect or Sectional warping system:
    • Noman Weaving Mills Ltd 43 Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe fabric. The sectional warping depends on some parameters such as:  Head stock  Control device.  Creel arrangement. Operation procedure of sectional warping: In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is transferred to the sized beam. M/C Specification: Name of the m/c: Benninger supertronic Name of origin: Switzerland V-reed capacity: 650 Eye reed capacity: 650 Creel capacity: 576 R. p. m : 800 Components of sectional warping: Noman Weaving Mills Ltd 43 Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe fabric. The sectional warping depends on some parameters such as:  Head stock  Control device.  Creel arrangement. Operation procedure of sectional warping: In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is transferred to the sized beam. M/C Specification: Name of the m/c: Benninger supertronic Name of origin: Switzerland V-reed capacity: 650 Eye reed capacity: 650 Creel capacity: 576 R. p. m : 800 Components of sectional warping: Noman Weaving Mills Ltd 43 Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe fabric. The sectional warping depends on some parameters such as:  Head stock  Control device.  Creel arrangement. Operation procedure of sectional warping: In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is transferred to the sized beam. M/C Specification: Name of the m/c: Benninger supertronic Name of origin: Switzerland V-reed capacity: 650 Eye reed capacity: 650 Creel capacity: 576 R. p. m : 800 Components of sectional warping:
    • Noman Weaving Mills Ltd 44 Indirect Warping process: Noman Weaving Mills Ltd 44 Indirect Warping process: Noman Weaving Mills Ltd 44 Indirect Warping process:
    • Noman Weaving Mills Ltd 45 40*40 102*70 Total ends =5900 Reed density/inch = 46 Reed cound =92 Reed width =64.1 PPI =70 Warp length =1300(1300+118) Order quanty =1100 Pattern chart of warp & weft Construction:- Warp pattern Navy Optical white Total 6 7 13 Weft pattern All optical white In warp Color Navy Optical white Total Ends 6 7 % of color Required warp in kg per color req. in kg remarks 46.15 53.85 116 116 54 62 116 % of color Required warp in kg picks per color req. in kg remarksColor White 1 100 84 84 In weft Noman Weaving Mills Ltd 45 40*40 102*70 Total ends =5900 Reed density/inch = 46 Reed cound =92 Reed width =64.1 PPI =70 Warp length =1300(1300+118) Order quanty =1100 Pattern chart of warp & weft Construction:- Warp pattern Navy Optical white Total 6 7 13 Weft pattern All optical white In warp Color Navy Optical white Total Ends 6 7 % of color Required warp in kg per color req. in kg remarks 46.15 53.85 116 116 54 62 116 % of color Required warp in kg picks per color req. in kg remarksColor White 1 100 84 84 In weft Noman Weaving Mills Ltd 45 40*40 102*70 Total ends =5900 Reed density/inch = 46 Reed cound =92 Reed width =64.1 PPI =70 Warp length =1300(1300+118) Order quanty =1100 Pattern chart of warp & weft Construction:- Warp pattern Navy Optical white Total 6 7 13 Weft pattern All optical white In warp Color Navy Optical white Total Ends 6 7 % of color Required warp in kg per color req. in kg remarks 46.15 53.85 116 116 54 62 116 % of color Required warp in kg picks per color req. in kg remarksColor White 1 100 84 84 In weft
    • Noman Weaving Mills Ltd 46 Why sectional warping is different? In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly than solid dyed fabric. The computerized sectional warping can automatically calculates the following: 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 6. Memory of yarn breakage during warping for beaming Faults in warping 1. Practically for winding 2. Machine fault 3. Operator misconception 4. Low quality yarn 5. others Problems in warping a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length f. Big knot Checking have to done during warping: 1. Lot mixing 2. Count mixing 3. Color variation Noman Weaving Mills Ltd 46 Why sectional warping is different? In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly than solid dyed fabric. The computerized sectional warping can automatically calculates the following: 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 6. Memory of yarn breakage during warping for beaming Faults in warping 1. Practically for winding 2. Machine fault 3. Operator misconception 4. Low quality yarn 5. others Problems in warping a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length f. Big knot Checking have to done during warping: 1. Lot mixing 2. Count mixing 3. Color variation Noman Weaving Mills Ltd 46 Why sectional warping is different? In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly than solid dyed fabric. The computerized sectional warping can automatically calculates the following: 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 6. Memory of yarn breakage during warping for beaming Faults in warping 1. Practically for winding 2. Machine fault 3. Operator misconception 4. Low quality yarn 5. others Problems in warping a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length f. Big knot Checking have to done during warping: 1. Lot mixing 2. Count mixing 3. Color variation
    • Noman Weaving Mills Ltd 47 Calculation of sectional warping: Construction: 40*40 102*70 57 Reed dents per inch =46 Reed count =92 Reed width =64.1 PPI =70 winding angle = .8 Total ends =5900 Solutions: Total ends *10 warp width Mesured phase or e/cm = Number of ends = Fabric width *EPI Number of section = Total ends Repeat size Fabric width = Total ends EPI Warp density= d tex * total ends * 0.8 400 * warp width(mm) d tex = 5905 Ne = 147.625 = 5900 *10 1900 = 31.052 cm = 57*102 = 5814 5900 13 = = 453.846 = 5900 102 = 57.843 = 147.625*5900*0.8 400*1900 = 0.91mm Noman Weaving Mills Ltd 47 Calculation of sectional warping: Construction: 40*40 102*70 57 Reed dents per inch =46 Reed count =92 Reed width =64.1 PPI =70 winding angle = .8 Total ends =5900 Solutions: Total ends *10 warp width Mesured phase or e/cm = Number of ends = Fabric width *EPI Number of section = Total ends Repeat size Fabric width = Total ends EPI Warp density= d tex * total ends * 0.8 400 * warp width(mm) d tex = 5905 Ne = 147.625 = 5900 *10 1900 = 31.052 cm = 57*102 = 5814 5900 13 = = 453.846 = 5900 102 = 57.843 = 147.625*5900*0.8 400*1900 = 0.91mm Noman Weaving Mills Ltd 47 Calculation of sectional warping: Construction: 40*40 102*70 57 Reed dents per inch =46 Reed count =92 Reed width =64.1 PPI =70 winding angle = .8 Total ends =5900 Solutions: Total ends *10 warp width Mesured phase or e/cm = Number of ends = Fabric width *EPI Number of section = Total ends Repeat size Fabric width = Total ends EPI Warp density= d tex * total ends * 0.8 400 * warp width(mm) d tex = 5905 Ne = 147.625 = 5900 *10 1900 = 31.052 cm = 57*102 = 5814 5900 13 = = 453.846 = 5900 102 = 57.843 = 147.625*5900*0.8 400*1900 = 0.91mm
    • Noman Weaving Mills Ltd 48 Required weight of yarn per cone in creel, Suppose Cone weight =2000gm Count = 30 Creel capacity =512 Length of one cone = 1.6933*30*2000 = 101598 mts Number of cone =200 * 200 =20319600 mts =22221514.56 yds length per creel stand =22221514.56/512 = 43401.3956 yds = 43401.3956 840*30 =1.72227 lbs Following terms should be considered 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% What is sizing: The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the tensions and the rubbing caused by weaving. Purpose of sizing:  To improve the weave ability of the warp yarn  To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn.  To increase the tensile or breaking strength for cellulose yarn. Noman Weaving Mills Ltd 48 Required weight of yarn per cone in creel, Suppose Cone weight =2000gm Count = 30 Creel capacity =512 Length of one cone = 1.6933*30*2000 = 101598 mts Number of cone =200 * 200 =20319600 mts =22221514.56 yds length per creel stand =22221514.56/512 = 43401.3956 yds = 43401.3956 840*30 =1.72227 lbs Following terms should be considered 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% What is sizing: The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the tensions and the rubbing caused by weaving. Purpose of sizing:  To improve the weave ability of the warp yarn  To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn.  To increase the tensile or breaking strength for cellulose yarn. Noman Weaving Mills Ltd 48 Required weight of yarn per cone in creel, Suppose Cone weight =2000gm Count = 30 Creel capacity =512 Length of one cone = 1.6933*30*2000 = 101598 mts Number of cone =200 * 200 =20319600 mts =22221514.56 yds length per creel stand =22221514.56/512 = 43401.3956 yds = 43401.3956 840*30 =1.72227 lbs Following terms should be considered 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% What is sizing: The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the tensions and the rubbing caused by weaving. Purpose of sizing:  To improve the weave ability of the warp yarn  To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn.  To increase the tensile or breaking strength for cellulose yarn.
    • Noman Weaving Mills Ltd 49  To increase the elasticity  To remove the protruding/floating fibers  To reduce electrostatic formation for synthetic or blended yarn Sizing Technique: All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of preventing that they get entangled and are not wound up with the correct sequence. A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s beam. Reason for different sizing recipe: Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon as warping is completed, to the sizing machine where they are assembled. There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when a particularly thick size is required. Machine specification: Noman Weaving Mills Ltd 49  To increase the elasticity  To remove the protruding/floating fibers  To reduce electrostatic formation for synthetic or blended yarn Sizing Technique: All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of preventing that they get entangled and are not wound up with the correct sequence. A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s beam. Reason for different sizing recipe: Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon as warping is completed, to the sizing machine where they are assembled. There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when a particularly thick size is required. Machine specification: Noman Weaving Mills Ltd 49  To increase the elasticity  To remove the protruding/floating fibers  To reduce electrostatic formation for synthetic or blended yarn Sizing Technique: All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of preventing that they get entangled and are not wound up with the correct sequence. A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s beam. Reason for different sizing recipe: Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon as warping is completed, to the sizing machine where they are assembled. There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when a particularly thick size is required. Machine specification:
    • Noman Weaving Mills Ltd 50 Scematric diagram and control system of sizing m/c: Shade-02 Machine Name : Sucker Muller Brand :Hacoba Origin : Switzerland R.P.M :60 each roller Cylinder : 12 V-reed : 1450 Lease : 14 Beam capacity : 16 Winding pressure : 4500 bar Press tension : 3500 bar Lease tension : 2000 bar (Maximum) Cylinder temperature : 145 degrees Production capacity/day: 30000 meters Shade-01 Machine Name :Benninger Origin : Switzerland R.P.M :160 Max Cylinder : 14 Lease : 29 Beam capacity : 32 V-reed : 1372 Cylinder Temperature : 145 degree Winding pressure : 1800 N Creel tension : 700 N Production capacity/day: 40000-45000 Max Noman Weaving Mills Ltd 50 Scematric diagram and control system of sizing m/c: Shade-02 Machine Name : Sucker Muller Brand :Hacoba Origin : Switzerland R.P.M :60 each roller Cylinder : 12 V-reed : 1450 Lease : 14 Beam capacity : 16 Winding pressure : 4500 bar Press tension : 3500 bar Lease tension : 2000 bar (Maximum) Cylinder temperature : 145 degrees Production capacity/day: 30000 meters Shade-01 Machine Name :Benninger Origin : Switzerland R.P.M :160 Max Cylinder : 14 Lease : 29 Beam capacity : 32 V-reed : 1372 Cylinder Temperature : 145 degree Winding pressure : 1800 N Creel tension : 700 N Production capacity/day: 40000-45000 Max Noman Weaving Mills Ltd 50 Scematric diagram and control system of sizing m/c: Shade-02 Machine Name : Sucker Muller Brand :Hacoba Origin : Switzerland R.P.M :60 each roller Cylinder : 12 V-reed : 1450 Lease : 14 Beam capacity : 16 Winding pressure : 4500 bar Press tension : 3500 bar Lease tension : 2000 bar (Maximum) Cylinder temperature : 145 degrees Production capacity/day: 30000 meters Shade-01 Machine Name :Benninger Origin : Switzerland R.P.M :160 Max Cylinder : 14 Lease : 29 Beam capacity : 32 V-reed : 1372 Cylinder Temperature : 145 degree Winding pressure : 1800 N Creel tension : 700 N Production capacity/day: 40000-45000 Max
    • Noman Weaving Mills Ltd 51 Factors for warp sizing: Warp sizing is an essential process to coat warp yarns with elastic films and bind fibers of yarns as lowering fluff or hairiness so that yarns may be so strong that resist the mechanical strain in weaving process, and maintain or improve weaving efficiency. Quality of warp sizing generally evaluated by the following factors Cohesive strength: Total strength including elasticity of sized yarn to resist such mechanical strains in weaving process as tensing, bending, rubbing, shedding, etc Fluff binding: Very important factor to prevent yarns from clinging among yarns. It is particularly required in weaving a high-density fabric or by a high-speed air jet loom. Sized yarns without fluff may be shed smoothly in weaving loom. Size pickup (SPR): The amount of size picked up by yarns. An ideal size pickup is pre-determined according to yarn/fabric construction, by which you can formulate a size recipe and set squeeze roll pressure and other mechanical condition. Size must be picked up by yarn sheet evenly. Smoothness & Softness: Another important factor of sized yarn as well as cohesive strength particularly in weaving high-count yarns into a high-density fabric by a high-speed air jet loom. Size cooking condition: Determine the quality of size solution in terms of viscosity, particle size, etc. In other words, a good size solution can be prepared in a good cooking process. Noman Weaving Mills Ltd 51 Factors for warp sizing: Warp sizing is an essential process to coat warp yarns with elastic films and bind fibers of yarns as lowering fluff or hairiness so that yarns may be so strong that resist the mechanical strain in weaving process, and maintain or improve weaving efficiency. Quality of warp sizing generally evaluated by the following factors Cohesive strength: Total strength including elasticity of sized yarn to resist such mechanical strains in weaving process as tensing, bending, rubbing, shedding, etc Fluff binding: Very important factor to prevent yarns from clinging among yarns. It is particularly required in weaving a high-density fabric or by a high-speed air jet loom. Sized yarns without fluff may be shed smoothly in weaving loom. Size pickup (SPR): The amount of size picked up by yarns. An ideal size pickup is pre-determined according to yarn/fabric construction, by which you can formulate a size recipe and set squeeze roll pressure and other mechanical condition. Size must be picked up by yarn sheet evenly. Smoothness & Softness: Another important factor of sized yarn as well as cohesive strength particularly in weaving high-count yarns into a high-density fabric by a high-speed air jet loom. Size cooking condition: Determine the quality of size solution in terms of viscosity, particle size, etc. In other words, a good size solution can be prepared in a good cooking process. Noman Weaving Mills Ltd 51 Factors for warp sizing: Warp sizing is an essential process to coat warp yarns with elastic films and bind fibers of yarns as lowering fluff or hairiness so that yarns may be so strong that resist the mechanical strain in weaving process, and maintain or improve weaving efficiency. Quality of warp sizing generally evaluated by the following factors Cohesive strength: Total strength including elasticity of sized yarn to resist such mechanical strains in weaving process as tensing, bending, rubbing, shedding, etc Fluff binding: Very important factor to prevent yarns from clinging among yarns. It is particularly required in weaving a high-density fabric or by a high-speed air jet loom. Sized yarns without fluff may be shed smoothly in weaving loom. Size pickup (SPR): The amount of size picked up by yarns. An ideal size pickup is pre-determined according to yarn/fabric construction, by which you can formulate a size recipe and set squeeze roll pressure and other mechanical condition. Size must be picked up by yarn sheet evenly. Smoothness & Softness: Another important factor of sized yarn as well as cohesive strength particularly in weaving high-count yarns into a high-density fabric by a high-speed air jet loom. Size cooking condition: Determine the quality of size solution in terms of viscosity, particle size, etc. In other words, a good size solution can be prepared in a good cooking process.
    • Noman Weaving Mills Ltd 52 Size machine condition: In terms of size box temperature, squeeze pressure, draft, dry cylinder temperature, etc. This may determine the quality of the above factors. Basics of ideal SPU (for regular cotton woven cloth) Yarn count 10/S 20/S 30/S 40/S 50/S 60/S 80/S SPU (±1.0%) 8.0 9.0 10.0 12.0 14.0 15.0 16.0 [SPU: Size concentration × Squeezing ratio] 90-120% by polyester/ cotton blends 100-150% by 100% cotton 120-170% by 100% rayon 100% or less by 100% polyester (Depending on machine and squeeze roller condition) Basically, For cotton : 2.5 KN Pc : 2.0 KN Ideal amount of moisture for sized yarn: For 100% cotton 6.5-7.0% 100% rayon 9.0-9.5% 100% polyester 1.0-1.5% 35/65 polyester/cotton 3.0-3.5% Sizing chemicals and their costing: Chemical Name Cost/kg Kollatex 05 54.96 Tk Penetrose 50 35 Tk Glysofill soft 160 Tk Elastex 44 Tk Tape 50 Tk Pinitex 194.52 Tk PVA 173 tk Quick solan SPR 108 Tk Noman Weaving Mills Ltd 52 Size machine condition: In terms of size box temperature, squeeze pressure, draft, dry cylinder temperature, etc. This may determine the quality of the above factors. Basics of ideal SPU (for regular cotton woven cloth) Yarn count 10/S 20/S 30/S 40/S 50/S 60/S 80/S SPU (±1.0%) 8.0 9.0 10.0 12.0 14.0 15.0 16.0 [SPU: Size concentration × Squeezing ratio] 90-120% by polyester/ cotton blends 100-150% by 100% cotton 120-170% by 100% rayon 100% or less by 100% polyester (Depending on machine and squeeze roller condition) Basically, For cotton : 2.5 KN Pc : 2.0 KN Ideal amount of moisture for sized yarn: For 100% cotton 6.5-7.0% 100% rayon 9.0-9.5% 100% polyester 1.0-1.5% 35/65 polyester/cotton 3.0-3.5% Sizing chemicals and their costing: Chemical Name Cost/kg Kollatex 05 54.96 Tk Penetrose 50 35 Tk Glysofill soft 160 Tk Elastex 44 Tk Tape 50 Tk Pinitex 194.52 Tk PVA 173 tk Quick solan SPR 108 Tk Noman Weaving Mills Ltd 52 Size machine condition: In terms of size box temperature, squeeze pressure, draft, dry cylinder temperature, etc. This may determine the quality of the above factors. Basics of ideal SPU (for regular cotton woven cloth) Yarn count 10/S 20/S 30/S 40/S 50/S 60/S 80/S SPU (±1.0%) 8.0 9.0 10.0 12.0 14.0 15.0 16.0 [SPU: Size concentration × Squeezing ratio] 90-120% by polyester/ cotton blends 100-150% by 100% cotton 120-170% by 100% rayon 100% or less by 100% polyester (Depending on machine and squeeze roller condition) Basically, For cotton : 2.5 KN Pc : 2.0 KN Ideal amount of moisture for sized yarn: For 100% cotton 6.5-7.0% 100% rayon 9.0-9.5% 100% polyester 1.0-1.5% 35/65 polyester/cotton 3.0-3.5% Sizing chemicals and their costing: Chemical Name Cost/kg Kollatex 05 54.96 Tk Penetrose 50 35 Tk Glysofill soft 160 Tk Elastex 44 Tk Tape 50 Tk Pinitex 194.52 Tk PVA 173 tk Quick solan SPR 108 Tk
    • Noman Weaving Mills Ltd 53 Size ingredient and their function: During sizing there used different types of size chemicals. Those chemicals are mainly categorized by  Adhesive or Starch  Softener  Binder Adhesive or Starch: It is the main ingredient of solution preparation. It is two types-  Natural starch  Synthetic starch Natural starch: Natural starches are generally made from potato, maize, wheat, corn, sago. Those are native starch. Some native starches are- Name Country Brand Viscosity Solid % Penetrose Pakistan Low modified 75-80 Tape Thailand Apple Low modified 75-80 Synthetic starch: Synthetic starches are made from different chemical composition. Those are modified and highly modified starch. Some modified starches are- Name Country Brand Viscosity Solid % PVA Singapore PVA 217 High modified 98-99 Kollotex Holland Avebe Medium modified 85-90 SPR Holland Avebe High modified 90-96 Functions:  To make coating on the yarn  To improve yarn strength  To increase smoothness  To increase elasticity and stiffness. Softener: It is the second main ingredient of size solution preparation. Some softening agent’s are- Pinitex (Holland), Glysofill softener. Functions:  To make the yarn soft and slippery  To smoothen the yarn and  To reduce stiffness Binder: It is another essential ingredient of size solution preparation, has some impacts during sizing. The binding agent’s are-  Size CA (Indonesia)  Elastex (Pakistan) Noman Weaving Mills Ltd 53 Size ingredient and their function: During sizing there used different types of size chemicals. Those chemicals are mainly categorized by  Adhesive or Starch  Softener  Binder Adhesive or Starch: It is the main ingredient of solution preparation. It is two types-  Natural starch  Synthetic starch Natural starch: Natural starches are generally made from potato, maize, wheat, corn, sago. Those are native starch. Some native starches are- Name Country Brand Viscosity Solid % Penetrose Pakistan Low modified 75-80 Tape Thailand Apple Low modified 75-80 Synthetic starch: Synthetic starches are made from different chemical composition. Those are modified and highly modified starch. Some modified starches are- Name Country Brand Viscosity Solid % PVA Singapore PVA 217 High modified 98-99 Kollotex Holland Avebe Medium modified 85-90 SPR Holland Avebe High modified 90-96 Functions:  To make coating on the yarn  To improve yarn strength  To increase smoothness  To increase elasticity and stiffness. Softener: It is the second main ingredient of size solution preparation. Some softening agent’s are- Pinitex (Holland), Glysofill softener. Functions:  To make the yarn soft and slippery  To smoothen the yarn and  To reduce stiffness Binder: It is another essential ingredient of size solution preparation, has some impacts during sizing. The binding agent’s are-  Size CA (Indonesia)  Elastex (Pakistan) Noman Weaving Mills Ltd 53 Size ingredient and their function: During sizing there used different types of size chemicals. Those chemicals are mainly categorized by  Adhesive or Starch  Softener  Binder Adhesive or Starch: It is the main ingredient of solution preparation. It is two types-  Natural starch  Synthetic starch Natural starch: Natural starches are generally made from potato, maize, wheat, corn, sago. Those are native starch. Some native starches are- Name Country Brand Viscosity Solid % Penetrose Pakistan Low modified 75-80 Tape Thailand Apple Low modified 75-80 Synthetic starch: Synthetic starches are made from different chemical composition. Those are modified and highly modified starch. Some modified starches are- Name Country Brand Viscosity Solid % PVA Singapore PVA 217 High modified 98-99 Kollotex Holland Avebe Medium modified 85-90 SPR Holland Avebe High modified 90-96 Functions:  To make coating on the yarn  To improve yarn strength  To increase smoothness  To increase elasticity and stiffness. Softener: It is the second main ingredient of size solution preparation. Some softening agent’s are- Pinitex (Holland), Glysofill softener. Functions:  To make the yarn soft and slippery  To smoothen the yarn and  To reduce stiffness Binder: It is another essential ingredient of size solution preparation, has some impacts during sizing. The binding agent’s are-  Size CA (Indonesia)  Elastex (Pakistan)
    • Noman Weaving Mills Ltd 54  Pinitex (Pakistan)  Acry size (Pakistan) Possible uses percentages of size chemicals: Starch : 85% Softener : 3% Binder : 12% During size solution preparation those percentages may be 2-3% adding or reducing. Recipe for Sucer Muller sizing machine: Construction 30×30 × 58” 110×70 Set length 5000meter Solution: Total ends×100 Cover Factor = √count × beam width 6380×100 = √30×2400 = 48 It is possible to running one size box. Total ends= 110×58 = 6380 6380×5000 Weight of yarn= 1.6933×30 = 62796 gm =627kg Liquored required = 627+ 35% = 627+219 = 846kg Total liquor required= 846+ 300 [Here, 300kg required for size box] = 1146kg Chemical‫׃‬ Water 1‫׃‬ 5 Noman Weaving Mills Ltd 54  Pinitex (Pakistan)  Acry size (Pakistan) Possible uses percentages of size chemicals: Starch : 85% Softener : 3% Binder : 12% During size solution preparation those percentages may be 2-3% adding or reducing. Recipe for Sucer Muller sizing machine: Construction 30×30 × 58” 110×70 Set length 5000meter Solution: Total ends×100 Cover Factor = √count × beam width 6380×100 = √30×2400 = 48 It is possible to running one size box. Total ends= 110×58 = 6380 6380×5000 Weight of yarn= 1.6933×30 = 62796 gm =627kg Liquored required = 627+ 35% = 627+219 = 846kg Total liquor required= 846+ 300 [Here, 300kg required for size box] = 1146kg Chemical‫׃‬ Water 1‫׃‬ 5 Noman Weaving Mills Ltd 54  Pinitex (Pakistan)  Acry size (Pakistan) Possible uses percentages of size chemicals: Starch : 85% Softener : 3% Binder : 12% During size solution preparation those percentages may be 2-3% adding or reducing. Recipe for Sucer Muller sizing machine: Construction 30×30 × 58” 110×70 Set length 5000meter Solution: Total ends×100 Cover Factor = √count × beam width 6380×100 = √30×2400 = 48 It is possible to running one size box. Total ends= 110×58 = 6380 6380×5000 Weight of yarn= 1.6933×30 = 62796 gm =627kg Liquored required = 627+ 35% = 627+219 = 846kg Total liquor required= 846+ 300 [Here, 300kg required for size box] = 1146kg Chemical‫׃‬ Water 1‫׃‬ 5
    • Noman Weaving Mills Ltd 55 Water = 600leter PVA =10kg Penetrose =70kg Kollotex =25kg Size CA =12kg Pinitex =3kg Total volume = (120+600) + 12 %( steam) = 806kg Solid percentage of chemicals: PVA =.97×10= 9.7 Penetrose =.75×70 = 52.5 Kollotex =.85×25 = 21.25 Size CA =.30×12 =3.6 Total = 87.05 87.0 Refraction value= ×100 806 =10.7 % Recipe for Beninger sizing machine :( shed 01) 40×40 Construction × (61”+61”) 124×96 Set length=10000meter Solution: Total ends = 124×122 = 15128 Total ends×100 Cover Factor= √count× beam width 15128 ×100 = [Here, used 2size box] √40 × 2400 ×2 = 49.86 Noman Weaving Mills Ltd 55 Water = 600leter PVA =10kg Penetrose =70kg Kollotex =25kg Size CA =12kg Pinitex =3kg Total volume = (120+600) + 12 %( steam) = 806kg Solid percentage of chemicals: PVA =.97×10= 9.7 Penetrose =.75×70 = 52.5 Kollotex =.85×25 = 21.25 Size CA =.30×12 =3.6 Total = 87.05 87.0 Refraction value= ×100 806 =10.7 % Recipe for Beninger sizing machine :( shed 01) 40×40 Construction × (61”+61”) 124×96 Set length=10000meter Solution: Total ends = 124×122 = 15128 Total ends×100 Cover Factor= √count× beam width 15128 ×100 = [Here, used 2size box] √40 × 2400 ×2 = 49.86 Noman Weaving Mills Ltd 55 Water = 600leter PVA =10kg Penetrose =70kg Kollotex =25kg Size CA =12kg Pinitex =3kg Total volume = (120+600) + 12 %( steam) = 806kg Solid percentage of chemicals: PVA =.97×10= 9.7 Penetrose =.75×70 = 52.5 Kollotex =.85×25 = 21.25 Size CA =.30×12 =3.6 Total = 87.05 87.0 Refraction value= ×100 806 =10.7 % Recipe for Beninger sizing machine :( shed 01) 40×40 Construction × (61”+61”) 124×96 Set length=10000meter Solution: Total ends = 124×122 = 15128 Total ends×100 Cover Factor= √count× beam width 15128 ×100 = [Here, used 2size box] √40 × 2400 ×2 = 49.86
    • Noman Weaving Mills Ltd 56 15128×10000 Weight of yarn= 1.6933× 40 =2233.50kg Liquored required = 2233.50+35% =3015kg Total liquored required: = 3015+300 [Here, 300kg used for 2size boxes] = 3315kg [Chemical: Water] 1:5 Recipe: Water : 600liter PVA : 30kg Penetrose : 73kg Size CA : 14kg Pinitex : 3kg Total volume = (600+120) +12 %( steam) = 806kg Solid percentages of chemicals: PVA =.97×30=29.1 Penetrose =.75×73=54.75 Size CA =.30×14=4.2 Total = 88.05 Solid % Refraction value = total volume 88.05 ×100 = 806 = 11% Noman Weaving Mills Ltd 56 15128×10000 Weight of yarn= 1.6933× 40 =2233.50kg Liquored required = 2233.50+35% =3015kg Total liquored required: = 3015+300 [Here, 300kg used for 2size boxes] = 3315kg [Chemical: Water] 1:5 Recipe: Water : 600liter PVA : 30kg Penetrose : 73kg Size CA : 14kg Pinitex : 3kg Total volume = (600+120) +12 %( steam) = 806kg Solid percentages of chemicals: PVA =.97×30=29.1 Penetrose =.75×73=54.75 Size CA =.30×14=4.2 Total = 88.05 Solid % Refraction value = total volume 88.05 ×100 = 806 = 11% Noman Weaving Mills Ltd 56 15128×10000 Weight of yarn= 1.6933× 40 =2233.50kg Liquored required = 2233.50+35% =3015kg Total liquored required: = 3015+300 [Here, 300kg used for 2size boxes] = 3315kg [Chemical: Water] 1:5 Recipe: Water : 600liter PVA : 30kg Penetrose : 73kg Size CA : 14kg Pinitex : 3kg Total volume = (600+120) +12 %( steam) = 806kg Solid percentages of chemicals: PVA =.97×30=29.1 Penetrose =.75×73=54.75 Size CA =.30×14=4.2 Total = 88.05 Solid % Refraction value = total volume 88.05 ×100 = 806 = 11%
    • Noman Weaving Mills Ltd 57 Size mixing curve: 2 Min aggetate 900 C Steam PVA Cooking time 30 minute Fig: Sizing Cruve Add Another chemical Viscosity of size solution: For better warp sizing, it is important to maintain ideal viscosity of size solution. If size has extreme high viscosity, it may permeate in warp yarns well which might be rough and hard handling touch, and be bound as a tape. On the contrary, if size solution without enough viscosity is applied in warp yarns, their fluffs may not be laid down well, and/or SPU may be lower than expected because size may be easily squeezed out. In general, ideal viscosity is between 10 and 20 seconds by 6- mm viscosity cup. Noman Weaving Mills Ltd 57 Size mixing curve: 2 Min aggetate 900 C Steam PVA Cooking time 30 minute Fig: Sizing Cruve Add Another chemical Viscosity of size solution: For better warp sizing, it is important to maintain ideal viscosity of size solution. If size has extreme high viscosity, it may permeate in warp yarns well which might be rough and hard handling touch, and be bound as a tape. On the contrary, if size solution without enough viscosity is applied in warp yarns, their fluffs may not be laid down well, and/or SPU may be lower than expected because size may be easily squeezed out. In general, ideal viscosity is between 10 and 20 seconds by 6- mm viscosity cup. Noman Weaving Mills Ltd 57 Size mixing curve: 2 Min aggetate 900 C Steam PVA Cooking time 30 minute Fig: Sizing Cruve Add Another chemical Viscosity of size solution: For better warp sizing, it is important to maintain ideal viscosity of size solution. If size has extreme high viscosity, it may permeate in warp yarns well which might be rough and hard handling touch, and be bound as a tape. On the contrary, if size solution without enough viscosity is applied in warp yarns, their fluffs may not be laid down well, and/or SPU may be lower than expected because size may be easily squeezed out. In general, ideal viscosity is between 10 and 20 seconds by 6- mm viscosity cup.
    • Noman Weaving Mills Ltd 58 Introduction to Loom: Introduction: Weaving is a mandatory part of textile, mainly the physical textile. To set up a weaving project a lot of preparation is required. So, this is a very big investment project, but this technology is related to our culture. Now days some weaving industry is established in Bangladesh. Weaving is a mechanism through which two sets of yarns are interlaced together to form fabric by the machine called loom. One set of yarn is called warp and another set is weft. Weaving is done on a machine called a loom. All the weaves that are known today have been made for thousands of years. The loom has undergone significant modifications, but the basic principles and operations remain the same. Warp yarns are held taut within the loom, and weft yarns inserted and pushed into place to make the fabric. At the first time the shuttle loom is used for making fabric. Actually shuttle is a kind of weft inserting element used previous time. During the industrial revolution mass production high speed looms were developed. Today the industries uses modern looms like projectile, rapier, air jet, water jet looms. These looms are high speedy and production capacity is very high. The modern loom consists of two beams, a warp beam and a cloth or fabric beam, Kolding the warp yarns between them. Warp yarns that sufficient for length, width, and density of the fabric to be woven are wound carefully onto a warp beam. Objectives:  To know about the different weaving machine.  To get knowledge about the projectile mechanism for weft insertion also the projectile loom.  To gather knowledge of rapier loom and the rapier driving mechanism.  To know about the different parts of rapier loom and rapier set for picking the filling yarns.  To know of cam adjustment of rapier loom for various construction depending on it the heald shaft movemet.  To know about air jet loom and different parts of air jet loom.  Carefully evaluate the weft insertion system of air jet loom.  To get knowledge of the valves and nozzles and know about the required amount of air to run a machine for exact construction. Basic Mechanisms of Power Loom: In order to interlace wrap and weft threads to produce a fabric, the following mechanisms are necessary on any type of loom:  Primary mechanisms  Secondary mechanisms  Auxillary mechanisms Noman Weaving Mills Ltd 58 Introduction to Loom: Introduction: Weaving is a mandatory part of textile, mainly the physical textile. To set up a weaving project a lot of preparation is required. So, this is a very big investment project, but this technology is related to our culture. Now days some weaving industry is established in Bangladesh. Weaving is a mechanism through which two sets of yarns are interlaced together to form fabric by the machine called loom. One set of yarn is called warp and another set is weft. Weaving is done on a machine called a loom. All the weaves that are known today have been made for thousands of years. The loom has undergone significant modifications, but the basic principles and operations remain the same. Warp yarns are held taut within the loom, and weft yarns inserted and pushed into place to make the fabric. At the first time the shuttle loom is used for making fabric. Actually shuttle is a kind of weft inserting element used previous time. During the industrial revolution mass production high speed looms were developed. Today the industries uses modern looms like projectile, rapier, air jet, water jet looms. These looms are high speedy and production capacity is very high. The modern loom consists of two beams, a warp beam and a cloth or fabric beam, Kolding the warp yarns between them. Warp yarns that sufficient for length, width, and density of the fabric to be woven are wound carefully onto a warp beam. Objectives:  To know about the different weaving machine.  To get knowledge about the projectile mechanism for weft insertion also the projectile loom.  To gather knowledge of rapier loom and the rapier driving mechanism.  To know about the different parts of rapier loom and rapier set for picking the filling yarns.  To know of cam adjustment of rapier loom for various construction depending on it the heald shaft movemet.  To know about air jet loom and different parts of air jet loom.  Carefully evaluate the weft insertion system of air jet loom.  To get knowledge of the valves and nozzles and know about the required amount of air to run a machine for exact construction. Basic Mechanisms of Power Loom: In order to interlace wrap and weft threads to produce a fabric, the following mechanisms are necessary on any type of loom:  Primary mechanisms  Secondary mechanisms  Auxillary mechanisms Noman Weaving Mills Ltd 58 Introduction to Loom: Introduction: Weaving is a mandatory part of textile, mainly the physical textile. To set up a weaving project a lot of preparation is required. So, this is a very big investment project, but this technology is related to our culture. Now days some weaving industry is established in Bangladesh. Weaving is a mechanism through which two sets of yarns are interlaced together to form fabric by the machine called loom. One set of yarn is called warp and another set is weft. Weaving is done on a machine called a loom. All the weaves that are known today have been made for thousands of years. The loom has undergone significant modifications, but the basic principles and operations remain the same. Warp yarns are held taut within the loom, and weft yarns inserted and pushed into place to make the fabric. At the first time the shuttle loom is used for making fabric. Actually shuttle is a kind of weft inserting element used previous time. During the industrial revolution mass production high speed looms were developed. Today the industries uses modern looms like projectile, rapier, air jet, water jet looms. These looms are high speedy and production capacity is very high. The modern loom consists of two beams, a warp beam and a cloth or fabric beam, Kolding the warp yarns between them. Warp yarns that sufficient for length, width, and density of the fabric to be woven are wound carefully onto a warp beam. Objectives:  To know about the different weaving machine.  To get knowledge about the projectile mechanism for weft insertion also the projectile loom.  To gather knowledge of rapier loom and the rapier driving mechanism.  To know about the different parts of rapier loom and rapier set for picking the filling yarns.  To know of cam adjustment of rapier loom for various construction depending on it the heald shaft movemet.  To know about air jet loom and different parts of air jet loom.  Carefully evaluate the weft insertion system of air jet loom.  To get knowledge of the valves and nozzles and know about the required amount of air to run a machine for exact construction. Basic Mechanisms of Power Loom: In order to interlace wrap and weft threads to produce a fabric, the following mechanisms are necessary on any type of loom:  Primary mechanisms  Secondary mechanisms  Auxillary mechanisms
    • Noman Weaving Mills Ltd 59 Primary Mechanisms: These are fundamental or essential mechanisms. Without these mechanisms, it is practically impossible to produce a fabric. It is for this reason that these mechanisms are called ‘primary’ mechanisms. The primary mechanisms are three in number. a. Shedding mechanism b. Picking mechanism c. Beat-up mechanism a. Shedding mechanism The shedding mechanism separates the warp threads into two layers or divisions to form a tunnel known as ‘shed’ b. Picking mechanism The picking mechanism passes weft thread from one selvedge of the fabric to the other through the shed by means of a shuttle, a projectile, a rapier, a needle, an air-jet or a water-jet. The inserted weft thread is known as “pick”. c. Beat-up mechanism The beat-up mechanism beats or pushes the newly inserted length of weft thread (pick) into the already woven fabric at a point known as “fell of the cloth”. These three mechanisms namely shedding, picking and then beat-up are done in sequence. Secondary Mechanisms These mechanisms are next in importance to the primary mechanisms. If weaving is to be continuous, these mechanisms are essential. So they are called the ‘secondary’ mechanisms. They are: a. Take-up motion b. Let-off motion. a. Take-up motion The take-up motion withdraws the cloth from the weaving area at a constant rate so as to give the required pick-spacing (in picks/inch or picks/cm) and then winds it on to a cloth roller. b. Let-off motion. The let-off motion delivers the warp to the weaving area at the required rate and at constant tension by unwinding it from the weaver’s beam. The secondary motions are carried out simultaneously. Auxillary Mechanisms To get high productivity and good quality of fabric, additional mechanisms, called auxiliary mechanisms, are added to a plain power loom. The auxiliary mechanisms are useful but not absolutely essential. This is why they are called the ‘auxiliary’ mechanisms. These are listed below.  Warp protector mechanism Noman Weaving Mills Ltd 59 Primary Mechanisms: These are fundamental or essential mechanisms. Without these mechanisms, it is practically impossible to produce a fabric. It is for this reason that these mechanisms are called ‘primary’ mechanisms. The primary mechanisms are three in number. a. Shedding mechanism b. Picking mechanism c. Beat-up mechanism a. Shedding mechanism The shedding mechanism separates the warp threads into two layers or divisions to form a tunnel known as ‘shed’ b. Picking mechanism The picking mechanism passes weft thread from one selvedge of the fabric to the other through the shed by means of a shuttle, a projectile, a rapier, a needle, an air-jet or a water-jet. The inserted weft thread is known as “pick”. c. Beat-up mechanism The beat-up mechanism beats or pushes the newly inserted length of weft thread (pick) into the already woven fabric at a point known as “fell of the cloth”. These three mechanisms namely shedding, picking and then beat-up are done in sequence. Secondary Mechanisms These mechanisms are next in importance to the primary mechanisms. If weaving is to be continuous, these mechanisms are essential. So they are called the ‘secondary’ mechanisms. They are: a. Take-up motion b. Let-off motion. a. Take-up motion The take-up motion withdraws the cloth from the weaving area at a constant rate so as to give the required pick-spacing (in picks/inch or picks/cm) and then winds it on to a cloth roller. b. Let-off motion. The let-off motion delivers the warp to the weaving area at the required rate and at constant tension by unwinding it from the weaver’s beam. The secondary motions are carried out simultaneously. Auxillary Mechanisms To get high productivity and good quality of fabric, additional mechanisms, called auxiliary mechanisms, are added to a plain power loom. The auxiliary mechanisms are useful but not absolutely essential. This is why they are called the ‘auxiliary’ mechanisms. These are listed below.  Warp protector mechanism Noman Weaving Mills Ltd 59 Primary Mechanisms: These are fundamental or essential mechanisms. Without these mechanisms, it is practically impossible to produce a fabric. It is for this reason that these mechanisms are called ‘primary’ mechanisms. The primary mechanisms are three in number. a. Shedding mechanism b. Picking mechanism c. Beat-up mechanism a. Shedding mechanism The shedding mechanism separates the warp threads into two layers or divisions to form a tunnel known as ‘shed’ b. Picking mechanism The picking mechanism passes weft thread from one selvedge of the fabric to the other through the shed by means of a shuttle, a projectile, a rapier, a needle, an air-jet or a water-jet. The inserted weft thread is known as “pick”. c. Beat-up mechanism The beat-up mechanism beats or pushes the newly inserted length of weft thread (pick) into the already woven fabric at a point known as “fell of the cloth”. These three mechanisms namely shedding, picking and then beat-up are done in sequence. Secondary Mechanisms These mechanisms are next in importance to the primary mechanisms. If weaving is to be continuous, these mechanisms are essential. So they are called the ‘secondary’ mechanisms. They are: a. Take-up motion b. Let-off motion. a. Take-up motion The take-up motion withdraws the cloth from the weaving area at a constant rate so as to give the required pick-spacing (in picks/inch or picks/cm) and then winds it on to a cloth roller. b. Let-off motion. The let-off motion delivers the warp to the weaving area at the required rate and at constant tension by unwinding it from the weaver’s beam. The secondary motions are carried out simultaneously. Auxillary Mechanisms To get high productivity and good quality of fabric, additional mechanisms, called auxiliary mechanisms, are added to a plain power loom. The auxiliary mechanisms are useful but not absolutely essential. This is why they are called the ‘auxiliary’ mechanisms. These are listed below.  Warp protector mechanism
    • Noman Weaving Mills Ltd 60  Weft stop motion  Temples  Brake  Warp stop motion (Predominantly found in automatic looms) a. Warp protector mechanism The warp protector mechanism will stop the loom if the rapier gets trapped between the top and bottom layers of the shed. It thus prevents excessive damage to the warp threads, reed wires and shuttle. b. Weft stop motion The object of the weft stop motion is to stop the loom when a weft thread breaks or gets exhausted. This motion helps to avoid cracks in a fabric. c. Temples The function of the temples is to grip the cloth and hold it at the same width as the warp in the reed, before it is taken up. d. Brake The brake stops the loom immediately whenever required. The weaver uses it to stop the loom to repair broken ends and picks. e. Warp stop motion The object of the warp stop motion is to stop the loom immediately when a warp thread breaks during the weaving process AIR PREPARATION STAGE 1. Receive 2. Filtration 3. Compress the air (dew point 10ᵒC and 6 bar pressure) 4. Drying 5. Separation. 6. Micro-filtration 7. Reserved (pressure 7-8 bar) AIR COMPRESSOR TYPES Type Oil free/oiling Water/ air cooling Reciprocating Oil free Water cooling Oiling Water cooling Screw Oil free Water/ air cooling Oiling Water/ air cooling Noman Weaving Mills Ltd 60  Weft stop motion  Temples  Brake  Warp stop motion (Predominantly found in automatic looms) a. Warp protector mechanism The warp protector mechanism will stop the loom if the rapier gets trapped between the top and bottom layers of the shed. It thus prevents excessive damage to the warp threads, reed wires and shuttle. b. Weft stop motion The object of the weft stop motion is to stop the loom when a weft thread breaks or gets exhausted. This motion helps to avoid cracks in a fabric. c. Temples The function of the temples is to grip the cloth and hold it at the same width as the warp in the reed, before it is taken up. d. Brake The brake stops the loom immediately whenever required. The weaver uses it to stop the loom to repair broken ends and picks. e. Warp stop motion The object of the warp stop motion is to stop the loom immediately when a warp thread breaks during the weaving process AIR PREPARATION STAGE 1. Receive 2. Filtration 3. Compress the air (dew point 10ᵒC and 6 bar pressure) 4. Drying 5. Separation. 6. Micro-filtration 7. Reserved (pressure 7-8 bar) AIR COMPRESSOR TYPES Type Oil free/oiling Water/ air cooling Reciprocating Oil free Water cooling Oiling Water cooling Screw Oil free Water/ air cooling Oiling Water/ air cooling Noman Weaving Mills Ltd 60  Weft stop motion  Temples  Brake  Warp stop motion (Predominantly found in automatic looms) a. Warp protector mechanism The warp protector mechanism will stop the loom if the rapier gets trapped between the top and bottom layers of the shed. It thus prevents excessive damage to the warp threads, reed wires and shuttle. b. Weft stop motion The object of the weft stop motion is to stop the loom when a weft thread breaks or gets exhausted. This motion helps to avoid cracks in a fabric. c. Temples The function of the temples is to grip the cloth and hold it at the same width as the warp in the reed, before it is taken up. d. Brake The brake stops the loom immediately whenever required. The weaver uses it to stop the loom to repair broken ends and picks. e. Warp stop motion The object of the warp stop motion is to stop the loom immediately when a warp thread breaks during the weaving process AIR PREPARATION STAGE 1. Receive 2. Filtration 3. Compress the air (dew point 10ᵒC and 6 bar pressure) 4. Drying 5. Separation. 6. Micro-filtration 7. Reserved (pressure 7-8 bar) AIR COMPRESSOR TYPES Type Oil free/oiling Water/ air cooling Reciprocating Oil free Water cooling Oiling Water cooling Screw Oil free Water/ air cooling Oiling Water/ air cooling
    • Noman Weaving Mills Ltd 61 Turbo Oil free Water cooling Oiling Water cooling Weft path diagram of air jet: Package Ballon breaker tensoner Guide Pirn winder ballon breaker PFT Fixed Nozzle movable Nozzle Cutter First end of fabric Relay nozzle Weft yarn Last end of fabric FD1 FD2Selvedge yarn Fig. Passage diagram of air-jet loom filling yarn Weft parameters of air jet:  Balloon breaker  Tensioner  Pre-winder  PET  Fixed nozzle  Movable nozzle  Filling cutter  Relay nozzle  FD1  FD2 Machine specification: Name of the machine : Toyota Brand : Toyota JAT 710 Origin : Japan Noman Weaving Mills Ltd 61 Turbo Oil free Water cooling Oiling Water cooling Weft path diagram of air jet: Package Ballon breaker tensoner Guide Pirn winder ballon breaker PFT Fixed Nozzle movable Nozzle Cutter First end of fabric Relay nozzle Weft yarn Last end of fabric FD1 FD2Selvedge yarn Fig. Passage diagram of air-jet loom filling yarn Weft parameters of air jet:  Balloon breaker  Tensioner  Pre-winder  PET  Fixed nozzle  Movable nozzle  Filling cutter  Relay nozzle  FD1  FD2 Machine specification: Name of the machine : Toyota Brand : Toyota JAT 710 Origin : Japan Noman Weaving Mills Ltd 61 Turbo Oil free Water cooling Oiling Water cooling Weft path diagram of air jet: Package Ballon breaker tensoner Guide Pirn winder ballon breaker PFT Fixed Nozzle movable Nozzle Cutter First end of fabric Relay nozzle Weft yarn Last end of fabric FD1 FD2Selvedge yarn Fig. Passage diagram of air-jet loom filling yarn Weft parameters of air jet:  Balloon breaker  Tensioner  Pre-winder  PET  Fixed nozzle  Movable nozzle  Filling cutter  Relay nozzle  FD1  FD2 Machine specification: Name of the machine : Toyota Brand : Toyota JAT 710 Origin : Japan
    • Noman Weaving Mills Ltd 62 RPM : 800 Solenoid Valve : 15 use 14 Tuck-in : 03 no. Temple : Ring Shedding : Tapped & Dobby Weft insertion : By Air Required pressure : 5.5 Bar Operating system : Computerized Weavers beam Back rest Droper Heald shaft reed Fall of the cloth take up roller Guide cloth roller Fig. Passege diagram of warps in loom Noman Weaving Mills Ltd 62 RPM : 800 Solenoid Valve : 15 use 14 Tuck-in : 03 no. Temple : Ring Shedding : Tapped & Dobby Weft insertion : By Air Required pressure : 5.5 Bar Operating system : Computerized Weavers beam Back rest Droper Heald shaft reed Fall of the cloth take up roller Guide cloth roller Fig. Passege diagram of warps in loom Noman Weaving Mills Ltd 62 RPM : 800 Solenoid Valve : 15 use 14 Tuck-in : 03 no. Temple : Ring Shedding : Tapped & Dobby Weft insertion : By Air Required pressure : 5.5 Bar Operating system : Computerized Weavers beam Back rest Droper Heald shaft reed Fall of the cloth take up roller Guide cloth roller Fig. Passege diagram of warps in loom
    • Noman Weaving Mills Ltd 63 Compressor Air Quality: The compressed air for weft insertion should be as high quality in order to run the air-jet loom efficiently some important factors is given. Moisture: a. Liquid should be completely removed. b. Moisture in air should be removed. The dew point of the moisture should be 10ᵒC or lower. c. If moisture is not removed from the compressed air then, 1. Metallic part of the equipment and piping corrode. 2. Dust and other impurities will adhere in the pipe. Passage resistance as presence will increase. And pin holes made in the pipe wall result in air leakage. 3. The need will soil, this will produce faulty fabric. Grease: a. Oil, aerosol (0.8-0.01 micron) particle and larger grease should be removed. b. If remove is incomplete then, 1. The metallic part of the equipment and piping will corrode. 2. Foreign particle will adhere in the compressed air pipe. 3. Woven cloth will soil. 4. Operational environment will not hygienic. Foreign particle and carbon: a. 0.3 micron or larger foreign particle and carbon should be removed. b. If they are not removed then, 1. Nozzle efficiency will reduce and valve will not work properly. 2. Particle mixed with moisture grease will spoil the reed and cause equipment mal functioning. Causes of warp breakage:  Loose yarn/ weak yarn.  Crossing of warp.  Sticky end.  Back rest position.  Low sized yarn.  Friction in different part. Loom piping system: Noman Weaving Mills Ltd 63 Compressor Air Quality: The compressed air for weft insertion should be as high quality in order to run the air-jet loom efficiently some important factors is given. Moisture: a. Liquid should be completely removed. b. Moisture in air should be removed. The dew point of the moisture should be 10ᵒC or lower. c. If moisture is not removed from the compressed air then, 1. Metallic part of the equipment and piping corrode. 2. Dust and other impurities will adhere in the pipe. Passage resistance as presence will increase. And pin holes made in the pipe wall result in air leakage. 3. The need will soil, this will produce faulty fabric. Grease: a. Oil, aerosol (0.8-0.01 micron) particle and larger grease should be removed. b. If remove is incomplete then, 1. The metallic part of the equipment and piping will corrode. 2. Foreign particle will adhere in the compressed air pipe. 3. Woven cloth will soil. 4. Operational environment will not hygienic. Foreign particle and carbon: a. 0.3 micron or larger foreign particle and carbon should be removed. b. If they are not removed then, 1. Nozzle efficiency will reduce and valve will not work properly. 2. Particle mixed with moisture grease will spoil the reed and cause equipment mal functioning. Causes of warp breakage:  Loose yarn/ weak yarn.  Crossing of warp.  Sticky end.  Back rest position.  Low sized yarn.  Friction in different part. Loom piping system: Noman Weaving Mills Ltd 63 Compressor Air Quality: The compressed air for weft insertion should be as high quality in order to run the air-jet loom efficiently some important factors is given. Moisture: a. Liquid should be completely removed. b. Moisture in air should be removed. The dew point of the moisture should be 10ᵒC or lower. c. If moisture is not removed from the compressed air then, 1. Metallic part of the equipment and piping corrode. 2. Dust and other impurities will adhere in the pipe. Passage resistance as presence will increase. And pin holes made in the pipe wall result in air leakage. 3. The need will soil, this will produce faulty fabric. Grease: a. Oil, aerosol (0.8-0.01 micron) particle and larger grease should be removed. b. If remove is incomplete then, 1. The metallic part of the equipment and piping will corrode. 2. Foreign particle will adhere in the compressed air pipe. 3. Woven cloth will soil. 4. Operational environment will not hygienic. Foreign particle and carbon: a. 0.3 micron or larger foreign particle and carbon should be removed. b. If they are not removed then, 1. Nozzle efficiency will reduce and valve will not work properly. 2. Particle mixed with moisture grease will spoil the reed and cause equipment mal functioning. Causes of warp breakage:  Loose yarn/ weak yarn.  Crossing of warp.  Sticky end.  Back rest position.  Low sized yarn.  Friction in different part. Loom piping system:
    • Noman Weaving Mills Ltd 64 3" 3" 2" Figure A Piping Example 3" 3" Figure B Piping example General operation of air jet: The operation principle is the following: the thread, prepared in a given length (corresponding to the reed width) by pre-measuring weft carriers is launched through the shed by a jet of compressed air. The air jet weaving machines require air ducts capable of maintaining an effective air flow on the whole weaving width. To obtain this, the machine manufacturers prefer today to use the system with profiled reed, in which the air and the thread are guided through a tunnel-shaped reed The weft is placed in the groove formed by the reed’s profiled dents, in which it remains until the reed stroke. In the air jet weaving machines, the impulse causing weft launch is provided by a main nozzle but the jet of compressed air, being blown in a room of same kind, looses very quickly its own energy. Consequently, if the weft has to be transported along reasonable widths, the use of additional gears, that is of secondary or auxiliary (or relay) nozzles is necessary; these, besides pushing the weft forward, have also the task of keeping it inside the guide channel. The auxiliary nozzles are stationed along the whole reed width and operate according to the relay principle, the nozzle holder blocks are Noman Weaving Mills Ltd 64 3" 3" 2" Figure A Piping Example 3" 3" Figure B Piping example General operation of air jet: The operation principle is the following: the thread, prepared in a given length (corresponding to the reed width) by pre-measuring weft carriers is launched through the shed by a jet of compressed air. The air jet weaving machines require air ducts capable of maintaining an effective air flow on the whole weaving width. To obtain this, the machine manufacturers prefer today to use the system with profiled reed, in which the air and the thread are guided through a tunnel-shaped reed The weft is placed in the groove formed by the reed’s profiled dents, in which it remains until the reed stroke. In the air jet weaving machines, the impulse causing weft launch is provided by a main nozzle but the jet of compressed air, being blown in a room of same kind, looses very quickly its own energy. Consequently, if the weft has to be transported along reasonable widths, the use of additional gears, that is of secondary or auxiliary (or relay) nozzles is necessary; these, besides pushing the weft forward, have also the task of keeping it inside the guide channel. The auxiliary nozzles are stationed along the whole reed width and operate according to the relay principle, the nozzle holder blocks are Noman Weaving Mills Ltd 64 3" 3" 2" Figure A Piping Example 3" 3" Figure B Piping example General operation of air jet: The operation principle is the following: the thread, prepared in a given length (corresponding to the reed width) by pre-measuring weft carriers is launched through the shed by a jet of compressed air. The air jet weaving machines require air ducts capable of maintaining an effective air flow on the whole weaving width. To obtain this, the machine manufacturers prefer today to use the system with profiled reed, in which the air and the thread are guided through a tunnel-shaped reed The weft is placed in the groove formed by the reed’s profiled dents, in which it remains until the reed stroke. In the air jet weaving machines, the impulse causing weft launch is provided by a main nozzle but the jet of compressed air, being blown in a room of same kind, looses very quickly its own energy. Consequently, if the weft has to be transported along reasonable widths, the use of additional gears, that is of secondary or auxiliary (or relay) nozzles is necessary; these, besides pushing the weft forward, have also the task of keeping it inside the guide channel. The auxiliary nozzles are stationed along the whole reed width and operate according to the relay principle, the nozzle holder blocks are
    • Noman Weaving Mills Ltd 65 connected group wise to the distributors of compressed air by means of flexible pipes. The multi-hole relay nozzles applied on modern air jet weaving machines accelerate the weft motion in the best way, at the same time reducing the stress on the yarn and helping towards increasing machine yield and performance. The manufacturers are increasingly installing on the weft delivery side of the shed a suction nozzle which has the function of maintaining stretched the weft pending the stroke of the slay and the consequent weft binding in the fabric. This ensures a perfect stretching of the weft inside the shed with any kind of yarn, even with the most critical yarns. Among the various optional devices offered by some manufacturers, we point out in particular the auxiliary main nozzle; the combination of an auxiliary main nozzle with the main nozzle accelerates the weft motion but under low pressure, thus avoiding damaging the yarn. A particular characteristic of the last models of weaving machines is the automation and the supervision of the machine with the aid of microprocessors. An automatic regulation system optimizes the air pressure in the machine, adjusting it to the variations of yarn Machine Indicator Light: ·► Green Light : Normal Stop ·►Yellow Light : Weft Stop ·► Red Light : Warp Stop Noman Weaving Mills Ltd 65 connected group wise to the distributors of compressed air by means of flexible pipes. The multi-hole relay nozzles applied on modern air jet weaving machines accelerate the weft motion in the best way, at the same time reducing the stress on the yarn and helping towards increasing machine yield and performance. The manufacturers are increasingly installing on the weft delivery side of the shed a suction nozzle which has the function of maintaining stretched the weft pending the stroke of the slay and the consequent weft binding in the fabric. This ensures a perfect stretching of the weft inside the shed with any kind of yarn, even with the most critical yarns. Among the various optional devices offered by some manufacturers, we point out in particular the auxiliary main nozzle; the combination of an auxiliary main nozzle with the main nozzle accelerates the weft motion but under low pressure, thus avoiding damaging the yarn. A particular characteristic of the last models of weaving machines is the automation and the supervision of the machine with the aid of microprocessors. An automatic regulation system optimizes the air pressure in the machine, adjusting it to the variations of yarn Machine Indicator Light: ·► Green Light : Normal Stop ·►Yellow Light : Weft Stop ·► Red Light : Warp Stop Noman Weaving Mills Ltd 65 connected group wise to the distributors of compressed air by means of flexible pipes. The multi-hole relay nozzles applied on modern air jet weaving machines accelerate the weft motion in the best way, at the same time reducing the stress on the yarn and helping towards increasing machine yield and performance. The manufacturers are increasingly installing on the weft delivery side of the shed a suction nozzle which has the function of maintaining stretched the weft pending the stroke of the slay and the consequent weft binding in the fabric. This ensures a perfect stretching of the weft inside the shed with any kind of yarn, even with the most critical yarns. Among the various optional devices offered by some manufacturers, we point out in particular the auxiliary main nozzle; the combination of an auxiliary main nozzle with the main nozzle accelerates the weft motion but under low pressure, thus avoiding damaging the yarn. A particular characteristic of the last models of weaving machines is the automation and the supervision of the machine with the aid of microprocessors. An automatic regulation system optimizes the air pressure in the machine, adjusting it to the variations of yarn Machine Indicator Light: ·► Green Light : Normal Stop ·►Yellow Light : Weft Stop ·► Red Light : Warp Stop
    • Noman Weaving Mills Ltd 66 ·► White Light : Technical Problem ·► Red + Yellow Light : Warp + Weft Stop ·► Green + Red Light : Selvedge + Wastage Stop ·► Green + Yellow Light : Bobbin Breakage CAUSES OF WEFT BREAKAGE 1. Package position. 2. Entanglement of yarn with machine parts. 3. Worm tension. 4. Low pressure in a. Pre-winder b. Fixed nozzle c. Movable nozzle d. Relay nozzle 5. High pressure in a. Pre-winder b. Fixed nozzle c. Movable nozzle d. Relay nozzle 6. High speed of pre-winder 7. Mal functioning of magnet pin 8. Clogging of yarn in pre-winder 9. Wrong passage of filling yarn. Rapier weaving machines: The rapier weaving machines are the most flexible machines on the market. Their application range covers a wide variety of fabric styles. Their present weaving speed of about 600-700 strokes/min is Noman Weaving Mills Ltd 66 ·► White Light : Technical Problem ·► Red + Yellow Light : Warp + Weft Stop ·► Green + Red Light : Selvedge + Wastage Stop ·► Green + Yellow Light : Bobbin Breakage CAUSES OF WEFT BREAKAGE 1. Package position. 2. Entanglement of yarn with machine parts. 3. Worm tension. 4. Low pressure in a. Pre-winder b. Fixed nozzle c. Movable nozzle d. Relay nozzle 5. High pressure in a. Pre-winder b. Fixed nozzle c. Movable nozzle d. Relay nozzle 6. High speed of pre-winder 7. Mal functioning of magnet pin 8. Clogging of yarn in pre-winder 9. Wrong passage of filling yarn. Rapier weaving machines: The rapier weaving machines are the most flexible machines on the market. Their application range covers a wide variety of fabric styles. Their present weaving speed of about 600-700 strokes/min is Noman Weaving Mills Ltd 66 ·► White Light : Technical Problem ·► Red + Yellow Light : Warp + Weft Stop ·► Green + Red Light : Selvedge + Wastage Stop ·► Green + Yellow Light : Bobbin Breakage CAUSES OF WEFT BREAKAGE 1. Package position. 2. Entanglement of yarn with machine parts. 3. Worm tension. 4. Low pressure in a. Pre-winder b. Fixed nozzle c. Movable nozzle d. Relay nozzle 5. High pressure in a. Pre-winder b. Fixed nozzle c. Movable nozzle d. Relay nozzle 6. High speed of pre-winder 7. Mal functioning of magnet pin 8. Clogging of yarn in pre-winder 9. Wrong passage of filling yarn. Rapier weaving machines: The rapier weaving machines are the most flexible machines on the market. Their application range covers a wide variety of fabric styles. Their present weaving speed of about 600-700 strokes/min is
    • Noman Weaving Mills Ltd 67 the result of the use of a state-of-the-art construction technique, characterized by the use of gear sets without plays and by minimum vibrations of the reed, the slay and the heald frames. Picanol: Machine specification: Name of the Machine : Picanol  Optimax  Gamma Origin : Belgium R.P.M : Optimax-650 : Gamma 8R-500 Loom type : Rapier Rapier : Double end rapier Shedding system : Tappet &Dobby Rapier insertion system: The weft, which is under constant proper control, remains connected to the cloth as a consequence of the previous insertion (or it remains blocked under the temple in the other cases) (fig. 36). At the right moment the selection gear acts in a way, that the end of the weft is caught by the bearing rapier 1 mounted on a flexible tape or on a rod and at the same time is cut by shears on the selvedge side. The weft, after adequate braking, is transported to the center of the shed, where the bearing rapier meets the drawing rapier 2, which takes over the weft thread and, while holding it by its end, transports it back to the opposite side, where the rapier leaves it free, thus completing the insertion. The weft exchange between the two rapiers in the middle of the shed can take place in two different ways, that is:  Negative system  Positive system. Noman Weaving Mills Ltd 67 the result of the use of a state-of-the-art construction technique, characterized by the use of gear sets without plays and by minimum vibrations of the reed, the slay and the heald frames. Picanol: Machine specification: Name of the Machine : Picanol  Optimax  Gamma Origin : Belgium R.P.M : Optimax-650 : Gamma 8R-500 Loom type : Rapier Rapier : Double end rapier Shedding system : Tappet &Dobby Rapier insertion system: The weft, which is under constant proper control, remains connected to the cloth as a consequence of the previous insertion (or it remains blocked under the temple in the other cases) (fig. 36). At the right moment the selection gear acts in a way, that the end of the weft is caught by the bearing rapier 1 mounted on a flexible tape or on a rod and at the same time is cut by shears on the selvedge side. The weft, after adequate braking, is transported to the center of the shed, where the bearing rapier meets the drawing rapier 2, which takes over the weft thread and, while holding it by its end, transports it back to the opposite side, where the rapier leaves it free, thus completing the insertion. The weft exchange between the two rapiers in the middle of the shed can take place in two different ways, that is:  Negative system  Positive system. Noman Weaving Mills Ltd 67 the result of the use of a state-of-the-art construction technique, characterized by the use of gear sets without plays and by minimum vibrations of the reed, the slay and the heald frames. Picanol: Machine specification: Name of the Machine : Picanol  Optimax  Gamma Origin : Belgium R.P.M : Optimax-650 : Gamma 8R-500 Loom type : Rapier Rapier : Double end rapier Shedding system : Tappet &Dobby Rapier insertion system: The weft, which is under constant proper control, remains connected to the cloth as a consequence of the previous insertion (or it remains blocked under the temple in the other cases) (fig. 36). At the right moment the selection gear acts in a way, that the end of the weft is caught by the bearing rapier 1 mounted on a flexible tape or on a rod and at the same time is cut by shears on the selvedge side. The weft, after adequate braking, is transported to the center of the shed, where the bearing rapier meets the drawing rapier 2, which takes over the weft thread and, while holding it by its end, transports it back to the opposite side, where the rapier leaves it free, thus completing the insertion. The weft exchange between the two rapiers in the middle of the shed can take place in two different ways, that is:  Negative system  Positive system.
    • Noman Weaving Mills Ltd 68 Driving gears for rapier belts: To transform a uniform rotary motion into an alternating motion, all kinds of gears are used. Among these gears, the cam motion system is the most used as it is possible to study the cam profile in order to obtain an accelerating movement of the rapiers which permits the most delicate handling of the yarn. This fact is particularly important during the critical moments of the thread clamping at the beginning of the cycle, during the rapier exchange in the middle of the shed and during the release of the weft at its exit from the shed at the opposite side. In all these cases the weaver tries to operate at the lowest possible speed rates. Fig. 39 Floating guide We give hereunder some examples driving systems for flexible rapiers. A manufacturer uses in his machines the following disk cam system with complementary cam profile the rotating shaft 1 carries fixed a couple of disk cams with complementary profile 2 (the other couple of cams serves to move the reed) which transmits, through a roller cam follower 3, a swinging movement to a lever with adjustable arm (not visible in the figure), which lever is linked to the connecting rod 4. This last transmits the swinging motion to the block 5, mounted eccentrically on shaft 6, which by a system of side gears and planet wheels converts the movement into the alternating rotary movement of a crown wheel with pinion 7 and of the toothed wheel 8. The flexible rapier belt, which is driven by this wheel, moves on a straight level and transforms the alternating rotary motion into a straight rotary motion. Of course a similar gear carries out the control of the other rapier. Noman Weaving Mills Ltd 68 Driving gears for rapier belts: To transform a uniform rotary motion into an alternating motion, all kinds of gears are used. Among these gears, the cam motion system is the most used as it is possible to study the cam profile in order to obtain an accelerating movement of the rapiers which permits the most delicate handling of the yarn. This fact is particularly important during the critical moments of the thread clamping at the beginning of the cycle, during the rapier exchange in the middle of the shed and during the release of the weft at its exit from the shed at the opposite side. In all these cases the weaver tries to operate at the lowest possible speed rates. Fig. 39 Floating guide We give hereunder some examples driving systems for flexible rapiers. A manufacturer uses in his machines the following disk cam system with complementary cam profile the rotating shaft 1 carries fixed a couple of disk cams with complementary profile 2 (the other couple of cams serves to move the reed) which transmits, through a roller cam follower 3, a swinging movement to a lever with adjustable arm (not visible in the figure), which lever is linked to the connecting rod 4. This last transmits the swinging motion to the block 5, mounted eccentrically on shaft 6, which by a system of side gears and planet wheels converts the movement into the alternating rotary movement of a crown wheel with pinion 7 and of the toothed wheel 8. The flexible rapier belt, which is driven by this wheel, moves on a straight level and transforms the alternating rotary motion into a straight rotary motion. Of course a similar gear carries out the control of the other rapier. Noman Weaving Mills Ltd 68 Driving gears for rapier belts: To transform a uniform rotary motion into an alternating motion, all kinds of gears are used. Among these gears, the cam motion system is the most used as it is possible to study the cam profile in order to obtain an accelerating movement of the rapiers which permits the most delicate handling of the yarn. This fact is particularly important during the critical moments of the thread clamping at the beginning of the cycle, during the rapier exchange in the middle of the shed and during the release of the weft at its exit from the shed at the opposite side. In all these cases the weaver tries to operate at the lowest possible speed rates. Fig. 39 Floating guide We give hereunder some examples driving systems for flexible rapiers. A manufacturer uses in his machines the following disk cam system with complementary cam profile the rotating shaft 1 carries fixed a couple of disk cams with complementary profile 2 (the other couple of cams serves to move the reed) which transmits, through a roller cam follower 3, a swinging movement to a lever with adjustable arm (not visible in the figure), which lever is linked to the connecting rod 4. This last transmits the swinging motion to the block 5, mounted eccentrically on shaft 6, which by a system of side gears and planet wheels converts the movement into the alternating rotary movement of a crown wheel with pinion 7 and of the toothed wheel 8. The flexible rapier belt, which is driven by this wheel, moves on a straight level and transforms the alternating rotary motion into a straight rotary motion. Of course a similar gear carries out the control of the other rapier.
    • Noman Weaving Mills Ltd 69 Fig. Driving system by double conjugated cam Projectile weaving machines The projectile weaving machine made its appearance in the market at the beginning of the 50’s and is today still used in the whole world. Thanks to its steady renovation and to the use of advanced electronic systems as well as of microprocessors for the supervision and the control of the various devices, this machine is characterized by a good productivity level (450 rpm and 1050 m/min of inserted weft) and by high operational reliability. It is established especially in the field of machines with high reed width. M/C SPECIFICATION: General operation In this weaving machine the weft insertion is carried out by small clamp projectiles (fig. 45), which number depends on the weaving width and which with their grippers take out the weft yarn from big cross-wound bobbins and insert it into the shed always in the same direction. The projectiles work in sequence, that is they are launched in succession. They run therefore one after the other, describing in the space a continuous, endless route, as if they would be stuck on a Noman Weaving Mills Ltd 69 Fig. Driving system by double conjugated cam Projectile weaving machines The projectile weaving machine made its appearance in the market at the beginning of the 50’s and is today still used in the whole world. Thanks to its steady renovation and to the use of advanced electronic systems as well as of microprocessors for the supervision and the control of the various devices, this machine is characterized by a good productivity level (450 rpm and 1050 m/min of inserted weft) and by high operational reliability. It is established especially in the field of machines with high reed width. M/C SPECIFICATION: General operation In this weaving machine the weft insertion is carried out by small clamp projectiles (fig. 45), which number depends on the weaving width and which with their grippers take out the weft yarn from big cross-wound bobbins and insert it into the shed always in the same direction. The projectiles work in sequence, that is they are launched in succession. They run therefore one after the other, describing in the space a continuous, endless route, as if they would be stuck on a Noman Weaving Mills Ltd 69 Fig. Driving system by double conjugated cam Projectile weaving machines The projectile weaving machine made its appearance in the market at the beginning of the 50’s and is today still used in the whole world. Thanks to its steady renovation and to the use of advanced electronic systems as well as of microprocessors for the supervision and the control of the various devices, this machine is characterized by a good productivity level (450 rpm and 1050 m/min of inserted weft) and by high operational reliability. It is established especially in the field of machines with high reed width. M/C SPECIFICATION: General operation In this weaving machine the weft insertion is carried out by small clamp projectiles (fig. 45), which number depends on the weaving width and which with their grippers take out the weft yarn from big cross-wound bobbins and insert it into the shed always in the same direction. The projectiles work in sequence, that is they are launched in succession. They run therefore one after the other, describing in the space a continuous, endless route, as if they would be stuck on a
    • Noman Weaving Mills Ltd 70 conveyor belt. The first projectile takes and holds in its back the weft in form of a tail; then, pushed by the release of the projectile thrower, it passes through the shed and deposits the weft inside the warp; subsequently the projectile falls and is collected by a device which, by passing under the array of the warp threads, takes it at reduced speed back to the starting point. Here the projectile goes up to take up a new weft; meanwhile the other projectiles have run after each other making the same operation. Fig. 45 shows the projectile conveyor chain (shuttle return chain), the projectile (shuttle) with its back clamp to seize the yarn (thread grippers), the cutting tool (scissors) to separate the inserted weft from the bobbin and the strap which, through twisting, launches the projectiles Projectile guide The limited weight and the reduced volume of the projectile make a projectile guide necessary (fig. 47). The projectiles therefore do not come into contact with the threads, but run inside a sort of channel composed of the thin prongs of a Noman Weaving Mills Ltd 70 conveyor belt. The first projectile takes and holds in its back the weft in form of a tail; then, pushed by the release of the projectile thrower, it passes through the shed and deposits the weft inside the warp; subsequently the projectile falls and is collected by a device which, by passing under the array of the warp threads, takes it at reduced speed back to the starting point. Here the projectile goes up to take up a new weft; meanwhile the other projectiles have run after each other making the same operation. Fig. 45 shows the projectile conveyor chain (shuttle return chain), the projectile (shuttle) with its back clamp to seize the yarn (thread grippers), the cutting tool (scissors) to separate the inserted weft from the bobbin and the strap which, through twisting, launches the projectiles Projectile guide The limited weight and the reduced volume of the projectile make a projectile guide necessary (fig. 47). The projectiles therefore do not come into contact with the threads, but run inside a sort of channel composed of the thin prongs of a Noman Weaving Mills Ltd 70 conveyor belt. The first projectile takes and holds in its back the weft in form of a tail; then, pushed by the release of the projectile thrower, it passes through the shed and deposits the weft inside the warp; subsequently the projectile falls and is collected by a device which, by passing under the array of the warp threads, takes it at reduced speed back to the starting point. Here the projectile goes up to take up a new weft; meanwhile the other projectiles have run after each other making the same operation. Fig. 45 shows the projectile conveyor chain (shuttle return chain), the projectile (shuttle) with its back clamp to seize the yarn (thread grippers), the cutting tool (scissors) to separate the inserted weft from the bobbin and the strap which, through twisting, launches the projectiles Projectile guide The limited weight and the reduced volume of the projectile make a projectile guide necessary (fig. 47). The projectiles therefore do not come into contact with the threads, but run inside a sort of channel composed of the thin prongs of a
    • Noman Weaving Mills Ltd 71 rake, which form reminds a semiclosed hand. This rake goes up from under the threads at the moment of the projectile launch and has of course to fall back lowering itself at the slay stroke. To enable this movement, the rake is secured on the slay and is positioned very close to the reed; the rake’s laminas are not in contact with the warp, or touch it very lightly because the reed opens them the way. The latest models of the projectile machine have been equipped with new types of guide dents, which are divided and placed in alternate position, in order to reduce the stress on weft and warp threads. This permits to use in warp even very delicate yarns as for instance untwisted or entangled yarns and at the same time to cope with high quality requirements Noman Weaving Mills Ltd 71 rake, which form reminds a semiclosed hand. This rake goes up from under the threads at the moment of the projectile launch and has of course to fall back lowering itself at the slay stroke. To enable this movement, the rake is secured on the slay and is positioned very close to the reed; the rake’s laminas are not in contact with the warp, or touch it very lightly because the reed opens them the way. The latest models of the projectile machine have been equipped with new types of guide dents, which are divided and placed in alternate position, in order to reduce the stress on weft and warp threads. This permits to use in warp even very delicate yarns as for instance untwisted or entangled yarns and at the same time to cope with high quality requirements Noman Weaving Mills Ltd 71 rake, which form reminds a semiclosed hand. This rake goes up from under the threads at the moment of the projectile launch and has of course to fall back lowering itself at the slay stroke. To enable this movement, the rake is secured on the slay and is positioned very close to the reed; the rake’s laminas are not in contact with the warp, or touch it very lightly because the reed opens them the way. The latest models of the projectile machine have been equipped with new types of guide dents, which are divided and placed in alternate position, in order to reduce the stress on weft and warp threads. This permits to use in warp even very delicate yarns as for instance untwisted or entangled yarns and at the same time to cope with high quality requirements
    • Noman Weaving Mills Ltd 72 Chapter – 07 Quality Assurance system Quality : The totality of features and characteristics of the product or services that bear on its ability to satisfy stated or implied needs. Quality assurance & Fabric Inspection system: Noman Weaving Mills Ltd 72 Chapter – 07 Quality Assurance system Quality : The totality of features and characteristics of the product or services that bear on its ability to satisfy stated or implied needs. Quality assurance & Fabric Inspection system: Noman Weaving Mills Ltd 72 Chapter – 07 Quality Assurance system Quality : The totality of features and characteristics of the product or services that bear on its ability to satisfy stated or implied needs. Quality assurance & Fabric Inspection system:
    • Noman Weaving Mills Ltd 73 Quality assurance is defined as all those possible planned and systematic actions necessary to provide adequate confidence than a product or service will satisfy given requirements for quality. The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of manufacturing. Objects of Quality Control:  Specification test  Raw material control  Process control  Process development  Product testing  Research Finish Fabric Inspection: Purpose: To ensure that an acceptable quality fabric is used for producing garments and proper quality of shipment is received from the supplier. Procedure:  Store in charge will check the received fabric with the report length and type of fabric with the stated shipment document quantity and the actual order quantity.  The finding will be recorded in inventory report and discrepancy regarding fabric type, color and length will be notified to the AGM/ ASTT Manager.  For in house product quality control officer will guide all over inspection.  Quality inspector ( fabric) will check 100% receive fabric for quality. He will identify any defect, hole or stain in the fabric and make calculating below- Four Point System: Defect area Point 0 to 03 inch 1 3 to 06 inch 2 06 to 09 inch 3 Above 09 inch 4 For any hole in fabric 4 Noman Weaving Mills Ltd 73 Quality assurance is defined as all those possible planned and systematic actions necessary to provide adequate confidence than a product or service will satisfy given requirements for quality. The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of manufacturing. Objects of Quality Control:  Specification test  Raw material control  Process control  Process development  Product testing  Research Finish Fabric Inspection: Purpose: To ensure that an acceptable quality fabric is used for producing garments and proper quality of shipment is received from the supplier. Procedure:  Store in charge will check the received fabric with the report length and type of fabric with the stated shipment document quantity and the actual order quantity.  The finding will be recorded in inventory report and discrepancy regarding fabric type, color and length will be notified to the AGM/ ASTT Manager.  For in house product quality control officer will guide all over inspection.  Quality inspector ( fabric) will check 100% receive fabric for quality. He will identify any defect, hole or stain in the fabric and make calculating below- Four Point System: Defect area Point 0 to 03 inch 1 3 to 06 inch 2 06 to 09 inch 3 Above 09 inch 4 For any hole in fabric 4 Noman Weaving Mills Ltd 73 Quality assurance is defined as all those possible planned and systematic actions necessary to provide adequate confidence than a product or service will satisfy given requirements for quality. The Quality Assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of manufacturing. Objects of Quality Control:  Specification test  Raw material control  Process control  Process development  Product testing  Research Finish Fabric Inspection: Purpose: To ensure that an acceptable quality fabric is used for producing garments and proper quality of shipment is received from the supplier. Procedure:  Store in charge will check the received fabric with the report length and type of fabric with the stated shipment document quantity and the actual order quantity.  The finding will be recorded in inventory report and discrepancy regarding fabric type, color and length will be notified to the AGM/ ASTT Manager.  For in house product quality control officer will guide all over inspection.  Quality inspector ( fabric) will check 100% receive fabric for quality. He will identify any defect, hole or stain in the fabric and make calculating below- Four Point System: Defect area Point 0 to 03 inch 1 3 to 06 inch 2 06 to 09 inch 3 Above 09 inch 4 For any hole in fabric 4
    • Noman Weaving Mills Ltd 74  If point grade is 40 or below than the fabric is ok. If the result is more than 40 points, then inform it to AGM or respective Manager.  The fabric is also checked for shedding defect in side by side and length. Any non- conformities/ shedding will be noticed to asst. manager using reports. Roll wise color uniformity card is maintained for identification of shade variations.  During the fabric inspection if the yardage of any roll is reported more or less by the fabric inspection machine then the one specified in the roll, the roll will be measured manually using measuring tape. Only calibrated measuring tape should be used. The result of fabric inspection will be recorded in fabric inspection report. The quality assurance system followed by this factory is given below: Inspection Mending Recheck Folding List of the equipments:  Mending table Glass box  Thread cutter Comb  Nipper Correction pen  Pocket box Inspection Machine  Electronic balance Inspection Procedure: The grey fabric produced from different loom shed is collected by the quality inspector and thoroughly inspected in front of a white board light. During inspection different types of fault happened during weaving like holes, oil spot, reed mark, temple mark, miss pick, double pick, starting mark, broken pick, shade variation in case of yarn dyed fabric is checked. Then fabrics transferred to the mending section for some adjustment done through hand. Then fabric is rechecked and finally folding is done for storage. Noman Weaving Mills Ltd 74  If point grade is 40 or below than the fabric is ok. If the result is more than 40 points, then inform it to AGM or respective Manager.  The fabric is also checked for shedding defect in side by side and length. Any non- conformities/ shedding will be noticed to asst. manager using reports. Roll wise color uniformity card is maintained for identification of shade variations.  During the fabric inspection if the yardage of any roll is reported more or less by the fabric inspection machine then the one specified in the roll, the roll will be measured manually using measuring tape. Only calibrated measuring tape should be used. The result of fabric inspection will be recorded in fabric inspection report. The quality assurance system followed by this factory is given below: Inspection Mending Recheck Folding List of the equipments:  Mending table Glass box  Thread cutter Comb  Nipper Correction pen  Pocket box Inspection Machine  Electronic balance Inspection Procedure: The grey fabric produced from different loom shed is collected by the quality inspector and thoroughly inspected in front of a white board light. During inspection different types of fault happened during weaving like holes, oil spot, reed mark, temple mark, miss pick, double pick, starting mark, broken pick, shade variation in case of yarn dyed fabric is checked. Then fabrics transferred to the mending section for some adjustment done through hand. Then fabric is rechecked and finally folding is done for storage. Noman Weaving Mills Ltd 74  If point grade is 40 or below than the fabric is ok. If the result is more than 40 points, then inform it to AGM or respective Manager.  The fabric is also checked for shedding defect in side by side and length. Any non- conformities/ shedding will be noticed to asst. manager using reports. Roll wise color uniformity card is maintained for identification of shade variations.  During the fabric inspection if the yardage of any roll is reported more or less by the fabric inspection machine then the one specified in the roll, the roll will be measured manually using measuring tape. Only calibrated measuring tape should be used. The result of fabric inspection will be recorded in fabric inspection report. The quality assurance system followed by this factory is given below: Inspection Mending Recheck Folding List of the equipments:  Mending table Glass box  Thread cutter Comb  Nipper Correction pen  Pocket box Inspection Machine  Electronic balance Inspection Procedure: The grey fabric produced from different loom shed is collected by the quality inspector and thoroughly inspected in front of a white board light. During inspection different types of fault happened during weaving like holes, oil spot, reed mark, temple mark, miss pick, double pick, starting mark, broken pick, shade variation in case of yarn dyed fabric is checked. Then fabrics transferred to the mending section for some adjustment done through hand. Then fabric is rechecked and finally folding is done for storage.
    • Noman Weaving Mills Ltd 75 Quality Standard: For quality standard this factory follows 4 point system. The acceptable quality grades depending on the buyer’s requirements are: Grade-A: Maximum 10 point in 100 meter fabric is considered for first grade. Grade-B: Maximum 11-15 points in 100 meter fabric are considerable for second grade. Grade-C: Maximum 16-20 points are considerable for 100 meter fabric in third grade. Following Table shows common faults and response by inspection section at Noman Weaving Mills ltd: No Faults Response 1 Reed Mark Uneven warp & weft tension 2 Miss Pick Uneven weft yarn tension 3 Snarl Uneven air pressure 4 Hole Uneven knotting 5 Slubs Yarn fault 6 Thick thin place Uneven tension 7 Weft Wrong weft yarn supply 8 Double end Wrong denting 9 Wrong denting Double end 10 Double pick Wrong air tension 11 Wrong drawing Operator fault 12 Loose warp Wrong beam winding 13 Tight warp Do 14 Oil line/ Stain Carelessness 15 Crease mark Do 16 Uneven tension Wrong operational setup Faults & points:  Starting Mark 4 point  Miss pick 4 point  Half pick 4 point  Double pick 4 point  Running pick 3 point  Cut pick 2 point Noman Weaving Mills Ltd 75 Quality Standard: For quality standard this factory follows 4 point system. The acceptable quality grades depending on the buyer’s requirements are: Grade-A: Maximum 10 point in 100 meter fabric is considered for first grade. Grade-B: Maximum 11-15 points in 100 meter fabric are considerable for second grade. Grade-C: Maximum 16-20 points are considerable for 100 meter fabric in third grade. Following Table shows common faults and response by inspection section at Noman Weaving Mills ltd: No Faults Response 1 Reed Mark Uneven warp & weft tension 2 Miss Pick Uneven weft yarn tension 3 Snarl Uneven air pressure 4 Hole Uneven knotting 5 Slubs Yarn fault 6 Thick thin place Uneven tension 7 Weft Wrong weft yarn supply 8 Double end Wrong denting 9 Wrong denting Double end 10 Double pick Wrong air tension 11 Wrong drawing Operator fault 12 Loose warp Wrong beam winding 13 Tight warp Do 14 Oil line/ Stain Carelessness 15 Crease mark Do 16 Uneven tension Wrong operational setup Faults & points:  Starting Mark 4 point  Miss pick 4 point  Half pick 4 point  Double pick 4 point  Running pick 3 point  Cut pick 2 point Noman Weaving Mills Ltd 75 Quality Standard: For quality standard this factory follows 4 point system. The acceptable quality grades depending on the buyer’s requirements are: Grade-A: Maximum 10 point in 100 meter fabric is considered for first grade. Grade-B: Maximum 11-15 points in 100 meter fabric are considerable for second grade. Grade-C: Maximum 16-20 points are considerable for 100 meter fabric in third grade. Following Table shows common faults and response by inspection section at Noman Weaving Mills ltd: No Faults Response 1 Reed Mark Uneven warp & weft tension 2 Miss Pick Uneven weft yarn tension 3 Snarl Uneven air pressure 4 Hole Uneven knotting 5 Slubs Yarn fault 6 Thick thin place Uneven tension 7 Weft Wrong weft yarn supply 8 Double end Wrong denting 9 Wrong denting Double end 10 Double pick Wrong air tension 11 Wrong drawing Operator fault 12 Loose warp Wrong beam winding 13 Tight warp Do 14 Oil line/ Stain Carelessness 15 Crease mark Do 16 Uneven tension Wrong operational setup Faults & points:  Starting Mark 4 point  Miss pick 4 point  Half pick 4 point  Double pick 4 point  Running pick 3 point  Cut pick 2 point
    • Noman Weaving Mills Ltd 76  Mesh 4 point Daily grey inspection report: Sl No Construction Width (Meter) Loom Shift Dam: Mtr. Name of faults A B 1 30*30/ 72*64 64 146 30 34 64 Temple cut 2 30* 30/ 72*52 98 15 118 100 218 Starting mark 3 30*30/ 77* 68 60 93 50 40 90 Starting mark, running pick 4 16*10/ 48*44 96 130 30 40 70 Starting mark, half pick 5 40*40/ 110*80 63.5 153 98 57 155 Temple cut 6 30*30/ 72* 44 98 113 08 36 44 Starting mark, miss pick Folding: 24033 meter Inspection: 21393 meter Calculations of points is done by- Actual point × 100 Inspected Total Yard Shift Total fabric inspection (meter) Percentage (%) A 14608 68.28% B 3164 14.79% C 2351 10.99% Inspection Waste 62 0.28% Folding waste 77 0.35% Noman Weaving Mills Ltd 76  Mesh 4 point Daily grey inspection report: Sl No Construction Width (Meter) Loom Shift Dam: Mtr. Name of faults A B 1 30*30/ 72*64 64 146 30 34 64 Temple cut 2 30* 30/ 72*52 98 15 118 100 218 Starting mark 3 30*30/ 77* 68 60 93 50 40 90 Starting mark, running pick 4 16*10/ 48*44 96 130 30 40 70 Starting mark, half pick 5 40*40/ 110*80 63.5 153 98 57 155 Temple cut 6 30*30/ 72* 44 98 113 08 36 44 Starting mark, miss pick Folding: 24033 meter Inspection: 21393 meter Calculations of points is done by- Actual point × 100 Inspected Total Yard Shift Total fabric inspection (meter) Percentage (%) A 14608 68.28% B 3164 14.79% C 2351 10.99% Inspection Waste 62 0.28% Folding waste 77 0.35% Noman Weaving Mills Ltd 76  Mesh 4 point Daily grey inspection report: Sl No Construction Width (Meter) Loom Shift Dam: Mtr. Name of faults A B 1 30*30/ 72*64 64 146 30 34 64 Temple cut 2 30* 30/ 72*52 98 15 118 100 218 Starting mark 3 30*30/ 77* 68 60 93 50 40 90 Starting mark, running pick 4 16*10/ 48*44 96 130 30 40 70 Starting mark, half pick 5 40*40/ 110*80 63.5 153 98 57 155 Temple cut 6 30*30/ 72* 44 98 113 08 36 44 Starting mark, miss pick Folding: 24033 meter Inspection: 21393 meter Calculations of points is done by- Actual point × 100 Inspected Total Yard Shift Total fabric inspection (meter) Percentage (%) A 14608 68.28% B 3164 14.79% C 2351 10.99% Inspection Waste 62 0.28% Folding waste 77 0.35%
    • Noman Weaving Mills Ltd 77 Chapter-08 Maintenance of Machinery Noman Weaving Mills Ltd 77 Chapter-08 Maintenance of Machinery Noman Weaving Mills Ltd 77 Chapter-08 Maintenance of Machinery
    • Noman Weaving Mills Ltd 78 Maintenance: Maintenance is the actions taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order. Machine, building, & facilities are subjected to deterioration due to their use & exposure to environmental condition. Process of deterioration if unchecked, culminates in rendering these service facilities unserviceable & brings them to a standstill. In industry therefore has no choice but to attend them from time to repair & recondition them so as to elongate their life to extent it is economically & physically possible to do so. Objectives of maintenance:  To keep the factory plants, equipments, machine, tools in optimum working order.  To ensure accuracy of product & time schedule to delivery customers.  To minimize downtime of machine.  To prolong the useful life of factory plant & machine.  To modify or improve productivity of existing machine to meet the need for production & thus avoid sinking of additional capital. Reactive / Break down maintenance: Reactive maintenance is basically the “ run it till it breaks” maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. Preventive maintenance: Preventive maintenance can be define as action performed on a time or machine run based schedule that detect, preclude or mitigate degradation of a component or system with the aim of sustaining or extending its useful life time to an acceptable level. Routine maintenance: Maintenance of different machines is prepared by expert engineer of maintenance department. Normally in case of weaving machine is done after every 07 days for complete checking of different important parts are done. Maintenance procedure of different machine:  Warping machine  Sizing machine  Weaving machine Noman Weaving Mills Ltd 78 Maintenance: Maintenance is the actions taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order. Machine, building, & facilities are subjected to deterioration due to their use & exposure to environmental condition. Process of deterioration if unchecked, culminates in rendering these service facilities unserviceable & brings them to a standstill. In industry therefore has no choice but to attend them from time to repair & recondition them so as to elongate their life to extent it is economically & physically possible to do so. Objectives of maintenance:  To keep the factory plants, equipments, machine, tools in optimum working order.  To ensure accuracy of product & time schedule to delivery customers.  To minimize downtime of machine.  To prolong the useful life of factory plant & machine.  To modify or improve productivity of existing machine to meet the need for production & thus avoid sinking of additional capital. Reactive / Break down maintenance: Reactive maintenance is basically the “ run it till it breaks” maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. Preventive maintenance: Preventive maintenance can be define as action performed on a time or machine run based schedule that detect, preclude or mitigate degradation of a component or system with the aim of sustaining or extending its useful life time to an acceptable level. Routine maintenance: Maintenance of different machines is prepared by expert engineer of maintenance department. Normally in case of weaving machine is done after every 07 days for complete checking of different important parts are done. Maintenance procedure of different machine:  Warping machine  Sizing machine  Weaving machine Noman Weaving Mills Ltd 78 Maintenance: Maintenance is the actions taken to prevent a device or component from failing or to repair normal equipment degradation experienced with the operation of the device to keep it in proper working order. Machine, building, & facilities are subjected to deterioration due to their use & exposure to environmental condition. Process of deterioration if unchecked, culminates in rendering these service facilities unserviceable & brings them to a standstill. In industry therefore has no choice but to attend them from time to repair & recondition them so as to elongate their life to extent it is economically & physically possible to do so. Objectives of maintenance:  To keep the factory plants, equipments, machine, tools in optimum working order.  To ensure accuracy of product & time schedule to delivery customers.  To minimize downtime of machine.  To prolong the useful life of factory plant & machine.  To modify or improve productivity of existing machine to meet the need for production & thus avoid sinking of additional capital. Reactive / Break down maintenance: Reactive maintenance is basically the “ run it till it breaks” maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. Preventive maintenance: Preventive maintenance can be define as action performed on a time or machine run based schedule that detect, preclude or mitigate degradation of a component or system with the aim of sustaining or extending its useful life time to an acceptable level. Routine maintenance: Maintenance of different machines is prepared by expert engineer of maintenance department. Normally in case of weaving machine is done after every 07 days for complete checking of different important parts are done. Maintenance procedure of different machine:  Warping machine  Sizing machine  Weaving machine
    • Noman Weaving Mills Ltd 79 Warping Machine:  To check the motor and motor belts  To check all the gear and gear boxes  To examinant all the sensors of the warping machine  Lubrication should be done to the lubrication points of the machine.  Cleaning of different parts which are covered by fiber and dust  To verify tension devices and guides. Sizing Machine Maintenance Points:  Gear & gear box  Motor & motor belt  Different sensor  Lubrication  Cleaning of various parts which are covered by flies and dust Maintenance in the Weaving section For proper running of the machine it is necessary to maintain the machine. This is done by cleaning the machine after every 15-20 days. This is basically the servicing of the machine. This is done because - To maintain the quality of the fabric - To reduce the fabric fault - Removal of dust from the machine - Cleaning of different parts of the machine During servicing the following things are checked weather they are in good condition or not. These are cleaned and also replaces if necessary. These are  Relay nozzle  Stress nozzle  Cam box  Filling detector  Reed Noman Weaving Mills Ltd 79 Warping Machine:  To check the motor and motor belts  To check all the gear and gear boxes  To examinant all the sensors of the warping machine  Lubrication should be done to the lubrication points of the machine.  Cleaning of different parts which are covered by fiber and dust  To verify tension devices and guides. Sizing Machine Maintenance Points:  Gear & gear box  Motor & motor belt  Different sensor  Lubrication  Cleaning of various parts which are covered by flies and dust Maintenance in the Weaving section For proper running of the machine it is necessary to maintain the machine. This is done by cleaning the machine after every 15-20 days. This is basically the servicing of the machine. This is done because - To maintain the quality of the fabric - To reduce the fabric fault - Removal of dust from the machine - Cleaning of different parts of the machine During servicing the following things are checked weather they are in good condition or not. These are cleaned and also replaces if necessary. These are  Relay nozzle  Stress nozzle  Cam box  Filling detector  Reed Noman Weaving Mills Ltd 79 Warping Machine:  To check the motor and motor belts  To check all the gear and gear boxes  To examinant all the sensors of the warping machine  Lubrication should be done to the lubrication points of the machine.  Cleaning of different parts which are covered by fiber and dust  To verify tension devices and guides. Sizing Machine Maintenance Points:  Gear & gear box  Motor & motor belt  Different sensor  Lubrication  Cleaning of various parts which are covered by flies and dust Maintenance in the Weaving section For proper running of the machine it is necessary to maintain the machine. This is done by cleaning the machine after every 15-20 days. This is basically the servicing of the machine. This is done because - To maintain the quality of the fabric - To reduce the fabric fault - Removal of dust from the machine - Cleaning of different parts of the machine During servicing the following things are checked weather they are in good condition or not. These are cleaned and also replaces if necessary. These are  Relay nozzle  Stress nozzle  Cam box  Filling detector  Reed
    • Noman Weaving Mills Ltd 80  Drop wire  PFT  Pre winder  Full body Cleaning points: Draw roller Tension roller Guide roller Size box Immersion roller Squeezing roller Delivery roller Separating roller V-reed Measuring roller Spreading roller Eliminate laps from the warping beam Size material pipe Air blast nozzle Oiling & Greasing points: All roller bearing squeezing roller bearing Cylinder roller bearing All gear boxes Health & Safety :  Noman Weaving Mills Ltd have a separate sounding fire alarm, that is distinct & audible in all parts of the workplace & that can be rung from various points throughout the facility.  Emergency evacuation routes are marked on floors.  Workers are trained in emergency procedures.  NWML provides one first aid kit per 100 employees.  First aid kits are fully stocked.  NWML provides eating areas that are separate from the main work area, clean, protected from the weather & with enough seating for all workers on break at once.  Safe drinking water is available for all workers at all time.  NWML have functional & clean toilets for worker use.  Work areas are ventilated.  NWML have adequate temperature & humidity control.  Workers wear footwear to avoid foot injury.  Chemicals are stocked & used in designated areas which are adequately ventilated.  Electrical boxes are covered & switches are labeled.  Doctor is available. Noman Weaving Mills Ltd 80  Drop wire  PFT  Pre winder  Full body Cleaning points: Draw roller Tension roller Guide roller Size box Immersion roller Squeezing roller Delivery roller Separating roller V-reed Measuring roller Spreading roller Eliminate laps from the warping beam Size material pipe Air blast nozzle Oiling & Greasing points: All roller bearing squeezing roller bearing Cylinder roller bearing All gear boxes Health & Safety :  Noman Weaving Mills Ltd have a separate sounding fire alarm, that is distinct & audible in all parts of the workplace & that can be rung from various points throughout the facility.  Emergency evacuation routes are marked on floors.  Workers are trained in emergency procedures.  NWML provides one first aid kit per 100 employees.  First aid kits are fully stocked.  NWML provides eating areas that are separate from the main work area, clean, protected from the weather & with enough seating for all workers on break at once.  Safe drinking water is available for all workers at all time.  NWML have functional & clean toilets for worker use.  Work areas are ventilated.  NWML have adequate temperature & humidity control.  Workers wear footwear to avoid foot injury.  Chemicals are stocked & used in designated areas which are adequately ventilated.  Electrical boxes are covered & switches are labeled.  Doctor is available. Noman Weaving Mills Ltd 80  Drop wire  PFT  Pre winder  Full body Cleaning points: Draw roller Tension roller Guide roller Size box Immersion roller Squeezing roller Delivery roller Separating roller V-reed Measuring roller Spreading roller Eliminate laps from the warping beam Size material pipe Air blast nozzle Oiling & Greasing points: All roller bearing squeezing roller bearing Cylinder roller bearing All gear boxes Health & Safety :  Noman Weaving Mills Ltd have a separate sounding fire alarm, that is distinct & audible in all parts of the workplace & that can be rung from various points throughout the facility.  Emergency evacuation routes are marked on floors.  Workers are trained in emergency procedures.  NWML provides one first aid kit per 100 employees.  First aid kits are fully stocked.  NWML provides eating areas that are separate from the main work area, clean, protected from the weather & with enough seating for all workers on break at once.  Safe drinking water is available for all workers at all time.  NWML have functional & clean toilets for worker use.  Work areas are ventilated.  NWML have adequate temperature & humidity control.  Workers wear footwear to avoid foot injury.  Chemicals are stocked & used in designated areas which are adequately ventilated.  Electrical boxes are covered & switches are labeled.  Doctor is available.
    • Noman Weaving Mills Ltd 81 Chapter -09 Utility services Noman Weaving Mills Ltd 81 Chapter -09 Utility services Noman Weaving Mills Ltd 81 Chapter -09 Utility services
    • Noman Weaving Mills Ltd 82 Utility: It is a complete department. Its purpose is to deals with air, gas, electricity required for the factory to run the production and facilitate the all power related factors. It has some sections that are-  Power plant  Boiler  Chiller/ Compressor/Humidifier/ AC plant Power plant: Capacity : 5.15 MW No. of generator : 5 Capacity of each generator : 1030 KW Generator type : Gas generator Maximum generation is 80% depending on the use Gas required/ month : 332492 m3 × pressure factor (constant) = 671068 m3 Per unit price : 3.74 tk Total cost : 671068 × 3.74 taka = 2509796 taka Boiler: Boiler type : Fire tube (02) Gas consumption / month : 47252 × pressure factor m3/hr 47252 × 2.0183 95368.2 m3 Per unit price : 5.86 taka Total cost : 95368 × 5.86 Noman Weaving Mills Ltd 82 Utility: It is a complete department. Its purpose is to deals with air, gas, electricity required for the factory to run the production and facilitate the all power related factors. It has some sections that are-  Power plant  Boiler  Chiller/ Compressor/Humidifier/ AC plant Power plant: Capacity : 5.15 MW No. of generator : 5 Capacity of each generator : 1030 KW Generator type : Gas generator Maximum generation is 80% depending on the use Gas required/ month : 332492 m3 × pressure factor (constant) = 671068 m3 Per unit price : 3.74 tk Total cost : 671068 × 3.74 taka = 2509796 taka Boiler: Boiler type : Fire tube (02) Gas consumption / month : 47252 × pressure factor m3/hr 47252 × 2.0183 95368.2 m3 Per unit price : 5.86 taka Total cost : 95368 × 5.86 Noman Weaving Mills Ltd 82 Utility: It is a complete department. Its purpose is to deals with air, gas, electricity required for the factory to run the production and facilitate the all power related factors. It has some sections that are-  Power plant  Boiler  Chiller/ Compressor/Humidifier/ AC plant Power plant: Capacity : 5.15 MW No. of generator : 5 Capacity of each generator : 1030 KW Generator type : Gas generator Maximum generation is 80% depending on the use Gas required/ month : 332492 m3 × pressure factor (constant) = 671068 m3 Per unit price : 3.74 tk Total cost : 671068 × 3.74 taka = 2509796 taka Boiler: Boiler type : Fire tube (02) Gas consumption / month : 47252 × pressure factor m3/hr 47252 × 2.0183 95368.2 m3 Per unit price : 5.86 taka Total cost : 95368 × 5.86
    • Noman Weaving Mills Ltd 83 = 558860.65 taka Chiller: Pressure for loom : 6.00 bar Pressure for weaving shed : 7.00 bar In chiller natural air is generated Specification of Utility machines SL NO Name of Machine Manufacturer Name Country of origin Quantity (nos) 1. Generator Cattrrpiller U.S.A 5 2. Chiller L.S Koria 1 Carrier (Old from Tongi) U.S.A 1 3. Compressor Atlascopco Belgium 7 4. Dryer Atlascopco Belgium 7 5. Boiler Schnelder Germany 2 A/C Plant Dae Lim Koria 2 6. Overhead Luwa Switzarland 3 7. Electrojet spain 16 Noman Weaving Mills Ltd 83 = 558860.65 taka Chiller: Pressure for loom : 6.00 bar Pressure for weaving shed : 7.00 bar In chiller natural air is generated Specification of Utility machines SL NO Name of Machine Manufacturer Name Country of origin Quantity (nos) 1. Generator Cattrrpiller U.S.A 5 2. Chiller L.S Koria 1 Carrier (Old from Tongi) U.S.A 1 3. Compressor Atlascopco Belgium 7 4. Dryer Atlascopco Belgium 7 5. Boiler Schnelder Germany 2 A/C Plant Dae Lim Koria 2 6. Overhead Luwa Switzarland 3 7. Electrojet spain 16 Noman Weaving Mills Ltd 83 = 558860.65 taka Chiller: Pressure for loom : 6.00 bar Pressure for weaving shed : 7.00 bar In chiller natural air is generated Specification of Utility machines SL NO Name of Machine Manufacturer Name Country of origin Quantity (nos) 1. Generator Cattrrpiller U.S.A 5 2. Chiller L.S Koria 1 Carrier (Old from Tongi) U.S.A 1 3. Compressor Atlascopco Belgium 7 4. Dryer Atlascopco Belgium 7 5. Boiler Schnelder Germany 2 A/C Plant Dae Lim Koria 2 6. Overhead Luwa Switzarland 3 7. Electrojet spain 16
    • Noman Weaving Mills Ltd 84 Chapter -10 Store and Inventory Noman Weaving Mills Ltd 84 Chapter -10 Store and Inventory Noman Weaving Mills Ltd 84 Chapter -10 Store and Inventory
    • Noman Weaving Mills Ltd 85 Inventory: Physical inventory: Physical inventory is a kind of inventory the material that is necessary available at the store. Two types of physical inventory: Fast Moving Item Slow Moving Item Paper office file Plug connection 8630215 Ball pen Air jack base plate Rolling paper Water meter File box Interface module 8760182 Duplicating book Sizing belt P# 7462023 Correction pen Air pressure regulator P# 774702202 Envelop 11" × 5" Reed switch P# 780301021 Envelop 10" × 12" Encoded cupping P#7491318 Measurement book Proximity switch p# 8360005 White paper 9" × 12" Limit switch 240 V File box plastic Wax level sensor Staff officer attendance register Module P# 8760196 Textile marker classic Pneumatic cylinder P# 780108301 Staple pin big size Pneumatic valve P# 743601806 Lithium battery 3.6 V Squeezing roller side protection P# 7086007 Steel scale 01 meter Lighting wire P# 7423028 Aromatic soap Turn bucket Steel Roller 01 meter Load cell P# 8200183 Shampoo 200 ML Motor A/C P# 801205202 Specification of Inventories Godown:  Yarn go down: 02 Volume of one go down: 50' × 80' × 10' Volume of another go down: 80'× 80' × 10'  Main spare parts: 40' × 50' 10'  Chemical go down: 50' × 60' ×10'  Wastage go down: 40 '× 50 '× 10'  Fabric go down : 50' × 80' × 10' Noman Weaving Mills Ltd 85 Inventory: Physical inventory: Physical inventory is a kind of inventory the material that is necessary available at the store. Two types of physical inventory: Fast Moving Item Slow Moving Item Paper office file Plug connection 8630215 Ball pen Air jack base plate Rolling paper Water meter File box Interface module 8760182 Duplicating book Sizing belt P# 7462023 Correction pen Air pressure regulator P# 774702202 Envelop 11" × 5" Reed switch P# 780301021 Envelop 10" × 12" Encoded cupping P#7491318 Measurement book Proximity switch p# 8360005 White paper 9" × 12" Limit switch 240 V File box plastic Wax level sensor Staff officer attendance register Module P# 8760196 Textile marker classic Pneumatic cylinder P# 780108301 Staple pin big size Pneumatic valve P# 743601806 Lithium battery 3.6 V Squeezing roller side protection P# 7086007 Steel scale 01 meter Lighting wire P# 7423028 Aromatic soap Turn bucket Steel Roller 01 meter Load cell P# 8200183 Shampoo 200 ML Motor A/C P# 801205202 Specification of Inventories Godown:  Yarn go down: 02 Volume of one go down: 50' × 80' × 10' Volume of another go down: 80'× 80' × 10'  Main spare parts: 40' × 50' 10'  Chemical go down: 50' × 60' ×10'  Wastage go down: 40 '× 50 '× 10'  Fabric go down : 50' × 80' × 10' Noman Weaving Mills Ltd 85 Inventory: Physical inventory: Physical inventory is a kind of inventory the material that is necessary available at the store. Two types of physical inventory: Fast Moving Item Slow Moving Item Paper office file Plug connection 8630215 Ball pen Air jack base plate Rolling paper Water meter File box Interface module 8760182 Duplicating book Sizing belt P# 7462023 Correction pen Air pressure regulator P# 774702202 Envelop 11" × 5" Reed switch P# 780301021 Envelop 10" × 12" Encoded cupping P#7491318 Measurement book Proximity switch p# 8360005 White paper 9" × 12" Limit switch 240 V File box plastic Wax level sensor Staff officer attendance register Module P# 8760196 Textile marker classic Pneumatic cylinder P# 780108301 Staple pin big size Pneumatic valve P# 743601806 Lithium battery 3.6 V Squeezing roller side protection P# 7086007 Steel scale 01 meter Lighting wire P# 7423028 Aromatic soap Turn bucket Steel Roller 01 meter Load cell P# 8200183 Shampoo 200 ML Motor A/C P# 801205202 Specification of Inventories Godown:  Yarn go down: 02 Volume of one go down: 50' × 80' × 10' Volume of another go down: 80'× 80' × 10'  Main spare parts: 40' × 50' 10'  Chemical go down: 50' × 60' ×10'  Wastage go down: 40 '× 50 '× 10'  Fabric go down : 50' × 80' × 10'
    • Noman Weaving Mills Ltd 86 Chapter -11 Marketing activities & Cost Analysis Noman Weaving Mills Ltd 86 Chapter -11 Marketing activities & Cost Analysis Noman Weaving Mills Ltd 86 Chapter -11 Marketing activities & Cost Analysis
    • Noman Weaving Mills Ltd 87 Marketing: Marketing is main department for a industry where setting all of the the production depend. By the causes of product demand and price. They decide where product sale, product price and quality of product. Sequence of Marketing Activities Order taken from buyer Counter sample Approved sample Cost analysis for bulk production Bulk Production Quality Inspection Shipment Analysis the sample or swetch Name of Buyer:  Ikea  Hemtex  Spring Canada  C & A / H & M  Iusaka  Promod Ltd. Noman Weaving Mills Ltd 87 Marketing: Marketing is main department for a industry where setting all of the the production depend. By the causes of product demand and price. They decide where product sale, product price and quality of product. Sequence of Marketing Activities Order taken from buyer Counter sample Approved sample Cost analysis for bulk production Bulk Production Quality Inspection Shipment Analysis the sample or swetch Name of Buyer:  Ikea  Hemtex  Spring Canada  C & A / H & M  Iusaka  Promod Ltd. Noman Weaving Mills Ltd 87 Marketing: Marketing is main department for a industry where setting all of the the production depend. By the causes of product demand and price. They decide where product sale, product price and quality of product. Sequence of Marketing Activities Order taken from buyer Counter sample Approved sample Cost analysis for bulk production Bulk Production Quality Inspection Shipment Analysis the sample or swetch Name of Buyer:  Ikea  Hemtex  Spring Canada  C & A / H & M  Iusaka  Promod Ltd.
    • Noman Weaving Mills Ltd 88  Padma Ltd.  Lidle  Carre four  Ia re doute  Joine max  La balance  Van dillen Costing: Sum of expenditure incurred in making a product or service available at a point from where it is to be sold is known as costing. 1. Required yarn calculation 2. Identify the yarn cost 3. Sizing cost 4. Weaving cost 5. Dyeing cost Construction: 40×40 = 58" 133×100 Total ends = 133×58 = 7714 Noman Weaving Mills Ltd 88  Padma Ltd.  Lidle  Carre four  Ia re doute  Joine max  La balance  Van dillen Costing: Sum of expenditure incurred in making a product or service available at a point from where it is to be sold is known as costing. 1. Required yarn calculation 2. Identify the yarn cost 3. Sizing cost 4. Weaving cost 5. Dyeing cost Construction: 40×40 = 58" 133×100 Total ends = 133×58 = 7714 Noman Weaving Mills Ltd 88  Padma Ltd.  Lidle  Carre four  Ia re doute  Joine max  La balance  Van dillen Costing: Sum of expenditure incurred in making a product or service available at a point from where it is to be sold is known as costing. 1. Required yarn calculation 2. Identify the yarn cost 3. Sizing cost 4. Weaving cost 5. Dyeing cost Construction: 40×40 = 58" 133×100 Total ends = 133×58 = 7714
    • Noman Weaving Mills Ltd 89 Weight of warp = 0.26 lbs/yds Weight of weft = 0.21 lbs/yds Total weight = (0.26+0.21) lbs/yds = 0.47 lbs/yds Price of yarn = 233.38 tk/lbs So, yarn cost = 233.38* 0.47 = 110 tk Sizing chemical cost = 3.05 tk/lbs M/C cost + overhead cost Weaving cost = tk/yds Total production per M/C/day 9300 = tk/yds 394 = 23.60 tk/yds So total manufacturing cost = (23.60+110.00+3.05+22) tk/yds = 158.65 tk/yds Noman Weaving Mills Ltd 89 Weight of warp = 0.26 lbs/yds Weight of weft = 0.21 lbs/yds Total weight = (0.26+0.21) lbs/yds = 0.47 lbs/yds Price of yarn = 233.38 tk/lbs So, yarn cost = 233.38* 0.47 = 110 tk Sizing chemical cost = 3.05 tk/lbs M/C cost + overhead cost Weaving cost = tk/yds Total production per M/C/day 9300 = tk/yds 394 = 23.60 tk/yds So total manufacturing cost = (23.60+110.00+3.05+22) tk/yds = 158.65 tk/yds Noman Weaving Mills Ltd 89 Weight of warp = 0.26 lbs/yds Weight of weft = 0.21 lbs/yds Total weight = (0.26+0.21) lbs/yds = 0.47 lbs/yds Price of yarn = 233.38 tk/lbs So, yarn cost = 233.38* 0.47 = 110 tk Sizing chemical cost = 3.05 tk/lbs M/C cost + overhead cost Weaving cost = tk/yds Total production per M/C/day 9300 = tk/yds 394 = 23.60 tk/yds So total manufacturing cost = (23.60+110.00+3.05+22) tk/yds = 158.65 tk/yds
    • Noman Weaving Mills Ltd 90 Chapter-12 Conclusion Noman Weaving Mills Ltd 90 Chapter-12 Conclusion Noman Weaving Mills Ltd 90 Chapter-12 Conclusion
    • Noman Weaving Mills Ltd 91 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction Noman Weaving Mills Ltd 91 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction Noman Weaving Mills Ltd 91 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction
    • Noman Weaving Mills Ltd 92 Conclusion: Findings: As a textile everybody should perform industrial attachment and project report. Undoubtedly this industrial training was very helpful to learn about textile technology, production process, textile machineries, industrial management, match with industrial environment. It was the first opportunity to work on the industry. Limitations:  Because of secret act, the data of costing and marketing activities have not been supplied.  It is not possible to in compass the whole process in such a small frame as this report.  Some of the points in different chapters are not included as these were not available  We did not get enough supervision from the responsible persons of different sections due to their busy schedule. So, there may some limitations of data of different section in this report.  We had a very limited time. In spite of willingliness to study in more details it was not possible to do so. Suggestions:  Due to shortage of technical persons (Textile Engineers) sometimes quality level drops which need to be minimize by employing technical person. Especially at night.  During our training period, most of the time the product were not first time right and need to be reprocessed, increasing the production cost these problems has to be overcome.  We observed that there is lack of understanding between top level personnel and floor level workplace, weakening the chain of command.  Supervisor or in- charge did not follow the program. So sometimes operators deviate from the set procedure which may hamper the quality of the product.  Weaving production needs to increase as well as technical persons need to employ there.  The machine stoppage time should be analyzed and minimized. The maintenance should be carried out regularly.  More skilled labor should be used in the project to improve productivity. Noman Weaving Mills Ltd 92 Conclusion: Findings: As a textile everybody should perform industrial attachment and project report. Undoubtedly this industrial training was very helpful to learn about textile technology, production process, textile machineries, industrial management, match with industrial environment. It was the first opportunity to work on the industry. Limitations:  Because of secret act, the data of costing and marketing activities have not been supplied.  It is not possible to in compass the whole process in such a small frame as this report.  Some of the points in different chapters are not included as these were not available  We did not get enough supervision from the responsible persons of different sections due to their busy schedule. So, there may some limitations of data of different section in this report.  We had a very limited time. In spite of willingliness to study in more details it was not possible to do so. Suggestions:  Due to shortage of technical persons (Textile Engineers) sometimes quality level drops which need to be minimize by employing technical person. Especially at night.  During our training period, most of the time the product were not first time right and need to be reprocessed, increasing the production cost these problems has to be overcome.  We observed that there is lack of understanding between top level personnel and floor level workplace, weakening the chain of command.  Supervisor or in- charge did not follow the program. So sometimes operators deviate from the set procedure which may hamper the quality of the product.  Weaving production needs to increase as well as technical persons need to employ there.  The machine stoppage time should be analyzed and minimized. The maintenance should be carried out regularly.  More skilled labor should be used in the project to improve productivity. Noman Weaving Mills Ltd 92 Conclusion: Findings: As a textile everybody should perform industrial attachment and project report. Undoubtedly this industrial training was very helpful to learn about textile technology, production process, textile machineries, industrial management, match with industrial environment. It was the first opportunity to work on the industry. Limitations:  Because of secret act, the data of costing and marketing activities have not been supplied.  It is not possible to in compass the whole process in such a small frame as this report.  Some of the points in different chapters are not included as these were not available  We did not get enough supervision from the responsible persons of different sections due to their busy schedule. So, there may some limitations of data of different section in this report.  We had a very limited time. In spite of willingliness to study in more details it was not possible to do so. Suggestions:  Due to shortage of technical persons (Textile Engineers) sometimes quality level drops which need to be minimize by employing technical person. Especially at night.  During our training period, most of the time the product were not first time right and need to be reprocessed, increasing the production cost these problems has to be overcome.  We observed that there is lack of understanding between top level personnel and floor level workplace, weakening the chain of command.  Supervisor or in- charge did not follow the program. So sometimes operators deviate from the set procedure which may hamper the quality of the product.  Weaving production needs to increase as well as technical persons need to employ there.  The machine stoppage time should be analyzed and minimized. The maintenance should be carried out regularly.  More skilled labor should be used in the project to improve productivity.