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1. Ahsanullah University of science and
Technology
4th year 2nd semester
Department of Textile Engineering
Course No: Tex- 500
Course Title: Industrial Training
Padma PolyCOtton Knit fabrics limited
SUBMITTED BY:
NAME
ID
Arif Rahman
08.02.06.022
SUBMITTED TO
MD. Ruhul Amin
Assistant Professor
Department of Textile Engineering

2. INDEX
CHAPTER
NAME
CHAPTER CONTENT
PAGE NO
CHAPTER 1
INTRODUCTION
1.1 MILL LOCATION
6
1.2 GENERAL INFORMATION ABOUT THE MILL
8
1.3 BOARD OF DIRECTOR
10
2.1 MANAGEMENT SYSTEM
12
2.2 SHIFT CHANGE
12
2.3 RESPONSIBILITIES OF HR
12
2.4 JOB DESCRIPTION AND RESPONSIBILITIES
13
3.1 TYPES OF RAW MATERIALS
15
3.2 YARN
15
3.3 SOURCES OF RAW MATERIALS
16
3.4 REMARKS
16
4.1 MACHINE AT A GLANCE
18
4.2 MACHINE DESCRIPTION OF KNITTING SECTION
19
4.3 MACHINE SPECIFICATION OF 1ST FLOOR
20
4.4 LAY OUT OF THE 2ND FLOOR OF KNITTING SECTION
21
4.5 MACHINE SPECIFICATION OF 2ND FLOOR
23
4.6 LAY OUT OF COLLAR AND CUFF SECTION
24
4.7 MACHINE SPECIFICAITON OF COLLAR AND CUFF
SECTION
25
5.1 CLASSIFICAITON OF KNITTING
27
5.2 PROCESS FLOW CHART OF KNITTING
28
5.3 DESCRIPTION OF PRODUCTION PROCESS
29
5.4 PROCESS REQUIREMENT
29
5.5 MINIMUM REQUIRMENT OF PRODUCTION
PARAMETERS
30
CHAPTER 2
MANPOWER
MANAGEMENT
CHAPTER 3
CHAPTER 4
CHAPTER 5
RAW MATERIALS
MACHINE DESCRIPTIONS
PROCESS PLANNING AND
OPERATION
5.6 CONSIDERABLE POINTS TO PRODUCE KNIT FABRICS
5.7 PASSES OF YARN IN CIRCULAR KNITTING MACHINE
30
31
1

3. INDEX
5.8 DIFFERENT PARTS OF CIRCULAR KNITTING MACHINE
5.9 FUNCTION OF KNITTING ELEMENTS
37
5.11 COMMENTS
40
6.1 QUALITY ASSURANCE
42
6.2 OBJECTIVE OF QUALITY CONTROL
42
6.3 QUALITY ASSURANCE SYSTEM
42
6.4 YARN QUALITY
42
6.5 KNITTING QUALITY
42
6.6 RESPONSE TO FAULT
44
6.7 LIST OF QUIPMENT OF QUALITY CONTROL
44
6.8 QUALITY ASSURANCE SYSTEM
45
6.9 SOME COMMON KNITTING FAULT
QUALITY ASSURANCE
SYSTEM
32
5.10 PRODUCTION CALCULATION
CHAPTER 6
32
46
CHAPTER 7
SAMPLE ANALYSIS
DIFFERENT SAMPLE ANALYSIS
48
CHAPTER 8
MAINTENANCE
MANAGEMENT
8.1 OBJECTIVE OF MAINTANANCE
55
8.2 TYPES OF MAINTENANCE
55
8.3 PREVENTING MAINTENANCE
55
8.4 ROUTINE MAINTENANCE
55
8.5 MAINTENANCE TOOLS AND EQUIPMENTS
56
2

4. INDEX
CHAPTER 9
60
60
9.3 MACHINES FOR UTILITY SERVICES
60
9.4 AIR COMPRESSOR
CONCLUSION
9.1 UTILITY REQUIRED IN TEXTILE INDUSTRY
9.2 SOURCE OF UTILITY
CHAPTER 10
UTILITY SERVICES
61
10.1 CONCLUSION
63
3

5. Industrial training summery
Textile engineering education is based on industrial ground. Theoretical background is not
sufficient so, industrial training is an essential part of study to make a technologist technically
sound in this field. Industrial training provides us that opportunity to gather practical
knowledge.
Padma PolyCotton Knit Fabrics Limited is a truly integrated undertaking. The textile
division has the capability to offer a complete product range for the export & domestic textile
markets. The goal of the textile division is to become the preferred partner for sourcing high
quality fabrics & clothing from Bangladesh. With high advanced technology & an emphasis
on developing local human resources, the textile division has the potential to make an important
contribution to the nation’s growing readymade garments export sector.
The rationale behind the existing structure & future expansion of the textile division is to
capture value added at each stage of the textile manufacturing process. Despite Bangladesh’s
lack of indigenous cotton production capability, Padma PolyCotton Knit Fabrics Limited has
leveraged Bangladesh’s labor cost advantage & export competitiveness to maximum level.
4

6. CHAPTER 1
INTRODUCTION
5

7. 1.1 Mill Location:
6

8. Padma PolyCotton Knit Fabrics Ltd. is a 100% export oriented composite plant for knit
fabrics and garments. Padma PolyCotton Knit Fabrics Ltd. is well equipped with most
modern & sophisticated European state of the art textile finishing equipment & Japanese
made sewing machineries operated by highly skilled 4,500 technicians & managed by a
vastly experienced management. Padma PolyCotton kint Fabrics Limited committed to
render best services on timely shipment of garments to the valued customers all over the
world.
Padma PolyCotton Knit Fabrics Limited is knit composite mill consists of fabric manufacturing
(knitting), Knit dyeing, Printing & Garments manufacturing departments. With an area of
300,000 square feet Padma PolyCotton kint Fabrics Limited is located in Tejgaon, Industrial Area,
Dhaka.
Padma PolyCotton kint Fabrics Limited is very much distinctive about the quality of the
product as in the knitting & dyeing section varieties of product is produced. All of the
machineries used in this company are branded, modern & sophisticated machineries. All of the
manpower of this company are highly trained and consists of skillful knowledge.
This company deals with various foreign buyers those are very much renowned worldwide for
their supremacy. Among these buyers I may include S.Oliver, Tom Tailor, Esprit, C & A, Defacto,
New Look etc
7

9. 1.2 General Information about the Mill:
Name of the mill :
Padma PolyCotton Knit Fabrics Limited
Status :
Private Limited Company
Type :
100% Export oriented industry knit composite mill.
Year of establishment :
1995 Year
Year of starting production :
1995 Year
Location:
131 Tejgaon Industrial Area,Dhaka.
Address: Factory:
131 Tejgaon Industrial Area,Dhaka.



Head Office:


Raw Materials:
5, Rajuk Avenue,Dhaka-1000
Tel: 9460917-20. Fax: 880956204
Email: Padma@bd.com







100% cotton
100% polyester
a) Spun
b) Filament
100% Viscose
95% cotton 5% lycra
95% polyester 5% lycra
95% viscose 5% lycra
60% cotton 40% polyester
50% polyester 50% sulcool
48% cotton 48% modal 4% lycra
a)
b)
c)
d)
e)
f)
g)
8 Ton/Day
25 Ton/day
65000 Pcs/day
60000 Pcs/day
60000 Pcs/Day
35000 Pcs/Day
15000 Pcs/Day
Production Capacity:
a)
b)
c)
d)
e)
f)
g)
Knitting Section
Dying Section
Cutting Section
Sewing Section
Printing Section
Embroidery Section
Garment Washing
Capacity
8

10. Yearly Turnover:
2 Million US dollar per year(approx.)
Different Departments:
a) Knitting Section
2 Knitting section
Inspection
b) Dyeing Section
Batch section
Dyeing lab.
Dyeing section
Quality control
Finishing
c) Garments Section
Cutting
Sewing
R.N.D. / Sample
Finishing & packing
Quality Control
I.E.N. & planning
Store
d) Merchandising & Marketing
e) Maintenance Section
Electrical
f) Store Section
Supporting Departments
Mechanical
Security department
HRD
9

11. Marketing
Procurement
Finance and accounting
Personnel administration
Total Manpower:
Over 4000
Major Customers:
S.Oliver, Tom Tailor, Esprit, C&A ,New
Look, TEMA, Defacto
1.3 Board of Directors:
Khan Mohammed Ameer
CEO
Padma Group
Mrs. Parveen Sultana Khan
Managing Director
Padma Group
Mrs. Rukshana Ameer
Director
Padma Group
10

12. CHAPTER 2
Manpower management
11

13. 2.1 Management System:









Buyer sample is send to G.M.
Matching is done by lab in charge.
Sample is prepared by asst. dyeing master.
Sample is send to the buyer for approval.
Approved sample is returned and taken as std. Sample for bulk production.
Asst. dyeing master gives responsibilities to production officer
Then production officer, with the supervisors start bulk production
On line and off line quality check is done by lab in charge and asst. dyeing master.
After dyeing finishing in charge controls the finishing process with the supervision of
production officer
 After finishing, the material is checked by asst. dyeing master
 Finally G.M. checks the result with asst. dyeing master and decision is taken for
delivery
2.2 Shift Change:
Three shifts (A, B, C): each of 8 hrs
 A Shift: 6 A.M to 2 P.M.
 B Shift: 2 P.M. to 10 P.M
 C Shift: 10 P.M. to 6 A.M
 General Shift: 9 A.M to 8 P.M.
 Office Time : 9 AM to 5 PM
2.3 Responsibilities of HR:
1.
2.
3.
4.
5.
6.
7.
Man Power Planning.
Man Power recruitment.
Man Power Selection.
To monitor Performance of Management.
To Observe Disciplinary cases.
To look after the welfare of worker.
To handle Grievances of worker
12

14. 2.4 Job description and Responsibilities:
 Title
: Supervisor
Dept. /Section : knitting
Report to
: Shift Incharge
Job summary: To guide the operator and helpers working at the production unit, motivation the
workers when necessary, Check the materials list whether they are at the right quantity or not.
 Title
: Shift Incharge
Dept. /Section : knitting
Report to
: Production Officer
Job summary: To follow the workers movement, To maintenance the production sequence,to
check the sample at certain time interval, To set programs for the supervisions.
 Title
: Production Officer
Dept/Section : knitting
Report to
: Manager
Job summary: To plan, execute & follows up the production activities & control the quality
Production with related activities.
 Title
: Manager
Dept/Section : knitting
Report to
: General Manager
Job summary: To plan for the sequence of production, To arrange necessary raw material for
the production, to follow up the production and give solution to the production problems, To
supervise the personal working under him.
 Title
: General Manager
Dept/Section : knitting
Report to
: Director and Chairmen
Job summary: To plan,apply and administrative function, To set up the price for the product,
To deal with the buyer and merchandiser .
13

15. CHAPTER 3
Raw materials
14

16. Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in continuous production and for high quality fabric. Padma PolyCotton Knit Fabrics
Limited Takes yarn as its raw materials for its initial production of knitted fabrics to make
garments. It is dependent on different spinning mills of home and abroad to collect different
types of yarn as it requires.
3.1 Types of raw material:
Natural and synthetic, cellulosic, non-cellulosic all kind of yarn are used as raw materials in this
mill. Generally cotton, polyester, viscose, nylon is most widely used.
3.2 Yarn
Cotton yarn used in the Padma PolyCotton knit Fabrics Limited according to yarn count.
Serial No:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
Yarn Count
18CD
20CD
20CB
22CD
22CB
24CD
24CB
26CD
26CB
28CD
28CB
30CD
30CB
32CD
32CB
34CD
34CB
36CD
36CB
40CD
40CB
Brand Name
ARIF
AMAN
MOTIN
NRG
NRG
SQR
PRIME
VIYELLA
AMAN
MALAK
MALAK
MSA
MSA
DELTA
DELTA
BEXTEX
BEXTEX
AKBAR
AKBAR
KADER
KADER
*CB= Combed, CD=Carded
15

17. 3.3 Sources of raw materials:
 Square spinning mills ltd.
 ARIF KNITSPIN LTD.
 N.R.G Spinning mills ltd.
 Akbar composite ltd.
 The delta spinning ltd.
 BEXTEX LTD.
 TRIDENT LTD.
 MSA spinning limited.
 MATIN SPINNING MILL’S LTD.
 THERMAX SPINNING LTD.
 SQUARE TEXTILE LTD.
 PRIME COMPOSITE MILLS LTD.
 Aman cotton fibrous ltd.
 Kader compact Spinning
 VIYELLATEX
3.4 Remarks:
Padma PolyCotton Knit Fabrics Limited uses the best quality raw materials, maximum
amount for raw materials are collected from home and rest of amount is collected from India,
Korea, and Vietnam etc. Raw materials are tested before going for production.
16

18. CHAPTER 3
Machine description
17

19. Knitted structures are progressively built up from row of intermeshed loops. The newly feed
yarn converted into a new loop in each needle hook. The needle then draws a new loop head
first through the old loop, which remains from previous knitted cycle. The needles at the
same time release the old loop so that they hang suspended by their heads from the feet of
the new loops whose heads are still held in the hook of the needles.
A cohesive knitted loop structure is thus produced by a combination of the intermeshed
needle loops and yarn that passes from needle loop to needle loop.
Padma PolyCotton Knit Fabrics Limited is well equipped modern export oriented industry. It
has high quality machinery with large production. There are 2 types of machine in this
industry.
These are:-
 Circular knitting machine


Single jersey machine
Double jersey machine
 Flatbed machine (cuff & collar).
4.1 Machine at a glance:
Machine type
Machine name
Total no
Circular knitting machine
Single jersey
28
Double jersey
14
Collar , cuff
33
Flat knitting machine
18

20. 4.2 Machine Description of knitting section:
Circular Knitting machines:
In total there are 42 knitting machine are present in Padma PolyCotton Knit Fabrics Limited
and which are divided in to two floor. First floor contain 30 circular knitting machine.
FIGURE: LAYOUT OF FIRST FLOOR (KNITTING SECTION)
19

21. 4.3 Machine Specification of 1st floor:
Serial
No:
Machine
Name
Machine Type
Origin
Machine
Diameter
Machine
Gauge
No of
Feeder
1.
Origio -1
Single Jersey
Italy
26”
24G
84
2.
Origio -2
Single Jersey
Italy
26”
24G
84
3.
Origio -3
Single Jersey
Italy
30”
24G
96
4.
Origio -4
Single Jersey
Italy
30”
24G
96
5.
Origio -5
Single Jersey
Italy
30”
24G
96
6.
Origio -6
Lycra Rib
Italy
30”
18G
60
7.
Origio -7
Lycra Interlock
Italy
:30”
18G
60
8.
Origio -8
Fleece
Italy
20”
20G
96
9.
Origio -9
Single jersey
Italy
30”
20G
96
10.
Origio -10
Single Jersey
Italy
30”
24G
96
11.
Origio -11
Single Jersey
Italy
30”
24G
96
12.
Origio -12
P/Interlock
Italy
30”
22G
96
13.
Origio -13
P/Interlock
Italy
30”
24G
96
14.
Origio -14
P/Interlock
Italy
30”
22G
96
15.
Origio -16
Rib
Italy
36”
18G
72
16.
Origio -17
Lycra Rib
Italy
36”
18G
72
17.
Baso - 6
Fleece
China
32”
20G
102
18.
Baso - 7
Fleece
China
35”
24G
108
19.
Mayer - 1
Fleece
Germany
30”
20G
96
20

22. 20.
Mayer – 2
Fleece
Germany
30”
20G
96
21.
Mayer - 7
Rib
Germany
36”
18G
62
22.
TERROT-17
Single jersey
Germany
22”
24G
70
23.
TERROT-25
Single jersey /
Germany
24”
20G
70
Heavy jersey
24.
Terrot -26
Single jersey
Germany
34”
24G
108
25.
Terrot -27
Lycra Rib
Germany
34”
18G
60
26.
Terrot -28
Rib
Germany
36”
18G
64
27.
Terrot -29
Lycra Rib
Germany
30”
18G
54
21

23. 4.4 Layout of the 2nd floor of knitting section:
Second floor contain total 12 circular knitting machine.
FIGURE: LAYOUT OF SECOND FLOOR (KNITTING SECTION)
22

24. 4.5 Machine Specification of 2nd floor:
Serial
No:
Machine
Name
Machine Type
Origin
28.
Pailung - 1
Single jersey
29.
Pailung -2
30.
Machine
Diameter
Machine
Gauge
No of Feeder
Taiwan 34”
24G
102
Fleece /terry
Taiwan 36”
24G
108
Pailung - 3
Single jersey
Taiwan 36”
24G
108
31.
Pailung - 4
Single jersey
Taiwan 42”
24G
126
32.
Pailung - 5
D/Interlock
Taiwan 40”
24G
80
33.
Lisky – 1
Fleece
Taiwan 32”
20G
102
34.
Lisky - 2
Fleece
Taiwan 32”
20G
102
35.
Baso - 1
Single jersey
Taiwan 28”
24G
84
36.
Baso - 2
Single jersey
Taiwan 34”
24G
102
37.
Baso - 3
P/Interlock
Taiwan 38”
24G
76
38.
Baso - 4
Single jersey
Taiwan 36”
24G
108
39.
Baso - 5
Single jersey
Taiwan 30”
24G
90
23

25. 4.6 LAYOUT OF COLLAR AND CUFF SECTION:
Collar-cuff section contain 19 semi-automatic and 12 automatic flatbed machine.
FIGURE: LAYOUT OF COLLAR AND CUFF SECTION
24

26. 4.7 Machine Specification of Collar and cuff section:
Machine Type
Company Name
Brand name
Gauge
Origin
Total no of
machine
Fully Automatic
Flat bed knitting
machine
Matsuya Corporation
-
G 14
Japan
19
Computerized
Flat Bed knitting
machine
Sheng Meel machine
manufacturing limited
Flying Tiger
G 14
Taiwan
6
Computerized
Flatbed knitting
machine
Shima Seiki
manufacturing limited
-
G 14
Japan
7
Tape Making
Machine
Saehwa Precision
Machine Company
Saehwa loom -
Korea
1
25

27. CHAPTER 5
Process planning & operation
operation
26

28. 5.1 Classification of Knitting
Classification of knitting can be prevented as below:
Knitting
Warp knitting
Weft knitting
Circular knitting
Flat knitting
Single jersey
Double jersey
Weft knitting:
A method of making a fabric by normal knitting means in which the loops made by each weft
thread are formed substantially across the width of the fabric, characterized by the fact that
each weft thread is fed more of less at right angle to the direction in which the fabric is
produced.
Single jersey:
A fabric in which all the loops of the Wales are intermeshed in one direction is called single
jersey only cylinder to make single jersey fabric.
27

29. Double jersey:
A fabric in which all loops of the alternate Wales are intermeshed in one direction and all the
loops of the other Wales knitted at the same course intermeshed in the other direction is called
double jersey Dial and cylinder is used to make this type of fabric.
5.2 Process Flow Chart Of Knitting:
Yarn in cone form
↓
Feeding the yarn cone in the creel
↓
Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension device
↓
Knitting
↓
Withdraw the rolled fabric and weighting
↓
Inspection
↓
Numbering
28

30. 5.3 Description of Production Process:
In every mill, there maintains a sequences in production processing. It is also followed in this
mill where we were in industrial attachment. The process sequences are in list below:
1) Firstly, knitting manager gets a production shit from the merchandiser as accordance as
consumer requirements then he informs or orders production officer about it.
2) Production officer informs technical in charge and knows about machine in which the
production will be running.
3) Technical in charge calls for leader of mechanical fitter troops, they two take decision
about machine for production considering machine condition, production capacity,
maintenance complexity, etc.
4) Production officer with experienced mechanical fitter adjusts required stitch length and
grey GSM for required final GSM.
5) Supervisor checks daily production regularity and make operator conscious about finishing
tin due time.
6) Operators operate machine in high attention as if there were no faults in the fabrics. If he
thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty.
Mechanical fitter then fixes it if he can or he informs technical in charge. Then he comes in
spot.
7) After required production and final inspection in 4-point system, they sent in dyeing
section.
5.4 Process Requirements:
We have already discussed there are basically three kinds of machine which is used to
Produce knit fabric and these are:
1. Circular knitting machine (Single Jersey Machines).
2. Circular knitting machine (Double Jersey Machines).
3. Flat knitting machine.
29

31. 5.5 Minimum Requirement of Production Parameters:
For Machine:
1. Machine Diameter
2. Machine rpm (revolution per minute)
3. No of feeds or feeders in use
4. Machine Gauge
5. Counter setup
6. Required time (M/C running time)
7. Machine running efficiency.
For Lycra:
1. Should be good elasticity
2. Yarn should be uniform
3. Elastic recovery 100%
Other:
1. Needle oil; should be water soluble
2. Belt
3. Grease
4. Kerosene: etc.
5.6 Considerable Points to Produce Knit Fabrics:
When a buyer orders for fabric then they mention some points related to production and
quality. Before production of knitted fabric, these factors are needed to consider. Those are as
follows- Type of Fabric or design of Fabric.
- Finished G.S.M.
- Yarn count
- Types of yarn (combed or carded)
- Diameter of the fabric.
- Stitch length
- Color depth.
30

32. 5.7 Passes of Yarn in Circular knitting Machine
Creel
Cone
Tube
Knot Catcher
Magnet Pressure
Sensor
Ceramic Eye Pot
Yarn Wheel
Guide
Sensor
Guide
Ceramic eye pot (Feeder Ring)
Feeder
31

33. 5.8 Different parts of circular knitting machine:
1. Creel
2. Pipe
3. VDQ Pulley
4. Pulley belt
5. Brush
6. Knot Cather
7. Tension Disk
8. Inlet top motion
9. Yarn guide
10. MPF Wheel
11. MPF
12. Outlet stop motion
13. Feeder ring
14. Feeder
15. Needle
16. Needle track
17. Sinker
18. Sinker ring
19. Cam box
20. Cam
21. Lycra Attachment
22. Lycra stop motion
23. Inverter
24. Cylinder/dial
25. Screen
26. Cylinder Balancer
27. ON/OFF Switch
28. Power Switch
29. Automatic oiler
30. Motor
31. Machine motherboard
32. Manual drive
5.19 Function of knitting elements
Name: Needle
The needle is the primary knitting element. Needle is a thin metal bar.
Function:

It is used to produce a loop
32

34. Name: Sinker
The sinker is the second primary knitting element. It is a thin metal plate.
Function:



Holding down
Knocking over
Loop formation
Name: Knitting Cam
Cam is the devices which convert rotary machine drive in to a suitable reciprocation action
for the needle.
Knit cam
Function:

To produce knit loop
Tuck cam
Function:

To produce Tuck loop.
Miss cam
Function:

To produce miss loop.
Name: Cam Box
Function:

To set cam on the slider.
33

35. Name: Oiling Point
Function:

To pass oil into the needle.
Name: Air Pipe
Function:

To flow air into the cam
and needle.
Name: Quality Adjustments Pulleys
Function:

It is used to control GSM
Name: Hemminge Positive Feeder
Function:

It is use to apply positive
Feed of the yarn.
Name: Lycra Feeding Device
Function:

It is use to apply positive
Feed of the spandex.
34

36. Name: Needle Detector
Function:

It is used to detect faulty
Needle in the machine.

Stop the machine when
it finds out faulty needle.
Name: Creel
Function:

Creel is a part of a knitting machine.
Hear yarn package are store and
Ready to feed in the machine
.
Name: Pulley Belt
Function:

It controls the rotation of the MPF wheel.
Name: Yarn Guide
Function:

Help the yarn to feed the feeder.
.
Name: Feeder
Function:

Feeder is help yarn to feed in to the machine.
.
35

37. Name: Needle Trick
Function:

Where all needle is placed together in a decent design.
Name: Stop Sensor
Function:

Indicates when yarn becomes worn out.
Name: Screen and On Off Switch
Function:

Indicates the all information of the machine switch use to
Start or stop the machine.
36

38. 5.10 Production Calculation:
A. Production / shift in Kg at 100% efficiency
=
𝑅𝑃𝑀 × 𝑁𝑜. 𝑂𝑓 𝑓𝑒𝑒𝑑𝑒𝑟 × 𝑁𝑜 𝑜𝑓 𝑛𝑒𝑒𝑑𝑙𝑒 × 𝑆𝐿 × 60 × 12
10 × 25.4 × 36 × 840 × 2.2046 × 𝑌𝑎𝑟𝑛 𝐶𝑜𝑢𝑛𝑡
B. Production/shift in meter
=
=
𝐶𝑜𝑢𝑟𝑠𝑒/ 𝑚𝑖𝑛
𝐶𝑜𝑢𝑟𝑠𝑒/𝑐𝑚
𝑅𝑃𝑀×𝑁𝑜.𝑜𝑓 𝑓𝑒𝑒𝑑𝑒𝑟×60×12×𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑐𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×100
C. Fabric width in meter
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜.𝑜𝑓 𝑤𝑎𝑙𝑒𝑠
=
𝑊𝑎𝑙𝑒𝑠/𝑐𝑚×100
=
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜.𝑜𝑓 𝑛𝑒𝑒𝑑𝑙𝑒𝑠 𝑖𝑛 𝑘𝑛𝑖𝑡𝑡𝑖𝑛𝑔
𝑤𝑎𝑙𝑒𝑠/𝑐𝑚×100
D. GSM Calculation
1.
=
=
𝑆𝑡𝑖𝑡𝑐ℎ 𝑑𝑒𝑛𝑠𝑖𝑡𝑦×𝑆𝑡𝑖𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚)×59
𝑌𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡(𝑖𝑛 𝑁𝑒)
𝐶𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×𝑤𝑎𝑙𝑒𝑠/𝑐𝑚×𝑠𝑡𝑖𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚) ×59
𝑌𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡(𝑖𝑛 𝑁𝑒)
2.
=
=
𝑆𝑡𝑖𝑡𝑐ℎ 𝑑𝑒𝑛𝑠𝑖𝑡𝑦×𝑆𝑡𝑖𝑡𝑐ℎ 𝐿𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚)×𝑌𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡 ( 𝑖𝑛 𝑡𝑒𝑥)
10
𝐶𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×𝑤𝑎𝑙𝑒𝑠/𝑐𝑚×𝑠𝑡𝑖𝑡𝑐ℎ 𝑙𝑒𝑛𝑔𝑡ℎ(𝑖𝑛 𝑐𝑚) ×𝑦𝑎𝑟𝑛 𝑐𝑜𝑢𝑛𝑡(𝑖𝑛 𝑡𝑒𝑥)
10
37

39. E. Length calculation
𝑊𝑒𝑖𝑔ℎ𝑡 (𝑖𝑛 𝑔𝑚) ×39.37
= 𝑊𝑖𝑑𝑡ℎ (𝑖𝑛 𝑖𝑛𝑐ℎ) ×𝐺𝑆𝑀
Fabric Type:
Single Jersey Plain
Number of Feeder
: 90
R.P.M. of Machine: 30
Machine Dia
: 30
Machine Gauge
: 24
Count of Yarn
: 24/1 Ne
Stitch Length
: 2.74
Efficiency
: 85 %
Production/8 hours shift =
90 x 30 x 60 x 8 x 0.85 x 3.14 x 30 x 24 x 2.74 Kg
10 x 2.54 x 36 x 840 x 24 x 2.2046
= 168 Kg
Actual production
Efficiency =
× 100%
Calculated production
=138/168×100
= 82%
38

40. Fabric Type:
1 X 1 RIB
No of Feeder: 60
R.P.M. of Machine: 25
Machine Dia: 30
Machine Gauge
Yarn Count
: 34/1
Efficiency
: 80 %
Production/ 8 hours shift =
Stitch length
: 20
: 2.54
60 x 25 x 60 x 8 x 0.8 x 3.14 x 30 x 20 x 2.54
Kg
10 x 2.54 x 36 x 840 x 34 x 2.2046
= 96 Kg
Actual production
Efficiency =
× 100%
Calculated production
= 83 %
39

41. Fabric Type:
Plain Interlock
No of Feeder: 108
R.P.M. of Machine: 26
Machine Dia: 34
Machine Gauge
Yarn Count
: 34/1
Efficiency
: 80 %
Production/day =
Stitch Length
: 24
: 1.54
108 x 26 x 60 x 8 x 0.8 x 3.14 x 34 x 24 x 1.54
Kg
10 x 2.54 x 36 x 840 x 34 x 2.2046
= 147 Kg
Actual production
Efficiency =
× 100%
Calculated production
= 74 %
5.11 Comments:




Actual production is less because of lower efficiency.
Machine is stopped after complesion of each roll. This is a reason for less actual
production.
Machine stops during shift change Which results less actual production.
Order sortage & Yarn sortage also responsible for less actual
production.
40

42. CHAPTER 6
Quality assurance system
41

43. 6.1 Quality Assurance:
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.
6.2 Object of Quality Control:






Specification test
Raw materials control
Process control
Process development
Product testing
Research
6.3 Quality Assurance System:Quality assurance procedure may be divided into two major parts:
1) Online quality control
2) Offline quality control
6.4 Yarn quality:
 check the quality by yarn test method( suitable for white color or dark color)
 check the yarn count( thick/thin, slub,neps,contamination, patta,hariness)
6.5 Knitting quality:
Working Area of ON Line Quality Control:
At the knitting production stage check the every fabric quality by online quality person. Also
check the program sheet with the knit card (like buyer, order, yarn count, machine diameter,
gauge, stitch length, yarn lot etc.)
42

44. a) On line circular knit:
Function:
1. Design & shade approval.
2. Yarn & m/c evaluation.
3. QC parameter checking.
4. Body& Rib Inspection.
b) On line flat knit:
Function:
1. Design & shade approval.
2. Yarn & m/c evaluation.
3. QC parameter checking.
4. Collar & cuff. Inspection.
a) Grey inspection:
Function:
1. 100% Fabric Inspection.
2. Fabric transfer to store.
3. Area cleaning.
4. Co-ordination & reporting.
b) On line finishing:
Function:
1. 100% Fabric Inspection.
2. Problem Identification.
3. Problem Rectification.
4. Fabric Transfer for reprocesses.
43

45. 6.6 Response to Faults:
Following response is to be taken:
Faults
Response
Grey inspection
Inform yarn supplier & knitting department.
Knitting fault
Inform knitting Department
Finishing fault
Inform Finishing Department
Working Area of OFF Line Quality Control:
After knitting, check the grey fabric by inspection machine .find out the knitting fault & mark
by marker pen. Make a report sheet (on 4 point system).
6.7 List of equipment for quality control:
The list of equipment’s to assure quality:1) Inspection m/c.
2) Electronic balance
3) GSM cutter.
4) Measuring tape.
5) Scissors.
6) Indication sticker.
Following faults are detected & identified in final inspection for body:
A) Penalty points legends:
B) Faulty appearance:
H= Hole
US= Uneven shade
OS= Oil Stain
N= Neps
CS= Chemical stain
CR= Crease Mark
RS= Rust Stain
HR= Hairy
GS= Grease Stain
MS= Machine stoppage
MS= Missing Yarn
NL= Needle Line
DS= Drop Stitch
BR= Barre mark
D= Dirt Stain
Tension
CM= Crumple MarkUT= Uneven
DC= Dead Cotton
44

46. S= Stripe
BW= Bowing
OL= Oil Line
TT= Thick & Thin Yarn
S= Slubs
SM= Sinker Mark
FL= Fly Contamination
MY= Mixed Yarn
YC= Yarn Contamination
BE= Birds Eye
WD= Wrong Design
BR= Barre Mark
PH= Pin Holes
Besides roll to roll and meter to meter variation is checked.
6.8 Quality Assurance System
Padma PolyCotton Knit Fabrics Limited maintains the ISO: 9002 standard in case of quality.
Therefore, the four points system is followed to inspect fabric. The defects found and points
given against are recorded in the inspection sheet. Following table shows the four point grading
system followed by inspection at the Padma PolyCotton Knit Fabrics Limited.
Penalty point
Length of defects
3 inches or less
1
Over 3 inch but not over 6 inch
2
Over 6 inch but not over 9 inch
3
Over 9 inch
4
Hole
Penalty Point
1 inch or less
2
Over 1 inch
4
Total defect points per 100 square yards are calculated
45

47. 6.9 Some Common Knitting Faults:
NAME:
CAUSES :
FIGURE
1. Due to tide knots.
Hole
2. Needle break due to slub.
3. Defective needle on yarn.
Set up or press off
1. Due to drop stitch and empty
needle running into the yarn feeder.
2. If an empty needle (generally
after drop stitch) with a close latch
runs into the yarn feeders and
remove the yarn out
from the hook of the following
needles.
Sinker Line
1.Due to uneven movement of
sinker
46

48. 1. Due to defective needle.
Needle Line
2. Dirty needle slot.
3. Needle is too tight or loose in the
slot.
Thick and Thin places
1. Uneven tension.
2. Uneven courses.
3. Count mix, lot mix.
Oil Line
1. Over flow of oil
1. Faulty positive feed system
Missing Yarn
2. Wrong feeder setting.
3. Due to missing of cotton or
spandex yarn
47

49. CHAPTER 7
Sample analysis
48

50.  Single Jersey Plain
Structure
Sample
Needle and cam arrangement
 Polo Pique
Structure
Sample
Needle and cam arrangement
49

51.  Back Pique Or Double Lacoste
Structure
Sample
Needle and cam arrangement
 Two Yarns Fleece (In-Lay)
Structure
Sample
Needle and cam arrangement
50

52.  Three-Thread Fleece
Structure
Sample
Needle and cam arrangement
 1×1 Rib
Structure
Dial
Cylinder
Sample
51

53.  2×2 Rib
Structure
Dial
Cylinder
Sample
 Terry
Structure
cam arrangement
K
K
K
K
T
M
M
M
K
K
K
K
M
M
T
M
1234
Needle arrangement
52

54.  Plain Interlock
Structure
Sample
53

55. CHAPTER 8
Maintenance management
54

56. Maintenance is a process by which equipment is looked after in such a way that trouble
free. Services and increased machine life can be ensured and specific product quality
required by the customers is sustained.
8.1 Objective of Maintenance:




To keep the factory plants, equipment’s, machine, tools in an optimum working
condition.
To ensure specified accuracy to product & time schedule of delivery to customer.
To keep the down time of machines to the minimum thus to have control over the
production program.
To keep the production cycle within the stipulated range.
To modify the machine tools to meet the need for production
8.2 Types of Maintenance:-
Maintenance
Preventive Maintenance
Electrical
Maintenance
Mechanical
Maintenance
Break Down Maintenance
Electrical
maintenance
Mechanical
Maintenance
8.3 Preventive Maintenance
Preventive Maintenance is a predetermined routine activity to ensure on time inspection /
checking of facilities to uncover conditions that may lead to production break downs or
harmful depreciation.
8.4 ROUTINE MAINTENANCE
Routine maintenance usually denotes those activities of maintenance which are bare minimum to
ensure efficient working of machines. These activities have to be performed according to
predetermined frequencies which are based on technical and quality considerations.
55

57. Routine maintenance tasks followed in the factory
Daily work






Motor sound checking
Auto line checking
Positive feeder checking
Oil line checking
Airline checking
Take up roller checking








Gear box checking
All bearing checking
All bearing greasing
Panel board cleaning
Fan filter cleaning
Checking all control panels
Lubrication of all motor bearing
All cable terminal tighten
Every 15 days
8.5 Maintenance tools & equipment’s
Adjustable Wrench
Use
:

To set different type of nuts
And bolts

Tightening & loosening of nuts & bolts.
Double Head Spanner
Use
:


To set nuts and bolts.
Tightening & loosening of nuts & bolts.
56

58. Single Head Spanner
Use
:


To set nuts and bolts.
Tightening & loosening of nuts & bolts.
T-Type L-Key
Use
:


Use to fitting cam box
And other m/c parts.
Tightening & loosening of nuts & bolts.
Allen-Key
Use
:


Pin setter
Use
Use to fitting cam box
And other m/c parts.
Tightening & loosening of nuts & bolts.
:

To hold small m/c parts.
T-Type L-Key
Use
:

To fitting cam box
And other m/c parts.

Tightening & loosening
Of nuts & bolts.
Flat Screw Driver
Use
:


To fitting varies type screw.
Tightening & loosening of nuts & bolts.
57

59. I- Type L-Key
Use
:

To fitting cam box
And other m/c parts.

Tightening & loosening of nuts & bolts.
Hammer
Use
:

To beat metal parts.
Multi-Pliers
Use
:



To hold m/c parts,
Cut metal wire,
Set nuts and bolts.
Cutting-Pliers
Use
:

To cut metal wire.
Long Nose-Pliers
Use
:

To hold and set m/c parts
In thin or narrow space.
58

60. CHAPTER 9
Utility services
59

61. Utility is a very big factor in case of any industry. In textile industry there are various types of
utility has to be present for the smooth running of the operations. In case of any textile
processing industry following types of utility are very much necessary like;
9.1 Utility required in Padma PolyCotton Knit Fabrics Limited Textile
industry:
1.
2.
3.
4.
Electricity
Water
Steam
Compressed air
9.2 Sources of utility:
Electricity
Steam
Water
Compressed air
Gas
: Government supply and Factory own generator.
: Boiler
: Pump
: Compressor
: TITAS GAS LTD.
9.3 Machines for utility services:
Power generator:
In Padma PolyCotton Knit Fabrics Limited There are four power generator present and three
of them run by diesel fuel and the remaining one run with gas fuel.
Name
ENGINATOR
MODEL:
VHP-7100-GSID
MODEL:
1000
RPM:
415/240
VOLTS:
410/24 hours
60

62. 9.4 Air Compressor:
In order to compress the air and to raise its pressure Air compressor is used. The air compressor
sucks air from the atmosphere, compress it and then deliver the same under a high pressure to
a storage vessel. From the storage vessel it may be conveyed by the pipeline to a place where
the supply of compressed air is required. Padma PolyCotton Knit Fabrics limited does have
five compressors
Machine no
1
2
3
4
5
BRAND
KEISER
KEISER
LG
KEISER
-
ORIGIN
Germany
Germany
-
Germany
UK
SERIAL
4511922
4511922
6M37021558H
1824
SSRML50
POWER
30KW
30KW
-
55KW
-
3bar
3bar
5m3/min
11bar
8bar
CAPACITY
61

63. CHAPTER 10
conclusion
62

64. 10.1 Conclusion:
For every person who is fresher in the field of textile, industrial training works like learning
route. This course has given the opportunity to learn the industrial work & follow the process
sequence virtually. From our two month observation of the industry along with research &
development and knitting section specially, we can say that in the knitting sector, this industry
has strong possibility because the industry is running with all modern machineries & very
knowledgeable persons are working all the time. In the production floor the commanding
power of the officers, compliance, administration rules, everything is appealing. We hope that
this industrial training will help us a lot in the future period where ever we want to develop our
career. Finally wishing the best prospect for both the industry & praying for a good future for
us that we want to conclude.
63