3. 2 | P a g e L i t h e G r o u p
Page 2 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
m~wPcÎÑ Index
1. Finishing Process Flow Chart Page -4
2. Topic - Finishing -5
3. Finishing SOP -6
4. Organogram -7
5. Daily Work Schedule -8
6. Machine Wise Manpower Allocation -9
7. Job Responsibility
a. AGM (Md Mizanur Rahman) -14
b. Asst. Manager (Md Ashikur Rahman) -15
c. Deputy Manager (Md Mobarak Hossain) -16
d. Executive (Md Abdul Al Mamun) -17
e. In-charge (Md Tofail Ahmed) -17
f. In-charge (Md Shahadat Hossain) -18
g. Shift- incharge (Bulbul/Repon) -18
h. Others -19
8. Buyer (customer) List factory wise -22
9. Heat Set -23
10. Heat Set SOP -25
11. Heat Set Check list -27
12. Procedure of Fabrics Delivery -28
13. Finishing Standard Procedure -31
14. Finishing Machines introduce
A. Slitting Machine -33
B. Stenter Machine -35
C. Open width Compactor (Lafer) -37
D. Squeezer Machine -39
E. Dryer Machine -41
F. Calendar Machine -43
G. Tube Compact -45
H. Sueding Machine -47
I. Brush Machine -49
J. Hydro Extractor -51
K. Air Turning Machine -53
L. Sanforizing Machine -55
M. Tubular Fabrics Enzyme dust remover m/c -57
N. Trolley Management -59
O. Shade Check Management -61
P. Quality Management -61
Q. Quality Policy English -62
R. Roll Management (Process Loss Control -64
S. Spirality Control -66
4. 3 | P a g e L i t h e G r o u p
Page 3 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
15. Production Calculation -68
16. Factory Closing Preparation/Bangla -69
17. Chemical Use procedure/ Bangla -70
18. pH -74
19. Phenolic Yellowing Control -75
20. Store Management -76
21. Heat Set Parameter -77
22. Test process Approximate -78
23. Fabrication Wise SOP -79
24. Preventive Maintenance Schedule -80
25. Fabrication wise Stenter m/c set up -81
26. Compactor M/c Set up -82
27. Finishing Packing Poly size -83
28. Four point system -84
29. Skills Development analysis -86
30. Finishing Floor status format -87
31. Finishing Chemical -88
32. Process Loss Control -89
33. Fleece Fabrics Finishing Process -90
34. Polyester Fabrics Heat set -92
35. Challenge in Lithe Group -93
36. Production Increase -97
37. Report format -98
38. Finishing Floor Layout -99
39. AOP Finishing Process Flow Chart -100
40. AOP Finishing Organogram -101
41. AOP Finishing Manpower -102
42. Improvement data -103
43. AOP Finishing SOP -104
44. SOP daily work in finishing -105
45. Sub contract SOP -106
46. End -108
5. 4 | P a g e L i t h e G r o u p
Page 4 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Dyeing
Open Tube
Slitting Squeezer
Stenter Dryer
Calender
Sueding Brush
Tube Tex
Stenter
Compactor
Inspection
Store
Famkam Dyeing Ltd
Lithe Group
Dyeing Finishing Departmnt
14. 13 | P a g e L i t h e G r o u p
Page 13 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Required Exisiting Short Remarks
Operator 10 9 1
Asst Operator 10 6 4
Sewing oper 10 4 6
Helper 20 12 8
Required Exisiting Short Remarks
Operator 10 9 1
Asst Operator 10 8 2
Helper 20 5 15
Required Exisiting Short Remarks
Operator 4 4 0
Asst Operator 2 0 2
Helper 4 2 2
Required Exisiting Short Remarks
Operator 6 5 1
Asst Operator 6 2 4
Helper 6 2 4
Required Exisiting Short Remarks
Operator 2 4 -2
Asst Operator 0 0 0
Helper 2 1 1
Required Exisiting Short Remarks
Operator 4 2 2
Asst Operator 4 0 4
Helper 4 3 1
Required Exisiting Short Remarks
Asst Operator 2 0 2
Helper 4 2 2
Required Exisiting Short Remarks
Asst Operator 0 1 -1
Helper 6 2 4
Required Exisiting Short Remarks
Helper 14 9 5
Required Exisiting Short Remarks
Helper 4 4 0
Required Exisiting Short Remarks
Helper 2 1 1
Required Exisiting Short Remarks
Operator 36 33 3
Asst Operator 34 16 18
Sewing oper 10 4 6
Helper 86 43 43
166 96 70
Grend Total
Fabrics Handover & Hold up
Stenter M/c- 4 & Dryer M/c
Open Compactor-5 m/c
Tube Tex & Calender
Slitting m/c-3
Squezzer m/c-2
Brush & Peach m/c-2
Dyeing Finishing Department
SUMMARY
Collar & Cuff monitoring
Heat Set preparation
Tumble m/c-2
Divider m/c-2
15. 14 | P a g e L i t h e G r o u p
Page 14 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Job Responsibility:
Md Mizanur Rahman- AGM (Dyeing & AOP Finishing)
Responsibility- Department
Specially- Product Development, Heat Set, People Skill Develoment
1. Planning & Monitoring of Production Target in the Department
2. Ensure that the Quality Standard is being met by Forecasting & reviewing the
result.
3. Control finishing parameter during bulk production on the basis of standard
technical method
4. Ensure product execution through pre-production meeting with Merchandisers
and QA team to provide service right time with right quality to customers.
5. Develop Discipline, by implementing the Rules & Regulation in Department.
6. Ensure acceptable Quality level (AQL) in textile manner.
7. Give a continuous guidance to the Executive, along with others for target fabric
specification.
8. Supervision constantly to knitting parameter as per standard.
9. Give the full support the Research & Development Department.
10.Make a continuous study of work improvement & give report to the higher
authority.
11.Response & act in the customer complain & query.
12.Ensure that all safety followed by the team.
13.Continuously study the Cost saving of the Department.
14.Enthusiastic to wastage utilization.
15.Train up operators make the multiskill operators by continues Training
16.Optimize Manpower Utilization.
17.Worker Turnover & Absenteeism control as per Plan.
18.Skill Development in the Floor.
19.Ensure that all Lab test Report (Physical) are recorded.
20.Follow the concept of Top Management.
21.Regularly held a meeting to all people once in a week/ Time to time.
22. Co-ordination with all departments all quality parameter inform time to time all
department.
23.Check the hold fabric & give decision quickly.
16. 15 | P a g e L i t h e G r o u p
Page 15 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Job Responsibility:
Md Ashikur Rahman –
Asst. Manager
Responsibility -Production & Program
1. Planning & Monitoring of Production Target in dyeing Finishing
2. Ensure Production Every m/c as per Target with Customer requirement
3. Ensure proper maintenance of all machines by Maintenance
department as and when required.
4. As per plan should be complete within the time.
5. Ensure the process within as per set SOP.
6. Co-ordinate and ensure the department's machinery and equipment
are maintained to optimal levels of operation.
7. Responsible for using set principles and operating practices to
establish, maintain and improve the production process.
8. Develop Discipline, by implementing the Rules &Regulation in
Department.
9. Ensure on time Delivery and With right Quality
10. Ensure that all safety followed by the team.
11. Enthusiastic to wastage utilization.
12. Ensure that all Lab test Report (Physical) are recorded.
13. Follow the concept of Top Management.
14. Check the hold fabric & give decision quickly.
17. 16 | P a g e L i t h e G r o u p
Page 16 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Job Responsibility:
Md. Mobarak Hossain-
Deputy Manager
Responsibility- Sub-contract & Delivery within peocess loss as requirement
1. Planning & Monitoring of Delivery Target with ensure required process loss.
2. Ensure that the Quality Standard is being met by Forecasting & reviewing the
result.
3. Batch to batch process loss ensure with recorded rolls.
4. Ensure Any held up correction within the delivery plan date ( Within 24 hours)
5. Ensure the House Keeping as per required.
6. Responsible to fabrics finishing form out side if needed.
7. Coordinate and ensure the department's machinery and equipment are
maintained to optimal levels of operation.
8. Ensure any unwanted rolls or fabrics don’t have in the floor.
9. Ensure on time Delivery with Accessoris & Calulation process loss.
10. Response & act in the customer complain & query.
11. Enthusiastic to wastage utilization.
12. Ensure that all Lab test Report (Physical) are recorded.
13. Follow the concept of Top Management.
14. Check the hold fabric & give decision quickly.
18. 17 | P a g e L i t h e G r o u p
Page 17 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Job Responsibility:
Md. Abdullah Al Mamun
Executive
Responsibility – Process Loss Control
1. Ensure the process loss as per requirement.
2. Ensure every rolls available in the batch with ERP number.
3. Within the day all correction (Held up) should be complete.
4. Ensure Without Proper information Fabrics Not Available in the Floor
5. Make sure delivery OTD at Sub-contract
6. Ensure the compaction m/c’s production target
7. Controll wastage percentage
8. Compaction m/c’s production report with repocess %
9. Ensure House keeping in your end
10. Ensure optimum utilization of men and machines.
11. Follow the concept of Management.
Md. Tofail Ahmed
In-charge
Responsibility- Wet fabrics (Slitting & Squeezer)
1. Monitoring & Ensure of Production Target.
2. Ensure all rolls are available with ERP number
3. Ensure Accessories (Rib, Piping & Collar Cuffe) on time Finish with Batch
4. To check sensitive parameters of different machines for quality dyeing.
5. Selection of proper recipe for quality production.
6. Fabrics feeding in every stenter m/c’s as per planning with Quality parameter.
7. Ensure 1st in & 1st out procedure.
8. Fabrics yellow spot & Band line avoid
9. Every day at morning within 9:00 AM must be send production report by Whatsapp.
10. Have to confirm Batch to batch Same parameter as per set SOP
11. Ensure Quality Concept (Without QC Comments Fabrics don’t Started the Process)
12. Given guide line to Supervisor to Operator.
13. Check the hold fabric & give decision quickly.
14. Reduce Wastage percentage
19. 18 | P a g e L i t h e G r o u p
Page 18 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Md. Shahadat Hossain
In-charge
Responsibility- Heat Set (Inside & Out side)
1. Monitoring & Ensure of Production Target as per dyeing Plan.
2. Ensure Heat Set Qulaity, creas Mark, GSM variation within Roll, & Roll to Rolls also
3. Check Grey Parameter, Yarn count, Dia & GSM, SL & Recorded.
4. Set up in M/c As per SOP
5. Ensure after Hest set GSM & Dia As per SOP
6. Ensure by Check wash GSM with Calculation
7. Fabricstion wise confirm SOP as per customer
8. Not Use Maximum Overfeed during Heat set
9. Ensure Width not Plus more then one inch
10.Ensure GSM lower side from Requrement around 3%
11.Time to time Transfer data to management
12.Take Information from QAD section Every day
13.Ensure Roll to roll GSM within the tolerance.
14.Have to confirm Batch to batch Same parameter
15.Given guide line to Operator time to time.
16.Reduce Wastage percentage
Md Bulbul Ahmed / Md. Repon
Shift In-Charge
Responsibility- Stenter & Dryer Machine
1. Monitoring & Ensure of Production Target with Quality.
2. Ensure production target as per plan.
3. Ensure the Quality Standard proper Width 1 inch GSM 5%
4. Ensure & Control on process loss. By count rolls
5. Ensure Accessories with Match & finish within the time.
6. Given guide line to Supervisor to Operator.
7. Check the hold fabric & give decision quickly.
8. Ensure Finish Fabrics on the Plate or Store/ With poly pack
9. Ensure Without Proper information Fabrics Not Available in the Floor
10.Reduce Wastage percentage & Held up %
11.Before leaving the working place must be peoduction send by whatsapp.
12. Alwase keep clean the Machine as per SOP
13.Ensure on time Delivery with proper Quality
20. 19 | P a g e L i t h e G r o u p
Page 19 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Md Moffazul Hossain/ Md. Milon
Shift Incharge (Compactor)
Responsibility- All Compactor
1. Monitoring & Ensure of Production Target with Quality as per coustomer.
2. Ensure the Quality Standard proper Width 1 inch GSM 5%
3. Ensure & Control on process loss with rolls count.
4. Ensure Accessories (Rib, Piping & collar cuffe) finish with Batch
5. Given guide line to to Operator.
6. Check the hold fabric & give decision quickly.
7. Ensure Finish Fabrics on the trolley or Poly pack.
8. Ensure Without Proper information Fabrics Not Available in the Floor
9. Reduce Wastage percentage & Held up %
10. Before leaving the working place must be peoduction send by whatsapp.
11. Alwase keep clean the Machine as per SOP.
12. Ensure on time Delivery with proper Quality
Md. Masud Hossain
Fabrics Co-ordinator-
Responsibility- Held up & Fabrics weight
1. Ensure every batch weight complete with process loss count.
2. Ensure held up correction within 24 hours with process loss.
3. Segregation what type of Held up fabrics & report to department
4. Ensure don’t mistake any rolls which is held up.
5. Control on process loss.
6. Ensure don’t have any fabrics without poly pack.
7. Ensure Without Proper information Fabrics Not Available in the Floor
8. Every day at morning within 9:00 AM must be send Manpower report
(absentage) by Whatsapp.
9. Ensure House Keeping
10. Ensure on time Delivery with proper Quality
11. Reduce Wastage percentage
21. 20 | P a g e L i t h e G r o u p
Page 20 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Md. Nayeem Islam
Supervisor
Responsibility- Tube, Collar & Cuffe (Accessories)
1. Ensure Quantity which is in the mension on batch card
2. Ensure Quality level With Customer Standard
3. Have to confirm Accessories Complete as per Body Finish
4. If have any measurement should be ensure as customer requirement
5. If shade not match with body fabrics accordingly, take match immediately by
process.
6. As per delivery schedule accessories Match & Ready to delivery confirm
7. Take Approval before delivery.
Md. Razu Ahmed/ Md. Abdul Motin
Supervisor
Responsibility- Short Quantity Follow up
1. Follow up Program
2. Ensure finish within short time.
3. Ensure Quality Standard
4. 1st in 1st out finishing procedure.
5. Control Fabrics rejection
6. Directly finish check by dyeing unload.
7. Follow up Standard Parameter
8. Handover to Quality with document/ Sign
9. Keep Record in loge book.
23. 22 | P a g e L i t h e G r o u p
Page 22 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Buyer wise Marchindiser & Marketing Person
Sl No Name of Buyer Responsible Merchindiser Manager Remarks
1 Next
2 KiK
3 DSL
4 Champion
5 New Yorker
6 Bay City (Lidl)
7 Star Tex
8 Matalon
9 Kappa
10 Bay City
11 Zeeman Mr. Rasel
12 Takko
13 Lidl
14 GV Fashion
15
16
17
18
19
28. 27 | P a g e L i t h e G r o u p
Page 27 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
1 Batch No
2
3
4
5 Lots
6 Lots
7
8
9
10 GSM
11 GSM
12 GSM
13 GSM
14 GSM
15 GSM
16 GSM
17 GSM
18 GSM
19 GSM
20
21 L- W- Sp-
22 GSM
23
24 L- W- Sp-
25 GSM
26
27
28
29
Shrinkage- 10%
Result
Combination
After Wash (After heat Set)
Shrinkage
Dia
Calculaion
ProcesLoss-12%
(Before heat Set)
Grey Dia
After Wash
Shrinkage
Dia
Grey Dia
Grey Dia
Grey Dia
Grey Dia
Grey Dia
Grey Dia
Dia
Gauge
Stitch Length
Grey Dia
Grey Dia
Grey Dia
Heat Set Check list
Buyer
Order
Fabrication
Yarn Count
Denier
Famkam Dyeing Ltd
Lithe Group
Dyeing Finishing Departmnt
29. 28 | P a g e L i t h e G r o u p
Page 28 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Procedure of Delivery (sop)-1
1. Without Test Result Please don’t Delivery Any Quantity of Fabrics.
2. Without Rib/Single Jersey/ Back neck tap, don’t delivery.
3. Any Measurable part, Like Collar & Cuff, Stripe Yarn dyed Fabrics should be check as
buyer requirement.
4. Inline Fabrics All test should be check & Shrinkage CHECK from 3-4 rolls & Ensure
Acceptable tolerance,
5. Width ± 1”, More than need to Approval from Related Person. Also inform to cutting
department.
6. Cotton Fabrics GSM ±5% & Lycra Minus 7% & Plus 3% Accepted in fabrics stage, others
then don’t delivery.
7. Shrinkage issue not consider & Spirality also out of tolanerance.
8. Before Delivery must be Re-check by Shift In-charge, Width, GSM, Shrinkage delivery
report with Batch information or booking sheet.
9. 1st Batch Shade check & crosses check for confirmation.
10.All Approved shade must be keeping before dyeing from related Merchandiser
11.All shade check two person avoid the wrong decision. (Keep sign)
12.1st Batch check with Booking All information, like width, GSM, Accessories & Shade
Reference.
13.Every day at 1st All delivered batches should be showing to Responsible person & take
Sign
14.Unacceptable Issue don’t delivery & Discuss with Relative Merchandiser.
15.If any problematic fabrics need to delivery must be write down in top of the inspection
report.
We have committed good quality fabrics delivery which is customer Requirement
30. 29 | P a g e L i t h e G r o u p
Page 29 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Procedure of Fabrics Delivery-2
1. At 1st Check Booking, confirm Shade, Width & GSM also accessories instruction
2. Width acceptable ±1” & GSM ±5% from Requirement.
3. Shrinkage Length -5% Width -7% ,Spirality 5% , Slanted 5%, Bowing 5% (As per Customer)
4. Process loss- Excess loss don’t delivered, Inform to Planning department
5. Measurable part, Stripe, Collar & Cuff Check properly & confirm from Booking
6. 1st Batch Everything check with Booking & must be sign in document
7. Without test result fabrics don’t delivered, if needed inform to Garment & Related
Merchandiser then can delivery
8. Without Accessories (Rib, piping Caller & Cuff) don’t delivery, If needed inform to
Garment & Related Merchandiser then can delivery
9. Inline fabrics Shrinkage Check minimum 5 Rolls & Required test should be Acceptable
range.
10.All Approval Shade Take Related Merchandiser, 1st Batch cross check with Related
Person
11.Every day at morning Night Shift finished batches report showing to Responsible person
& Take sign
12.No have any urgency in Quality area, Fulfill the Quality requirement then delivery
13.Any quality issue 1st confirm from Quality department then discuss with Related
Department & also inform Related Merchandiser
14.Every day Not Ok List review & Give to Related Department & Merchandiser also take
receiving sign
15. Any not ok issue, if not take corrective action on time then give to reminder
16.Any not ok issue, if needed to discuss with Related Merchandiser, Production person
must be discuss as technical view. If possible to take approval must be take sign
17.If Problematic fabrics needed to delivery must be inform to-
a. Related Merchandiser
b. Cutting Manager
c. Garments Quality Manager
d. Write down in the inspection report
e. Take sign from related department
f. Best way to send mail to responsible person
We are Committed, We will Fulfill the Customer Quality Requirement
31. 30 | P a g e L i t h e G r o u p
Page 30 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Fabrics Delivery Approval Authority:
1. Check Buyer Requirement, Width, GSM, Shade match, Shrinkage, Accessories ( Rib,
Collar & Cuff, Piping, Back neck tap with Measurement)- Confirm from Online In-charge
& Executive (Shade)
2. Test Result (Shrinkage, Twist, Rubbing, Pilling & Wash Fastness)- confirm from
Physical Lab Manager
3. Fulfill the Buyer Requirement then possible to Delivered
i. GSM- 4-6% Low from Required, plus side max 2% average below from
requirement
ii. Shrinkage L-4% W-7% Spirality 5%
iii. Width ±1 inch
iv. Test as Buyer Requirement
v. Angle 5% from width wise
vi. Bowing 5% from width wise
4. Any problematic fabrics Approved by below authorization person –
i. GSM, Width & Shrinkage (Cotton) - Knitting GM & Manager, Finishing AGM &
Manager with Sign.
ii. GSM, Width & Shrinkage (Lycra)- Finishing AGM & Manager with Sign
iii. Shade, Uneven, Hairiness- AGM(Dyeing) with sign
iv. Test (Color Fastness, Pilling, Rubbing)- AGM(Dyeing), also Physical Lab
Manager with sign
5. Over all if take Responsibility Related Merchandiser then we can delivered any kind of
problems fabrics but need to take sign.
6. Any person if given the approval then we send mail to related person in the department
7. Without proper inspection not a single kg fabrics deliverey.
36. 35 | P a g e L i t h e G r o u p
Page 35 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
(Stenter Machine)
Objective of Stenter:
A machine or apparatus for stretching or stentering fabrics. The purpose of
the stenter machine is to bringing the length and width to pre determine
dimensions and also for heat setting and it is used for applying finishing
chemicals and also shade variation is adjusted. The main function of the
stenter is to stretch the fabric widthwise and to recover the uniform width.
wK KvR K‡i ÷¨v›Uvi †gwk‡bi mvnv‡h¨:
2. Heat setting is done by the stenter for lycra fabric, synthetic and
blended fabric.
3. Width of the fabric is controlled by the stenter.
4. Finishing chemical apply on fabric by the stenter.
5. Loop of the knit fabric is controlled.
6. Moisture of the fabric is controlled by the stenter.
7. Spirility controlled by the stenter.
8. GSM of the fabric is controlled by stenter.
9. Fabric is dried by the stentering processs
10. Shrinkage property of the fabric is controlled.
11. Curing treatment for resin, water repellent fabric is done by the
stenter.
38. 37 | P a g e L i t h e G r o u p
Page 37 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
(Compactor Machine)
The compacting machine is a knitted fabric shrinkage control machine,
which can compact the fabric in length wise direction, to provide over feed
to the fabric while processing in presence of steam and able to control the
shrinkage. In other words, this is a process of compacting the fabric in length
ways direction.
Function of Compactor Machine:
Compactor is important machine in knit fabric finishing process. There are a lot of
technical work which are done by compactor machine. The works are done by
compactor machine are pointed out below:
1. GSM control of the knitted fabric. For high GSM, overfeed is increased and fabric width
is decreased. For low GSM, overfeed is decreased and fabric width is increased.
2. Control shrinkage
3. Twisting control
4. Increase smoothness of fabric
Types of Compactor Machine:
Compactor machines are two types. They are-
1. Tubular compactor
2. Open compactor
40. 39 | P a g e L i t h e G r o u p
Page 39 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Squeezer Machine: WvBs Kivi ci Kvco‡K Wvqvi mvBR wVK Kiv Ges AwZwi³ cvwb AcmviY
Kiv nq I wms‡µBR †Kv›Uj Kiv nq, †hB wgwk‡bi mvnv‡q¨ Zvnvi bvg ¯‹zBRvi ev wW-IqvUvwis †gwkb e‡j|
¯‹zBRvi ev wW-IqvUvwis †gwkb:
1. WvBs Gi c‡i Kvc‡oi AwZwi³ cvwb Acmvi‡bi R‡b¨, Water Remove
2. Kvc‡oi Wvqvi mvBR wVK Kiv Dia control
3. wRGmGg wVK ivLv GSM control
4. ms‡KvPb K‡›Uvj Kiv Shrinkage Control
5. mdUbvi e¨envi Kiv Softener use
6. UzBó K‡›Uvj Kiv Twist Control
7. K¨vwg‡Kj wdwbwms Kiv Chemical use
44. 43 | P a g e L i t h e G r o u p
Page 43 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Calender Machine: Calendering, process of smoothing and
compressing a material (notably paper) during production by passing a
single continuous sheet through a number of pairs of heated rolls. The rolls in
combination are called calenders. Calender rolls are constructed of steel
with a hardened surface, or steel covered with fibre; in paper production,
they typically exert a pressure of 500 pounds per linear inch (89 kilograms per
centimetre). Coated papers are calendered to provide a smooth, glossy
finish.
47. 46 | P a g e L i t h e G r o u p
Page 46 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Batch Card
Machine
Parameter
Manpower
Check
Standard Operating Procedure
(Tube Tex)
1. Check Requirement
2. DIA, GSM, Shrinkage
3. Follow any Special Instruction
1. Need Clean or not/ Blanket
2. Air & Steam Pressure Sufficient or not
3. Temperature
1. Shrinkage Compaction percentage
2. Overfeed, Shoe Pressure & Speed
3. Temperature Fixed 110C
1) Back side-1, Person
2) Operating 1 person
3) Front side-1 person
1. Width, GSM, Over Compaction Mark
2. Shade give to Quality for confirm
3. Hand feel, Quality issue confirm from Quality
Note: If suddenly machine stop, please remove the fabrics which is inside of
Machine avoid the shade variation.
‡Kvb Kvi‡b †gwkb eÜ n‡q †M‡j, †gwk‡bi wfZ‡i _vKv Kvco †K‡U †d‡j w`‡Z n‡e, KviY †gwk‡b AvUKv
cov Kvco Ab¨ †mW aviY K‡i‡Q|
54. 53 | P a g e L i t h e G r o u p
Page 53 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Air Turning Machine: air turning machine is mainly used for overturning
of the tubular fabrics.It is simple in structure, easy to operate, high
efficient.This machine have the simple figuration, easy to operate and high
eifficient.
Technical parameters
1. Infeeding speed: 300M/MIN
2. Exit speed 330M/MIN
3. Diameter of the air cylinder 219MM
4. Dimension 5800mmX1100mmX1400mm
5. Totaolly weight 0.5ton
6. Power 9Kw
55. 54 | P a g e L i t h e G r o u p
Page 54 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Parameter
Batch Card
Manpower
Check
Machine
Standard Operating Procedure
(Air Turning)
1. Check Requirement
2. Confirm Dia Mark
3. Follow any Special Instruction
1. Need Clean or not/ Blanket
2. Air Pressure Sufficient or not
3. Steam Sufficient or not?
1. Set dia
2. Steam pressure
3. Speed set
1)Operator-1 person
2)Helper- 2 person
1. Check GSM & Dia
2. Any spots
3. Dia & Compaction%
56. 55 | P a g e L i t h e G r o u p
Page 55 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Sanforizing Machine:
Sanforizing is a textile finishing treatment, also called Sanfor ® treatment,
carried out in the piece in order to increase the dimensional stability of the
fabric when washing, or to prevent the fabrics from shrinking during washing.
Sanforizing Process-
Sanforizing is a mechanical finishing process of treating textile fabrics to
prevent the normal dimensional alternation of warp and weft. It is also called
anti-shrinkage finishing process. It is a process of treatment used for cotton
fabrics mainly and also for some other textiles made from natural and
synthetic fibers. It is a method of stretching, shrinking and fixing the woven
cloth in both length and width, before cutting and producing to reduce the
shrinkage which would otherwise occur after wash.
Function of Sanforizing-
1. Shade Control
2. Shrinkage Control
3. GSM Control
4. More Surface improved
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Page 56 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Batch Card
Parameter
Machine
Manpower
Check
Standard Operating Procedure
(Sanforizing Machine)
1. Check Requirement
2. Dia, GSM, Shrinkage
3. Follow any Special Instruction
1. Need Clean or not
2. Air Pressure Sufficient or not
3. Steam Sufficient or not?
1. Temparature
2. Blanket pressure
3. Speed set
1)Operator-1 person
2)Helper- 2 person
1) Check GSM & Dia
2) Shade Check
3) Compaction%
Note: We can change fabrics shade, So much in the Sanforizing M/c, GSM &
Shrinkage also.
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Page 59 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Finishing Trolley Management
Before Stenter we have to ready normally 3 batch (3 tons) Fabrics for Smooth
Production, If any batch not ok in Stenter stage we can take support from next
batch.
For Before Stenter,
Stenter No-5, per trolley 600 kg wet fabrics after Slitting & for 3 batch, we can
calculate per batch 1000 kg (3000/600=5 Trolley) = 5x5=25 Trolley
After Stenter be for Compactor also same for 6 m/c =6x5= 30 Trolley
Waiting For Brush 3 tons = 3x2= 6 Trolley
After Brush 2 tons = 2x2= 4 trolley
Waiting For Peach 3 tons = 3x2= 6 trolley
After peach 2 tons = 2x2= 4 trolley
Waiting for Approval (Buying office / Test) 10 tons =10x2 =20 trolley
For Sample – 6 trolly
Gross Total Required =136 Trolley
In present Available- 110 & Wheel Problem 101, Workable only = 9 pics trolley
Trolley Use Procedure (SOP)
1. Fabrics Unload from Dyeing by Dyeing (Round) trolley
2. After Slitting Which is Empty back to Dyeing
3. Stenter Empty trolley back to slitting
4. After stenter which is back from Compact
5. After Compact which trolley empty back to Stenter
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Page 61 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Shade Check Management
1. Take it 1st Approval Shade
2. Take shade Swatch from Dyeing unload batch then dry & Check with
Approval Shade
3. If confuse in unload shade than go for one roll finish & Confirm Shade &
Quality
- Shade
- Surface/ Naps, Hairiness
- Dia & GSM
- Color Fastness
- Hand feel
- Shrinkage
- Dead Cotton
- Hole
4. If quality given Approval than full batch finish Started
5. On line QC should be confirm in Stenter process, within three rolls,
6. Quality In-charge given sign in Batch card, if any decision
Quality Management
1. Quality Ensure by Shade Roll Check or Online
2. In Stenter Process up to 3-5 rolls ensure fabrics Quality
- Surface
- Naps
- Hairiness
- Dead Cotton
- Thick & Thin
- Dia & GSM
- Hole
- Hand feel
3. Should be given sign in Batch card any decision
4. Shrinkage & Test result Ok then go for Next Process
5. In compact stage
- Confirm Compaction%
- GSM & Width
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Page 62 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Quality Policy
1. Grey stage must be Ensure as quality Standard, don’t pass any
problematic fabrics without approved concen person.
2. Have to Ensure Roll Management System, (Bar code, Arrow Mark & Roll
weight)
3. Unload from dyeing immediately cut one piece & check shade, If
needed given to shade roll & confirm the Shade & Quality as per
customer concept.
4. Should be confirm Shade & Quality by online
5. Inspection sheet, must be maintained Sticker Roll Number
6. Ensure by Quality people, don’t finish any problematic fabrics.
7. If any not ok for Finishing, within 24 hours & for Dyeing 36 hours must be
Correction. Coordinate by Quality department.
8. If any rolls got not ok, within OTD date must be Correction & Ensure
delivery, fully take responsibility production people. Coordinate by
Quality department
9. Must be ensure any problamitic fabrics don’t delivery to garments,
without approval from concern person.
10. Should be ensure fabrics Ok/ not ok. If have any oK fabrics, take
decision wrong that’s fully liability by Quality department.
11. In the Floor all Packet Fabrics have taken responsibility by Quality
department
12. If any not ok fabrics, not take correction within time line, Quality
people given reminder & Everyday given to report COO Sir.
13. In NC meeting Quality Head must be present & take conformation
from department.
14. Every day at morning within 10: AM all problematic fabrics
reconfirm by Quality Head & given sign in the Batch card.
15. Any Quality report must be confirm by Quality Head.
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Page 66 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Spirality:
Definition- Spirality appears in the form of a twisted garment, after washing. The seams on
both the sides of the garment displace from their position & appear on the front & back of
the garment.
Causes-
1. Yarn twist (More twist)
2. Finer Count
3. Unbalance yarn twist factor
4. Number of feeders-though higher feeder numbers increases production,
5. Loos Knitted (Not use actual count)
6. Higher Stitch Length
7. Dyeing time longer
8. Unbalance knitting m/c speed
9. Variation of knitting tension
10.Width increase from actual
11.GSM reduce from actual
12.Improper angle direction
Remedial-
1. Proper yarn twist
2. Balancing of number of knitting feeder
3. Proper yarn count use
4. Finish with Proper width & GSM
5. Select actual Stitch length
6. Standard dyeing time
7. Proper Angle direction
8. Resin treatment
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Page 67 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Spirality Control-
Below-150 GSM- (Only Single Jersey)
Left Side Right Side
Mahlo (Weft Straightener)
Stenter
Fabrics
Speed Maximum-25 m/min
Overfeed – 50% (Maximum)
Note: Lycra, Rib, Interlock, Pique, Fleece no have any Spirality issue.
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Page 71 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Softener Recipe –
1. White Fabrics S/J- Upto-160 GSM
- Forsoft NID - 20 g/L Cost- 2.30 TK
- Hydrophilic 2253D - 10 g/L Cost- 1.16 TK
- Acid - 0.2 g/L Cost- 0.10 TK
Total Cost- 3.56 TK/KG
2. White Fabrics S/J- More then-160 GSM
- Forsoft NID - 30 g/L Cost-3.48 TK
- Hydrophilic 2253D - 10 g/L Cost- 1.16 TK
- Acid - 0.2 g/L Cost-0.10 TK
Total Cost- 4.74 TK/KG
3. Color Fabrics S/J- Upto-160 GSM
- Softening Agent S400 - 20 g/L – Cost-2.08TK
- Hydrophilic 2253D - 10 g/L- Cost-1.16 TK
- Acid - 0.2 g/L –Cost- 0.10 TK
Total Cost- 3.34 TK/KG
4. Color Fabrics S/J- more then-160 GSM
- Softening Agent S400 - 30 g/L – Cost-3.14 TK
- Hydrophilic 2253D - 10 g/L – Cost- 1.16 Tk
- Acid - 0.2 g/L- Cost- 0.10 TK
Total Cost- 4.40 TK/KG
5. Champion/ New Yorker/ Next
(Good hand feel with Straight Recovery)
- Hydromine HSC -20 g/L - Cost- 3.60 TK
- Softening Agent S400 - 20 g/L – Cost-2.10 TK
- Power Soft 180 - 10 g/L – Cost- 1.85 Tk
- Acid - 0.2 g/L- Cost- 0.10 TK
Total Cost- 7.65 TK/KG
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Page 72 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
6. Color Fleece CVC- 220-280 GSM
- Softening Agent S400 - 20 g/L – Cost-4.17 TK
- Power Soft 180 - 10 g/L- Cost-1.85 TK
- Acid - 0.2 g/L –Cost- 0.10 TK
Total Cost- 6.12 TK/KG
Note: Calculation pick up% Wet-35% & Dry-70 %
If we have 800 kg fabrics, want to finish with chemical, Softener 20 gpl, Wet Fabrics
Pick up=35%, Dry Fabrics Pick up-85%
We have Softener Solution 80%, how many litter we can take from here for 20 gpl.
Solution-
We have Solution tank- 1500 Litter, there 120 kg softener soluble.
Wet Fabrics we can calculate 35% pick up, So for 800 kg fabrics need water 800x35%=
2800 litter water
As per 20 gpl, we need softener 5600 gram/5.6 KG
If 80 grams softener solution with =1,000 gram water
So, 5600 grams softener solution with =1000x5600 gram water
80
= 70,000 gram
= 70,000/1,000= 70 litter
So, From 80 gpl solution we can take 70 litter, As per 20 gpl for 280 litter water, So we take
280-70=210 litter fresh water & 70 litter softener solution.
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Page 78 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Date: 02-01-2019
Name of Test Process Time
Tumble Dry 4 Hours
Line Dry 6 Hours
Tumble Dry 4 Hours
Line Dry 6 Hours
GSM Cutting 5 Minute
C/F to Rubbing--Dry Check 5 Minute
C/F to Rubbing--Wet Check 5 Minute
C/F to Wash --Color Staining
C/F to Wash --Color Change
C/F to Wash --Cross Staining
C/F to Water-- Color Staining
C/F to Water-- Color Change
C/F to Water-- Cross Staining
C/F to Perspiration(ACID)--Color Staining
C/F to Perspiration(ACID)--Color Change
C/F to Perspiration(ACID)--Cross Staining
C/F to Perspiration(ALKALI)--Color Staining
C/F to Perspiration(ALKALI)--Color Change
C/F to Perspiration(ALKALI)--Cross Staining
C/c to Saliva-- Color Staining
C/c to Saliva-- Color Change
C/c to Saliva-- Cross Staining
C/F to Phenolic Yellowing 17 Hours
C/F to Light 48/72 Hours
14400 4 Hours
7000 2 Hours
Bursting Check 5 Minute
Fabric pH Check 2.5 Hours
1 Time wash 2 Hours
5 Time Wash 8 Hours
Dye transfer in storage--Color staining
Dye transfer in storage--Color Change
Dye transfer in storage--Cross staining
1 Hours
5 Hours
Test Process Approximately time
Sonargaon, Narayangonj
Chaity Composite ltd.
Dimentional Stability to wash (Shrinkage)
Twisting(Spirality)
Pilling
Appearance after wash
48 Hours
5 Hours
5 Hours
5 Hours
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Page 79 of 108 Md Mizanur Rahman AGM (Fabrics Finishing)
Fabrication Wise SOP
Fabrics Type : Lycra S/J Combination : 34/1 Isrque 20D Lycra
Customer : New Yorker Knitting : 36x24x3.20
Required GSM : 180 Width : 68”
Color : Black Job : 2332
Grey GSM : Grey GSM :
Stenter- 03 Bruckner (Heat Set)
Temperature : 195
Padder Pressure : 2 Bar Speed : 23 (9 Chamber)
Width Set : 76” Extension : 10%
Overfeed : 35% Under Feed: 2%
Target GSM : 175 Dwell Time : 70
Softener : Ant-crease 1 g/l
Dyeing Program 85% loading
Scouring process :
Dyeing Time : Enzyme % :
Stenter- 03 After Brush
Temperature : 150
Padder Pressure : 2 Bar Speed : 30 (10 Chamber)
Width Set : 70” Extension : 2”
Overfeed : 40% Under Feed: 2%
Target GSM : 170 Dwell Time : 60
Softener : Cationic S400-20 g/l, Power Soft-10 g/l, Elastomeric-20 g/l
Compaction- 05
Temperature : 110
Blanket Pressure : 4 Bar Pinning Set: 20/20 T.GSM : 175
Width Set : 69” overfeed : 50% Speed : 25
Shrinkage: L-5% W-6% Sp 3% GSM 175-180