Industrial Attachment Report on DBL Group.pdf

DBL
GROUP
Jinnat Complex (Knitting Division)
Industrial Attachment
Report On
2023
Md. Ahsanul
Mobin
Prepared By
Roll: 1721048
Dept. of Textile Engineering
Khulna University of
Engineering & Technology
(KUET)
Dutimoyi
Jahangir
Submitted To
Lecturer
Khulna University of
Engineering & Technology
(KUET)

We thank you for your continued
support in our efforts to contribute to
the 1-month internship.
Contact
Md. Sirajul Islam
B. Sc in Textile Engineering (BUTEX)
Deputy Manager, Production
Knitting Division
Cell: +8801755607657, +8801914841006
Mail: sirajulknitting@dbl-group.com
ACKNOWLEDGEMENT
I am very thankful for the opportunity to complete my 1-month industrial
attachment with DBL Group. This experience has been incredibly valuable to
me and has provided me with a unique insight into the knitting industry.
During my time at DBL Group, I have had the privilege of working alongside
some of the most talented and dedicated professionals in the field. The skills
and knowledge I have gained will undoubtedly be useful in my future career.
I am particularly grateful to Md. Sirajul Islam for your guidance and support
throughout my attachment. Your willingness to share your knowledge and
expertise has helped me to develop my skills and gain a deeper understanding
of the industry.
Once again, thank you for providing me with this valuable opportunity. I am
grateful for your support and look forward to applying the skills and knowledge
that I have gained in my future endeavors.

The internship report on DBL Group is prepared by Md. Ahsanul Mobin and
Nuhas Immanual. This report is submitted in partial fulfillment of the
requirements for the degree of BACHELOR OF SCIENCE IN TEXTILE
ENGINEERING.
The whole report is prepared under my supervision and guidelines. During the
internship, the student was found to be sincere, punctual, and hard-working. I
wish him every success in life.
Md. Sirajul Islam
Industrial Supervisor
Deputy Manager, Production
Knitting Division
DBL Group
LETTER OF
ENDORSEMENT
To Whom It May Concern

This internship report has been submitted to the office of the Dept. of Textile
Engineering, KUET in partial fulfillment of the requirements for the BACHELOR
OF SCIENCE IN TEXTILE ENGINEERING by -
Md. Ahsanul Mobin of bearing ID: 1721048 and,
Nuhas Immanual of bearing ID: 1721060.
The report has been accepted and may be presented to the Internship
Committee for evaluation.
To Whom It May Concern
Dutimoyi Jahangir
Academic Supervisor
Lecturer
Khulna University of Engineering & Technology (KUET)
LETTER OF
ENDORSEMENT

DECLARATION
I the undersigned declare that this internship report is based on my own work
carried out in DBL Group Ltd. during the period of 4th February 2023 to 28th
February 2023.
I also confirm that the report is only prepared for my academic requirement,
not for any other purpose. It might not be used in the interest of the opposite
party of the corporation.
________________________
Md. Ahsanul Mobin
Roll: 1721048
________________________
Nuhas Immanual
Roll: 1721060

Introduction
01
Layout
Planning
03
Raw
Materials
Maintenance
05
09
Quality
Assurance
System
07
Manpower
Management
02
Essential
Files &
Toolbox
04
Production
Planning
Conclusion
Research &
Development
06
10
06
08
TABLE OF
CONTENTS

TABLE OF
CONTENTS
Acknowledgment
Letter of Endorsement (Academic Supervisor)
Letter of Endorsement (Industrial Supervisor)
Letter of Approval
Declaration
Table of Contents
Executive Summary
Company Profile
Overview of the Organization
Vision, Mission & Values
Board of Directors
Share Holders & Equity Distributors
DBL Organogram
Sister Concerns of DBL Group
Production Capacity of DBL Group
Process Flowchart of DBL Group
Production Flowchart of Knitting Section
Project Description
Location
Organogram of JAL (Knitting)
Mission. Vission & Objectives
Layout Plan of Factory Premises
Management System
Staff of the Knitting Section (Circular & Flat)
Job Description & Responsibilities
List of Top Buyers
______________________________________________________________________
CHAPTER 1: INTRODUCTION
______________________________________________________________________
CHAPTER 2: KNITTING SECTION & MANPOWER MANAGEMENT

TABLE OF
CONTENTS
Floor Layout
Circular Knitting Machine
Machine Specification
Different Parts of the Circular Knitting Machine
Derivatives of the Knitted Structures
Production Flow Chart
Flat Bed Knitting Machine
Machine Specification
Different Parts of the Flat Knitting Machine
Knit Shelf Overview
Knit Card
Order Card
Swatch
Other Toolbox
OTIF Rack
Temporary Keeping Box
Technical Servicing Toolbox
Operations Checker Board
Reckoning Machine
All-in-One PC
Instructions for Knitting Operators
Different Types of Yarn
Pricing
Sourcing
Annual Requirements
CHAPTER 3: LAYOUT PLANNING & MACHINE DESCRIPTION
______________________________________________________________________
CHAPTER 4: ESSENTIAL FILES & TOOLBOX
______________________________________________________________________
CHAPTER 5: RAW MATERIALS

TABLE OF
CONTENTS
Production Parameres
Production Process
Process Flow Chart of Knitting
Required Yarn Count for GSM Setting
Relation of GSM with Other Parameters
Single Jersey
Interlock
Rib
GSM Control
Production Calculation
Methods of Increasing Production
QA & QC
Quality Process Flow Chart
SOP of Quality Inspector
Online Inspection (QA)
FPS Analysis
Offline Inspection (QC)
Yarn Test Procedures
Fabric Manual Inspection Machinery
Fabric Defects
Inspection PC
Quality Report
4-Point Inspection System
Fabric Grading
SOP for Fabric Rejection
Heat Sealing Tooth Marks
Weight Scale Machine
Red Tag Zone
CHAPTER 6: PRODUCTION PLANNING
_____________________________________________________________________
CHAPTER 7: QUALITY ASSURANCE SYSTEM

TABLE OF
CONTENTS
R&D Roadmap
Flowchart of R&D
Design Studio
Development Hanger Room
DBL Group Fabric Capability
Fabric Produced in JAL
Audit Checklist
Function of Maintenance
Maintenance Procedures
Maintenance Sequence for Circular Knitting Machine
_____________________________________________________________________
CHAPTER 8: RESEARCH & DEVELOPMENT
_____________________________________________________________________
CHAPTER 8: MAINTENANCE
_____________________________________________________________________
CHAPTER 8: CONCLUSION

EXECUTIVE
SUMMARY
Production Management
Quality Assurance Division (QAD)
Research & Development (R&D)
Supply Chain Management (SCM)
Maintenance/Utility
This report is prepared on the basis of my four weeks of practical experience in
different departments of DBL Group. This internship helped me to have a
practical idea about different sections of DBL Group.
DBL Group is a large diversified conglomerate based in Bangladesh. The
company operates in a range of industries, including textiles and apparel,
pharmaceuticals, and ceramics. DBL Group is committed to sustainability and
has implemented a number of initiatives to reduce its environmental footprint
and promote social responsibility. The company's mission is to create value for
its stakeholders by delivering high-quality products and services while
operating in an ethical and socially responsible manner.
DBL Group has a smart quality team to provide quality products to their
customers. This report has been presented based on my observation and
experience gathered from the company. The organization has many
divisions and departments but this internship focuses on -
In this internship, I have gathered detailed knowledge about those five specific
departments and I have enriched my evaluation ability in a bigger picture
through SWOT analysis of every section. The report also consists of
recommendations and a conclusion according to my point of view, which I
think would improve the organization in the following aspects.

The businesses include apparel, textiles, textile printing, washing,
DBL Group
also known as Dulal Brothers Group, Founded in 1991, which is a family-
owned business. Its first company was named Dulal Brothers; today, the
organization is a diversified conglomerate in Bangladesh.
INTRODUCTION
DBL Group is a large diversified conglomerate based in Bangladesh. The
company operates in a range of industries, including textiles and apparel,
pharmaceuticals, and ceramics. DBL Group is committed to sustainability
and has implemented a number of initiatives to reduce its environmental
footprint and promote social responsibility. The company's mission is to
create value for its stakeholders by delivering high-quality products and
services while operating in an ethical and socially responsible manner.
The company's knitting section is a key component of its operations,
producing high-quality fabrics for use in a range of products, including t-
shirts, polo shirts, and other apparel items.
The knitting section of DBL Group is equipped with state-of-the-art
machinery, enabling the company to produce a wide range of fabrics in a
variety of colors and designs. The section employs a skilled workforce of
over 2,000 people, who work tirelessly to ensure that each fabric
produced meets the company's exacting standards.
Overall, the knitting section of DBL Group plays a vital role in the
company's success, producing high-quality fabrics that are used in a wide
range of products around the world. With a focus on quality,
sustainability, and innovation, DBL Group is well-positioned to continue
to lead the textile and apparel industry for years to come.

Company's
Vision
Company's
Mission
Company's
Values
We envision to sustain and grow as a diversified global conglomerate.
We strive to attain our vision by practicing corporate governance,
empowering and inspiring our associates, being transparent in our work
process, continuously developing expertise, meeting & exceeding
customer needs, demands & expectations, maintaining quality &
consistency of our products & services, engaging with community, caring
for environment and maintaining networks with our global partners.
Integrity
Care Excellence
Passion Adaptability
OVERVIEW OF THE
ORGANIZATION

Board of
Directors
Abdul Wahed
Chairman
M. A. Rahim
Vice Chairman
M. A. Jabbar
Managing Director
M. A. Quader
Deputy Managing Director
& Group CEO
Share Holders &
Equity Distributors
Abdul
Wahed
25%
each
M. A.
Jabbar
M. A.
Rahim
M. A.
Quader

Corporate
Office
Director
Finance
GM
A &
Finance
Adl HR
GM
Knitting
GM
Security
GM
Security
GM
Production
GM
Production
GM
Utility
DGM
Production
GM
Production
Project
Manager
Manager
Planning
GM
Maintenance
Sr. Manager
Admin
Manager
HR
Marketing &
Sourcing
Factory
Manager
AGM -
Production
Managing
Managing Manager
Marketing
GM
Admin & HR
Chief
Engr.
AGM Store Manager
Marketing
GM
Security
GM
Security
GM
Security
GM -
Security
GM
Security
DGM
HR
AGM
Complaint
Manager
IT & MIS
GM
Marketing
GM
Corporate
Sr.
Manager
HR
Sr. Manager
Procurement
GM
Cost &
Budget
Secretary
Board
GM
Admin
AGM
Commercial
Manager
Marketing
Managing
Director
Chairman
Managing
Director
Chairman
DB Tex
Ltd &
Color City
Ltd
Thanbee
Director
Finance
Director
Technical
Director
Finance
Managing
Director
Managing
Director
Garments
Division
Textile
Division
Spinning
(MSML)
Packaging
(PPPL)
DBL
Ceramics
Ltd
DBL
Telecom
Printing
Division
DBL Group
DBL Organogram

Sister Concerns of
DBL Group
DBL Ceramics Ltd.
DBL Telecom Ltd.
DBL Communications Pvt. Ltd.
DBTEL
DBL Sports Ltd.
DBL Dredging Ltd.
Neural Semiconductor
Color City Ltd.
(Eco-threads & Yarn)
Ceramics
ICT & Telecommunication
Sports
Dredging
VLSI Design
Sewing Thread
Dulal Brothers Ltd.
Jinnat Apparels Ltd.
Flamingo Fashions Ltd.
Jinnat Fashions Ltd.
Jinnat Knitwears Ltd.
Mawna Fashions Ltd
Matin Spinning Mills Ltd.
Mymun Textiles Ltd.
Hamza Textiles Ltd.
Color City Ltd.
DB Tex Ltd.
Thanbee Print World Ltd.
Parkway Packaging & Printing Ltd.
DBL Distribution Ltd.
Apparels & Knitting
Cotton Spinning
Fabric Dyeing & Finishing
Fabric Printing
Garments Printing
Packaging
Distribution

Production Capacity of DBL Group
Spinning 51 tons/day
Knitting 100-110 tons/day
Dyeing 130 tons/day
All Over Printing 35 tons/day
Screen Printing 20,000 pcs/day
Apparels 13 Mn Pcs/month
Washing
Normal wash - 68,440
Acid wash - 20,000 pcs/day
Packaging 40,000 pcs/day; 3 ply & 5 ply
Ceramic Tiles 50,000 square meters/day
PRODUCTION
CAPACITY

Cotton Import
Spinning
Knitting
Dyeing & Finishing
All Over Printing
Cutting
Screen Printing
Finishing
Sewing
Packaging
Washing
Shipping
PROCESS
FLOWCHART

Order Receive from
Market
Online Yarn Rquisition
to Store
Yarn Received in
Knitting Floor
Knit in Production
Fabric Inspection
Delivery to
Dyeing Store
PRODUCTION
FLOWCHART
(KNITTING SECTION)

KNITTING
SECTION &
MANPOWER
MANAGEMENT
Project Description
Jinnat Apparels Ltd., where we completed our Industrial Attachment is a
sister concern of DBL (Dulal Brothers Ltd.) GROUP. DBL Group is a rapidly
developing group of Industries in the Textile sector of Bangladesh. It has a
bunch of organizations under its ownership.
Knitting Department
Garments Departments
Merchandising Department
TYPE: Knitting & Garments
YEAR OF ESTABLISHMENT: 2000
PROJECT COST: 400,00,00,000 TK
ADDRESS: Sardaganj, Kashimpur, Gazipur
DIFFERENT DEPARTMENT:
.ANNUAL PRODUCTION CAPACITY: 2600 tons/year
SHIFT CHANGES: Shift of Twelve hours. Shift changes after a week on
Saturday.

Jinnat Apparels Ltd. is situated at Sardaganj, Kashimpur, Gazipur. It is
located on the East Side of Nabinagar-Kaliakair road.
Location
Layout Plan of Factory Premises
Staff Residence
Yarn Storage
Fabric
Storage
Extended
Knitting
Floor
Knitting, V-Bed &
Embroidery
Main Building
(Knitting &
Garments Section)
Garden
Garden
Pond
Canteen
Car
Parking
E W
S
N

Manager
Asst. Manager
Sr. Officer
Officer
Asst. Officer
Supervisor
R&D (Reporter)
Loader
DGM (R&D)
Sr. Manager Sr. Manager Tech. Sr. Manager
DGM (Knit) DGM (Quality) DGM (Store)
Sr. Manager
Manager
(Production)
Deputy
Asst.
Sr. Officer
Officer
Asst. Officer
Supervisor
Operator
Helper
Loader
Manager
Sr. Executive
Executive
Jr. Executive
Supervisor
Sr. Tech
Tech. Officer
Asst. Tech
Technician
Supervisor
Deputy
Asst.
Sr. Officer
Officer
Asst. Officer
Supervisor
Quality
Helper
Asst. Manager
Sr. Officer
Officer
Asst. Officer
CPO
Loader
CPO
Organogram of JAL (Knitting)

Implementation of transparency & accountability throughout the
processes.
Establishing knitting production culture through quality at source,
creativity & commitment.
Assuring time management to improve process, productivity & waste
reduction.
Identify & nurture talent through coaching, mentoring & developing
programs
Slogan, Mission, Vision &
Objectives
Customer Satisfaction by OTIF with Zero Defect
Work for Transformation 4.0
Knitting Slogan
Mission
Vision
Objectives
Enhance creativity & develop skill
Effective engagement with positive attitude
Maximize resources utilization

Staff of the Knitting Section
CIRCULAR KNITTING
Designation No. of Employees
CPO 1
DGM 1
Sr. Manager 1
Manager 2
Deputy Manager 2
Production Officer 4
Asst. Production Officer 12
Supervisor 18
Operator 72
Helper 16
Sr. Fitter 8
Asst. Fitter 10
Quality Supervisor 3
Quality Inspector 10
Quality Helper 13
Store Officer 1
Store Keeper 4
Asst. Storekeeper 5
Work Study Officer 4
Time Keeper 11
Driver 9
Office Boy 8
Car Helper 7
Cleaner 17
FLAT KNITTING
In Charge 1
Operator 5
Helper 3

Job Description & Responsibilities
SENIOR PRODUCTION OFFICER
PRODUCTION OFFICER
Remarks
Follow-up knitting production
Regular observation of the knitting floor
Prepare knitting order status regularly
Maintain the quality of the product
In a knitting factory, a senior production officer plays a great role in
production and manpower management. Here we enlist the duties of a
senior production officer:
Follow up overall knitting production
Decide every m/c utilization during production
Recruit new labor
To inform the authority on the overall knitting prod. and make it
financially profitable
Regular m/c maintenance
Maintain sub-contract orders
Help the knitting manager & also guide the junior officers of the
section, etc.
The production officer is the right hand of the senior production officer
and he is directly related to production manpower and informs the senior
production officer from time to time. Here are his listed duties:
From getting an order from the upper level all responsibilities are on the
production officers. They work with a team of operators, helpers,
technical fitters, etc. to finish the production in due time.
.Production runs with the help of Technical fitters. For any kind of
mechanical fault of any machine, they fix and work under the technical
in-charge.

LAYOUT
PLANNING &
MACHINE
DESCRIPTION
Floor Layout of JAL 1
During my internship in the knitting section, I had the opportunity to be a
part of the team responsible for designing the floor layout. This involved
analyzing the space available, the production flow, and the various
machines and equipment requirements. Based on this analysis, I
designed the floor layouts for Jinnat Apparel Limited while ensuring the
production process was streamlined and efficient.
According to my observation, the result was a well-organized and
efficient workspace that contributed to the success of the manufacturing
unit.

During my internship, I observed various aspects of the circular knitting
machine in action, such as the yarn feed mechanism, the needle bed, and
the control systems. I also learned about the various features and
accessories that can be added to circular knitting machines to enhance
their functionality and efficiency, such as automatic yarn feeders, pattern
controllers, and auto-stop motion systems.
Overall, my experience observing a circular knitting machine during my
internship provided me with valuable insights into the workings of this
important textile manufacturing machine. I gained a better
understanding of its capabilities, applications, and potential for
innovation in the textile industry.
An Overview of Circular Knitting Machine

Specification of Circular Knitting Machine
Understanding the specifications of circular knitting machines is essential
for textile engineers and other professionals working in the industry. By
selecting the right machine for a particular application and configuring it
correctly, it is possible to produce high-quality fabrics that meet the
needs of customers and consumers alike.
SINGLE JERSEY
Brand
M/C
Type
M/C Dia M/C GG Feeders
No. of
M/C
Avg
Capacity/
Machine
(Kg)
Mayer & Cie S/Jersey 24 24 78 1 200
Mayer & Cie S/Jersey 26 24 84 3 230
Mayer & Cie
S/Jersey 28 24
90
8 260
Fukuhara 84
Terrot 90
Mayer & Cie
S/Jersey 30 24
96
35 280
Fukuhara 98
Mayer & Cie S/Jersey 30 24 96
Terrot S/Jersey 30 24 96
Lisky Fleece 30 20 96 4 260
Fukuhara
S/Jersey 32 24
102
42 320
Mayer & Cie 102
Terrot 102
Lisky Fleece 32 20 108 16 290
Fukuhara S/Jersey 34 24 108
50 360
Terrot S/Jersey 34 24 54
Lisky Fleece 34 20 108 23 300

SINGLE JERSEY
Brand M/C Type
M/C
Dia
M/C
GG
Feeders
No. of
M/C
Avg
Capacity/
Machine
(Kg)
Fukuhara
S/Jersey 36 24
116
49 380
Terrot 114
Lisky Fleece 36 24 114
Fukuhara
S/Jersey 38 24
120
25 440
Mayer & Cie 123
Terrot 122
Fukuhara
S/Jersey 40 24
128
14 450
Terrot 128
Masa 120
Masa
S/Jersey 42 24
126
4 460
Terrot 134
Total No. of Machine & Capacity 274 94550
ENGINEERING STRIPE
Brand M/C Type
M/C
Dia
M/C
GG
Feeders
No. of
M/C
Avg
Capacity/
Machine
(Kg)
Terrot
Engg. Stripe (S/J)
30 24 48
6 100
Mayer & Cie 30 24 48
Fukuhara Engg. Stripe (S/J) 34 24 84
4
220
Terrot Engg. Stripe (S/J) 34 24 48 120
Mayer & Cie Engg. Stripe (Rib) 34 18 54 2 100
Fukuhara Engg. Stripe (Rib) 34 18 54 2 100

RIB
Brand M/C Type
M/C
Dia
M/C
GG
Feeders
No. of
M/C
Avg
Capacity/
Machine
(Kg)
Fukuhara Rib 32 18 68 2 260
Terrot
Rib
34 18
96
17
270
Rib 60 270
Lisky
Rib 34 18 68
270
Interlock 34 18 102
Spacer 34 18 68
Rib 34 18 68
270
Interlock 34 18 102
Spacer 34 18 68
Rib 34 12 34
270
Rib 34 12 68
Rib 34 12 68
Mayer & Cie Rib 34 16 70 270
Mayer & Cie Rib 36 18 74
6
280
Terrot Rib 36 18 64 280
Fukuhara Rib 36 18 74 280
Terrot Rib 38 18 68
8
280
Fukuhara Rib 38 18 78 300
Terrot Rib 40 18 72
14
300
Fukuhara
Rib 40 18 82
330
Rib 40 18 82
Rib 40 18 82
Fukuhara Rib 42 18 86 14 340
Fukuhara Rib 44 18 90 4 350

INTERLOCK
Brand M/C Type
M/C
Dia
M/C
GG
Feeders
No. of
M/C
Avg
Capacity/
Machine
(Kg)
Mayer & Cie Interlock 30 24 96 2 190
SPECIAL MACHINE
Brand M/C Type
M/C
Dia
M/C
GG
Feeders
No. of
M/C
Avg
Capacity/
Machine
(Kg)
Pailung S/J + Rib 36 18 36/72 1 50
Pailung S/J + Fleece 32 10 64/96 1 50
Pailung S/J, Terry, Denim 32 20 72/96 1 50
Pailung Rib + Interlock 34 18 84 1 50
Pailung
Rib 30 18 54
1 50
Eyelet 30 18 36
Pointal 30 18 36
Pailung
Rib 34 18 54
1 50
Eyelet 34 18 36
Pointal 34 18 36
Pailung
Polar Fleece 30 20 46X2
3 50
Terry Fleece 30 20 46X2
S/Jersey 30 20
Liskey
Share Far 30 20 60
2 50
Rib 30 20 60
Pailung
Polar Fleece 32 20 49X2
3 50
Terry Fleece 32 20 49X2
S/Jersey 32 20

JACQUARD MACHINE
Brand M/C Type
M/C
Dia
M/C
GG
Feeders
No. of
M/C
Avg
Capacity/
Machine
(Kg)
Fukuhara Jacquard (S/J) 30 24 72 2 100
Fukuhara Jacquard (D/J) 34 18 54 2 100
Terrot Jacquard Rib 34 18 54 2 100

Different Parts of Circular Knitting Machine
Auto Stop Motion
When a fault is detected, the Auto
Stop Motion Light will illuminate,
signaling to the operator that the
machine has stopped
automatically. The operator can
then identify the cause of the fault
and take appropriate action to
rectify it, such as replacing a
broken needle, fixing a yarn
breakage, or adjusting the tension
of the yarn.
Auto Counter Monitor
The Auto Counter Monitor is
designed to track the number of
stitches or rounds produced by
the machine and to provide the
operator with an accurate count
of the fabric being produced. The
system uses sensors to detect the
movement of the machine and to
record the number of stitches or
rounds produced.

Automatic Lubrication
System
An automated lubrication system
is an essential component of a
knitting machine that helps to
ensure efficient and reliable
production by reducing downtime
and improving the lifespan of the
machine.
Lubricator/Oiler
A type of automated lubrication
system that is used in circular
knitting machines.
One of the main advantages is
that it is fully automated, meaning
that it requires minimal input
from the operator. Additionally,
the system is designed to use a
minimal amount of lubricant,
reducing waste and lowering
operating costs.

Infrared Optical Readers
These readers are designed to
detect the position of the needles
as they move through the knitting
process, allowing the machine to
accurately control the movement
of the yarn and the formation of
the knitted fabric. It works by
emitting a beam of infrared light
and then detecting the reflection
of that light off the surface of the
needles. By analyzing the pattern
of reflections, the reader is able to
determine the precise position of
each needle at any given moment.
Lint Removal System
In a knitting machine, lint is a
common byproduct of the
knitting process, which can
accumulate on various
components of the machine, such
as needles, sinkers, and cams. Lint
buildup can lead to poor machine
performance, increased
downtime, and lower-quality
knitted fabrics. To address this
issue, many knitting machines are
equipped with a lint blower
system.

VDQ Pulley
The VDQ pulley consists of a
grooved wheel and a belt that fits
into the groove of the wheel. The
belt is used to transmit power
from the driving motor to the
driven machinery. It controls the
stitch length by regulating the
speed of the needle bed, which
determines the distance between
the stitches. By adjusting the
diameter of the pulley or the
position of the belt on the pulley,
the operator can control the
speed of the needle bed and thus
the stitch length of the fabric.
Side Creel Stand
This is a type of yarn-feeding
system used in knitting machines
that allows for the simultaneous
feeding of multiple yarns into the
machine. The side creel is typically
located at the side of the machine
and consists of a series of yarn
cones or spools arranged in a
vertical position. The yarns are
threaded through guide tubes
and tensioning devices before
entering the knitting machine.

Start, Stop, and Inching
Buttons
These buttons are used to control
the operation of the machine,
allowing the user to start and stop
the machine as needed, and to
move it in small increments when
required.
In knitting machines, these
buttons are located on a control
panel or console.
Positive Feeder and Negative
Feeder
The choice between positive and
negative feeders depends on the
specific requirements of the
knitting application.
Positive feeders are generally
preferred for their reliability and
efficiency, while negative feeders
are used when the risk of fiber
damage or snarling is a concern.
Both types of feeders play an
important role in the knitting
process and help to ensure that
yarn is delivered to the machine in
a consistent and reliable manner.

Fabric Take-Up System
The fabric take-up system is
typically controlled by a separate
motor or drive system that is
synchronized with the rest of the
machine. This allows the system
to adjust its speed and tension in
response to changes in the
knitting process, ensuring that the
fabric is wound up at the proper
rate and with the correct tension.
Finger Box
This is a key component of an auto
stripe knitting machine that is
responsible for creating complex
patterns and designs in knitted
fabrics. It is typically located at the
front of the machine and consists
of a series of movable fingers or
sliders that can be adjusted to
control the flow of yarn through
the machine.
The finger box works by allowing
the operator to program a specific
pattern or design into the
machine, which is then executed
automatically during the knitting
process.

Lycra Feeder
Lycra feeder is an essential
component of a circular knitting
machine for manufacturers who
specialize in the production of
stretch fabrics. By allowing elastic
yarns to be fed into the machine
in a controlled and precise
manner, the Lycra feeder enables
the production of high-quality
fabrics with excellent stretch and
recovery properties.
Yarn Guide
The yarn guide is a critical
component of a circular knitting
machine that is responsible for
guiding the yarn as it is fed into
the machine. It is typically located
at the front of the machine and
consists of a series of guides,
rollers, and other components
that work together to ensure that
the yarn is fed into the machine at
the correct tension and rate.
By guiding the yarn into the
machine at the correct tension,
rate, and angle, the yarn guide
helps to ensure that the final
product meets the desired
specifications and standards.

Needle, Sinker, and Cam
these three components work
together to form a wide range of
different stitch patterns and fabric
structures. By controlling the
movement of the needle and
sinker, the cam can create
everything from simple knit to
more complex patterns. The
precise shape and positioning of
the needle, sinker and cam can
also be adjusted to create
different fabric densities, textures,
and stretch characteristics.
Cam Box
The cam box typically consists of a
metal housing that contains a set
of interchangeable cams, each of
which has a unique shape and
controls the movement of the
needle and sinker in a specific
pattern.
Selecting different cams and
adjusting their position within the
cam box, can create a wide range
of stitch patterns and fabric
structures.

Air Blower
The air blower helps to keep the
machine clean and running
smoothly, reducing the risk of
downtime due to clogs or
malfunctions.
It is mainly used to remove dust,
lint, and other debris from the
needles, sinkers, and other parts of
the machine.
Creel Tube
It is typically mounted on a creel
frame, which can hold multiple
tubes in a vertical or horizontal
arrangement. Yarn is threaded
through the creel tubes and then
fed into the knitting machine,
where it is used to create the
knitted fabric.

Different Derivatives of Knit Structures
Derivatives of S/Jersey Fabric
Single Jersey Plain Fabric
Single Jersey Plain with Lycra
Slub Single Jersey
Mélange Single Jersey
Single Lacoste
Double Lacoste
Single Pique
Double pique
Two Thread Terry
Three Thread Terry
3 Thread Twill
4 Thread Twill
Derivatives of D/Jersey Fabric
1×1 Rib
2×2 Rib
1×1 Rib with Lycra
2×2 Rib with Lycra
Single Pique
Double Pique
Plain Interlock
Plain Interlock with Lycra
Ottoman Rib
Pointy Interlock
Mesh
Waffle

Production Flow Chart of S/Jersey
Creeling
Yarn passes through the creel
Yarn passes through the guide
Yarn passes through the knot catcher
Yarn wrapping in the storage wheel of
positive feed
Yarn passes through outlet stop motion
Yarn is feed through feeder
Yarn goes through the needle hook for
loop formation
Take down roller pulls the produced
fabric
Fabric is wound down by cloth roller

Production Flow Chart of S/Jersey with Lycra
Creeling
Yarn without spandex passes through
the creel
Yarn passes through the guide
Spandex yarn is supplied by positive
feed device
Magnetic tensioner is placed after knot
catcher to raise the tensioner in yarn
Yarn is feed through the inlet stop
motion
Yarn wrapping in the storage wheel
of positive feed
Yarn to needle hook for loop formation
cycles
Fabric is being wound down by cloth
roller
Take down roller pulls the produce fabric

Production Flow Chart of Rib/Interlock
Creeling
Yarn passes through the creel
Yarn passes through the magnetic
tensioner
Yarn passes through inlet stop motion
Yarn wrapped in storage wheel
Yarn goes through outlet stop motion
Yarn goes through the needle of both dial
and cylinder for loop formation
Take down roller pulls the produced
fabric
Fabric is wound down by cloth roller

As part of my internship, I was able to observe the setup of the flat
knitting machine, including the installation of yarn feeders, needle beds,
and control panels. I also learned about the various types of stitches that
can be produced by the machine, as well as the importance of tension
control and yarn placement in achieving the desired fabric texture and
appearance. Additionally, I observed the use of computerized flat knitting
machines, which offer greater flexibility and precision in fabric creation.
An Overview of Flat Knitting Machine

V-BED MACHINE
Brand M/C Type Carriage M/C GG No. of M/C
Avg
Capacity/
Machine
(Kg)
Remarks
Shima Seiki Flat Knit Single 45"X14 2 250 set
Full
Jacquard
Shima Seiki Flat Knit Double 60"X14 12 500 set
Semi
Jacquard
Matsuya Flat Knit Double 80"X14 2 500 set
Semi
Jacquard
Matsuya Flat Knit Single 72"X16 4 350 set
Full
Jacquard
Total No. of Machine & Capacity 20 8900 set
Specification of Flat Knitting Machine
Understanding the specifications of flat knitting machines is essential for
the successful production of collars, cuffs, and plackets with the
optimization of manufacturing processes in the textile industry. In this
report, we will explore the key specifications of the flat knitting machine,
including its technical features, operating parameters, and production
capabilities, to gain an in-depth understanding of the machine's
capabilities and performance.

Different Parts of Flat Knitting Machine
During my internship in the knitting department, I was involved in the
design of the floor layout, which required me to assess the available
space, production flow, and equipment needs. Utilizing this information, I
created a layout for the Flat Knitting Machine floor that was efficient and
streamlined the production process.
As a result of my efforts, the workspace was well-organized and
contributed significantly to the success of the manufacturing unit.
Carriage
The yarn carriage typically consists
of two main parts: the feeder and
the guide. The feeder is
responsible for providing the yarn
to the guide, which then directs it
through the needles. The guide
ensures that the yarn is correctly
positioned and tensioned,
resulting in high-quality knitted
fabric.
Carriage Rail
The carriage rail is designed to
withstand the weight and
pressure of the carriage and other
components. It is crucial that the
carriage rail is properly
maintained and lubricated to
ensure the smooth and efficient
operation of the machine.

Cone Stand Plate
The cone stand plate is designed
to accommodate multiple yarn
cones, usually up to four or six
cones, depending on the
machine's specifications. It has
multiple slots or holes to allow the
yarn to pass through and into the
yarn carrier or tensioner.
Controller
The control monitor allows the
operator to set up and save
various knitting programs and
patterns, making it easy to switch
between different knitting styles
and designs. In addition, it
provides diagnostic and
troubleshooting features that can
quickly identify and address any
issues or errors that may occur
during the knitting process.
Fabric Take Down Roller
The fabric take-down roller can be
controlled manually or through
the machine's control system,
allowing the operator to adjust its
speed and tension as needed.

Feeder
It is typically located above the
needle bed and consists of a series
of metal plates with V-shaped
grooves that guide the yarn from
the yarn carrier to the needles.
Lycra Feeder
Lycra feeder is a specialized
attachment that is used to feed
elastic yarns such as Lycra or
Spandex into the knitting process.
It typically consists of a separate
yarn carrier and a tensioning
mechanism that applies the
appropriate amount of tension to
the elastic yarn as it is being fed
into the machine.
Separation Yarn
In flat knitting machines,
separation yarn is a specialized
yarn that is used to separate the
knitted fabric from the needle bed
during the knitting process. This
yarn is typically made of a
material that is strong enough to
hold the knitted fabric in place
but can also be easily removed
without damaging the fabric.

Main Power Switch
This switch is typically located on
the front panel of the machine
and is used to turn the machine
on and off.
Needle Bed
The needle bed of a flat knitting
machine is a flat surface with
numerous needle slots that hold
the needles in place during the
knitting process.
Side Tensioner
The side tensioner of a flat knitting
machine is a device that ensures
the proper tension of the knitting
yarn during the knitting process.
It is typically located on the side of
the machine and consists of a
tension arm and a tension spring
that applies pressure to the yarn.

Signal Lamp
There are three indications of this
lamp as follows:
i. Green Lamp
The machine is in operation.
ii. Blinking Green Lamp
The machine is stopped by
operation.
iii. Blinking Yellow Lamp
The machine is stopped because
of an error, or completion of a
piece.
Yarn Storage Feeder
As the yarn is fed into the
machine, it is pulled from the
spool and passed through the
tensioning mechanism. The
tensioning mechanism can be
adjusted to ensure that the yarn is
fed into the machine at the
correct tension, which is crucial
for producing high-quality knitted
fabrics.
Yarn Tensioner
The yarn tensioner ensures that
the yarn is fed at a consistent
tension, which is crucial for
producing high-quality knitted
fabrics.

ESSENTIAL FILES &
TOOLBOX
Knit Shelf Overview
During my internship in the
knitting section, I observed a shelf
that has a significant role in the
efficient functioning of the
knitting machine. The shelf holds
a knit card specific to the knitting
machine and provided
information related to fabric
structures. This information
allowed the operator to select the
appropriate settings for the
machine to produce the desired
fabric.
Additionally, the shelf had a box
to store spare parts such as
broken needles, broken yarn, oil
tubes, and pots. The availability of
spare parts ensured that any
malfunction or breakdown could
be immediately addressed, thus
minimizing the downtime of the
machine.
Overall, this shelf served as a crucial tool in ensuring the smooth and
uninterrupted operation of the knitting machine, ultimately contributing
to the overall productivity of the manufacturing unit.

Knit Card (for Circular Knitting Machine)
The knit card also serves as a reference tool for quality control purposes,
as it helps to ensure that the produced fabric meets the required
specifications. In case of any production issues or machine breakdowns,
the knit card can be used to troubleshoot the problem and identify any
necessary adjustments that need to be made.
In addition, I also observed that the shelf had a box for storing spare parts
of broken needles, yarns, and oil tubes and pots. This helps to keep the
spare parts organized and easily accessible, ensuring that the machine
can be quickly repaired in case of any unexpected breakdowns.
A knit card is an essential tool for the
production of knit fabrics. It is a
rectangular card that contains all
the necessary information needed to
produce a specific fabric structure
on a particular knitting machine.
The knit card includes information
such as the machine gauge, needle
arrangement, cam settings, yarn
type, stitch structure, and fabric
weight.
During my internship, I observed
that the knit card is usually placed
on a shelf along with other related
information about the fabric
structure. This allows the machine
operator to quickly access the knit
card and reference it during the
production process.

JAL KNITTING
KNIT CARD (Program ID#123456789)
Order Type - In-House
1 M/C No M/C DXG
2 FINISH DIA
3 BUYER NAME
4 ORDER NO REF. NO.
5 PROG. ORDER QTY
6 YARN COUNT
7 YARN BRAND & LOT
8 STITCH LENGTH
9 GREY GSM FINISH GSM
10 FABRIC TYPE
11 A. FABRIC TYPE
12 COLOR
13 PRODN START DATE
14 PRODN TARGET
15 M/C RPM
16 USE OF FABRIC
17 PROCESS TYPE
18 PROG. REMARKS
19 PLAN REMARKS
20 DELAY/SYNC TIMING
21 TENSION
22 LYCRA %
23 DRAFT RATIO
24 YARN TENSION LYCRA TENSION
25 TAKEDOWN TENSION CAM TRACK
Knit Card (for Circular Knitting Machine)
T. GSM
T. St Len
Q. GSM
Q. St Len
SL
________
T. Qty/Shift
------------
____________
PREPARED BY
____________
TEC. INCH
____________
TEX S-V
____________
QAS - V

Knit Card (for Flat Knitting Machine)
During my internship, I observed a
knit card for a flat knitting
machine that contains all the
necessary information for
producing various flat knit fabrics
such as cuffs, collars, and packets.
The knit card serves as a blueprint
for the fabric structure and guides
the operator in setting up the
machine with the appropriate
needles, yarns, and tension.
The knit card contains important
information such as the gauge,
stitch density, yarn count, and
machine settings required for
producing a specific fabric
structure. The card also includes a
visual representation of the fabric
structure, showing the placement
of the needles and yarns.
In addition to the fabric structure information, the knit card also includes
instructions for various steps in the production process, such as casting
on, decreasing, and increasing stitches. This helps ensure consistency in
the production of the fabric.
The knit card shelf is a designated space where knit cards are kept for
easy access by the machine operator. It is also a storage area for spare
parts like broken needles, broken yarn, and oil tube and pot. By having
spare parts readily available, it minimizes downtime during production
and ensures that the knitting process runs smoothly.

Fabric Swatch
Fabric swatches are commonly used
in the textile industry for quality
control and to assess the suitability
of a fabric for a particular end-use.
Fabric swatches can vary in size but
are typically small enough to be
easily stored and transported. They
may be cut directly from a larger
piece of fabric or produced
separately as a standardized sample.
Fabric swatches can be analyzed for
various properties such as
colorfastness, durability, and texture,
and are an essential tool for
designers, manufacturers, and
suppliers in the textile industry.

The Process of Swatch Analysis
Step 1: Detect the Type of Fabric
At first, the R&D team is assigned
to find out the type of fabric
which is the first step in analyzing
a swatch.
Whether it is yarn-dyed or solid-
dyed. Solid dyed is the grey-
colored fabric and the yarn-dyed
fabric is a type where individual
yarns are colored or dyed.
Step 2: Detect the Type of Yarn
It indicates the number of plied
yarns. e.g. Single or double. Here,
the single yarn has only one ply,
and the double yarns are two-
plied yarns.

Fabric Swatch
Stitch Length
Finished Size
Grey Size
No. of Needles
CPI
WPI
GSM
Step 3: Detect Other Parameters

OTHER TOOLBOX
OTIF Rack
The purpose of the OTIF rack is to provide visibility into the delivery
performance of suppliers and to help identify any issues or delays in the
supply chain. This allows manufacturers to take corrective action and
ensure that production schedules are not disrupted due to late or
incomplete deliveries. The OTIF rack is an essential tool for maintaining a
lean and efficient supply chain in manufacturing and production
facilities.
The "On Time" aspect of OTIF measures the delivery of products within
the agreed-upon time frame, while the "In Full" aspect measures whether
the entire order was delivered without any shortages or damages.
Companies use OTIF to evaluate their supply chain performance, identify
areas for improvement, and optimize logistics operations to ensure timely
and complete deliveries. A high OTIF score indicates that the company
has a well-managed and efficient supply chain that meets customer
expectations.

Temporary Keeping Box
This box is usually located near
the knitting machines to
ensure easy access and to
prevent any delay in the
production process. The fabrics
stored in the temporary
keeping box may include those
that have defects or require
alterations, as well as those
that need to be cleaned or
undergo any other necessary
treatments.
The temporary keeping box is
also used for storing spare
parts of the knitting machines,
such as needles, sinkers, and
cams, as well as other tools and
accessories that are required
for maintenance and repair
work.
By keeping these items in a
central location, the knitting
team can easily access them
when needed, thereby
minimizing downtime and
ensuring that the machines are
always in top condition.

Temporary Servicing Toolbox
This box is usually located near
the knitting machines to
ensure easy access and to
prevent any delay in the
production process. The fabrics
stored in the temporary
keeping box may include those
that have defects or require
alterations, as well as those
that need to be cleaned or
undergo any other necessary
treatments.
The temporary keeping box is
also used for storing spare
parts of the knitting machines,
such as needles, sinkers, and
cams, as well as other tools and
accessories that are required
for maintenance and repair
work.
By keeping these items in a
central location, the knitting
team can easily access them
when needed, thereby
minimizing downtime and
ensuring that the machines are
always in top condition.

Operations Checker Board
It typically displays the target production list for each supervisor or team,
including information such as the quantity of items to be produced, the
timeline for production, and the status of each item in the production
process. This allows supervisors and team members to quickly identify
any potential issues or delays and take action to keep production on
track.
The checkerboard typically consists of a grid with columns representing
different production per shift under the supervision of a supervisor and
rows representing days of the week. The targets and actual production
numbers are displayed in each cell of the grid. This enables supervisors to
quickly identify any issues and take corrective actions to ensure that the
production targets are met on time.
Overall, the operations checkerboard is an essential tool for managing
the production process efficiently and achieving the desired output. It
provides supervisors with a clear and concise overview of the production
process and enables them to make informed decisions to optimize the
production process.

Reckoning Machine
Its primary function is to wind the
remaining yarns from several cones onto
a single cone, creating an exact package
that can be installed in a creel stand.
This process helps to maintain a smooth
production flow, as the exact package
ensures that the machine can continue
running without interruption.
By consolidating several partially used
cones into one, they can reduce the
amount of waste and save money on
materials. The machine also helps to
reduce downtime by ensuring that the
creel stand always has a steady supply of
yarn.
Overall, the reckoning machine plays a
crucial role in the knitting industry,
helping to streamline production and
reduce waste.

All In One PC
Technical
Servicing
Maintenance
Sample
Production
Air Flow
QC
Yarn Store
Floor Off
Change Over
Admin
The MIS department of the
manufacturing unit provides an
All In One PC, which is a vital tool
to manage and monitor the
functioning of the daily
production process. This system
helps to keep track of shift
changes, production details, etc.,
and can input any complaints
related to machine problems to
notify the technical team
promptly.
It serves multiple functions,
including:
It enables the production team to access critical information related to
the production process and make informed decisions to optimize
production efficiency.

Serial
No.
Instructions for the Knitting Operators
1
At the start of the new shift, all the required information must be gathered from the previous shift
operator.
2
If there was any problem in the machine or the fabric from the previous operator, the Technician, or
the production
super must be informed at the start of the shift.
3 Check the Fabric scanner, Oil, Air line Setting, and Wheel free at the start of the shift.
4 Check Yarn count, Lot, Bran, S.L. open, Tube according to the Knit Card.
5
First check, the machine handles to see if its free or not if its free run the Inch Motion for a few cycles
before running the machine.
6
If there's a problem in the machine, it must remain idle and the Technical supervisor must be
informed.
7 Check if the wheels have at least 20-25 turns of yarn wound.
8
Wheel can't be wound having the Wheel lock free, Wheel must be wound keeping the belt in high
tension.
9 The R.P.M. of the machine can't be changed without the permission of the Technical Supervisor.
10
While cutting the role the machine must be aired properly, and the roll must be cut in the middle of
the aired portion.
11
Before starting a new program or changing the old program, the Quality Control The supervisor must
be informed.
12
The yarn used for the previous program must be removed from the creel stand and also taken away
from the machine side at once.
13
Before starting the program for White, P./C.V.C., G Melange, and Yarn Dyed fabric production, the
machine must be cleaned and polyethylene must be used as a cover around the machine.
14 The machine can't be cleaned with a fabric while it's running.
15 Clean the surrounding of the machine. Yarn can't be wound around the creel or the Air Suction Net.
16
In case of any accident or emergency the Technical Super must be made aware of the situation. No
machine should be.
permitted to run in these circumstances.
17
While cutting the role of the Walmart Buyer, the polyester yarn must be wound for a few cycles and
the roll must be cut through the center.
18
Polyester Yarn and Lycra, Denier fabric lose and intact, yarns form different dates can't be mixed
together.
19 In case of Yarn Dyed fabric yarn from different batches can't be mixed.
20
Fabric must be collected through the middle of the Roller Drain, In the case of Lycra S/J the dia mark
setting must be done.
21
Gray fabric can't be used to clean or wipe the machine, dyed or rejected fabric has to be used for
cleaning.
22 The machine must not be marked with pen, marker or anything else.
23 Always wear Air Plug, Musk, ID card, Uniform while working.
24
In case of Open Dia Machine, the roll can't be cut while pushing it against the stand or the gate of the
machine.
25
After cutting a roll the new fabric end has to be wound around the roller and roller lock has to be
used.
26
Rollers can't be kept vertically on the floor tiles. Roll has to be removed by keeping the roller laying
on the floor.
27
While attaching the Barcode precaution must be taken so that hands/ fingers don't get burnt under
the hot portion.
28
While attaching the Barcode on the roll, M/C no. Order no. fabric type Color must be checked and
confirmed.
29
If the operator doesn’t understand the cause of the machine malfunctioning, he/she should inform
Floor Inch/Tech/Pd. Sup/Qc. Sup.
30
According to all these instructions, the operators must operate the machine and the Supervisors and
Incharges must
monitor them.
Instructions for Knitting Operators

Different Types of Yarn
RAW MATERIALS
Natural and synthetic, Cellulosic and non-cellulosic all kinds of yarn are
used as raw materials in this mill. Generally, Cotton, Polyester, Viscose and
Nylon are mostly used in knitting departments.
Yarn Count
Cotton (100%) 20's
Cotton (100%) 24's
Cotton (100%) 26's
Cotton (100%) 28's
Cotton (100%) 30's
Cotton (100%) 34's
Cotton (100%) 40's
Lycra (100%) 20D/40D
CVC 10's/12's
CV 10's/12's
PC 10's/12's
Polyester 50D-110D
Melange 10's/18's

Cotton kg/year approx.
Polyester kg/year approx.
Lycra kg/year approx.
Sourcing
Annual Requirements
The main source of yarn for this knitting factory is Matin Spinning Mills
Ltd.
Pricing
Price of yarn varies from mill to mill and as different count.

Production Parameters
Production Process
PRODUCTION
PLANNING
Machine Diameter
Machine RPM
No. of Feeders
Machine Gauge
Count of Yarn
Required Time (M/C Running Time)
Machine Running Efficiency.
The process sequences are in the list below:
1) Firstly, the knitting manager gets a production sheet from
merchandisers in accordance with consumer requirements. Then he
informs or orders the senior production officer about it.
2) Senior production officer informs the technical in charge and knows
about the m/c in which the production will be running.
3) Technical in charge calls for the leader of technical officers, they two
take decisions about m/c for production considering m/c condition,
production capacity, maintenance complexity, etc.
4) Production officer with an experienced technical officer adjusts the
required stitch length and grey GSM (gram per square meter) for the
required final GSM.
5) Supervisor checks daily production regularity and makes operators
conscious about finishing in due time.
6) Operators operate machines with high attention as if there were no
faults in the fabrics. If he thinks or is sure about any fabric fault, then he
calls for a technical officer on duty. The technical officer then fixes it if he
can or he informs the technical in charge. He then comes to the spot.
7) After the required production and final inspection in the 4-point
system, they are sent to the dyeing section.

Process Flowchart of Knitting
Yarn in cone package form
Place the Yarn package in the creel
Feeding the yarn in the feeder
Set the m/c as per design & GSM
Knitting
Withdraw the Roll fabric & Weightening
Roll making
Inspection
Numbering
Dispatch

YARN
COUNT
FINISHED GSM
Single Jersey(Plain) 1x1 Rib Plain Interlock
20/1 200-220 260-280 --
24/1 180-200 240-260 --
26/1 160-180 220-230 270-280
28/1 140-160 210-220 255-270
30/1 130-140 180-200 240-255
34/1 120-130 -- 220-240
40/1 110-120 -- 190-200
Required Yarn Count for GSM Setting
Relation of GSM with Other Parameters
SINGLE JERSEY
Fabric Type
M/c Dia X
Gauge
Gray Dia
(Inch)
Finished Dia
(Inch)
Yarn Count
(Ne)
Gray GSM Finished GSM
Stitch
Length (mm)
Color
Plain
30x24 38-43 30-33 24/1 138-140 180 2.85-2.90 Dark
30x24 38-43 30-33 24/1 142-145 180 2.85-2.90 Light
30x24 38-43 30-33 24/1 152-155 200 2.68-2.75 Light
30x24 38-43 30-33 24/1 147-150 200 2.85-2.88 Dark
36x24 50-52 37- 38/72(op) 24/1 138-140 180 2.85-2.88 Dark
36x24 50-52 37- 38/72(op) 24/1 142-144 190 2.75-2.80 Dark
36x24 50-52 37- 38/72(op) 24/1 142-144 180 2.85-2.88 Light
36x24 50-52 37- 38/72(op) 24/1 148-150 200 2.68-2.75 Dark
36x24 50-52 37- 38/72(op) 24/1 152-155 200 2.65-2.68 Light
30x24 42 31 28/1 118-120 160 2.80 Medium
30x24 42 29-31 30/1 120+2 160 2.58-2.60 Dark
30x24 42 29-31 30/1 123+2 160 2.55-2.58 Light
30x24 42 29-31 34/1 110+2 150 2.52 Dark
Plain
(Lycra)
30x24 37-40 20-22 34/1 + 20D 140+2 180 2.70 Medium
30x24 42 29-31 34/1 + 20D 150+4 200 2.68-2.70 Medium
30x24 42 29-31 30/1 + 40D 145+4 200 3.00 Medium
36x24 38-42 33-35 34/1+20D 140+2 180 2.90 Medium
36x24 42 29-31 34/1 + 20D 143+2 190 2.85 Medium
36x24 42 29-31 34/1 + 20D 148+2 200 2.90 Medium
36x24 42 29-31 30/1 + 20D 150+2 200 2.70 Medium
Lacoste
30x24 46 42-43 26/1 160+2 220 2.58-2.60 Medium
30x24 46 42-43 28/1 155+2 210 2.62 Medium
30x24 46 42-43 30/1 150+2 180 2.40 Medium
36x24 53-55 49-50 26/1 165+2 225 2.55-2.56 Medium
36x24 53-55 49-50 30/1 135+2 180 2.70 Medium
36x24 53-55 49-50 34/1 125+2 160 2.55-2.58 Medium
Pique
36x24 52 50 26/1 135+2 190 2.90 Medium
36x24 53-55 49-50 34/1 125+2 160 2.60 Medium

RIB
Fabric Type
M/c
Dia X Gauge
Grey Dia
(Inch)
Finished
Dia
(Inch)
Yarn Count
(Ne)
Grey GSM
Finished
GSM
Stitch
Length
(mm)
Color
1x1 Rib
30x16 37-39 30-31 20/1 195-200 260-265 3.15-3.17 Dark
30x16 37-39 30-31 20/1 190-195 260-265 3.17-3.20 Medium
30x16 37-39 30-31 20/1 186-192 260-265 3.20-3.25 Light
34x16 41 35.5-36.5 20/1 200 260-265 3.20 Dark
34x16 41 35.5-36.5 20/1 200 260-265 3.25 Light
34x16 41 35.5-36.5 24/1 155-160 230-240 2.80 Light
34x16 41 35.5-36.5 24/1 170-175 240 2.75-2.77 Medium
34x16 41 35.5-36.5 24/1 190 250 2.60 Medium
34x16 41 35.5-36.5 26/1 150-155 220-230 2.80-2.85 Medium
34x16 41 35.5-36.5 26/1 155-160 230-240 2.75-2.80 Light
34x18 41-42 34-35 26/1 155-160 220-230 2.80-2.83 Dark
34x18 41-42 34-35 28/1 155-160 220 2.65-2.70 Medium
36x16 42-45 31-34 26/1 156-160 230-240 2.70 Medium
36x16 41 31-34 28/1 155 220 2.65 Medium
36x16 41 31-34 30/1 140-145 200 2.65 Medium
36x18 41-43 35-37 26/1 170-172 240 2.85 Medium
36x18 41-43 35-37 28/1 168-170 220 2.50 Medium
36x18 41-43 35-37 30/1 145-150 190-200 2.50-2.60 Medium
Rib (Lycra)
34x16 38-40 32-35 26/1+ 40D 190 270 2.80 Medium
36x16 38 31.5 30/1+ 40D 190 260 2.70 Medium
36x18 40 35 30/1+ 40D 180 240 2.75 Medium
2x1 Rib 36x18 45 37 26/1 170-172 240 2.85 Medium
INTERLOCK
Fabric Type
M/c
Gauge
Yarn Count
(Ne)
Grey
GSM
Finished
GSM
Stitch
Length (mm)
Color
30/1 190-192 260 1.62-1.63 Dark
Plain 22 30/1 175-180 240 1.68 Light
Interlock 30/1 180-185 250 1.65 Dark
34/1 158-160 220 1.62 Light

GSM Control
Major control by the quality pulley
Minor control by stitch length adjustment
1.
2.
G.S.M.
Changing of G.S.M
Points that should be considered in case of GSM changing
VDQ (Variable Dia. Quality Control) pulley diameter
Yarn count
M/C gauge
Cam's position
Take up motion
Factors that should be considered for changing Fabric Design
Cam arrangement changing
Needle butt setting & needle dropping
Using different colors in the selected feeder
Using of jacquard mechanism
Size of the loop shape
Recommendable points of a buyer
Dia of the fabric
Design of the fabric
GSM of the fabric
Total wt. of the fabric
Yarn count
Types of yarn
Color of the fabric
Finishing of fabric
Handling & fastness property.
It is a technical term that indicates the weight of the fabric per square
meter
The GSM of the fabric is changed by altering the position of the tension
pulley. If the pulley moves towards the positive direction then the GSM is
decreased and in the reverse direction, GSM will increase.
a.
b.
c.
d.
e.
a.
b.
c.
d.
e.
a.
b.
c.
d.
e.
f.
g.
h.
i.

Production Calculation
Methods of Increasing Production
Production/shift in kg at 100% efficiency
RPM x No of Feeder x No of Needle x SL (mm) x 60 x 8
= -------------------------------------------------------------------------
10 x 2.54 x 36 x 840 x 2.205 x Yarn Count
By increasing the m/c speed
Increasing the number of feeders
By using the machine with a higher gauge
By imposing automation in the m/c
Quick starting & stopping for an efficient driving system
Automatic m/c lubrication system for smoother operation
Photoelectric fabric fault detector
By imposing other developments
Using a creel-feeding system
Applying yarn supply through a plastic tube eliminates the
possibility of yarn damage
Using a yarn feed control device
Using auto lint removal
Higher the m/c speed faster the movement of the needle and ultimately
production will be increased.
If the number of feeders is increased in the circumference of the cylinder,
then the number of courses will be increased in one revolution at a time.
The more the machine gauge, the more the production is. So by using
machines of higher gauge production can be increased.
i.
ii.
iii.
iv.
v.
vi.
vii.

Quality Assurance (QA) involves the activities and processes that are used
to prevent defects in a product or service. This is done by setting up
quality standards, ensuring that they are followed, and continuously
monitoring and improving the production process. It is an online process
of QAD (Quality Assurance Department) that includes the use of
technology to analyze and monitor various factors that affect the quality
of the fabric, such as the tension, yarn count, and twist. One such tool
used in QA is the Fabric Processing Sheet (FPS) analysis.
On the other hand, Quality Control (QC) involves the activities that are
used to detect and correct defects in a product or service. This is done by
inspecting and testing the product or service and comparing it against
the established quality standards. It is an offline checking system of the
QAD team that involves visually inspecting the fabric for any defects or
issues after it has been produced. The 4-point system and grading are
commonly used in QC.
QA & QC
QUALITY ASSURANCE
SYSTEM

Quality Process Flow Chart
Check Knit Card (Knitting Parameter) with
Standard FPS (Fabric Processing Sheet)
After Start Knitting, Check Running Fabric
Quality (At least 2 times/mc)
After Produce Fabric, Send to QA
Department
Fabric Inspection According To
the 4-Point System
Check the Fabric Grade
Reject
Send It
To Grey Store
(Reject Area)
Fabric Racking
for Delivery
Deliver
to OTIF Store
Online
Inspection
Offline
Inspection

SOP of Quality Inspector
Receive Roll for Inspection Properly
Roll Inspection and report Making
Select the Grade Standard of the Fabric
by 4-Point System
Check Roll Writing Properly
Fabric Inspection According To
the 4-Point System
Keep the Roll in Correct Place after
Inspection
Identify the Problematic Machine and
Inform to Online QC
Sorting Good Quality and Reject Fabric
Properly

Online Inspection (QA)
FPS Analysis

Fabric Processing Sheet (FPS) is a document that contains all the
necessary information about the fabric production process from the yarn
stage to finishing. It is a crucial document that helps to maintain
consistency in the production process and ensure that the final product
meets the required quality standards.
The FPS includes details about the yarn used, such as the type, count,
twist, and supplier. It also includes information on the knitting or weaving
machine used, such as the machine type, gauge, and the number of
feeds. Additionally, it includes details about the processing stages, such
as dyeing, printing, and finishing, including the recipe, time, temperature,
and chemicals used in each process.
The FPS helps to ensure that the fabric meets the required quality
standards by providing a reference document for the production process.
It allows the production team to monitor the production process and
make adjustments if necessary to ensure that the fabric meets the
required specifications.

Yarn Test Procedures
Offline Inspection (QC)
Yarn Count Check Machine
The machine works by wrapping a
fixed length of yarn around a
spindle and then measuring the
weight of the yarn. The yarn is
then unraveled and the length is
measured.
The thickness or fineness of the yarn is then calculated based on the
measurements, and the yarn is assigned a numerical count based on its
fineness.
Yarn Evenness Check Machine
Yarn evenness check machine is
used to visualize the yarn
evenness by entangling over the
machine. In weaving and knitting,
the machine is used to check the
evenness of the yarn before it is
used to produce the fabric.
Tumble Drying & Washing
To check the shrinkage of the
fabric, a sample of the fabric is cut
from the production lot and
marked with a reference code.
The sample is then washed in a
washing machine under specified
conditions, which may vary
depending on the type of fabric
and its end-use application.
Tumble drying is a process that involves drying the fabric by tumbling it
in a machine with hot air. The purpose of tumble drying is to remove any
moisture from the fabric after it has been washed or treated.

Fabric Manual Inspection Machinery
Fabric Inspection Table
The table has a flat, smooth
surface with good lighting to
ensure that the fabric can be
viewed clearly. The fabric is
placed on the table and spread
out, allowing the quality
inspector to examine it for
defects such as holes, tears,
stains, or variations in color or
pattern. The inspector will also
check the weight, width, and
length of the fabric to ensure
that it meets the required
specifications.
UV Light Box
The box emits ultraviolet light,
which causes certain
substances in the fabric, such as
optical brighteners, to fluoresce
and appear more visible. This
allows inspectors to more easily
detect defects such as stains,
spots, or discoloration that may
not be visible under normal
lighting conditions.

Fabric Defects
Fabric defects refer to any imperfections or irregularities found on a piece
of fabric. These defects can occur during any stage of the production
process, including spinning, weaving/knitting, dyeing, printing, finishing,
and transportation. Some common types of fabric defects include:
Yarn Related Problems
Conta
Color Conta
Poly Conta
Fly Conta
Black Space/White Space
Barre (Patta)
Slub
Neps
Thick-Thin
Miss Yarn
Double Yarn
Count Mix
Lot Mix
Denier Mix
Knitting Related Problems
Hole
Loop
Setup
Needle Mark
Sinker Mark
Stop Mark
Crease Mark
Star Mark (Cita Tara)
Needle Broken
Needle Butt Mistake
Latch Problem
Lycra Related Problems
Lycra Out
Lycra Drop
Lycra Mix/Misplacing
(Cotton/Denier)
Lycra Cut
Other Problems
Wheel Free
Oil Spot
Oil Line
Design Mistake

Inspection PC
The All In One PC system provides a centralized platform for recording
and managing all the quality-related data of the production process. By
entering the details of the defects into the system, the inspectors create a
record that can be used to track the quality of the fabric and monitor the
performance of the production process.
The data recorded in the system can be used to generate reports that
provide valuable insights into the quality of the fabric being produced
and help in making data-driven decisions to make quality reports of the
production process.
Quality inspectors play a crucial role in ensuring the quality of the fabric
produced. Once they identify a defect, they record the details of the
defect, including its location, size, and nature, into the All In One PC
system.

SHIFT: A SHIFT: B
TYPE OF
DEFECT
ROLL-1 ROLL-2 ROLL-3 ROLL-1 ROLL-2 ROLL-3
SLUB
HOLE
NEEDLE/SINKE
R
LINE
STAIN
THICK &
THIN
YARN
CONTAMINATIO
N
BARRE/STRIPE
DIRT
OIL MARK
PIN HOLE
DROP STITCH
M/C STOPAGE
OTHER
SPECIFY
TOTAL
POINT(P)
GREY WIDTH :
ROLL WT(W)
REJECT
QTY.(KG)
LENGTH(MTR)
Quality Report
BUYER:
ORDER NO:
FABRIC TYPE:
GREY GSM:
FINISH GSM:
FINISH WIDTH:
NAME OF THE INSPECTORS:
GREY FABRIC INSPECTION REPORT
DATE:
M/C NO:
M/C GAUGE:

Size Of the Defect Penalty Point Assigned
Defects up to 3" 1
3"-6" 2
6"-9" 3
Above 9" 4
Size Of the Defect Penalty Point Assigned
1" or less than 1" 2
Above 1" 4
4-Point Inspection System
The 4-point system is a method used in fabric inspection to classify and
grade fabric defects based on their size and severity. The system assigns
points to different types of defects based on their size and severity, with
the maximum point value being 4. Defects are typically classified as
major or minor, with major defects being more severe and carrying a
higher point value.
Fabric defects are assigned point based on following:
For Holes and Openings (Largest Dimension),

The grading acceptable level is listed below:
Points Grade
Upto 12.5 A
12.5 to 24 B
Above 24 C
Fabric Grading
Total Penalty Number X 3600
Total points/100 sq. yard = --------------------------------------------------------------
Fabric Length (yds) X Fabric Width (inches)
Fabrics that are graded as A and B are stored in the grey fabric storage
area, while fabrics graded as C are subject to review by the quality control
department for a final determination on whether they will be accepted
or rejected.
SOP for Fabric Rejection
Grey Fabric Roll Receive
Grey Fabric Inspection
Grey Fabric Rejection
(If Quality Level is Not Satisfactory)
Rejected Fabric Stored in Reject Rack
and Updated Accordingly
Rejected Fabric Delivered to Grey Store

Heat Sealing Tooth Marks
When a fabric roll is unloaded from a
knitting machine, it is marked with a
toothmark that contains unique barcodes.
This barcode helps to identify the fabric
roll as a unique roll and allows for tracking
throughout the production process. The
barcode is then scanned and the
necessary data is inputted into the All-In-
One PC system.
This data includes important information
such as the date of production, the type of
yarn used, and any other relevant details.
This ensures that each fabric roll can be
traced back to its origin and that any
issues or defects can be identified and
addressed. The toothmark and barcode
system is an important quality control
measure that helps to maintain
consistency and ensure that all fabrics
meet the necessary standards.

Red Tag Zone
Weight Scale Machine
After a fabric roll is unloaded from the
knitting machine, it is weighed using a
weight scale. This is an important step
in the quality control process, as it
ensures that each roll meets the
weight requirements specified in the
production plan.
The red tag serves as an identification marker
that helps to differentiate approved fabric
rolls from others that the buyer had
approved and sealed for that particular
sample for production. The red tag zone is a
designated area where these approved fabric
rolls are stored until they are ready for further
processing.
Once the roll is approved, it is marked with a
red tag and stored in a specific area that is an
approval for the production go-ahead to the
factory.

R&D Roadmap
R&D
Duplication Innovation
One potential way to address R&D duplication in a knitting factory is to
make use of development samples. This can help to ensure that everyone
is aware of the ongoing work and can build on each other's research,
rather than duplicating efforts. Additionally, development samples can
help to identify potential issues or challenges early on in the
development process, allowing teams to address them before they
become more significant problems.
R&D innovation refers to the process of creating new or improved
products, services, or processes through the application of scientific or
technical knowledge. The R&D innovation process typically involves
several stages, including idea generation, research, and analysis,
development and testing, and commercialization.
R&D (Research & Development) efforts may involve the creation of new
knitting patterns, textures, and structures that offer new aesthetic or
functional possibilities. In the area of materials, R&D efforts may involve
the development of new fibers or yarns that offer improved performance
or sustainability. This may include the use of recycled materials, bio-
based materials, or nanomaterials to create new properties and
functionalities.
RESEARCH &
DEVELOPMENT

Flowchart of R&D
Getting Swatch from Buyer for
Duplication
Analysis
Planning for Sampling
Yarn Ordering
Yarn Testing
Inspection
Sample Knitting
Numbering
Sample Approval
Dispatch
Bulk Production
Yarn Selection

Development Hanger Room
Design Studio
The Design Studio typically includes computers with specialized
software, as well as knitting machines for testing and development.
Designers use the software to create digital designs, incorporating colors,
patterns, and textures. They can also make adjustments and
modifications to the design until it meets their desired specifications.
Once the design is finalized, the software converts it into machine-
readable instructions, known as sample programs. These programs
provide precise instructions to the knitting machine's computer control
system on how to produce the desired design. The sample programs are
then tested on the knitting machines to ensure that the design is
produced correctly.
The development hanger room
is an important section of the
Research and Development
(R&D) department where
development samples are
placed for buyers.
This room is dedicated to
showcasing a range of fabric
samples, giving buyers an
opportunity to touch, feel and
evaluate the quality of the fabric
before placing an order.

DBL Group Fabric Capability
Single Jersey Jacquard
Double Jersey Jacquard
Spacer & Scuba
Sustainable Fabric
Sweater Look Fabric
Knit Denim
Waffle Fabric
Bonded Fabric
Sporty Synthetic Base
Fleece & Terry
Lurex & Metallic Thread Base
Fabric Development
Injected, Nappy, Vario Siro, Siro,
Fiber Dyed
Snow, Negative Slub, Twisted
Fiber Dyed
Linen Blend Fabric
BCI, Organic PUMA Quality
Fabric
Air-Covered Yarn Base Fabric
Loose Knitted
Ponte-Di-Roma
Rib & Interlock
Slub Fabric
Multi Gauge
Snit Jersey
Engineering Striper

FABRIC NAME
SAMPLE
FACE BACK
Single Jersy
(Plain)
Single Jersy
(Lycra)
Single Lacoste
Double
Lacoste
Polo Pique
1X1 Rib
2X1 Rib

FABRIC NAME
SAMPLE
FACE BACK
Plain Interlock
Mesh
Waffle
Fleece (2
Thread)
Fleece (3
Thread)

Inspection:
Lubrication:
Record & Analysis:
Operating manual of the m/c
Maintenance Manual
History card
Inspection card
Logbook
Planning & Scheduling:
Operation:
Replacement of Faulty Parts:
Storage & Record:
Faulty parts are identified &their present condition is checked. And also
the availability of stand-by equipment are also checked.
Before starting maintenance all moving & frictional parts are lubricated
so to facilitate &draw off the parts.
Previous records & history of the maintenance are checked and analyzed.
Before maintenance the following records should be checked:
Taking of proper plan & make of specific schedule for how the
maintenance should be performed properly.
The maintenance operation is performed as stated below.
The faulty parts which are identified are replaced by new parts.
The faulty parts which are rejected stored properly & keep top to bottom
record of this operation.
Function of Maintenance
MAINTENANCE

Maintenace Procedures
If there is any mechanical fault in the machine which is responsible
for the production hamper, the operator informs the Technical Officer
on duty. Technical Officers come and observe the problem first, and
then they begin to fix it.
If Technical Officer is unable to fix it, then they inform the technical in
charge, and he then comes to the spot and fixes it.
If there is any electrical problem with the machine or a serious
founding mechanical problem, the mechanical and electrical
departments are informed, and they come and fix the problem. They
commence work after informing of knitting manager.
For restorative maintenance, the senior production officer orders
Technical Officersto fit the required machine for cam and needle
arrangement and other necessary requirements in case of new design
development.

Maintenace Sequence for
Circular Knitting Machine
Power On/Off
MPF/Positive Feeder Current Line Off
MPF Belt Out/Loss
Yarn Cut
Cleaning and Oiling
Needle & Sinker Cleaning by Oil
Cam Box Out
Cam Box Cleaning by Air
Needle & Sinker Out
Needle & Sinker Out
Fabric Out by Handle

I am writing to express my sincerest gratitude to my Industrial Supervisors for the
incredible support and guidance that provided me during my internship at Jinnat
Apparels Ltd. Their guidance and support throughout the internship have been
invaluable in helping me grow both personally and professionally. Thanks to them
once again.
CONCLUSION
DBL is a well-known manufacturing and distribution organization in
Bangladesh, renowned for its efficient corporate operations. The
company is constantly striving for innovation and improvement in its
textile business practices. Jinnat Apparels Ltd., Knitting Division of DBL,
use innovative B2B marketing methods to target factory engineers and
promote their services through social media and online channels
nationwide.
During my internship with DBL Group, I had the opportunity to gain
practical knowledge and experience in their work processes. I learned a
great deal about their operation policies, which I can now relate to my
academic studies. This experience has been a valuable achievement for
me, and the knowledge I gained during my 4 weeks internship will
undoubtedly be useful throughout my career.

Industrial Attachment Report on DBL Group.pdf

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