I add some little information about knitting, dyeing & garments section for just present.

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2. in
CRYSTAL COMPOSITE LTD.
( A Concern of Crystal Group )
October 2017
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3. Supervised by
Md. Ramij Howlader
Lecturer
Department of Textile Engineering
BGMEA University of Fashion & Technology
Presented by
Noorul Islam Saiful
ID: 132-071-0-155
Batch: 132 TE-2
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4. Outlines
 About Company
 My Activities
 Where I was
 Achievements
 Recommendation
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5. Company at a Glance
Company Name CRYSTAL COMPOSITE LTD.
Founded Year 2006
Holding Company Crystal Group
Production Capacity Knitting- 5 Ton/Day, Dyeing – 8 Ton/Day ,
Garment– 40000 Pcs/Day.
Products Polo Shirt, T-Shirt, Short Pant, Tank Top,
Laggings, Kids Knit Items etc.
Managing Director Sultan Ahmed
Workers 2000
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6. Organizational Evaluation
 Good & friendly environment
 Kind, friendly & respectful employee
 Good management
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7. ◊ Collect m/c name & their function.
◊ Sourcing materials.
◊ Fabric & garments inspection.
◊ Operation follow-up.
◊ Fabric consumption.
◊ Costing.
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8.  Knitting section.
 Dyeing section.
 Garments section.
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9. Fabric feature & design:
 Single Jersey:
 The head of the loop is straight.
 Courses of face side are straight and parallel.
 Only knit cam used to knitting.
 Knitting loops are produced by needle and sinker.
 Cam Design:
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10. Fabric feature & design:
 11 Rib:
 The head of the loop is in the cross.
 Fabric more stretchable to width.
 Only needle used to knitting.
 Fabric is knitted by setting cam in dial and cylinder.
 Cam Design:
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11. Fabric feature & design:
 Interlock:
 Two heads of loop are face to face.
 The fabric is soft comparably.
 More stable than jersey fabric.
 It doesn’t recover very well after being stretched.
 Cam Design:
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12. Fabric feature & design:
 Single Lacoste:
 Tear resistance
 Color fastness
 Smooth texture
 Cam Design:
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13. Fabric feature & design:
 Fleece:
 Produced in single jersey m/c.
 Face side is looking like s/j face side.
 It’s warm and comfortable.
 Easy to sew and clean.
 Cam Design: Three needle truck m/c
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14. Fabric feature & design:
 Pique:
 Much weaker than fabrics without ribs.
 Just like Lacoste fabric.
 Good dimensional stability.
 Soft and resilient.
 Cam Design: Single pique
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15. Fabric faults in Knitting:
 Hole Mark:
 Causes:
 Higher GSM.
 Yarn feeder badly set.
 Needle Mark:
 Causes:
 Breaking or curving needle.
 Faulty needle use in m/c.
 Oil Spot:
 Causes:
 Excess oil / Grease use.
 Jamming of needle & sinker.
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16. Fabric faults in Knitting:
 Sinker Mark:
 Causes:
 Sinker not clean.
 Use defected or broken sinker.
 Fabric Shrinkage:
 Causes:
 Increase twist factor.
 Knitting tension.
 Broken Needle:
 Causes:
 Breakage of hook, butt in needle.
 High yarn tension.
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17.  GSM Control during knitting:
 By yarn count selection.
 By increase or decrease stitch length.
 By selecting higher or lower gauge m/c.
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Yarn Count (Ne): GSM:
Yarn Count (Ne): GSM:

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Stitch Length: GSM:
Stitch Length: GSM:
Gauge Dia: GSM:
Gauge Dia: GSM:

19. GSM Calculation Without GSM Cutter
› Fabric type taken- s/j
› Yarn count- 26 (Ne)
› Fabric length taken- 10 cm
› Fabric width taken- 10 cm
› Fabric weight- 1.59 gm
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GSM = Fabric weight × 10000/ fabric area
= 1.59 × 10000/ 10 × 10
= 159

20. Increase production:
› By increase m/c speed.
› By increase number of feeder.
› By selection m/c of higher gauge.
› By imposing automation in the m/c
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21. Quality assurance system of knitting division:
 Some points are needed to maintain for high quality fabric-
› Brought good quality yarn.
› Machines are oiled and greased accordingly.
› G.S.M, Stitch length, Tensions are controlled accurately.
› Machines are cleaned every shift and servicing is done after a month.
› Grey Fabrics are checked by 4 point grading system.
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22. Knitting m/c servicing:
Power on/off
↓
Positive feeder current line off
↓
Yarn cut
↓
Fabric out by handle
↓
Cleaning m/c by air gun
↓
Oiling
↓
Cam box out
↓
Needle & sinker out
↓
Needle & sinker cleaning by oil
↓
Cam box & cylinder cage cleaning by air
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23. Dyeing process in Crystal Composite:
Grey fabric received

Batching

Select m/c no

Fabric loading

Select production program

Pre treatment

Select recipe for dyeing

Recipe confirm by D.M/ S.P.O

Dyeing

After treatment

Unload
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Turning

24.  Dyes used in Crystal Composite:
Reactive dyes
Disperse dyes
Direct dyes
Pigment dyes
Sulphur dyes
Basic dyes
Acid dyes
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25.  Chemicals used in Crystal Composite:
Weighting agent
Sequestering agent
Leveling agent
Soaping agent
Fixing agent
Caustic soda
Soda ash
Stabilizer
Anti-crease
Anti-foaming
Hydrogen peroxide
Acid &
softener
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26. Dyeing faults:
 Uneven Dyeing:
 Causes:
 Uneven pre-treatment.
 Improper color dosing.
 Using dyes high fixation property.
 Batch to Batch Shade Variation:
 Causes:
 Fluctuation of Temperature.
 Improper dosing time of dyes & chemicals.
 Dyes lot variation.
 Patchy Dyeing Effect:
 Causes:
 Faulty injection of alkali.
 Improper addition of color.
 Due to hardness of water.
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27. Dyeing faults:
 Roll to Roll Variation:
 Causes:
 Poor migration property of dyes.
 Improper dyes solubility.
 Faulty m/c speed.
 Crease Mark:
 Causes:
 Poor opening of the fabric rope.
 Shock cooling of synthetic material.
 Due to high speed of m/c running.
 Dye Spot:
 Causes:
 Improper dissolving of dye particle in bath.
 Improper dissolving of caustic soda particle in bath.
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28. Finishing Process (tube line):
Squeezing

Drying

Compacting

Folding & packaging

Inspection

Delivery
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Turning

29. Finishing faults:
 Wet Squeezer Marks:
 Causes:
 Due to excessive pressure of the squeezer rolls
on the wet fabric.
 GSM Variation:
 Causes:
 Roll to roll variation in the process
parameters of the fabric.
 Skewing:
 Causes:
 Improper feeding of the fabric while compacting.
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30. Finishing faults:
 Shrinkage:
 Causes:
 Due to high tension during the knitting, dyeing
and the finishing processes.
 Over Compaction:
 Causes:
 Excess shoe pressure.
 Excess overfeed.
 Bowing:
 Causes:
 Uneven distribution of tension
across the fabric width.
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31. Sequence of Fabric Spreading & Cutting:
Received Finished Fabric

Inspection

Spreading (manual)

Cutting (power knife)

Shorting & Numbering

Inspection

Sent to sewing
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Received pattern
from sample section

32. During Cutting Quality Control:
 Miss cut
 Matching plies
 Ragged cutting
 Notches
 Pattern check
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33.  Sewing thread
 Needle &
 Sewing machine
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34. Cutting fabric load in sewing section

Line plan according to style or design

Matching according to bundle no.

Sewing according to Garments design or style

Quality inspection after sewing

Excess Thread cutting

Remove dirt & dust from Gmts surface

Quality Audit

Send to next process.
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35. Input cut fabric

Shoulder joining

Neck joining

Neck serving

Neck piping

Piping edge covering

Back top sin

Sleeve hemming

Sleeve attaching

Side seam with care label

Bottom hemming

Main label attaching

Inspection
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36. Sewing Defects:
Needle damage
Skip stitches
Thread Breakages
Broken Stitches
Seam Grin
Seam Puckering
Pleated Seam
Wrong stitch density
Uneven stitch density
Staggered stitch
Improperly formed stitches
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37.  General formula of SMV:
SMV= Basic time + Allowance
Basic time= Observed time X Rating/ 100
For Relaxation allowance- 15%
For Machine Delay Allowance- 10%
Rating= The operator is performing the job.
Let, the operator performance rating- 85%.
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 SMV Calculation:
Element
Rating
%
Observe
Time
Occurrence
Basic
Time
Standard
Time
SMV
Input cut fabric 85 0.216 1/1 0.183 0. 201
3.59
Shoulder joining 85 0.166 1/1 0. 141 0.162
Neck joining 85 0.304 1/1 0.258 0.296
Neck serving 85 0.153 1/1 0.13 0.149
Neck piping 85 0.116 1/1 0.141 0.162
Piping edge covering 85 0.122 1/1 0.103 0.118
Back top sin 85 0.233 1/1 0.198 0.227
Sleeve hemming 85 0.225 1/1 0.191 0.219
Sleeve attaching 85 0.366 1/1 0.311 0.357
Side seam with care label 85 0.70 1/1 0.595 0.684
Bottom hemming 85 0.225 1/1 0.191 0.219
Main label attaching 85 0.211 1/1 0.179 0.205
Inspection 85 0.636 1/1 0.54 0.594

39. Garments Finishing Process:
Sewn garments received in finishing section
↓
Initial quality check
↓
Spot removing if there’s any spot
↓
Ironing or pressing
↓
Inspection
↓
Hang tag attaching
↓
Folding
↓
Poly bag
↓
Metal check
↓
Packaging or cartooning
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40. Shrinkage
Dirty spot
Iron spot
Oil line
Dye spot
Water spot
Seam Tear
Soil
Folding Defects
Pin holes
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41.  Work Experience.
 Experience of team work.
 Ability to work under pressure.
 Self responsibility.
 Choose Professional career area.
 Create an advantage to get job.
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42. Recommendations
 Increase the duration of internship.
 Assist to gain useful knowledge.
 Assigned report that I have ability to
completed.
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