Industrial attachment of hams washing & dyeing ltd.

Industrial Attachment Report Page 1 of 56
HAMS WASHING & DYEING LTD.
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT

Chapter 1
Introduction
As a part of course curriculum of Bangladesh College of Textile Engineering &
Technology we were send for industrial attachment for two months starting from 17th
June 2006
to 17th
August 2006 to HAMS Washing & Dyeing Ltd. During the attachment we worked as a
trainee textile engineer and had to attend the official working days in general working times i.e.
9 am to 5 pm.
AIM AND OBJECTIVES OF INDUSTRIAL ATTACHMENT
 To enhance our University learning experience through involvement in industrial and
commercial field, thus enabling us to relate theoretical concepts with practical situations;
 To develop our ability to evaluate issues and situations critically and propose well
considered options and solutions;
 To develop and enhance our professional awareness and communication skills;
 To provide experiences that will enable us to achieve a breadth of understanding that will
form a framework or agenda for our final year of study.

The experience offered by industrial training varies. However, by the end of the
placement we were expected to have substantially met most or all of the following objectives:
 Undertaken problem solving activities in the workplace;
 Further developed my communication skills;
 Shown the ability to accept responsibility, work independently, manage my own time
and schedule my work;
 Understood the constraints of a formal working environment and the benefits of team
work;
 Appreciated the relevance of my academic work and have applied this to new situations;
 Used new tools and techniques to supplement those covered on my scheme of study;
 Acquired the experience to understand, discuss and evaluate the professional issues
relating to textile engineering.
 Gained an understanding of which final year courses will provide the best foundation for
my int ended career.
SUPERVISION DURING THE INDUSTRIAL ATTACHMENT
During our industrial attachment we were overseen by our industrial tutor. We kept a log
of our activities during my industrial attachment in a diary supplied from our institute, which
was re-checked and signed by our industrial tutor.
We were also visited by our academic professionals of different departments whom
discussed about our progress with our industrial tutor. Thus we had the opportunity to learn from
our academic tutors in a practical field.
A routine was maintained to meet with our head of department. Once in every 15 days
we met with our head of department and discussed about solutions of some problems that we
had in the industry.

Chapter 2
Overview of the Industry
This chapter contains general overview of the industry where we have carried out the
industrial attachment.
OVERVIEW
 Company Name: M/S HAMS WASHING & DYEING LTD.
 Company Nature: Privet Limited Company
 Established Date: September, 1998
 Location: Tejgaon Industrial Area, Dhaka
 Project Cost: 57.04 Cror Tk.
 Total area: 20,000 Square Feet (approx.)
 Man-power: 200
 Business field: Readymade Garments Washing & Dyeing
 Main product: Denim long pant, short pant, overall skirt, cotton sweater .
 Manufacturing capacity: 2000 Dozens/Day
 Types of wash:
o Garments Wash o Acid Wash
o Heavy Garments Wash o Bio Wash
o Pigment Wash o Bleach Wash
o Sand Blasting / Spray Blasting o Stone Wash
o Tinting Wash o Deep Dye
o Stone Enzyme Wash o Tie Dye
o Sand Wash o Silicon Wash
o Enzyme-Silicon Wash o Whickering

 Local Buying House:
 Washing Capacity:
o Dye & Tint 12000 PCs/day
o Enzyme Wash 15000 PCs/day
o Bleach Wash 20000 PCs/day
o Enzyme Stone Wash 16000 PCs/day
o Pigment Wash 25000 PCs/day
o Garments Wash 40000 PCs/day
o Enzyme Silicon Wash 25000 PCs/day
o Avg. All type of Wash 22000-23000 PCs/day
 Major customers:
o Jc-penny
o Primark
o Vermukt
o Walmart
o K-Mart
o Route-66
o Li & Fung (BD Ltd.) o Linmark
o Nor Wester o ABA Group
o Pelican Resources inc. o Auchan
o Lindex o Texel Ltd.
o Jecepenny o NASSA
o DAC Pacific o Tex-EBO
o Epic Designers

o Fashion Traders
o Auchan
 Sales & Marketing policy: Improvement through Research and
development for better marketing.
 Banks: Premier Bank Ltd. Gulshan Branch
National bank.
 Address: 190, Tejgaon I/A, Dhaka-1208, Bangladesh
 Telephone: 9885674, 9886406(off.) 8814365, 8814923(fac.)
 Fax: 880-2-9881067
 e-mail: hfl@bdcom.com
 Web: www.hamsgroup.com
 Different departments: Sample section, Washing & Dyeing section, Drying
section, Sand Blasting section, Quality assurance section, Laboratory, Storage section.
 Sister Concern: HAMS Fashion Bijoy (Pvt.) Ltd.
HAMS Fashions Ltd. Fashion-2000 Ltd.
Pacific Label Ltd.
HISTORY
Md. Shafiqur Rahman, founder & managing director of this company, is a textile
engineer himself who provided service for five year in garments washing and dyeing sector. In
September 1998 with five local made garments washing and dyeing machine he launched M/S
HAMS WASHING & DYEING LTD. The commitment was “TO MAINTAIN QUALITY AND
TO DELIVER TIMELY” and still strongly believes it.
Within five years the industry earned good reputation in garments washing & dyeing
sector. Now HAMS WASHING & DYEING LTD. is one of the leading garments washing &

dyeing industry in Bangladesh.
The industry is now equipped with modern washing & dyeing machines. The total
numbers of machine are three times than the initial set up.
Chapter 3
Man power Management
The company includes over 150 employees with some highly skilled personnel. Most of
the staffs are self-motivated and hard working.
ORGANOGRAM
MAN POWER-ADMINISTRATION:
SL.
No.
Designation
No
. of
Po
st
Gender Qualification Local
Foreign
expert
1 Managing Director 1 Male
B.Sc. in Textile
Technology  
2 Director(admin) 1 Male Bachelor  
3 Director(production) 1 Male
B.Sc. in Textile
Technology  
4 Director(marketing) 1 Male Bachelor  
ORGANOGRAM-ADMINISTRATION:
Managing Director

Director (Admin.)
  
Manager (Account) Manager (Admin.) Manager (Compliance)

ORGANOGRAM-PRODUCTION:
Managing
Director

Director
(Production)

Production
Manager

Asst. production
manager

   
Supervisor
(Washing)
Supervisor
(Dyeing)
Supervisor
(Drying)
Supervisor
(Sand
Blasting)
   
Machine Operator
Machine
Operator
Machine
Operator
Machine
Operator
   
Assistant
Operator
Assistant
Operator
Assistant
Operator
Assistant
Operator

ORGANOGRAM-QUALITY CONTROL:
Production Manager

Super Visor (Quality)

Assistant (Quality)

ORGANOGRAM LABORATORY:
Production Manager
  
Machine Operator
(Sample washing machine)
Assistant
(Laboratory)
Machine Operator
(Sample drying machine)
 
Assistant Operator Assistant Operator
ORGANOGRAM MAINTENANCE:
Production manager

Supervisor
(Maintenance)

Technician

Assistant
ORGANOGRAM FINANCE:
Director (Finance)

Accountant

Asst. Accountant

MANAGEMENT
Management system: Vertical type



Figure: Symbolic representation of vertical type management system.
Shift Change: 12 hours shift (two shifts per day).
Responsibilities of Production Manager:
 To give washing & dyeing slip.
 To match production sample with target sample.
 To collect production sample for sample matching for next production.
 To identify disputed garments & report to director.
 Also execute overall floor works.
 To maintain loading & unloading record.
 Any other assignment given by higher authority.

Chapter 4
Machine Description
There are three (3) sample washing machines and fifteen (15) industrial machines in
washing section, seven (7) guns in sand blasting section, one (1) sample drying and twelve (12)
industrial drying machines in drying section, four (4) hydro extractors in hydro extraction
section. There is a modern sample washing machine, a modern industrial washing machine in
washing section and a modern hydro extractor in hydro extraction section. The industry is in the
process of upgrading it’s existing machines. Specifications of some incoming machines are also
given in this chapter.
GARMENTS WASHING & DYEING MACHINES
SAMPLE WASHING MACHINES
 No. of machines: 03
 Manufacturing company: Bengal Heavy Electric Engineering.
 Manufacturing country: Bangladesh.
 Features:
° Single door design for general washing, sample washing.
° Machine body and essential parts are made of stainless steel.
° Preset front and backward rotation.
° Conventional machine.
 Specifications:
° Capacity: 30 kg
° Inner Cylinder: 28”X34”
° Thickness of inner drum: 3mm
° Outer Cylinder: 34”X40”
° Motor (HP): 1HP, 0.75KW
° Power Consumption: 2.3 Amp
° Steam Consumption: 2 HP, 31 Kg
° Water Inlet: 2”, 1 way in.
° Steam Inlet: 1”, 1 way in.

° Water Discharge: 3”, 1 way out.
INDUSTRIAL WASHING MACHINES
 Features:
 Specifications:
° Capacity: 200 kg
° Inner Cylinder: 42”X88”
° Thickness of inner drum: 3mm
° Outer Cylinder: 54”X960”
° Motor (HP): 10HP, 7.5KW
° Power Consumption: 17 Amp
° Steam Consumption: 15 HP, 230 Kg
° Water Inlet: 2”, 2 ways in.
° Steam Inlet: 1”, 2 ways in.
° Water Discharge: 3”, 2 ways out
MORDERN SAMPLE WASHING MACHINES
 Manufacturing company: STEFAB INDIA LIMITED
 Model no: LXS 35.
 Manufacturing country: India.
 Features:
° Single door, front-loading, open pocket.
° Automatic timed. Auto reverse. Automatic 5 water level & auto digital
temperature control.
° Electric solenoid water & steam valves.

° Non-clog motorised drain valve.
° Full electric protection.
 Specifications:
° Capacity: 35 kg (Dry: Wet =1:10)
° Inner cylinder: 950 mm dial X 500mm
° Wash motor: 0.75 KW
° Extract speed: 200 RPM
° Main door opening: 500 mm dial
° Water connection consumption: 25 mm dial, 120 litres.
° Drain: 75 mm dial, 1 way out
° Steam connection consumption: 15 mm dial, 25 Kg/hr.
° Electric heating: 12 KW
° Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H)
MORDERN INDUSTRIAL WASHING MACHINES
 Manufacturing company: STEFAB INDIA LIMITED,
 Model no: LXS 280.
 Features:
 Specifications:
° Capacity: 280 kg (1:10)

° Inspection door opening: 300 mm dial
° Drain: 115 mm dial, 2 ways out
° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.
HYDRO EXTRACTORS
 Manufacturing company: Tongxin Ltd.
 Manufacturing country: China.
 Features:
° Due to its solid constructions it can be positioned onto firm floorings to operate.
° It has excellent electrical layout in prevention of electricity leakage, shock, which
is important in wet conditions in the operations.
° Machine operations are made easy, with convenient start-stop operations for
maximum efficiency.
° The inner stainless steel is well balanced, thus achieving longer life span and
assuming energy efficiency of machine.
° Shock absorbers are well paced in the three suspension points to reduce
vibrations.
° Stainless steel constructions in major parts ensure durability.
 Specifications:
° Model no: SHE-42
° Capacity: 280 LBS
° Inner cylinder: 1067dial X 419mm
° Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H).

MODERN HYDRO EXTRACTORS
 Features:
° Full stainless steel outer drum and inner basket. Strong welded construction.
Basket can be dismantled without dismantling outer casing. Electrically
interlocked top lid stops the machine when opened. Three position drain
connection. Outer casing mounted on heavy galvanised plate base frame. Long
rust free life and strength.
° Direct drive. Basket is directly mounted on to a specially designed high torque
heavy-duty motor resting on spigot of the base frame with built-in rubber buffer
cushion for self-balancing. No v-belts, no speed loss, quick self-balancing.
Noiseless & vibration less operation.
° Automatic timed. Automatic DC injection for braking. Safety devices against
single phasing reverse phasing & motor overload. Great convenience & safety.
No foot pedals, no levers, no brake liners, no maintenance.
 Specifications:
° Model no: HX 50
° Capacity: 80 Kg
° Volume: 235 Litres
° Basket speed: 750 R.P.M.
° Drain: 75 mm dial

SAMPLE DRYING MACHINES
 Features:
° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body
not painted. Long rust free life and sheen.
° Built in solvent filter housed in the top tank receives soiled from the base tank
through a powerful centrifugal pump which pushes the soiled solvent through
several fine mesh cylindrical filters for reuse. Maximum recovery of clean
solvent.
° Low spin extract. Separate motors for dryclean & extract. Vibrationless during
extraction. Low spin extract makes articles lighter to unload. No solvent dripping.
No wastage of solvent.
° Automatic timed. Auto reverse. Full electrical protection against single phasing
& motor overload. Operator’s convenience & machine safety. Efficient cleaning.
 Specifications:
° Capacity: 18 Kg
° Basket size: 700 mm (dial) X 470 mm
° Dry clean motor: 0.37 KW
° Extract motor: 1.5 KW
° Extract speed: 220 rpm
° Loading door opening: 400 mm (dial)
° Base tank capacity: 250 Litres
° Filter tank capacity: 250 Litres
° Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H)

INDUSTRIAL DRYING MACHINES
 Features:
° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body
painted.
° Low spin extract. Vibration less during extraction. Low spin extract makes
articles lighter to unload.
° Automatic timed. Full electrical protection against single phasing & motor
overload. Operator’s convenience & machine safety. Efficient cleaning.
 Specifications:
° Capacity: 35 Kg
° Basket size: 950 mm (dial) X 500mm
° Dry clean motor: 0.75 KW
° Extract speed: 200 rpm
° Loading door opening: 500mm (dial)
° Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H)

INCOMING MACHINES
INDUSTRIAL WASHING PROCESSING & DYEING MACHINES
 Manufacturing company: STEFAB INDIAL LIMITED,
 Features:
 Specifications:
° Capacity: 280 kg (1:10)
° Inspection door opening: 300 mm dial
° Drain: 115 mm dial, 2 ways out
° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.

HYDRO EXTRACTOR MACHINE:
 Features:
° Full stainless steel outer drum and inner basket. Strong welded construction.
Basket can be dismantled without dismantling outer casing. Electrically
interlocked top lid stops the machine when opened. Three position drain
connection. Outer casing mounted on heavy galvanised plate base frame. Long
rust free life and strength.
° Direct drive. Basket is directly mounted on to a specially designed high torque
heavy-duty motor resting on spigot of the base frame with built-in rubber buffer
cushion for self-balancing. No v-belts, no speed loss, quick self-balancing.
Noiseless & vibration less operation.
° Automatic timed. Automatic DC injection for braking. Safety devices against
single phasing reverse phasing & motor overload. Great convenience & safety.
No foot pedals, no levers, no brake liners, no maintenance.
 Specifications:
° Model no: HX 50
° Capacity: 80 Kg
° Basket speed: 750 R.P.M.
° Drain: 75 mm dial

GARMENTS SAND-BLASTING MACHINES
INDUSTRIAL SAND-BLASTIG GUNS
 Manufacturing company: Made in China
 Features:
 Specifications:
° Model: SBT-650
° Capacity: 200 Litres
° Dimension: 800mm X 1000mm X 1250mm
° Sand contains: 200 Kg
OTHER COMPONENTS/ACCESSORIES
 No. of cabinets: 07
 Hopper (for controlling dust in cabinets): 02
 Helmet: 07 Pcs
 Musk: 07 Pcs
 Gloves: 07 pairs.
 Air preserver-1, capacity of 2000 c.c.
 Air preserver-2, capacity of 900 c.c.

OTHER MACHINES
 Spray machines: 03 Nos.
Manufacturing country: Hong Kong
 Compressor: 03 Nos.
Two compressors with same following specifications.
o Brand: ELGI
o Capacity: 10 Jule/Bar
o Made in INDIA
One compressor with following specifications:
o Brand: OSD
o Made in ITALY
o Includes Change Over
o MCCB
 Boiler:
Brand name: Sacca
Manufacturer: Made in ITALY
Production capacity: 1.5 Tons/Hr.
Pressure: 7.5 Jule Bar (5.0 Bar used)
Supply system: Automatic Pressure control.
Chimney: 50 Feet with 12-inch diameter.
 Generator
Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"
production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI)
alternators. All alternators are three phase, four pole, single bearing, synchronous type,
cosj=0.8, 50Hz.
 Water supply pump: 03 Nos.
02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse
Power.
01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power.
REMARKS

No live industry can keep place with the advance of technology without continuous
renewal & transformation of its production facilities. Existing equipments must be kept on the
defensive, compelled always to justify its tenure against the challenge of new & more modern
machines. If any piece of existing equipment fails to meet this challenge, it must be displaced,
regardless of its age or condition & regardless of whether it is physically “worn out”.
Keeping the above in view, this industry is always replacing its existing machines in
order to increase productivity & improve quality.
Chapter 5
Raw materials
Different sections of the industry require raw materials i.e. chemicals of various types in
different quantity. Most of the chemicals are purchased locally. A few are imported directly.
RAW MATERIALS USED IN GARMENTS WASHING
 Caustic Soda (NaOH)
° Type : Alkali
° Unit price : Taka 24 per Kg
° Source : Bangladesh
° Uses : Neutralize acidic materials, saponify glycerides (waxes
and oils), solubilize silicate
° Monthly requirements: 4050 kg (approximately)
 Soda Ash (Na2CO3)
° Type : Alkali
° Unit price : Taka 14 per kg
° Source : China
° Uses : Used to alkaline the solution/medium. Control PH

 Wetting agent:
° Type : Combination of Detergent & Surfactant
° Uses : Emulsify oils, fats and waxes; remove oil-stains; suspend
materials after they have been removed. Reduce surface
tension & minimize inter facial tensions.

Anti-back
° Type : Anti back staining agent
° Source : India, China
° Uses : Prevent back staining
 Acetic Acid
° Type : Organic acid
° Source : Korea
° Uses : Used to make solution/medium acidic. Control PH
 Sodium Hypo Chloride (NaOCl)
° Type : Oxidizing agent
° Source : India, China
° Uses : Used to uniform lightening of the colour of the indigo or
sulphur dyed garments in bleach wash.
 Bleaching Powder [Ca (OCl)Cl]
° Type : Oxidizing agent
° Unit price : Taka 21 per kg (KCI, 33% Chlorine), Taka 105 per kg
(Japan, 65% Chlorine)
° Source : India
° Uses : Used to decolouration of fabric
° Monthly requirements: 3590 kg (KCI), 142 (Japan) (approximately)
 Enzyme
° Type : Enzyme
° Unit price : Taka 300 per kg (liquid), Taka 400 per kg (powder)
° Source : China
° Uses : Used to breaks down the long starch molecular chain into
smaller sections, that can be easily washed from the

garments.
° Monthly requirements: 1500 kg (liquid), 1000 kg (powder) (approximately)
 Peumic Stone
° Type : Washing stone
° Unit price : Taka 280 per bag (25 kg)
° Source : China
° Uses : It is used to have an abrasion/irregular-fading effect of
stone on garment.
° Monthly requirements: 200 bags (approximately)
 Silicon
° Type : Softener
° Source : Korea
° Uses : Creates the fabric surface oily/ used for lubrication
 Softener Flax
° Type : Softener
° Source : Korea
° Uses : Soften fabric handling
 Potassium Permanganate
° Type : Decolouration agent
° Unit price : Taka 80 to 370 per kg
° Source : India, Bangladesh
° Uses : Used to decolouration of fabric
° Monthly requirements: Locally purchased when required.
 Sodium Meta bi Sulphate
° Type : De-chlorination agent
° Source : China
° Uses : Used to neutralize activity of chlorine on fabric/solution

 Peroxide (H2O2)
° Type : Oxidising agent
° Source : Korea
° Uses : OH-
ions destroy the colouring material and improve
whiteness
 Common Salt
° Type : Salt
° Unit price : Taka12 per kg
° Uses : Used as electrolyte for solution, improves shining of
fabric.
RAW MATERIALS USED IN GARMENTS DYEING
The following raw materials are used in garments dyeing in addition to some of the raw
materials already listed above.
 Dyestuff
o Type : Direct dye
o Unit price: Taka 300-1200 per Kg
o Source: China, Switzerland.
o Use: Cotton & Viscose garments dyeing.
o Monthly requirements: Depends on ordered quantity.
o Type: Reactive dye
o Unit price: Taka 275-850 per Kg.
o Source: China, Switzerland.
o Use : Cotton & Viscose garments dyeing.

o Type : Pigment dye
o Unit price: Taka 300-500 per Kg
o Source: Switzerland.
o Use: Cotton & Viscose garments dyeing.
 Glauber salt
o Type : Salt
o Unit price: Taka 14 per Kg
o Source: China.
o Use: Levelling agent.
 Fixing Agent
o Use: Colour fixation.
 Dispersing agent
o Use: Assists in the process of particle size reduction of dye.
REMARKS
The monthly requirements of raw materials vary depending on the type of washing &
ordered quantity. Sometimes the price of the materials also varies due to the availability of the
materials in the market.

Chapter 6
Production Planning, Sequences & Operations
Production process consist of different types of washing methods such as normal wash,
bleach wash, stone wash, acid wash, enzyme wash, super white wash, dirty wash etc and dyeing
methods with reactive, direct, sulphur etc dyes are done. Recently sandblast and chemical
sprayer added to the production process.
PRODUCTION FLOW CHART OF GARMENTS WASHING
Batching

Pre-treatment

Washing

Hydro Extraction

Drying

Quality Control

Storage

PRODUCTION FLOW CHART OF GARMENTS DYEING
Batching

Pre-treatment

Dyeing

Sample Check

Hydro Extraction

Drying

Quality Control

Storage

PROCESS TECHNIQUE OF SOME WASHING & GARMENTS DYEING METHODS
 ENZYME-BLEACH WASH WITH TINTING:
Batch 60 PCs. Liquor 400 Litre
Step 01 Water is added (400 Lt)
Desizing 
Garments are added

Machine started running

500 gm Soda Ash added

500 gm Caustic Soda added

200 gm Bio. D added

Steam to raise temp 60°C

Process time 25 minutes

Drop liquor

Wash down twice

Enzyme Wash 

200 ml liquid, 400 gm powder
type Enzyme added

150 ml Acetic Acid Added

200 gm Anti back added

10 Kg Peumic Stone added



Drop liquor
Bleaching 

4 Kg KCI (35% Cl2) added





Drop liquor
Neutral Wash 

500 gm Hypo sulphide added



Drop liquor
Tinting 


0.02% Direct Brown GTL &
0.01% Direct Black V-200 added

4 Kg Salt added



Check Shade

Drop the liquor
Step 06 Garments are then taken out
Drying 
Hydro extracted

Send to dryer for drying of garments.
 ACID WASH
Batch 100 PCs.
Liquor 500
Litre
Desizing 
Garments are added





200 gm Bio. D added



Drop liquor

Wash down twice
Normal
Wash


Steam to raise temperature 40°C


Drop liquor


Take out the garments

Hydro extract the garments

Dry the garments
Step 03
Load the pre-treated & dried
garments in another washing machine
Acid Wash 

Add stones soaked with potassium per magnate
double the volume of garments

Continue machine running for 7 minutes

Unload the garments from the machine
Step 04
Load the garments into another washing
machine
Neutral
Wash

Water is added (500 Lt)



1.5 Kg detergent is added



Drop liquor
Neutral
Wash


500 ml Auxalic Acid added


Check Shade

Drop the liquor

Garments are then taken out

Hydro extracted


Send to dryer for drying of garments.
 COTTON GARMENTS DYEING PROCESS (Sample Dyeing)
Batch 1.4 Kg
Liquor
14 Litre
Desizing 
Garments are added




100 gm Bio. D added


Process time 45~60 minutes

Drop liquor
Hot Wash 




Drop liquor
Step 03
Scouring &
Bleaching
Water is added 14 litre

Start machine running

Added 1 litre H2O2

50 gm Stabiliser added



100 gm Bio-D added

Process temp 80° C



Drop the liquor
Hot Wash 



Drop liquor
Neutral Wash 

200 ml Acetic Acid added


Drop the liquor
Dyeing 
Start machine running


560 gm Salt is added

Reactive dye (T. Blue. G) - 0.2% &
Drimerine – Blue K2RL-0.03% is added

20% Soda Ash is added

Processing temp 80° C

Processing time 60 minutes

Drop the liquor
Washing 

1 % Detergent is added



Drop liquor

Again Add water of 14 litre



Drop liquor

Unload the Garments

Hydro extractor

Drying

PRODUCTION REPORTS
Date: 08.11.2004
Sl.
No.
Name of
Buyer
Name of
Garments
Order/
Style no.
Types of
Process
Total
received
(pcs)
Delivery
Amount
(pcs)
Balance
(pcs)
1 Snoopy Utah
Washing
Sand Blast 17745 14899 2846
2 Snoopy Yoke Design G-21 Sand Blast +
Bleach
4129 778 3351
3 Caree
Four
Tusuka
Fashion
100341/2 Rewash 5100 3576 1524
4 Etam Aba Fashion Enzyme Silicon 18935 15127 3808
5 Caree
Four
Aba Fashion Enzyme Silicon 19576 15679 3897
6 Etam Export Knit 6094619 Enzyme Silicon 8696 8124 572
7 Texel Sportx Gmts. 100093 Enzyme + Dyed 7990 7191 99
8 Texel Sportx Gmts. 100093 Enzyme Wash 7628 5500 2128
9 Primark Universal 52510 Sand Blast +
Dyed
1200 1200
10 RN Sha Sha
Gmts.
1161R Sand Blast +
Dyed
5793 3767 2029
11 RN Sha Sha
Gmts.
8488 Sand Blast +
Enzyme
2934 798 2136
12 Nor
Wester
Leader Gmts. 25021X
Z
Sand Blast +
Enzyme
7404 2932 3122
13 Nor
Wester
Leader Gmts. 25027X
Z
Sand Blast +
Enzyme
5903 1500 4633
14 Nor
Wester
Fasnoor
Gmts.
25069X
Z
Enzyme Silicon 5155 4506 649
15 Nor
Wester
Tamanna Ltd. 25074/75 Silicon Wash 4527 3769 758
Grand Total 3275

Chapter 7
Maintenance
Maintenance is considered as important as other engineering functions. It makes
responsible for provision of a condition of machines, buildings and services that will permit
uninterrupted implementation of plans requiring their use.
OBJECTIVES OF MAINTENANCE:
 To keep the factory-plants, equipments, machine tools etc. in an optimum working
conditions.
 To ensure specified accuracy to products and time schedule of delivery to customers.
 To keep the down time of machines to the minimum thus to have control over the
production program.
 To keep the production cycle with in the stipulated range.
 To modify the machine tools to meet the augmented need for production.
Degree of maintenance effort.
Total cost
Labour & Overhead
Cost of spares &
maintenance
Cost of down time
Cost of down
in efficient operation
>
 To improve productivity of existing machine tools and to avoid sinking of additional
capital.
 To reduce the maintenance costs as for as possible thereby leading to a reduction in
factory overheads.
 To prolong the useful life of the factory, plant and machinery, while retaining their
acceptable level of accuracy of performance thus avoiding or prosponding incurring of
heavy capital expenditure involved in their replacement.

ECONOMIC CONSIDERATION OF MAINTENANCE
 It is very profitable activity & ensures maximum productivity at minimum costing.
 It improves product quality.
 It ensures less time to produce a specific product.
 It improves machine accuracy.
 It maintains a long life of the machine.
 No chance of back order.
MAINTENANCE FLOW CHART
Head of Maintenance

Technician

Assistant
FUNCTIONS OF MAINTENANCE PERSONNEL
 Inspection or Check-Ups:
° External inspections: Watching and detecting defects form abnormal sound,
vibration, heat, smoke etc when machine is in operation.
° Internal inspections: Inspection of parts such as gears, bushes, bearings,
tolerances in the parts etc. when machine is under pre-planned shutdowns.
° Inspections of important machines: Machines, which can disrupt whole of the
production, are delicate and require much time for the repair. Attentions are given
for inspection of these machines and schedule for inspection, cleaning lubrication
are done rigidly.
° Inspections of ordinary machines: Frequency of inspection of ordinary
machines is kept as low as they do not affect the production.

 Lubrication: Mechanical components like gears, bearings, bushes and other friction
surfaces etc. give good performance for long periods when they are systematically
lubricated. Systematic lubrication means the application of right type of lubricants at the
right time, at right place and in right quantity. For lubrication, a lubrication schedule
should be prepared and that should be followed strictly. Here lubrication is done
whenever is needed.
 Planning and scheduling: Every preventive maintenance work should be pre-planned
in detail on the basis of the analysis done on the past records. A scheduled programme
thus prepared should be followed strictly. Thus programme should be in detail specifying
the point-requiring daily, weekly, monthly, half yearly or yearly attention.
 Records and analysis: Good record keeping is essential for good maintenance, as it
helps in for casting maintenance. For this purpose following records are generally
maintained:
° Operation manual
° Maintenance and instruction manual
° History Cards and History Registers
° Spares Procurement Registers
° Spare Procurement Register
° Inspection Register
° Log books
° Defect Register etc.
 Training of Maintenance personnel: For the success of maintenance a sound
training is essential for the maintenance personnel. Hence the technicians and
supervisors are trained to carry out maintenance, inspection and repaired in a systematic
way.
 Storage of Spare Parts: Sometimes machine remains idle for want of spare parts for
considerable time and thus it affects considerable loss of production. Hence it is essential
to keep the spare parts so as to avoid loss of production.

Maintenance practices are made from the following ways:
 Capital replacement: capital replacement is undertaken if analysis reveals that the
retention of equipment no more remains an economical proposition.
 Provision of stand-by-capacity: Stand by capacity is often provided for items of
equipment that we are critical to production. It is sometimes an economical maintenance
practice to install such spare capacity to be put into operation while the original unit is
under repair or is over-hauled.
 Break-down maintenance: Break-down maintenance practice allows a machine or
any other facility to run without much of routine attention, till it actually breaks down to
be then put back into commission.
 Scheduled maintenance: Scheduled maintenance system provides for inspection,
overhaul lubrication, and servicing of certain machines at predetermined dates. Over-
hauling of machines, cleaning of tanks and white washing of buildings is normally done
in this manner.
 Planned maintenance: Planned maintenance visualise the work contained in a future
job determines the best method to be adopted and skills required for its execution;
estimates the time, material and costs involved assigning jobs to individuals;
programmes the work to specific time periods on the basis of priority and after
ascertaining production requirements; arranges for availability of material tools and man-
power and for release of machines in time.
 Preventive maintenance: It consists of routine actions taken in a planned manner to
prevent breakdowns and to ensure operational accuracy to the extent it is economically
and practically possible to do so.

MAINTENANCE TOOLS & THEIR FUNCTIONS
Tools Nos. Specifications Uses
Measuring Tape 02 Both British and Metric system
measurement.
Mostly used for linear
measurement
Hammer 01 It is just a weighted head and a
handle that directs its course.
The Hammer is very simple
striking tool.
Screw Driver (flat
type)
02 10” steel shank, with flat blade and
plastic handle.
To loosen or tighten screws.
Screw Driver
(Phillips head)
01 8” steel shank, with star blade and
plastic handle.
To loosen or tighten screws
Pliers 01
Nose Pliers 01
Wrench (Locking
adjustable)
02 For exerting a twisting strain
in turning bolt & nuts
Wrench (Pipe) 03
Wrench (Double
head open end)
06
Wrench
Hacksaw Adjustable frame Used to saw metal
Chisels (cold, flat
point)
01 Made of good grade tool steel Used for cutting or chipping
metals.
Table vice 01
File
Mobil Gun 01
Wielding Machine 01
Hand Grinding
Machine
01
Fixed Grinder 01
Hand drill 01

Chapter 8
Utility Services
Man, Machine and Material, the three main things that can accelerate the production, if it
is used in proper and organized way. In the Industry, UTILITY plays an important role in case
of production. Production and profit are closely related. In order to get a quality-finished
product, it needs fresh raw materials as well as effective manpower and machinery in good
working condition. Utility is closely related to the three M's plays a vital role to maximize the
production as well as profit.
FUNCTIONS OF UTILITY
 Utility ensures power supply by generator.
 Utility ensures water supply by pump.
 It ensures steam by boiler.
 It ensures compressed air handling by vacuum planning system.
 It provides fuel and gas supply.
 It provides workshop facilities.
AVAILABLE UTILITIES
The following utility facilities are available at HAMS WASHING & DYEING LTD.
 Water.
 Steam.
 Electricity.
 Gas.
 Compressed air.
 Covered Van for Transportation.

SOURCES OF UTILITIES
 Water: Own Supply (Pump)
 Steam: Own supply (Boiler)
 Electricity: Generator & PDB
 Gas: Titas Gas Transmission & Distribution Co. Ltd.
 Compressed Air: Own supply (Air compressor)
CAPACITY & OTHER TECHNICAL DETAILS
 WATER: Water is supplied by pump. Pump supplies water on the basis of pressure.
Pump pressure ranges 0-10 bar. The pump is operated at 2-4-bar pressure. 3 motors are
used for uniform water supply. These are automatic on-off system motor. When the
pressure is reduced to the desired level (2 bars) then the motor is turned on. Similarly
when the pressure is above the desired level (4 bars) then the motor is turned off. So, it
has variable water supply capacity & supplies water as required.
The water, which is used for cooling, is brought to a tank & again supply by a pump.
There are 3 deep tube wells used in this project. Water is directly used in washing &
dyeing & other subsequent process.
02 PCs. Deep Tube wells are submersible, Made in ITALY, BG brand with 30 Horse
Power.
01 PC. Deep Tube well is submersible, Sigma branded, Made in ITALY with 42 Horse
Power.
 STEAM: Heat generation is a very important factor for washing and dyeing process.
Steam is a very efficient & easy way to transfer heat. There is a boiler to generate steam.
By pipe line the generated steam is supplied to the washing and dyeing machines &
where it is necessary. The boiler has the capacity to generate steam 1.5 Tons/Hr.
Technical details about the boiler:

Boilers function is to transfer the heat produced by the combustion of fuel (gas) to water
and ultimately to generate steam.
Brand name: Sacca
Manufacturer: Made in ITALY
Production capacity: 1.5 Tons/Hr.
Pressure: 7.5 Jules Bar (5.0 Bar used)
Supply system: Automatic Pressure control.
Chimney: 50 Feet with 12-inch diameter.
 ELECTRICITY: It is totally impossible to continue the production without electricity.
A frequent supply of electricity is very essential for soundless production. Here all the
machines in washing and dyeing section are provided electricity by the govt. electricity
with own standby generator of the industry.
Technical Details about the Generator:-
Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"
production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI)
alternators. All alternators are three phase, four pole, single bearing, synchronous type,
cosj=0.8, 50Hz.
Model Rated power Voltage Alter-
nator
Diesel engine
specification
Dimensions Weight
KVA KW V LxWxH cm Kg
E275VM 275 220 400/230 MA "VOLVO" TWD1210G,
6 cyl., turbocharg
300x110x192
2400
 Electric Substation:
o 500 KVA Transformer (11 KV to 440 KV)
 Brand: Power man
 Three phase
 Rated power: 500 KVA
 Standard: Bs-171
 Class: A
 Rated Frequency: 50 Hz
 Type of cooling: ONAN

 AMBIENT Temperature: 50°C
 Duty: Continuous.
 Voltage: 11000 Volt (HT) 415 (LT)
 Rated Current: [HT - 26] [LT - 695] AMP
 Vector group Dyn – 11
 Impedance Voltage: 0.5%
 Total Weight: 179 Kg
 Lift able Weight: 990 Kg
 Oil Weight: 610 Kg
 Winding Temperature: 55°C
 Manufacturing Year: 2003
 Made in Bangladesh.
o High Tension Switch.
o Switch Gear
 Brand: Power Man
 Voltage: 415 Volt, 50 Hz
 Phase: 3 Phase, 1 Neutral
 Incoming: 800 AMP
 MCCB/ACB
 Made in Bangladesh
o ACB (Air-Circuit-Breaker)
 Brand: SPARK Energy
 Model: OSLO 6E
o MCCB (Magnetic Contact Current Circuit Breaker)
o PFI (Power Factor Improvement Plant, 6 step auto control)
 Brand: Power man
 Rating: 200 KV
 Voltage: 415V, 50 Hz
o Change Over
o Bash Bar Panel Board.
 Compressor: Two compressors with same following specifications.
o Brand: ELGI

o Made in INDIA
One compressor with following specifications:
o Brand: OSD
o Made in ITALY
o Includes Change Over
o MCCB
 Air Condition:
o Exhaust Fan: 03 Nos.
o Air Cooler: 02 Nos.
 Fire Fighting Tools:
o Washing section: 10 Nos. Fire Extinguisher
 Air Dryer:
o For Compressor: 3 Nos.
 Cover Van:
o 3 Cover Van used to carry garments.
 Gas: The company gets natural gas from Titas Gas Transmission & Distribution Co. Ltd.
Capacity of gas line is variable ie. line able to supply gas according to the requirements.
COST OF UTILITIES
 Water: Own supply (Pump)
 Electricity Required- 46 KW/Hr. Cost 5 TK/KW.
 Steam: Own Supply (Boiler)
 Gas required: 670 Meter3
/Hr. Cost 5.60 TK/ Meter3
(Aprox.)
 Compressed Air: Own Supply (Air compressor)
REMARKS
There is problem with water supply in the company. The supply of water is not
sufficient, which create problem in washing and dyeing. The quality of water is not up to the
level. The hardness & presence of iron in water is high. A water treatment plant is very essential

to continue the production without disturb & to increase the production.
The generator of the industry is too old to supply the electricity fluently. Sometimes it
trip without any warning. So, it’s necessary to have a new generator for the industry.
The boiler also very old to maintain it high bar pressure. It should be replaced with
modern boiler for better service.
Chapter 9
Store & Inventory Control
In HAMS WASHING & DYEING LTD. there are different inventory systems for
different raw materials and finished materials.
DYE & CHEMICAL STORE
There is a different store for dyes & chemicals. Various types of dyes & chemicals are
stored here according to the dyes & chemical company.
Different types of dyes & chemicals are listed in a sheet. In the sheet the stored quantity
of dyes & chemicals are also included. Everyday the sheet is updated & a copy of this sheet is
supplied to the GM (production), Dye house & lab section.
SPARE STORE
In HAMS WASHING AND DYEING LTD. required amount of spears of different
machines are stored in the mechanical storeroom. All the spears are listed in a sheet, which is
controlled by the mechanical & maintenance personnel. Spares are arranged in the storeroom
according to their size, quantity & requirements. There are shelves in the storeroom to keep the
small spare parts.
FINISHED PRODUCT STORE
HAMS WASHING AND DYEING LTD. supplies its finished dyed fabrics to its
garments section. So, dyed finished fabrics are stored for short time in the finishing section. All
the delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics
diameter, buyer’s name, colour& considering other technical parameters.

OTHERS STORE
There is a central store at HAMS WASHING AND DYEING LTD. In that store the
various types of forms, papers, stationary & other necessary goods are kept.
Chapter 10
Cost analysis
Cost analysis is a crucial step for any business organization, specially if it is a
manufacturing company. Here cost analysis is done in conventional method.
SAMPLE COST ANALYSIS
 Issue Date: 10-07-2004
 Buyer: Nassa – Pinacle
 Po-Style-Ref. : 21051
 Type of Garments: Denim Long Pant
 Type of Wash: Enzyme/ Bleach/ Tint
 Quantity/ Machine: 60 PCs.
 Weight of Total Garments: 62 Kg.
Process Chemicals Quantity Temp Time Total
Desizing Caustic Soda 500 gm 12 /=
Soda Ash 500 gm 60°C 15 min 7 /=
Bio. D 400 gm 25 /=
Enzyme Wash Enzyme Powder 400 gm 152 /=
Enzyme Liquid 200 gm 48 /=
Anti Back Staining 200 gm 40°C 55-60 min 25 /=
Acetic Acid 100 gm 7 /=
Stone ½ bag 212 /=
Bleaching Bleaching (Japan) 500 gm 50°C 6-8 min 46 /=
Neutral Wash Hypo Sulphide 500 gm Cold 5 min 9 /=
Peroxide H2O2 500 gm 50°C 10 min 18 /=
Bio. D 100 gm 12 /=
Tinting Dir Brown GTL 20gm 14 /=
Dir Yellow 2 gm 50°C 20 min 2 /=
Salt 4 Kg 28 /=
Total Chemical Cost= 617/=
Add 10% Wastage = 678/=
Per Dozen = 135.6/=

Chemical Cost in USD/Doz = 2.47/=
Overhead Cost USD/Doz = 1.5/=
Total Cost USD/Doz = 3.97/= ~ 4.00/=
Profit USD/ Doz = 0.75/=
Final Cost USD/Doz = 4.75/=
Chapter 11
Conclusion
As a ready made garments washing and dyeing sector, HAMS WASHING & DYEING
LTD. is excellent among the industries of Bangladesh. Garments washing and dyeing sector
comprise varieties of machineries. It is still completely running position.
The Management system of the factory is quite well too. All the personnel of the factory
are co-operative and friendly with us. The security system is very good too.
In the training period, we were introduced as a member of the factory. For that, they gave
us all kind of facilities and scope for learning about washing and dyeing production and
machineries.
Above all the industrial attachment has given us new ideas for practical life.

Industrial attachment of hams washing & dyeing ltd.

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Viewers also liked

Viewers also liked (20)

Similar to Industrial attachment of hams washing & dyeing ltd.

Similar to Industrial attachment of hams washing & dyeing ltd. (20)

More from Md. Mazadul Hasan Shishir

More from Md. Mazadul Hasan Shishir (19)

Recently uploaded

Recently uploaded (20)

Industrial attachment of hams washing & dyeing ltd.