Industrial attachment of noman weaving mills limited

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Industrial attachment of noman weaving mills limited

  1. 1. Noman Weaving Mills Ltd 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Noman Weaving Mills Limited Noman Weaving Mills Ltd 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Noman Weaving Mills Limited Noman Weaving Mills Ltd 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT Noman Weaving Mills Limited
  2. 2. Noman Weaving Mills Ltd 2 Noman Weaving Mills Ltd 2 Noman Weaving Mills Ltd 2
  3. 3. Noman Weaving Mills Ltd 3 Acknowledgment “In the name of Allah, the most merciful and beneficent” All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Sunnah, the everlasting source of guidance and knowledge for humanity. At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his supervision. Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University have made our efforts for training & report writing successful. During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their valuable time on the very busy schedule. Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this training and ultimate success could not come out a good result. Noman Weaving Mills Ltd 3 Acknowledgment “In the name of Allah, the most merciful and beneficent” All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Sunnah, the everlasting source of guidance and knowledge for humanity. At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his supervision. Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University have made our efforts for training & report writing successful. During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their valuable time on the very busy schedule. Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this training and ultimate success could not come out a good result. Noman Weaving Mills Ltd 3 Acknowledgment “In the name of Allah, the most merciful and beneficent” All praise to Almighty Allah, the most Gracious and compassionate. Who created the universe and bestowed mankind with the knowledge and blessings of Allah be upon the Holy Prophet Muhammad (S.A.W.) who guided mankind with the Holy Quran and Sunnah, the everlasting source of guidance and knowledge for humanity. At first we want to pay cordial gratitude to Almighty Allah. Our industrial training was conducted in Noman Weaving Mills Ltd. We are greatly thankful to the authority of Noman Group for their whole hearted cooperation and cordial support in providing information and assisting our training activates. Specially we want pay thank to Nure Yasmin Fatima DMD-1 & Md.Zaber Abdullah, DMD-2, Noman Group for giving us opportunity to performing our internship of their reputed industry. We also thankful to Md. Shohrab Hossain (Babar) DGM of the Noman Weaving Mills Ltd, for his special guidance and Md. Abdul Mumen of production Manager, for grant us his precious time and valuable discussion during the training period. It has been a great opportunity to be a trainee under his supervision. Guidance from Professor Syed Fakhrul Hassan, Chairman, Department of textile Engineering of Southeast University and Md. Mahmudul Islam, Lecturer, Department of Textile Engineering, Southeast University have made our efforts for training & report writing successful. During the eight week long period a lot of staffs of Noman Weaving Mills Ltd helped us very honestly. Gratefully we mention the names Md. Habibur Rahman,Assistant manager ( R&D) , Md. Saiful Islam, Production Officeer, Weaving (Picanol), Mohammad Ali, production officer, Sectional Warping. Mustaq Ahmed Master, Sizing department. Md. Fazlul Haque, production officer, Md. Arif Hassan, Production officer. Md. Sarwar Uddin, Rashidur Rahman, Assistant Manager (Mechanical). Eng. Anisur Rahman, Technical Manager (Mechanical). Whose are very helpful and given us their valuable time on the very busy schedule. Finish but not yet we are thankful to all the staffs whose name is not listed but without their help this training and ultimate success could not come out a good result.
  4. 4. Noman Weaving Mills Ltd 4 TABLE OF CONTENTS Acknowledgement Project Description Introduction Objectives Duration of study Location of factory General information of the factory Units of Noman Group Layout plan Product mix Different departments of factory Manpower Management General organ gram Manpower setup Machine Description Specifications of the machines Layout plan of weaving section Information’s of raw materials Research & Development R & D department Production Planning, Sequences & Operation Sequence of operation Winding Yarn path diagram of winding Noman Weaving Mills Ltd 4 TABLE OF CONTENTS Acknowledgement Project Description Introduction Objectives Duration of study Location of factory General information of the factory Units of Noman Group Layout plan Product mix Different departments of factory Manpower Management General organ gram Manpower setup Machine Description Specifications of the machines Layout plan of weaving section Information’s of raw materials Research & Development R & D department Production Planning, Sequences & Operation Sequence of operation Winding Yarn path diagram of winding Noman Weaving Mills Ltd 4 TABLE OF CONTENTS Acknowledgement Project Description Introduction Objectives Duration of study Location of factory General information of the factory Units of Noman Group Layout plan Product mix Different departments of factory Manpower Management General organ gram Manpower setup Machine Description Specifications of the machines Layout plan of weaving section Information’s of raw materials Research & Development R & D department Production Planning, Sequences & Operation Sequence of operation Winding Yarn path diagram of winding
  5. 5. Noman Weaving Mills Ltd 5 Warping Calculations of high speed warping Calculations of sectional warping Sizing Machine specification Control system of sizing Size chemicals & their costing Calculation of sizing Drawing & Denting Loom Basic mechanism of power loom Weft path diagram of air jet loom Machine specification of air jet Compressor air quality Loom piping system General operation of air jet Rapier loom Specification of picanol Basic mechanism of rapier Setting of rapier Projectile loom Machine specification Operation procedure Quality Assurance System Quality assurance system Inspection system Quality standard Noman Weaving Mills Ltd 5 Warping Calculations of high speed warping Calculations of sectional warping Sizing Machine specification Control system of sizing Size chemicals & their costing Calculation of sizing Drawing & Denting Loom Basic mechanism of power loom Weft path diagram of air jet loom Machine specification of air jet Compressor air quality Loom piping system General operation of air jet Rapier loom Specification of picanol Basic mechanism of rapier Setting of rapier Projectile loom Machine specification Operation procedure Quality Assurance System Quality assurance system Inspection system Quality standard Noman Weaving Mills Ltd 5 Warping Calculations of high speed warping Calculations of sectional warping Sizing Machine specification Control system of sizing Size chemicals & their costing Calculation of sizing Drawing & Denting Loom Basic mechanism of power loom Weft path diagram of air jet loom Machine specification of air jet Compressor air quality Loom piping system General operation of air jet Rapier loom Specification of picanol Basic mechanism of rapier Setting of rapier Projectile loom Machine specification Operation procedure Quality Assurance System Quality assurance system Inspection system Quality standard
  6. 6. Noman Weaving Mills Ltd 6 Maintenance Maintenance of machine Maintenance procedure Utility Services Utility services Available utility facilities Store & Inventory Inventory Cost Analysis & Marketing Activities Cost analysis Marketing activities Conclusion Conclusion Limitations Suggestions Noman Weaving Mills Ltd 6 Maintenance Maintenance of machine Maintenance procedure Utility Services Utility services Available utility facilities Store & Inventory Inventory Cost Analysis & Marketing Activities Cost analysis Marketing activities Conclusion Conclusion Limitations Suggestions Noman Weaving Mills Ltd 6 Maintenance Maintenance of machine Maintenance procedure Utility Services Utility services Available utility facilities Store & Inventory Inventory Cost Analysis & Marketing Activities Cost analysis Marketing activities Conclusion Conclusion Limitations Suggestions
  7. 7. Noman Weaving Mills Ltd 7 Chapter -01 Project description Noman Weaving Mills Ltd 7 Chapter -01 Project description Noman Weaving Mills Ltd 7 Chapter -01 Project description
  8. 8. Noman Weaving Mills Ltd 8 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction Noman Weaving Mills Ltd 8 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction Noman Weaving Mills Ltd 8 Introduction: Industrial training is an important part of a student of textile engineering. Internship helps a student to get practical knowledge about the whole process of textile technology. After the 11 th semester of four year B.sc Textile Engineering we had a mandatory training on the advanced subject. We finished our internship from Noman Weaving Mills Ltd, a 100% export oriented weaving mill. The industry is concerned with grey woven fabric and Yarn dyed fabric. During the eight months long period we have tried our best to perform our duty perfectly. The authority of this factory helped us a lot to perform our duty very freshly. For that reason we got the required data very shortly. Every employee towards this factory tried to help us honestly from their position and busy schedule. This internship helped us to minimize the gap between theoretical and practical knowledge. We think this idea will help to our future practical work. Objectives:  The main purpose of our entire training schedule is to know about the difference between the theoretical and practical on different processing of textile.  To know about the whole sections of the industry  To get a very strong about the processing of textile product.  To be able to handle the weaving section and production  To know about the activities of mechanical & electrical sections  To know about the inventory & costing on different purpose  To gather the maintenance & various utility services  To know about the quality parameters of the product Place of study: We have completed our industrial training on Noman Weaving Mills Limited. It is situated at Mawna, Sreepur, Gazipur. This is a 100% export oriented weaving factory. Actually this factory is very much sincere about the quality level so this is a very perfect place for industry. Duration of study: The total duration of training period was eight week Method of study: We worked here as trainee and our working method was Auto Instruction
  9. 9. Noman Weaving Mills Ltd 9 Noman Weaving Mills Mawna Bazar Tangail Joydebpur Dhaka Candana Gazipur Maymensing N Noman Weaving Mills Ltd 9 Noman Weaving Mills Mawna Bazar Tangail Joydebpur Dhaka Candana Gazipur Maymensing N Noman Weaving Mills Ltd 9 Noman Weaving Mills Mawna Bazar Tangail Joydebpur Dhaka Candana Gazipur Maymensing N
  10. 10. Noman Weaving Mills Ltd 10 GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD  Name of the factory : Noman Weaving Mills Ltd. (An enterprise of Noman Group)  Location : (kewa westside), Mawna, Sreepur, Gazipur.  Business Type : 100%Export Woven Factory  Status : Private Ltd. Company.  Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120, Motijheel C/A, Dhaka-1000.  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282 History of the project development: Land purchase : June 2006 Machine setup : December 2006 Year of production : January 2007 Total area of land : 25 Bigha Production floor: (a) Airjet floor : 47581 sft (b) Sizing shed : 44762 sft (c) Sectional warping : 18036 sft (d) Picanol floor :11620 sft No. of machine: (a) Toyota air jet loom : 128 pcs (b) Picanol loom : 40 pcs Production capacity: (a) Toyota airjet loom : 45000 Mtr (b) Picanol loom : 9000 Mtr Total production : 54000 Mtr Per month production : 1404000 Mtr Noman Weaving Mills Ltd 10 GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD  Name of the factory : Noman Weaving Mills Ltd. (An enterprise of Noman Group)  Location : (kewa westside), Mawna, Sreepur, Gazipur.  Business Type : 100%Export Woven Factory  Status : Private Ltd. Company.  Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120, Motijheel C/A, Dhaka-1000.  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282 History of the project development: Land purchase : June 2006 Machine setup : December 2006 Year of production : January 2007 Total area of land : 25 Bigha Production floor: (a) Airjet floor : 47581 sft (b) Sizing shed : 44762 sft (c) Sectional warping : 18036 sft (d) Picanol floor :11620 sft No. of machine: (a) Toyota air jet loom : 128 pcs (b) Picanol loom : 40 pcs Production capacity: (a) Toyota airjet loom : 45000 Mtr (b) Picanol loom : 9000 Mtr Total production : 54000 Mtr Per month production : 1404000 Mtr Noman Weaving Mills Ltd 10 GENERAL INFORMATION ABOUT NOMAN WEAVING MILLS LTD  Name of the factory : Noman Weaving Mills Ltd. (An enterprise of Noman Group)  Location : (kewa westside), Mawna, Sreepur, Gazipur.  Business Type : 100%Export Woven Factory  Status : Private Ltd. Company.  Head office (Corporate Office) : Adamjee Court (5th &6th Floor), 115-120, Motijheel C/A, Dhaka-1000.  Phone No.7176207-8,9572135,9569669,Fax-880-2-9565282 History of the project development: Land purchase : June 2006 Machine setup : December 2006 Year of production : January 2007 Total area of land : 25 Bigha Production floor: (a) Airjet floor : 47581 sft (b) Sizing shed : 44762 sft (c) Sectional warping : 18036 sft (d) Picanol floor :11620 sft No. of machine: (a) Toyota air jet loom : 128 pcs (b) Picanol loom : 40 pcs Production capacity: (a) Toyota airjet loom : 45000 Mtr (b) Picanol loom : 9000 Mtr Total production : 54000 Mtr Per month production : 1404000 Mtr
  11. 11. Noman Weaving Mills Ltd 11 Man power: Officer Staff Worker a) Male : 41 Male : 93 Male : 418 b) Female : 01 Female : 02 Female : 144 Total manpower of the factory : 699 people Toilet: a) Officer/staff : 13 pcs b) Male worker : 08 pcs c) Female worker : 05 pcs Fire Extinguisher: a) DCP : 99 pcs b) CO2 : 55 pcs c) Water : 20 pcs d) Foam : 06 pcs Dormitory: a) Officer/staff & F.Q : 01 pcs b) Worker : 01 pcs Emergency gate : 01 pcs Units of Noman Group:  Sufia fabrics ltd.  Talha Tex pro Ltd.  Artex Fabrics Ltd.  Noman Fabrics Ltd.  Nice Denim Mills Ltd.  Marium Textile Mills Ltd.  Zaber Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Noman Weaving Mills Ltd.  Sufia cotton Mills Ltd.  Zarba Textile Mills Ltd. Noman Weaving Mills Ltd 11 Man power: Officer Staff Worker a) Male : 41 Male : 93 Male : 418 b) Female : 01 Female : 02 Female : 144 Total manpower of the factory : 699 people Toilet: a) Officer/staff : 13 pcs b) Male worker : 08 pcs c) Female worker : 05 pcs Fire Extinguisher: a) DCP : 99 pcs b) CO2 : 55 pcs c) Water : 20 pcs d) Foam : 06 pcs Dormitory: a) Officer/staff & F.Q : 01 pcs b) Worker : 01 pcs Emergency gate : 01 pcs Units of Noman Group:  Sufia fabrics ltd.  Talha Tex pro Ltd.  Artex Fabrics Ltd.  Noman Fabrics Ltd.  Nice Denim Mills Ltd.  Marium Textile Mills Ltd.  Zaber Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Noman Weaving Mills Ltd.  Sufia cotton Mills Ltd.  Zarba Textile Mills Ltd. Noman Weaving Mills Ltd 11 Man power: Officer Staff Worker a) Male : 41 Male : 93 Male : 418 b) Female : 01 Female : 02 Female : 144 Total manpower of the factory : 699 people Toilet: a) Officer/staff : 13 pcs b) Male worker : 08 pcs c) Female worker : 05 pcs Fire Extinguisher: a) DCP : 99 pcs b) CO2 : 55 pcs c) Water : 20 pcs d) Foam : 06 pcs Dormitory: a) Officer/staff & F.Q : 01 pcs b) Worker : 01 pcs Emergency gate : 01 pcs Units of Noman Group:  Sufia fabrics ltd.  Talha Tex pro Ltd.  Artex Fabrics Ltd.  Noman Fabrics Ltd.  Nice Denim Mills Ltd.  Marium Textile Mills Ltd.  Zaber Spinning Mills Ltd.  Talha Spinning Mills Ltd.  Noman Weaving Mills Ltd.  Sufia cotton Mills Ltd.  Zarba Textile Mills Ltd.
  12. 12. Noman Weaving Mills Ltd 12  Noman Terry Towel Mills Ltd.  Yasmin Textile Mills Ltd.  Talha Fabrics Limited  Ismail Spinning Mills Ltd.  Zubair spinning mills Ltd.  Noman Textile Mills Ltd.  Zaber Zubair Fabrics Ltd.  Noman Spinning Mills Ltd.  Yasmin Spinning Mills Ltd.  Saad Saan Textile Mills Ltd.  Zaber &Zubair Accessories Ltd.  Noman composite Textile Ltd  Ismail Anzuman –Ara Fabrics ltd.  Saad Saan Apparels Ltd.  Noman Fashion Fabrics Ltd.  Zarba Rotor Spinnimg Mills Ltd. Noman Weaving Mills Ltd 12  Noman Terry Towel Mills Ltd.  Yasmin Textile Mills Ltd.  Talha Fabrics Limited  Ismail Spinning Mills Ltd.  Zubair spinning mills Ltd.  Noman Textile Mills Ltd.  Zaber Zubair Fabrics Ltd.  Noman Spinning Mills Ltd.  Yasmin Spinning Mills Ltd.  Saad Saan Textile Mills Ltd.  Zaber &Zubair Accessories Ltd.  Noman composite Textile Ltd  Ismail Anzuman –Ara Fabrics ltd.  Saad Saan Apparels Ltd.  Noman Fashion Fabrics Ltd.  Zarba Rotor Spinnimg Mills Ltd. Noman Weaving Mills Ltd 12  Noman Terry Towel Mills Ltd.  Yasmin Textile Mills Ltd.  Talha Fabrics Limited  Ismail Spinning Mills Ltd.  Zubair spinning mills Ltd.  Noman Textile Mills Ltd.  Zaber Zubair Fabrics Ltd.  Noman Spinning Mills Ltd.  Yasmin Spinning Mills Ltd.  Saad Saan Textile Mills Ltd.  Zaber &Zubair Accessories Ltd.  Noman composite Textile Ltd  Ismail Anzuman –Ara Fabrics ltd.  Saad Saan Apparels Ltd.  Noman Fashion Fabrics Ltd.  Zarba Rotor Spinnimg Mills Ltd.
  13. 13. Noman Weaving Mills Ltd 13 WEAVINGSHED SIZINGSHED DIGICLOTH STORE FOLDING&INSPECTIONDEPT GENERATOR CHIILLER W ORK SHOP WARPING OFFICE A/C STATION GATE01 SECURITY SECURITY POST NOMANWEAVING MILLSLTD GATE01 SECURITYAIR VESSEL SECURITY W ASTAGE STORAGE BOILER CANTENE FOR WORKER OFFICE ROOM TOILET MAINGATE SECURITYPERSON20 MAYMENSING DHAKA HIGH WAY N LAY-OUT PLAN OF THE FACTORY Noman Weaving Mills Ltd 13 WEAVINGSHED SIZINGSHED DIGICLOTH STORE FOLDING&INSPECTIONDEPT GENERATOR CHIILLER W ORK SHOP WARPING OFFICE A/C STATION GATE01 SECURITY SECURITY POST NOMANWEAVING MILLSLTD GATE01 SECURITYAIR VESSEL SECURITY W ASTAGE STORAGE BOILER CANTENE FOR WORKER OFFICE ROOM TOILET MAINGATE SECURITYPERSON20 MAYMENSING DHAKA HIGH WAY N LAY-OUT PLAN OF THE FACTORY Noman Weaving Mills Ltd 13 WEAVINGSHED SIZINGSHED DIGICLOTH STORE FOLDING&INSPECTIONDEPT GENERATOR CHIILLER W ORK SHOP WARPING OFFICE A/C STATION GATE01 SECURITY SECURITY POST NOMANWEAVING MILLSLTD GATE01 SECURITYAIR VESSEL SECURITY W ASTAGE STORAGE BOILER CANTENE FOR WORKER OFFICE ROOM TOILET MAINGATE SECURITYPERSON20 MAYMENSING DHAKA HIGH WAY N LAY-OUT PLAN OF THE FACTORY
  14. 14. Noman Weaving Mills Ltd 14 Product mix:  Plain  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Twill  2/1s twill, 3/2 S twill  Satin  5 ends satin, stripe satin poplin Voile Matt Canvas Oxford stripe fabric Noman Weaving Mills Ltd 14 Product mix:  Plain  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Twill  2/1s twill, 3/2 S twill  Satin  5 ends satin, stripe satin poplin Voile Matt Canvas Oxford stripe fabric Noman Weaving Mills Ltd 14 Product mix:  Plain  Poplin, Voile, Matt, Canvas, Oxford, stripe fabric, checks fabric.  Twill  2/1s twill, 3/2 S twill  Satin  5 ends satin, stripe satin poplin Voile Matt Canvas Oxford stripe fabric
  15. 15. Noman Weaving Mills Ltd 15 Check fabric 2/1s twill 3/2 S twill 5 ends satin Stripe Satin Different Department:  Administration dept.  Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  Production dept. Noman Weaving Mills Ltd 15 Check fabric 2/1s twill 3/2 S twill 5 ends satin Stripe Satin Different Department:  Administration dept.  Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  Production dept. Noman Weaving Mills Ltd 15 Check fabric 2/1s twill 3/2 S twill 5 ends satin Stripe Satin Different Department:  Administration dept.  Accounts dept.  Store dept.  Security dept.  Mechanical dept.  Electrical dept  Quality dept.  Mending &folding dept  Utility dept.  Workshop dept.  Preparatory dept.(sizing & warping )  R&D dept.  Production dept.
  16. 16. Noman Weaving Mills Ltd 16 Chapter- 02 Manpower Management Noman Weaving Mills Ltd 16 Chapter- 02 Manpower Management Noman Weaving Mills Ltd 16 Chapter- 02 Manpower Management
  17. 17. Noman Weaving Mills Ltd 17 D Noman Weaving Mills Ltd 17 D Noman Weaving Mills Ltd 17 D
  18. 18. Noman Weaving Mills Ltd 18 Manpower setup in different shift:  Administration dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 26 06 03 01 -04  Accounts dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 03 -02  Store dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 37 01 01 01 -04  Security dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 02 22 22 22 -17  Mechanical dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 18 19 19 19 -34  Electrical dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 09 05 05 05 -15  Quality dept. Shift General Shift “A” Shift “B” Shift “C” Short Noman Weaving Mills Ltd 18 Manpower setup in different shift:  Administration dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 26 06 03 01 -04  Accounts dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 03 -02  Store dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 37 01 01 01 -04  Security dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 02 22 22 22 -17  Mechanical dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 18 19 19 19 -34  Electrical dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 09 05 05 05 -15  Quality dept. Shift General Shift “A” Shift “B” Shift “C” Short Noman Weaving Mills Ltd 18 Manpower setup in different shift:  Administration dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 26 06 03 01 -04  Accounts dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 03 -02  Store dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 37 01 01 01 -04  Security dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 02 22 22 22 -17  Mechanical dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 18 19 19 19 -34  Electrical dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 09 05 05 05 -15  Quality dept. Shift General Shift “A” Shift “B” Shift “C” Short
  19. 19. Noman Weaving Mills Ltd 19 Manpower 3 2 2 2 -2  Mending &folding dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 130 16 20 -46  Utility dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 12 9 14 14 -15  Workshop dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 10 2 2 -3  Preparatory dept.(sizing & warping) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 6 27 27 27 -55  Production dept.(loom) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 11 59 59 59 -35 Noman Weaving Mills Ltd 19 Manpower 3 2 2 2 -2  Mending &folding dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 130 16 20 -46  Utility dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 12 9 14 14 -15  Workshop dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 10 2 2 -3  Preparatory dept.(sizing & warping) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 6 27 27 27 -55  Production dept.(loom) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 11 59 59 59 -35 Noman Weaving Mills Ltd 19 Manpower 3 2 2 2 -2  Mending &folding dept Shift General Shift “A” Shift “B” Shift “C” Short Manpower 130 16 20 -46  Utility dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 12 9 14 14 -15  Workshop dept. Shift General Shift “A” Shift “B” Shift “C” Short Manpower 10 2 2 -3  Preparatory dept.(sizing & warping) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 6 27 27 27 -55  Production dept.(loom) Shift General Shift “A” Shift “B” Shift “C” Short Manpower 11 59 59 59 -35
  20. 20. Noman Weaving Mills Ltd 20 Specification of machineries: List of the machine: Number of m/c Brand name Origin RPM Winding machine: 3 Tangsi Textile Machinery Co. Chine 1120 Warping machine: 4 Benninger /hacoba Switzerland 1200 Chapter -03 Machine description Noman Weaving Mills Ltd 20 Specification of machineries: List of the machine: Number of m/c Brand name Origin RPM Winding machine: 3 Tangsi Textile Machinery Co. Chine 1120 Warping machine: 4 Benninger /hacoba Switzerland 1200 Chapter -03 Machine description Noman Weaving Mills Ltd 20 Specification of machineries: List of the machine: Number of m/c Brand name Origin RPM Winding machine: 3 Tangsi Textile Machinery Co. Chine 1120 Warping machine: 4 Benninger /hacoba Switzerland 1200 Chapter -03 Machine description
  21. 21. Noman Weaving Mills Ltd 21 Sizing machine 2 Benninger sucker muller Switzerland 160 Picanol loom 40 Optimax Gamma Belgium 700/500 Air jet loom 128 Toyota JAT 710 Japan 800 Projectile loom 156 sulzer Switzerland 250 Desk loom 1 Bangladesh Knotting m/c 5 Staubli Switzerland Lay out plan of weaving section: Noman Weaving Mills Ltd 21 Sizing machine 2 Benninger sucker muller Switzerland 160 Picanol loom 40 Optimax Gamma Belgium 700/500 Air jet loom 128 Toyota JAT 710 Japan 800 Projectile loom 156 sulzer Switzerland 250 Desk loom 1 Bangladesh Knotting m/c 5 Staubli Switzerland Lay out plan of weaving section: Noman Weaving Mills Ltd 21 Sizing machine 2 Benninger sucker muller Switzerland 160 Picanol loom 40 Optimax Gamma Belgium 700/500 Air jet loom 128 Toyota JAT 710 Japan 800 Projectile loom 156 sulzer Switzerland 250 Desk loom 1 Bangladesh Knotting m/c 5 Staubli Switzerland Lay out plan of weaving section:
  22. 22. Noman Weaving Mills Ltd 22 Noman Weaving Mills Ltd 22 Noman Weaving Mills Ltd 22
  23. 23. Noman Weaving Mills Ltd 23 Information about yarn source and product mix: Important Yarn Receive From Count Blend Ratio Chapter -04 Raw Materials Noman Weaving Mills Ltd 23 Information about yarn source and product mix: Important Yarn Receive From Count Blend Ratio Chapter -04 Raw Materials Noman Weaving Mills Ltd 23 Information about yarn source and product mix: Important Yarn Receive From Count Blend Ratio Chapter -04 Raw Materials
  24. 24. Noman Weaving Mills Ltd 24 (Name of spinning mills) Nahar (India) 80s/1,60s/1,40s/1 CB/CP 100% Local Yarn Receive From (Name of spinning mills) Count Blend Ratio Zaber 30s/1 BC 100% Zaber 40s/1 CW 100% Zaber 50s/1 Comb 100% Zubair 30s/1,40s/1 CW 100% Zubair 40s/1,50s/1 CB/CP 100% Talha 16s/1,20s/1,24s/1 CTN 100% Talha 30s/1 KW 100% Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50% Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100% Yasmin 45s/1,46s/1 TC 65%+35% Yasmin 40s/1,45s/1,50s/1 CVC 60%+40% Yasmin 49s/1 Comb 100% Sufia 19.5s/1,45.5s/1 CTN 100% Sufia 30s/1 KC 60%+40% Sufia 45s/1 CVC 100% Ashik Comp. 9s/1 CTN 100% Ashik 16s/1 CTN Double Yarn Noman Weaving Mills Ltd 24 (Name of spinning mills) Nahar (India) 80s/1,60s/1,40s/1 CB/CP 100% Local Yarn Receive From (Name of spinning mills) Count Blend Ratio Zaber 30s/1 BC 100% Zaber 40s/1 CW 100% Zaber 50s/1 Comb 100% Zubair 30s/1,40s/1 CW 100% Zubair 40s/1,50s/1 CB/CP 100% Talha 16s/1,20s/1,24s/1 CTN 100% Talha 30s/1 KW 100% Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50% Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100% Yasmin 45s/1,46s/1 TC 65%+35% Yasmin 40s/1,45s/1,50s/1 CVC 60%+40% Yasmin 49s/1 Comb 100% Sufia 19.5s/1,45.5s/1 CTN 100% Sufia 30s/1 KC 60%+40% Sufia 45s/1 CVC 100% Ashik Comp. 9s/1 CTN 100% Ashik 16s/1 CTN Double Yarn Noman Weaving Mills Ltd 24 (Name of spinning mills) Nahar (India) 80s/1,60s/1,40s/1 CB/CP 100% Local Yarn Receive From (Name of spinning mills) Count Blend Ratio Zaber 30s/1 BC 100% Zaber 40s/1 CW 100% Zaber 50s/1 Comb 100% Zubair 30s/1,40s/1 CW 100% Zubair 40s/1,50s/1 CB/CP 100% Talha 16s/1,20s/1,24s/1 CTN 100% Talha 30s/1 KW 100% Yasmin 16s/1,24s/1,30s/1,38s/1,45s/1,50s/1 PC 50%+50% Yasmin 40s/1,45s/1,58s/1,70s/1 CW 100% Yasmin 45s/1,46s/1 TC 65%+35% Yasmin 40s/1,45s/1,50s/1 CVC 60%+40% Yasmin 49s/1 Comb 100% Sufia 19.5s/1,45.5s/1 CTN 100% Sufia 30s/1 KC 60%+40% Sufia 45s/1 CVC 100% Ashik Comp. 9s/1 CTN 100% Ashik 16s/1 CTN Double Yarn
  25. 25. Noman Weaving Mills Ltd 25 Receive From (Name of spinning mills) Count Blend Ratio Z&Z Fab 10s/2,16s/1 CTN 100% Z&Z Fab 36s/2 CVC 60%+40% Noman Tex 30s/2 CW 100% Noman Tex 40s/2 CB/CP 100% Zaber 32s/2 CW 100% Spuare 20s/2 CTN 100% Mytas 20s/2 CTN 100% R.k. Spg 20s/2 TC 35%+65% R.k. Spg 60s/2 CB/CP 100% R.k. Spg 20s/2 CTN 100% R.k. Spg 39s/2 CW 100% MIMTEX 40s/2 Comb 100% MIMTEX 60s/2 CB/CP 100% TAMIJ 80s/2 CB/CP 100% Dyed Yarn (For sample making) Receive From (Name of spinning mills) Count Blend Ratio Color Paramount 40s/1 CVC 60%+40% Opt.White Paramount 20s/1 CVC 60%+40% Beige Paramount 40s/1 PC 50%+50% Opt.white Paramount 20s/1 CTN 100% Opt.white Paramount 40s/1 CB/CP 100% Navy blue Noman Weaving Mills Ltd 25 Receive From (Name of spinning mills) Count Blend Ratio Z&Z Fab 10s/2,16s/1 CTN 100% Z&Z Fab 36s/2 CVC 60%+40% Noman Tex 30s/2 CW 100% Noman Tex 40s/2 CB/CP 100% Zaber 32s/2 CW 100% Spuare 20s/2 CTN 100% Mytas 20s/2 CTN 100% R.k. Spg 20s/2 TC 35%+65% R.k. Spg 60s/2 CB/CP 100% R.k. Spg 20s/2 CTN 100% R.k. Spg 39s/2 CW 100% MIMTEX 40s/2 Comb 100% MIMTEX 60s/2 CB/CP 100% TAMIJ 80s/2 CB/CP 100% Dyed Yarn (For sample making) Receive From (Name of spinning mills) Count Blend Ratio Color Paramount 40s/1 CVC 60%+40% Opt.White Paramount 20s/1 CVC 60%+40% Beige Paramount 40s/1 PC 50%+50% Opt.white Paramount 20s/1 CTN 100% Opt.white Paramount 40s/1 CB/CP 100% Navy blue Noman Weaving Mills Ltd 25 Receive From (Name of spinning mills) Count Blend Ratio Z&Z Fab 10s/2,16s/1 CTN 100% Z&Z Fab 36s/2 CVC 60%+40% Noman Tex 30s/2 CW 100% Noman Tex 40s/2 CB/CP 100% Zaber 32s/2 CW 100% Spuare 20s/2 CTN 100% Mytas 20s/2 CTN 100% R.k. Spg 20s/2 TC 35%+65% R.k. Spg 60s/2 CB/CP 100% R.k. Spg 20s/2 CTN 100% R.k. Spg 39s/2 CW 100% MIMTEX 40s/2 Comb 100% MIMTEX 60s/2 CB/CP 100% TAMIJ 80s/2 CB/CP 100% Dyed Yarn (For sample making) Receive From (Name of spinning mills) Count Blend Ratio Color Paramount 40s/1 CVC 60%+40% Opt.White Paramount 20s/1 CVC 60%+40% Beige Paramount 40s/1 PC 50%+50% Opt.white Paramount 20s/1 CTN 100% Opt.white Paramount 40s/1 CB/CP 100% Navy blue
  26. 26. Noman Weaving Mills Ltd 26 Paramount 40s/1 CVC 60%+40% Sky blue Paramount 20s/1 CVC 60%+40% Black Paramount 40s/1 PC 50%+50% Blue NOOR 30s/1 Comb 100% Black NOOR 30s/1 Comb 100% White Raw material for Sizing: Chemical Name  Kollatex 05  Penetrose 50  Glysofill soft  Elastex  Tape  Pinitex  PVA  Quick solan SPR Noman Weaving Mills Ltd 26 Paramount 40s/1 CVC 60%+40% Sky blue Paramount 20s/1 CVC 60%+40% Black Paramount 40s/1 PC 50%+50% Blue NOOR 30s/1 Comb 100% Black NOOR 30s/1 Comb 100% White Raw material for Sizing: Chemical Name  Kollatex 05  Penetrose 50  Glysofill soft  Elastex  Tape  Pinitex  PVA  Quick solan SPR Noman Weaving Mills Ltd 26 Paramount 40s/1 CVC 60%+40% Sky blue Paramount 20s/1 CVC 60%+40% Black Paramount 40s/1 PC 50%+50% Blue NOOR 30s/1 Comb 100% Black NOOR 30s/1 Comb 100% White Raw material for Sizing: Chemical Name  Kollatex 05  Penetrose 50  Glysofill soft  Elastex  Tape  Pinitex  PVA  Quick solan SPR
  27. 27. Noman Weaving Mills Ltd 27 Chapter -05 Research & development Noman Weaving Mills Ltd 27 Chapter -05 Research & development Noman Weaving Mills Ltd 27 Chapter -05 Research & development
  28. 28. Noman Weaving Mills Ltd 28 R&D Department: Sample analysis:  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  During sample making some parameters are considered-  Cover factor  Reed selection Cover Factor: Cover factor is important part during production like as loom running. It indicates the fabric consumption. Is it possible or not to go to production. Expressed as British method: EPI PPI C.F count count Germany Method: K1 EPI count K2 PPI count EPI PPI count K1 K2 28 C.F count Noman Weaving Mills Ltd 28 R&D Department: Sample analysis:  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  During sample making some parameters are considered-  Cover factor  Reed selection Cover Factor: Cover factor is important part during production like as loom running. It indicates the fabric consumption. Is it possible or not to go to production. Expressed as British method: EPI PPI C.F count count Germany Method: K1 EPI count K2 PPI count EPI PPI count K1 K2 28 C.F count Noman Weaving Mills Ltd 28 R&D Department: Sample analysis:  Fabric construction analyses from given sample  Identify the fabric type e.g. yarn dyed or grey fabric  Identify the weave structure of sample  Find out yarn count, EPI, PPI etc.  Measured the yarn consumptions according to the order quantity  Make warp and weft pattern.  During sample making some parameters are considered-  Cover factor  Reed selection Cover Factor: Cover factor is important part during production like as loom running. It indicates the fabric consumption. Is it possible or not to go to production. Expressed as British method: EPI PPI C.F count count Germany Method: K1 EPI count K2 PPI count EPI PPI count K1 K2 28 C.F count
  29. 29. Noman Weaving Mills Ltd 29 Reed selection: Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric construction & storage of reed. Construction: 124 96 40 40 58 * * Total ends 124 * 58 7192 Reed count EPI * Width of cloth Reed Width Reed Width Fabric With 100 * 100 + % regain 58 ** 100 + 12 100 64.96" Reed Count 124 * 58 64.96 110.7 Or Reed count = Finished EPI × 0 .9 = 124× .9 = 111.6 Noman Weaving Mills Ltd 29 Reed selection: Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric construction & storage of reed. Construction: 124 96 40 40 58 * * Total ends 124 * 58 7192 Reed count EPI * Width of cloth Reed Width Reed Width Fabric With 100 * 100 + % regain 58 ** 100 + 12 100 64.96" Reed Count 124 * 58 64.96 110.7 Or Reed count = Finished EPI × 0 .9 = 124× .9 = 111.6 Noman Weaving Mills Ltd 29 Reed selection: Reed Count: Number of dent per 2inch of reed is called reed count. Which is depends on fabric construction & storage of reed. Construction: 124 96 40 40 58 * * Total ends 124 * 58 7192 Reed count EPI * Width of cloth Reed Width Reed Width Fabric With 100 * 100 + % regain 58 ** 100 + 12 100 64.96" Reed Count 124 * 58 64.96 110.7 Or Reed count = Finished EPI × 0 .9 = 124× .9 = 111.6
  30. 30. Noman Weaving Mills Ltd 30 Reed Width= Total ends Reed Count 7192 111 = = 64.7 Contraction mesurment: Warp contruiction = EPI * 3 Warp count = 124 * 3 40 Weft contruction= *PPI 3 Weft count = 96 * 3 40 = 9.3 7.2= Total Contruction = (9.3 +7.2) * .85 = 14.02 Suppose, fabric required = 5000mtr Tape Length= Required length + (contruction % * .85) + 30mtr wastage 5000 + (14.02 * .85) + (30= = * 2) [Here, no of beam = 2] 5074 Noman Weaving Mills Ltd 30 Reed Width= Total ends Reed Count 7192 111 = = 64.7 Contraction mesurment: Warp contruiction = EPI * 3 Warp count = 124 * 3 40 Weft contruction= *PPI 3 Weft count = 96 * 3 40 = 9.3 7.2= Total Contruction = (9.3 +7.2) * .85 = 14.02 Suppose, fabric required = 5000mtr Tape Length= Required length + (contruction % * .85) + 30mtr wastage 5000 + (14.02 * .85) + (30= = * 2) [Here, no of beam = 2] 5074 Noman Weaving Mills Ltd 30 Reed Width= Total ends Reed Count 7192 111 = = 64.7 Contraction mesurment: Warp contruiction = EPI * 3 Warp count = 124 * 3 40 Weft contruction= *PPI 3 Weft count = 96 * 3 40 = 9.3 7.2= Total Contruction = (9.3 +7.2) * .85 = 14.02 Suppose, fabric required = 5000mtr Tape Length= Required length + (contruction % * .85) + 30mtr wastage 5000 + (14.02 * .85) + (30= = * 2) [Here, no of beam = 2] 5074
  31. 31. Noman Weaving Mills Ltd 31 Fabric wt calculation system: Oz/Yds² = 1.03 1.05 0.685 e e EPI PPI N warp N weft         GSM = 1.03 1.05 23.25 e e EPI PPI N warp N weft         eN = L w W l   Wt calculation = 39.37 1000 width GSM length  Warp wt in lbs (yarn consumption): EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) +20% waste of the total warp weight Ne warp × 840 Weft wt in lbs EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% waste of the total warp weight Ne weft × 840 Noman Weaving Mills Ltd 31 Fabric wt calculation system: Oz/Yds² = 1.03 1.05 0.685 e e EPI PPI N warp N weft         GSM = 1.03 1.05 23.25 e e EPI PPI N warp N weft         eN = L w W l   Wt calculation = 39.37 1000 width GSM length  Warp wt in lbs (yarn consumption): EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) +20% waste of the total warp weight Ne warp × 840 Weft wt in lbs EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% waste of the total warp weight Ne weft × 840 Noman Weaving Mills Ltd 31 Fabric wt calculation system: Oz/Yds² = 1.03 1.05 0.685 e e EPI PPI N warp N weft         GSM = 1.03 1.05 23.25 e e EPI PPI N warp N weft         eN = L w W l   Wt calculation = 39.37 1000 width GSM length  Warp wt in lbs (yarn consumption): EPI× fabric width in inch× (fabric length in yds +fabric length in yds× crimp %) +20% waste of the total warp weight Ne warp × 840 Weft wt in lbs EPI× fabric length in inch× (fabric width in yds +fabric width in yds× crimp %) +15% waste of the total warp weight Ne weft × 840
  32. 32. Noman Weaving Mills Ltd 32 Design identification: Fig: plain weaves (1/1) Fig: 2/1 z twill Fig: 5 end satin Move-3 Fig: 2/2 Matt Fig: Dobby design Noman Weaving Mills Ltd 32 Design identification: Fig: plain weaves (1/1) Fig: 2/1 z twill Fig: 5 end satin Move-3 Fig: 2/2 Matt Fig: Dobby design Noman Weaving Mills Ltd 32 Design identification: Fig: plain weaves (1/1) Fig: 2/1 z twill Fig: 5 end satin Move-3 Fig: 2/2 Matt Fig: Dobby design
  33. 33. Noman Weaving Mills Ltd 33 Chapter -06 Operation procedure Noman Weaving Mills Ltd 33 Chapter -06 Operation procedure Noman Weaving Mills Ltd 33 Chapter -06 Operation procedure
  34. 34. Noman Weaving Mills Ltd 34 Sequence of operation Yarn from spinning (Cone) Winding Weft (Cone form)Warping Sizing Drawing Knotting And Denting Inspection Mending Folding Packing Unwind the fabric from the cloth roller Looming Weaving warp weft Introduction of winding: Noman Weaving Mills Ltd 34 Sequence of operation Yarn from spinning (Cone) Winding Weft (Cone form)Warping Sizing Drawing Knotting And Denting Inspection Mending Folding Packing Unwind the fabric from the cloth roller Looming Weaving warp weft Introduction of winding: Noman Weaving Mills Ltd 34 Sequence of operation Yarn from spinning (Cone) Winding Weft (Cone form)Warping Sizing Drawing Knotting And Denting Inspection Mending Folding Packing Unwind the fabric from the cloth roller Looming Weaving warp weft Introduction of winding:
  35. 35. Noman Weaving Mills Ltd 35 Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be considered. Objectives:  To know about the winding process  To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To acquire perfect knowledge about winding and apply it in future. Purpose of winding:  To remove objectionable faults from the yarns  To produce good package containing long continuous length of yarn.  The winding package should facilitate smooth operation of the subsequent process  To make the suitable package for warping  To control the exact tension of the package Types of winding: Actually winding is divided into three types:  Parallel wound package  Near parallel wound package  Cross wound package Winding faults: Yarn faults  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Adhered loose fiber. Package faults  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls. 1 Machine Specification:  Cone winding machine Model : GA014MD- 120 Origin : China Spindle : 120  High speed cone/ Cheese winding machine M/c serial no : 1817 R. P .M : 1720 Noman Weaving Mills Ltd 35 Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be considered. Objectives:  To know about the winding process  To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To acquire perfect knowledge about winding and apply it in future. Purpose of winding:  To remove objectionable faults from the yarns  To produce good package containing long continuous length of yarn.  The winding package should facilitate smooth operation of the subsequent process  To make the suitable package for warping  To control the exact tension of the package Types of winding: Actually winding is divided into three types:  Parallel wound package  Near parallel wound package  Cross wound package Winding faults: Yarn faults  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Adhered loose fiber. Package faults  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls. 1 Machine Specification:  Cone winding machine Model : GA014MD- 120 Origin : China Spindle : 120  High speed cone/ Cheese winding machine M/c serial no : 1817 R. P .M : 1720 Noman Weaving Mills Ltd 35 Winding is the process of transferring yarn or thread from one type of package to another to facilitate subsequent processing. The rehandling of yarn is an integral part of the weaving process. Not only must the package and the yarn itself be suitable for processing on the next machine in the production process, but also other factors such as packing cases, pressure due to winding tension must be considered. Objectives:  To know about the winding process  To get knowledge of different parts of the winding machine.  To calculate the hardness of the cone  To measure the winding angle of the package  To get exact winding rate  To acquire perfect knowledge about winding and apply it in future. Purpose of winding:  To remove objectionable faults from the yarns  To produce good package containing long continuous length of yarn.  The winding package should facilitate smooth operation of the subsequent process  To make the suitable package for warping  To control the exact tension of the package Types of winding: Actually winding is divided into three types:  Parallel wound package  Near parallel wound package  Cross wound package Winding faults: Yarn faults  Weak yarn, Slub, Neps, Knots, Thick and thin places, Seed, leaf and other foreign matter, Adhered loose fiber. Package faults  Stitch or jail, Slough off, Entanglements, Wild yarns, Soft nose, Snarls. 1 Machine Specification:  Cone winding machine Model : GA014MD- 120 Origin : China Spindle : 120  High speed cone/ Cheese winding machine M/c serial no : 1817 R. P .M : 1720
  36. 36. Noman Weaving Mills Ltd 36 Yarn path diagram of winding: Winding package Yarn clearer Traverse Tension device Guide rod Bobbin holder Yarn package Fig:Yarn path in winding 2 Hardness of cone: Hardness = wt. of package/ volume of package D H  Cone winding machine Model : GA014MG Origin : China Tangsi Textile Machinery Co. Ltd Noman Weaving Mills Ltd 36 Yarn path diagram of winding: Winding package Yarn clearer Traverse Tension device Guide rod Bobbin holder Yarn package Fig:Yarn path in winding 2 Hardness of cone: Hardness = wt. of package/ volume of package D H  Cone winding machine Model : GA014MG Origin : China Tangsi Textile Machinery Co. Ltd Noman Weaving Mills Ltd 36 Yarn path diagram of winding: Winding package Yarn clearer Traverse Tension device Guide rod Bobbin holder Yarn package Fig:Yarn path in winding 2 Hardness of cone: Hardness = wt. of package/ volume of package D H  Cone winding machine Model : GA014MG Origin : China Tangsi Textile Machinery Co. Ltd
  37. 37. Noman Weaving Mills Ltd 37 We know, Volume of package = πR2 H /4 Where, R2 = D2 -d2 =142 -42 = 180cm So, volume = 3.1416*180*17/4 =2403 cm3 Hardness of cone = 1600/2403 gm/cm3 =0.6658 gm/cm3 Standard range of hardness: For soft cone …………………..0.350--0.500 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 Winding angle and Winding length calculation: Winding angle, Ѳ =2 tan-1 (t / π*d*n) Noman Weaving Mills Ltd 37 We know, Volume of package = πR2 H /4 Where, R2 = D2 -d2 =142 -42 = 180cm So, volume = 3.1416*180*17/4 =2403 cm3 Hardness of cone = 1600/2403 gm/cm3 =0.6658 gm/cm3 Standard range of hardness: For soft cone …………………..0.350--0.500 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 Winding angle and Winding length calculation: Winding angle, Ѳ =2 tan-1 (t / π*d*n) Noman Weaving Mills Ltd 37 We know, Volume of package = πR2 H /4 Where, R2 = D2 -d2 =142 -42 = 180cm So, volume = 3.1416*180*17/4 =2403 cm3 Hardness of cone = 1600/2403 gm/cm3 =0.6658 gm/cm3 Standard range of hardness: For soft cone …………………..0.350--0.500 gm/cm3 For hard cone ………………….0.550—0.700 gm/cm3 Winding angle and Winding length calculation: Winding angle, Ѳ =2 tan-1 (t / π*d*n)
  38. 38. Noman Weaving Mills Ltd 38 Where, Travers length, t= 150 mm Scroll number, n= 2 Bobbin dia, d = 5cm So winding angle, Ѳ=2 tan-1 (150/3.1416*50*2) =51.068 ◦ Winding length = 2t/ sin Ѳ/2 =2*150/sin 51.068/2 = 695.97mm Requirements for winding:  The fault level in the yarn must be reduced to an acceptable level.  The yarn must not be damaged in any way in the winding process.  The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed.  The package size, shape and build must be most technologically suitable for particular end use.  The package size should be controlled to meet the particular economic requirement.  The device must be reliable.  The device must not introduce difference in count.  It must be easily cleaning.  The operating surface must be smooth. Introduction: The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing (slashing). It depends on some aspects as different condition. What is warping? Warping is transferring many yarns from a creel of single end package forming a parallel sheet of yarns wound onto a beam or section beam. Noman Weaving Mills Ltd 38 Where, Travers length, t= 150 mm Scroll number, n= 2 Bobbin dia, d = 5cm So winding angle, Ѳ=2 tan-1 (150/3.1416*50*2) =51.068 ◦ Winding length = 2t/ sin Ѳ/2 =2*150/sin 51.068/2 = 695.97mm Requirements for winding:  The fault level in the yarn must be reduced to an acceptable level.  The yarn must not be damaged in any way in the winding process.  The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed.  The package size, shape and build must be most technologically suitable for particular end use.  The package size should be controlled to meet the particular economic requirement.  The device must be reliable.  The device must not introduce difference in count.  It must be easily cleaning.  The operating surface must be smooth. Introduction: The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing (slashing). It depends on some aspects as different condition. What is warping? Warping is transferring many yarns from a creel of single end package forming a parallel sheet of yarns wound onto a beam or section beam. Noman Weaving Mills Ltd 38 Where, Travers length, t= 150 mm Scroll number, n= 2 Bobbin dia, d = 5cm So winding angle, Ѳ=2 tan-1 (150/3.1416*50*2) =51.068 ◦ Winding length = 2t/ sin Ѳ/2 =2*150/sin 51.068/2 = 695.97mm Requirements for winding:  The fault level in the yarn must be reduced to an acceptable level.  The yarn must not be damaged in any way in the winding process.  The yarn must be wound in such a way as to permit unwinding in the following. process with minimum difficulties at required speed.  The package size, shape and build must be most technologically suitable for particular end use.  The package size should be controlled to meet the particular economic requirement.  The device must be reliable.  The device must not introduce difference in count.  It must be easily cleaning.  The operating surface must be smooth. Introduction: The preparation of warp yarn is more demanding and complicated than that of the weft or filling yarn. So correctly warping (Beaming) is very important for weaving and sizing (slashing). It depends on some aspects as different condition. What is warping? Warping is transferring many yarns from a creel of single end package forming a parallel sheet of yarns wound onto a beam or section beam.
  39. 39. Noman Weaving Mills Ltd 39 Depending on the kind of intermediate carrier used, the industrial warping process can be carried out according to two different technologies:  Sectional warping ( indirect or conical drum or dresser warping)  Beam warping or direct warping (preparatory beam warping) Objectives:  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To minimize the machine breakdown time. Purpose of warping  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To build a suitable package for the perfect sizing and weaving. Direct or high speed warping: Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer, from the wound packages in the creel.  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn this is also called direct beaming.  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends each. Noman Weaving Mills Ltd 39 Depending on the kind of intermediate carrier used, the industrial warping process can be carried out according to two different technologies:  Sectional warping ( indirect or conical drum or dresser warping)  Beam warping or direct warping (preparatory beam warping) Objectives:  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To minimize the machine breakdown time. Purpose of warping  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To build a suitable package for the perfect sizing and weaving. Direct or high speed warping: Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer, from the wound packages in the creel.  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn this is also called direct beaming.  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends each. Noman Weaving Mills Ltd 39 Depending on the kind of intermediate carrier used, the industrial warping process can be carried out according to two different technologies:  Sectional warping ( indirect or conical drum or dresser warping)  Beam warping or direct warping (preparatory beam warping) Objectives:  To know about different warping systems and machines.  To get knowledge of various parts of the warping machine.  To calculate the different terminology for exact production.  To minimize the machine breakdown time. Purpose of warping  To accelerate the next process.  To remove flies, dust, dirt particles from the yarns.  To find thin, weak place, large knots and modify.  To make the yarns uniform and control the yarn tension.  To increase the productivity and decrease the wastage of the yarns  To build a suitable package for the perfect sizing and weaving. Direct or high speed warping: Direct Warping Denotes the transference of yarns from single-end yarn packages, wound packages, directly to a beam in a one step process. This means that there are an equal number of packages in the creel area as there are ends on the beam, except in the case of a magazine creel. A magazine creel connects the tail of one wound package to the beginning of a new wound package for an easy package transfer, from the wound packages in the creel.  Direct warping can be used to directly produce the weavers beam in a single operation. That is use for strong yarn such as mono filament or multifilament yarn this is also called direct beaming.  In direct warping system there is a several method which is called intermediate beams. This beam is used in sizing then it wind in weavers beam. If the weavers beam contains 10000 warp ends, then there would be 9 warper’s beams of 1000 ends each.
  40. 40. Noman Weaving Mills Ltd 40 Operation procedure of direct warping: The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn parallel. M /C specification: Modern- Conventional- Name of the m/c: Benninger Name of the m/c: hacoba Name of origin: Switzerland Name of origin: China Creel capacity : 1224 Creel capacity : 720 R P M : 1200 R P M : 600 Beam width : 2400 mm Beam width : 2400mm Noman Weaving Mills Ltd 40 Operation procedure of direct warping: The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn parallel. M /C specification: Modern- Conventional- Name of the m/c: Benninger Name of the m/c: hacoba Name of origin: Switzerland Name of origin: China Creel capacity : 1224 Creel capacity : 720 R P M : 1200 R P M : 600 Beam width : 2400 mm Beam width : 2400mm Noman Weaving Mills Ltd 40 Operation procedure of direct warping: The direct warping section each and every works are done accordingly. From creel to warper’s beam the yarn are passes continues in a systematic device. Firstly input the cone in to the cone stand in creel according to weight or length wise that can be measured previously. Every stand contains nine package holders. The yarn are continues passes by the sensory guide which can measure the tension of yarn and identify the yarn. In this guide there has a suctioning system which cleans the device continuously. In Benninger warping machine the creel capacity is 1224 and these types of creel is called v-creel. The yarn is transferred from creel to warping machine by passes to the v-reed. The top of the machine contains v-reed which separates each yarn eventually. Then the yarn is passing upon pre roller and winding the warper beam. The warpers beam gets a pressure from pressure roller at the bottom of the machine. The pressure roller supported the warper beam continuously and keeping the yarn parallel. M /C specification: Modern- Conventional- Name of the m/c: Benninger Name of the m/c: hacoba Name of origin: Switzerland Name of origin: China Creel capacity : 1224 Creel capacity : 720 R P M : 1200 R P M : 600 Beam width : 2400 mm Beam width : 2400mm
  41. 41. Noman Weaving Mills Ltd 41 Diagram of direct warping: Calculations of high speed warping Noman Weaving Mills Ltd 41 Diagram of direct warping: Calculations of high speed warping Noman Weaving Mills Ltd 41 Diagram of direct warping: Calculations of high speed warping
  42. 42. Noman Weaving Mills Ltd 42 Total ends =7000 PPI =70 Warp length =1200 Creel capacity =875 40*40 120*70 Construction:- Beam required =8 solution: Each beaming time at 100% efficiency = 1200 800 = 15 min waste times are --- Creeling =60 min knoting =40 min Beam change =16 min Breakage time =80 min Total = 196 min wastes time for each beam = 196 8 = 24.5 min With waste per beaming time = 15 +24.5 = 39.5 minutes For one shift,/8 hours production = 480 39.5 = 12 beam So efficiency, = 12 39.5 *100 =37.9746 % 58 inch suppose,finish construction Indirect or Sectional warping system: Noman Weaving Mills Ltd 42 Total ends =7000 PPI =70 Warp length =1200 Creel capacity =875 40*40 120*70 Construction:- Beam required =8 solution: Each beaming time at 100% efficiency = 1200 800 = 15 min waste times are --- Creeling =60 min knoting =40 min Beam change =16 min Breakage time =80 min Total = 196 min wastes time for each beam = 196 8 = 24.5 min With waste per beaming time = 15 +24.5 = 39.5 minutes For one shift,/8 hours production = 480 39.5 = 12 beam So efficiency, = 12 39.5 *100 =37.9746 % 58 inch suppose,finish construction Indirect or Sectional warping system: Noman Weaving Mills Ltd 42 Total ends =7000 PPI =70 Warp length =1200 Creel capacity =875 40*40 120*70 Construction:- Beam required =8 solution: Each beaming time at 100% efficiency = 1200 800 = 15 min waste times are --- Creeling =60 min knoting =40 min Beam change =16 min Breakage time =80 min Total = 196 min wastes time for each beam = 196 8 = 24.5 min With waste per beaming time = 15 +24.5 = 39.5 minutes For one shift,/8 hours production = 480 39.5 = 12 beam So efficiency, = 12 39.5 *100 =37.9746 % 58 inch suppose,finish construction Indirect or Sectional warping system:
  43. 43. Noman Weaving Mills Ltd 43 Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe fabric. The sectional warping depends on some parameters such as:  Head stock  Control device.  Creel arrangement. Operation procedure of sectional warping: In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is transferred to the sized beam. M/C Specification: Name of the m/c: Benninger supertronic Name of origin: Switzerland V-reed capacity: 650 Eye reed capacity: 650 Creel capacity: 576 R. p. m : 800 Components of sectional warping: Noman Weaving Mills Ltd 43 Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe fabric. The sectional warping depends on some parameters such as:  Head stock  Control device.  Creel arrangement. Operation procedure of sectional warping: In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is transferred to the sized beam. M/C Specification: Name of the m/c: Benninger supertronic Name of origin: Switzerland V-reed capacity: 650 Eye reed capacity: 650 Creel capacity: 576 R. p. m : 800 Components of sectional warping: Noman Weaving Mills Ltd 43 Sectional warping is one of the most important and complicated section than high speed warping. Because it contain varies types of section or repeat which is directly input in sizing and weaving. In sectional warping total number of ends are added together then it sized. Every repeat is important for producing accurate width of the fabric and perfect cloth. So it will depend on good sectional warping, which is impossible in direct warping. For these reason it’s called sectional warping. By sectional warping we can produce cheek and stripe fabric. The sectional warping depends on some parameters such as:  Head stock  Control device.  Creel arrangement. Operation procedure of sectional warping: In the sectional warping system the yarn path is same like as direct or high speed warping. But it has some dissimilarity from high speed warping that is pattern drum, eye reed. Headstock, and control device. The drum and other control equipment are totally different. Firstly should have to calculate the repeat size, width and set the other parameters perfectly. Then arrange the creel according to the pattern chart. The yarn is transferred from cone to eye reed into a guide that contain some weight disk, because of getting parallel, separation and uniform tension of yarn. In there is some lease rod that is helps to separate the yarns from different creel. For winding purposes it passes in to v-reed, and then get the section width and wound in drum perfectly. The movements of drum and head stock are constant, that value is input into the device with respect to the repeat width. After finished the total length is transferred to the sized beam. M/C Specification: Name of the m/c: Benninger supertronic Name of origin: Switzerland V-reed capacity: 650 Eye reed capacity: 650 Creel capacity: 576 R. p. m : 800 Components of sectional warping:
  44. 44. Noman Weaving Mills Ltd 44 Indirect Warping process: Noman Weaving Mills Ltd 44 Indirect Warping process: Noman Weaving Mills Ltd 44 Indirect Warping process:
  45. 45. Noman Weaving Mills Ltd 45 40*40 102*70 Total ends =5900 Reed density/inch = 46 Reed cound =92 Reed width =64.1 PPI =70 Warp length =1300(1300+118) Order quanty =1100 Pattern chart of warp & weft Construction:- Warp pattern Navy Optical white Total 6 7 13 Weft pattern All optical white In warp Color Navy Optical white Total Ends 6 7 % of color Required warp in kg per color req. in kg remarks 46.15 53.85 116 116 54 62 116 % of color Required warp in kg picks per color req. in kg remarksColor White 1 100 84 84 In weft Noman Weaving Mills Ltd 45 40*40 102*70 Total ends =5900 Reed density/inch = 46 Reed cound =92 Reed width =64.1 PPI =70 Warp length =1300(1300+118) Order quanty =1100 Pattern chart of warp & weft Construction:- Warp pattern Navy Optical white Total 6 7 13 Weft pattern All optical white In warp Color Navy Optical white Total Ends 6 7 % of color Required warp in kg per color req. in kg remarks 46.15 53.85 116 116 54 62 116 % of color Required warp in kg picks per color req. in kg remarksColor White 1 100 84 84 In weft Noman Weaving Mills Ltd 45 40*40 102*70 Total ends =5900 Reed density/inch = 46 Reed cound =92 Reed width =64.1 PPI =70 Warp length =1300(1300+118) Order quanty =1100 Pattern chart of warp & weft Construction:- Warp pattern Navy Optical white Total 6 7 13 Weft pattern All optical white In warp Color Navy Optical white Total Ends 6 7 % of color Required warp in kg per color req. in kg remarks 46.15 53.85 116 116 54 62 116 % of color Required warp in kg picks per color req. in kg remarksColor White 1 100 84 84 In weft
  46. 46. Noman Weaving Mills Ltd 46 Why sectional warping is different? In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly than solid dyed fabric. The computerized sectional warping can automatically calculates the following: 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 6. Memory of yarn breakage during warping for beaming Faults in warping 1. Practically for winding 2. Machine fault 3. Operator misconception 4. Low quality yarn 5. others Problems in warping a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length f. Big knot Checking have to done during warping: 1. Lot mixing 2. Count mixing 3. Color variation Noman Weaving Mills Ltd 46 Why sectional warping is different? In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly than solid dyed fabric. The computerized sectional warping can automatically calculates the following: 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 6. Memory of yarn breakage during warping for beaming Faults in warping 1. Practically for winding 2. Machine fault 3. Operator misconception 4. Low quality yarn 5. others Problems in warping a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length f. Big knot Checking have to done during warping: 1. Lot mixing 2. Count mixing 3. Color variation Noman Weaving Mills Ltd 46 Why sectional warping is different? In sectional warping dyed yarns are used for making the sections according to the construction and repeat size also the total number ends that the number of colored yarns is required for completing the sections. Actually sectional warping is to done for check or stripe fabric production. It is very different from high speed warping. Only gray yarns are used for high speed warping so it has fewer hazards. For that reason check or stripe fabric is costly than solid dyed fabric. The computerized sectional warping can automatically calculates the following: 1. Number of sections on the beam and width of each section. 2. Constant warp tension regulation for uniform buildup 3. Automatic stops for predetermined length 4. Automatic stops for leasing 5. Constant warp tension over the full warp width 6. Memory of yarn breakage during warping for beaming Faults in warping 1. Practically for winding 2. Machine fault 3. Operator misconception 4. Low quality yarn 5. others Problems in warping a. Overlapping problem b. Soft yarn c. Incorrect form of beam d. Loose selvedge (depends on tension) e. Incorrect warp length f. Big knot Checking have to done during warping: 1. Lot mixing 2. Count mixing 3. Color variation
  47. 47. Noman Weaving Mills Ltd 47 Calculation of sectional warping: Construction: 40*40 102*70 57 Reed dents per inch =46 Reed count =92 Reed width =64.1 PPI =70 winding angle = .8 Total ends =5900 Solutions: Total ends *10 warp width Mesured phase or e/cm = Number of ends = Fabric width *EPI Number of section = Total ends Repeat size Fabric width = Total ends EPI Warp density= d tex * total ends * 0.8 400 * warp width(mm) d tex = 5905 Ne = 147.625 = 5900 *10 1900 = 31.052 cm = 57*102 = 5814 5900 13 = = 453.846 = 5900 102 = 57.843 = 147.625*5900*0.8 400*1900 = 0.91mm Noman Weaving Mills Ltd 47 Calculation of sectional warping: Construction: 40*40 102*70 57 Reed dents per inch =46 Reed count =92 Reed width =64.1 PPI =70 winding angle = .8 Total ends =5900 Solutions: Total ends *10 warp width Mesured phase or e/cm = Number of ends = Fabric width *EPI Number of section = Total ends Repeat size Fabric width = Total ends EPI Warp density= d tex * total ends * 0.8 400 * warp width(mm) d tex = 5905 Ne = 147.625 = 5900 *10 1900 = 31.052 cm = 57*102 = 5814 5900 13 = = 453.846 = 5900 102 = 57.843 = 147.625*5900*0.8 400*1900 = 0.91mm Noman Weaving Mills Ltd 47 Calculation of sectional warping: Construction: 40*40 102*70 57 Reed dents per inch =46 Reed count =92 Reed width =64.1 PPI =70 winding angle = .8 Total ends =5900 Solutions: Total ends *10 warp width Mesured phase or e/cm = Number of ends = Fabric width *EPI Number of section = Total ends Repeat size Fabric width = Total ends EPI Warp density= d tex * total ends * 0.8 400 * warp width(mm) d tex = 5905 Ne = 147.625 = 5900 *10 1900 = 31.052 cm = 57*102 = 5814 5900 13 = = 453.846 = 5900 102 = 57.843 = 147.625*5900*0.8 400*1900 = 0.91mm
  48. 48. Noman Weaving Mills Ltd 48 Required weight of yarn per cone in creel, Suppose Cone weight =2000gm Count = 30 Creel capacity =512 Length of one cone = 1.6933*30*2000 = 101598 mts Number of cone =200 * 200 =20319600 mts =22221514.56 yds length per creel stand =22221514.56/512 = 43401.3956 yds = 43401.3956 840*30 =1.72227 lbs Following terms should be considered 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% What is sizing: The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the tensions and the rubbing caused by weaving. Purpose of sizing:  To improve the weave ability of the warp yarn  To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn.  To increase the tensile or breaking strength for cellulose yarn. Noman Weaving Mills Ltd 48 Required weight of yarn per cone in creel, Suppose Cone weight =2000gm Count = 30 Creel capacity =512 Length of one cone = 1.6933*30*2000 = 101598 mts Number of cone =200 * 200 =20319600 mts =22221514.56 yds length per creel stand =22221514.56/512 = 43401.3956 yds = 43401.3956 840*30 =1.72227 lbs Following terms should be considered 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% What is sizing: The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the tensions and the rubbing caused by weaving. Purpose of sizing:  To improve the weave ability of the warp yarn  To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn.  To increase the tensile or breaking strength for cellulose yarn. Noman Weaving Mills Ltd 48 Required weight of yarn per cone in creel, Suppose Cone weight =2000gm Count = 30 Creel capacity =512 Length of one cone = 1.6933*30*2000 = 101598 mts Number of cone =200 * 200 =20319600 mts =22221514.56 yds length per creel stand =22221514.56/512 = 43401.3956 yds = 43401.3956 840*30 =1.72227 lbs Following terms should be considered 1. Floor temperature 28-32 degree ( 65 degree Farenhight) 2. For warping light should be 10 lumen per square feet 3. Warping efficiency 60% 4. Breakage at warping in comparison with others sections in weaving is 0.2-0.5% What is sizing: The process of applying a protective adhesive coating on the yarns surface of yarn is called sizing. This is the most important operation to attain maximum weaving efficiency. Especially for blended and filament yarns. Sizing increases elasticity of yarn, Yarn strength, weight of yarn, smoothness, frictional resistance. Sizing consists of impregnating the yarn with particular things which form on the yarn surface a film with the aim of improving yarn smoothness and tenacity during the subsequent weaving stage. Thanks to its improved tenacity and elasticity, the yarn can stand without problems the tensions and the rubbing caused by weaving. Purpose of sizing:  To improve the weave ability of the warp yarn  To maintain good fabric quality by reducing hairiness, weakness and by increasing smoothness, strength of yarn.  To increase the tensile or breaking strength for cellulose yarn.
  49. 49. Noman Weaving Mills Ltd 49  To increase the elasticity  To remove the protruding/floating fibers  To reduce electrostatic formation for synthetic or blended yarn Sizing Technique: All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of preventing that they get entangled and are not wound up with the correct sequence. A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s beam. Reason for different sizing recipe: Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon as warping is completed, to the sizing machine where they are assembled. There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when a particularly thick size is required. Machine specification: Noman Weaving Mills Ltd 49  To increase the elasticity  To remove the protruding/floating fibers  To reduce electrostatic formation for synthetic or blended yarn Sizing Technique: All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of preventing that they get entangled and are not wound up with the correct sequence. A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s beam. Reason for different sizing recipe: Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon as warping is completed, to the sizing machine where they are assembled. There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when a particularly thick size is required. Machine specification: Noman Weaving Mills Ltd 49  To increase the elasticity  To remove the protruding/floating fibers  To reduce electrostatic formation for synthetic or blended yarn Sizing Technique: All beams previously wound on the beam warper are mounted on a special beam creel. The threads are taken off in sequence from all beams and introduced into a vat containing the proper size. The warp enters then a drying unit, where the water contained in the threads is evaporated, this result is obtained by direct contact of the threads with cylinders having decreasing temperature having steam line. These last are a real innovation and operate as follows: the electromagnetic field generated by radio-frequency permits to extract the water contained in the glue, without heating the threads. By avoiding the thermal shock caused by hot air ovens, it is possible to maintain unchanged the chemical and physical properties of the yarn; this is a must when yarns sensitive to heat are processed. It is important to take care that during sizing the threads do not stick together, but remain separate in order not to create problems during the downstream processes. The drying unit is followed by a waxing device which is aimed at increasing the threads smoothness. The process concludes with the winding by an end frame of the threads on a weaver’s beam at a speed up to 80 meters/min. Between the drying unit and the end frame there are lease rods: these are available in the same number as the beams under process minus one and have the function of keeping the threads separate and of preventing that they get entangled and are not wound up with the correct sequence. A recent variation to the traditional system carries out sizing during beam warping and therefore assembles already sized beams. The advantage is the possibility of sizing beams, each with a warp rate (threads per cm) x times (x = number of beams) lower than the effective warp rate in the weaver’s beam. Reason for different sizing recipe: Sizing is a complementary operation which is carried out on warps formed by spun yarns with insufficient tenacity or by continuous filament yarns with zero twist. In general, when sizing is necessary, the yarn is beam warped, therefore all beams corresponding to the beams are fed, as soon as warping is completed, to the sizing machine where they are assembled. There is not just one sizing ″recipe″ which is valid for all processes, on the contrary the sizing methods depend on the type of weaving machine used, the construction of fabric, on the yarn type and count, on the technician’s experience and skill, but all kinds of material in progress. The only common consideration of the various sizing materials is that they have to be easily removable after weaving in order to allow carrying out without any problems for the selected finishing cycle. The substances used as sizing material are potato flour, starches, glues, fats but also talc and kaolin, when a particularly thick size is required. Machine specification:
  50. 50. Noman Weaving Mills Ltd 50 Scematric diagram and control system of sizing m/c: Shade-02 Machine Name : Sucker Muller Brand :Hacoba Origin : Switzerland R.P.M :60 each roller Cylinder : 12 V-reed : 1450 Lease : 14 Beam capacity : 16 Winding pressure : 4500 bar Press tension : 3500 bar Lease tension : 2000 bar (Maximum) Cylinder temperature : 145 degrees Production capacity/day: 30000 meters Shade-01 Machine Name :Benninger Origin : Switzerland R.P.M :160 Max Cylinder : 14 Lease : 29 Beam capacity : 32 V-reed : 1372 Cylinder Temperature : 145 degree Winding pressure : 1800 N Creel tension : 700 N Production capacity/day: 40000-45000 Max Noman Weaving Mills Ltd 50 Scematric diagram and control system of sizing m/c: Shade-02 Machine Name : Sucker Muller Brand :Hacoba Origin : Switzerland R.P.M :60 each roller Cylinder : 12 V-reed : 1450 Lease : 14 Beam capacity : 16 Winding pressure : 4500 bar Press tension : 3500 bar Lease tension : 2000 bar (Maximum) Cylinder temperature : 145 degrees Production capacity/day: 30000 meters Shade-01 Machine Name :Benninger Origin : Switzerland R.P.M :160 Max Cylinder : 14 Lease : 29 Beam capacity : 32 V-reed : 1372 Cylinder Temperature : 145 degree Winding pressure : 1800 N Creel tension : 700 N Production capacity/day: 40000-45000 Max Noman Weaving Mills Ltd 50 Scematric diagram and control system of sizing m/c: Shade-02 Machine Name : Sucker Muller Brand :Hacoba Origin : Switzerland R.P.M :60 each roller Cylinder : 12 V-reed : 1450 Lease : 14 Beam capacity : 16 Winding pressure : 4500 bar Press tension : 3500 bar Lease tension : 2000 bar (Maximum) Cylinder temperature : 145 degrees Production capacity/day: 30000 meters Shade-01 Machine Name :Benninger Origin : Switzerland R.P.M :160 Max Cylinder : 14 Lease : 29 Beam capacity : 32 V-reed : 1372 Cylinder Temperature : 145 degree Winding pressure : 1800 N Creel tension : 700 N Production capacity/day: 40000-45000 Max

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