Industrial attachment of paramount textile ltd

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Industrial attachment of paramount textile ltd

  1. 1. 1 INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT PARAMOUNT TEXTILE LIMITED
  2. 2. 2 Project Description
  3. 3. 3 PARAMOUNT TEXTILE LIMITED AT A GLANCE PARAMOUNT TEXTILE LIMITED 1. Name of the project : Paramount Textile Limited 2.Location : Gilar Chala,Sreepur, Gazipur. 3. Address : About 60 kms north of Dhaka city. Factory : Village:Gilar Chala, P.O: 1 No C&B Bazar Thana:Sreepur,Dist:Gazipur, Bangladesh. Tele-Fax: 880-6825 52555
  4. 4. 4 Office: Chaklader House (Level-6), House # 22,Road #113/A, Gulshan-2,Dhaka-1212,Banladesh Ph:(+8802) +8809890618,9890467 Fax:(8802)9890783 E-mail:ptexltd@gmail.com Web;www.paramountgroupbd.com 5. Board of directors : Chairman& Managing Director. Md. Shakhawat Hossain 7. Communication :The project is easily accessible by road. 8. Product name :Woven yarn dyed ,solid dyed . 100% Cotton & TC 9. Product Mix : A) Gray fabric: 1. Solid dyed 2. yarn dyed. a. Stripe. b. Check.
  5. 5. 5 B) Design. a. In Tappet loom. i. Plain. ii. Twill. iii. Sateen. iv. Some combination weave which are posible in tappet. v. Oxford. (Warp rib and weft rib). vi. Queen’s Oxford. vii. Matt. b. In Dobby loom: i. Various types of weave. ii. Diamond. iii. Diaper. iv. Herring bone. v. Honey comb. vi. The design which are possible in 16 heald frames. 10.Annual production capacity : 18millions per year. 11.Factory area :Approx. 180acres.(including ETP) 12.Type of the factory :Horizontally integrated 13.No. of employees :Approx. 100. 14.Project cost :Approx. 2000million taka 15.Different Departments : a) Adminstration.
  6. 6. 6 b) Human Resource and Develoment Dept. c) Weaving Preperatory d) Weaving. e) Woven finishing. f) Yarn dyeing Dept. g) Store. h) Planning Dept. i) Utility Dept. j) Procurement k) Merketing Location description: Paramount Textile Limited is located in Sreepur, Gazipur about 60 kms North from Dhaka while it takes about 90 minutes by bus.There are available bus services from Mohakhali Bus Terminal and also from Gulistan Bus Terminal. Transport: For the Paramount officer’s there are two micro bus and one private car which carry them on to the factory from Dhaka. Cost of Transport: About 100Taka per head from Gulistan HISTORY OF PARAMOUNT TEXTILE LIMITED: Paramount Textile limited was incorporated under the companies Act(Act-8) of 1994 in june 12, 2006 and went into commercial production in November 2008
  7. 7. 7 Man Power Management
  8. 8. 8 Oraganogram Chariman Deputy Managing Director Executive Director (Operation) Executive Director (Finance & Accounts) G. M. (Admin, H. R., Compliance) DGM (A/F) Manager (Admin / HR) Manager (Compliance) Manager (Purchase) Executive Executive Executive Jr. Executive Jr. Executive Jr. Executive Officer - 1 Officer - 1 Officer - 1 Peon Peon Peon SHIFT CHANGE: There are three shifts per day in P.T.L. So each shift contain eight hour. Shift Duration A 06.00 AM – 02.00 PM B 02.00 PM – 10.00 PM C 10.00 PM – 06.00 AM General shift 09.00 AM – 05.00 PM
  9. 9. 9 General shift, which is applicable for some officers. Man power in different section (weaving) of PTL
  10. 10. 10 JOB DESCRIPTION: SENIOR PRODUCTION OFFICER: In a weaving factory a senior production officer plays a great role in production and man power management who are production related. Here we enlist the duties of senior production officer: 1) Follow up weaving production, 2) Regular observation of weaving floor, 3) Prepare weaving order status regularly, 4) Maintain the quality of the product, 5) To help the senior prod. Officer & co-operate with others for fulfilling the required destination. PRODUCTION OFFICER:
  11. 11. 11 Production officer is the right hand of senior production officer and he is directly related with production manpower and informs senior production officer time to time. Here are his listed duties:- 1) Follow up overall weaving production, 2) Decide every m/c utilization during production, 3) Recruit new labor, 4) To inform the authority on the overall weaving prod. and make it financial profitable, 5) Regular m/c maintenance, 6) Maintain sub-contract orders, 7) Help weaving manager & also guide the junior officers of the section, etc.  Function area: Setting the different parameters of machines, using correct yarn for order, controlling machine store, controlling process quality system. Remarks: The organization and management system are good for mill environment and as the job description is classified, so duties are done honestly and sincerely.
  12. 12. 12
  13. 13. 13 Machine Description There are two ways woven fabric produced: 1. Solid dyed 2. Yarn dyed Generally yarn dyed fabrics are costly item. Because dyed yarn are costly and in case of yarn dyed fabric Sectional warping is necessary which is also costly and time consuming process. Weaving Solid dyed Yarn dyed
  14. 14. 14 ↓ ↓ Store Store ↓ ↓ Direct Winding Soft Winding ↓ ↓ Sizing Yarn Dyeing ↓ ↓ Drawing & Denting Hard Winding ↓ ↓ Weaving Sectional Waarping ↓ Sizing ↓ Drawing & Denting ↓ Weaving Now the machines used in every stage are described below- Soft winding: Machine Type: A (HS 101C) No. of M/cs:07 Name Of m/cs: Soft winding machine Brand name: CORAL TEXTILE Origin: China
  15. 15. 15 No of head: (54×2)/machine M/c rpm:2800 Machine Type: B (TH-8A) No. of M/cs:06 Name of M/ca: Soft winding machine Brand Name: TAIZHOU JINWEL TEXTILE Origin: China No. of head: (54x2)/mahine M/cs rpm: 2800 YARN DYEING A Dyeing machine M/c model No. of m/c Capacity Kg Power Kw Steam Kg/hr Water hrm /3 Labwin-3 1 4 2.1 2 .12 Labwin-6 2 8 3.5 34 .40 Labwin-12 4 12 8.5 62 .80 Allwin-53 3 48 11.5 214 1.9
  16. 16. 16 Allwin-70 1 81 15 382 3.2 Allwin-85 6 108 27 638 6.5 Allwin-105 3 288 39.9 1233 11.5 Allwin-120 2 432 47 1808 17.31 Allwin-145 1 648 76 2609 25.9 Allwin-166 1 828 94.8 3633 33.1 GF24INT-21 1 12 2.1 9 .12 GF24INT-42 1 12 5.5 47 .20 GF24INT-50 1 48 7 118 .70 GF24INT-187 1 140 58 3165 36.5 GF24INT-21 1 12 2.1 13 .20 GF24IHLC- 140 1 288 11.4 1105 15 30 B.Hydro-extractor No. of machine:6 Brand Name:STALAM(Shanghai) DYET Origin:China Rotation speed:1530rpm Capacity:32pkg Power consumtion:11kw/machine
  17. 17. 17 C.RF DRYER No. of machine:2 Brand Name:STALAM(Shanghai) DYET Origin:China Capacity:12tons Power consumtion:170kw/machine Steam Consumtion:450kg Hard Winding M/c Type:A(HS 101C) No. of machine:7 Name of m/c: Hard winding machine Brand Name:CORAL TEXTILE Origin:China No of head: (54×2)/machine M/c rpm:2800 M/c Type:B(TH-8A) No. of machine:3 Name of m/c: Hard winding machine Brand Name:TAIZHOU JINWEL TEXTILE Origin:China No of head: (54×2)/machine M/c rpm:2800
  18. 18. 18 M/c Type: C (SHA) No. of machine: 1 Name of m/c: Hard winding machine Brand Name: STLM (shanghai) DYET Origin: China No. of head: 108 Installed Power: 14kW WARPING A.High Speed Warping m/c No. of machine: 1 Brand Name:TSUDAKOMA Origin:JAPAN Creel capacity:644 Creel Type: V type Max beam width: 1780mm B. Sectional warping m/c Type 1 No. of machine: 2 Brand Name: UKIL MACHINARY Origin: KOREA Creel capacity: 720 Creel Type: V type Max beam width: 1780mm
  19. 19. 19 Type 2 No. of machine: 2 Brand Name: RABATEX Origin: INDIA Creel capacity:800 Creel Type: V type Max beam width: 1780mm Sizing: Type 1 No. of machine:1 Brand Name: Tsudakoma Origin: Japan Back beam capacity: 16 No of drying cylinder: 12 No of size box: 02 No of wax box: 01 Power consumption: 76kw Type 2 No. of machine: 1 Brand Name: JUPITAR Origin: INDIA Back beam capacity: 1 No of drying cylinder: 8
  20. 20. 20 No of size box: 02 No of wax box: 01 Power consumption: 76kw Loom Total no of looms: 218 Brand name of the Loom Shedding Device Weft Insertion RPM No. of Looms Picanol omniplus 800 Tappet 06 700-850 10 Picanol omniplus Tappet Dobby 04 650-900 52 Toyota JAT 710 Cam 06 725-950 15 Toyota JAT 710 Dobby 06 600-700 01 Toyota JA 600/610 Tappet Dobby 2+4+6 525-650 34 Tsudakoma ZAX 9100 Cam 06 750-850 12 Tsudakoma ZAX Dobby Tappet 04 500-650 13 Tsudakom ZAX 205,205i Cam 02,06 450-600 81
  21. 21. 21 Total 218 Finishing machines 1. Singeing and Desizing m/c No. of m/c: 01 Company Name: Jaingsu Redflag Printing & Dyeing machinery Co. Ltd. Origin: China Speed: 80-85 m/min (Standard: 70 m/min) Power Consumption: 60-70 kW 2. Scouring & Bleaching m/c No. of m/c: 01 Origin: China 3 baths for hot wash (90 -100 degree celcius) where the first 2 are chemical bath. One steamer (Steaming temperature: 100 degree celcius) Again 4 baths for hot wash Drying cylinder No. 24 Power Consumption: 70 kW 3. Stentering m/c: Company name: HUNAN VIROCK TEXTILE PRINTING AND DYEING MACHINERY CO. LTD.
  22. 22. 22 No. of m/c: 01 Origin: China Model: LVK4 000 – 200X8 Drying chamber: 08 Temperature: 120- 170 degree celcius Fan Speed: 1480 rpm Fabric dry: 43 m/min Power Consumption: 140 kW 4. Peach Finishing M/c: Company name: Xetma Vollenweider GmbH No. of m/c: 01 Origin: Germany Model: DE- 08280 Number: 160.008/NW 2200 Year of manufacturing : 2008 Power Consumption: 76 kW 5. Sanforizing m/c: Company name: WuXi Dakai Printing and dyeing machinery Co. LTD. No. of m/c: 01 Origin: China Model: LMH 4P2 – 200 Number: 0804 Year of manufacturing : 2008
  23. 23. 23 Power Consumption: 70 kW Remarks: Maximum m/cs are made of China& Japan. Looms are of old model. If technology would have better and new version m/cs been used productivity would have been greatly increased.
  24. 24. 24 Raw Materials
  25. 25. 25 Main raw Material is yarn. Yarn used mainly 100% cotton, PC, CVC, 100% Polyester, Lurax, lycra core spun yarn. Some common type of yarns are tabulated below with local price Count Type 10/1 Autocone 16/1 Autocone 16/1 Comb 20/1 Autocone 20/1 Comb 20/1 Kard 20/1 Open end 30/1 Comb 40/1 Comb 50/1 Comb 60/1 Comb 40/2 Comb 80/2 Comb 100/2 Comb 24/1 Slub 30/1 Slub 16/1 Kard
  26. 26. 26 Some of the manufacturing companies from where Paramount procure there yarn are 1 Zaber Spinning Mill 2.GTN (India)
  27. 27. 27 Production Planning, Sequences &Operations
  28. 28. 28 There are two ways Woven fabric produced: 1. Solid dyed. 2. Yarn dyed. Generally yarn dyed fabrics are costly item. Because dyed yarn are costly and, In case of yarn dyed fabric Sectional warping is necessary which is also costly and time consuming process. Weaving ↓ ↓ Store Store ↓ ↓ Direct Winding Soft Winding ↓ ↓ Sizing Yarn Dyeing ↓ ↓ Drawing & Denting Hard Winding ↓ ↓ Weaving Sectional Waarping ↓ Sizing ↓ Drawing & Denting ↓ Weaving Solid dyed Yarn dyed
  29. 29. 29 When Order Comes to the Marketing Section, then they contact with the Product development (in case of new product) or Design cell (in case of available product) that, is it possible or not possible in PARAMOUNT. They Send a Article Request paper. After reaching the Article Request paper Design cell produce Article Code and send mail to the planning and marketing section. Planning print a Dispo paper and send to 10 sections with related production of that fabric. Dispo Paper: Dispo Paper is a paper which contain All necessary information for the production of a specific item of fabric. A typical Dispo Paper is attached below: Buyer Merchandiser Marketing Design CellPlanning 1. Design Cell 2. Yarn Requisition 3. yarn store 4. winding 5. yarn dyeing 6. warping 7. Sizing 8. Drawing, denting 9. Weaving 10. Finishing. Send Dispo Paper
  30. 30. 30 Paramount Textiles Ltd. Y/D GREIGE FABRIC SPECIFICATION. PI No: T40824 Line No : 01 Conut ( Warp x Weft) 40X40 Costomer :Paramoun Textiles ………..C & A Yarn Composition (Warp x Weft) 100 % Cotton FINISHED FABRIC DETAILS Dispo No : F90001 Ends x Picks ( Finished ) 120X90 Fabrice Code : Blue Stripe Finished Fabric width ( inch 58/59" Design : Plain Required Finished Length ( Mater 9,076.00 Finish SOFT Delivery Date ( Finished 27/02/2009 GREIGE FABRIC DETAILS Dispo No:W90001 Req No : Ends x Picks ( Greige ) 112X90 Article Code Greige Width ( Inch 63" Reed No 108/2 Required Greige ( Mater ) 9,711.32 Reed Width ( Inch 65.55 Required Loom Production ( Mtr) 9809.41 Flow Code:TYD0412 R.P.M : 525 Required Warp Length ( Mtr) 11,630.04 Delivery Date 20/02/2009 Ground Ends 7080 D.C Comments D:4, G:1234,S:1234 Selvedge Ends 120
  31. 31. 31 Color Breakdown Count Shade Color Code Quantity ( kg) Length (Mtr) Warp 40/1 White 797 94874.90 40/1 Blue 443 47477.95 Warp Total 1240 Weft 40/1 White 920 Weft Total 920 DYED YARN DETAILS Dispo No : W90001 Delivery Date : 28/02/2009 BREAKDOWN OF YARN FOR DYEING Dispo Line Count Shade ALD NO Greige Yarn ( kg) Dyed Yarn ( kg) Yarn Type 1 40/1 White 1850 1805 2 40/1 Blue 478 466 Total 2328 2271 Design Cell: Design Cell is one of the most important department of PARAMOUNT TEXTILE LTD.(weaving). When a order comes to the marketing or merchandizing officer he/she send the fabric to the design cell that is it possible or not possible in PARAMOUNT. They send a Article request paper. Design cell analyze the fabric design and test the feasibility of
  32. 32. 32 produciton and create a Article code and send this article code the marketing or marchandizing officer and input data to the Data tex which is a software used in PARAMOUNT for all types of information by networking. PARAMOUNT’s Design department is equipped with hand loom and sophisticated software”TEX-DESIGN CLASSIC” by KOPPERMANN of GERMANY. After getting Article code planning discuss with marketing officer about costing. Then marketing officer send mail or discuss directly to the buyer about pricing of the product. If buyer agree with the price then marketing officer send mail to the central planning section with Article code. Planning take a print of dispo paper for the article code from the system data tex. After printing dispo paper they send it to the design cell to check or verify. Design cell check and give drawing and denting plan and send it to the planning section again. Planning then send it to the various section where these information required and at a time requisition all necessary raw materials or other materials. Organ gram of Design cell: Assistant Manager ↓ Data Entry + Design Analyzer (3 person) ↓ Peon (1 person)
  33. 33. 33 Dispo paper goes to the following sections: 1. Design cell. 2. Store. 3. Winding. 4. yarn dyeing. 5. warping. 6. sizing. 7. Drawing and denting. 8. Loom. 9. Finishing Dispo paper contains following types of informations: 1. Fabric Specification. 2. Yarn composition 3. Finished type. 4. Finished fabric’s EPI x PPI 5. Finished fabric’s width. 6. Required length. 7. Reed count. 8. Grey EPI and PPI. 9. Greige width.
  34. 34. 34 10.Reed width. 11.Reed EPI 12.Required greige length. 13.Required warp length. 14.Ground Ends. 15.Selvedge Ends. 16.Cover Factor. 17.Numerical Plan (Warp & Weft) 18.Drawing & Denting Plan. Possible Ends per inch by using Available Reed in Inventory in PARAMOUNT by denting 2,3 and 4 in a dent For yarn dyed fabric. a) Read available for air jet Looms Jat-600-ZAX(Tsudakoma) Si No Read No 1/1-2 Ends/EPI 2/1-3 Ends/EPI 3/1-4 Ends/EPI Present Required Short Remark 1 144 160 4 15 -11 2 131 146 218 291 3 3 0 Local 3 130 144 217 289 66 66 0 New 25 4 128 142 213 284 1 0 1 5 126 140 210 280 23 25 -2 10 New 6 122 136 203 271 41 41 0 7 120 133 200 267 36 36 0 37 Available 8 118 131 197 162 36 30 0 36
  35. 35. 35 9 116 129 193 258 2 10 -6 10 112 124 187 249 0 6 -6 11 108 120 180 240 89 90 -1 5 recount count 12 99 110 165 220 58 60 -2 New 1 + 25 13 98 109 163 218 2 10 -8 2 local 14 96 107 160 213 25 25 0 New 19 15 94 104 157 209 2 4 -2 16 92 102 153 204 3 10 -7 20indnt 17 90 100 150 200 42 42 0 40 New 18 86 96 143 191 3 8 -5 19 84 93 140 187 6 8 -2 20 82 91 137 182 1 10 -9 21 78 87 130 173 41 30 11 New 12+15+18 22 75 83 125 167 3 12 -9 23 72 80 120 160 3 12 -9 24 70 78 117 156 31 31 25 68 76 113 151 3 10 -7 26 66 73 110 147 3 3 0 27 65 72 5+6 12 -6 28 62 69 103 138 4 8 -4
  36. 36. 36 29 60 67 100 133 7 7 0 30 58 64 97 129 22 22 0 New20 31 54 60 90 120 5 5 0 32 52 58 87 116 5 5 0 33 50 56 83 111 6 6 0 34 48.5 54 81 108 9 9 0 35 46.25 51 77 103 10 10 0 36 41.5 46 69 92 8 8 0 37 38.5 43 64 56 6 6 0 38 37 41 62 82 2 2 0 39 35.75 40 60 79 5 5 0 Total 609 682 -73 b)Reed for picanol looms (10+7) Si No Reed No Present Required Short Remark 1 130 7 7 2 108 10 10 Came with loom 3 99 10 10 Indnted 4 65 4 10 -6
  37. 37. 37 b) Requirements of cut reed of picanol 45 loom Si No Reed No Present Require Short 1 130 4 4 0 2 108 35 36 -1 3 99 32 30 2 4 96 8 10 -2 5 90 32 32 6 87 4 7 86 2 8 78 8 9 72 1 10 71 1 11 58 1 12 65 5 10 5 Proposed Process Allowances For the different process:
  38. 38. 38 Section Yarn Dyeing Warp% Weft% Section Cumulative Section Cumulative Yarn Dyeing 2.00 23.32 2.00 26.59 Winding 0.50 20.86 0.50 24.06 Warping 3.00 20.25 23.44 Sizing 0.50 16.64 23.44 Weaving (Crimp) 8.00 16.06 13.5 23.44 Greige (Reject) 1.00 6.78 1.00 Process Loss 1.50 5.71 1.50 5.71 Shrinkage 2.00 4.12 2.00 4.12 Inspection (Rejection 2.00 2.04 2.00 2.04 Total 23.32% 26.59% Section Yarn Dyeing(pc/cvc) Warp% Weft%
  39. 39. 39 There are major departments are : 2. Winding. Section Cumulative Section Cumulative Yarn Dyeing 2.50 24.59 2.50 27.24 Winding 1.00 21.48 1.00 24.06 Warping 3.50 20.26 - 22.81 Sizing 0.50 16.05 - 22.81 Weaving (Crimp) 8.00 15.47 13.50 22.81 Greige (Reject) 1.00 6.23 1.00 6.23 Process Loss 1.50 5.17 1.50 5.17 Shrinkage 1.5 3.59 1.50 3.59 Inspection (Rejection 2.00 2.04 2.00 2.04 Total 24.59% 27.24%
  40. 40. 40 3. Warping. 4. Sizing. 5. Drawing, Denting. 6. Weaving. 7. Inspection. These departments are described below: Winding Section Definition: In fabric manufacturing (weaving) process this is the first stage where rewinding of supplied yarn is done on to a desired package suitable for use in the next process. Types of Winding: 1. Soft Winding. 2. Hard widing
  41. 41. 41 Soft Winding Section Soft Winding: where the grey yarn is wond on to a special dye spring or plastic bobbin and the package(spool) is made softer and bulkier to make it suitable for dye penetration in the(package) dyeing machine.
  42. 42. 42 Dye Spring Plastic bobbin Organogram: The organogram of this section is given below: Section in charge ↓ Senior Operator ↓ Operator ↓ Helper ↓ Cleaner Skill Level Man power Section-in charge 3 Senior Operator. 36 Operator Helper 27 Cleaner. 12 Total 72
  43. 43. 43 M/c Name : CORAL TEXTILE Manufacturer : Shanghai Coral Textile machinery Co. Ltd Manuf. Year : 2008 R.P.M. of Motor : 1430 No. of Head : 2 No. of Drum /head : 54 Traversing system : Grooved drum Motor : Individual Stop motion : Automatic No. of m/c : 07 Production per m/c : 86867 km /day [Assuming 80% efficiency]
  44. 44. 44 Flow Chart: DISPO ↓ Store Requisition ↓ Recieve the yarn ↓ Setting & Running ↓ Winding ↓ Checking(dia) ↓ Stop winding ↓ Quality assurance ↓ Root card making Delivery for dyeing Assignment in soft winding : 1. Finding out package density 2. Production calculation
  45. 45. 45 1.Finding out package density We know package density ρ =mass(m)/volume(v) gm/cc Volume= π( R2 -r 2 )h R= outer radius of package R= inner radius of pkg h= height of pkg Now we consider a sample of 40/1 cotton yarn whose R=4.138 r= 1.59 h=15.24 mass m=1000gm So package density ρ=1000/π(4.1382 -1.592 )15.24 gm/cc =1.433 gm/cc 2.Production calculation We know production= speed(m/min)×60×24 ×1.09/(840×40×2.2045) kg/day/head When speed is 800m/min at 80% efficiency Production=800×60×24×1.09/(840×40×2.2045)kg/day/head =10.5976kg/day/head Total production=10.5976×54×12kg/day =6867.2448kg/day
  46. 46. 46 YARN DYEING
  47. 47. 47 OBJECT: To dye grey yarn to produce check and stripe fabric. Dyeing procedure: Deminerelization ↓ Bleaching ↓ Hot wash ↓ Dye run ↓ Neutralization ↓ Finishing ↓ Hydro extracting ↓ Drying Dyeing process: Process Recipies
  48. 48. 48 Demineralization Ladiquest 0.5g/l Acetic acid 0.1g/l 70°-15min Bleaching Caustic 1g/l Per- oxide 4g/l 115°-20min Dyeing Ladiquest 0.80g/l Salt 40g/l Suffix Yellow SPD 4% Suffix Red SPD 0.2325% Suffix Nevy Blue 0.5663% Soda ash 10g/l Washing off Ladiphore RSK 0.4g/l Finishing Permafix RDX 0.7% Acetic acid 0.2g/l Assignments 1.Observing Hydro Extracting Cycle & production calculation 2.Production calculation 2.Observing Hydro Extracting Cycle & production calculation
  49. 49. 49 Hydro extracting cycle is with time required Lowering(30sec) ↓ Circulation( 12 sec) ↓ Operation(5min,40sec) ↓ Lifting(21sec) Water removing Efficiency: Weight of cone after dyeing: 2.38kg Weight of cone after drying: 1.11kg Water removing Efficiency=(2.38-1.11)/2.38% = 53.36% 3.Production calculation of RF Dryer Length of RF Dryer=13m At 28rpm it takes 21 min 9 sec to pass this length Along this length it can accommodate 416 pkgs i.e 416kgs So at 21 min9sec or 1269sec it can dry 416kgs So in 1hr or 3600sec it can dry=416×3600/1269 kg/hr =1180.14 kg/hr so Production per day=1180.14×24kg =22658.688 kg =22.66 tons Hard Winding Section
  50. 50. 50
  51. 51. 51 Hard Winding: Where the grey yarn dyeing machine is converted from spool to paper cone, to make the yarn easily be fed to the sectional warping machine. The organogram of this section is given below: Section in charge ↓ Senior Operator ↓ Operator ↓ Helper ↓ Cleaner Manpower Skill Level Man power Section-in charge 3 Senior Operator. 36 Operator Helper 27 Cleaner. 12 Total 72
  52. 52. 52 M/c Name : CORAL TEXTILE Manufacturer : Shanghai Coral Textile machinery Co. Ltd Manuf. Year : 2008 R.P.M. of Motor : 1430 No. of Head : 2 No. of Drum /head : 54 Traversing system : Grooved drum Motor : Individual Stop motion : Automatic No. of m/c : 07 Production per m/c : 6867 km /day [Assuming 80% efficiency] Flow Chart: Root card ↓ Checking ↓ Recieving ↓ Prepare batch card ↓ Start Hard Winding ↓ Measuring weight
  53. 53. 53 Assignment in Hard winding : 3. Finding out package density 4. Production calculation 1.Finding out package density We know package density ρ =mass(m)/volume(v) gm/cc Volume= π( R2 -r2 )h R= outer dia of package r = inner dia of pkg h= height of pkg Now we consider a sample of 40/1 cotton yarn whose R=3.99cm r= 1.60cm h=15.24cm mass m=1000gm So package density ρ=1000/π(3.992 -1.602 )15.24 gm/cc =1.563 gm/cc 2.Production calculation We know production= speed(m/min)×60×24 ×1.09/(840×40×2.2045) kg/day/head When speed is 800m/min at80% efficiency Production=800×60×24×1.09/(840×40×2.2045)kg/day/head =10.5976kg/day/head Total production=10.5976×54×12kg/day =6862.32kg/day
  54. 54. 54 Faults in winding section: Faults Causes 1. Excessive Hard package Excess tension 2. Excessive Loose package Less tension 3. Ring Faulty drum 4. Stitching Vibration of Package 5. Ribbon Ribbon breaker problem. 6. Bulging Improper alignment of Package 7. Entanglement Jerking package 8. Bunch Improper store and handling 9. Cut cone Package drop 10.Reverse winding Low pressure Types of Maintenance: 1. Schedule maintenance 2. Break down maintenance. Spare item types: 1. Readymade / purchase: 2. Fabrication tool in work shop / other side 3. Import item. Quality Control in winding Section: The following quality is maintained in preparatory stage.
  55. 55. 55 Shade matching: The dyed yarn compared with lab drip sample or swatch card. Level Checking: During package dyeing dyes chemical enter in to package by pressure. So there is a possibility to differ level in inner and outer side. It is checked and allow up to (5 -6)% Fastness: Water and color fastness is checked. Strength: CSP, tenacity, CV% of tenacity, elongation are tested. Package hardness: Soft wound package is checked by hand if it is hard improper dyeing will occur, the hard wound package also checked if it is less hard or too hard it will create problem in subsequent process. Material Handling Equipment For Winding Section: 1. Creel. 2. Trolley. 1. Creel: 2. Trolley
  56. 56. 56 Warping
  57. 57. 57 Operational Staff: Section in charge ↓ Senior Operator ↓ Operator ↓ Helper Direct Warping Process Flow: Dispo ↓ Yarn from store ↓ Creeling ↓ Warping
  58. 58. 58 A. High Speed Warping m/c No of m/c: 1 Brand name : TSUDAKOMA Origin:JAPAN Creel capacity : 644 Creel type : V type Maximum beamwidth: 1780mm High Speed Warping m/c Setting: Set up parameters Range Set value Cone no. of Creel 400-600 As required Warping Speed 1-1200 m/min Warping length 1-999999 m Shift selection 1-5 3 Beaming drum pressure 1-11 mm scale 5 mm scale Beam barrel dia 315 mm Fixed Beam flange dia. 987 mm Fixed Beam width 1800 mm As required Operation Procedure Direct Warping: 1. As per production program given by assistant manager, preparation through the yarn warp record register, the supervising
  59. 59. 59 officer collects griege yarn from store as per required count, lot number and quantity. 2. The machine operates and helpers open / break the yarn cartoon and place the cones in the creel head as per program and draw the head end of the cone through pretension rods, feeler guides, yarn guides and then through expanded comb of beaming unit. 3. The basic creel data setting and machine data setting are done according to the requirement as per m/c manufacturer operating instruction. 4. An empty beam is set in between driving clutch and engaged by means of electric switch. 5. All the ends from the creel is wrapped around the beam manually one round. 6. The press roller is moved towards the beam by means of electric switch. 7. The m/c is then run slowly and checked for yarn alignment with beam flange on both sides. To ensure alignment the expanded comb may be moved either to the right or left as required by switch. 8. Thus the m/c is ready and the operational switch is to be turned on. 9. As the present length is achieved the m/c will stop automatically. The beam is doffed by switch and another beam is mounted. 10.In this way a set of beams are made to feed the subsequent sizing process.
  60. 60. 60 Sectional Warping Process Flow: Dispo Yarn from store Creeling (According to warp plan) Machine setup Section wise warping Beaming
  61. 61. 61 B Sectional Warping m/c (Type 1): No of m/c: 2 Brand name : UK IL MACHINARY Origin: KOREA Creel capacity : 720 Creel type : H type Maximum beamwidth: 1780mm Warp width: Total Ends Warp Width Below 7200 1800 mm 7200 2000 mm Above 7200 2100 mm . Causes of yarn breakage in warping: 1. Weak yarn. 2. Sloughing off. 3. Over lapping. 4. Knots/ bad splice. 5. Slubs. 6. Loose yarn. 7. Pig tail. 8. Cut yarn. 9. Bad tip cone. 10.Short cone.
  62. 62. 62 Assignment: Observing the end breakage. Serial no Position of breakage Time consumed 1 Between reed& drum 12sec 2 Near package 1min 4sec 3 Far package 1min 44sec 4 Between reed& drum 13sec 5 Missing end on Drum 2min 21sec 6 Between reed& drum 25 sec 7 Breakage from pkg 1min 33 sec 8 Missing end on Drum 2 min 33 sec 9 Missing end on Drum 2min 25 sec 10 Missing end on Drum 2 min
  63. 63. 63 Sizing Sizing is the processof applying an adhesive coating on the yarn surface. it is done mainly to protect the yarn knot to get hairy while on weaving.Paramount has a sizing machine which facilites the sizing need of the whole factory. Machine Specification (Type 1): No.of m/c: 1 BrandName: Tsudakoma Origin:Japan. Back beem Capacity: 16 No. Of size Box: 2 No of Drying cylinder:12 No of Wax box:1 Power Consumption:76kw
  64. 64. 64 Units of the m/c: 1.Back Beam unit 2.Sizing Unit 3.Drying Unit 4.Leasing Unit 5.Beaming or Take up unit Controlling Points: 1.Speed of the Yarn Passing 2.Drying Unit-Cylinder temperature must not exceed 150˚C to maintain R.H. less than 6% which is a requisite for cotton yarn.
  65. 65. 65 3. Squeezing Pressure: A typical roller pressure for wide variteyof cotton yarn is given below. First Squeezee: 0.12MPa Secondsquzee:0.2MPa Immersion roller:0.1MPa 4.Separation Unit: Distances between the lease rods are to be care fully set up for solid dyed & yarn dyed fabrics 5.Headstock : All the settings are done from here. Size Box: There are two size boxes and one hot wash box.
  66. 66. 66 Main parts of size box are 301= TENSION DETECTION ROLL 302= IMMERSION ROLL 303= FIRST SIZING ROLL 304= FIRST SQUEEZE ROLL 306= SECOND SIZING ROLL 308= SIZE BOX 307= SECOND SQUEEZE ROLL 310= LEVEL ADJUSTER 311= STEAM PIPE 312= COVER
  67. 67. 67 Some typical size recipes used in PARAMOUNT given below with their function- Construction: 30x30/120x70 Total ends:6876 Recipes: Recipes: Yarn count 30/1 Total ends:6876 Yarn count 30/1 Total ends:6876 Water 600 Lt 600 Lt Sure Bond 60 kg 60 kg CMC 20 kg 18kg Size CA 15 kg 18 kg Wax 2 kg 3 kg Polytex. 460 20 kg 20 kg Function: 1. Sure Bond: It work’s as adhesive to increase solidity percentage in the size recipes. 2. Starch : It also works as adhesive. As its price is of low it is mainly used to reduce the size cost when yarn count is coarser 3. CMC: It is a synthetic adhesive used mainly to help in penetrating other chemicals into yarn. 4. PVC :This adhesive is only used on finer count yarn. 5. Size CA:Its mainfunction is to bind protruding fibres with yarn. 6. wax: It acts as a lubricating agent.
  68. 68. 68 Costing of Size Ingredients Ingredients Cost tk/kg Sure bond 43-53 Starch 29 CMC 139 PVA 267 Size CA 70 Wax 255 Assignment: Measuring of size take up% of a particular sample Yarn count 40/1 Total ends 7420. Recipes: Water: 600 Lt Sure bond: 60kg Startch: 20kg CMC: 20kg Size CA: 15kg Sized yarn Unsized yarn Wax: 2kg Wt of 1m of total yarn before sizing = 0.12kg Wt of 1m of total yarn before sizing=0.1340kg So, Size take up %=(0.134-0.12)/0.12% =11.67%
  69. 69. 69 Drawing, Denting Section Process definition: After a sized beam or weaver’s beam is made, it is time to mount this beam over the loom. There are two methods used to prepare this beam for mounting on a loom. 1. Warp tying or knotting (Quick style) change process. 2. Reaching – in /Drawing – in and beam gaiting.
  70. 70. 70 Warp tying: This method is limited to use where and exactly same article or quality of fabric is to be made that is already running in the loom. The following points are considered- 1. The total number of warp ends should be the same as that of running. 2. The count of yarn and weave design should be same. Before tying a new beam with an older one, the new beam is to undergo a process called leasing, whereby the adjacent yarns are kept separated by placing a yarn in between them. This is very essential in case of tying a yarn dyed beam; otherwise the warp pattern scheme will be disturbed and lost. For monocular beam (solid dyed beam), tying is performed without leasing. Drawing – in: The method of mounting weaver’s beam on to the loom, which is adopted for the same style of working of adjacent warp yarns or yarn interlacement, compared to that of running in looms. In this method warp yarns are separated individually as per count or color pattern from the adjacent yarn and hooked to the access of drawer’s hook called reaching – in.
  71. 71. 71 The yarn as it comes to “reach” or drawer’s hook is then drawn through dropper (or drop wire) and then passed through the split of the reed dent called denting. Operation procedure: Warp tying: 1. According to that plan, knotting – in – charge & Drawing – in – charge jointly arrange leasing of beams, the respective beams being identified from the sizing data sticker. 2. As leasing is completed the beam is transported to a specific loom and mounted on loom beam bracket. The tying frame is set on proper position. 3. The ends of old beam and the ends of the new beam are accurately brushed and gripped by the frame sothat older and newer ends, make and upper & lower set of yarn placed in proper tension. 4. The warp tying head is mounted over the tying frame. In case of STAUBLI machine, number of knots per repeat of color pattern is entered in to machine. 5. Then the machine is started. After the programmed number of knots per color is reached, knotting will stop. Operator will check the correctness of the knot and start again by switch. 6. Thus knotting will be completed up to the end of set, tying up per set of older yarn with lower set of new warp.
  72. 72. 72 7. As knotting is completed, the knotting operator make a quality card mentioning customer name, work number, beam number beam length, knotting operator’s name and date and time of knotting. 8. The sizing date sticker is set over the quality (of doffing) card, and the card is set over the loom. 9. The knotting operator also makes a work record in his register book. 10.As knotting is completed, tying head and frame are removed, the old piece odd knotted yarn is pulled through the machine, i.e. through heald wire and reeds and thus new warp set is allowed to pass and made ready to run. Drawing – in and reaching – in: 1. The customers fabric swatch is sent to the weaving section, generally after warping is done, either by enclosed to the order sheet to form or separately. Assistant manager (weaving) then analyzes the swatch for reproduction. In this stage the determines – a. The design of sample i.e. whether dobby or tappet or combination of two. b. The drawing – in, denting and lifting or tappet/ cam setting plan. c. The required number of heald frame and reed count, draw width etc.
  73. 73. 73 2. Then whenever the sized beam is ready, the worked out drawing – in plan, reed count etc. against an order number is given to the drawing – in – charge for production. Drawing – in – charge for production. Drawing – in – charge makes a work program considering the following: a. The availability of the run out loom for beam. b. The availability or required number of reed count. 3. Drawing – in – charge and senior drawer find out the desired sized beam number from the sizing production record, check against the specific work order number and from transport these to the drawing – in – section by trolley and start working there. 4. According to the work order number each design/ drawing – in plan is recorded in the register book, the produced sample being attached thereafter. 5. After drawing – in/ denting is completed each beam is set with a quality/ doffing card, the sizing data sticker is being attached on the card. 6. During deciding the loom number the drawing – in – charge takes into consideration designing scope and color insertion scope of the respective loom. 7. Finally beam gaiters carry this beam along with dropper, healds and reed with trolley onto the specified loom and mount. 8. They will pull the new yarn from the beam and set in the loom with dropper, healds and reed properly positioned and tie the new
  74. 74. 74 yarn with the old piece of cloth wrapped around the surface roller with a number of small knots. Equipment used in Drawing denting and pinning Section: Denting plate (Patti): Drawing Hook: Drop Wire:
  75. 75. 75 WEAVING SECTION Process Definition: The act of inter lacing Warp yarn(of a beam) with the inserted weft yarn in a definite order to form a fabric suitable for use as a dress material, domestic or industrial purpose is called weaving. The machine used for this purpose is called loom. Weaving Floor of PARAMOUNT
  76. 76. 76 Process equipment: Air jet loom Loom shed – 1: Total no of loom - 178 Loom shed – 2: Total no of loom - 40 EQUIPMENTS OF LOOM SECTION The machine used for the purpose of weaving can be categorized as follows: Brand name of the Loom Shedding Device Weft Insertion RPM No. of Looms Picanol omniplus 800 Tappet 06 700-850 10 Picanol omniplus Tappet Dobby 04 650-900 52 Toyota JAT 710 Cam 06 725-950 15 Toyota JAT 710 Dobby 06 600-700 01 Toyota JA 600/610 Tappet Dobby 2+4+6 525-650 34
  77. 77. 77 Tsudakoma ZAX 9100 Cam 06 750-850 12 Tsudakoma ZAX Dobby Tappet 04 500-650 13 Tsudakoma ZAX 205,205i Cam 02,06 450-600 81 Total 218 SPECIFICATIONS OF AIR JET LOOM: GENERAL SPECIFICATION Motor R.P.M : 1410 M/C speed : 625 PPM Motor pulley dia : 100mm M/C pulley dia : 225mm Reed : Profiled reed Shedding : Cam, Electric Dobby Take up motion : Electronic Let off motion : Electronic Warp stop : Electrical Weft stop : Electronic
  78. 78. 78 HEALD SHAFT SPECIFICATION Brand Name : New light Manufacturer : Nankai industrial Co. Ltd. Origin : Japan PHOTO ELECTRIC SENSOR Model : CY-21P-SK Manufacturer : Sunx Ltd. Origin : Taiwan LENO BOBBIN WINDER Brand Name : Precision spooler
  79. 79. 79 Model : PS Manufacturer : Sankin engineering Co. Ltd. Origin : Japan SIGNAL LAMP Manufacturer : Hayashi feeler Co. Ltd. Origin : Japan CABLE Manufacturer : Mitsubishi Cable Industries Ltd. Origin : Japan REED SPECIFICATION Brand Name : (i) RTOS (ii) Setia kiji reed Origin : Japan Type : Profile reed Reed Count : 129, 121, 116, 106, 99, 92, 88/2, 74/4, 72/4 etc. Reed Width 172.50cm WARP BEEM CARRIER Brand Name : TODO Model : S-1500 Manker : Marubeni Corp
  80. 80. 80 Origin : Japan OVER ALL CLEANER Brand Name : LUWA Type : Suction LOOM MOTOR SPECIFICATION (3 Phase Inductor Motor) R.P.M : 1410 Maker : Meidensha Corp H.P : 3KW SIGNAL LAMP: COLOR INDICATION Red : Warp breakage Green : Weft breakage White : Loom stop Yellow : Selvedge leno bobbin breakage LENO SETTING: Right side : 10° Left side : 280° PRODUCTION PROCEDURE:
  81. 81. 81 Operation stuff: Assistant Manager – section in charge Production officer – shift in charge Loom Technicians – shift wise running loom checking/ tuning/ setting & gauging Senior loom operator – as a line jobber, for production & Q.C. Loom Operator Helpers & movers – for supplying yarn and yarn cartoons Casual worker – For keeping the machine & section clean Different parts of Air Jet loom: 1. EDP(Electronic Drum Prewinder). 2. Tappet(Cam). 3. Lever and Puller. 4. Reed. 5. Dobby. 6. Easing roller. 7. Back rest. 8. Take up roller. 9. Cloth roller. 10.Weft Feeler. 11.Dummy selvedge stop.
  82. 82. 82 12.Weft cutter. 13.Drop wire and bar. 14.Leno selvedge attachment. 15.Main nozzle. 16.Sub nozzle. 17.Tample. 18.Dummy selvedge system. 19.Monitor and Mother board 20.Pressure control Switch. 21.Grease tank. Adjustment of setting: Cutter to reed distance: 1mm Tample to reed: 3mm EDP pin to bend: 0.5mm. Sub nozzle to sub nozzle: 88mm. Two pick gear: 0.23m Shed Size: →Plain: Shed angle: 30° Shed depth: 3 – 3.5cm →Plain + Shateen: Shed angle: 20°
  83. 83. 83 Shed depth: 2.5cm →Twill: Shed angle: 25° Shed depth: 3.5cm A= WARP BEAM B= BACK REST C= DROPPER D=HEALD FRAME E= REED F= FRONT REST G= TAKE UP ROLLER H= CLOTH ROLLER
  84. 84. 84 Threading of catch cord
  85. 85. 85 Fabric and recommended planetary yarn Fabric Filament yarn Spun yarn Oxford ,Industrial cloth Polyester texturized yarn 56dtex,84dtex LH 80S/2 RH 40S/1 2/2,twill clothing Polyester texturized yarn 56dtex,84dtex LH 120S/2 RH combed 60S/1 Poplin Polyester texturized yarn 56dtex,84dtex LH 120S/2 RH combed60S/1 Polyester fabric Polyester texturized yarn 56dtex,84dtex ---------------------------
  86. 86. 86
  87. 87. 87
  88. 88. 88 Hand Loom Section In PARAMOUNT Textile Ltd there is a hand loom section. There are several hand loom section with combined section, such as treadle, treadle pad dobby, treadle and jacquard. There is also hank winding frame, sample high speed warping machine, sectional warping machine also. When PARAMOUNT gets a new order without any swatch, then a cad is prepared and sends it to the Hand loom section. There a small size of sample is prepared. If the sample is prepared successfully according to specification, then the planning department took necessary step for bulk production.
  89. 89. 89 Finishing section Executive loom: Four persons can do the job- 1. first meter checker 2. loom checker 3. loom checker 4. loom checker(reliever)
  90. 90. 90 Grease inspection: Two persons can do the job- 1. loom checker 2. grease inspection checker First meter checking procedure: Approved sheet by executive Checking point: For solid dyed: 1. construction 2. width(standard+/- 1”) 3. weave design as std 4. selvedge 5. reed number 6. denting order 7. design/color/pattern For yarn dyed: 1. construction 2. width(standard+/- 1”) 3. weave design as std 4. selvedge 5. reed number 6. denting order 7. design/color/pattern
  91. 91. 91 All check points are checked by first meter checker and executive will confirm that ok or not ok. By comparing with the first meter of first loom and approved sample. Loom checkers job: Any type of fault like 1. stop mark 2. miss pick 3. double pick 4. wrong knotting etc found then this sample is not approved List of equipments: 1. scissor 2. pick counter 3. measuring tape Quality Standard : Given on the dispo paper FABRIC INSPECTION PROCESS DEFINATION: Fabric inspection is the process of identifying weaving faults in the fabric just after the grey fabric production in the loom. EQUIPMENT: 1. Inspection table 2. Fabric inspection machine(Nazer, L 90p, Pakistan)
  92. 92. 92 KEY ACCESSORIES: Nipper, Pointer, Cutter, Comb etc. INSPECTION PROCEDURE: Operation stuff: Shift In-charge ( 6 ) Operator( 36) Helper( 36 ) Cleaner( 6 ) OPERATION PROCEDURE: Operation Stuff: Operation stuffs of Inspection Process include: Factory Manager ↓ Manager, Quality Control ↓ Production Executive ↓ Supervisor ↓ Sr. Inspector ↓ Inspector ↓ Helper
  93. 93. 93 MACHINE SET-UP: M/C Set Value & Parameter Check : M/C Set Value & Functionality Check 1. Guide roller speed : 40 meter/min 2. Light : Artificial day light 3.Length measuring meter : Attached with the fabric & the m/c 4. Automatic cutter(knife) : Functionality check 5. Slippage measuring roller : Functionality observe 6. Batcher : Check batcher setting with motor Operation Procedure: The steps involved in the Inspection Process is as follows: 1. Inspector connects the batcher with motor and feeds the fabric by the guide roller. The fabric goes through a special table where there are arrangements for special lighting to detect faults in the fabric visually. 2. Fabric is inspected as per inspection procedure of 4-point system. After the inspection, the fabric is rolled or folded without any crease and is packed by polythene paper. The inspector puts the Identification Sticker on the fabric roll with details of the fabric (i.e. order no, customer, batch no, shade, roll no, usable width composition etc.).
  94. 94. 94 Type of fabric : Maximum Roll size (meter) 1. Poplin : 250 2. Yarn dyed : 250 3. T.C Fabric : 300 4. Twill : 150 3. The good as well as reject quantities are entered in the MASH module of Datatex system with respective quality codes and then they are transferred to the finished goods stores. Four Point Inspection System: Generally any piece of fabric with less than 40 points fault per 100 square yard is allowed to pass however for a roll; the average value should not exceed 28 points per 100 square yards. More than 40 points fault per 100 square yards is recorded as reject. Normally fabric faults are recorded using the 4-point system given below: 4-Point Grading System Fault length Points to be assigned (0 to 7.5) cm or less than 3” 1 points (7.5 to 15) cm or (3” to 6”) 2 points (15 to 22.5) cm or (6” to 9”) 3 points More than 22.5 cm or 9” 4 points
  95. 95. 95 Assessing Fabric Fault Faults name Definition Faults area Points Double pick In full width an extra pick 0 to 9 inch over 4 Miss pick Missing of one or more picks 0 to 9 inch over 4 Reverse pick After arriving reverse back and causes double pick 0 to 3 inch over 1 Broken or half pick Pick less than full length 0 to 9 inch over 4 Crack More than three pick missing 0 to 9 inch over 4 Snarling Bunch of weft yarn woven in one place 1 inch 2 Pressure loose Loop formed in the fabric Between 1 yards 4 Let-off mark Weft way mark for irregular pick dense 0 to 9 inch over 4 Wrong pattern Design broken on warp way 0 to 9 inch over Starting mark Weft way mark while starting the loom Full width 4 Reed mark Reed having more gap than the normal way.So warp way line visible Reject Temple mark Along the temple one or more pin mark visible Reject Count mixing Mixing of various count Reject Slubs Bunch fibres in yarn 0 to 1 inch 1 Double yarn One extra warp yarn woven along with regular warp Reject Loose warp One or more warp yarn having more looser than another warp Mandible Reject Tight warp One or more warp yarn having more Mandible Reject
  96. 96. 96 tighter than another warp Stitch/warp float One or more warp yarn not properly interlaced with weft for some distance 0 to 3 inch over 1 Oil spot Oil drop in the fabric Zala Bunch of warp yarn breakage 0 to 9 inch over 4 Bad selvedge Narrow or higher width of selvedge Informed weaving FINISHING SECTION Finishing Machineries 1. Singeing-Desizing 1 set 2. Washing machine 1 set 3. Stenter 1 set 4. Peach Finishing 1 set 5. Sanforizing 1 set 1. Singeing – Desizing: Singeing is a process by which projecting or floating fibers stand out on the surface of the fabric are burned off. Singeing is done to remove hairy fibers projecting from surface of cloth and given a smoothen face. It is also done to increase lusture in the finished fabric and to prepare the fabric for next process.
  97. 97. 97 Desizing is the first wet processing textile finishing technology employed to remove the sizing material from the fabric. It depends on the solubility of the film forming polymer, on the effects of numerous subsequent wet processing steps, on the interactions with added chemicals. It is done to remove starch from the fabric and to increase absorbency of the fabric. 2. Scouring and Bleaching: Scouring is the process by which all natural and adventilious impurities such as well as oil, wax, fat etc. are removed to produced hydrophilic and clean textile material. It is vital precess of wet processing. It is done to make the fabric highly hydrophilic and to remove impurities such as olis, waxes, gum, husks as completely as possible. Bleaching of textile material is chemical or commercial process which can be defined as destruction of natural coloring matters to impart a pure permanent and basic white effects suitable for the production of white finishes, level dyeing and desired printed shade with the minimum or on tendering or without diminishing the tensile strength. It is done to ensure a pure and permanent basic white color fabric and to destruction of natural coloring matters from the fabric. 3. Stentering: Stentering is done to soften and to control width of the fabric. It is done to give the required finish to the fabric.
  98. 98. 98 Some finishes: 1. Soft/regular finish 2. ETI (Easy to Iron)/wrinkle free finish/resin finish 3. Easy care 4. Paper touch finish 5. Peach finish Typical recipe: Soft finish: Construction: 40x40/120x80 Tubingal 11/2: 8 gm/L Jinssofter AS852: 20 gm/L Terasil NNO: 10 gm/L Acetic acid: 0.5 gm/L Resin finish: Construction: 50x50/144x90 Fixapreat eco: 50 gm/L Condensol Fm: 10 gm/L (Catalyst) Siligen pcp: 20 gm/L (Softening agent) Aniston EPD: 20 gm/L (Softening agent) Jinsofter AS822: 20 gm/L (Softening agent) Acetic acid: 0.5 gm/L Karoline jet B: 1gm/L (Wetting agent)
  99. 99. 99 4. Peach finish: Peach finishing is done to give soft, hairy and smooth surface effect to the fabric. For this emery rollers used. 5. Sanforizing: Sanforizing is mainly done to control shrinkage of the fabric. It is also done to give a better softening effect and controlling width of the fabric. Step wise process: Spraying Unit Steam Roller Rubber Belt Cylinder Steam Roller Blanket Cylinder (Ironing for permanent shrinkage control) Common Fabrics Produced In PARAMOUNT Fabric name: Plain Construction:130×80/40×40,60” Composition: 100% Cotton
  100. 100. 100 Finish Type: Peach Fabric Name: Plain Construction:110×80/50×50,58” Composition: 100% Cotton Finish Type: Soft Fabric Name: Oxford Construction:110×50/40×30/2,58” Composition: 100% Cotton Finish Type: Regular
  101. 101. 101 Fabric Name: 2/2 ‘s’ twill Construction:30×30/120×70,59” Composition: 100% Cotton Finish Type: Soft Fabric Name: 2/2 ‘z’ twill Construction:110×70/40/2×20,60” Composition: 100% Cotton Finish Type: Soft
  102. 102. 102 Fabric Name: Plain Construction:40×40/134130×80,60” Composition: 100% Cotton Finish Type: Regular Fabric Name: Plain Construction:40×40/120×80,59” Composition: 100% Cotton Finish Type: Soft (Silicon) Fabric Name: Dobby Construction:40×40/120×80,60” Composition: 100% Cotton Finish Type: Soft
  103. 103. 103 Fabric Name: Plain Construction:20×20/72×50,58” Composition: 100% Cotton Finish Type: Regular Fabric Name: 2/2 ‘z’ twill Construction:40/2×20/110×70,61” Composition: 100% Cotton Finish Type: Soft
  104. 104. 104 Fabric Name: 2/2 ‘z’ twill Construction:40×40/120×90,63” Composition: 100% Cotton Finish Type: Soft Fabric Name: Plain Construction:40×40/133×72,60” Composition: 100% Cotton Finish Type: Peach Fabric Name: 2/2 ‘z’ twill Construction:40/2x20/110×70,61” Composition: 100% Cotton Finish Type: Soft
  105. 105. 105 Fabric Name: Plain Construction:40×40/110×80,58” Composition: 100% Cotton Finish Type: Regular Fabric Name: 2/2 ’z’ twill Construction:40/2x20/110×70,61” Composition: 100% Cotton Finish Type: Soft
  106. 106. 106 Fabric Name: Plain Construction:40×40/133×100,60” Composition: 100% Cotton Finish Type: Regular Fabric Name: Plain Construction:40×40/130×80,60” Composition: 100% Cotton Finish Type: Peach
  107. 107. 107 Fabric Name: Plain Construction:40×40/130×80,59” Composition: 100% Cotton Finish Type: Peach Fabric Name: 2/2 ’s’ twill Construction:40x40/130×90,56” Composition: 100% Cotton Finish Type: Soft
  108. 108. 108 Quality Assurance System
  109. 109. 109 To ensure safe and consumer friendly fabric PARAMOUNT has its own high- tech laboratory and computer data processing system.The laboratory is fully equipped with modern testing equipments enabling them to check the fabrics in all the stages of required testing criteria and performances.Testing equipments are sourced from renowned companies,such as- JAMES H HEAL-UK SDL ATLAS-UK DATA COLOR Spectro Photometer-USA QUALITY ASSURANCE & LAB TESTING SECTION
  110. 110. 110 PHYSICAL TESTS: Test Name Equipments Manufacturer Thread per inch Thread counter James. H. Heal & Company, Halifax, England Gram per square meter G.S.M tester James. H. Heal & Company, Halifax, England Width test Measuring tape N/A Tensile strength Elmendorf tearing tester 1653 James. H. Heal & Company, Halifax, England Seam slippage Alphatens James. H. Heal & Company, Halifax, England Abrasion resistance Nu-Martindale Abrasion & Pilling tester James. H. Heal & Company, Halifax, England
  111. 111. 111 Pilling resistance ICI pilling box James. H. Heal & Company, Halifax, England Thermal stability Roaches Roaches engineering limited Crease resistance Shirley crease recovery tester James. H. Heal & Company, Halifax, England CHEMICAL TEST: Test Name Equipments Manufacturer Wash Fastness Gyro wash James. H. Heal & Company, Halifax, England Water Fastness Perspirometer & Carbolite James. H. Heal & Company, Halifax, England Sweat Fastness Perspirometer & James. H. Heal &
  112. 112. 112 Carbolite Company, Halifax, England Light Fastness Light fastness Tester(Mercury vapor lamp) James. H. Heal & Company, Halifax, England Crocking Fastness Crocometer James. H. Heal & Company, Halifax, England Washing stability Wascator James. H. Heal & Company, Halifax, England ANALYSIS: Test Name Equipments Manufacturer Fiber analysis Electronic microscope James swift U.K. Fabric analysis Balance, Thread counter N/A Design analysis N/A N/A
  113. 113. 113 DAILY WEAVING PERFORMANCE REPORT QUALITY ASSURANCE DEPARTMENT PARAMOUNT TEXTILES LIMITED Date: ……… Order # Customer Construction Quality Shade Starting time Loom # Sample Rcv Time Sign Remark
  114. 114. 114 Maintenance
  115. 115. 115 Maintenance is one of the main concerning points for any production oriented organization. PARAMOUNT having its own maintenance department is a strong section. It has a skilled group of maintenance manpower. Manpower: Section Name of No of Description Man Required Coverage for off day, Total Machine/Job Machine per Shift leave & absenteeism In charge 0 0 1 Asst Engineer 0 0 1 Maintenc Mechanical 218 Forman 0 0 1 loom Senior Fitter 2 2 8 Fitter 2 2 8 Asst Fitter 2 3 9 Helper 3 3+General shift6 18 Total=46 In a weaving factory, Maintenance is done mainly on Sizing machine and on looms. Maintenance of sizing machine Periodical Inspection Daily Inspec tion Remove any lint on the suction filter for the cooling fan for the driving motors in each section. Check any trouble and the following points: →Abnormal noise, →surface condition, vibration, rotation irregularity of each roll; →Tension in each section; →Steam, air size and oil leakage; →Steam pressure: a. Main supply pressure b. Supply pressure to the drying cylinder c. Supply pressure to the sizing section.
  116. 116. 116 →Air pressure: a. Main supply pressure, b. Pressure during power failure-at the beam stand and the middle section, c. pressure due to the cut mark device-standard 0.3MPa. →Steam drain exhaust; →Squeeze roll pressuring condition; drain in the air filter equipment. Weekly inspection →Exhaust drain from the air compressor and the pressure reducing valve with the filter; 1.Roll chain tention Adjust tension with tension wheel.If the chain has slack replace it.Some check points are- a.Sizing section: Sizing roll driving b.Drying Section: Pre-cylinder drying and main cylinder drying. c.Take-up section:Warp beam and doffing driving, Taking-up roll driving. 2.V-Belt Tension Slide the motor base and the V-belt tension.Checking points are- a.Size circulation pump b.Winding motor
  117. 117. 117 Every three month inspection 1.Steam strainer cleaning: Clean the strainer two or three days after starting operation for the first time.Clean it every three months after that. 2.Take up box frame and hydraulic unit: Check the oil amount in the take up box frame and hydraulic unit. Supply if it is necessary.If oil is dirty replace it. 3.Pressuredrop after passing the air filter in the pneumatic piping When the pressure difference between the primary and secondary side reaches 0.1MPa repace the element. 4.Cleaning of the steam trap Clean the steam trap two or three days after starting operation for the first time.Clean it every three months after that. Every six month inspection Polish the rubber rolls in the sizing section every six months. Check the bearings. #Tools for assembly 1. 1-ton chain block: Four sets 2. 1-ton forklift: 1-2 sets 3. Transit and stepladder # Man power A staff of four to six required to unpack, install and wire the machine. Lubrication 1. Lubrication position and required amount Model Oil or grease Application Q’ty/unit HS40 Oil Take-up gear box 6.5 litres
  118. 118. 118 Sizing gear motor 6.0 litres Heatproof Oil Centralized lubrication oil 3.0 litres Hydraulic actuation oil Oil tank 15.0 litres Grease Sliding section, bearing 1.0 liters 2. Recommended Oil Manufacturer Oil Grease Hydraulic actuation oil Centralized lubrication Nippon oil Corporation FBK OIL RO150 MULTINOC GREASE 2 FAIRCOL A46 ESSO Teresso 150 Beacon EP2 Teresso32 MOBIL Mobil DTE Extra heavy Mobilux Grease 2 Mobil Rarus 425
  119. 119. 119 Maintenance of loom Periodical Inspection and Maintenance #Routine Inspection and Maintenance Inspection Position Check points Maintenance Brake Check for abnormally highly temperature ASdjust Selvedge Check for abnormal noise Adjust to 0.2mm Feeler Head Check for dirt on the lens Clean the lens Cutter Check the weft is well Replace damaged edges Selvedge formation Check that the selvedge yarn is threaded properly and in uniform tension Correctly threading and adjust tension Temple Check that the temple marks do not appear Adjust Catch cord Check that the tuft is not wound on the take up roll Remove the tuft and clean Inspection and Maintenance After weaving Inspection Position Check points Maintenance Whole loom Check driving and lubrication section Remove lint and waste yarns lubricate Temple Check the temple ring rotates easily and are not worn out Remove lint and dirt,when neede replace FDP Check that lint has not adhered to the hook pin, main drum or pin drum Clean Heald frame Check that the heald frame height difference is 2mm or less compared Adjust the heald frame height
  120. 120. 120 with specific value Air filter Check if the drain is filled up Drain Let off Check that yarn has not adhered to the easing shaft Remove waste yarn Lubrication Grease nipples, teeth of open gears Apply grease with brush Every Six Month Inspection and Maintenance Inspection Position Check points Maintenance Thread guide Check for dirt Clean Hook pin assembly of FDP Check inside for dirt Clean Sensors Check that they function normally Replace Gear box of take-up and let-off Section Check for dirt of oil Replace Air Filter Check that the filter element is not clogged Clean ,replace Reed Check for adhesive monomer and abrasions Clean, replace Main nozzle Check that the pipe is not bent Replace Sub nozzle Check for bent on the tips Replace Yearly Inspection and Maintenance Inspection Position Check points Maintenance Warp beam Check that abrasion of journal section is 0.3mm or less Shock absorber Check the function Replace
  121. 121. 121 Cutter on the LH Check the edge for sharpness Grind or replace Hook pin assembly Check that abrasion is 0.5mm or less Remove burr Cloth roll metal bush Check that bush abrasion is 0.8mm or less Replace Every Three yearly Inspection and Maintenance Inspection Position Check points Maintenance Cloth roll Check that the roll rotates smoothly and cloth is wound Replace the brake lining Sub nozzle Check for dirt Clean Every Seven year Inspection and Maintenance Inspection Position Check points Maintenance Overhaul Loom, Bearings, Gear ,Cams, Hook pins, Main motor Shedding section, Let-off and take-up section,FDP section Lubrication Points Position Period Lubricant type Driving Section Gear box- 6 months Main motor-3 months Oil A Grease C Shedding Section Heald Frame Guide-1 week Gtrease A Let off Section Gear box-6 months Gears-After weaving Oil B Grease A Take-up Section Gear box-6 months Gears-6 months Oil B Oil A Selvedge Section Slide Gear-After weaving Grease A
  122. 122. 122 Bobbin Shaft-After weaving Cutter Section Cutter lever pin-After weaving Cutter cam-After weaving Grease A Automation Support Bracket-After weaving Grease A Recommended Lubricants Manufacturer Name NIPPON OIL CORPORATION FBK Oil RO100 SHELL Tellus Oil C100 JOMO Ratus 100 MOBIL Mobil DTE Oil Heavy EXXON Teresso 100 Tools and Their Functions Name Functions Pulley Puller Adapter For removing the motor pulley from the main motor shaft G6 type puller For pulling out the loom pulley from the crank shaft Turnbuckle For opening the split of the motor base Tube Cutter When cutting the synthetic flexible tube Torque wrench When mounting the reed on the reed holder Adjusting Bracket When adjusting the vertical position of the tension metal supporter G3 type puller For disassembling the FDP drum to remove the drum holder Lifting rod bar Moving up the press roll in gaiting
  123. 123. 123 Utility Services
  124. 124. 124 Utility Services There are following utility services are available in Paramount: 1. Gas. 2. Water. 3. Electricity. 4. A/c Plant (Chiller). 5. Compressed Air. 6. Steam. 7. Efluent treatment plant.
  125. 125. 125 Power generation Facility: The main utility electricity is generated by generators which are operated by Gas and Diesel engine. The diesel engine works as standby engine. There are 5 gas engine operated generators Engine Name: JENBACHER GAS ENGINE Manufacturing Country: AUSTRIA Capacity: Total Capacity: 3543KW. 0.3 – 0.4 m3 Gas is required per KW electricity generation Gas is supplied from Titas Gas. Specification: 1. Gas engine used. 2. 20cylinders per engine 3. Overall efficiency – 90% 4. Heat recovery possible from 4 engines 5. Stroke of engine – 185 mm 6. Cylinder capacity – 71.6 dm3 7. Ignition pressure – 90 bar 8. Piston speed – 9m/s 9. Air flow of full load = 1.65 kg /hour. 10. Exhaust flow of full load= 1.7 kg /hour. 11. Exhaust gas temperature =500ºC
  126. 126. 126 12. Pressure of gas = 60 -62 millibar 13. Air pressure =10 bar 14. Engine rpm=1500 15. Engine temperature= 85º C – 90ºC 16. Cylinder Temperature = 550º C – 650ºC 17. Oil change after 750 hours 18. Oil required /engine = 180 lt. Distribution: Different Section of PTL WEAVING 1299KW YARN DYEING 1623KW OTHERS 620KW Steam generation Facility: Pure steam with required temperature must be produced to meet the conditions demand of steam in different sections. Fire tube type boiler is used to steam generation. No. of boiler: 2 twine boiler Capacity: Total : 8+6=14 ton /hr. Steam flow 9 ton/hr each (approximately) Specification: 1) 3 phase heating system 2) The lower drum is 100% water filled and the top drum is 60% water & 40% steam filled.
  127. 127. 127 3) Measuring meter for water supply. 4) 4” depth greasol insulation so no heat at outside. 5) Steam pressure 8.2 kg/cm2 6) Water pressure 10.3 kg/cm2 7) Origin: Korea 8) Steam temperature: 185ºC 9) Boiler temperature (inner): 225 -275ºC Chemicals used for boiler feed water: NaCl solution for regeneration. NALCO-4654 (Scale removal) Distribution: 1. The major portion of the steam is supplied to the PTL dye house. To heating the drying Cylinder. To heating the calendar rollers. Heating the chemicals liqor. 2. Sizing section of PTL For Size cooking Size box to keep required viscosity Compressed Air Facility: Natural gas is drawn by pipe through the filters above the compressor & the air is compressed. In such a case the air becomes slightly hot. Hence cold water is drawn to reduce the temperature of compressed air. Thus the cold water becomes slightly hot & goes through outlet pipe to the overhead deserver. Then the water falls
  128. 128. 128 slowly through a sieve and becomes cool & feed to the compressor. At the other hand the cooled compressed air along with some vapors are transferred to the reservoir where the vapors are condensed and outlets drop by drop. The moist compressed air is transferred to the dryer & a slight warm compresses air is delivered to required sections of PARAMOUNT TEXTILE LIMITED. Capacity: Total number of Compressor : 2+4 =6 Capacity : 41.4 * 6= 248.4 Pressure of deliver air : 8.5 bars (designed) 6.5 – 7.0 bars (actually produced) The compressors deliver oil and moisture free compressed air. Specification: a) Name: Air compressor (Cop co). b) Brand name: Electronikon-ZR5 c) Manufacturer: ATLAS COPCO AIR POWER n.v. WILRIJK, BELGIUM. d) Model: 2T-250V SD e) Type: Rotary screw type. f) Year of manufacture: 2007-2009 Parameters Set value Unloading pressure 7 bar Pressure difference 0.6 bar Oil pressure 7 bar Motor running time 15 sec Distribution: 1. The major consumption of compressed air is in weaving section. min 3m
  129. 129. 129 2. To the looms for pick insertion (for Air jet loom). 3. To clean different section and machinery 4. To the sensors where pneumatic pressure required (computerized control machines). 5. For the compensator movement. 6. Pneumatically controlled loading and unloading of yarn dyeing machinery 7. Pneumatically controlled loading and unloading of different machinery. Air conditioning Facility: Water is cooled down below its normal temperature (i.e. 9 – 9.5ºC) through A/C plant. A/C plant to maintain required amount of relative humidity and temp. Capacity: Number of A/C plant: 2 Refrigerant specification: 1. Lower shell pressure = 6.2 mm Hg (Absorbed +Evaporator) 2. Upper shell pressure = 49.8 mm Hg (Low temp. generator) 3. High temp. generator pressure = 671.5 mm Hg. 4. Dilute solution concentration = 58.6% 5. Medium solution concentration = 61.0% 6. Strong / concentrated solution concentration=63.4%
  130. 130. 130 Distribution: The maintenance of relative humidity and temp is very important for weaving to reduce yarn breakage and produce quality fabric. A/C plant maintain required amount of relative humidity (80 – 85%) and temp (22 – 26ºC) in weaving 1,2,3 section. warping, winding and Final inspection section. Water Facility: Continuous supply of iron and hardness free water for PTL, PYDL must be ensured by pump. Capacity: Mainly two pumps are used for water pick up. Pump Capacity Setup Submersible pump – I 160m3/hr Discharge value: 100% open Submersible pump – II 150 m3/hr Discharge value: 100% open Depth of pump: 140 ft. Also pump for chemical dosing & centrifugal pump for yarn dyeing. Chemicals used:  Soda Ash.  Manganese – di – Oxide.  Grease or lubricant. Distribution: The major distributions of water are: 1. PTL dye house. 2. PTL weaving preparetoryhouse. 3. Boiler house for steam generation.
  131. 131. 131 Gas The gas is supplied from Titas Gas. Gas is used for steam production. Gas is used for power generation. Generally 36 m3 gases are required to produce 1 ton steam. 0.3 – 0.4 m3 Gas is required per KW electricity generation. Cost: Utility Cost Electricity 2.75 Tk/ KW Air 0.30-0.35 Tk/m3 Water 17Tk/m3. Waste water 13 Tk/m3 Steam 500 Tk/ton. Effluent Treatment Plant ETP is used to treat the water used in various purposes in textile processing in PARAMOUNT TEXTILE LTD.to make the water environment friendly. Number of plant: 1 Area of Plant :30 acres Type of ETP : Chemi-Biological Plant Capacity /day : 150 tons ( 150m3)
  132. 132. 132 Aeration Tank Biological Tank-2 Biological Tank-1 Clearifier-1 Clearifier2 2222222222 Clear water tank Clear water tank Blowing Tank Chemical mixing Tank Biological tank 3 Sludge Tank E.T.P COLORED WATER
  133. 133. 133 Number of treatment plant and their names: 1. Tank 1:Blowing tank 2. Tank 2:Chemical mixing tank 3. Tank 3:Clarifier 1 4. Tank 4:Clarifier 2 5. Tank 5: Boilogical tank 1 6. Tank 6: Boilogical tank 2 7. Tank 7: Boilogical tank 3 8. Tank 8:Clear water tank Chemicals used in ETP Name Amount Price tk./kg Lime 200 kg 8.5-9 Ferrous Sulphate 250 kg 17 Polyelctrolyte 2 kg 300 Biological Organ : Bacteria produced naturally PH Controlling: PH in ETP is less than 9. If PH is decreases in the ETP, the amount of lime is increased. If PH is increases in the ETP, the amount of Ferrous sulphate is increased. Costing Total treating capacity per day is 150 tons( 150m3) Total cost per month is 1.5 lacs So,water treating cost =150000/(150000×30) =0.03 tk/kg of water Remarks: Most utility are made of own machines. So the continuous supply is possible. The costs of utilities are also less than government supply. For large project it consumes more utilities.
  134. 134. 134 Store & Inventory Control
  135. 135. 135 STORE & INVENTORY CONTROL INTRODUCTION: Inventory is planning and execution involves participation by most of the fundamental segment of business sales, production, purchase, finance and accounting. Inventory is a wider sense is defined as any idle resource of an enterprise how ever it is semi-finished packing spares and other stocked in order to meet an expected demand or distribution. OBJECTIVES OF INVENTORY CONTROL: 1) Financial activities: a) To save amount of investment b) To know the cash position 2) Property Protection: a) Preventable waste b) Insurable damage c) Unauthorized use 3) Operating: a) To obtain the best overall balance between production and inventory carrying cost. b) To minimize losses c) To avoid stock out and to keep inventory holding costs in costs in balance.
  136. 136. 136 INVENTORY SYSTEMS: For Raw Materials: In this factory, Paramount Textiles Limited, raw materials are yarn of different type, different of count . As according to Weaving section demand yarn is produced in different spinning mills, some times from foreign country and they are kept in the store for raw materials in accordance with type and count. As like as polyester, cotton, lycra are kept separately and also to their count variation. Inventory office keeps record of this raw materials amount, their usage and storage. Raw material partially received from production planning & directly from head office. Material receiving & inspection report (MRIR) is prepared. Receive quantity is mentioned & noted down. Department gives store requisition to warehouse. As per requisition materials supplied & this record is noted down. There is a software which is networking with various section where these information are required. The software is Data tex. For Spares: Different spare parts of Weaving machines and other equipments are kept in store as inventory so that there are no time and money losses while it is being used. Here also Data tex software is used. For Finished Goods: Finished goods in Paramount Textiles are the Finished Fabric. Finished fabrics are delivered to the garments section or to the buyer. Here also Data tex software is used.
  137. 137. 137 STORE ROOM: There are four type store room in PARAMOUNT TEXTILE Limited. a) Yarn Store. a. Grey. b. Dyed. b) Fabric Store. a. Greige. b. Finished. c) Main Store. The main store room contain this following goods- a) Size Chemicals. b) Packing materials. c) Stationary books. d) Electrical & Mechanical parts. e) All kinds of weaving parts. FREQUENCY ON INVENTORY UPDATE:  Monthly inventory control  Annual inventory control SCOPE OF INVENTROY CONTROL:  Raw materials : Yarn (Grey & Dyed)  Finished fabric  Spare parts  General store (Capital equipment, Accessories, Stationary, Maintenance parts) REMARKS:  The space is noticed to be insufficient considerably.  An expansion of space is thus desired for sound inventory.  The department is computer oriented .
  138. 138. 138 Cost Analysis
  139. 139. 139 Costing is the most important tools in any business. In the weaving process, all the functions may go right but if the costing is wrong, the total process will go on loss in spite of profit. PARAMOUNT has its own technique of costing. Though it is a matter of secrete for the company welfare, PARAMOUNT has given us idea about costing. Some important costing parameters of PARAMOUNT are given below Average ppm of loom 600 Efficiency 80% Total running hour/day 24 Average PPI 60 Fixed cost/loom/day (Considering facility and overheads) tk.6000 Production cost /picks tk.0.030 Some typical calculation #Total production =(PPM/PPI)×24×60×Efficiency = (600/60)×24×60×0.80 = 292 meters/day #Costing on picks Production cost /pick tk.0.025 Production cost /min ( Production cost /pick)×PPM = 0.030×600= 18 tk Production cost /DAY ( Production cost /min)×60×24 =18×60×24 =25920 TK. Total Production Cost /day = Production cost /DAY + Fixed cost/loom/day =(25920+6000) tk. =31920 tk. Production cost /meters = (Total Production Cost /day )/( Total production /day) = 31920/292 tk =109.31 tk #selling price Considering profit 20% tk.(109.31+109.31*20%) =tk.131
  140. 140. 140 Some important data regarding costing #Costs of raw materials Count Type Price$ 10/1 Autocone 1.6 16/1 Autocone 1.8 16/1 Comb 2.1 20/1 Autocone 2.15 20/1 Comb 2.15 20/1 Kard 2.0 20/1 Open end 1.85 30/1 Comb 2.25 40/1 Comb 3.5 50/1 Comb 3.7 60/1 Comb 4.5 40/2 Comb 3.1 80/2 Comb 6.5 100/2 Comb 7.00 24/1 Slub 3.3 30/1 Slub 3.4 16/1 Kard 1.95 #Some typical process costing Construction: 40X40/120X90, 58/59” Soft Warp yarn cost: 0.367 Weft yarn cost: 0.260 Warp dye cost: 0.231 Weft dye cost: 0.111 Weaving cost: 0.509 Finishing cost: 0.176 Total cost/mtr: 1.71
  141. 141. 141 Construction: 40X40/110X70, 58/59” Soft Warp yarn cost: 0.336 Weft yarn cost: 0.203 Warp dye cost: 0.231 Weft dye cost: 0.128 Weaving cost: 0.396 Finishing cost: 0.176 Total cost/mtr: 1.45 Construction: 50X50/150X90, 58/59” Soft Warp yarn cost: 0.475 Weft yarn cost: 0.270 Warp dye cost: 0.231 Weft dye cost: 0.131 Weaving cost: 0.509 Finishing cost: 0.176 Total cost/mtr: 1.75 Construction: 50X50/120X96, 58/59” Soft Warp yarn cost: 0.392 Weft yarn cost: 0.288 Warp dye cost: 0.185 Weft dye cost: 0.140 Weaving cost: 0.543 Finishing cost: 0.176 Total cost/mtr: 1.71 #Some typical and their selling price Name Construction Price-TK/meter Plain 40X40/120X80 147 Plain 50X50/144X76 144 Plain 40X40/110X70 151 2/2,s-twill 30X30/110X70 143
  142. 142. 142 Marketing Activities
  143. 143. 143 PARAMOUNT has a strong marketing policy including a strong marketing managent.It has a group of skilled manpower that looks after the strong marketing strategy. Man power of markeking Deputy Managing Director ↓ Executive Director ↓ General Manager ↓ Deputy General Manager ↓ Assistant General Manager ↓ Manager ↓ Deputy Manager ↓ Assistant Manager ↓ Senior executive ↓ Executive ↓ Junior Executive CONSUMER OF THE PRODUCTS: The mill has a great number of renowned and international consumers. The main consumers of this factory are European country such as Germany, France, Netherlands, Denmark, Italy & England. Following are some regular consumers: 1) C&A 2) H&M 3) M&S 4) TEMA
  144. 144. 144 5) MONDIAL 6) RADHAMONI 7) DEKKO 8) CELLIO 9) VISION APPAREL 10) SHIRT MAKER 11) DEFACTO 12) CHERRY FIELD 13) NEW YORAER 14) NAK FASHION 15) ULLA POPKEN 16) PROMINENT 17) DAVID HAWARD Importing Countries Yarn Size materials Dyes and chemicals Machineries INDIA INDIA INDIA JAPAN THAILAND KOREA INDIA CHINA KOREA Duties & Responsibilities of Marketing Officer: Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A marketing officer also has some other duties. The main duties responsibilities of a marketing officer are given below :-  To prepare cost sheet by dealing with the buyer.  To take different steps by discussing with the high officials & merchandisers.  To maintain a regular & good relationship between commercial officer & merchandisers.  To maintain a regular communication with the buyer & buying houses.  Communicate with the new buyers.  Display the better criteria of the products.
  145. 145. 145 Remarks :- The marketing activities of this mill is so good. The marketing & merchandising section is well organized CONCLUSION
  146. 146. 146 The industrial training gives us the opportunity to work in mills. It is an experience of normal academic learning, This training gives us actual picture about man, machine, material, methods and market. We have earned the direct knowledge about the raw materials, actual running condition of the m/c’s. Works technologist and administration. This mill is a well planed with enough expansion facilities. Their exist are wonderful employer and worker relation. Working environment for the labors is also good. During our training we visited administration section, store, boiler section, generator room, compressor section etc. Everywhere we got cordial behavior from all employees Above all this training for 46 days in the Paramount Textile Ltd. has given us a new experience for practical life. College of Textile Technology has given me the field to perform the industrial attachment with Paramount Textile Ltd. This attachment seems to me as a bridge to minimize the gap between theoretical and practical knowledge. Undoubtedly, this attachment paved us the way to learn more
  147. 147. 147 about Textile Technology, industrial practices, and industrial management and production process. Besides this attachment gave us the first opportunity to work in an Industry and acquainted us with the internal sight and sound of Textile Industries. I believe with all these, the experience of the industrial attachment will help our future life as a Textile Technologist.

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