This document summarizes Noorul Islam Saiful's internship experience at Crystal Composite Ltd. It provides details about the company, his activities and responsibilities in different departments, including knitting, dyeing, sewing, and finishing. It also discusses fabric and garment defects, quality control measures, and standard minute values for sewing operations. Overall, the internship helped him gain work experience and professional skills.

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2. in
CRYSTAL COMPOSITE LTD.
( A Concern of Crystal Group )
October 2017
2

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

18. 18
Stitch Length: GSM:
Stitch Length: GSM:
Gauge Dia: GSM:
Gauge Dia: GSM:

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

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

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

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

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

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