Industrial attachment of paramount textile ltd

1

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTPARAMOUNT TEXTILE LIMITED

2

Project Description

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

Office:

Chaklader House (Level-6), House # 22,Road #113/A,

Gulshan-2,Dhaka-1212,Banladesh

Ph:(+8802) +8809890618,9890467 Fax:(8802)9890783

E-mail:[email protected] 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

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

b) Human Resource and DevelomentDept.

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) of1994 in june 12, 2006 and went into commercial production in November 2008

7

Man Power Management

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 shiftcontain 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

General shift, which is applicable for some officers.

Man power in different section (weaving) of PTL

10

JOB DESCRIPTION:

SENIOR PRODUCTION OFFICER:

In a weaving factory a senior production officer plays a great role inproduction and man power management who are production related. Here weenlist 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 fulfillingthe required destination.

PRODUCTION OFFICER:

11

Production officer is the right hand of senior production officer andhe is directly related with production manpower and informs senior productionofficer 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 itfinancial 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 correctyarn for order, controlling machine store, controlling process qualitysystem.

Remarks:

The organization and management system are good for millenvironment and as the job description is classified, so duties are donehonestly and sincerely.

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 arecostly and in case of yarn dyed fabric Sectional warping is necessarywhich is also costly and time consuming process.

Weaving

Solid dyed Yarn dyed

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

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. ofm/c

CapacityKg

Power Kw SteamKg/hr

Waterhrm /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

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

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


M/c rpm:2800

M/c Type:B(TH-8A)

No. of machine:3


Brand Name:TAIZHOU JINWEL TEXTILE

Origin:China


M/c rpm:2800

18

M/c Type: C (SHA)

No. of machine: 1


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


19

Type 2

No. of machine: 2

Brand Name: RABATEX

Origin: INDIA

Creel capacity:800

Creel Type: V type


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

No of size box: 02

No of wax box: 01

Power consumption: 76kw

Loom

Total no of looms: 218

Brand nameof the Loom

SheddingDevice

WeftInsertion

RPM No. ofLooms

Picanolomniplus 800

Tappet 06 700-850 10

Picanolomniplus

TappetDobby

04 650-900 52

Toyota JAT710

Cam 06 725-950 15

Toyota JAT710

Dobby 06 600-700 01

Toyota JA600/610

TappetDobby

2+4+6 525-650 34

TsudakomaZAX 9100

Cam 06 750-850 12

TsudakomaZAX

DobbyTappet

04 500-650 13

TsudakomZAX 205,205i

Cam 02,06 450-600 81

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 arechemical 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 DYEINGMACHINERY CO. LTD.

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


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


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


Remarks:

Maximum m/cs are made of China& Japan. Looms are of oldmodel. If technology would have better and new version m/cs been usedproductivity would have been greatly increased.

24

Raw Materials

25

Main raw Material is yarn.

Yarn used mainly 100% cotton, PC, CVC, 100% Polyester, Lurax, lycracore 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

Some of the manufacturing companies from where Paramount procurethere yarn are

1 Zaber Spinning Mill

2.GTN (India)

27

Production Planning,

Sequences &Operations

28

There are two ways Woven fabric produced:

1. Solid dyed.

2. Yarn dyed.

Generally yarn dyed fabrics are costly item. Because dyed yarn arecostly and, In case of yarn dyed fabric Sectional warping is necessarywhich 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

When Order Comes to the Marketing Section, then they contactwith the Product development (in case of new product) or Design cell (incase of available product) that, is it possible or not possible inPARAMOUNT. They Send a Article Request paper. After reaching theArticle Request paper Design cell produce Article Code and send mail tothe planning and marketing section.

Planning print a Dispo paper and send to 10 sections with relatedproduction of that fabric.

Dispo Paper:

Dispo Paper is a paper which contain All necessary information for theproduction of a specific item of fabric. A typical Dispo Paper is attachedbelow:

Buyer Merchandiser Marketing

Design CellPlanning

1. Design Cell2. Yarn Requisition3. yarn store4. winding5. yarn dyeing6. warping7. Sizing8. Drawing, denting9. Weaving10. Finishing.

Send Dispo Paper

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 xWeft) 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

DispoNo: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

FlowCode: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

ColorBreakdown

Count Shade Color Code Quantity (kg)

Length(Mtr)

Warp

40/1 White 797 94874.90

40/1 Blue 443 47477.95

Warp Total 1240

Weft40/1 White 920

Weft Total 920

DYED YARN DETAILS

Dispo No : W90001 Delivery Date : 28/02/2009

BREAKDOWN OF YARN FOR DYEING

DispoLine Count Shade ALD NO Greige

Yarn ( kg)DyedYarn ( kg)

YarnType

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 PARAMOUNTTEXTILE LTD.(weaving). When a order comes to the marketing ormerchandizing officer he/she send the fabric to the design cell that is itpossible or not possible in PARAMOUNT. They send a Article requestpaper. Design cell analyze the fabric design and test the feasibility of

32

produciton and create a Article code and send this article code themarketing or marchandizing officer and input data to the Data tex whichis a software used in PARAMOUNT for all types of information bynetworking.

PARAMOUNT’s Design department is equipped with hand loomand sophisticated software”TEX-DESIGN CLASSIC” byKOPPERMANN of GERMANY.

After getting Article code planning discuss with marketing officerabout costing. Then marketing officer send mail or discuss directly to thebuyer about pricing of the product.

If buyer agree with the price then marketing officer send mail tothe central planning section with Article code.

Planning take a print of dispo paper for the article code from thesystem data tex. After printing dispo paper they send it to the design cellto check or verify. Design cell check and give drawing and denting planand send it to the planning section again.

Planning then send it to the various section where theseinformation required and at a time requisition all necessary rawmaterials or other materials.

Organ gram of Design cell:

Assistant Manager

↓

Data Entry +

Design Analyzer (3 person)

↓

Peon (1 person)

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

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 inPARAMOUNT by denting 2,3 and 4 in a dent For yarn dyed fabric.

a) Read available for air jet Looms Jat-600-ZAX(Tsudakoma)

SiNo

ReadNo

1/1-2Ends/EPI

2/1-3Ends/EPI

3/1-4Ends/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 37Available

8 118 131 197 162 36 30 0 36

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 recountcount

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 New12+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

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 Camewith loom

3 99 10 10 Indnted

4 65 4 10 -6

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

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%

SectionYarn Dyeing(pc/cvc)

Warp% Weft%

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

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

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

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

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

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

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

YARN DYEING

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

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.Observing Hydro Extracting Cycle & production calculation

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

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

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

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


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

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

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

Warping

57

Operational Staff: Section in charge

↓

Senior Operator

↓

Operator

↓

Helper

Direct Warping

Process Flow:

Dispo

↓

Yarn from store

↓

Creeling

↓

Warping

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

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

Sectional Warping

Process Flow:

Dispo

Yarn from store

Creeling

(According to warp plan)

Machine setup

Section wise warping

Beaming

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 nameof the Loom

SheddingDevice

WeftInsertion

RPM No. ofLooms

Picanolomniplus 800

Tappet 06 700-850 10

Picanolomniplus

TappetDobby

04 650-900 52

Toyota JAT710

Cam 06 725-950 15

Toyota JAT710

Dobby 06 600-700 01

Toyota JA600/610

TappetDobby

2+4+6 525-650 34

77

TsudakomaZAX 9100

Cam 06 750-850 12

TsudakomaZAX

DobbyTappet

04 500-650 13

TsudakomaZAX 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

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

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

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

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

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

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

Threading of catch cord

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

---------------------------

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

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

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

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

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

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

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

Assessing Fabric Fault

Faults name Definition Faults area PointsDouble pick In full width an extra pick 0 to 9 inch

over4

Miss pick Missing of one or more picks 0 to 9 inchover

4

Reverse pick After arriving reverse back andcauses double pick

0 to 3 inchover

1

Broken or halfpick

Pick less than full length 0 to 9 inchover

4

Crack More than three pick missing 0 to 9 inchover

4

Snarling Bunch of weft yarn woven in oneplace

1 inch 2

Pressure loose Loop formed in the fabric Between 1yards

4

Let-off mark Weft way mark for irregular pickdense

0 to 9 inchover

4

Wrong pattern Design broken on warp way 0 to 9 inchover

Starting mark Weft way mark while starting theloom

Full width 4

Reed mark Reed having more gap than thenormal way.So warp way line visible

Reject

Temple mark Along the temple one or more pinmark visible

Reject

Count mixing Mixing of various count RejectSlubs Bunch fibres in yarn 0 to 1 inch 1Double yarn One extra warp yarn woven along

with regular warpReject

Loose warp One or more warp yarn having morelooser than another warp

Mandible Reject

Tight warp One or more warp yarn having more Mandible Reject

96

tighter than another warpStitch/warp float One or more warp yarn not properly

interlaced with weft for somedistance

0 to 3 inchover

1

Oil spot Oil drop in the fabricZala Bunch of warp yarn breakage 0 to 9 inch

over4

Bad selvedge Narrow or higher width of selvedge Informedweaving

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

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

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:


Tubingal 11/2: 8 gm/L

Jinssofter AS852: 20 gm/L

Terasil NNO: 10 gm/L

Acetic acid: 0.5 gm/L

Resin finish:


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

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

Finish Type: Peach

Fabric Name: Plain



Finish Type: Soft

Fabric Name: Oxford

Construction:110×50/40×30/2,58”


Finish Type: Regular

101

Fabric Name: 2/2 ‘s’ twill



Finish Type: Soft

Fabric Name: 2/2 ‘z’ twill

Construction:110×70/40/2×20,60”


Finish Type: Soft

102

Fabric Name: Plain

Construction:40×40/134130×80,60”



Fabric Name: Plain



Finish Type: Soft (Silicon)

Fabric Name: Dobby



Finish Type: Soft

103

Fabric Name: Plain





Construction:40/2×20/110×70,61”


Finish Type: Soft

104




Finish Type: Soft

Fabric Name: Plain



Finish Type: Peach


Construction:40/2x20/110×70,61”


Finish Type: Soft

105

Fabric Name: Plain




Fabric Name: 2/2 ’z’ twill

Construction:40/2x20/110×70,61”


Finish Type: Soft

106

Fabric Name: Plain




Fabric Name: Plain



Finish Type: Peach

107

Fabric Name: Plain



Finish Type: Peach

Fabric Name: 2/2 ’s’ twill

Construction:40x40/130×90,56”


Finish Type: Soft

108

Quality Assurance System

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

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

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:


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

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:


Fiber analysis Electronic microscope James swift U.K.

Fabric analysis Balance, Thread

counter

N/A

Design analysis N/A N/A

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

Maintenance

115

Maintenance is one of the main concerning points for any productionoriented organization. PARAMOUNT having its own maintenance departmentis a strong section. It has a skilled group of maintenance manpower.

Manpower:

Section Name of No of DescriptionManRequired

Coverage for offday, Total

Machine/Job Machine per Shiftleave &

absenteeismIn charge 0 0 1Asst Engineer 0 0 1

Maintenc Mechanical 218 Forman 0 0 1loom Senior Fitter 2 2 8

Fitter 2 2 8Asst Fitter 2 3 9Helper 3 3+General shift6 18

Total=46

In a weaving factory, Maintenance is done mainly on Sizing machine and onlooms.

Maintenance of sizing machine

Periodical Inspection

Daily Inspec tion

Remove any lint on the suction filter for the cooling fan for the driving motorsin 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

→Air pressure:

a. Main supply pressure,

b. Pressure during power failure-at the beam stand and the middlesection,

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 withthe filter;

1.Roll chain tention

Adjust tension with tension wheel.If the chain has slack replace it.Some checkpoints 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

Every three month inspection

1.Steam strainer cleaning:

Clean the strainer two or three days after starting operation for the firsttime.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 isnecessary.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 sidereaches 0.1MPa repace the element.

4.Cleaning of the steam trap

Clean the steam trap two or three days after starting operation for the firsttime.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 sets2. 1-ton forklift: 1-2 sets3. 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

Sizing gear motor 6.0 litres

Heatproof Oil Centralizedlubrication oil

3.0 litres

Hydraulicactuation oil

Oil tank 15.0 litres

Grease Sliding section,bearing

1.0 liters

2. Recommended Oil

Manufacturer Oil Grease Hydraulicactuation oil

Centralizedlubrication

Nippon oilCorporation

FBK OILRO150

MULTINOCGREASE 2

FAIRCOL A46

ESSO Teresso 150 Beacon EP2 Teresso32

MOBIL Mobil DTEExtra heavy

MobiluxGrease 2

Mobil Rarus425

119

Maintenance of loom

Periodical Inspection and Maintenance#Routine Inspection and MaintenanceInspection Position Check points Maintenance

Brake Check for abnormallyhighly 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 selvedgeyarn is threaded properlyand in uniform tension

Correctly threading andadjust tension

Temple Check that the templemarks do not appear

Adjust

Catch cord Check that the tuft is notwound on the take up roll

Remove the tuft and clean

Inspection and Maintenance After weaving

Inspection Position Check points MaintenanceWhole loom Check driving and

lubrication sectionRemove lint and wasteyarnslubricate

Temple Check the temple ringrotates easily and arenot worn out

Remove lint anddirt,when neede replace

FDP Check that lint has notadhered to the hook pin,main drum or pin drum

Clean

Heald frame Check that the healdframe height differenceis 2mm or less compared

Adjust the heald frameheight

120

with specific valueAir filter Check if the drain is filled

upDrain

Let off Check that yarn has notadhered to the easingshaft

Remove waste yarn

Lubrication Grease nipples, teeth ofopen gears

Apply grease with brush

Every Six Month Inspection and Maintenance

Inspection Position Check points MaintenanceThread guide Check for dirt CleanHook pin assembly ofFDP

Check inside for dirt Clean

Sensors Check that they functionnormally

Replace

Gear box of take-up andlet-off Section

Check for dirt of oil Replace

Air Filter Check that the filterelement is not clogged

Clean ,replace

Reed Check for adhesivemonomer and abrasions

Clean, replace

Main nozzle Check that the pipe isnot bent

Replace

Sub nozzle Check for bent on thetips

Replace

Yearly Inspection and Maintenance

Inspection Position Check points MaintenanceWarp beam Check that abrasion of

journal section is 0.3mmor less

Shock absorber Check the function Replace

121

Cutter on the LH Check the edge forsharpness

Grind or replace

Hook pin assembly Check that abrasion is0.5mm or less

Remove burr

Cloth roll metal bush Check that bushabrasion is 0.8mm orless

Replace

Every Three yearly Inspection and Maintenance

Inspection Position Check points MaintenanceCloth roll Check that the roll

rotates smoothly andcloth is wound

Replace the brake lining

Sub nozzle Check for dirt Clean

Every Seven year Inspection and Maintenance

Inspection Position Check points MaintenanceOverhaul Loom, Bearings, Gear

,Cams, Hook pins, Mainmotor Shedding section,Let-off and take-upsection,FDP section

Lubrication PointsPosition Period Lubricant typeDriving Section Gear box- 6 months

Main motor-3 monthsOil AGrease C

Shedding Section Heald Frame Guide-1week

Gtrease A

Let off Section Gear box-6 monthsGears-After weaving

Oil BGrease A

Take-up Section Gear box-6 monthsGears-6 months

Oil BOil A

Selvedge Section Slide Gear-After weaving Grease A

122

Bobbin Shaft-Afterweaving

Cutter Section Cutter lever pin-AfterweavingCutter cam-Afterweaving

Grease A

Automation Support Bracket-Afterweaving

Grease A

Recommended Lubricants

Manufacturer NameNIPPON OIL CORPORATION FBK Oil RO100SHELL Tellus Oil C100JOMO Ratus 100MOBIL Mobil DTE Oil HeavyEXXON Teresso 100

Tools and Their FunctionsName FunctionsPulley PullerAdapter

For removing the motor pulley from the main motor shaft

G6 type puller For pulling out the loom pulley from the crank shaftTurnbuckle For opening the split of the motor baseTube Cutter When cutting the synthetic flexible tubeTorquewrench

When mounting the reed on the reed holder

AdjustingBracket

When adjusting the vertical position of the tension metalsupporter

G3 type puller For disassembling the FDP drum to remove the drum holderLifting rod bar Moving up the press roll in gaiting

123

Utility Services

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

Power generation

Facility:The main utility electricity is generated by generators which areoperated by Gas and Diesel engine. The diesel engine works as standbyengine.

There are 5 gas engine operated generators

Engine Name: JENBACHER GAS ENGINEManufacturing Country: AUSTRIA

Capacity:Total Capacity: 3543KW.

0.3 – 0.4 m3 Gas is required per KW electricity generationGas is supplied from Titas Gas.

Specification:1. Gas engine used.2. 20cylinders per engine3. Overall efficiency – 90%4. Heat recovery possible from 4 engines5. Stroke of engine – 185 mm6. Cylinder capacity – 71.6 dm37. Ignition pressure – 90 bar8. Piston speed – 9m/s9. 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

12. Pressure of gas = 60 -62 millibar13. Air pressure =10 bar14. Engine rpm=150015. Engine temperature= 85º C – 90ºC16. Cylinder Temperature = 550º C – 650ºC17. Oil change after 750 hours18. Oil required /engine = 180 lt.

Distribution:Different Section of PTLWEAVING 1299KWYARN DYEING 1623KWOTHERS 620KW

Steam generation

Facility:Pure steam with required temperature must be produced to meet theconditions 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 system2) The lower drum is 100% water filled and the top drum is

60% water & 40% steam filled.

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: Korea8) Steam temperature: 185ºC9) 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 PTLFor Size cookingSize box to keep required viscosity

Compressed AirFacility:

Natural gas is drawn by pipe through the filters above thecompressor & the air is compressed. In such a case the air becomesslightly hot. Hence cold water is drawn to reduce the temperature ofcompressed air. Thus the cold water becomes slightly hot & goesthrough outlet pipe to the overhead deserver. Then the water falls

128

slowly through a sieve and becomes cool & feed to the compressor. Atthe other hand the cooled compressed air along with some vapors aretransferred to the reservoir where the vapors are condensed and outletsdrop by drop.The moist compressed air is transferred to the dryer & a slight warmcompresses air is delivered to required sections of PARAMOUNTTEXTILE LIMITED.

Capacity:Total number ofCompressor

: 2+4 =6

Capacity : 41.4 * 6= 248.4Pressure 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-ZR5c) Manufacturer: ATLAS COPCO AIR POWER n.v. WILRIJK,

BELGIUM.d) Model: 2T-250V SDe) Type: Rotary screw type.f) Year of manufacture: 2007-2009

Parameters Set valueUnloading pressure 7 barPressure difference 0.6 barOil pressure 7 barMotor running time 15 sec

Distribution:1. The major consumption of compressed air is in weaving section.

min3m

129

2. To the looms for pick insertion (for Air jet loom).3. To clean different section and machinery4. To the sensors where pneumatic pressure required (computerized

control machines).5. For the compensator movement.6. Pneumatically controlled loading and unloading of yarn dyeing

machinery7. Pneumatically controlled loading and unloading of different

machinery.

Air conditioningFacility:

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 relativehumidity 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

Distribution:The maintenance of relative humidity and temp is very important

for weaving to reduce yarn breakage and produce quality fabric. A/Cplant maintain required amount of relative humidity (80 – 85%) andtemp (22 – 26ºC) in weaving 1,2,3 section. warping, winding and Finalinspection section.

WaterFacility:

Continuous supply of iron and hardness free water for PTL, PYDLmust be ensured by pump.Capacity:Mainly two pumps are used for water pick up.

Pump Capacity SetupSubmersible pump – I 160m3/hr Discharge value: 100% openSubmersible 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

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 CostElectricity 2.75 Tk/ KWAir 0.30-0.35 Tk/m3Water 17Tk/m3.Waste water 13 Tk/m3Steam 500 Tk/ton.

Effluent Treatment Plant

ETP is used to treat the water used in various purposes in textileprocessing in PARAMOUNT TEXTILE LTD.to make the waterenvironment friendly.Number of plant: 1Area of Plant :30 acresType of ETP : Chemi-Biological PlantCapacity /day : 150 tons ( 150m3)

132

Aeration Tank

Biological Tank-2

Biological Tank-1

Clearifier-1

Clearifier22222222222

Clear water tank

Clear water tank

BlowingTank

Chemical mixing Tank

Biological tank 3

SludgeTank

E.T.P

COLORED WATER

133

Number of treatment plant and their names:1. Tank 1:Blowing tank2. Tank 2:Chemical mixing tank3. Tank 3:Clarifier 14. Tank 4:Clarifier 25. Tank 5: Boilogical tank 16. Tank 6: Boilogical tank 27. Tank 7: Boilogical tank 38. Tank 8:Clear water tank

Chemicals used in ETPName Amount Price tk./kgLime 200 kg 8.5-9Ferrous Sulphate 250 kg 17Polyelctrolyte 2 kg 300

Biological Organ : Bacteria produced naturallyPH 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.CostingTotal treating capacity per day is 150 tons( 150m3)Total cost per month is 1.5 lacsSo,water treating cost =150000/(150000×30)

=0.03 tk/kg of water

Remarks:Most utility are made of own machines. So the continuous supply ispossible. The costs of utilities are also less than government supply. Forlarge project it consumes more utilities.

134

Store & Inventory Control

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 definedas any idle resource of an enterprise how ever it is semi-finished packingspares and other stocked in order to meet an expected demand ordistribution.

OBJECTIVES OF INVENTORY CONTROL:

1) Financial activities:a) To save amount of investmentb) To know the cash position

2) Property Protection:a) Preventable wasteb) Insurable damagec) 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 inventoryholding costs in costs in balance.

136

INVENTORY SYSTEMS:

For Raw Materials:In this factory, Paramount Textiles Limited, raw

materials are yarn of different type, different of count . As according toWeaving section demand yarn is produced in different spinning mills,some times from foreign country and they are kept in the store for rawmaterials in accordance with type and count. As like as polyester, cotton,lycra are kept separately and also to their count variation. Inventoryoffice keeps record of this raw materials amount, their usage andstorage.Raw material partially received from production planning & directlyfrom head office.Material receiving & inspection report (MRIR) is prepared. Receivequantity 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 wherethese 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 timeand money losses while it is being used. Here also Data tex software isused.

For Finished Goods:Finished goods in Paramount Textiles are the

Finished Fabric. Finished fabrics are delivered to the garments section orto the buyer. Here also Data tex software is used.

137

STORE ROOM:There are four type store room in PARAMOUNT TEXTILELimited.

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

Cost Analysis

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 willgo on loss in spite of profit.PARAMOUNT has its own technique of costing. Though it is a matter of secretefor the company welfare, PARAMOUNT has given us idea about costing.Some important costing parameters of PARAMOUNT are given belowAverage ppm of loom 600Efficiency 80%Total running hour/day 24Average PPI 60Fixed cost/loom/day (Considering facility and overheads) tk.6000Production 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 picksProduction cost /pick tk.0.025Production cost /min ( Production cost /pick)×PPM

= 0.030×600= 18 tkProduction 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 )/( Totalproduction /day)

= 31920/292 tk=109.31 tk

#selling priceConsidering profit 20% tk.(109.31+109.31*20%)

=tk.131

140

Some important data regarding costing

#Costs of raw materialsCount Type Price$10/1 Autocone 1.616/1 Autocone 1.816/1 Comb 2.120/1 Autocone 2.1520/1 Comb 2.1520/1 Kard 2.020/1 Open end 1.8530/1 Comb 2.2540/1 Comb 3.550/1 Comb 3.760/1 Comb 4.540/2 Comb 3.180/2 Comb 6.5100/2 Comb 7.0024/1 Slub 3.330/1 Slub 3.416/1 Kard 1.95

#Some typical process costing

Construction: 40X40/120X90, 58/59” SoftWarp yarn cost: 0.367Weft yarn cost: 0.260Warp dye cost: 0.231Weft dye cost: 0.111Weaving cost: 0.509Finishing cost: 0.176Total cost/mtr: 1.71

141




#Some typical and their selling priceName Construction Price-TK/meterPlain 40X40/120X80 147Plain 50X50/144X76 144Plain 40X40/110X70 1512/2,s-twill 30X30/110X70 143

142

Marketing Activities

143

PARAMOUNT has a strong marketing policy including a strong marketingmanagent.It has a group of skilled manpower that looks after the strongmarketing strategy.

Man power of markekingDeputy 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. Themain consumers of this factory are European country such as Germany, France,Netherlands, Denmark, Italy & England. Following are some regular consumers:

1) C&A2) H&M3) M&S4) TEMA

144

5) MONDIAL6) RADHAMONI7) DEKKO8) CELLIO9) VISION APPAREL10) SHIRT MAKER11) DEFACTO12) CHERRY FIELD13) NEW YORAER14) NAK FASHION15) ULLA POPKEN16) PROMINENT17) DAVID HAWARD

Importing CountriesYarn Size materials Dyes and

chemicalsMachineries

INDIA INDIA INDIA JAPANTHAILAND KOREA INDIA

CHINAKOREA

Duties & Responsibilities of Marketing Officer:

Dealing with the buyer & convince the buyer is the main duty of themarketing officer. A marketing officer also has some other duties. The main dutiesresponsibilities 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

Remarks :- The marketing activities of this mill is so good. The marketing &merchandising section is well organized

CONCLUSION

146

The industrial training gives us the opportunity to work in mills. It is anexperience 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 rawmaterials, actual running condition of the m/c’s. Works technologist andadministration.

This mill is a well planed with enough expansion facilities. Their exist arewonderful employer and worker relation. Working environment for the laborsis also good.

During our training we visited administration section, store, boilersection, generator room, compressor section etc. Everywhere we got cordialbehavior from all employees

Above all this training for 46 days in the Paramount Textile Ltd. has given us anew experience for practical life.

College of Textile Technology has given me the field to perform theindustrial attachment with Paramount Textile Ltd. This attachment seems tome as a bridge to minimize the gap between theoretical and practicalknowledge. Undoubtedly, this attachment paved us the way to learn more

147

about Textile Technology, industrial practices, and industrial managementand production process.

Besides this attachment gave us the first opportunity to work in anIndustry and acquainted us with the internal sight and sound of TextileIndustries. I believe with all these, the experience of the industrial attachmentwill help our future life as a Textile Technologist.

Industrial attachment of paramount textile ltd

Engineering

Transcript of Industrial attachment of paramount textile ltd