Industrial attachment of viyellatex group

Industrial attachment Page no. 1

VIYELLATEX GROUP

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTVIYELLATEX GROUP


VIYELLATEX GROUP

CHAPTER:01

PROJECT DESCRIPTION

1. Name of the Company: VIYELLATEX GROUP

2. Status: Private Ltd. Company

3. Type: 100% Export oriented composite knit Dyeing Industry

4. Year of establishment: 2001

5.Year of starting production: 2002

6. Location: Gazipura, Tongi

7. Address:

Factory : 297, Khortoil, Tongi, Gazipur- 1712

Head office: 297, Khortoil, Tongi, Gazipur- 1712

Tel. No. 8819281-2 Fax No. 880-2-8810445

E-mail : [email protected]

8. Sponsors: Mr. Rezaul Hasnat

9. Product Mix: 100% cotton,

100% polyester

a) Spun

b) Filament

Nylon

Chief Value Cotton (CVC)

Polyester Cotton blend

Grey mélange (15% Viscose 85% cotton

10% Viscose 90% cotton

30% Viscose 70% cotton)

Ash mélange (1% Viscose 99% cotton)


VIYELLATEX GROUP

10. Production Capacity:

a) Knitting section 19Tons per day (Body fabric)20,000 pcs (Collar & cuff)

b) Dyeing Section 28 Tons per day

c) Garments Section 18 million pieces per year

11. Project cost: 20 million $

12. Different Departments: a) KNITTING SECTION:

Knitting

Inspection

b) DYEING SECTION:

Batch section

Dye house

Dyeing lab.

Quality control

Finishing

c) GARMENTS SECTION:

Merchandising

Sample

d) MAINTENANCE SECTION:

Electrical

Mechanical

e) STORE SECTION

13.Supporting department:

a) Personnel administration

b) HRD

c) Marketing

d) Procurement

e) Finance and accounting


VIYELLATEX GROUP

f) Security department

13. Total Manpower:

a) Knitting section 250

b) Dyeing Section Dyeing- 300Finishing- 250

c) Garments Section 3200

14. Major customers: a) Marks & Spencer

b) S. Oliver

c) ESPRIT

d) Tesco

e) Puma

g) GAP

h) G.Star

i) Wool worths

j) TU


VIYELLATEX GROUP

W

Maintenanceroom

Maintenanceroom

Maintenanceroom

Was

hing

Groundfloor

LIFT

LIFT

LIFT

LIFT

2

1

3

4

7

6

5

Emer

genc

yEx

itSt

airs

Emer

genc

yEx

itSt

airs

Receptionroom

IT, guest &conference room

Office

Office

ProductDevelopment

Office

Restroom

Dinning and Prayer room

Workshop

Sewing floor

Cuttingroom

CADRoom

Central store (Fabric& accessories)

Sewing floor

Sewing floor

Medicalcentre

Inspectionroom

Finishingsection

Chemicalstore

Rawmaterialstore

Garmentsstore

Child carecentre

Store Room

ViyellaTex LTD(Dyeing andfinishing)

Maintenancemanager

LabmanagerTe

xtile

Tes

ting

Corp

orat

ion

1st floor

Gro

und

Cen

tral

stor

e

Fashionplastic &packageLTD

ETP

cont

rol

cent

re ETP

Boilerroom

Boilerroom

Substation &maintenanceroom

Cargolift

WTP Oxidationplant

Generatorroom

Chemicalroom

Fashion plastic &packaging sub stationroom

RMS room Securityroom

Store

Bondedwarehouse

Generator room

Generator room

Garden & rainfall

Mai

n ga

te

Pocket gate

Was

hing

Embr

oide

ryPr

intin

g

Yarn

Sto

re

1st floor


VIYELLATEX GROUP

Mohakhali

Airport

Uttara modeltown

Tongi busstation

Station road,tongi

Collegegate

Gazipura,tongi

Barobari

Boardbarzar

Nationaluniversity

Ashulia

BishwaEstema

Shatrashta

College ofTextileTechnology NS

Location Of TheVIYELLATEX Group

VIYELLATEX

NS


VIYELLATEX GROUP

15. Physical Infrastructure:

The mill is built in such a way that there is possibility for further expansion of the mill. Thestructure such as mill, office buildings, record rooms, guardrooms & dining room etc. are madeof solid hard concrete & brick mtls. . The whole area is surrounded by safety brick wall .Themain set up for m/c’s are built of corrugated iron & iron sheet, transparent hard plastics withenough ventilation & scope for passing light & air.

Remarks:

VIYELLATEX LTD. is a well established knit composite industry. The industry standson industrial area of Gazipur. VIYELLATEX GROUP. is a Group of Companies, Viyella spinning,Youngone’s fashion LTD, Viyella knitting and dyeing,. VIYELLATEX LTD. is going to prove itsown standard about product quality in world market as they know that their reputation depends on itsquality. VIYELLATEX LTD. is a profitable project and contributes the economy of our country.


VIYELLATEX GROUP

CHAPTER -02

MAN POWER MANAGEMENT

Organogram of manpower:

Company Organogram

Finance

CHIEF EXECUTIVE OFFICER (CEO)

CHIEF OPERATING OFFICER (COO)

HEAD OFPRODUCTION

HEAD OFMERCHANDISING

HEAD OFCOMMERCIAL &ACCOUNTS

HEAD OFBU HRD

HEAD OFQUALITYASSURANCE

HEAD OFDESIGN &PRODUCTDEVELOPMENT

HEAD OFPLANNING/ IE

HEAD OF ACCOUNTS & COMMERCIAL

ACCOUNTS DEPARTMENT COMMERCIAL DEPARTMENT

FAVP(Preparation of Financial

Statement & Group Cheque Issue)

PRINCIPAL OFFICER(Salary & Wages)

OFFICER(Petty Cash &Staff Salary)

IMPORT DIVISION(In-Charge & FAVP)

EXPORT DIVISION(In-Charge & FAVP)

PRINCIPAL OFFICER

Sr OFFICER SPO OFFICER

Jr OFFICER


VIYELLATEX GROUP

Organogram from knitting

Organogram of Dyeing

DGM/AGM

Manager / Asst. Manager(Store)

Sr. Executive/ Executive

Jr. Executive(Yarn)

Jr. Executive(Grey Fabric)

Store Asst.(Yarn)

Store Asst.(Grey Fabric)

Loader(Yarn)

BatchHelper/Loade

r

Manager/Asst. manager(Technical)

Sr. Fitter / Fitter

Asst. Fitter

Servicingman

Needle man

Servicinghelper

Manager / Asst. Manager(Prodn & Plan)

Knitting Master/Executive (Flat)

Operator /Asst. Operator

Sr. Fitter /Fitter

Helper

Sr. Executive(Prodn,Plan & Sample)

Executive /Jr. Executive(Prodn, Plan & Sample)

Sr. Supervisor/ Supervisor

Asst. Operator

Sr. Operator/ Operator

Production Helper

Samplesupervisor

Sample asst

DGM/AGM

Manager

Planning

Asst.Manager

Sr.Executive/Executive

Jr.Executive

Sr.Supervisor/Supervisor

Production

Asst.Manager


Jr.Executive


Store

Asst.Manager


Jr.Executive


Washing

Asst.Manager


Jr.Executive



VIYELLATEX GROUP

JOB DESCRIPTION ( IN GARMENTS SECTION)

TITLE: DEPUTY GENERAL MANGER

Job summary: Overall supervision of Garment Section.Responsibilities: Has the responsibilities for running the garment department including

production planning, operation control, measuring and monitoring ofproduct and the process.

Establishing and maintaining identification and traceability requirement. Inspection test status, taking corrective and preventive action. Controlling nonconforming products at intermediate and final stages in

Garment Department. Analyzing product and process performance form measurement process

to identify area for improvement. Provide supports for approval and maintenance of equipment related to

Garment Department and training of stuff in the department.

TITLE: PRODUCTION MANAGERJob summary: Overall supervision of sewing section.Responsibilities: Receives cutting fabrics according style, color and size form cutting

section. Prepare sewing lines of floor & report to A.G.M. in three time everyday Distribute the cutting fabrics according to style, size & color to the

respective line supervisors. Control the Sewing In charge, Q.C, Assist Q.C., supervisor, Asst. Supervisor,

quality Inspector, Operator & helper Maintain floor discipline & cleanness. Any other works as & when required by the management.

TTILE: Q.C. (SEWING)Job summary: Directly control the quality of complete garment in the sewingline.Responsibilities: Check every complete garment, oil mark, dirty spot, yarn marks, fabric

fault. Check the ironing of complete garment. Control the measurement and tolerance. Prepare the pre-final quality control report. Checks getup property. Shade matching base to base & country wise. Any other works as and when required by the management.


VIYELLATEX GROUP

TITEL: Q.C. (CUTTING)

Job summary: Overall supervision of cutting section.Responsibilities: Prepare batch wise cutting report and send to the authorized person. After complete the fabrics cutting report to A. G. M. of garment. Prepare weekly cutting report. Control the pattern master, Cutting master, Cutting supervisor, Cutting

man, Neck man, Cutting helper & Labor Control the cutting quality for bulk production, shrinkage & consumption. Look after the cutting & band knife machine.

TITEL: SEWING IN CHARGE

Job summary: Overall supervision of sewing sectionResponsibilities: Receives cutting fabrics according to style, color & size from cutting

section. Prepare sewing lines of floor & report to A. G. M. in three time everyday. Distribute the cutting fabrics according to style, size & color to the

respective line supervisors. Control the sewing in charge Q.C., Asst. Supervisor, quality inspector,

operator & helper. Maintain floor discipline & cleanness. Any other works as & when required by the management

TITEL: FINISHING IN CHARGE

Job summary: Overall supervision of finishing section.Responsibilities: Looks after the overall finishing section Supervising the poly packing & cartooning. Maintains shipment schedule Procurement of required accessories & cartoons Maintain the daily finished garments record Any other works as & when required by the management

REMARKS :Production runs with the help of mechanical fitters.for any kind of mechanicalfaults of any machine they fix and work under technical in-charge.


VIYELLATEX GROUP

CHAPTER -03MACHINE DESCRIPTION

SL ITEM DESCRIPTION (MESUREMENT) PCS.

1 Gerber Cutter L=174inch, W=109.5inch 1

2 Band Knife L=59.5inch, W=83inch 1

3 Straight Knife 18

4 Spreader Machine L=108inch, W=100inch 4

5 Spreader Table L=32.53m, W=2.23m 2



8 Manual Table L=12.59m, W=2.236m 1

9 Manual Table L=10.76m, W=1.5238m 1

10 Scissor 70

11 Small Table L=38.5inch, W=30inch 98

12 GSM Cutter 1

13 GSM Weight Machine 1

14 Fabric Weight Machine 1

15 Input Rack L=470inch, W=40inch, Height=84inch 12Self,Capacity=KD-5000, TESCO-1500 Per Self

7

16 Input Fabric Rack L=90inch, W=72inch, Height=72inch Per Self,Capacity=1500-1600kg

6


VIYELLATEX GROUP

Some industrial sewing machine

Name No. ofneedle

Thread Stitchlength (mm)

SPM

Lockstitch m/c

1/2 5mm 1500-5500

Chainstitch m/c

1/more 1/more 1.4-4.5mm

1800-6000

Overlock/ overedge m/c

½ 2-5 4mm 6500-8000

Zig-zag m/c

1 2 2-2.5mm

5500

Flatlock m/c

Up to4

4-9 SPI 8-16

6000

Blindstitch m/c

1 1/2 3-8mm 2500

Button8holing m/c

Bartack m/c

Smocking m/c

33 66

Work AidsThe extra m/c parts which may be attached to speed up to the production and improve

quality in sewing m/c are called work aids .Some work aids are:

1.Guide

2.Compensating foot

3.Specialized pressure foot

4.stitching zig

5.Rack guide

6.Light

7.Folder

8.Slack feeder

9.Elastication

10.thread cutting

11.Latch back device


VIYELLATEX GROUP

Specification of Cutting Machines

Spreader Table (Tube):Model: SY: 100Fabric Ply: 7cmLength: 35 ydsWidth: 52 inchBrand:Gerber (USA)

Spreader Table (Open):Model: SY: 100Length:35 ydsWidth: 80 inch

Auto Spreader Machines:(3)Model: SY101Brand: Gerber (USA)Speed:75 m\min

Auto Spreader Machine:(1)Brand: AutexCountry: Spain

Computerised Cutting m/c: (1)Model: Gerber Cutter GT 7250Brand:Gerber (USA)Serial number: 7552Year built: December 2002Cutting Time: 1-15minutesCapacity: 50000 gts\day

Band Knife:Model: EC-900NBrand: EastmanCountry: USA


VIYELLATEX GROUP

Straight Knife

Number of m\c: 18

Active=14, Inactive=4

Brand: KM-14

Eastman-4

Knife Length=12inch

Knife Length used in cutting=7-8cm

M\c no. Brand name Serial Speed Volts AMPS Cycle Phase

1 Eastman 2F61378-5 2850 220 4.2 50 1

2 Eastman 2F61159-5 2850 220 4.2 50 1

4 Eastman 2F61163-5 2850 220 4.2 50 1

5 KM 242430 3000-3600 220 3.3\2.6 50\60 1

6 KM 264021 3000-3600 220 3.3\2.6 50\60 1

10 KM 276350 3000-3600 220 3.3\2.6 50\60 1

11 KM 270124 3000-3600 220 3.3\2.6 50\60 1

12 KM 270152 3000-3600 220 3.3\2.6 50\60 1

13 KM 276369 3000-3600 220 3.3\2.6 50\60 1

14 KM 270149 3000-3600 220 3.3\2.6 50\60 1

15 KM 247606 3000-3600 230 3.3\2.6 50\60 1

16 KM 264059 3000-3600 220 3.3\2.6 50\60 1

17 KM 276337 3000-3600 220 3.3\2.6 50\60 1

18 KM 261615 3000-3600 220 3.3\2.6 50\60 1


VIYELLATEX GROUP

SEWING SECTION

List of Machineries

SL Sewing Machine Quantity Brand

1 1-Needle Lockstitch (auto thread trimmer) 471 Juki, Brother, Sunstar,Puff

2 1-Needle Chain Stitch, Flatbed 10 Joje, Feiyue

3 Vertical Trimmer 25 Juki, Sunstar

4 2-Needle Lockstitch 6 Sunstar

5 2-Needle Chain Stitch, Flatbed 16 Kansai, Joje, Feiyue

6 Multi Needle Chain Stitch 10 Kansai

7 4-Thread Over Lock (With electrical chaincutter)

201 Juki, Pegasus, Kansai

8 2- Needle Piping (Backtape) 11 Pegasus, Kansai

9 2/3-Needle Covering Stitch (Flatlock) 167 Juki, Pegasus, Kansai

10 Zig-Zag Machine (Computerized) 2 Juki, Sunstar

11 Bartack Machine (Computerized) 30 Juki, Brother, Sunstar

12 Button Hole Machine (Computerized) 23 Juki, Brother

13 Button Sewing Machine (Computerized) 23 Juki, Brother

14 Smocking Machine (12 & 33 needle) 2 Kansai

15 Shirring Machine 1 needle elastic threads (12ndl)

1 Kansai

16 Picoting Machine 2 Kansai

17 Rib Cutting Machine 12 Idea, Iu-922

18 Blind Stitch (Overlock) 4 Pegasus

19 Heat Transfer Machine 13 Lee way, Local

20 Hot Fixing Machine 4 Salli

21 Snap Button 13 Nyto, Uzu, Max

22 Fusing Machine 8 Hashima

23 Shaddle Stitch 4 Joje

Grand Total=2248


VIYELLATEX GROUP

NEEDLE GROUPS & SIZE

Machine Name Needle Group SizePM DB*1 9PM DB*1 11PM DC*1 14OL DC*1 9OL DC*1 11FL UY*128 9Picoting FL UY*128 11BH Tone DB*5 11BS DP*17 11Kansai Special UO*113 11

Nobilon Tape: Used in shoulder

Accessories used in Garments Sewing:1. Button2. Thread3. Zipper4. Main Label5. Logo6. Sticker

Allowance: (ILO)1. Relaxation Allowance: 3%2. Fatique Allowance: 3%3. Personal Needs: 4%4. Contingency Allowance:1%5. Delay: Depends on Breakdown)


VIYELLATEX GROUP

Machine Band Country

SUNSTAR KOREA

KANSAI SPECIAL JAPAN

JUKI JAPAN

PEGASUS JAPAN

BROTHER JAPAN

PUFF JAPAN

FIG:BAND KNIFE FIG:STRAIGHT KNIFE


VIYELLATEX GROUP

FIG:AUTO4 SPREADER FIG: GERBER CUTTER


VIYELLATEX GROUP

Fig:SMOCKING M/C

No of needle: 33No of needle thread:33No of looper thread:33Country origin:Srilanka

REMARKS:Viyella tex group well planned factory.Every thing which required for good workingcondition is present here.All section in garments are well furnished.

2


VIYELLATEX GROUP

CHAPTER -04RAW MATERIALS

In garments section different types of raw materials are used .They are describebelow

1.Fabrics:(Feed back from viyella tex knitting section)

1. Single jersey2. 1*1 Rib3. 2*2 Rib4. Interlock5. 3- thread fleece6. 2- thread fleece7. Single lacost8. Auto striper Rib9. Double lacost10.Auto striper Single jersey11.Auto striper lycra Single jersey

12.2.Thread:(Feed back from WELL,Coats Sylko,Purl,Merathon,Air Plane,Basic)13.Spun polyster-4000m/cone14.Filament thread -4500m-5000m/cone15.Metal thread(gold,silver,bronge) -2500m-3000m/cone16.Nylone thread17.Aramid thread18.Soft cotton thread19.Glaced cotton thread20.silk thread


VIYELLATEX GROUP

Thread required for

Basic T-shirt -120m-130mBasic Polo-shirt -140m-180m

Basic Trouser forFleece fabric -250m

Rib fabric -175m-180mSingle jersey -150m-160m

Package:Spool -100m-500mCop -1000m-2500m

Cone- 5000mVicone-filament thread & soft thread

ContainerLarge pakage-20000m


VIYELLATEX GROUP

SHORT NOTEThread Consumption: (Depends on G.S.M)

Plain machine:

Single Jersey: 2.5-2.75/inchRib/Fleece:3/inch

Overlock:

Single Jersey/Rib: 19-20/inchFleece:25-27/inch

Chain:

Single Jersey/Rib:5-6/inch (Single needle) 11-12/inch (Double needle)

Fleece: 8/inch (Single needle) 16/inch (Double needle)

Flatlock:

Single Jersey/Rib: 2 needle + 1 looper: 14/inch 3 needle + 2 looper: 29/inch

2 needle + 2 looper: 20/inchFleece: (Same as Single Jersey/Rib)

Smocking machine: 8/inch

Button holing m/c:2 round: 25-30/inch

1 round: 22-23/inch

Button attaching m/c: 2hole:14/inch 4hole:16/inch 6hole:20/inch 6hole (Puma): 36/inch

Bartack: 28/(1/2)inch

Thread need for Garments making:Basic T-Shirt:120-130mBasic Polo-Shirt: 140-150mBasic Trouser: Fleece: 250m

Single Jersey/Rib: 175-180m


VIYELLATEX GROUP

3.Trimmings:

ChainZipperLabel & motifButton :plastic,metal,wooden,horn.chalk,printed button2-hole button3-hole button6-hole button(desin for PUMA)Interlining :tearable,soft,hard,fusion.LinningHook & loop fasteningLace braid &elasticCare label code forWashingChlorine bleachIroningDry cleaningDry condition

Remarks:Viyella tex compomsite mill is self sufficient for collecting it fabrics .But it collectsthread & others trimmings & accessories from differents sources.


VIYELLATEX GROUP

CHAPTER -05PRODUCTION PLANNING SEQUENCE & operation

PROCESS FLOW CHART( CAD DEPARTMENT)

MERCHANDISING CUTTING

Art work + Spread Sheet RCVD buyar approvalFrom Merchandiser Master Pattarn

Making Pattern Completion of Gradingas per Spread Sheet+ Art Work As per spec sheet / sample

Computer processing Grading pattern with marker sendtoOrder Model cutting section for Trial cut / Sizeset

Marker Making Pattern update after getting sizesetAs per Color Art Work Report as per color wise

Manual Work for neck rib+ The separate color patternComputerBinding or Back Tape marker making as per ratio

Marker Delivery to Concern Delivery to cuttingMerchandiser for approval production


VIYELLATEX GROUP

LAYOUT PLAN OF CUTTING SECTION

LAYOUT PLAN OF CUTTING SECTION

LAY OUT PLAN OF SEWING FLOOR ( 2nd floor right)


VIYELLATEX GROUP

Cutting Section (Sequence)File collect from merchandiser

Fabric collect from store

Marker come from CAD

Fabric spreading (Lay)

Marker setting on the lay

Cutting(By using Straight knife, Band knife, Gerber cutter)

Sticker attach & hand check

Reject part change

Bundling

If required Print / Embroidery

Store on input rack


VIYELLATEX GROUP

LINE BALANCING OF A LONG PANT

SL PROCESS MACHINE QTY FOLDER GUIDE SO ASO1 Care label joint PM 1 N/A PG 1 12 Back rise joint OL 1 N/A N/A 1 13 Front rise joint OL 1 N/A N/A 14 Fly inside overlock OL 1 N/A N/A 15 Back rise top FL 1 N/A NG 16 Fly false tack PM 1 N/A PG 17 Front rise top FL 1 N/A NG 18 Fly top FL 1 N/A NG 1 19 Pocket side tack PM 1 N/A PG 110 Pocket opening 2 part tack PM 1 N/A PG 111 Pocket opening top FL 1 N/A TG 1 112 Pocket tack with side PM 1 N/A PG 113 Pocket bag overlock OL 1 N/A N/A 114 Side seam OL 1 N/A N/A 2 115 Side seam top FL 1 N/A NG 1 116 Waist band make PM 2 N/A PG 117 Waist band contrast rib tack PM 1 N/A PG 118 Hole stitch HS 1 N/A N/A 1 119 Elastic make PM 1 N/A PG 120 Waist band round tack PM 1 N/A PG 121 Waist band joint OL 1 N/A N/A 122 Waist band top FL 1 N/A NG 1 123 Drawcord make PM 1 N/A PG 1 124 Drawcord tack PM 1 N/A PG 225 Pocket flap make PM 1 N/A PG 1 226 Flap top PM 2 N/A PG 127 Pocket folded tack PM 1 N/A PG 1 128 Pocket box top PM 1 N/A 1/16 CL 129 Pocket rolling FL 1 N/A TG 130 Pocket joint with lower panel PM 2 N/A PG 1 131 Pocket panel 1/16 top PM 2 N/A 1/16 CL 132 Pocket panel 1/4 top PM 2 N/A 1/4 CR 133 Pocket joint with body PM 1 N/A PG 1 134 Pocket 1/16 top PM 1 N/A 1/16 CR 135 Pocket flap joint + 1/16 top PM 2 N/A PG 236 Pocket flap 1/4 top PM 1 N/A 1/4 CR 137 Inseam OL 1 N/A N/A 138 Leg hemp tack PM 1 N/A PG 1 139 Leg hemp FL 1 N/A TG 1 140 Leg top FL 1 N/A TG 141 Bartack BTK 1 N/A N/A 1 3


VIYELLATEX GROUP

LINE BALANCING OF A SHORT SLEEVE polo-SHIRT

SL PROCESS MACHINE QTY FOLDER GUIDE OP HP1 Placket Rolling PM 1 N/A PG 1 2

2 Placket Join PM 1 N/A PG 1 1

3 Placket Kacha PM 1 N/A PG 1

4 Placket Inside Fals Tack PM 1 N/A PG 1 1

5 Nose Tack PM 1 N/A PG 1 1

6 Placket 1/16 Top PM 1 N/A 1/16 CL 1

7 Placket Box PM 2 N/A PG 2

8 Shoulder Joint OL 1 N/A N/A 1 1

9 Care Label Joint PM 1 N/A PG 1

10 Collar Joint VT 1 1 cm N/A 1 2

11 Back Neck Tape Joint PM 1 1 cm N/A 1 1

12 Back Neck Tape Top PM 1 N/A 1/16 CL 1

13 Sleeve Hemp FL 1 N/A TG 1 1

14 Sleeve Joint OL 2 N/A N/A 2 1

15 Sleeve Opening Tack PM 1 N/A PG 1 1

16 Side Seam OL 2 N/A N/A 2 1

17 Sleeve 1/4 Tack PM 1 N/A 1/4 CL 1

18 Body Hemp FL 1 N/A TG 1 1

19 Side Seam Tack PM 1 N/A PG 1

20 Side Vent Top PM 2 N/A 1/4 CR 2

21 Hole Stitch HS 1 N/A N/A 1 1

22 Button Stitch BS 1 N/A N/A 1 1

23 Main Label Attach HEAT SE 1 N/A N/A 1 1

24 Bartack BTK 1 N/A N/A 1 3


VIYELLATEX GROUP

LINE BALANCING OF A SHORT SLEEVE T-SHIRT

SL PROCESS MACHINE QTY FOLDER GUIDE SO ASO

1 Front part shearing SM 1 N/A N/A 1 2

2 Arm hole + Neck shape tack PM 2 N/A PG 2 1

3 Shoulder joint (1) OL 1 N/A N/A 1 3

4 Back neck piping joint PM 2 1CM TG 2 2

5 Neck binding FL 1 8MM TG 1 1

6 Neck binding tack PM 1 N/A PG 1

7 Shoulder joint (2) OL 1 N/A N/A 1 1

8 Neck binding 1/4 tack PM 1 N/A 1/4CR 1

9 Care label joint PM 1 N/A PG 1

10 Sleeve overlock OL 1 N/A N/A 1

11 Sleeve rolling FL 1 N/A TG 1 1

12 Sleeve joint OL 2 N/A N/A 2 2

13 Sleeve opening tack +Underarm tack

PM 2 N/A PG 2

14 Side seam OL 2 N/A N/A 2 1

15 Sleeve 1/4 tack PM 1 N/A 1/4CR 1

16 Bottom overlock OL 2 N/A N/A 2 1

17 Main label joint PM 1 N/A N/A 1 4

18 Label joint PM 1 N/A N/A 1


VIYELLATEX GROUP

Merchandising

Garment merchandising is an intricate and detail oriented job. If it can be done properlycan be very rewarding. On the country, if it is done with lack of knowledge, insufficient skilland thoroughness, it can be destructive.

In the VIYELLATEX GROUP, very skilled and experienced personnel run themerchandising section. After receiving an order, the merchandiser with the help of patternmaster calculates the total consumption of fabric. Then according to the cost detail sheet andthe price mentioned by the buyer costing is done. After the price is negotiated with the buyerorder is placed to the suppliers of raw material and accessories.

The manufacturing factory as per the requirement suppliers the fabric and a ledger ismaintained regularly to assess the production status. The accessories such as label, button,zipper, sewing thread, packing materials are collected from outside [sometime mentioned bythe buyer] through back-to-back L/Cs. The merchandising department also looks for thesources for procuring yarns to produce fabric.

Merchandising section monitors the production status regularly and ensures timelydelivery of the shipment.

Job responsibilities of Merchandising Team:

Job responsibilities of Merchandising TeamDEVELOPMENT AND COSTING

01 Reviewing the development packs RCVD from buyer. Put the developments into work with product development team. Clarify all necessary info with buyer as much as possible. Follow up on the delivered sample deadline. Work out the initial costing (all costing must be checked by

merchandising manager) Price negotiation with buyer. Follow up with buyer reg. the feed back of the sample and costing

ORDER CONFIRMATION

02 Quoting the delivery dates to buyer after checking factory’s capacitysituation.

Checking all the details in the order sheet once received form buyer. Communicate with buyer reg. any discrepancy in the order sheet. Passing the correct order sheet to all concerned dept i.e. planning,

production, commercial etc.


VIYELLATEX GROUP

Job responsibilities of Merchandising Team

SAMPLING

03 Updating production development tem reg. different samplerequirement of buyer at various stage (sales man, fit , sz set, ppsample etc)

Coordinating all fabric + trims which are required for samplingpurpose.

Coordinating print, embroidery, wash for sampling. Checking all the technical aspects of samples before releasing to

customer. Checking all the aesthetic aspects of samples before releasing to

customer Checking the quantity requirement of each sample. Checking the necessary paper work of reach sample. Follow up the buyer reg. each sample comments.

BULK FARBIC

04 Work out the consumption for each new styles from CAD. Provide fabric booking to fabric department with correct quantity

and all necessary information. Follow up on the labdips/ strike off submission and chase approval

comments. Follow up on the fabric delivery against critical path Follow up on all fabric approval related issues. Prioritizing the fabric delivery schedule based on the garment

delivery dates.BULK TRIM

05 Preparing the cost sheet/ check list for individual trims required for astyle.

Chasing the trim details from the buyer. Submitting required trims to buyer for approval. Provide booking for individual trims to the approved source. Chasing the P/I from the most ensure ontime delivery. Monitoring the B/B L/C or TT payment status. Sourcing all trims form the most commercially viable source. Follow up with suppliers to ensure ontime delivery. Lialise with store in order to ensure all trims RCVD in correct

quantity and quality.ESTABLISHMENT

06 Chasing the correct artwork for all print/embroidery from buyer. Develpping the design in the best possible method Provide capacity booking to print /embroidery plant in advance. Submitting print/embroidery strike off for buyer’s approval


VIYELLATEX GROUP

Passing approved copy of the strike off to the print/embroidery plant. Negotiating the price with the subcontractors. Monitoring the panels sent and receive dates to ensure smooth

production flow Communicate with supplier for general issues.

FILING & CORRESPONDENSE

07 Maintaining style file for all running orders Maintaing the development file. General correspondence with buyer and suppliers. Critical correspondence with buyer and suppliers Weekly updates for buyer, such as audit schedule, production status

etc.MEETING

08 Meeting with foreign buyers and suppliers. Meeting with local buyers and suppliers. Internal meeting with production, planning, quality, commercial and

HRD.

Remarks:

VIYELLATEX GROUP. has a well learned marketing & merchandising team. They alwayscommunicate with the buyers. VIYELLATEX GROUP. has some fixed buyers. Themarketing section also looks the quality & quantity buyers.

Chapter-06


VIYELLATEX GROUP

QUALITY ASSURANCE SYSTEM

QUALITY CONTROL OF PRIECE GOODS:To get quality products it requires good quality control of piece goods.Even the most modern manufacturing methods cannot ensure quality ofthe product if the material is defective. Fabric and the end product mustmeet the expected requirement of the valued customer. It is theresponsibility of the manufactures and the fabric suppliers to ensure thequality. Standar

All holes regardless of 8size will be penalized 4 points No linear yard is to be penalized more than 4 points The average point value per shipment should not exceed 28 points

per 100 square yards Individual rolls exceeding 40 8points will be rejected and put out of

2production process The maximum number of 1-point defect per 10 square yards is 20.

But the average number of 1-point defects must be 14 or less perfabric delivery.

MAJOR & MINOR DEFECTS:MAJOR DEFECTS:A defect that if so conspicuous that it would cause the item to be a‘Second ’ is called a major defect. [A ‘Second’ is a garment with aconspicuous defect that affects the saleability or serviceability of theitem.]

MINOR DEFECTS:A defect that would not cause the product to be termed a second eitherbecause of severity or location. When inspecting piece goods prior tocutting, it is necessary to rate questionable defects as major.

GENERAL PROCEDURE:i. Fabric / Garments are placed for visual Inspectionii. An inspection table which is used to check the roll of fabric visually


VIYELLATEX GROUP

Types of fabrics faultSlub (Major)Knot (Major)Missing yarn (Major)Spot (Major)Contamination (Major)Weaving FaultThick yarn (4 point)Stop markDyeing stainHole (4 point)Crease & stick markJerk inOil Spot (4 point)

Quality control in sewing sectionFront joint

↓Make Section

↓Collar closing

↓One robbing QC check

↓Output table checking

Working procedureFront Joint 1 QC check 100%Make Section 1 QC check 100%Collar closing 1 QC check 100%One robbing QC check full timeOutput table 4 QC check 100%

Input section (Quality Checking)Label measurementLabel placementShoulder pointBack yoke attachmentBack partBox platePocketd Group in all steps of production maintain and ensure the quality ofpiece goods and as well as the end product. The process of piecegoods inspection of Standard Group is described below-

Piece Goods Inspection:


VIYELLATEX GROUP

It is ensured by the Standard Group that suppliers carries out 100%inspection prior to shipment. In addition 15% random inspection basedon 4-point system has to be carried out and a report must besubmitted to the group. Upon receipt of that report the inspectionteam of the group again inspect the goods and accept / reject those.

Quality to inspect:At least 10% goods covering all the lots of every colour and dye ofeach shipment is inspected prior to spreading.

Selection of Rolls:At least one roll of each colour is inspected.

Defect Classification:

The 4-point system followed by the group is described below:Size of Defects Penalty point

Defects up to 3” in length 1 point

Defects up to 6” length 2 point

Defects up to 9” length 3 point

Defects over 9” length 4 point

Qualitypts/100 sq meter=(Total point*G.S.M)/( roll weight*10)


VIYELLATEX GROUP

Make SectionV-V measurementBand overallBand widthCollar pointTop stitchBand rollingCuff overall measurementCuff rollingTop stitch

Collar ClosingSize labelV-V measurementCollar to collar band jointBand down stitchShoulder joint accuracySleeve length

Quality Control Finishing SectionGet up checkingCollar closingSide seamSleeve placket attachCuff attachBottom hemBack yokeEvery parts of a body

RecordsRecords of check list for inspection of accessories and packing

materialRecords of swatch cards of approved accessoriesRecords of production swatchRecords of daily QC reportRecords of cutting problem reportRecords of inspection report during embroidery

REMARKS: Quality of viyella tex group is very good. 4-point system is used toassure quality. From knitting to finishing in garment section quality is checkedstep by step.


VIYELLATEX GROUP

Chapter-07MAINTENANCE

Name of different maintenance equipment’s or tools:1. Screw driver (Flat & Star)2. LN key3. Hand Socket Wrench Set4. Manual & Digital Slide Calipers5. Slide Wrench6. T – Wrench7. Pipe wrench8. Dull Wrench9. Phile (Half round, round, triangular, flat, square)10. Pliers (Normal & Nose)11. Stop ring pliers (Inside & Outside)12. Timing gauge13. Table vice14. Hand vice15. Hack saw16. Hack saw frame17. Hand drill machine18. Stand drill machine19. Hammer20. Ball pin Hammer21. Mobil gun22. Grinder23. Welding machine24. Drill bit25. Top bit26. Top bit drill27. Varnier outside calipers28. Tester29. Multi meter30. Sucker31. Shouldering wire32. Electronic balance33. Digital lux


VIYELLATEX GROUP

SEWING MACHINE LUBRICANTPHYSICAL AND CHEMICAL PROPERTIES

SPECIFICATION EJ58/0521 Supplier MOBILE OIL CORP2 Viscosity ISO VG223 Color CLEAR + 30 (SAYBOLT)4 Relative density 0.849 G/CM3

5 Flash point 2040C6 Pure point -12.50C7 Viscosity at 40C 21.0 CST8 Viscosity at 1000C 4.3 CST9 Usage for FOR E, L, M, W ETC

TO MAINTAIN MACHINE TROUBLE FREE:The following instruction must be carried out to secure the utmost inproduction and to the prolong the life of your machine-

Before morning start To oil every moving parts with one or two drops of oil To check whether needle is correctly set or not damage To check whether threading is correct To check whether chaining thread of approximately 10 mm long

remain behind pressure foot.

PLAIN MACINEChanging Over The Specified Voltage And Changing The Fuse

Be sure to turn off the power to the machine before starting theprocedure

Insert a slotted screwdriver into the slot of change over the voltageand set the voltage to a desired voltage. Set the operating voltage to theposition with ‘’ mark

Replacing the fuseBe sure to turn off the power to the machine before starting the procedureStarting the procedure and remove the cap from the fuse holder. Then, takeout the fuse and replace it with a new one.


VIYELLATEX GROUP

Error MessageThe error will be shown by the number of times of flashing on an off of theLED lamp in the control box when any error is detected during operation.

No of timesof LEDFlashing

ErrorDescription

Item of confirm

1 DefectiveED-2

Check whether connector of the ED-2is securely inserted

Check whether adjustment of materialdetection is properly performed

2 Abnormalmemory

Turn OFF and return ON the powerswitch

3 Abnormalsynchronizer

Check whether connector of thesynchronizer is securely inserted.

4 Abnormalpanelcommunication

Check whether the panel cordconnector is disconnected or loose

5 Motor lock Check whether thread is caught in themotor pulley shaft

Check whether anything is entered inthe motor pulley cover

Check whether the v-belt is not on themotor pulley

Safely CircuitryThe machine incorporates the following safety circuitry

If the V-belt is not on the motor pulleyIf the sewing machine is driven with its V-belt off, the safety

circuitry is actuated in about 2 seconds to stop the whole operation. If thishappens, turn the power OFF, properly mount the V-belt before turning thepower ON again. This safely circuitry is also actuated when the sewingmachine has been subjected to any abnormal load.

If a needle position detector has failedFailure of the upper or lower needle stop position detecting function is

automatically directed by the safety circuitry. Then, the machine actuatesas one with a clutch motor, and it is possible for the motor to be used in thisstate until it is repaired


VIYELLATEX GROUP

OVER LOCK MACHINE

To protect against possible personal injury due to abrupt start of the m/c, besure to start the work after turning the power off and ascertaining that themotor is at rest.

Position of the needle thread take up and the needle thread eyelet The needle thread take up shall be positioned at the lower dead pt. Position of the looper thread take up and the looper thread guide Checking the cartridge filter and replacing it after a long period of

usage, cartridge filter may become clogged with dust Insert a cartridge

Remove first oil discharging screwRemove screw and lift top cover just above until it comes off

Dimensions use to adjust the looper and the needle guard Lubrication

Remove the oil capPoor juki m/c oil 18 into the oil reservoirSupply oil until the pointer bar almost reaches the upper red markerline when oil guage is observed from the side.

BUTTON ATTACHING MACHINE:Checking the needle

Always check that the tip of the needle is not broken and also theneedle is not bent before starting sewing

Cleaning the Rotary HookPull the shuttle race cover toward you to open it and then remove the

bobbin caseOpen the setting claw in the direction indicated by the arrow and

then remove the shuttle race body and the shuttle hookClean all the dust and thread ends from around the driver, the top of

the rotary hook thread guide and the shuttle race

Lubrication Fill the arm-side oil tank with oil Fill the bed side oil tank with oil Add oil to the felt of the shuttle race base

When setting up the sewing machine and when it hasn’t been used foran extended period of time, be sure to add 2-3 drop oil to the feltIf using the liquid cooling tank, fill it with silicon oil.


VIYELLATEX GROUP

BUTTON HOLING MACHINE

Turn off the power switch before carrying out cleaning, otherwise themachine may operate if the treadle is depressed by mistake, whichcould result in injury.

Be sure to wear protective goggles and gloves when handling thelubricating oil and grease so that they do not get into your eyes oronto your skin otherwise inflammation can result.

Furthermore do not drink the oil or eat the grease under anycircumstances as they can cause vomiting and diarrhea, keep the oilour of the reach of children.

Cleaning Remove lint and dust from the thread passages Remove lint and dust form around the work clamp Remove the bobbin case and remove lint and dust from around the

shuttle Clean away any thread scraps and cotton dust from around the lower

thread trimmer mechanism.

BAR-TAKE MACHINE:Maintenance of Bar-take machine Adjust the height of the needle bar Adjusting the needle to shuttle relation Adjusting the lift of the work clamp foot Adjusting the rising amount of the thread tension dist The moving knife and counter knife Cleaning the filter Draining waist oil Replacing the fuse

REMARKS: This mill has strong maintenance fitter`s troop to fix up theproblem. They are very active to perform their duty.S


VIYELLATEX GROUP

KNITTING SECTION

INTRODUCTIONKnitting is one kind of fabric manufacturing process in which fabric is produced byinterlooping among loops formed by single or several yarn feeding simultanesously.Knittedfabrics produced with stitch formation.Stitch is most important structural element of knitted fabrics .The stitch consists of a head,two legs ,two feet and upper&lower connection point.

Knitting Process Flow Chart

Yarn collect by cone package from spinning

Setup yarn on creel

Yarn passage through different tentioner and possitive feeder

Adjust stitch length and GSM by VDQ pulley

Produce ½ inch fabric and inspection

Knitting the fabrics and without any fault / If fault correct it

Cut the roll of fabric

Marking theroll

Inspection and grading according to Quality Control

Transferred the fabric to grey store.


VIYELLATEX GROUP

MACHINE DESCRIPTION

SLNO.

M/CNO.

Model Type of m/c Dia &Gauge

No. offeeder

No.ofneedle

Safetyrpm

Brandname

1. 061612

PL-XRA/CE Rib 38”*18 76 2124 23 PAI LUNG

2 061610

pL-XS4B/A/CE Single jersey 36”*24 144 2712 25 PAI LUNG

34567 05119

4PL-XS3B5MW/A/B/CE

Single jersey30”*24

90 2256 25 PAILUNG

89101112 Single jersey 26”24 78 1856 22 FUKUHA

RA1314 07082

8PL-XS3B/A/CE Single jersey 26”24 78 1856 22 PAI

LUNG15 05119

4PL-XS3B5MW/A/B/CE

Single jersey 30”*24 90 2256 25 PAI LUNG

16 051194

PL-XS3B5MW/A/B/CE


17 051194

PL-XS3B5MW/A/B/CE


18 051194

PL-XS3B5MW/A/B/CE


19 051194

PL-XS3B5MW/A/B/CE


20 36”*22 CAOTRR21 36”*18 24 CARROT22 06061

3PL-XS3B/A/CE Single jersey 24”*24 72 1800 40 PAILUN

G23 06061


G24 05119


G


VIYELLATEX GROUP

25 051192

PL-XS3B/A/CE Single jersey 25”*24 74 1872 42 PAINGLU

26 061242

PL-XF3B-LD/C Single jersey 30”*20 90 1872 25 PL

27 061242

PL-XF3B-LD/C Single jersey 30”*20 90 1872 25 PL

28 Single jersey 36”*22 72 2484 25 PL29 PL-XD2B/CE Interlock 36”*22 72 2484 25 PL30 06061

7PL-XRA/CE Rib 38”*18 72 2160 23 PL

31 060618

PL-XR2B/CE Rib 38”*18 76 2124 23 PL

32 060618

PL-XR2B/CE Rib 38”*18 76 2124 23 PL

33 060618

PL-XR2B/CE Rib 38”*18 76 2124 23 PL

34 Single jersey 30”*24 32 MAYER& CIE

35 Single jersey 30”*24 32 MAYER& CIE

36 O70832

PL-XRA/CE Rib 40”*18 80 2256 22 PL

37 O70832

PL-XRA/CE Rib 40”*18 80 2256 22 PL

38 070821

PL-XR2B/CE Single jersey 42”*14 84 2370 21 PL

39 070821

PL-XR2B/CE Single jersey 42”*14 84 2370 21 PL

40 070831

PL-XRA/CE Rib 36”*16 72 1800 25 PL

41 051192


42 051192


43 070828

PL-XS3B/A/CE Single jersey 26”24 78 1856 22 PAILUNG

44 070828

PL-XS3B/A/CE Single jersey 26”24 78 1856 22 PAILUNG

45 NOT FOUND FUKUHARA

46 061610

pL-XS4B/A/CE Single jersey 36”*24 144 2712 25 PAI LUNG

47 Rib PAILUNG

48 Single jersey 30”*24 PAILUNG

49 051195

PL-XSCS/6 Single jersey 30”*24 42F*6C

2256 20 PAILUNG

50 051196

PL-XSCS/6 Single jersey 30”*24 42F*6C

2256 20 PAILUNG

51 06123 PL-XDCS/E-U Rib 36”*18 54 2040 16 PAILUN


VIYELLATEX GROUP

V-Bed Knitting machine specification:

M/CNO.

MODEL NO. GAUGE DATE

1 M-100 14 10.20002 M-100 14 10.20003 M-100 14 10.20004 M-100 14 10.20005 M-100 14 10.20006 M-100 14 10.20007 M-100 14 04.20018 M-100 14 04.20019 M-100 14 04.2001

9 G52 06124

0PL-XDCS/E-U Rib 36”*18 54 2040 16 PAILUN

G53 07082

3PL-XSCS/6 Single jersey 30”*24 42F*6

C2256 20 PAI

LUNG54 07082

2PL-XSCS/6 Single jersey 30”*24 42F*6

C2256 20 PAI

LUNG55 06082

4PL-XSCS/6 Single jersey 36”*24 50*6(

Sinker)

2256 22 PAILUNG

56 070825

PL-XSCS/6 Single jersey 36”*24 50 2712 19 PAILUNG

57 Single jersey 26”24 78 1856 22 FUKUHARA




61 VXC-3.2S Single jersey 30”*28 FUKUHARA




65 VXC-3S Single jersey 28”*24 FUKUHARA





VIYELLATEX GROUP

10 M-100 14 04.2001

11 M-100 14 04.200112 M-100 14 04.200113 M-100 14 04.200314 M-100 14 04.200315 M-100 14 04.200316 M-100 14 04.200317 M-100 14 04.200318 M-100 14 04.200419 M-100 14 04.200420 M-100 14 04.200421 M-100 14 04.200422 M-100 14 04.200423 M-100 14 04.200424 M-100 14 04.200425 M-100 14 04.2004

FLAT BED M/C CAPACITYProductin/1 hr= 21 pcs (m/c manufacture date 2003,2004 =13)Total production=13*21*8=2184 pcs/shiftProductin/1 hr= 14 pcs (m/c manufacture date 2000,2001 =12)Total production=12*14*8=1344 pcs/shiftTotal production=3528 PcsNote: All m/cs are conventional . There is no modern m/s. It is not suitable for industry.

FABRIC WIDTH: Two types of fabric width1) Open width2) Tubular width

Difference between Open width & Tubular widthOpen width Tubular width

Mark line contains for fabric cutting No mark lineFabric dyes in open form Fabric dyes in tubular formOpen width is double than tubularwidth

Tubular width=1\2*open width

For single jersey For Rib, Interlock


VIYELLATEX GROUP

Production Calculation:

asM/CNO.

M/C Dia&Gauge

Fabrictype

Productionkg/shift

Yarn type S.L/GG

1 38”*18 Rib 126 30’s CB 2.522 36”*24 Single

jersey115 26/1 CD 2.70

3 36”*18 Rib 78 26/1 D/L SCHOCO 2.654 36”*18 Rib 72 34/Spun poly 2.405 36”*18 Rib 72 28/1 CD 2.406 30”*24 Single

lacoste65 26/1 CD 2.62

7 30”*24 Singlejersey

107 28/1 CD 2.75


100 26/1 CD 2.70


112 28/1 CD 2.75

10 30”*24 Doublelacoste

72 28/1 CD 2.62


110 26/1 CD 2.84


85 2.75


86 26/1 CD 2.84


110 26/1 CD 2.70


64 34/1 CD+20Dlycra 3.02

16 30”*20 Fleece 55 34/1 CB+75D Poly 28017 30”*20 Fleece 55 34/1 CB+75D Poly 23018 36”*2419 30”*2420 36”*22 Fleece 45 150/2 Poly+20D Lycra 21521 36”*18 Rib 80 28/1 CD+40D Lycra 28022 24”*24 Single

jersey90 26/1 CD 2.70


80 26/1 CD 2.70


90 24/1 CD 2.70


90 24/1 CD 2.70


80 34/1 CD+12/1 CD 235


88 34/1 CD+12/1 CD 235

28 36”*22 Single 34/1 CD+20D Lycra 3.02


VIYELLATEX GROUP

jersey29 36”*22 Interlock 70 150D Poly+20D Lycra 21530 38”*18 Rib 125 30/1 2.5231 38”*18 Rib 115 30/1 CD+40D Lycra 20032 38”*18 Rib 112 30/1 CB 2.7533 38”*18 Rib 110 30/1 CB 2.7534 30”*28 Single

jersey70 34/1 CB 2.52


34/1 CB 2.52

36 40”*18 Rib 140 34/1 CB 2.6837 40”*18 Rib 140 34/1 CB 2.6838 42”*18 Rib 130 34/1 CB 2.5239 42”*18 Rib 135 34/1 CB 2.5240 36”*18 Rib 90 28/1 CD+40 Lycra 28041 25”*24 Single

jersey100 24/1CD 2.84


100 24/1CD 2.84


110 28/1 CB 2.70


100 28/1 CB 2.70


123 28/1CD 2.98


30/1 CB 2.68

4748 30”*24 Single

jersey98 26/1 CD 2.75

49 30”*16 Doublejersey

36 24/2GM+22/2L+ZADE+M.Navy

4.23


22 28/1metal+white+black+30/1GHTR

2.75

51 36”*18 Rib 26/1 TAVPEMARL/SCHOCO/OFFWHITE/ROSE

2.65

52 2.8053 30”*24 Single

jersey19 20/1 D/Y DK-

CALICO+RED3.20


22 28/1D/Y+WHITE+BLACK+30/1GHTR

2.75


28 28/1 WHITE+ DK+DKNAVY+30/1 GHTR

2.75


30 28/1 WHITE.30 g.mtl+28/1CB

2.70


110 28/1 WHITE.30 g.mtl+28/1CB

2.70

58 26”*24 Single 112 28/1 WHITE.30 g.mtl+28/1 2.68


VIYELLATEX GROUP

jersey CB59 26”*24 Single

jersey108 26/1 CD 2.75


90 26/1 C D 2.70


60 40/1 CB-PT44O8 2.52


53 40/1 CB-PT44O8 235

63 30”*20 Fleece 75 34/1 CV+75D Poly+10/1 cvc 23564 30”*24 Fleece 76 34/1 CB+75D Poly+1`2/1\2

CB2.70


92 28/1 CB 2.75


146 28/1 CB 2.75


168 28/1 CB 2.75

68

Total production/shift =5242 kgTotal inactive m/cs =8

KNITTING

MACHINS


VIYELLATEX GROUP

Types of YarnYarn:

1. Combed (60\1,50\1)2. Carded(34\1)

CVC=Chief Value of Cotton (60%Cotton+40%Polyester,65%Cotton+35%Polyester,70%Cotton+30%Polyester)

PC=Polyester-Cotton (60%Polyester+40%Cotton)Mellange:

1. Anthra (5%Viscose+95%Cotton)2. Ecru (2%Viscose+98%Cotton)3. Normal (10%Dyed+90%Undyed)

*100% Cotton Mellange : 10%Dyed+90%Undyed , 10%Dyed+90%Undyed

COSTING OF YARN

Combed yarn:Count Price ($/KG)

40/1 3.70/7234/1 3.40/4232/1 3.3530/1 3.3028/1 3.2526/1 3.20/2224/1 3.1522/1 3.15/10


VIYELLATEX GROUP

20/1 3.05Carded yarn:

Count Price ($/KG)34/1 3.0530/1 2.95/9028/1 2.8226/1 2.8024/1 2.6022/1 2.4520/1 2.2516/1 1.9012/1 1.80/8510/1 1.757/1 1.70

Spandex:Count Price ($/KG)

20D 13.7040D 8.8070D 8.60

Machine Maintenance Flow ChartBelt open

Thread cutting

Running machine with oil

Fabric cutting

Cam box open

Needle open

Clean cylinder & dial

Separate reject needle


VIYELLATEX GROUP

Creel capacity:Single jersey (PAI LUNG)=31*9=279Single jersey (FUKUHARA)=26*8=208CARROT=16*8=128MAYER & CIE=24*8=192

CONCLUSION

Bangladesh export 37%(2007) knitted fabrics to differnt countries such as USA,UK,Germany but cotton produce 0% in Bangladesh.It is a great problem for us. On the other hand cotton produce in USA 23% ,China

37%,Pakistan 10%,India 23%,Uzbek 6%(2007).From knitting section we can learn about different types of m/cs, m/cs design change,production capacity, helping us.it will be very helpful for our practical life.layout plan,knitting elements,fabrics faults & solution etc. Thanks to knitting AUTOSTRIPER=126*4=504

DYEING SECTION

Flow chart of dyeing SectionGrey fabric from knitting section

Batching

Dyeing

Transfer to finishing


VIYELLATEX GROUP

Flow chart of finishing Section

Flow chart for Peach finish/Brush:SlittingStenterSueding/RaisingStenterCompacting

For Lycra:SlittingHeat SettingSewingDryingSlittingStenterCompactin

Finishing section

Open fabric Tube fabric

Slitting machine

Stentering

Compactingmachine

Finalinspection

Dewatering machine

Drying machine

Tube Compactingmachine

Finalinspection

Line Diagram of Jet

Dyeing M/c


VIYELLATEX GROUP

No of Machine for Dyeing and Finishing Section:

Specification of Different Machines:

DYEING SECTION:

Dyeing Machine. 01(Fongs)_Type Jet Dyeing MachineManufacturer name FONG’SCountry ChinaModel No. ECO-38-2TYear of manufacturing 2003Temp. Range 00-980CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 500 KG

Dyeing Machine.02(Thies)Type Jet Dyeing MachineManufacturer name THIESCountry GermanyModel No. D-48653 COESFELDYear of manufacturing 2004Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo Of Nozzle 04

Dyeing Section1. Dyeing Machine 152. Sample Dyeing Machine 07

Finishing Section1. Super Slitter 032. Dewatering Machine 023. Stenter 024. Dryer 025. Tube compactor 026. Open width compactor 027. Raising Machine 028. Sueding Machine 029. Turning Machine 0110. Slitting & Dewatering

Machine01


VIYELLATEX GROUP

Dyeing Machine. Thies-03Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653 COESFELDYear of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4

Dyeing Machine. THIES-04Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. ECOSOFT PLUSYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1

Dyeing Machine. THIES-05Type Jet Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41350Year of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 500 KGNo. of Nozzle 2

Dyeing Machine. THIES-06Type HTHP Dyeing MachineManufacturer name THIESCountry GERMANYModel No. 41354Year of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed Air


VIYELLATEX GROUP

No. of Motor 7Production Capacity 1000 KGNo. of Nozzle 4

Dyeing Machine. FONGS-07Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 200 KGNo. of Nozzle 1Permissible Working Pressure 380 KpaTest Pressure 585 Kpa

Dyeing Machine. FONGS-08Type Jet Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-1TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 250 KGNo. of Nozzle 1Permissible Working Pressure 380 KPATest Pressure 585 Kpa

Dyeing Machine. FONGS-09Type BULK Dyeing MachineManufacturer name FONGSCountry CHINAModel No. ECO-6-3TYear of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 7Production Capacity 750 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 585 Kpa


VIYELLATEX GROUP

Dyeing Machine. FONGS-10Type High Speed jumbo Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 8Production Capacity 1120 KGNo. of Nozzle 4Permissible Working Pressure 350 KpaTest Pressure 520 KPa

Dyeing Machine. FONGS-11Type HSJ Dyeing MachineManufacturer name FONGSCountry CHINAModel No. HSJ-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 8Production Capacity 840 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 520 Kpa

Dyeing Machine.FONGS-12Type HSJ Dyeing MachineManufacturer name FONGSCountry ChinaModel No. HSJ-SR-3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 3Production Capacity 560 KGNo. of Nozzle 3Permissible Working Pressure 380 KpaTest Pressure 520 KPa


VIYELLATEX GROUP

Dyeing Machine.FONGS-13Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 6TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 1680KGNo. of Nozzle 6

Dyeing Machine.FONGS-14Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 3TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 840 KGNo. of Nozzle 3

Dyeing Machine.FONGS-15Type HSJ Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. HSJ SR 4TYear of manufacturing 2007Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 1120 KGNo. of Nozzle 4

Sample Dyeing Machine.FONGS-01Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINA


VIYELLATEX GROUP

Model No. P-D 5500-2000-CAT -2Year of manufacturing 2003Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 25KGNo. of Nozzle 1

Sample Dyeing Machine.THIES-02Type Sample Dyeing MachineManufacturer name THIESCountry GERMANYModel No. D-48653-COESFELDYear of manufacturing 2002Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Inhalt Capacity 523 LitreNo. of Nozzle 1

Sample Dyeing Machine.FONGS-03Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 30KGNo. of Nozzle 1

Sample Dyeing Machine.FONGS-04Type ALL FIT-120 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2005Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed Air


VIYELLATEX GROUP

No. of Motor 9Production Capacity 120 KGNo. of Nozzle 1

Sample Dyeing Machine.FONGS-05Type ALL FIT-30 Dyeing MachineManufacturer name FONG’SCountry CHINAModel No. P-D 5500-2000-CAT -2Year of manufacturing 2006Temp. Range 00-1400CUsed Utilities Water, Steam, Electricity, Compressed AirNo. of Motor 9Production Capacity 30 KGNo. of Nozzle 1




VIYELLATEX GROUP

FINISHING SECTION:

Finishing:Textile finishing , in a restricted sense , is the term used for a series of processesto which all bleached , dyed , printed and certain grey fabrics are subjected beforethey are put on the market . In fact , finishing includes the final treatment ofevery kind of fabric made from every kind of fiber .

Objective of finishing:- Improving the appearance – Lustre , whiteness , etc .- Improving the feel , which depends on the handle of the material and its

softness , suppleness , fullness , etc .- Wearing qualities , non – soiling , anticrease , antishrink , comfort , etc .- Special properties required for particular uses – water – proofing , flame –

proofing , etc. .- Covering of the faults in the original cloth.- Increasing the weight of the cloth.

Types of finishing:1) Chemical finishing:

1) Chemical reaction of auxiliaries with fibers.2) Application of the handle modifying products / additives.

2) Mechanical finishing: Mechanical treatment with machines. Finishing effects: Easy – care Crease recovery. Dimensional stability. Good abrasion resistance. Improved tear strength. Good sewability Soft or stiff handle. Shine or luster


VIYELLATEX GROUP

FINIS

HING

MAC

HINS

(OPE

N

LINE)

Slitting,De-

watering &

Detwisting

m/c

St

en

te

rRaising

m/c

Seudi

ng

m/c

Open

Compa

ctor


VIYELLATEX GROUP

Open fabric line for finishingSlitting and dewatering machineMachine specification:

Brand name: CORINO MACCHINEType/model no:Company: ItalyYear: 2005No of motor: 08

Function of the Machine: Used to remove excess water after pretreatment and dyeing To slit the tube fabric by the knife for opening of the fabric and ready for

stentering Delivered fabric is crease free state Before squeezing balloon is formed with the help of compressed air

passing by a nozzle or air sprayer It can control the diameter of fabric and GSM and shrinkage by over

feeding mechanism To impart soft finish to the fabric by using required softener.

Main parts of the machine:- Squeeze roller (to remove water)- Stretcher (to control width)- Over feeding wheels (to control GSM)- De-twisting device (To delivery the fabric roll in untwisted form)- Folding device (to delivery the fabric in folded form)- Squeezing roller- Padder for softener

Controlling points or Control system:1. Overfeed control2. Pressure3. Speed control4. Width control

Power consumption:Voltage: 400VFrequency: 50HzMaximum power: 24kwatt

Manpower Required:Worker: 02


VIYELLATEX GROUP

Production:Capacity: 10 tones/shiftActual production: 7 tones/shift.

Utility:i) Waterii) Electricityiii) Compressed air or Processed air (to form the tube fabric into ballon with a

view to remove crease)

Feed roller pressure:

Bar PSI Kg Lbs1 14.5 90 2002 29 205 4503 43.5 315 7004 58 425 9405 72.5 540 12006 87 650 1440

Work instruction:

Fabric Type Pad pressure Speed Over FeedS/J 2.5 – 3 40 -50 40PK 3 40 -50 401x1 Rib 3 -3.5 50 -60 25

Minipadder

De-twister

Rubber coatedpadder

Wooden padder

Plaiter

Camera

Dancing roller

Dancingroller

Fabric path of Slitting, De-watering &De-twisting m/c

FeedDelivery


VIYELLATEX GROUP

2x2 Rib 3 – 3.5 60 40P/I 3 – 3.5Mer S/J 2 40 40Mer PK 2.5 40 40Mer 1x1 Rib 2.5 – 3 50 25Mer 2x2 Rib 2.5 – 3 60 40Mer P/I 2.5

Find out the limitations and faults of the machine and advise for removing these.i) Workers does not record the pressure, in dia and out dia of different fabric in

record bookii) Workers set the pressure of squeeze roller for different fabrics same. But

higher GSM fabric needs more pressure than lower GSM fabric. So removalof excess water is not sufficient.

iii)

Stenter machine

Machine no. 01Machine specification:

Brand name: BRUCKNER +MAHLOType/model no: 72276-0463Company:Country: GermanyYear: 2004

Other specification:Speed range:

15-30 m/min (for knit)15-80m/min (woven)

Temperature range: 20-2500CNo of motor in drying unit: 29Total no of motor: 49Maximum width = 102Minimum width = 30Steam pressure: 2 barAir pressure: 10 barApplied for: Open width fabric


VIYELLATEX GROUP

Machine no. 02M\c specification:

Brand name: SUN SUPER.Country: KOREA.

Other specification:Speed range:

Max: 110m/min.Use: 45 m/min.

Temperature range:Max: 500 CUse: 180 C (For heat set).

No of motor in drying unit:Total no of motor:Max dia: 295cm.Min dia: 95cm.Steam pressure: 2 barAir pressure: 10 barApplied for: Open width fabric

Fabric path of stenter

Overfeed & pinning

Fabric in the chain


VIYELLATEX GROUP

Extra attachment:iv) Mahlo attachment for bowing control.v) Selvedge gumming devicevi) Selvedge cutting device

Function of the Machine:i) Dryingii) GSM control:If overfeed increases,then GSM increases and vice versa.iii) Width control :The width is controlled by means of Spreader,Expander.iv) Shrinkage controlv) Decrease spriralityvi) Decrease Bowing effectvii) Softener applicationviii) Surface coating for Teflon finishix) Soil release chemical finishx) Heat set for cotton lycra fabric

Main parts of the machine:i) Feed zone

-Centering deviceii) Chemical padding zone

-Squeezing roller-Chemical tray

iii) Bowing control zone-Bowing roller (rubber roller, no of roller -2)-Sensor (no of sensor -6)-Uncurling roller

iv) Chain entry zone-Uncurling device (both side of the chain entry)-Sensor (both side of the chain entry)-Brush roller (for attaching the fabric with the pin of the chain, no of

brush roller -4)-Selvedge gumming device with gum box under the chain entry

v) Drying zone-Gas rotamatic burner (10)

vi) Cooling zonevii) Delivery zoneviii) Relax R/rix) Padderx) Pin rollerxi) PLC profivassleeve converter.xii) Plaiter rollerxiii) Take up rollerxiv) Wheel

Burner used in Bruckner:Radiomatic burners are used.The parameter of radiomaticburner is as follows

Capacity:150kwVoltage:230-240VFreequency:50-60HzFuel:Natural gas


VIYELLATEX GROUP

Pressure:50 mbarFunction of angular roller:

Stripe controlBowing controlStraightness of fabric

Chemical used:Silicon softener (It is used to soft and slippery of the fabric)


Production:Capacity: 5 tones/shiftActual production: 3.5-4.5 tones/shift.

Heating arrangement:No of Rotamatic burner: 10There are 5 heating chamber in this machine. Each chamber has two burners which isplaced two sides of the machine.

Chamber Burner Burner01 1A 1B02 2A 2B03 3A 3B04 4A 4B05 5A 5B

Temperature:Maximum = 2500CSample = 1100CAverage = 130-1700C

Utility:i) Gasii) Electricityiii) Compressed air.

Parameters used for different types of fabric:

BRUCKNER

Fabric Req.GSM

FinishGSM

R F B Temperature Speedm/min

Overfeed

S/J 140 - 68” 71” 67” 140 14 60%” 160 150/52 56” 64” 60” 150 20 10%” 180 170/72 54” 56” 54.5” 110 12 60%“ 190 188/90 58” 61” 57” 110 15 60%H/J 280 270/75 64” 67” 62” 110 7 50%Loopback

280 255/60 74” 78” 75” 110 9 60%

Fleece 260 260/65 74” 80” 75” 110 9 60%1×1 rib 240 224/26 72” 75” 74” 110 10 60%


VIYELLATEX GROUP

SUNSUPER

Fabric Req.GSM

FinishGSM

R B F Temperature Speedm/min

Overfeed

S/J 190 178 58” 56” 60” 110 24 50%S/J(c.v.c) 180 180 56” - 59” 110 35 50%H/J 280 276 70” 72” 73” 120 18 50%1*1 Rib 240 244 72” 73” 75” 120 18 40%Boltonstripe

330 335 62” 66” 70” 130 16 60%

Fleece 280 270 76” - 78” 110 16 50%

Open compactorMachine no. 01Machine specification:

Brand name: HELIOT InternationalType/model no: HC2000GLCompany: FranceNo of motor: 08Over feed = m/minMachine speed = m/minSpeed range: 13-22m/minTermperature range: 100-1400CMaximum width 86Minimum width 36Applied for: Open fabricLeft over feed: -20%+20%Right over feed: -20%+60%High production: -20%+60%Front over feeding cylinder: -20%+60%Middle belt: -20%+60%

Check point:1. Check steam & air line pressure2. adjust felt temperature3. Blanket pressure:3.5-4.0-4.5

Some instructions for optimum performance:

1. Center the felt blankets on the cylinder. Ensure that all cylinders are running parallelrelative to each other. Adjust the limit switch against the edge of the felt.

2. Place the felt under tension. Upper felts tension-2 bar, Lower felt tension-1 bar.3. raise the heated drum working temperature to 200 f| & set the speed to 11-22

yd/min(10-20 m/min)4. Open the humidification ramp in order that felts are in a steam atmosphere.5. As soon as these conditions are reached, let the felt run for 2.5 m


VIYELLATEX GROUP

Machine no. 02Machine specification:

Brand name: FERRAROType/model no: COMPTEX-RE 2800.Company: ITALY.No of motor: 17Over feed = Max + 35%, Min -35%.Machine speed = Max 32m/min, Min 4m/min.Termperature range: 100-2000CMaximum width =240cmMinimum width =100cmApplied for: Open fabricLeft over feed: -20%+20%Right over feed: -20%+60%High production: -20%+60%Front over feeding cylinder: -20%+60%Middle belt: -20%+60%

Function of the Machine:1. To compact the fabric2. To control the shrinkage3. To maintain proper width and G.S.M

Heating system:Steam

Main parts of the machine:1. Heating chamber2. Blower (2, one at the entry chain zone for uncurling and another at the

entry of compacting zone)3. Synthetic blanket as a conveyor,4. Folder5. Exhaust fan6. Unpinning cylinder (-40%+40%)7. Belt cylinder (-40%+40%)8. Uncurling device at entry of compacting zone.9. sensor10. brush roller

Additional attachment:i) Selvedge cuttingii) Selvedge safetyiii) Pinning safetyiv) Selvedge unrollingv) Selvedge dryingvi) Steam zone heating


VIYELLATEX GROUP

Controlling points:- Water pressure 2.5 lb- Air pressure 4 lb

- Steam pressure 6 lb

Manpower Required: Worker: 06Production: Capacity: 5 tones/shifActual production: 4 tones/shifUtility: Steam Electricity, Compressed air.

Special finishing machineSueding

A sueder is sometimes referred to a s a sander since the machine consists of one or morerolls covered with sand paper as the abrasive. Fabrics traveling over these rolls develop avery low pile and the material's surface can be made to feel like suede leather. The hand willdepend on the fiber composition, the filament count in the yarn and the intensity with whichthe fabric is worked.Filament fabrics can be made to feel like a spun fabric and all fabrics will have a softer hand.

Brush: The brushes of Sueding mcs are made up of Silicon carbide.

Sueding machine

Machine parts:Suction hood


VIYELLATEX GROUP

Fabric slowing rollerDrag cylinderSueding brushFeeding rollerFolding unitInlet tighter

Machine specification:Brand name: Lafer SPAType/model no: GSI106Company: ItalyYear: 2002

Other specification:No of motor: 08Winch speed: 10-30m/minMachine speed: 50m/min (max)Drum speed: 30-35-50 rpm (Max 70)Pile roller no: 06Pile made of PlasticPlaiter tension: 6kgTaker in tension: 20kgFabric return driver Tension: 25kgDrum Tension: 50kgSpeed range: 10-40 m/minNo of cylinder/drum:

2 for double cylinder1 for single cylinder

No of pin roller: 24 2 = 4824 1= 24Cylinder r.p.m (General): 100Tension: 3 kg


Production:Capacity: 40 tones.

Raising m/c:In which process a layer of fibers lifting from the body of the fabric to achievesoft and lofty effect on the surface is called raising.

Raising machine -1 (Single drum)Machine specification:

Brand name: Lafer SPAType/model no: GRI 124CCountry: ItalyYear: 2002No of motor: 04No of pile roller: 24Machine speed: 50Drum speed: Max 120


VIYELLATEX GROUP

Manpower Required: Worker: 05Production : Capacity: 2 tones/shift

Actual production: 1 tones/shift.Utility : Electricity, Compressed air.

Raising machine-2 (Double cylinder)

Machine specification:Brand name: Lafer SPAType/model no: GRI 224ACountry: ItalyYear: 2003No of cylinder: 2No of pile roller: 24+24Machine speed: 50Drum speed: Max 120No of motor: 05Speed range: 20-30 m/minNo of cylinder/drum: 1No of pin roller: 6Cylinder r.p.m (General): 100Tension: 3 kg

Production: Capacity: 5 tones/shiftActual production: 3 tones/shift.

Utility : Electricity, Compressed air.


VIYELLATEX GROUP

Tube fabric line for finishingDewatering machine -1

Dewatering MachineNo. of the machine 02Manufacturer name Heliot InternationalCountry FranceModel No. EXP-24CSpeed 90 m/minUsed Utilities Water Electricity, Compressed AirNo. of Motor 06

Slitting machine

Sutter SlitterManufacturer name AKABCountry SwedenModel No. CR-2400Year of manufacturing 2003Used Utilities Electricity, Compressed AirNo. of Motor 03

De-twister

Rubber coatedpadder

Conveyor belt

Width controller


VIYELLATEX GROUP

Tensionless Dryer MachineFunctions:

1. To dry the fabric with help of steam2. To control the shrinkage3. To prepare for next subsequent process4. To dry tubular and open width fabric without tension

Machine specification:Brand name:HELIOT internationalSerial no: D700HWTCompany: FranceSpeed range: 4-30m/minTemperature range: 110-1600CEach motor required 300 watt.No of motor: 08Worker: 04

Main parts of the machine:1. Heating chamber (2)2. Blower (8)3. Synthetic blanket as a conveyor4. Folder5. Exhaust fan

Production:Capacity: 10 tones/shiftActual production: 8 -9 ton/shift.

Heating arrangement:Heating chamber: 3No of rotamatic burner: 3

Heating system:1. Gas fired

Temperature of the machine:

PV PV PV129.50C 1300C 1350CSV SV SV1300C 1300C 1350C

Utility:1. Gas (to make fire)2. Electricity (to rum the machine)3. Compressed air (to spread the fire)


VIYELLATEX GROUP

Parameters used for different types of fabric:

Types offabric

Buyer Batch Color India

Outdia

Overfeed Machine speed

Temperature

Vibration

Collar TESCO White 6 (m).10(monitor)

6 1300C 120

5885 Blue 6 .10 7.0 1400C OffS.Oliver

5843 0147 6 .10 4.0 1600C Off

11 Rib 6.10 7.0 1300C 120TESCO 5870 White 36 34 6.10 7.5 1300C 120

5874 Helapink

6.10 8.5 1400C 120

5888 Black 38 36 6.10 7.0 1500C 120ESPRIT

5836 Black 38 35 6.10 5.0 1600C

22 Rib W.W 1480/06 Blue 6.10 5.0 1500C 12052 Rib M&S Sample Pink 6.10 5.0 1400C 120Interlock 1300C 120Singlelacost

TESCO 5882 RED 6.10 8.0 1400C 120

Doublelocost

EMA 5828 White 46 44 9.10 5 1400C 120

Fabric path Dryer

Conveyor belt

FeedDelivery

Conveyor belt

Feed roller

Vibrating roller

Burner


VIYELLATEX GROUP

Find out the limitations and faults of the machine and advise for removing these.

i) Selvedge drying system is not properly functioning.ii) Maximum over feed of the machine is +60%.iii) When the steam temperature is 1000C-1200C, then delivered fabric temperature is

45-500C. But there is no cooling zone in this machine to reduce the excesstemperature. So a cooling zone in delivery zone can be attached.

Tube compactor machine -1,2

Machine specification:Brand name: HELIOT InternationalType/model no: HCPPICompany: FranceNo of motor: 07Over feed = 40m/minMachine speed = 25m/minSpeed range: 16-35m/minTermperature range: 110-1450CMaximum width 52Minimum width 16Applied for: Tube fabric


Production:Capacity: 5 tones/shift or 10 tones/dayActual production: 4 tones/shift.

Heating arrangement:Temperature: 1100C

Utility:Steam, Electricity, Compressed air.


VIYELLATEX GROUP

REMARKS:VIYELLATEX GROUP. is a well equipped industry. As the quality of the

machineries of dyeing, finishing & testing section are good, so the quality level of theproduct is also good.Sequence of Operation for Knit Dyeing:

Grey fabric received from knitting section

Batching

Fabric turning

Loading to the m/c

Select production programme

Pre-treatment (Scouring & Bleaching)

Select recipe for Dyeing

Recipe confirmed by DM/SPO

Dyeing

Post Treatment

Unload

Steamarrangement

Upper shoe

Lowershoe

Bigcylinder

Fabric Path of Tube Compactor

Feed

Delivery

Feed roller


VIYELLATEX GROUP

Production Parameters:

1) PH

- During H2O2 bleaching PH 9.2-12(Alkaline)- During reactive dyeing PH 10.5-12.5(Alkaline)- During disperse dyeing PH 4.5-6.0 (Acidic)

2) Temperature:- For cotton scouring: 900-950C- For cotton cold wash: 300-400C- For cotton hot wash: 700-800C- For cotton acid wash: 600-700C- For cotton dyeing: 80-900C (For hot brand)

600C (For cold brand)- Polyester dying: 1000-1300C

3) Time:- For Scouring: 60-90 minutes- For Disperses dyeing 60-90 minutes.

4) M: L ratio:- For reactive dyeing M: 1 ratio maintained between 1:6 to 1:10.

Description of Production Process:Washing for colored fabrics: The colored fabrics, to be washed is loaded in the machine Required amount of water is taken. Felosan NOF (detergents) added & washing continued at 800 C for 20 minutes. Cold washing

Scouring-bleaching: Fabric, to be scoured is loaded in the machine Required amount of water is loaded Washing agent| detergent is added Steam pipes are on & scouring agents (i.e., caustic soda/ soda ash) added when the

temperature reaches at 700 C Then H202 is added. Temperature is then raised to 1050 C & the process is then carried out for 60-90

minutes depending on the requirements. The liquors are then drained. Then wash with Felosan NOF (detergent) at 980C for 5 min.


VIYELLATEX GROUP

Then cold wash, at 350-450C & acid wash, at 600-700C is done.Dyeing: After acid wash all liquors are drained out. Required amounts of water is taken Then leveling agents, anti-creasing agents, de-foaming agents are added according to

the requirements. Steam pipes are on & after 10-15 minutes dyes are added. Salts are added and runtime is 15-20 minutes. Then soda ash, after another 35minutes. Then the temperature is raised slowly up to the mark. The process is carried on & samples are taken after every 30-40 minutes to match

with the target shade. It continues until shade matching. If the sample is matched, then the liquor is drained out. Then cold wash at 350-450C. Wash with Cibapon R (Washing agent) for 5 minutes. Acid wash at 550C is done. Fixing agent is added at 450C for 15 minutes. Then softener is added at 450C for 15 minutes.

Dyeing Curve:

600C

900C&10’

CBB+NOF

Caustic H2O2

1050C& 30’

700C

600C

980C&10’

Drain

Drain

Acid PCAcid Bioace

900C&10’

CS

DrainDrainDrain

NOF

Scouring & Bleaching Curve

600C&10’

550C&30’

A. Acid+C+DBC

Color Dosing(20’)

Salt

Soda Dosing(35’)

CheckShade

Dyeing Curve

10

R

Acid Bioace

Drain

550C& 30’

HotWash

450C& 30’

EC

450C& 30’

Acid Softener

ColdWash

FabricUnload

15’ 20’ 20’


VIYELLATEX GROUP

Production Flow Chart:

Production flow chart for 100% cotton fabric:

Dyeing procedure for dark shade

Felosan NOF/Wetting agent = 0.5g/lKappazon H53NEU/Stabilizer (H2O2) = 0.5 g/lAnticreasing agent = 1.0 g/l [Only for S/J]

60oC x 5'Caustic → 2 g/l

60oC x 15'Hydrogen peroxide → 2.5 g/l [Dosing 10']

(60oC - 80oc)Temperature rise up to 105oC

30'Acetic acid → 1.0 g/l

H2O2 killer → 0.5 g/l

60oC x 10'Acetic acid → 0.8 g/l (To control pH = 4.5-5.5)

Enzyme → 1.5 g/l

55oC x 45' - 60'Kappaquest FE / Sequestering Agent → 0.35 g/l

90oC x 5'Sarabid LDR → 0.5 g/l (leveling agent)

60oC x 5'Gluber Salt (Runtime → 10')

60oC x 10'Dye stuff

60oC x 35' Runtime 20'Soda ash

60oC x 40' Runtime 60'Bath drop after shade matching

Hot rinse

60oC x 10'


VIYELLATEX GROUP

Soaping

80o - 95oC x 10'Cold rinse

45oC x 10'Neutralize (Acetic acid = 0.5 g/l)

45oC x 10'Fixing

40oC x 15'Softening

Unload

Dyeing procedure for Light / Medium ShadeFelosan NOF/ Wetting agent = 0.5 g/lKappazon H53NEU /H2O2 Stabilizer = 0.5 g/lAnticreasing agent = 1.0 g/l

60o x 5'Caustic = 2 g/l

60oC x 15' [Dossing]Hydrogen peroxide (H2O2) = 2.5 g/l

(60o - 80oC)Temp rise up to 105oC & Run - 30'

Acetic acid = 1.0 g/l

H2O2 killer / Kappaquest FE = 0.5 g/l

60oC x 10'Acetic acid = 0.8 g/l [To control PH - 4.5 - 5.5')

Enzyme = 1.5 g/l

55oC x 45' - 60'Sequestering agent = 0.35 g/l

90oC x 5'Sarabid LDR /Levelling agent = 0.5 g/l

Anticreasing - 0.5 g/l

60o x 5'Dye stuff

60o x 35' - Run time - 20'Glauber Salt

Dosing - 60o x 10' - run time - 20'Soda ash

60 x 40'

Bath drop after shade matching


VIYELLATEX GROUP

Hot rinse - 10' x 60oC

Soaping80o - 90oC x 10'

Neutralization / Acetic acid45oC x 10

Cold rinse - 45o x 10'

Softening

Unload

Dyeing Procedure for White Colour

Felosan NOF/wetting agent → 0.5 g/lKappazon H53NEU /Stabilizer → 0.5 g/lAnticreasing agent → 1.0 g/l [Only for S/J]Caustic → 3 g/l

60oC x 15'Hydrogen peroxide → 10.0 g/l

60oC x 10'Syno white 4BK/Optical brightener (60o → 80oC)

105o x 60'Acetic acid → 1.0 g/l

NT x 10'Acetic acid → 0.8 g/l [To Control PH- 4.5 - 5.5]Enzyme → 1.5 g/l

55oC x 45' - 60'Sequestering agent → 0.5 g/l

90oC x 5'Acetic acid → 0.35 g/lSoftener → 1.5 g/l

40oC x 10'N. Hot

Unload

Remarks:

VIYELLATEX GROUP., strictly follow up the production parameters like time,temperature, M:L ratio, PH etc. As they do some difficult shade, it takes more time for theproduction of the batch and the dyeing process may vary from the dyeing flow chart fordifferent types of fabric & different types of shade.


VIYELLATEX GROUP

WORKING PROCEDURE FOR LABSAMPLE IN (FABRICS)

Physical Test Wet Lab.

Color fastness to light Bursting strength Color Fastness To Washing Dimensional Stability Pilling Crocking Prepare the sample

Pre-Production Sample Final SampleEvaluate the Sample Wash the sample according to buyer measure

Test TeststReport Making Tumble dry

Prepared the ReportKeep the sample Flat in conditioned temp

Pass Fail at least two hours before measurePass Fail

Delivery Refinish Measure the sampleGo for the final Refinish

Need to test again Prepared the ReportNeed to test again

Pass Fail

Ready to deliver Refinish

Need to test again


VIYELLATEX GROUP

1.Procedure of the Different Tests:

Different types of fastness tests of the dyed fabric are done in quality controldepartment of the VIYELLATEX GROUP LTD. Different types of method (Standard orbuyer’s recommended) are followed for different types of tests. The process of the differenttests of fabrics & lab. dip dyeing is described in the following section:Color Fastness Test ProcedureColor Fastness:

The “color fastness” of a colored textile is defined as its resistance to these changeswhen subjected to particulates of conditions. It follows that color fastness must be specifiedin terms of these changes and expressed in terms of the magnitude.

1. Color Fastness to Wash Test

Required materials:1. Sample size 40 100 mm2. Multifiber at 40 100 mm3. ECE detergent (WOB) – 4g/L4. Sodium Perborate (Na2BO3.H2O2.3H2O2-1g/L) - 1g/L5. Distilled water6. Normal cold water7. Steel balls

Required instrument:1. Rota Wash2. Scissor3. Stitch machine

Procedure :

1. Cut sample & multifibre at 100 400 mm and then stitch.2. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the

sample.For Marks & Spencer, the solution is taken by the following formula:

(Sample fabric + Multifibre weight) 50 ml3. The sample is kept in 600C for 30 minutes in Rota Wash Machine4. Rinse the sample twice with cold water.5. Dry at 60°C by hanging or by Flat iron pressing but temperature should not

be more than 150°C.Report:

Dry the specimen and the change of shade & degree of staining is measured by GreyScale & Staining Scale.


VIYELLATEX GROUP

2. Color Fastness to Perspiration Test

Test specimen: Sample fabric – 50 mm 50 mmMultifibre fabric – 50 mm 100 mm Cut the multifibre into two piece Sandwich the test specimen between two piece of multifibre

Testing Solution:

1. Alkaline Solution:Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/LNaCl – 5.00 g/LDisodium hydrogen orthophosphate (Na2HPO4.2H2O) – 2.5 g/LPH – 8 (Adjust by 0.1 N NaOH)

2. Acidic Solution:Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/LNaCl – 5.00 g/LSodium di-hydrogen orthophosphate (NaH2PO4.2H2O) – 2.2 g/LPH – 5.5 (Adjust by 0.1 N NaOH)

Method:- The composite specimen is put in a peri dish (2 specimen of a sample).- Solution (Alkaline & Acidic) is taken in the two peri dish. Here, M:L is taken

1:20.- Bubble is made out from the specimen by tapping.- The specimen is put for 30 minutes.- A glass plate is placed on the composite specimen for 15 minutes at room

temperature.- Excess solution is poured off.- Peri dish with composite specimen & glass plate is placed into the incubator at

(372) 0C for 4 hours.- The specimen is dried (Temp 600C)

Report:- Change of shade & degree of staining is measured by the Grey Scale & Staining

Scale.3. Color Fastness to Water Test

Test specimen: Sample fabric – 50 mm 50 mmMultifibre fabric – 50 mm 100 mm Cut the multifibre into two piece Sandwich the test specimen between two piece of multifibre


VIYELLATEX GROUP

Testing Solution:Water is taken as required

Method:- The composite specimen is put in a peri dish (2 specimen of a sample).- Water is taken in the peri dish as required.- Bubble is made out from the specimen by tapping.- The specimen is put for 30 minutes.- A glass plate is placed on the composite specimen for 15 minutes at room

temperature.- Excess solution is poured off.- Peri dish with composite specimen & glass plate is placed into the incubator at

(372) 0C for 4 hours.- The specimen is dried (Temp 600C)

Report:- Change of shade & degree of staining is measured by the Grey Scale & Staining

Scale.

5. Color the Fastness to Rubbing (Dry & Wet) TestSample:

- Dyed fabric – 15 cm 5 cm- White Test Cloth - 5 cm 5 cm

Procedure:- White test cloth is put on to the grating and stag by steel wire.- The sample is run twenty times manually for ten seconds. and the rubbing

fastness of the sample cloth and degree of staining is accessed.- For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked

and squeeze. The wet rubbing cloth is placed on to the grating and stag withstainless steel wire and run ten times manually then assess the staining on to therubbing cloth and the rubbing fastness of the sample cloth is accessed.

Report:- Change of shade of the sample is measured with grey scale and degree of staining

of the white test cloth is measured by Staining Scale.

There are also some tests are done in the lab. And the process is described below-

A. Measuring the Dimensional Stability (Shrinkage & Spirality):

Sample: Two piece of 50 cm 50 cm fabric is taken for test.

Procedure:a. Conditioning: Put the sample in table for 4 hrs for conditioning before starting

test.


VIYELLATEX GROUP

b. Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample(3 sides) by over lock sewing machine.

c. Put sample in washing machine and run according to buyer’s choice.d. Drying: All Buyers’ requirement is tumble Dry except ECHO SCOURING is

flat dry.

SHRINKAGE TEST CALCULATION:Before wash – After wash

Shrinkage % = X 100Before wash

Spirality test calculation:S = (S1+S2) / 2

Spirality = (S+S L)/100.Suppose,

S1 = The right side distance of the specimen from the stitch line afterwash.S2 = The left side distance of the specimen from the stitch line afterwash.L = Length before wash

B. pH of a Dyed Fabric TestTest specimen:

2 gm of dyed fabric is taken. The fabric is cut into pieces of (0.5 cm 0.5 cm)

Procedure:1. The sample is taken into conical flax.2. 100 ml distilled water (slightly warm) is taken into the conical flax.3. The conical flax is put on the Magnetic Stirrer for 30 minutes.

Report:The PH of the conical flax is measured by Digital PH meter.

Remarks:VIYELLATEX GROUP. always aware about the quality of the product. The quality

of the product is always approved by the buyer. They follow the quality standard: ISO -9002:2000. VIYELLATEX GROUP. is well equipped for checking the quality of theproduct. They sent the quality report to the buyer time to time/batch to batch.


VIYELLATEX GROUP

PrintSample Preparation

After getting work order from product development dept.

Prepare design according to outwork

Screen preparation

Sample preparation

Approved Sample

Bulk productionBulk Production:

Screen Preparation

Print Paste preparation

Printing is done on the mc or manually

Drying

Curing

Final InspectionPrinting m/cs:1. Flat bed Screen Printing (04 m/cs)

Red Chili( USA )No of Head-10Stroke-02

Conveyor Dryer(04 M/cs )Radicure(USA)

Three chambers:Chamber 1-Temp.-200 CChamber 2-Temp-200 cChamber 3-Temp.-200c

Expose Room:1. Sensitizing emulsion-Polymer type,Photocure TXR -97%2. Hardener-3%3. Mesh-90-1304. Heat


VIYELLATEX GROUP

Heat Press machine-02 m/csTemperature-160 cPressure-5-6 KgTime-3-5-10-15 seconds.

Types of Printing in VIYELLATEX GROUP:1. Pigment printing2. Plastic printing3. Rubber printing

Capacity:Average 30000 pcs/day.

EMBROIDERY SECTION:No of machines:08Brand Name:TajimaCountry:JapanNo of Head:20Electronic multiheaded automatic embroidery machines20 Head machine-0712 Head machine-01Highest RPM-1200 (It depends on design of fabric)The following types of stitches are used here:

Run stitchTatami stitchSateen stitchMotif stitchJig-jag stitch

Threads Used in Embroidery Section:Polyester, Cotton, Rayon, Metalic threads

Capacity: 3000pcs/shift(1 shift = 12 hr


VIYELLATEX GROUP

CHAPTER 08

UTILITY SERVICEIntroduction:

VIYELLATEX GROUP LTD. is a big project and so of course having a vastproject of utility service. Here the total account of utility facilities are available. The utilitiesare

a) Waterb) Gasc) Electricityd) Compressed Aire) Steam.

WATERWater treatment plant:

(Water Softening Method – Base Exchange Process)

Source of water is deep tube well.Production capacity – 80 m3 /hr = 1920000 liter/dayActual Production – 1500000 liter/dayRequired water - 1300000 liter/day

TechnicalDetails

Raw Watertank

Filter Tank (1) Filter Tank (2) HardnessRemoving Tank

Size Length – 30´Width - 15´Height – 6’

Diameter – 6´Height - 15´

Diameter – 6´Height - 15´

Salt reqd:190 kg/day/tankRegenerationtime 1.30 hrCapacity 360 Ton

Source Natural sourceDeep tube well

Raw WaterTank

Filter Tank (1) Filter Tank (2)

ELECTRICITY

Gas Generator is used for supplying electricity for the dyeing, knitting & office of theVIYELLATEX GROUP LTD.Total power produced by Gas Generator – 945 KW = 1134 KVAFactory (Dyeing & Knitting) Power Needed for Installation – About 1200 KWFactory (Dyeing & Knitting) Power Needed at Running stage – About 720 KWPower Needed for Office – About 250 KWSpecification of Gas Generator is given below:

Technical Details Generator DataType Gas Generator


VIYELLATEX GROUP

Manufacturer Cummins Power GenerationNo. of Gas Generator 03Model No. 315 GFBAManufactured Country EnglandYear of Construction 2002Rated Power PrimeRated 315 KWPower Factor 0.8Voltage 400Rated Current (amp) 568Frequency (Hz) 50Rotating Speed (RPM) 1500Battery Volts 24Control System PCCPSite altitude before derate 800 MASLSite ambient temp. before derate 400C

Source of Power used for Garments – DESAPower Capacity – 750 KVA = 900 KWThere is a diesel Generator in the industry.Capacity of Diesel Generator – 800 KWSpecification of Diesel Generator is given below:

Technical Details Generator DataType Diesel GeneratorManufacturer CATERPILLARNo. of Diesel Generator 02Model No. SR4B | SR4Manufactured Country U.S.A.Year of Construction 2004Rated 649 H.P. or 484.0 KWRotating Speed (RPM) 1500Voltage 400Rated Current (amp) 723Maximum Temp. 1050C by Resistance


VIYELLATEX GROUP

COMPRESSED AIR

Compressed air is produced by air compressor.There are two air compressors for producing compressed air.

Specification of the air compressor is given below:

Technical Details Air Compressor 1 Air Compressor 2Type Atlas Copco Atlas CopcoManufacturer Atlas Copco Airpower Atlas Copco AirpowerModel No. GA 30 GA 55Manufacturer Country Belgium BelgiumYear of Construction 2002 2004Maximum Working Pressure 10 bar 10 barFree air delivery 78 liter/sec 145 liter/secNominal Shaft Power 30 KW 55 KWRotational Shaft Speed 3000 r/min 3000 r/minGross Weight 995 Kg 1550 Kg

STEAMSteam is produce by Boiler.From the Water Treatment Plant, water is stored in a reserve tank and from there water goesto boiler & steam is produced.Specification of the Boiler is given below:

Technical Details Boiler DataType Fire Tube BoilerManufacturer OMNICAL BORSIG ENERGYModel No. DDHI 60 – 10Manufacturer Country GermanyYear of Construction 2002Thermal Capacity 3.9 MWMaximum Steam Out 6 ton/hourMaximum WorkingPressure

10 bar-g

Content up to NW 10940


VIYELLATEX GROUP

GASThe source of Gas is TITAS GAS LTD.The gas is supplied to gas generator or different section (Boiler- for heating water) from themain line of the TITAS GAS LTD.

Sources of Utility:Electricity : PDB & GeneratorSteam : BoilerWater : PumpCompressed air : CompressorGas : TITAS GAS LTD.

Remarks:

As the biggest project the VIYELLATEX GROUP., so the vast utility systems.There is a skill manpower group of engineers and other technical staffs to look after theseutility services. They have to remain aware of solution on a great sense of responsibility forany type of problem due to utility supply


VIYELLATEX GROUP

CHAPTER: 09STORE AND INVENTORY CONTROLCHAPTER 1Inventory Control:

Store is the place where every type of raw materials, spares, finished goods are keptin proper system. Inventory control means the accurate calculation and data of every type ofraw materials spares and finished goods in time to time store 4 inventory control arenecessary, because –

1. To know about the required amount of raw material2. To know about the job no – which would be processed3. To be continued the production process4. To find out the profit or loss of a company5. Stock and stock value for consumption measuring

Frequency of Inventory Update:- Monthly inventory control.- Annual inventory control.

Scope of Inventory Control:- Raw materials

Dyes store. Other chemicals. Grey fabrics.

- Finished fabric.- Spare parts.- General store:

Capital equipments. Accessories. Stationary. Maintenance parts.

Inventory System for Raw Material:- Raw materials partially received from production planning & directly from head office. Material receiving & inspection report (MRIR) is prepared. Received quantity is

mentioned and noted down. Submitted to Q.C. department. Some are OK & few rejected. Entry of data of goods in DATATEX. Goods are arranged according to OK or rejected group. Department gives store requisition to warehouse. As per requisition materials supplied & this record are noted down.


VIYELLATEX GROUP

In VIYELLATEX GROUP LTD. there are different inventory systems for different rawmaterials.

Grey Fabric Store:-All the grey fabrics are stored in the fabric store near the batch section. Different types

of fabric are listed in the sheet according to fabric types, quantity and consumer’srequirement. Fabrics GSM, shrinkage, diameter & other properties are also taken intoconsideration. The batches are prepared by taking the required fabrics from the grey store.

Stages of Grey Fabric Inventory Control:

After knitting production. Grey inspection. Warehouse. Batch preparation. Dye house.

Dyes And Chemicals:-There is a different store for dyes and chemicals. Varies types of dyes and chemicals are

stored here according to dyes and chemicals companies. Different types of dyes andchemicals are listed in a sheet. In the sheet the stored quantity of dyes and chemicals are alsoincluded. Every day the sheet is updated and a copy of this sheet is supplied to the dyeingmanager, dye house and lab section.

Spares:-In VIYELLATEX GROUP LTD. required amount of spears of different machines are

stored in the mechanical store room. All the spears are listed in a sheet which is controlledby the mechanical & maintenance personnel. Spares are arranged in the store roomaccording to there size, quantity & requirements. There are shelf's in the store room to keepthe small spare parts.

Finished Goods:-VIYELLATEX GROUP LTD. supplies its finished dyed fabrics to its garments

section. So, dyed finished fabrics are stored for short time in the finishing section. All thedelivered fabrics are noted on the tally khata according to the lot no, quantity, fabricsdiameter, buyer's name, Color & considering other technical parameters.

Stages of Finished Fabric Inventory Control:

Finishing section. After final inspection. Warehouse.


VIYELLATEX GROUP

Others:There is a central store at VIYELLATEX. In that store the various types offorms, papers; stationary & other necessary goods are kept.

Inventory Procedure Bin Card Store Requisition Store Ledger Account Daily Inspection & Package Report Monthly Stock & Consumption Report Monthly L/C wise Delivery Report Received Delivery & Balance Stock

Remarks:-VIYELLATEX GROUP. has individual stores for raw materials, finished goods etc.

There is not enough space to store the finished goods. It requires increasing the store area.In VIYELLATEX GROUP. the store for inventory control is satisfactory. Sometime, theyfluctuate from ideal process otherwise they are ok.


VIYELLATEX GROUP

CHAPTER :10

COSTING

Introduction:

Costing is a process by which the setting price of a product is calculated. It is a veryimportant task for a factory which runs for business purposes.And it is also strictly followed in the VIYELLATEX GROUP. Costing of the productsconsidering the raw materials expenditure, salary and wages of officers and workers,distributions and advertisement expenses etc. all direct and indirect expenses is done in thisfactory. It is determined by a troop of accountants with advice and consultancy of executivedirector.

Costing Of the Product

The following points are considered for costing any dyed product in VIYELLATEX.1. Total dyes & chemical cost2. Total utility cost3. Salary4. Payment5. Transport cost6. Lunch7. Entertainment cost8. Miscellaneous cost9. Government cash incentive

Price of the Product:Generally price of product is determined by the required profit adding to the total

expenses. So,

Price of products= (Direct expenses + Indirect expenses + FactoryOverhead) + Required profit

Price Range of Different Products:T-Shirt = $0.75 - $4.50 /PcsPolo Shirt =$2.00 - $6.50 /PcsKids Wear ==$0.75- $2.15 /Pcs

Knitting Charge of Different Fabrics:

Fabric name Charge perkg(Tk)

1. Single Jersey 092. Single Jersey with Lycra 30


VIYELLATEX GROUP

3. Single locust PK 164. Double lacost PK 165. Single PK 166. Double PK 167. Rib 178. Rib with Lycra 309. Interlock 2510. Auto striper 8011. Auto striper with Lycra 10012. Fleece 22-25

Dyeing Charge of Different Fabrics:

Name of fabric process Charge perkg(Tk)

1. White with Enzyme 352. White without Enzyme 303. Avg. color with Enzyme 854. Avg.color without Enzyme (Light&

med.)75

5. Deep shed with Enzyme (Black) 1106. Deep shed without Enzyme (Black) 957. Only wash (Tubular) 258. Only wash (Open) 459. Double dyeing (Face & Back) 115

Finishing Charge of Different Fabrics:

Name of fabric process Charge perkg(Tk)

1. Slitting only 52. Stenter only 253. Compacting only 154. Stenter + Compacting 355. Stenter + Compacting+ wash 506. Tube Compacting 10


VIYELLATEX GROUP

Costing Of the Product:Let price of yarn is $ 3.00/ kg.Process loss of yarn for knitting (10%) = $0.30Knitting fabric cost = $3.30Cost of dyes & chemicals = $2.50Process loss for dyeing (12%) = $0.30Dyed fabric cost = $ 6.10Packing cost = $0.05Production cost of fabric=$6.15Fabric price (with 25% margin) =$7.79

Fabric consumption/ doz. =(Body length + Sleeve length) x Chest length x 2 x GSM x12 /10000000

Garments specification:Body length=78 cmSleeve length=33 cmChest length=62 cmGSM=210

Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000= 3.469 kg

Fabric consumption/doze (with 10% wastage) = 3.816 kgBody fabric cost / doz. =$(7.79x 3.816)

= $29.73Cost of collar& cuff/doz = $ 4.00Cost of Trims=$ 2.25Cost of Trims (with 5% Process loss) = $2.36Production Cost of Garments/ doz=$36.09Garments Price/doz (with 25% Profit) =$45.12

Remarks:Costing is very important for a productive factory. Without proper costing all production

curriculums will go to vain. Because a factory cannot reach to its goal without achievinggood profit and good profit is not possible without skillful costing. In VIYELLATEX Thereare some skillful personnel to do this job.


VIYELLATEX GROUP

CHAPTER:11MARKETING ACTIVITIES

Name of the Buyer:

Buyer1) Marks & Spencer (M&S)2) S. Oliver3) TESCO4) PUMA5) ESPRIT

6) G.Star

Product Label:Product label differs from buyer to buyer. The product labels are

prepared according to the fabric criteria & the buyer requirements. Sample of some productlabel are given bellow:-

Main label Care label Size labelNot provided Not provided Not provided

Package Size & Label Market:

Package size & label differs from buyer to buyer. The Package size & label areprepared according to the buyer requirements. Normally the following package sizes areused:-

60 x 40 x 40 cm.58 x 33 x 44 / 43 / 42 cm.58 x 33 x 25 cm.58 x 33 x 13 / 16 / 18 cm.

Importing Countries:There are some countries which are importing goods from VIYELLATEX GROUP LTD.Which are given below- United State of America England Germany Denmark Europe Europe Union


VIYELLATEX GROUP

Manpower of Marketing:

Marketing plays a vital role in the field of displaying / showing the goods criteria of theproducts to the buyer & to communicate with the buyer. There are about 20 people in themarketing section of the industry.

Marketing Strategy:Marketing strategy is a very important factors to sale the products to the buyer. If the

marketing strategy is not so developed, it will be very hard to reach the goal. In case ofgarments marketing the dealings with the buyer is a very important factor.

By both side understanding the rate & the order quantity are fixed.A well defined marketing strategy has the following characteristics:

Good quality Low price or competitive price Prompt service Good commitment Good business communication

Duties & Responsibilities Of Marketing Officer:

Job summery:i) Market searchii) Market developmentiii) Customer’s motivationiv) Production follow upv) Technical assistance of customer

Dealing with the buyer & convince the buyer is the main duty of marketing officer. Amarketing officer also has some other duties. The main duties & responsibilities of amarketing officer are given bellow- 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 communication with the buyers and buying houses Communicate with better criteria of the products

Actually the responsibilities & duties of marketing officer begins from getting order of buyer& ends after receiving foods by the buyer. So, he should be always smart, energetic &sincere.

Remarks:

VIYELLATEX GROUP. has a well learned marketing & merchandising team. Theyalways communicate with the buyers. VIYELLATEX GROUP. has some fixed buyers.The marketing section also looks the quality & quantity buyers.


VIYELLATEX GROUP

CHAPTER :12

CONCLUSION

Conclusion:

We have completed our industrial attachment successfully by the grace of Allah.

Industrial attachment sends us to the expected destiny of practical life. The completion of thetwo months Industrial attachment at VIYELLATEX GROUP, we have got the impressionthat factory is one of the most modern export oriented knit composite complex inBangladesh. Though it was established only a few year’s ago, it has earned “very goodreputations” for its best performance over many other export oriented textile mills.

During our training period, talking with the clients of this mill we knew that the mill isfulfilling the country’s best export oriented white finished fabric as well as very goodcolored fabric due to its modern machinery & good management system.Mill is settled with utility to give all convenient supports to the productions for twenty-fourhours. It had self-power generator system to satisfy total power consumptions of the mill.We are enough fortunate that we have got an opportunity of having a training in this mill.During the training period we are received co-operation and association from the authorityfull & found all man, machines & materials on appreciable working condition. All stuffs &officers were very sincere & devoted their duties to achieve their goal.

There are some suggestions from us within our limited knowledge

Some Suggestions: The dyeing floor is watery most of the time: it should be cleaned all the time. To increase overall efficiency, more skilled labor should be used in a project. The m/c stoppage time should be analyzed and minimized. The maintenance should

be carried out when the m/c is out of action (wherever possible) and routinemaintenance should be carried out regularly.

There should be a yarn dyeing project. Sitting arrangement of production officers should be improved.


VIYELLATEX GROUP

Limitations of the Report: Because of secrecy act, the data on costing and marketing activities has not been

supplied in details. In spite of our limited time, we could not study in detail.

Some of the points in different chapter are not described as these were not available.

The whole process is not possible to bind in such a small frame as this report, henceour effort spent on summarizing them.

Lastly:We tried our best to gather all necessary information but it is true that within this

short period it is quite impossible to achieve 100% success but as a whole this industrialtraining was a satisfactory one and once again wed would like to thank the authority ofVIYELLATEX GROUP. as well as our honorable teachers far their altruistic help andadvice. We are fortunate enough that we have got an opportunity to have training in thismill. During the training period we have received enough co-operation and association fromthe authority and found all personnel. All stuffs and officers were very sincere and devotedtheir duties to achieve their goal.

Date post:	18-Jan-2017
Category:	Engineering
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Industrial attachment of viyellatex group

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