Industrial Attachment of Zubair spinning mill Introducing & Overview the Report Textile spinning and weaving is one of the oldest reflections of human ingenuity and cotton yarn is the great significance for the textile industry. With progress of civilization, the demand of cotton yarn, not only increased in terms of quantity also flourished in many splendor varieties. In recent yarn years fabrics exports based on cotton yarn have earn the most foreign currency for the nation. The government of most yarn producing countries as well as Bangladesh also heavily involved in yarn production marketing and formulate a textile policy with a view to attain eventual self-sufficiency in textile and clothing, because socio economic and strategic importance. Textile Engineering is a vast practical oriented subject and as its engineering; some sort of engineering must be pushed here. Actually the textile engineers, unless get any chance for the thrive of engineering, will just go fade. So practical implication is very essential for any textile person, engineer or student. It is beyond saying that textile industry is the heart of Bangladesh economy and industries are run by successful, skilled engineers. They are again the heart of any textile company. To gather this skill, practical involvement is very urgent, even from the student life. Textile technology education is based on industrial back ground. Theoretical background is not so important. By industrial training we can achieve vast knowledge about practical knowledge. So industrial training is a very essential part of our study to make us technically strength. Daffodil International University is serving the nation with her education, building successful engineers. At the same time, arranging an industrial attachment for each batch to different industries, this Varsity is contributing to increase the know-how of the students. Industrial training as offered by the University is very useful which gives the directions and ideas about the production, manufacturing, capacity, power etc. of a certain
Transcript
Industrial Attachment of Zubair spinning mill
Introducing & Overview the Report
Textile spinning and weaving is one of the oldest reflections of human ingenuity and cotton yarn is the great significance for the textile industry. With progress of civilization, the demand of cotton yarn, not only increased in terms of quantity also flourished in many splendor varieties. In recent yarn years fabrics exports based on cotton yarn have earn the most foreign currency for the nation. The government of most yarn producing countries as well as Bangladesh also heavily involved in yarn production marketing and formulate a textile policy with a view to attain eventual self-sufficiency in textile and clothing, because socio economic and strategic importance. Textile Engineering is a vast practical oriented subject and as its engineering; some sort of engineering must be pushed here. Actually the textile engineers, unless get any chance for the thrive of engineering, will just go fade. So practical implication is very essential for any textile person, engineer or student. It is beyond saying that textile industry is the heart of Bangladesh economy and industries are run by successful, skilled engineers. They are again the heart of any textile company. To gather this skill, practical involvement is very urgent, even from the student life.
Textile technology education is based on industrial back ground. Theoretical background is not so important. By industrial training we can achieve vast knowledge about practical knowledge. So industrial training is a very essential part of our study to make us technically strength.
Daffodil International University is serving the nation with her education, building successful engineers. At the same time, arranging an industrial attachment for each batch to different industries, this Varsity is contributing to increase the know-how of the students.
Industrial training as offered by the University is very useful which gives the directions and ideas about the production, manufacturing, capacity, power etc. of a certain mill and with these ideas getting adopted, a student can flourish his debut in the engineering field.
Zubair spinning mills ltd is on the thirst strategic business units of the company. Zubair spinning with its 72576 spindles is one of the modern spinning mills of the country. It equipped with the most modern machines and equipments, this unit is creating to export oriented Spinning factories of the country.
A rational behind the existing structure & future expansion of the textile division is to capture value added at each stage of textile manufacturing process. Inspire Bangladesh’s lack of producing of Export Quality Yarn Zubair spinning mills Ltd tries to produces export Quality of yarn. Zubair Spinning Mills Ltd keeps Export competitiveness to maximum level.
Site plan
The factory plant of Zubair Spinning Mills Ltd was setup to Gilarchala, Masterbari, Sreepur at Gazipur, near about Maona and beside the link road which connected with the Dhaka-Mymensing high way on about 64 bigha of land. It has covered the floor space of total about 3, 50,000SFT (Factory, Raw Cotton & Finished Godown).The Factory is the one storied building. Factory is a biggest project of Noman group. Zubair Spinning Mills Ltd is the new bright baby of the textile sector of Bangladesh. The project went into commercial operation
from 15th July 2008. All plant is acquitted with modern machineries these are imported from Japan, Germany, china and Switzerland.
Background of Noman Group
Noman group is a family business which was established in the year of 1986 by Md. Nurul Islam. The business initially stated as Garments Manufacturing Unit on its own premises which is also currently the corporate office. The vision of the management gradually turned into a reality with the formation of the member units marketing a growth pattern of the group.
To uphold social commitment at highest level and for achieving expected Quality production of exported garments, the board of Director has decided to establish a 100% export oriented cotton spinning mills to turn the group as composite knit project in true sense.
Keeping the above in view this good management has started Zubair Spinning Mills Limited with 72576 spindles to get 25000kgs production per day. The total investment is about USD 24 Million. The produced yarn will be consumed by sister concern.
Company Profile
Name of the Company : Zubair spinning mills Ltd (ZuSML)Chairman : Md. Nurul IslamGeneral Manager : Engr.AbdusSamadType: Spinning mill
Commercial production: 15th July 2008 Business line : Manufacturing and Marketing of Cotton Yarn Nature of the Company: Private Limited Company.Number of spindles installed (Ring Section):1008*72 = 72576 [Here 72 Ring Frame machine and each machine with 1008 spindles]Number of Spindle installed (Rotor section): 130*6= 1560 [Here 6 Ring Frame machine and each machine with 130 spindles]Product Mix: Ring Yarn:Carded YarnCombed Yarn: Rotor/OE yarnMajority wastage (short fiber) and cotton fiber.Count Range: Ring Yarn 40 - 100 Ne: Rotor/OE yarn07s~30s OEProduction Capacity: 30 ton/dayProduction capacity Achievement: 85%
Different Department:
1. Production Department.2. Quality Control and Assurance Department.3. Maintenance Department.4. Utility Department5. Store Department6. Power Generation Department7. Workshop Department8. Administration Department9. Medical Department10. Security Department
Zubair Spinning Mills Ltd is organized into three major parts-Factory, Sales & Production Department, and Finance & Accounts Department of which the factory consists of five departments namely Production, Maintenance, Quality Control & Assurance, Administration and Information Technology.
Company mission
Each of Zubair Spinning Mills Ltd activities must benefit and add value to the common wealth to our society. They firmly believe that, in the final; analysis they are accountable to each of the constituents with who are interacting; namely; their employees, their customers, their follow citizens and their client. Zubair Spinning Mills is a profitable project of Noman Group of Industry. Noman Group earns a lot of foreign currency and contributes the economy of our country.
MANPOWER MANAGEMENT
Organization structure & Man power
Manpower Administration
Zubair Spinning Mill is a well Organized Company. Its management system and manpower management is completely different from other local company.
Production Department:
Serial No. Designation Number of Post1 AGM Production 12 A.P.M Production 13 Sr. Production Officer 54 Production Officer 45 Ass. Production Officer 146 Worker 2200
Total 2228
Quality Control Department:
Serial No. Designation Number of Post1 Manager 12 Sr.Quality Control Officer 13 Quality Control Officer 24 Ass. Quality Control Officer 45 Lab Asstt. 126 Lab Boy 8
Total 28
Maintenance Department:
Serial No. Designation Number of Post1 Manager 12 ENGINEER 23 FITER 44 HELPER 48
Total 55
Administration:
Serial No. Designation Number of Post1 D.G.M (Admin) 12 Sr.Admin Officer 13 Admin Officer 44 Accounts Officer 25 Time Keeper 56 Exec. Security 17 Secu.Inspector 48 Secu.Guard 309 PC Operator 110 Admin.Asst 111 Driver 5
12 Forklift Operator 313 Peon 514 Swep/Gardenar 6
Total 69
Medical Department:
Serial No. Designation Number of Post1 Medical Officer 12 Medical Asst. 23 Nurse 2
Total 5
MIS Department:
Serial No. Designation Number of Post1 MIS Officer 12 Jr.MIS Officer 2
Serial No. Designation Number of Post1 Manager 12 Asst. Manager 13 Store Keeper 5
Total 07
Responsibilities of a Production Officer:
To collect necessary information and instruction from the previous shift officer. To run his shift smoothly and accurately. To make decisions how to operate whole production process. To supervise junior officer and worker. To check the worker setting for the process. To control the production process and quality parameters.
Ensure target production of each m/c with appropriate quality.
In case of m/c breakdown he has to start it as early as possible.
To control the workers so that they can operate the m/c as per instruction. To ensure target production of each m/c. To check the rules and regulation inside the factory. To arrange necessary punishment for the worker if they violate discipline.
Ensure cleanliness of all m/c and floor.
To train up the learners. To Checking of m/c setting, drafting zone cleaning. To check the proper use of waste sliver and “pneumafil” in the Blow room. To minimize m/c down time. To take necessary steps to reduce wastage. To check the production report. Checking of sticker, defective cone and package weight in finishing avoiding mixing. To hand over the shift with all information to the coming shift officer.
Shift Change:
A-Shift : 6 am to 2 pm B-Shift : 2 pm to 10 pm C-Shift : 10 pm to 6 am General Shift : 8 am to 5 pm
Job Description of Sr. Production Officer & Production Officer:
Production monitoring of Blow room to finishing achieving target production.
To cheek count wise and lot wise process parameter from Blow room to finishing. To take the charge from the outgoing shift and hand over the charge to the incoming
shift. To control unusable wastage in every stage from Blow room to Finishing. To allow leave of workers & subordinate supervising staffs in systematic way. To supervise performance evaluation. To cheek attendance. To check Humidity of the different section. To control count mixing, lot mixing of sliver, roving yarn and mixing / Bale
management of raw cotton. To charge Ring traveler as per schedule.
To cheek count wise and lot wise process parameter from Blow room to finishing against standard value.
To attend duties self and subordinate supervising staff and workers by minimum 15 minutes earlier.
To charge Ring traveler as per schedule. To maintain doff ticket and control of doffing time in ring section.
Management philosophy
Problem solving procedure
A co-ordination meeting is held regularly with all departmental heads and floor officers are participated in this meeting. Various problems are discussed in this meeting and solutions also find out from the meeting. On the other hand internal notes are given to the departmental heads from floor officers in case of any kind of problem.
Appraisal System
In our mill we have maintained a decent appraisal system where following criteria are included:
Worker facilities In ZuSML mill following facilities are given to the workers. Annual Increment Annual Games and sports Merit scholarship for poor students Financial help from benevolent fund. Maternity leave Pure drinking water system Medical facilities Gratuity Festival Bonus and festival leave. Proper sanitation Productivity decreases for different types of problem at ZuSML Personal affairs/ Family affairs
Most of our workers are female and they are muscularly dominating by their husbands. Poverty is the main problem to lead their life through a superb way. They are bound to perform their household works and factory works simultaneously. So, excessive leave is required to beat their personal problems.
Habitual absent, especially at night shift
Some workers are habitually insincere to act in accordance with the service rules. At times, they remain absent from their duties without informing their section in charge. Besides, they can’t show any reasonable causes to support their non-attendance. During night shift this type of tendency increases.
Sickness
Generally, a worker takes his/her leave due to sickness. Some workers are not conscious to inform their section in charge about their sickness in due time. That’s why section officers are unable to favor them with required leave through the systematical (Official) way. Moreover, at times, section officer faces difficulties to run his section smoothly because of worker shortage.
Managerial problem
A supervisor should have the competence to inspire his subordinates and must have to be familiar with his subordinates. Otherwise, he will not be able to organize their activities. He should have the ability to provide solution at what time a worker is in distress. It is a matter of regret that some officers are incapable of scheming excessive leave and absenteeism of worker.
Faulty settings as well as gauging
A faulty setting of gear or any other parts of any machine increase the depreciation of the respective machine and deteriorates quality of the product.
Recommendation
People should be treating fairly. Employee needs should be satisfied. Work related goal should be setting. Reward should be given on job performance basis. Increase the wages of direct worker after analysis the work-study is needed for actual
working load and idle worker should be removed so that we can increase the wages. Motivation is needed and performance related pay is required to given. For this
reason, performance should be measured accurately & carefully. Adequate medical facilities both doctor & medicine is required for treatment which is
the part of motivation. Management training is required for the supervising officers. Ethical development is needed though proper training. Job design is needed for some officers & workers. Chain of command should be maintained. We can apply scientific management
approach
PROCESS FLOWCHART AND MACHINE DESCRIPTION
Process flow Chart of Ring Spinning:
Combed yarn is more precise than card yarn. Here is the process flowchart of Combed Yarn and carded yarn. To produce Carded Yarn needs fewer steps to follow to make a yarn than the Combed yarn. The main purpose of Combed yarn manufacturing is to create a yarn which
is highly finer and highly qualified and combed yarn is most precious, finer and thinner than the carded yarn.
Carding:
“Card is the heart of spinning mills” and “well carded is half spun” are two proverbs of experts. Carding maybe defined as the reduction of an entangled mass of fibers to a filmy web working between two closely spaced, relatively moving surface clothed with sharp wire points. The carding is the heart of spinning and well card is half of spun demonstrate the immense significance of carding for the final result of the spinning operation. The importance of carding is still greater where new spinning systems are concerned.
The Objective of Carding:
The fiber to fiber separation. To effect a through mixing of fibers. Removed of trash in the lap or opened cotton in blow room process. Conversion of lap or opened cotton in the blow room process into sliver from suitable
for further processing
Flow chart of card yarn:
Combing:
For high quality yarn, an extra process is introduced called combing. Combed sliver has a “silkier” appearance than card sliver because of the enhanced fiber alignment.
The objective of combing machine:
Combing is the process which is used to upgrade the raw material. It influences the yarn quality like yarn evenness, strength, cleanness, smoothness, visual appearance Remove short fiber.
In addition to the above, combed cotton needs less twist than a card yarn and Improve fiber orientation
Flow chart of Combed yarn:
Machine Description:
Contents: Brand name. Manufacturer. Number of machine. List of machines. Remarks.
Blow room: Flow Chart of Blow Room
Layout of Blow Room
Blow room
Building Space (m2) : 1020No. of Line / Passage: Two (2)
Machine Description for Blow Room:
BLENDOMAT:
No. of machine: One
Manufacturer : GARMANYBrand name : TRUTZSCHLERModel No. : BOA-2300Function : To plucking raw material and forward to next.
PRE OPENER:
No. of machine: OneManufacturer : GARMANYBrand name : TRUTZSCHLERModel No. : BO-COIFunction : To remove the dust and trash particle.
SP-EM:
No. of machine: TwoManufacturer : GARMANYBrand name : TRUTZSCHLERModel No. : SP-EMFunction : To mix the fiber and store.
PER-CLEANER:
No. of machine: TWOManufacturer : GARMANYBrand name : TRUTZSCHLERModel No. : CL-PFunction : It works as super cleaner.
MULTIMIXER:
No. of machine: TWOBrand name : TRUTZCHLERManufacturer : GARMANYFunction : To detect fire
CLEANOMAT CLEANER:
No. of machine: TWOBrand name : TRUTZCHLERManufacturer : GARMANYFunction : To detect heavy Mattel.
LOPTEX:
No. of machine: TwoBrand Name: TrutzchlerManufacturer: Germany Function: It sorts out the colored contamination by optical means and also detects the colorless (e.g. Poly propylene) contamination by ultrasonic means.
OPTOSONIC SORTER:
No. of machine: TWOManufacturer : ITALY
FOREIGN FIBER AND PP DETECTOR:
No. of machine: TWOManufacturer : GARMANYDelivery System: Chute Feed System Equipment.
Carding machine is called The Heart of Spinning. Because the Quality of yarn fully depends on the performance of carding. It mainly removes Neps, Short fiber and also impurities. The short fiber is removed by the action of flat and Cylinder. The most important part of carding is various setting points for better performance. The small tuft turns sliver by the help of carding machine.
No. of machine: 24Model: TC-06Manufacturer: TRUTZSCLER (GERMANY)
Manufacturing year: 2008Efficiency: 95%Delivery speed: 62kg/hrFeed roller diameter: 172 mm Feed roller speed: 17-30 rpmOpening roller diameter: 292 mm Chute Feed SystemOpening roller speed: 850 rpmDelivery roller diameter: 156 mmDelivery roller speed: 17-30 rpmFeed roller diameter: 100 mmFeed roller speed: 17-30 rpmLicker in diameter: 253 mmLicker in speed: 1300-1700 rpmCylinder diameter: 814 mmCylinder diameter speed: 500-900 rpmDoffer diameter: 680 mmDoffer speed: Depends on deliveryStripping roller diameter: 118 mmStripping roller speed: Depends on deliverySqueezing roller diameter: 80 mm Squeezing roller speed: Depends on deliveryCleaning roller diameter: 100 mmCleaning roller speed: Depends on deliveryDisc roller diameter: 72 mmDisc roller speed: Depends on deliveryFlat speed: Depends on cylinderNo of flat: 84Pre carding segment in licker in.
Cleaning efficiency depends on Suction hood & Knife
Gauge Setting: Feed plate to feed weight: 0.15 mm: Feed roller to Licker in : 0.80 mm: Licker in to Cylinder : 0.20 mm: Cylinder to Flat : 0.225 mm: 0.20 mm: 0.150 mm: Doffer to Cylinder : 0.175: Doffer to Stripping roller : 0.15 mm: Stripping to Squeezing : 0.175 mm
Breaker Draw Frame:
The carded sliver is feed in Breaker Draw Frame. In ZuSML 8 (eight) card sliver cans are feed in each Breaker Draw frame. The more no of doubling give more remove of irregularity. If doubling is more than draft should also more. But more draft leads more unevenness in the drawn sliver. So optimum doubling should be maintained.
Name of m/c: Breaker draw frameCompany name TOYOTACountry of origin: JAPANModel no. DX-8 Manufacturing Year: 2008No of m/c: 08Drafting system: 4 over 3Roller Dia:
Bottom mmFront 40Middle 35Back 35
Roller gauge:
Front to middle: 40 mmMiddle to back: 38 mmCot roller hardness: 70 Shore (comb), 80(card)Creel roller dia: 70 mmQuartz length: 157 mmNo of doubling: 6-8Maximum speed: 700 m/min.Pneumatic pressure: 140 bar (card), 120 bar (comb)Size of Condenser: 4.6 mm (inside dia)Type of roller: Black (comb), Gray (card)
Top mmFront 38Second 38Third 42Back 38
No of sensor: Delivery sensor, can change sensorPresent of autoleveller: NoSliver wt: 69.4 gr/ydPower consumption: 5.65 kW
Features:
Auto doffingAuto stop motionProblem indicating lamp signalsMore uniform sliver by doubling and drawingMaking more parallel fiber.
Finisher Draw Frame:
This machine is use both card and comb yarn. The card and comb sliver both are fed to the Finisher draw Frame. If any fault is occurred in this process it cannot be removing in further process. The main deference of finisher draw frame is auto leveler. If sliver mass variation is occurred then it tries to remove it. The auto leveler can remove only ±25% variation. The scanning roller consistently scans any unevenness in sliver and send signal to the servo motor. The result is excellent short, medium, and long term evenness.
Name of m/c: Finisher draw frameCompany name: TOYOTACountry of origin: JAPANModel no. DX-8 LTManufacturing Year: 2008No of m/c: 08Drafting system: 4 over 3
Front to middle: 40 mmMiddle to back: 38 mmCot roller hardness: 70 Shore (comb), 80 (card)Creel roller dia: 70 mmQuartz length: 157 mmNo of doubling: 6-8Maximum speed: 500 m/min.Pneumatic pressure: 140 bar (card), 120 bar (comb)Size of Reducer: 3.5 mm (Comb), 4.2mm (Card)Type of roller: Black (comb), Gray (card)No. of sensor: Delivery sensor, can change sensorPresent of autoleveller: YesSliver wt: 69.4 gr/ydPower consumption: 5.78 kW Lap former is used to produces combed yarn. In ZuSML lap former is used. Good lap are the important for satisfactory combing. In lap former slivers produces faultless lap sheet by distributing the fiber evenly the whole lap width.
No. of m/c: 04Company: RieterManufacturing Year: 2005Country of origin: SwitzerlandModel no.E-32No. of doubling: 26 (maxm -28)Delivery speed: 110 m/minDrafting system: 3 over 3Front roller dia: 39 mmBack roller dia: 32 mmLap dia: 650 mm (maxm)Delivery length: 200 mmLap weight: 17 kg
Combing is process for better quality of combed yarn. To upgrading the quality of combed yarn combing process must be done. It influence the quality by-
Extraction of short fiber in order to improve the staple diagram. Remove the excessive Neps which cannot remove from carding. More parallelization of fiber. Finally formation of combed sliver with necessary cohesive force.
The finisher draw frames slivers are fed to the simplex. The sliver is extent and small amount of twist is inserted. This twist only helps to hold the fiber during winding and unwinding of roving.
Name of m/c: SimplexCompany: TAIHANGModel no.FA-425AManufacturing Year: 2008No of m/c: 24No of creel: 4Total creel capacity: 120Drafting system: 4 over 4
Cover open sensorRoving breakage sensorRoving breakage in bobbin sensorSliver breakage sensorMaximum rpm in ZSML: 1000
Advantages of modern Simplex:
More speedHigh efficiency
Automatic tension controllerAuto Greasing System After 70 hours for 6 minBobbin information:Wt.237.337 gmLength: 44.5 cmOuter upper dia: 4.5 cmOuter lower dia; 6 cmBobbin color: Blue, orange black, white, red, brown, yellow.Power consumption of simplex: 10.64 kW
ROVING BOBBIN DIMENSION:
Layout Plan of Ring to Finishing
Bobbin length=44mm
Winding margin=35mm
Avoiding area=100mm
Lift length=385mm
45°
Identification:
Ring Frame
The roving is fed Ring Frame to produce yarn. The necessary amount of draft is also need. The twist is inserted to improve the strength. But excessive twist decreases the strength. The traveler is mainly inserted the twist. The Ring bobbins are doffed automatically.
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Sticker zone
Ring Frame=72
Re Winding=01
Winding m/c=21
Manufacturer: JINGWEI (Suessen, EliTErCompactset)Country of origin: CHINAModel no: F1520Manufacturing Year: 2008No of m/c: 72No. of Spindle/machine: 1008Spindle speed: Up to 18000 rpmSpindle gauge: 75 mmLift: 7 inchRing cup dia: 40 mmSpindle type: Eye typeDrafting system: 3 over 3(SKF-PK2025)
Roller dia:
Roller gauge:
Back to middle: 51mmMiddle to front: 44mm
Apron specification:
ROLLER TOP BOTTOMFront 28.5 mm 27 mmMiddle 28.5 mm 27 mmBack 28.5 mm 27 mm
Top-37 mm*27.8 mm*1 mmBottom-73 mm*30 mm*1.1 mmSpacer color: YELLOW, RED, VIOLETCradle type: OH 2024Cradle size: 36 mmSpecification of bobbin cops:Total lift length-180 mmRing bobbin dia-Top-21 mm, Bottom-27 mmRing bore dia (38, 40) mmBobbin length-210 mm
The autoconer machine is used to build the large package. The faulty part of yarn is cut during winding. It cuts the faulty parts of yarn and then join is done by the help of air. USTER analyzer is works here.
Name of machine: Process conerBrand name: MuratecCountry of origin: JapanModel no: 21C (Magazine type)No of m/c: 21Power consumption: 13 kW
Main Parts: Drum Pilot motor Suction mouth Retie pipe Cutter Balcon Cradle Tensor box Loepfy (electronic yarn clearer )
Important Parameter:
PARAMETERS VALUES
Winding Position 60Drum Dia 100 mmTensioning Device Tensor boxYarn Speed 1200 ~1550m/minSplicing System AutoFinished Package Wt. 2083 gmYarn Length Depend on countElectronic Clearer LoepfyYarn Strength Depend on count
Package Hardness As per requird
Foreign matter detector Without cotton, any type of dark substanceSplicing zoned Under measuring systemMagazine 9 bobbin feedMeasuring head Ray typeCutter CeramicTraverse length 7 inchDrum type 2.5 turns
Paper Cone Measurement
Heat Setting:
Xorella is used to insert the twist permanently. It has a chamber where the yarn is subjected to proper temperature and pressure. Heat setting also removes the hairiness and increase the strength of yarn.
41mm
172mm
67.5mm
28mm
5°57'
2.2mm
Wastage Percentage & Efficiency in Different Stage:
Serial No Name of Stage Wastage % Efficiency %1 Blow Room 22 Carding 8 983 Breaker Draw Frame 0.75 88 – 904 Finisher Draw Frame 0.75 80 – 855 Lap Former 0.75( Reiter) 90( Reiter)6 Comber 17( Reiter) 80( Reiter)7 Simplex 1 85 – 908 Ring Frame 2 95 – 979 winding 2 70
CLASSIMAT SYSTEM & EYC
The appearance of a fault in the finished product i.e. a woven or knitted fabric is largely determined by its size. A yarn fault classification according to cross-section and length is therefore the basis for the assessment of yarn faults. By classification we understand the arrangement of yarn faults within a schematic (CLASSIMATE matrix) according to the fault data.
Tried and tested for many years, the classification matrix consists of 23 classes for the classification of “normal” thick and thin places. For a better assessment of yarn types with different structure. Such as a core yarn or compact yarns, the classification matrix was extended by four additional classes. of course, the extended classes can also be used for conventional yarns and can even provide additional helpful information .
Classimat defect classification:
Fault Cross-sectional size
+400
+250
+150
+100
+45%
-30%
-45%
-75%
0.1 1 2 4 8 32 CM
A4 B4 C4 D4
A3 B3 C3 D3
A2 B2 C2 D2
A1 B1 C1 D1
F G
H1 I1
H2 I2
Packing Section
Length of packing bag: 37 inchHeight of packing bag: 48 inch TR weight: 1 kg 300 gm (Cone + poly bag)Total packing bag wt.51.1~51.250kgsYarn wt.50 kgs
Contains in Sticker:
CountLot no.QuantityNet wt.Serial no.Packing dateNo. of cone/packing bag: 24(Generally)Relative humidity of packing section: 6
RAW MATERIALS and BALE INFORMATION
Raw Material:
Raw cotton used in Zubair Spinning Mills Ltd.:
Zubair Spinning Mills Ltd. Produces 100% export quality yarn. So they need very good quality yarn. To produces best quality yarn Zubair Spinning Mills Ltd mainly uses CIS cotton. The benefits of CIS are the cotton is Absolute Contamination free and the trash percentage very low. The MIC value Varies from 3.6 to 5.2. But Zubair Spinning Mills Ltd uses only 4.8 – 5.2 mic to produces their yarn. The main benefits of CIS are it comes with green card. Besides CIS cotton they also use
Memphis USA 29-30mm 3.8Shankar India 26-28mm 4.5MCU-5 USA 27.5-30mm 4.5Pakistani Pakistan 24-26mm 5.0Camaron Africa 28-30mm 3.5
Source of raw materials:
Required raw materials are purchased by L/C. Price: Cents/lbInformation found on a bale:
1. Binding material used for bales: Steel wire
2. No of binder: 103. Bale size: Height: 59 cm, Length: 95 cm, Width: 80 cm4. Bale weight: 220 kg5. Tare weight: 2.6 kg6. Bale loading & unloading system: It is done by FORKLIFT.7. Capacity of raw cotton godown: 12000 bales8. Bales used in per lay down: 60 bale9. Bales consumption/day: 180Bales
Contaminations of raw cotton :
Black cotton Piece of cotton cloth Color thread Piece of polythene Piece of white cloth Piece of plastic White thread Polypropylene Feather Wooden piece Bale covering cloth Color cotton Jute Hair & Wool Others
PROCESSING OF COTTON BEFORE BALE FORM:
Cotton fiber originated from seed, which is called seed cotton. In cotton plant several cotton pot or ball produced. Cotton growing origins are USA, CIS countries, Egypt, Africa, Australia, China and also India and Pakistan. In our country cotton is mainly imported from huge cotton grower USA, CIS, Australia, Africa, Egypt etc. because cotton of India and Pakistan fails to meet our demand from view of quality and quantity. During harvesting seed cotton pots are collected from the plant which is known as picking of cotton. Picking can be done manually and mechanically. Manual picking can ensure cotton pot selection, segregation and collection separately. So manual picked cotton is less trashy but collection/production is very low. Again in mechanical picking, production rate is very high but have no choice. Big cotton growing countries like USA use mechanical picking which in the other hand reduce cost of cotton. After picking seed cottons, fibers are separated from seed by ginning machine for subsequent processing. Seedless cotton fibers are then compressed to bales of around 500 lbs for easy shipment to users. Seed cotton process flow and a typical bale size (95cm*59 cm*80 cm) is shown as below. In ZUBAIR SPINNING MILLS LTD.CIS (Uzbekistan) cotton and MCU-5 (India) is used.
Spinning mill purchase those cotton bales under contract of some fiber property like fiber length, fineness, strength, trash content etc. But modern spinning mills test all fiber properties for each and every bale under Id. no. prior use taking representative samples of about 4 ounces from both side of each bale. For this, thousands of bales need to be tested within very short time where HVI has no alternatives. HVI i.e. High Volume Instrument offers all possible fiber property tests at a very high speed.
Breaker Drawing: DX-08, TOYOTA Production speed =550 m/minProduction rate (100%) = 300kg/hrEfficiency = 80%Finisher Drawing:DX – 08, ToyotaProduction speed =500m/minProduction rate (100%) =300kg/hrEfficiency =80 Simplex:Tiahang FA-425ASpindle speed =1000 rpmDelivery Speed =24m/min TPI =1.12No of Flyer per m/c=120Efficiency =82%
Ring frame: JINGWEI 1520Spindle speed =15000-18500TM =3.2-4.10TPI =as per countDelivery Speed =200m/minNo of Spindle per m/c=1008Efficiency =94%nm
Winding: MURATEC 21 CWinding speed =1450m/minNo of Drum per m/c=60Drum dia =100 mmEfficiency =80%Description of Production Process:Types of Production process:100%cotton comb (WEAVING) 100% cotton card (KNIT)Flow chart for 100% cotton (combed) process:
The Quality assurance and quality control department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. Zubair Spinning Mills Ltd. is more about concern about quality. In this factory quality assurance is more preferred than quality control, but both are in advancement.
After collecting fiber, sliver, roving, yarn from different m/c, they are needed to be inspected or assured required quality by the quality inspectors as if there were no big production hampered and no complain from the buyers. Here are the details about it.
Objects of Quality Control:
Research. Selection of raw materials. Process control. Process development. Product testing. Specification test
Scope for quality control, quality assurance and testing:
Testing lab Machine auditing system A good training system Excellent analytical back up
Technical expertise
List of testing equipment and their manufacturer and model no:
m/c name Manufacturer Model noLea strength tester INDIA
USTER auto sorter 5 SwitzerlandElectronic twist tester INDIA
Aduent laser tachometer England A2103/LSR/003Uster Tensojet-5 Switzerland
Hand held moister meter EnglandSliver roving reel England
Electronic wt balance(for package wt) ChinaWrap block INDIA
AFIS USA AFIS PRO-2HVI USA HVI 1000
USTER TESTER-5 Switzerland YGO41Wrap reel INDIA
USTER HVI Spectrum:
Name of the equipment: Uster HVI (High Volume Instrument) (Version: Spectrum)
Objectives: To measure MIC, Maturity, SCI, Length, Amt, Uniformity, Strength, Short Fiber Index, Elongation, Moisture, Rd, +b, Color grade, Trash Content, Trash Area, Trash Grade, UV.
3. Testing type:
System testing –
Length, Moisture, maturity, SCI, Rd, +b, length uniformity, SFI, strength, elongation, micronaire, trash and color determined together
Module testing –
Length & Strength module Micronaire module Color & Trash module
4. Test parameters:
a) Main menu –
System testing Module testing Calibration Data manager Status Man-made fiber test Diagnostics
b)Quality parameter –
ICC (International Cotton Calibration) mode Fiber length (2.5% span length, 50% span length in mm or inch) Length uniformity (Uniformity Ratio) & SFI Strength & Elongation HVI (High Volume Instrument) mode Fiber length (Upper Half Mean Length, Mean length in mm or inch) Length uniformity (Uniformity Ratio)& SFI Strength & Elongation
5. Operating procedure:
Switch on the power of the machine. Calibrate the color, MIC, length and trash. At first MIC of the fiber sample is carried out followed by the color and length-
strength test. The print-out of test results can be obtained.
6. Report type:
HVI Quality Report Results of each tested sample Summary of the results with statistics Graphical presentation of each and every parameter
7. Inspection procedure method:
Visual inspection of the printed individual and summary test results.
Segregation of the raw cotton bales and reject the below standard bales. Bale management is carried out with BIAS from these results.
8. Details about three modules:
A) Micronaire (MIC) module:
Working Principle→ Air flow method Fibre thickness↑, Inter space↑, Air pass↓, MIC↑, Fineness↓ Sample weight→ 8.5—11.5 gm Application range of MIC→ 2.0—7.0
Micronaire: Micronaire is the measure of fiber fineness and maturity. An airflow instrument is used to measure the air permeability of a constant mass of cotton fibres compressed to a fixed volume. The rate of airflow represents fiber fineness as per previous calibration and expressed in terms of Micronaire i.e. per inch fiber weight in microgram [1µg=10-6gm].
Fiber maturity: The fiber indeed a hollow pipe like material where the degree of the cell wall thickness is expressed in terms of fiber maturity.
The table below can be used as guidance in interpreting micronaire and maturity measurement:
Fiber fineness (µg ) Fibre Maturity (Maturity Ratio)below 3.3 Very fine below 0.7 Uncommon3.4-4.3 Fine 0.7-0.8 Immature4.4-5.0 Average 0.8-1.0 Mature5.1-5.8 Coarse above 1 Very mature
B) Color & Trash module:
Working principle→ Electro-optical method Color grade is determined by the combination of Rd and +b. Rd→ Expresses degree of brightness Rd↑, Brightness↓ Application range of Rd→ 35%—90% +b→ Expresses degree of yellowness or degree of pigmentation +b↓, more white cotton Application range of +b→ 4.0—18.0 Leaf grade→ Trash is expressed by Leaf grade or Trash code Application range of leaf grade→ 1.0—7.0
Measure of color →This module offers some light source to expose over the cotton sample that placed on the color tray/window. What happened are the exposed light partially absorbed by the cottons and the rest subjected to reflection. Light absorption results the degree of pigments in cotton sample i.e. yellowness (+b) and reflectance (Rd) measured from the light reflection from cotton sample which sensed by a video camera. The HVI Rd reading indicates how bright or dull a sample is and the +b indicates the degree of color pigmentation. A three
digit color code is thus determined by plotting the values on the Nickerson-Hunter cotton colorimeter diagram and locating the point at which the Rd and +b values intersect. Each grade area in the diagram aside is subdivided into quadrants to denote small color differences.
The color of cotton fibers can be affected by rainfall, freezes, insects and fungi, and by staining through contact with soil, grass or the cotton plants leaf. Excessive Moisture and temperature levels can also affect color deterioration while cotton is being stored.
C) Length & Strength module:
Working Principle→ For length→ Photo-electric cell or Electro-optical method For strength →Pneumatic or Mechanical break Fibro-comb and Fibro-sampler are used to prepare sample. A test sample is prepared
with Fibro-comb by Fibro-sampler.
Length measurement →Fiber length and length distribution (Uniformity) measured through light scanning prior strength measurement. HVI tests fiber length in terms of span length by geometrical analysis of fiber array (orderly arrangement). Here 2.5% Span Length (S2.5%) is very close to classer’s staple length. It also tests 50% Span Length (S50%) and Uniformity Ratio (UR) to evaluate length distribution of fiber in ICC mode. In HVI mode respective terms are Upper Half Mean Length (UHML), Mean Length (ML) and Uniformity Index (UI).
UR=
UI =
Fiber length and uniformity affects yarn strength, evenness and the efficiency of the spinning process. Some USDA (United States Department of Agriculture) cotton grades are given as under:
Upper Half Mean Length Uniformity IndexBelow 0.99 Short below 77 Very low0.99 ~ 1.10 Medium 77 ~ 79 Low1.11 ~ 1.26 Long 80 ~ 82 Averageabove 1.26 Extra long 83 ~ 85 High
above 85 Very highFiber length and uniformity is also related to short fiber (< ) content. Cotton with a low uniformity index is likely to have a high percentage of
Short fibers. It is in HVI expressed as Short Fiber Index (SFI) and can be defined as follows:
SFI = 122.56 – (12.55 UHML) – (1.22 UI)
Strength measurement → Strength module is offered the very same test sample beard gripped with Fibro-comb by one end. A moveable clamp grips the sample fiber beard at ⅛″ distant opposite end and moves until break just after length test. Measurement of fiber strength is reported in terms of gm/tex. A tex is equal to the weight in grams of 1000 meters of fiber. Therefore the strength reported is the force in grams required to break a bundle of fibers of
one tex unit in size. The bundle fiber of course elongates to some extent prior breakage. An elongation percentage also measured from initial clamp distance (L1) i.e. over final clamp distance (L2) prior fiber breakage during strength measurement.
Elongation% =
The following tabulation can be used as guideline in inter fiber strength & elongation measurement
Fiber strength(⅛″ gauge strength in gm/tex) Fiber elongation (%)17 & below Very weak Below 5.0 Very low18 ~ 21 Weak 5.0 ~ 5.8 Low22 ~ 25 Average 5.9 ~ 6.7 Average26 ~ 29 Strong 6.7 ~ 7.6 High30 & above Very strong Above 7.6 Very high
In ICC mode fiber strength is accurate; on the other hand in HVI mode strength is 25% more than the actual.
Bale Management: Bale management is defined as the choice of cotton bale according to according to fiber characteristic in order to achieve acceptable and economical processing condition of a constant yarn quality.
Factors consider for efficient Bale Management:
Origin
Length and length uniformity Fineness (MIC value) SCI ( spinning consistency index) Strength and elongation
Color
Trash %
Objective of Bale Management:
To get uniformity yarn quality. To get minimize shade variation of the finished fabric. To reduce or control fabric “Barre”.
Procedure of Bale Management:
Assumed a fiber lot no. 82 Total bale: 10000 Sample collection: 9850 samples (maximum 250 gm each sample)
HVI testing
Collecting of raw data for 10000 samples Category define, define micronair value, maturity and (+b) as category
Discard the lower MIC and color grade bales Daily requirement: 100 bales Layout of mixing Delete the consumed bale from the current bale
COTTON GRADING:
The following tabulation may illustrate the Color Code concept clearly:
Color Grade Step(Rd) Symbol Color Group (+b)1.White 2. Light
Switch on the power of the m/c. Select measurement from the main menu. Select module Select identifier Select sample type Input filename Press start button. Feed the prepared samples in the feed nozzle The print out of the tested results could be obtained after the test.
Report type:
AFIS quality report Results of each tested sample Summary of the results with statistics Graphical representation of each and every parameters e.g. histogram etc.
Inspection:
Visual inspection of the printed individual and summary test results. Raw cotton selection is done from the measured neps, SFC, Maturity Ratio etc. Test results help to select proper process parameter.
For Slivers: 1 Slot For Roving: 1 Slot For Yarn : 2 Slot
Measuring principle:
Electronic Capacitance Method.
Testing speed:
For yarn – 400 m/min For roving – 50 m/min For sliver – 50 m/min
Testing results:
Mass variation (U%, CV %) Imperfections (Thin/km, Thick/km, Neps/km) Hairiness Periodic faults of machine parts
Fabric Construction.
Quality parameters:
a. Unevenness (Um %, CVm% at different cut length)
Cut length –
For sliver: 20mm For roving: 12mm For yarn: 8mm
b. Imperfections
Thin place/km : at -30%,-40%,-50%&-60% sensitivity Thick place /km : at +35%,+50%,+70%&+100% sensitivity Neps/km : at +140%,+200%,+280%&+400% sensitivity
c. Hairiness (at different cut length and CV% of hairiness)
d. Periodic faults (mechanical)
Operating System:
Switch on the power of the machine. Select “Test Program” and then press recall button. Write the changeable parameter through keyboard and start the test with start button. Feed the test sample manually through the proper guide. No interruption is valid
during test period. The printer automatically prints a report along with diagrams just after a test is being
Name of the equipment : Twist Tester Machine specification : Sample clamp Load adjusting cursor Scale Level adjusting screw
Plum bob Change lever of untwisting direction both ‘S’ and ‘Z’ twist. Sample elongates and shrinks scale Handle for move the revolve chuck.
Operating procedure:
Set the reference length (e.g. 10 cm) in the twist tester. Adjust deflecting needle deflection ‘0’ degree as weight free. Select proper weight from weight table. Adjust deflecting needle again to the centre of the graduated scale (i.e. deflection ‘0’
degree) while attaching the sample yarn with rear end by fixed and rotating jaw. Rotate the wheel against the twist in the yarn allowing the deflection needle to move
not or more than three graduations. Rotate the wheel until deflection angle becomes ‘0’ degree again.
Report type: Calculation of twist per inch or cm from display counter
Inspection: Check the twist variation and take necessary action.
Machine, buildings and other facilities are subjected to deterioration due to their use and exposure to environmental condition. Process of deterioration, if unchecked, culminates in rendering these service facilities unserviceable and brings them to a standstill. In Industry, therefore has no choice but to attend them from time to time to repair and recondition them so as to elongate their life to the extent it is economically and physically possible to do so.
Objectives of Maintenance:
To keep the factory plants, equipments, machine tools in an optimum working condition.
To ensure specified accuracy to product and time schedule of delivery to customer. To keep the downtime of machines to the minimum thus to have control over the
production program. To keep the production cycle within the stipulated range. To modify the machine tools to meet the need for production
Maintenance of Machinery:
Preventive Maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time inspection / checking of facilities to uncover conditions that may lead to production break downs or harmful description.
Break Down Maintenance:
In this case, repairs are made after the equipment is out of order and it cannot perform its normal functions.
Routine Maintenance:
Maintenance
Preventive Maintenance
Break Down
ElectricalMechanicalElectrical Mechanical
Maintenance of different machines is prepared by expert engineer of maintenance department. Normally in case of dyeing machine maintenance after 30 days complete checking of different important parts are done.
Maintenance Procedure:
Normally preventive maintenance should be done. During maintenance procedure following points should be checked:
SL. No. Items need to be checked & ServicedCheck and tightening all motor terminals.Check and clean pressure sensor and tightening terminalsCheck and clean the interfacing and data cables.Check and tightening the proximity switch terminals.Inspection, cleaning and tightening all the terminals in the panel.Check and tightening limit switch, safety door guard and the emergency switch.Functional test of the fiber, sliver, roving and yarn detector.
BLOW ROOM MAINTENANCE:
At the beginning of the maintenance operation, all the covers of the machines are opened and the machine is cleaned with a cloth internally. This is called as general cleaning. Inside the machine the conveyor belt tension (if present) is checked and wooden lattice is also cleaned and conveyor belt is cleaned if needed. Jam in the two sides of spiked lattice is opened and under cover of spiked lattice is opened and cleaned. Jam in the sides of the bearing house of evener roller, cleaner roller with oils or lubricants as instructed by the manufacturer. Chain box is checked and jam is cleaned if necessary. M/c parts are checked conveniently and or changed if necessary.
MAINTENANCE FOR BLOWROOM:
Cleaning of dust and collected fly from the m/c Cleaning of motor air intake screens Cleaning of flat belts, v-belts and sprockets Cleaning the brush roller Checking the condition & tension of flat belt & chain drives. Oil change in gear motors Lubrication works of bearing of supporting shaft and tension pulley. Cleaning of fiber accumulating from the grid bars and the pins of the beaters. Cleaning of the intake grill of the fan cover of the driving motor.
MAINTENANCE FOR CARDING:
General cleaning of machinery by the operator. Checking of lube oil Checking of stop motion photo switches etc. Belt tension and condition Checking of doffer to cylinder driving gears Full setting / re-setting Checking of auto leveler.
Checking the condition of wire of cylinder-in doffer and flat combs. Checking the bearings & motor shafts Checking of trumpet, calendar roller & gears Under casings setting and checking the condition Wire replacement of cylinder, doffer & flats. Wire replacement of T-in Grinding of cylinder, doffer and flats Replacement of flat stripping comb. Flat stripping fillet and scrapper blades.
MAINTENANCE OF DRAW FRAME:
General cleaning of machine, cleaner pad by operator Cleaning of top roller cots with suitable solvent Checking the drive / motion of clearer cloth, clearer pad, positive drive comb, can
change drive. Checking the function of oil pump of outer side, gear end side, filling the oil in oil
tank. Function of stop motion limit switches etc. Greasing the top bushes having bearings Top roller cot treatment Roller gauge checking / re-setting Pressure checking / re-setting Cleaning the bottom fluted roller with wire brushes Cleaning and polishing of coiler tube and brush Tightening the loose nuts, bolts, Allan screws etc. Checking the condition of trumpets, sliver guides, air pipes, grease nipples etc. Checking of timing belt tension Checking of machine gears Checking the eccentricity of top and bottom roller (if needed)
MAINTENANCE OF LAP FORMER:
General cleaning of creel part and drafting part by the operator. Function of limit switches, photo switches etc. Top roller cot treatment / greasing Gauge checking / resetting Over hauling of pneumatic unit Cleaning and plashing of sliver table, calendar rollers etc. Cleaning of top roller bushes by spindle oil. Greasing the ball / needle bearings shell roller bearings open gear. Checking and tightening of nuts, bolt etc. Top roller cot buffing / grinding and pressure setting. Replacement of top roller cots
MAINTENANCE OF COMBER:
Cleaning of nipple jaws Cleaning and straightening of cylinder needles and top combers Topping the oil the tank Check functioning of limit switches, photo switches, stop motions etc. Top roller cots treatment greasing Gauge checking / re-setting
Greasing / lubricating the top detaching roller. Checking and tightening of nuts, bolt etc. Change of lubricating oil Top roller cot buffing / grinding Replacement of top roller cots Replacement of top comb brackets, top comb strips, brushes.
MAINTENANCE OF SPEED FRAME:
Check functioning of oil pump Checking the function of limit switches, photo switches etc Topping of oil Building motion setting
General cleaning of machine by operator –
Flyers, fly rail, bobbin rail position Creel rollers, sliver guide Drafting parts bottom fluted rollers, apron, top rollers top arm cradles. Top roller cost treatment / greasing Roller gauge checking / re-setting Bottom roller truing (if required). Centering / alignment the sliver guide, collector and condenser in relation to cot. Alignment of bottom apron tensioning pulley W.R.I knurled roller. Checking & tightening of loose nuts blots etc. Pressure checking / re-setting Top roller cot grinding Lubricating oil change Replacement of top roller cots
MAINTENANCE OF RING FRAME:
General cleaning of spindle rail drafting zone wooden clearer, jockey pulley, tin pulley knee brake etc. by operators
Function of limit switches, photo switches etc Checking of oil pump (working) Refilling of oil Tension of V-belts and spindle tapes Checking of gears & gear meshing Pneumafil pie setting and clips Inverter checking A/C (Input & Output), D.C voltage, ring data motor, sensor ring
data cable
MAINTENANCE OF WINDING MACHINE:
General cleaning of magazine peg. cone holder, conveyer belt, blow cleaner. Checking and removal of blow cleaner waste General cleaning of blower motor, filter cam shaft, motor filter control box clipper
filter. Checking of blow clearing Checking of motor ampere Measuring head checking
Al micro switch checking Gauge checking / re-setting Drum checking Checking / replacement of reversing roller gear, drum belt, tension unit. Checking / replacement of splicing Checking / replacement of all cutters i.e. tension cutter, splicing cutter etc. Spray lubricant for cutter Checking of cone sensor Spray grease for drive gear / spindle oil for cam shaft Checking of drum bearing, splicing bearing, blower shaft bearing
1 Blow Room Line – 1 & Line - 2 202 Carding DK 803 (4) & TC 06 ( 20) 103 Preparatory Section DF – 8 ,Comber – 17 , Lap Former – 4,
Simplex - 2415
4 Ring Ring Frame – 72 255 Finishing Muratec-21 20
Mounting
Mounting is done at carding machine, Mounting is a process to replacement of component from the machine when its performance is very poor cannot be increased the performance. So that component should be replaced for better performance.
Grinding is done according to the machine performance and efficiency. The maintenance department must have a grinding schedule for better performance of machine. ZuSML also follow a grinding schedule strictly.
Humidity Plant
Humidity plant is a plant which maintains the temperature. It is a machine which provides cool air or air to control the temperature. It required RH and temperature is given below.
Maintenance of m/cis very essential to prolong the m/c life and good maintenance is important consideration. It is necessary to check that all routine maintenance is being done regularly and properly otherwise efficiency of each department will be reduced.
UTILITY SERVICES
In Zubair Spinning Mill the available Utility Services are given below:
Electrical & Electronics Generator Boiler Chiller A/C Plant Compressor GENERATOR: Brand Name: WAUKESHA Country of Origin: USA Type: Gas Generator No. of Generator: 10 Capacity of each Generator: 900 KW Total Capacity: 6.18 MW Mill requirement (existing): 7 MW/day
BOILER:
Function: To produce steam Brand name: SCHNEIDER-KESSEL
Country of Origin: Germany No. of Boiler: 2 Capacity of Boiler: 2.94 ton/hr 2.94 ton/hr Steam of boiler is used for chiller.
CHILLER:
Function of chiller: To produce cool water for AC plant. No. of chiller: 5 (2 steam,3 Hot-Water) Brand name: LS (USA) Capacity Total : 1890 USRT
COMPRESSOR:
Company name: Hitachi Country of origin: Japan Compressor supplier: SAF International No. of m/c: 06 Power consumption for a compressor: 60KW/Pcs Capacity:13.6m/min Normal pressure:5.5 bar Pressure after compressed: 8.6 bar
The main function of A.C plant is to control relative humidity in different section during processing of yarn. Humidity control is very important factor for spinning. If humid is out of control then it is difficult to process the yarn various disturbances arise e.g. excessive breakage roller lapping, static electricity formation specially for polyester processing.
Manufacturer: LUWA
Set up by LUWA COMMERCIAL LTD.
NECESSARY INFORMATION:
Section Serial Number No. of A/C.Blow room A.C. No. – 1(Unit-1) 1Carding, Draw frame, comber, Lap former, Simplex.
A.C. No. – 2(Unit-2) 1
Ring frame A.C. No. – 3,4,5,6. (Unit-3) 4Finishing A.C. No. –7(Unit-4) 1
RLATIVE HUMIDITY IN DEFERENT SECTION:
RING SECTION: 53%PREPARATORY: 50%BLOW ROOM: 52%FINISHING : 60%TEMPERATURE OF DIFFERENT SECTION:
Gas Cutter machine Gas cutting, gas welding EnglandHand Grinding machine Light Grinding KoreaHand Drill Machine Light drilling China
Fire fighting
Team
ZuSML have a trained team who can straightforwardly fight against any type of fire exposure. Every one of this team is endow with a distinct costume and requisite equipment to stand before the fire hazard.
Equipment
ZuSML installed a modernized fire hydrant system covering the entire area of the factory. Fire extinguishers of CO2 and ABC gas powder are available in every section of the factory. A fire can rapidly spare in a spinning mill if it cannot be control. Cotton ignited very fast. The worker and other related person are always ready for any kind of accident with their modern equipment.
STORE AND INVENTORY CONTROL
Inventory Control:
Store is the place where every type of raw materials, spares, finished goods are kept in proper system. Inventory control means the accurate calculation and data of every type of raw materials spares and finished goods in time to time store 4 inventory control are necessary, because –
To know about the required amount of raw material To know about the job no – which would be processed To be continued the production process To find out the profit or loss of a company
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. As per requisition materials supplied & this record are noted down.
Raw cotton store:
All the raw cotton is stored in godown, near the blow room section
Spears:
In this mills required amount of spears of different machine are stored in mechanical store room. All the spears are listed in a sheet which is controlled mechanical and maintenance personal. Spears are arranged in store room according their size, quantity and requirements. There are selves in store room to keep small spear parts.
Finished goods:
ZSML supplies its finished yarn to different fabric manufacturing industry. So package yarns are stored for short time in the finishing section. All the delivered yarns are noted on tally khata according to lot no, count, quantity, buyer’s name and other technical parameter.
1. Inventory Procedure2. Store Requisition3. Store Ledger Account4. Daily Inspection & Package Report5. Monthly Stock & Consumption Report6. Monthly L/C wise Delivery Report7. Received Delivery & Balance Stock
COST ANALYSIS
Costing is the Method used by a company to fix or change their Prices with regards to costs, profit targets, the activities of competitors and perceived value of the product by customer. ZuSML spinning follows Standards cost pricing. The standards variable cost per unit is calculated by adding the total variable costs of production ( such as the cost of material, direct labor & cost of bought in component ) , and dividing the sum by the number of units produced.
According to ZuSML to calculated a standard cost price they follow the steps as below.
Calculated the standard variable cost per unit. Calculated the fixed cost per unit Determine the profit required per unit during the same period. Add the three to give a temporary price. Analyze market prices for competitive products. Adjust temporary prices as necessary to take account of market price level.
In Zubair spinning mills Ltd. the main raw material is cotton. The conversion of fiber into yarn is made in spinning department of a textile mill. Since the cost center wise computation of the cost of productions the lengthy and consuming process, presentation of such an exercise is not possible in a short training course. The board of categories of cost of spinning process is mention bellow:
Raw materials Packing materials Power and Gas Store & Gas
Salary & Wages Depreciation Other manufacturing overhead
Raw material cost:
Cotton is raw materials used in spinning mill for the production of yarns. Raw material costs constitute about 55% to 65% of total yarn costs.
A typical example of the computation of raw material cost is given bellow:
Cotton supplier name and price/Lbs. (U.S.Cents and Taka) for the year of 2009
Name of the fibre Fibre Lot Price($) Price(Tk)CIS-Uzbek 01/05(I,II) 83.70 50.22
Zubair Spinning Mills produce only Export Quality Yarn. This company does not sell yarn in local market.
Package Sticker:
Package level contain following information Yarn count. Types of yarn Code no. Lot no. Factory name. Date of making yarn. Weight in kg
Measurement of Packing Bag:
Length of Packing bag =37” Height of Packing bag =48” . Bag weight = 51.3kg A bag contains 24 cones. Each cone contains 2.04 kg yarn.
Importing country:
Raw cotton is imported mainly from Uzbek
Exporting country:
Zubair Spinning Mills Ltd. does not export yarn directly. They sell yarn to the various factory of DBL group and other export oriented factory. They make knitted garments & dyed fabric, then export final product.
Marketing strategy:
The marketing men at first analysis value of raw cotton present time & future time. If they see that it will be better to buy cotton at present time, they will contract with foreign company by L.C. immediately. Otherwise they will buy cotton in future time.
Analysis the market. Price strategy How will act the market 100% export oriented To take part on the economical condition of Bangladesh To earn foreign currency
Responsibilities & duties of sales man:
The main duty and responsibility of a sales man are-
Introductory call script Standard call script Create new customer by giving them concession To introduce into new product. To increase use procedure To protect competition To express the quality product for the customer To analysis the test of customer To bring stability of sales by following different techniques.
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 of garments marketing the dealings with the buyer is a very important factor.
Zubair Spinning Mills Ltd.Mainly senior marketing officers& higher officials deal with the buyer. There are some fixed buyers of the industry. The buyers give their orders continuously all over the year.
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
Responsibilities & duties of marketing officer:
Marketing officer is a very important parson of a company and his duty and responsibilities are-
Buying, Selling and Transportation. Financing and Packaging. Publicity and advertising. Collection of marketing information. Development of strategy for attacking & penetrating customer master list. They analysis total consumption of yarn all over the year. They produce a cost sheet of yarn. They visit different textile mills to realize total yarn required. They always look after to world market.
