Industrial Training At BEXIMCO Textiles Limited
General Information about the factory: FACTORY NAME: BEXIMCO TEXTILES LIMITED LOCATION: Beximco Industrial Park, Chokroborty, (5 km north from DEPZ) Address: Operational HQ Beximco Textiles Limited, Beximco Industrial Park, Sarabo, Kashimpur, Gazipur. Corporate HQ 17 Dhanmondi R/A, Road No. 2 Dhaka -1205, Bangladesh Phone: 880-2-8611891-5, 8618220-7 9677701-5, 7701165 E-mail: beximchq@bextex.net Web Site: www.bextex.net Sponsors: World Bank, M Arubeni CDC, DEG. Sonali Bank Local office- Motejheel C/A, Dhaka-1000. City Bank N.A. Chamber Building, 122-124, Motijheel C/A, Dhaka-1000. State Bank of India, 24-25, Dilkusha C/A, Dhaka. Standard Chatard Bank , 18-20, Motijheel C/A, Dhaka-1000.
BEX TEX PROFILE Factory
: Sarabo, Kashimpur, Gazipur.
Date of incorporation
: 30 May, 1984
Commercial production
: 1990
Business line
: Manufacturing & Marketing of high Quality fabric.
Listing status
: Public listed company
Stock Exchange listing Authorized capital in Taka Paid up capital Factory Equipment
: Dhaka & Chittagong : 3000 million Taka : 1,882.50 Million Taka :
Different types of weaving, Knitting, Dyeing, Cutting, Sewing, Finishing and Generator machines Supplied by mostly Germany, Italy, U.K, U.S.A., Japan, Taiwan etc.
Number of Shareholders
: 37,929
Number of Woven loom installed
: 293
Number of spindled installed
: 119,520
Number of Denim loom installed
: 56
Number of circular knit machine installed: 30 Production Capacity Number of employees
: 28 Million LM : 5181
Web site: www.beximco.org Owners of the mill: •
A S F Rahman Chairman.
•
Salman F Rahman Vice Chairman.
•
M A Qasem Director.
•
A B Siddiqur Rahman Director.
MANAGEMENT TEAM: •
Syed Naved Husain, Chief Executive Officer.
•
Sardar Ahmed Khan, Chief Operating Officer.
•
Ajay Pratap Singh, Chief Financial Officer.
COMPANY SECRETARY: •
Md. Asad Ullah, FCS
Mission: BEX TEX Ltd. is a full service vendor with strong vertically integrated production facilities as well as creative & analytical capabilities which clearly set us apart from most other South Asian vendors. Each of their activities must benefit and add value to the Common wealth of our Society. We firmly believe that, in the final analysis we are Accountable to each of the Constituents with whom we interact; namely: our Employees, our valued Customers, our suppliers, our business associates, our Shareholders and our fellow Citizens. Vision: • Gain market leadership in high value added apparel in USA & Europe. • Use “Innovation” & “Speed” as prime drivers, rather than cotton & cheap labor. • Dominate these markets in high quality: •
Men's, Women’s, Children dresses.
•
Shirts ( formal & Casual )
•
Blouses (formal & casual), Skirts, Jackets.
•
Jeans & Casual non - denim bottoms.
•
Knitted tops & bottoms.
LAY OUT OF BTL:
DENTI NG AND DRAW ING UNIT
DYE HOUSE
WINDING UNIT
WARPING UNIT
WEAVING UNIT Shed 3,4
SIZING UNIT WEAVING UNIT Shed 1, 2
GRAY INSPECTION ORGANIZATIONAL CHARTS: 1. Organization chart - Overall Org. chart for Bextex Ltd.:
Chief Executive
BTD
Director of Operator BTD Asst. Mgr. Sr. Exec. Factory Planning
Jr. exec. Personal Asst to Director of Operation
GM Dept Head
DGM Dept Head Weaving BTL
Dept. head Quality Assu. BTL
Dept head Admin BTL, BKL
Dept. Head Team Services BTL
Mgr. Service Assignment BTL
Mgr. Mgr. ActingActing In In chargecharge BKL Factory BDL Factory
2. Org. chart of Beximco Textile Ltd. (Fabric Preparation): Deputy General Manager WeavingManager Preparatory Manager (Sizing) Deputy Manager (Winding) Deputy Manager(Design)
Deputy Manager(Maintenance) Asst. Manager(Warping) Asst. Manager
Manpower Management: Section in charge Production Officer/ Shift in charge Technician (Mechanical / Electrical) Senior Operator Operator Helper & Mover Cleaner
Products: Yarn Products: • • • •
Count - Ranging from 6 – 120 Fiber - Cotton ( super – combed, combed, carded) CVC - 60% cotton, 40% polyester TC - 65% polyester-35% cotton; 100% polyester both regular and sewing thread Lyocell, Tencel, Modal, Rayon, Viscose etc.
Fabric products: Solid Dyed Yarn Dyed Finishing • Poplins • Ginghams • Wrinkle Free • Twills • Stripes • Easy Care • Dobbies • Fil-a-fils/End-on• Peach • Oxfords ends • Chintz • Seersuckers • Chambrays • Paper Touch • Canvas • Seersuckers • Teflon Coated • Ribstops in 100% • Pinpoint • Water Repellent Combed Cotton • Oxfords • Water Resistance • CVC and CVS/TC • Dobbies • Stretch • Plaids in 100% • Rubberized Combed Cotton • CVC and CVS/TC • Satten • Stretch •
Satten
Dobby Designs Yarn Count • Herringbones • Ranging from 7 to • Bedford 120 Cords/Coteles • Waffles and various structures in 100% Combed Cotton •
CVC and CVS/TC
Denim Products: • • • •
Chambray : In classic indigo colors ranging from 4oz to 5.5oz/Yd2 Denim (blue) : In classic indigo colors ranging from 4oz to 15oz/ Yd2 Denim (black) : In sulfur black color ranging from 4oz to 15oz/ Yd2 Colored Denim : In a variety of colors - both in sulfur & reactive dyes(warp dyed)
• •
Over dyed Denim : In a variety of colors on indigo blue & sulfur black Stretch Denim : In classic indigo colors ranging from 4.5 oz to 13.75 oz/Yd2
• • • • • •
Honorable Buyers: • • • •
• •
Calvin Klein J.C Penny Long Street Rocha Wear VAN Heusen Zara
Arizona H&M Levis Tom Tailor Next Antigua
WOVEN FABRIC LOOMS: No. of looms installed: 299 No. of looms actually operated: 299 Output capacity (Lm.): Installed capacity: 40,800,000 Lm Actual production: 34,966,037 Lm Process Flow Chart: Ring Bobbin Winding (cone / cheese)
Warp Preparation Warping
Direct
Sectional Sizing
Drawing & Denting Weaving Fabric Inspection Dye House Final Inspection
Weft Preparation
Folding Packing Delivery WINDING: Definition: winding is a process of wounding of yarn to form yarn packages. Types of winding: there are two types of windingTypes of Winding
Brand Name
Soft Winding
FADIS Winder HARISH Winder RJK Winder
Hard Winding
Country of No of Speed origin M/C Switzerland 2 650m/min Switzerland
1
650m/min
India
2
650m/min
Textool Winder RJK Winder
Switzerland
10
650m/min
India
2
650m/min
HARISH Winder KAMITSU Winder
Switzerland
3
650m/min
Japan
4
650m/min
24 1. Soft Winding 2. Hard Winding. Machine Specification:
Key Accessories: Cone diameter gauge. Chemical Used: Paraffin wax (rarely used). WARPING:
Definition: To convert supply yarn package or reprocessed cone into a sheet of yarn comprising of predetermined number, length and tension. Types of Warping: 1. Direct Warping: for solid dyed grey production. 2. Sectional Warping: for yarn dyed grey production. COUNT(Ne) Types of Warping 16Brand Name
Direct Warping
TENSION(CN)
20
27 Country 22 Origin
30KAWAMOTO
15 Japan
40
11
of No of Creel M/C Capacity
Speed
2
550
550m/min
45BENINGER (ZC10 Switzerland 50R-1800) 09
2
640
600m/min
07 Switzerland Sectional Warping 60BENINGER Supertronic-2200
3
720
600m/min
Machine Specification: Count wise Creel Tension in BENINGER:
Figure: Warping Section Sectional Warping Calculation: Warp Width × Ends/Section Width (mm) = Total no of ends Total no of ends Ends/cm = Warp Width (cm)
dtex× Total no of ends × Cone figure Feed 1 = 10 × Warp Width (mm) × Density Dtex = Grams/10000 m Yarn Density = Grams/dm3 Cone Figure = 5 SIZING: Definition: the process by which warp yarn is chemically treated for strengthening, reducing hairiness and to make more flexible. Machine Specification:
Brand Name
Country of origin
No of Size Bath
BENINGER Zell
Switzerland
1
Beam Capacity 20
BENINGER Zell
Switzerland
2
20
KAWAMOTO
Japan
1
16
Creel
Chemical Used for Sizing: • Adhesive Material: modified starch, synthetic chemicals e.g. Kollotex 5, Avetex K. • Chemicals: Quicksolon SPR. • Acrylic Sizing Agent: e.g. size CA20. • Lubricants Softener: Solwax -50, Mutton Tallow. Size Recipe for Grey Yarn: H2O = 400L Starch = 50 kg PVA (SPR) = 32 kg Acrylic (Trisize) = 15 kg Soul Wax = 5 kg Size Recipe for Dyed Yarn: H2O = 490L Starch = 50 kg PVA (SPR) = 25 kg Acrylic (Trisize) = 12 kg Soul Wax = 5 kg • • •
Size Box Temperature = 85°c Cylinder Dryer Temperature = 125°c Refractrometer is used to check the dispersion of size materials.
Squeezimg Roller Emersion Roller
Figure: Size Bath
Figure: Sized Beam
Chart for different parameters used in sizing for different construction:
M/C no
Total Ends
Construction
Refrectromete r%
Pick Up %
Moist ure %
Spee d
Warp Tensio nN
Size Tension N
Strec h%
2
8450
12
17.5
6.0
40
4200
4190
0.98
1
7080
40×40/133×10 0 40×40/20×70
12
16.8
6.0
38
2658
2630
1.0
2
8450
40×40/130×90
12
16.2
6.0
40
4200
4192
0.98
1
7080
40×40/130×90
12
16.2
6.0
38
1961
1940
0.98
1
7080
40×40/130×90
12
16.2
6.0
38
1961
1936
0.98
2
8450
40×40/130×90
12
15.8
6.0
38
4114
4108
0.98
2
5900
20×16/100×80
10
14.1
6.5
30
3923
3906
1.0
Weaving: Definition: The process of interlacement of two sets of yarn named warp & weft by the means of weaving machine or loom to produce woven fabric is called weaving. Machine Specification: Model
Shedding Device
Toyoda, JAT Negative 600RS190 cam shedding Toyoda, JAT Negative 600RS190 cam shedding Toyoda, JAT Electronic 600RS190 Dobby Toyoda, JAT Electronic 600RS190 Dobby Toyoda, JAT Electronic 610RS190 Dobby Toyoda, JAT Negative 610RS190 cam shedding Toyoda, JAT Negative 610RS190 cam shedding Toyoda, JAT Twin Beam
Weft insertion capacity 2
No of Maximum loom RPM
Country of origin
82
720
Japan
4
30
720
Japan
2
16
620
Japan
6
16
620
Japan
4
4
620
Japan
4
98
720
Japan
6
36
720
Japan
4
10
720
Japan
610RS190 Toyoda, JAT 710 Eurotech
Positive cam shedding
4
7
299 Lay out plan of Weaving Section:
Figure: Evacuation plan of loom shed 1, 2
1200
Japan
Figure: Evacuation plan of loom shed 3,4
Figure: Loom Shed
Figure: Toyoda, JAT 600RS190
Figure: Toyoda, JAT 710 Eurotech Chart for loom stops, production, RPM and efficiency in A shift for different looms (5) which are run by a operator: Loom No 230:
Construction 40×322 / 120×70
Causes stoppages Warp Miss
of Times
min
Production
Efficiency %
RPM
12
52
25.5 m
29.3
496
WF1 Miss (1)
4
6
WF1 Miss (2)
12
19
WF2 Miss (1)
0
0
WF2 Miss (2)
6
89
Manual Stops
4
54
Others
1
0
Loom No 231: Construction 40×(40+40)/120×70
of Times
min
Production
Efficiency %
RPM
13
132
26 m
39.4
394
WF1 Miss (1)
0
0
WF1 Miss (2)
2
16
WF2 Miss (1)
1
9
WF2 Miss (2)
0
0
Manual Stops
0
0
Others
1
5
Causes stoppages Warp Miss
Loom No 232: Construction 40×40 / 120×70
of Times
min
Production m
Efficiency %
RPM
15
98
20.2 m
29.2
495
WF1 Miss (1)
9
16
WF1 Miss (2)
2
5
WF2 Miss (1)
22
47
WF2 Miss (2)
1
1
Manual Stops
4
51
Others
0
0
Causes stoppages Warp Miss
Loom No 233: Construction 40×40 / 180×80
of Times
min
Production
Efficiency %
RPM
25
130
24 m
55.7
355
WF1 Miss (1)
3
4
WF1 Miss (2)
0
0
Causes stoppages Warp Miss
WF2 Miss (1)
4
11
WF2 Miss (2)
0
0
Manual Stops
2
2
Others
0
0
Loom No 234: Construction
of Times
min
Production
Efficiency %
RPM
21
160
33.8 m
48.0
512
WF1 Miss (1)
1
0
WF1 Miss (2)
1
0
WF2 Miss (1)
3
3
WF2 Miss (2)
0
0
Manual Stops
0
0
Others
0
0
Causes stoppages Warp Miss
40×40 / 110×70
Quality Management System: Grey yarn test report: Date: 25-06-2010 Count: 45/1, CVC Lot no: 33/10 Property Tenacity (CN/Tex) CV% of tenacity Elongation (%) CV% of Elongation Max value Min value
Cone :1 18.01
Cone:2 17.95
Cone:3 18.17
Cone:4 18.34
9.03 5.18 11.63
8.70 5.82 9.99
10.76 5.74 10.91
8.62 5.31 12.18
20.84 14.67
22.82 13.91
22.54 14.21
21.52 14.04
Total test: 4/2000 MTR
Overall results: Tenacity (CN/Tex) =18.12 CV% of Tenacity =9.29 Elongation (%) =5.51 CV % of elongation =12.13 USTER TESTER: Test no 1/1
Thick place (+35%) 333
Thick place (+50%) 65
Thick place (+70%) 10
Neps (+140% ) 322
Neps (+200% ) 125
Neps (+400% ) 12
Hairines s (-) 3.86
Thin place(30%) 907
Thin place(40%) 122
Thin place(50%) 10
1/2
269
48
10
273
99
12
3.79
917
115
5
1/3
250
47
9
258
108
8
3.91
785
119
4
1/4
227
35
2
269
87
4
3.86
769
112
8
Grey yarn test report: Date: 10-06-10 Count: 40/1, cotton Lot no: 08/10 Property Tenacity (CN/Tex) CV% of tenacity Elongation (%) CV% of Elongation Max value Min value
Cone :1 19.90
Cone:2 19.27
Cone:3 19.42
Cone:4 19.87
8.02 6.04 7.02
8.20 5.99 7.43
7.74 6.01 7.11
6.79 6.12 6.09
23.51 14.85
22.95 14.14
22.45 15.86
23.20 17.37
Total test: 4/2000 MTR Overall results: Tenacity (CN/Tex) =19.61 CV% of Tenacity =7.77 Elongation (%) =6.04 CV % of elongation =6.92 USTER TESTER:
Test no
Thick place (+35%)
Thick place (+50%)
Thick place (+70%)
Neps (+140 %)
Neps (+200 %)
Neps (+400%)
Hairine ss (-)
Thin place(30%)
Thin place(40%)
Thin place(50%)
1/1
116
23
6
192
53
3
4.08
360
31
0
1/2
204
35
8
408
123
4
4.09
593
39
0
Grey yarn test report: Date: 06-02-10 Count: 20/1 card Lot no: 08/10 Property Tenacity (CN/Tex) CV% of tenacity Elongation (%) CV% of Elongation Max value Min value
Cone :1 18.53
Cone:2 18.46
Cone:3 17.50
Cone:4 18.18
6.23 5.50 7.91
6.71 5.54 5.81
7.42 5.41 9.64
6.87 5.61 6.31
20.56 16.54
20.84 15.17
22.03 14.05
20.84 15.92
Total test: 4/2000 MTR Overall results: Tenacity (CN/Tex) =18.17 CV% of Tenacity =6.80 Elongation (%) =5.51 CV % of elongation =7.59 USTER TESTER: Test no 1/1
Thick place (+35%) 201
Thick place (+50%) 36
Thick place (+70%) 5
Neps (+140% ) 332
Neps (+200 %) 82
Neps (+400 %) 7
Hairine ss (-) 2.80
Thin place(30%) 332
Thin place(40%) 13
Thin place(50%) 0
1/2
207
41
7
388
104
5
3.26
493
29
0
1/3
181
24
5
335
88
6
3.22
371
14
0
1/4
147
26
6
315
99
0
3.13
430
27
1
Grey yarn test report: Date: 16-03-10 Count: 30/1, card Lot no: 20/10 Property Tenacity (CN/Tex) CV% of tenacity Elongation (%) CV% of Elongation Max value Min value
Cone :1 17.18
Cone:2 17.57
Cone:3 17.12
Cone:4 17.02
7.55 4.03 9.34
8.22 4.95 9.11
8.80 4.20 9.06
8.28 4.96 9.55
19.80 13.84
21.81 13.59
19.98 13.73
22.04 13.50
Total test: 4/2000 MTR Overall results: Tenacity (CN/Tex) =17.22 CV% of Tenacity =8.21 Elongation (%) =4.53 CV % of elongation =9.26 USTER TESTER: Test no 1/1
Thick place (+35%) 475
Thick place (+50%) 103
Thick place (+70%) 10
Neps (+140 %) 891
Neps (+200 %) 217
Neps (+400 %) 4
Hairine ss (-) 4.84
Thin place(30%) 850
Thin place(40%) 74
Thin place(50%) 2
1/2
415
77
16
851
217
14
4.74
835
71
2
1/3
430
88
9
763
171
3
5.22
875
79
1
1/4
417
89
15
752
182
2
5.09
820
72
0
Grey yarn test report: Date: 07-03-10 Count: 60/1 comb Lot no: 6060c/10
Property Tenacity (CN/Tex) CV% of tenacity Elongation (%) CV% of Elongation Max value Min value
Cone :1 27.09
Cone:2 26.48
Cone:3 26.98
Cone:4 26.34
8.04 4.43 8.20
8.78 4.55 8.18
8.49 4.40 9.49
7.61 4.52 9.72
34.16 19.85
30.30 19.32
32.57 18.48
29.85 23.03
Total test: 4/2000 MTR Overall results: Tenacity (CN/Tex) =26.72 CV% of Tenacity =8.23 Elongation (%) =4.47 CV % of elongation =8.89 USTER TESTER: Test no 1/1
Thick place (+35%) 150
Thick place (+50%) 8
Thick place (+70%) 1
Neps (+140% ) 226
Neps (+200 %) 35
Neps (+400 %) 1
Hairine ss (-) 2.85
Thin place(30%) 826
Thin place(40%) 100
Thin place(50%) 6
1/2
151
15
1
221
34
1
2.19
774
93
8
1/3
132
12
1
248
49
0
2.18
794
95
3
1/4
159
16
0
303
68
3
2.91
947
168
7
Quality assurance system Quality assurance procedure may be divided into two major parts: 1. On line quality control. 2. Off line quality control.
On Line Quality Control: On line quality control is done at different stages, such as : Winding: Soft or hard package. Warping: Color pattern, width of repeat, section repeat. Sizing: pick up %, size paste quality check Weaving: Dropper check, loose warp check, reed mark, wrong denting etc.
Off Line Quality Control: Sample collection: One meter sample of every order is collected by online inspector. Every sample is clearly identified with a sticker. QC department checks the fabric in the loom and at that time the loom remains stops. He ensure the quality parameter such as free of hole or spot, reed mark, repeat size, width of fabric etc. TEST PROCEDURE Fabric weight (G.S.M): The procedure for fabric weight test of finished fabric: - M/C used: G.S.M. cutter. -Frequency: Every order. -Procedure: 3 samples pieces are cut with G.S.M. cutter. Find their average wt. Gram per square meter (GSM) = Average wt*100 Ounce per square meter (oz/yd2)=G.S.M.*0.0296 -Performance STD: According to buyer’s given std. -In case of non-conformity: To increase G.S.M.: Reduce width mechanically. To decrease G.S.M: Increase width mechanically
Width Test: Machine used : Measuring tape. Frequency : Every order & after every finishing process. Procedure : Manual measurement by tape. Overall width : Total width. Useable width : Width without selvedge. Pref. Std. : 150+2 cm or specified by the customer. In case of non-conformity: Re-finish. Tensile strength: M/C used : Alphateus Tensile Tester. Frequency : Every order. Procedure : According to customers requirements. In case of non-conformity: To increase tensile strength reMercerize (increase of 5-10%) and re-finish. Tear strength: M/C used : Element Tearing Tester. Manufacture : Messmer Instruments Ltd. Frequency : Every order (only for 100% cotton light fabric). Procedure : According to customers requirements. In case of non-conformity: To increase tearing strength re-mercerize & re-finish. Pilling Resistance: M/C used Manufacturer
: ICI Pilling box. : James H. Heals.
Frequency : Whenever required. Procedure : BS 5811(36000 rear) ASTM D 3512. Performance std : Grade 4; Grade 3(For each fabric). In case of non-conformity: Re-singeing followed by resin finish. Fabric inspection: It is the responsibility of both the textile supplier and garment manufacturer to inspect all textiles to ensure their compliance with the buyer standard. Textile which are being exported to another country for use in the assembly of a finished product are required to be inspected by the buyer’s designed inspection service prior to shipment. It is the sole responsibility of the textile supplier to ensure that the textiles are inspected prior to shipment. For textiles which are to be assembled in the country of textile origin, inspection is required only if requested by the buyer. Once requested it is the responsibility of the textile supplier to ensure that the textiles are inspected prior to shipment. The fabric control service will be divided in the following subgroups: A. Pre-control: “feel” examination, appearance, verification of any unpleasant odorous, colors, shades, weight, listing and ending; verification of dye uniformity between center and selvedge by means of a special fabric strip “sleeve” and dimensional checking by means of a steam test, production of the shade continuity cards. B. Control: All textile inspections will be conducted in accordance with the 4 point system. The control consists in checking of fabrics on appropriate machines, permitting complete tension free sliding and measuring of the fabric. The pieces will always be processed in rolls or humpback, never folded in order to avoid permanent creases in the fabric. Tension free measuring will be carried out electronically with or without metric labeling on the selvedge and the accuracy will be guaranteed with a maximum approximation of 0.5%. Measuring will be expressed in yards. References for pattern and finishing will be certified by a fabric swatch indicated by the Garment conductor, colors by colors chart/shade chart. This sample will be reference sample taken from the first delivery of the production or a sample taken from a sample piece. Sample dimensions will be such as to permit verification of all characteristics, pattern, colors, etc. of the fabric to be inspected. TEXTILE SPECIFICATIONS AND EVALUATION All textile inspections will be conducted in accordance with the Four Point System. The Four Point System derives its name from the basic grading rules: 1. 2.
No more than four penalty points may be assigned for any single defect. No more than four penalty points may be assigned to one linear yard, regardless of number of defects within that one yard.
Penalty point evaluation
Defects in both the warp/weft direction will be assigned points using the following criteria: 1 point 2 points
-Defects size not exceeding 3” -Defects size exceeding 3” but not exceeding 6”
the
3 points 4 points
-Defects size exceeding 6” but not exceeding 9” -Defects size exceeding 9”
•
A continuous defect running (9”) or longer shall be assigned four points for each yard in which it occurs within the shipment. • For continuous defects such as side to side shading, side-center-side shading, end to end shading, off shade, no penalty points shall be assigned. However, the entire roll shall be graded as “Second Quality” whole lot cannot be shipped. The following fabric penalty point grading standards are to be used when inspecting all textiles. The standards are intended to be comprehensive; rise to occasion, whenever a specific fabric condition is mot described. When this occurs, the shipment will be aborted if the inspection was failed, and the inspection service will contact the garment contractor/supplier for disposition. Running Defect: •
Any defects found to repeat and/ or run in a continuous manner will constitute a running defect. Any running defect will be assigned four penalty points for each yard in which the defect occurs. For a roll containing more than five continuous yards per100 linear yards with running defects, the whole roll will be graded as second quality and cannot be shipped.
Full width defects: • •
Any roll that contains more than six full width defects per 100 linear yards shall be graded as second quality and cannot be shipped. No roll will be accepted as an A grade roll which contains a full width defect in the first or last three yards. This roll will be graded as B grade.
• No roll will be accepted as first quality where baggy cloth occurs. A roll which exhibits a noticeable degree of looseness (waviness) or tightness along either or both selvedge or ripples, puckers, folds, creases in the body of the fabric and would prevent the fabric from lying flat when being spread in a conventional manner. This roll will be graded as second quality and cannot be shipped. HOLES AND DROPPED STITCHES •
A hole consists of two or more broken yarns and is considered to be a defect. A hole or a dropped stitch, regardless of size will be penalized maximum of 4 points.
Roll length verification: •
Any roll of less than 30 yards in length shall be graded as second quality and cannot be shipped. The roll ticket length will be verified during the inspection
Points Calculation: Textiles are evaluated on square yard consumption. The formula used to determine the point count level of a roll of fabric is as follows: 1. Individual piece:
Points per linear yard ×36”×100 square yard
Cuttable width in inches ×inspected yard =Points for 100 square yards Total points per linear yard × 36”×100 sqr yard 2. Average Shipment piece: Total inspected yards × average cuttable width =Average points per 100 square yard per shipment •
The average point value per shipment should not exceed 20 points per 100 square yards and not contain any second quality / rejected roll.
•
A grade acceptance- Individual roll within 25 points per 100 square yards.
•
B grade acceptance- Individual roll within 26-30 points per 100 square yards.
•
Second quality /Rejected-Individual roll with in 25points per 100 square yards.
•
Maximum 20% of “B” grade fabric yards are allowed with in a shipment.
Maintenance Maintenance is a process by which equipment is looked after in such a way that trouble free. Service and increased machine life can be ensured and specific product quality required by the customers is sustained. On time maintenance increase m/c lifetime & ensures trouble free services.
MAINTENANCE OF MACHINERY:
Maintenance
Preventive Maintenance
Mechanical Maintenance
Electrical Maintenance
Break Down Maintenance
Mechanical Maintenance
Electrical Maintenance
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 can not perform its normal functions. Routine Maintenance: Maintenance of different machines is prepared by expert engineer of maintenance department. Normally in case of dyeing m/c maintenance after 30 days complete checking of different important parts are done. MAINTENANCE TOOLS & EQUIPMENTS: 1. Socket/ Spanner /Impact socket sets: Suitable for driving metric/AF, BSW,BSFand BA hexagonal nut/BOH. 2. Table / Drill vice: Ideal for small drilling task. 3. Screw driver: Ideal for service / repairing loss. 4. Circlip pliers: Opening & setting of circlip. 5. Pliers & cutters. 6. Centre punch: With knurnled grip & squire head with 60* gasket point . Used for well defined impression for cutting / drilling etc. 7. Pipe cutter : Used for steel conduct, copper brass or aluminium. 8. Nose pliers. 9. File set: Squire, half round, three square, round, flat. 10. Hammer: Ball point, soft faced etc. 11. Hexagon keys: Short age “L” shaped key, long arm “L” shaped. 12. Hole punch. 13. Hack-saw. 14. Adjustable wrench. 15. Single end spanner. 16. Riveters. 17. Puller. 18. Ranching ring. 19. Torque wrench. 20. Tri-squire. 21. Measuring tape. 22. Spirit level. 23. Thread gauge. 24. Deep gauge. 25. Wire gauge. REMARKS: Maintenance of machines is very essential to prolong the m/c life and good maintenance is important consideration. In this industry maintenance program is done by expert maintenance team. So production is stopped due to m/c problem for a short time. Utility Department Generator:
Brand name : Watsila Origin : France System : PLC control Capacity : 1 MW each No of cylinder : 16 Generator type : Gas generator (1% gas: 11.5% air) No of generator :9 Overall efficiency : 80 % Stand by diesel generator which capacity is 750 KW and also two gas turbine which production capacity is 9 MW used for other project in bex- tex ltd . Maintenance: # After 750 hours Lube oil is changed, and 40 grade oil is used for this purpose. # Clean the spark plug after 2000 hour. # Tappet clearance after 750 hour. Oil category: Company: Mobile Name : Pagases 805 Compressor: No. of compressor Type Model Origin Capacity .
Pressure
: 10 : Screw type rotary compressor Oil free (6) ,oil injected (4) : Atlas (oil free), Fini , ELGI . : Belgium (oil free), Italy (atlas), India : 46.5 m3/min (6) 13.7m3/min (1) 9.6m3 /min (1) 6.4m3 /min (1) 14.7m3 / min (1) , total = 323.4 m3 / min : 7.5 bar
Oil category Speed
: lube oil (mineral oil) : 1450 rpm
BOILER: Type: Horizontal fire tube boiler Manufacturer: Thermex Origin: India Fuel : Gas Maximum pressure: 10 bar Working pressure : 9 bar Heating surface : 3315 square feet. Chiller: Brand name Origin Capacity System Chemical
: Thermex : India : 210(3) ton+500(1)ton ,total=1130 ton : vapor absorption system : Hydro chem.+ steam, Lithium Bromide , Lithium ethanol, octail alcohol .
No of machine : 04 Humidification: Relative humidification depends on : Motor condition Room temperature Due point Return fan. The Effluent Treatment Plant (ETP): The effluent generated from different sections of a textile mill must be treated before they are discharged to environment. Various chemicals & physical means are introduced for this purpose. The effluent treatment plant in Beximco is chemical biological combination process developed by India. Flowchart of effluent treatment: Raw effluent ↓ Skin Chamber ↓ Collection Sump ↓ Dissolved air floatation tank ↓ Clarifier ↓ Aeration tank ↓ Setting tank ↓ Clear water,pH check ↓ Carbon filter ↓ Drain