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One Composite Mills Pvt Ltd (Wet Processing Technology) Introduction The purpose of this report is to aware the viewer about the technical processes that takes place in a mill. Technical education, practical experience is almost equally necessary in association with the theoretical knowledge. The industrial attachment is the most effective process of achieving the practical experience. It provides us sufficient practical knowledge about production management, productivity, evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory control, purchasing, utilities and Maintenance of machinery and their operation technique etc. ONE COMPOSITE MILLS LTD. is a well established knit composite industry. The industry stands on industrial area of Gazipur. ONE COMPOSITE MILLS LTD. Is a Group of Companies, ONE SP1NNING,ONE DENIM. ONE GROUP LTD. is going to prove its own standard about product quality in world market as they know that their reputation depends on its quality. ONE GROUP LTD. is a profitable project and contributes the economy of our country. OBJECTIVE OF INDUSTRIAL ATTACHMENT Physical infrastructure: The mill is built in such a way that there is possibility for further expansion of the mill. The structure such as mill, office buildings, record rooms, guardrooms & dining room etc. are made of solid hard concrete & brick . The whole area is surrounded by safety brick wall .The main set up for are built of corrugated iron & iron sheet, transparent hard plastics with enough ventilation & scope for passing light & air. Management System: • • • •

Intercom telephone Fax Written letters & Oral

Shift Change: There are three shifts in the industry. So the shifts are changed at every 8 hours. Shift Change! for worker of Security: A Shift — 06:00 — 14:00 B Shift — 14:00 — 22:00 C Shift—22:00—06:00 General shift: 09:00— 18:00


Office Time 09:00 — 18:00 Responsibilities of Production Officer: 1. To give dyeing program slip. 2. To match production sample with target shade. 3. To collect production sample for sample matching next production. 4. To observe dyed fabric during finishing running & also after finishing. S. To identify disputed fabrics & report to P.M/G.M for necessary actions. 6. To discuss with P.M. about overall production if necessary. 7. To sign the store requisition & delivery Chillan in the absence of P.M. 8. Also to execute overall floor works. 9. To maintain loading/unloading khata. 10.Any other assignment given by higher authority. Job Description of P.O & S.P.O: Job title: Production officer & Senior Production officer Report to: Production Manager Purpose: To control shift accoTding to the plan made by the production manager Territory:Dyeing section (major) Batching and Finishing section (minor) ~~ure and Scope: Role within the organization: Responsible for own shift production with good quality and minimum time. Environment: Production officer has to work under huge stress. He has to work in acute heat under physical and mental pressure. Also he has to work in acute heat all the year round. Job Description of Production Officer: Report To: Sr. production officer Job Summary: To plan, execute & follows up the production activities & control the quality production with related activities. Duties & Responsibilities:  Overall supervision of dyeing, finishing production.  Batch preparation & PH check.


    

Dyes & chemical requisition issue & check. Write fabrics loading & loading time from mlc. Program making, sample checking, color management. Control the supervisors, operator, asst. operator & helpers of dyeing milk. And also any other work as & when required by the management.

Job Description of Sr. Production Officer: Report To: P.M (production) Job Summary: To plan, execute & follows up the production activities & control the quality production with related activities. Duties & Responsibilities:      

Overall supervision of dyeing, fmishing production. Checks the different log books of different areas & report to management. Checks the sensitive parameters of different machine for smooth dyeing. Checks out the plan to control the best output from supervisor & workers. To trained up & motive the subordinates how to improve the quality production. Maintenance of machine & equipment. Any other works & when required by the management.  Control the supervisors, operator, asst. operator & helpers of dyeing mlc. REMARKS: The manpower management system ONE GROUP LTD. is well arranged. Every officers & stuffs are responsible for their duty. But there are only six textile engineers in the industry (2 for dyeing, Finishing). It is sufficient for fluent production. The efficiency of the worker should be increased for more quality production. Knitting Knitting section is divided in 1ou.r sections, 1. Inspection section 2. Circular Knitting section 3. Store section 1. Cloth Inspection Section: In cloth inspection section two machines are available. Specification of those machines is given below. Type Cloth Inspection Machine Manufacturer name Uzu fabric Inspection Country Thailand Model No. UZ 900.31


2.

Circular Knitting Section:

This section contains 13 circular knitting machines. Circular knitting machines are of different types, made by same manufacturer. In this section body fabric for knitted garments is produced. The different specifications of different machines are given one after another. Knitting Machine Machine no: 01 Machine no: 2 Machine type: Single jersey Machine type: Single jersey Brand: Brand: Mayer & Cie Origin: Mayer & Cie Origin: Germany Germany Machine dia &Gauge: 30”; 24G Machine dia &Gauge: 26”; 24G Extra cylinder: 30”; 20G Noofneedle: 1932 No of needle: 1860 No of feeder: 78 No of feeder: 90 Machine no: 03 Machine type: Single jersey Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 26”; 24G No of needle: 1932 No of feeder: 78

Machine no: 04 Machine type: Single jersey Brand: Origin: Kobe, Japan Machine dia &Gauge: 30”; 24G Extra cylinder: No of needle: 2268 No of feeder: 90

Machine no: 05 Machine type: Single jersey Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 36”; 24G No of needle: 2712 No of feeder: 108

Machine no:6 Machine type: Rib Brand: Mayer & dc Origin: Germany Machine dia &Gauge:34”; 1 8G No of needle: 3840

Machine no: 7 Machine type: Interlock Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 30”; 24G No of needle:4 128 No of feeder: 90

Machine no: 8 Machine type: Interlock Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 30”; 24G No of needle:4 128 No of feeder: 90

Machine no:9

Machine no: 10


Machine type: Flece Brand: Mayer & Cie Origin: Germany / Machine dia &Gauge: 30”; 24G No of needle:4128 No of feeder: 90

Machine type: Fleece Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 30”; 24G No of needle:4 128 No of feeder: 90

Machine no: 11 Machine type: Rib Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 34”; 18 G No of needle:3840 No of feeder: 90

Machine no: 12 Machine type: Auto strip Brand: Mayer & Cie Origin: Germany Machine dia &Gauge: 30”; 24G No of needle:2208

No of Machine for Dyeing and Finishing Section:

DYEING SECTION: Dyeing Machincthies-O1 Type Jet Dyeing Machine Manufacturer name Country Germany Model No. ECO-38-2T Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity

Thies 2002 0°-140°C Water, Steam, Electricity, Compressed Air 7 10 KG

Dyeing Machine.02 Type Jet Dyeing Machine Manufacturer name Country Germany Model No. ECO-38-2T Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

This 2002 0°-140°C Water, Steam, Electricity, Compressed Air 7 10 KG I

Dyeing Machine.03 Type

Jet Dyeing Machine


Manufacturer name Country Model No. Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

Thies Germany ECO-38-2T 2002 0°-140°C Water, Steam, Electricity, Compressed Air 7 30 KG 1

Dyeing Machine. 04 Type Manufacturer name Country Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

Jet Dyeing Machine Thies Germany 2000 0°-140°C Water, Steam, Electricity, Compressed Air 7 250 KG 1

Dyeing Machine.05 Type Manufacturer name Country Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

Jet Dyeing Machine Thies Germany 2000 0°-140°C Water, Steam, Electricity, Compressed Air 7 350 KG 2

DYEING SECTION:06 Type Jet Dyeing Machine Manufacturer name Country Germany Model No. ECO-38-2T Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity

Thies 2002 0°-140°C Water, Steam, Electricity, Compressed Air 7 10 KG


Dyeing Machine. Thies-07 Type Manufacturer name Country Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

Jet Dyeing Machine THIES Germany 2002 0°-140°C Water, Steam, Electricity, Compressed Air 9 500 KG 2

Dyeing Machine. Thies-08 Type Manufacturer name Country Year of manufacturing Temp. Range Used Utilities No. of Motor Production Capacity No. of Nozzle

Jet Dyeing Machine THIES Germany 2000 0°-140°C Water, Steam, Electricity, Compressed Air 7 750 KG. 3

FINISHING SECTION: Finishing: Textile finishing, in a restricted sense, is the term used for a series of processes to which all bleached, dyed, printed and certain grey fabrics are subjected before they are put on the market. In fact, finishing includes the final treatment of every kind of fabric made from every kind of fiber. Objective of finishing:  Improving the appearance — Lecture, whiteness, etc.  Improving the feel, which depends on the handle of the material and its softness, suppleness, fullness, etc.  Wearing qualities, non — soiling, ant crease, antis rink, 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. 2. 3. 4.

Chemical finishing: Chemical reaction of auxiliaries with fibers. Application of the handle modifying products I additives. Mechanical finishing:         

Mechanical treatment with machines. Finishing effects: Easy—care Crease recovery. Dimensional stability. Good abrasion resistance. Improved tear strength. Good sew ability. Soft or stiff handle. Shine or luster

Raw Material for Knitting The raw material for knitting is the yarn. Different types of yarn of wide range of count are used. In yarn store section we had the chance to know about different yarns of different count used in ONE COMPOSITE MILLS LTD . We also have known different yarn manufacturer/suppliers name for this knitting section i.e. sources of yarn. Both carded and combed yarn is used for knitting. Generally used yarn and their count: Cotton 24.s, 26S 28~, 3çjS 32S 34S Polyester75D, 100D Spandex yarn Grey Mélange (C_ Ecru Mélange (C-85% V-15%) Anthra Mélange (C-65% V-35%) PC (65%Polyester & 35% cotton) CVC 24s, 25S 28S .30S

20D,40D, 70D 24s, 26S 24S 26s~, 28s 24S 26S 28S 24S 26S 28S 30S

Count 24S

Tyep carded

Composition 100%

30S

Carded Combed Combed

100%

40S 100D 75 D 28/

Polyester Polyester cbac

Price/ Kg 140/140/170/180/150/=


Raw Material for Dyeing

ONE COMPOSITS MILLS LTD. is a knit composite textile industry. In the industry the raw materials used for production are: 1. Grey fabrics 2. Dyes 3. Chemicals. 1. Grey Fabrics: Following types of gray fabrics are dyed:  Single jersey  Single jersey with lycra  Polo pique  Single lacoste  Fleece  Interlock  Interlock with lycra  Rib  Rib with lycra  1X1 rib  2X2 rib  Different types of collar & cuff 2. Chemicals: List of Chemicals Used In ONE COMPOSTT MILLS Ltd. Acid 1. Acetic Acid 2. Hydrochloric Acid Detergent 1. FelosanNOF Washing Agent 1. CibaponR Levelling Agent 1. Cibacel DBC Sequestering Agent 1. Invatex CS SALT 1. Gluber Salt 2. Common Salt Whitening Agent 1. UvitexBAM


2. Uvitex BHV 3. Hostalux ETBN (For polyester fabric) 4. BlutonBBV Softener

5.

1. Alkamine CWS 2. SapamineFPG 3. Sapamine 544 4. Magasoft TET Megasoft FMG (For White Fabric)

Fixing Agent 1. Reducing Agent 1.

Sandofix BC Hydrose

Bleaching Agent 1. H2O2 Enzyme 1. Bioace 2. Tinozyme 44L Stabilizer 1. Tinoclarite CBB Anticreasing Agent 1. CibafuidC PH Controller 1. Acid 2. Neutracid RBT (Non volatile) 3. Soda Ash 4. Caustic Per-oxide Killer 1. Invatex PC Source: Dyeing department of ONE COMPOSITE MILLS LTD. receive grey fabric from knitting department of this company. According to buyer order, store officer receive the grey fabric and he maintains the delivery of finished fabric. Source of the Dyes of ONE COMPOSITE MILLS LTD. are Swiss Color, Dyestar, Bezema, Clariant, Impo color etc. Annual Requirements,: To determine annual requirements is very tuff It mainly depends on the buyer order and subcontract order. When the buyer order is large then the consumption is high and vice-versa. The annual requirements of grey fabric depend on the buyer order and the requirements of dyes and chemicals depend on the colour depth. Remarks: For smooth running of a factory uninterrupted supply of raw materials is very


essential. As far as we saw the raw material control of ONE COMPOSITE MILLS LTD. is good. Sequence of Operation for Knit Dyeing: Grey fabric inspection Batching Fabric turning Loading to the mlc Pre-treatment (Scouring & Bleaching) Dyeing Dewatering Drying Compacting & Calendaring Final inspection & packing Production Parameters: 1) P11 - During H202 bleaching pH 9.2-12 - During reactive dyeing pH 10.5-12.5 - During disperse dyeing pH 4.5-6.0 1) Temperature: For cotton scouring: 90°-95°C -For cotton cold wash: 30°-40°C -For cotton hot wash: 70°-80°C -For cotton acid wash: 60°-70°C For cotton dyeing: 80-90°C (For hot brand) 60°C (For cold brand) Polyester dying: 100°-130°C 2)

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

3) 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 80° C for 20 minutes. Cold washing

Scouring tab1eaching: • 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 * caustic soda! soda ash) added when the temperature reaches at 70° C • Then H202 is added. • Temperature is then raised to 105° C & the process is then carried out for 60-90 minutes depending on the requirements. • The liquors are then drained. • • Dyeing: • o • • • • • • • • • • • •

Then wash with Felosan NOF (detergent) at 98°C for 5 mm. Then cold wash, at 35°-45°C & acid wash, at 60°-70°C is done. After acid wash all liquors are drained out. Required amounts of water is taken Then leveling agents, anti-creasing agents, dc-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 35°-45°C. Wash with Cibapon R (Washing agent) for 5 minutes. Acid wash at 55°C is done. Fixing agent is added at 45°C for 15 minutes. Then softener is added at 45°C for 15 minutes.

The Quality assurance Department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. ONE COMPOSITE 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 fabric rolls from different rn/cs, 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: 1.Research. 2.Selection of raw materials. 3.Process control. 4.Process development. 5.Product testing. 6.Specification test Scope for quality control quality assurance and testing: 1.Testing lab 2.Machine auditing system 3.A good training system 4.Excellent analytical back up 5.Teclmical expertise Quality Control in Grey Fabric Inspection: Some Points Are Needed To Maintain For High Quality Fabric: a) b) c) d) e)

Brought good quality yarn. Machines are oiled and greased accordingly. G.S.M, Stitch length, Tensions are controlled accurately. Machines are cleaned every shift and servicing is done after a month. Grey Fabrics are checked by 4 point grading system.

List of Equipments: In this factory ONE COMPOSITE MILLS LTD. this is the list of equipments to assure quality: 1) 2) 3) 4) 5) 6) 7)

Inspection mlc # 1 Inspection mlc #2 Scissors Electronic balance GSM cutter Indication sticker Measuring tape

Quality Assurance Procedure: 1)Body & Rib Inspection: All rolls are kept in front of the inspection rn/c time to time and are inspected over the inspection mlc visually in a pre-set speed against light. For any major or minor faults like thick-thin, barer mark, fall out, contamination, fly, holes, oil lines, needle line, stubs etc are recorded in inspection report to classify the fabric based on the four point system. 2)Collar & Cuff Inspection:


Collar& cuff are inspected visually under the light box, any major or minor faulty collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly counted and recorded. Quality Standard: ONE COMPOSITE MILLS Ltd. maintains the ISO: 9002 standard in case of quality. Therefore, the four point system is followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by inspection at ONE COMPOSITE MILLS Ltd. Four point grading system Size of defects 3 inches or less Over 3 inch but not over 6 inch Over 6 inch but not over 9 inch Over 9 inch

Penalty 1 point 2 point 3 point 4 point

Following table shows common body and rib faults and response by inspection section at ONE COMPOSITE MILLS Ltd. :Rejection criteria for body & ribs No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Faults Needle mark Stripe Bane mark: Contamination & fly Slubs Thick thin place Birds eye Pinholes Wrong design Mixed yam Sinker mark Missing yarn Holes Oil line/stain Chemical Dirt stain Crease line Uneven tension

Response Major needle line is rejected Major needle line is rejected Rejected Approved for color but for white shed I point is assigned 1 point Reject 1 point 1 point Reject Discuss with manager Major sinker mark is rejected. Use 4 point Do Do Do Do Do Discuss with manager


Following table shows common collar and cuff fault and response taken by inspection section at ONE COMPOSITE MILLS Ltd.: Rejection criteria for collar & cuff No. Faults 1. Wrong ply 2. Hole 3. Needle line 4. Slubs 5. Wrong design 6. Wrong tripping 7. Fly & contamination 8. First round problem 9. Uneven tension 10. Missing yarn 11. Crease line 12. Rust line 13. Oil stripe 14. Thick-thin 15. Wrong tube

Response Reject Reject Reject Reject Reject Reject : Acceptable for color but not for white Reject Discuss with manager Reject Reject Reject Reject Reject Reject

Following table shows the acceptance calculation followed by the inspection section at ONE COMPOSIT MILLS Ltd.:Acceptance calculation Factory: Roll yardage (A) Total points founds(B) Formula :

Xl 00 points per 100 yard

Classification: < 40 points = Atype 41-60 =Btype 61-80 =Ctype Above 8opoin =Reject Quality Control in Dyeing And Finishing: ONE COMPOSITE MILLS LTD. assures the quality of the products of dyeing section in the following three steps: 1. In laboratory 2. In Dyeing section & 3. In Finishing Section


Procedures are described below: In laboratory: Swatch card from buyer according to their requirement Recipe prediction for sample dyeing Sample dyeing until matching with swatch card Fastness & other tests of the fabric or yarn are done here. In dyeing section: According to the buyer’s sample, sample dyeing is done in sample dyeing machine in dyeing shed & again matched with the approved sample. If result is OK, then bulk production. During dyeing, samples are taken until accurate shade matching. The interval may be 3 0-40 minutes. After dyeing sample is collected after softening matching is done. Last of all, sample is collected after fixation & matched. Then allowed the fabrics to be finished. In finishing section: By using a series of finishing machines correct width, softness & appearance are maintained according to requirements. Then sampling is done for several times to test GSM, Shrinkage & fastness properties. Finally fabric is inspected & prepared for delivery. Quality Standard: ONE COMPOSITE MILLS LTD. follows the quality standard: ISO-9002:2000. List of Equipments: In the Quality Assurance Department the followings equipments are used  Yarn Grade Tester  78-i Magnetic Stirrer  KERN Electronic Balance  Spray Rating Tester  Incubator  Iron  Button Tester  Ahiba Nuance Lab. Dip Dyeing Machine  Thermostatic Water Bath  Digital Pipette  Creda Dryer  Rota Wash


         

Electrolux Washcator Orbitor Pilling & Snaging Tester Marks & Spencer Holoscope Tm Brust Crock Meter Push — pull tester Megasol (Light fastness tester) Spectro Photometer with software (Data Color) Thermo hygrograph a pH meter

Tests There are two types of tests are done in Quality Assurance Department. They are — 1. Physical Tests 2. Chemical Tests Physical Tests:  Yam Grade  GSM test  Shrinkage test  Spirality test  Tensile strength  Abrasion resistance  Pilling resistance  Button Strength Testing  Lycra% determination  Crease resistance Chemical Tests: • Fastness to washing. • Fastness to light • Fastness to actual laundering • Fastness to sea water • Fastness to water • Fastness to perspiration Fabric Inspection: The inspection of fabric is a procedure by which the defects of fabric are identified and fabric is classified according to degree or intensity of defects. The fabric inspection is done for both grey and finished fabric. Grey Fabric Inspection: Grey fabric inspection is performed according to 4-point system. Finished Fabric Inspection: 4 point numbering system is followed for finished fabric inspection. Defects found in the final inspection:


1.Uneven shade 2. Oil spot 3.Neps 4.Crease mark 5.Machine Stoppage mark 6.Listing 7.Line mark 8.Pick missing 9.Double yarn 10.Dead cotton 11. Bowing 12.Fly yarn contamination Procedure of the Different Tests: Different types of fastness tests of the dyed fabric are done in quality control department of the ONE COMPOSITE MILLS LTD. Different types of method (Standard or buyer’s recommended) are followed for different types of tests. The process of the different tests of fabrics & lab. dip dyeing is described in the following section: Color Fastness Test Procedure Color Fastness: The “color fastness” of a colored textile is defined as its resistance to these changes when subjected to particulates of conditions. It follows that color fastness must be specified in terms of these changes and expressed in terms of the magnitude. 1. Color Fastness to Wash Test Required materials: 1. Sample size 40 x 100 mm 2. Multifiber at 40 x 100 mm 3. ECE detergent (WOB) — 4gIL 4. Sodium Perborate (Na2BO3.H202.3H202-lg/L) - lgfL 5. Distilled water 6. Normal cold water 7. Steel balls Required instrument: 1. Rota Wash 2. Scissor 3. Stitch machine Procedure: 1. Cut sample & multifibre at 100 x 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 + Muitifibre weight) x 50 ml 3. The sample is kept in 60°C for 30 minutes in Rota Wash Machine 4. 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 Grey Scale & Staining Scale. 2. Color Fastness to Perspiration Test Test specimen: • Samplefabric—5Ommx 50nmi • Multifibre fabric —50 mm x 100 ram • Cut the multifibre into two piece • Sandwich the test specimen between two piece of multifibre Testing Solution: 1. Alkaline Solution: Histidine monohydro chloride monohydmte (C 6H10C1N302.H20)— 5.00 g/L NaC1— 5.OOg/L Disodium hydrogen orthophosphate (Na2HPO4.2H20) — 2.5 g/L pH —8 (Adjust by 0.1 N NaOH) 2. Acidic Solution: ilistidine monohydro chloride monohydrate (C6H10CIN3O2.1120)— 5.00 g/L NaC1 - 5.00 gIL Sodium di-hydrogen orthophosphate (NaH2PO4.2H20) — 2.2 g/L PH — 5.5 (Adjust by 0.1 N NaOH) 3.Method:  The composite specimen is put in a pen dish (2 specimen of a sample).  Solution (Alkaline & Acidic) is taken in the two pen 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.  Pen dish with composite specimen & glass plate is placed into the incubator at (37±2) °C for 4 hours.  The specimen is dried (Temp _ 60°C)  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—SO mm x 50mm • Multifibre fabric —50 mm x 100 mm • Cut the multifibre into two piece • Sandwich the test specimen between two piece of multifibre 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 pen 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.  Pen dish with composite specimen & glass plate is placed into the incubator at (37±2) °C for 4 hours.  The specimen is dried (Temp _ 60°C) Report: Change of shade & degree of staining is measured by the Grey Scale & Staining Scale. 5.

Color the Fastness to Rubbing (Dry & Wet) Test

Sample:  Dyed fabric—l5cmx5cm  White Test Cloth - 5 cm x 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 with stainless steel wire and run ten times manually then assess the staining on to the rubbing 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 & Spiral it)

Sample: • Two piece of 50 cm x 50 cm fabric is taken for test. Procedure: a. Conditioning: Put the sample in table for 4 hrs for conditioning before starting test. 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%=

1x1oo Before wash Spiraled test calculation:

S=(S1-I-S2)12 Spiraled = (S+S x L)/100. Suppose, S1 = The right side distance of the specimen from the stitch line after wash. S2 = The left side distance of the specimen from the stitch line after wash. L = Length before wash B.pH of a Dyed Fabric Test Test specimen: 1. 2 gm of dyed fabric is taken. 2. The fabric is cut into pieces of (0.5 cm x 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 P1’ of the conical flax is measured by Digital p” meter. Lab. Dip Dyeing 1. Sample: Type - 100 % cotton fabric 2. -Weight—Sgm Procedure: At first the recipe for the sample is calculated according to the sample weight. -The fabric is kept in the dyeing chamber. -Then the dyes, chemicals, salt & required amount of water is taken in that dyeing chamber by digital pipeting on the basis of stock solution. -Then the beaker is set into the lab. dip. dyeing machine for dyeing. -The program for dyeing is started for 20 mm at 40°C. -After 20 mm soda is added by pipeting. -Then the dyeing program is set for 60 mm at 60°C.  When the dyeing time is finished the sample is taken out from the machine at  40°C. Then the sample is washed off. At first cold wash & then hot wash is done. After it soaping is done. Then the sample is dried and compared with standard. Recipe Curve: Progressive Process For Lab. Dip. Dyeing Recipe Calculation: A dyeing recipe for purple color is given below: Sample Weight —5 gm M : L—l:10 Liquid Required —50 c.c.


Sunfix Yellow S3RD —9.3 c.c. (Shade — 1.86%) Sunflx Red S3BD — 10.2 c.c. (Shade —4.08%) Sunflx Yellow S3RD —9.3 c.c. (Shade — 1.86%) Remazol Blue RR — 6.5 c.c. (Shade — 1.3%) Salt (80 g/L) — 10 c.c. (40% stock) Soda (20 g/L) — 2.5 c.c. (40% stock) Water— 11.5 c.c. Salt and soda is taken on the basis of the shade%. The salt and soda is used according to the following table: Shade %Salt g/l 0.001-0.100 0.101-0.500 0.501-1.000 1.001-2.000 2.00 1-3.000 3.001-4.000 Above 4.000 1

Soda g/l 20 24 30 40 50 60 80

6 8 10 12 14 16 20

Response of Q.C Officer: Response to Q.C Faults: Faults Yarn fault Knit fault

Response Inform yarn supplier Inform knitting department

Response to Machine Fault:Faults Response Any electrical fault Inform electrical maintenance Any mechanical fault Inform mechanical maintenance Remarks: ONE COMPOSITE MILLS LTD. 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. ONE COMPOSIT MILLS LTD. is well equipped for checking the quality of the product. They sent the quality report to the buyer time to time/batch to batch. We think as ONE COMPOSITE MILLS LTD. strictly meet up the quality level that’s why they are the only one direct manufacture of Marks & Spencer garments. Maintenance: 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 unser: ~able 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 themachine tools to meet the need for production Maintenance of Machinery: Maintenance Preventive Maintenance Electrical Mechanical Maintenance Maintenance

Break Down Maintenance Electrical

Mechanical Maintenance

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 cannot perform its normal functions. Routine Maintenance: Maintenance of different machines are 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. Manpower Set-Up For Maintenance • AShift 6AM - 2PM • B Shift 2PM 10PM * General Shift 9AM - 6 PM Maintenance Manager Mechanical Mechanical In charge —02 Diploma (Mechanical) — 02 Welder and fitter — 01 Fitter —01

Electrical

Electrical foreman Diploma (Electrical) —02 Electrician - 02


Maintenance Procedure: Normally preventive maintenance should be done. During maintenance procedure following points should be checked: Maintenance of knitting machine/flat knitting machine: Items need to be checked & Serviced 1) Check and tightening all motor terminals. 2) Check and clean pressure sensor and tightening terminals 3) Clean the ventilation fans of panel board and circular fan on top of machine. 4) Check and clean the interfacing and data cables. 5) Check and tightening the proximity switch terminals. 6) Inspection, cleaning and tightening all the terminals in the panel. 7) Check and tightening limit switch, safety door guard and the emergency switch. 8) Functional test of the yarn detector. Maintenance of finishing department: Equipment name: Mahlo zone of stenter: Items need to be checked & serviced I. Check and tightening all motor terminals and clean the motor fan (3Odays). 2. Check activity of wide and sensor and pneumatic regulator. 3. Check and clean pressure sensor and tightening terminals 4. Clean the A/C ventilation fans of panel board 5. Check the fan and the heat sink o the inverters in the panel board. 6. Check and tightening the edge sensors. 7. Check and tightening the photo sensor terminals. 8. Check and tightening the safety light barrier and tightening the terminals. 9. Inspection, cleaning and tightening all the terminals in the panel. 10. Check and tightening limit switch, safety door guard and the emergency switch. Check List of Different Parts Maintenance Mechanical MachineDyeing machine Items need to be checked & Serviced 1 2 3 4 5 6 7

Crease the rn/c bearing. Complete cleaning of machine. Cleaning of drain valves, replace seals if required. Check air supply filters, regulators auto drain seals Clean filters element and blow out. Greasing of unloading roller bearing. Checking of oil level and bolts of unloading roller gearbox.


8 9 10 11 12

Checking of unloading roller coupling and packing. Checking & cleaning (if required) of main vessel level indicator. Check the oil level of pump bearing and refill if required. Check the function of heat and cool modulating valves Check all door seals.

Maintenance : Electrical Machine : Dyeing machine SL. No. Items need to be checked & Serviced 1.Check & clean fluff and dirt at dirt at all motor fan covers. 2.Check all motorâ&#x20AC;&#x2122;s terminals 3.Check main panels (by using compressed air) 4.Check panel cooling fan & clean its filter 5.Clean main pump inverter and its cooling fan. 6.Check all circuit breaker, magnetic conductors and relays. 7.Check current setting of all circuit breaker & motor over load. 8.Visual checking of all power & control cables. 9.Check all pressure switches 10.Check calibration of main vessel & all addition tank 11.Check all pneumatic solenoids 12.Check calibration of heating/cooling modulating value 13.Check setting of tangle sensor. 14.Check setting & operation of lid safely switches. 15.Check all emergency switches 16.Check all indicating lamps 17.Check all onloff switches 18.Check all signal isolators. Maintenance Tools & Equipments: 1.

Combination tools / spanner

Function: Function: Function: Function: Function: Function: Function: Function: Function: Function: Function: Function: Function: Function:

Tightening & loosening of nuts & bolts.2. Socket ratchet set Tightening of nuts & bolts. 3. Slide range Tightening & loosening of nuts & bolts.4. Monkey pliers Tightening & loosening of nuts & bolts.5. Pipe threat cutting tools To cut the threat in pipe.6. Bearing puller To assist the opening of bearing from shaft. industrial attachment7. Pipe range Tightening & loosening of pipe joint.8. Pipe cutting tools For pipe cutting.9. Hole punch Punching the hole.10. Divider For circle marking on metal & wood. 11. Easy opener To open the broken head bolt. 12. External threat die For external threat cutting. 13. Heavy scissor Cutting of gasket & steel sheet. 14. Oil can Oiling of moving parts. 15. Drill machine and drill bit.


Function: Function: Function: Function: Function: Function: Function: Function: Function:

For drilling. 16. Grease gun For greasing of moving parts of rn/c. For grinding & cutting of mild steel. 18. Welding ni/c For welding & cutting. 19. Spirit leveler For perfect leveling. 20. File For smoothing the surface. 21. Hammer For scaling & right angling. 22. Circlip tools Circlip opening & closing. 23. Hacksaw blade For metal cutting. 24. Handsaw (wood)

Remarks: Maintenance of ni/c’s are very essential to prolong the mlc 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. Introduction: ONE COMPOSIT MILLS LTD. is a big project and so of course having a vast project of utility service. Here the total account of utility facilities are available. The utilities are a) Water b) Gas c) Electricity d) Compressed Air e) Steam. WATER Water treatment plant: (Water Softening Method — Base Exchange Process) Source of water is deep tube well. Production capacity — 80 m3 /hr 1920000 liter/day Actual Production — 1500000 liter/day Required water - 1300000 liter/day ELECTRICITY Gas Generator is used for supplying electricity for the dyeing, knitting & office of the ONE COMPOSITE MILLS LTD. Total power produced by Gas Generator — 945 KW = 1134 KVA Factory (Dyeing & Knitting) Power Needed for Installation — About 1200 KW Factory (Dyeing & Knitting) Power Needed at Running stage — About 720 KW Power Needed for Office — About 250 KW


Specification of Gas Generator is given below: Technical Details Type Gas Generator Manufacturer No. of Gas Generator Model No. Manufactured Country

Generator Data Cummins Power Generation 03 315 GFBA England

Year of Construction 2002 Rated Power Prime Rated 315KW Power Factor 0.8 Voltage 400 Rated Current (amp) 568 Frequency (Hz) 50 Rotating Speed (RPM) 1500 Battery Volts 24 Control System PCCP Site altitude before derate 800 MASL Site ambient temp. before derate 40°C Source of Power used for Garments — DESA Power Capacity — 750 KVA = 900 KW There is a diesel Generator in the industry. Capacity of Diesel Generator —800 KW Specification of Diesel Generator is given below: Technical Details Type Manufacturer No. of Diesel Generator Model No. Manufactured Country Year of Construction Rated Rotating Speed (RPM) Voltage Rated Current (amp) Maximum Temp.

Generator Data Diesel Generator CATERPILLAR 02 SR4B SR4 U.S.A. 2004 649 H.P. or 484.0 KW 1500 400 723 105°C by Resistance

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 Type Manufacturer Model No. Manufacturer Country Year of Construction Maximum Working Pressure Free air delivery Nominal Shaft Power Rotational Shaft Speed Gross Weight,,

Air Compressor 1 Air Compressor 2 Atlas Copco Atlas Copco Atlas Copco AirpowerAtlas Copco Airpower GA 30 GA 55 Belgium Belgium 2002 2004 10 bar 10 bar 78 liter/sec 145 liter/sec 30 KW 55 KW 3000 r/min 3000 r/min 995 Kg 1550 Kg

STEAM • •

Steam is produce by Boiler. From the Water Treatment Plant, water is stored in a reserve tank and from there water goes to boiler & steam is produced.

Specification of the Boiler is given below: Technical Details Type Manufacturer Model No. Manufacturer Country Year of Construction Thermal Capacity Maximum Steam Out Maximum Working Pressure Content up to NW

Boiler Data Fire Tube Boiler OMNICAL BORSIG ENERGY DDHI 60— 10 Germany 2002 3.9 MW 6 ton/hour 10 bar-g 10940

GAS The source of Gas is TITAS GAS LTD. The gas is supplied to gas generator or different section (Boiler- for heating water) from the main line of the TITAS GAS LTD. Sources of Utility: Electricity Steam Water Compressed air Gas

: PDB & Generator Boiler Pump : Compressor : TITAS GAS LTD.


Remarks: As the biggest project the ONE COMPOSITE MILLS LTD. so the vast utility systems. There is a skill manpower group of engineers and other technical staffs to look after these utility services. They have to remain aware of solution on a great sense of responsibility for any type of problem due to utility supply. The Effluent Treatment Plant: 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 ONE COMPOSITE MILLS LTD. is chemical biological combination process. Objects: This process is provided for treating the effluents of dyeing, printing, finishing, weaving & thus allow to discharge effluent as per by World Bank dept of environment of Bangladesh. Consumption of the chemical used: Chemical Name H2S04 & HCI Alam Polymer H3P04 Urea

Chemical Used 25 Kg/day 250 Kg/day 0.5 Kg/day 250 mi/day 3 Kg/day

Product Quality Check: Following chemical tests are carried out to check the quality: -BOD COD Total suspended solids Total dissolved solids Colour pH Typical Output of the Plant: Raw effluent color Raw effluent pH Treated effluent color Treated Effluents pH Treated Effluent Temp

Black 11 Light greenish 6-6.5 38째C

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 arc necessary, because — 1. 2. 3. 4. 5.

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 Stock and stock value for consumption measuring

Frequency of Inventory Update:  Monthly inventory control.  Annual inventory control. Scope of Inventory Control: o 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.

In ONE COMPOSIT MILLS LTD. there are different inventory systems for different raw materials. 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: ONE COMPOSIT MILLS LTD. 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 ONE COMPOSIT MILLS LTD. the store for inventory control is satisfactory. Sometime, they fluctuate from ideal process otherwise they are ok. Introduction: Costing is a process by which the setting price of a product is calculated. It is a very important task for a factory which runs for business purposes. And it is also strictly followed in the ONE COMPOSITE MILLS LTD. Costing of the products considering the raw materials expenditure, salary and wages of officers and workers, distributions and advertisement expenses etc. all direct and indirect expenses is done in this factory. It is determined by a troop of accountants with advice and consultancy of executive director. Costing Of the Product The following points are considered for costing any dyed product in ONE COMPOSITE MILLS LTD. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Total dyes & chemical cost Total utility cost Salary Payment Transport cost Lunch Entertainment cost Miscellaneous cost 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 + Factory Overhead) ± required profit Price Range of Different Products: T-Shirt = $0.75 - $4.50 /Pecs Polo Shirt =$2.O0 - $6.50 /Pecs Kids Wear $0.75- $2.15 /Pecs Knitting Charge of Different Fabrics: Fabric name

Charge per kg


1. Single Jersey 2. Single Jersey with Lycra 3. Single locust PK 4. Double lacost PK 5. Single PK 6. Double PK 7. Rib 8. Rebirth ycra 9. Interlock 10. Auto striper 11. Auto striper with Lycra 12. Fleece Dyeing Charge of Different Fabrics: Name of fabric process 1. 2. 3. 4. 5. 6. 7. 8. 9.

White with Enzyme White without Enzyme Avg. color with Enzyme Avg. color without Enzyme (Light& med.) Deep shed with Enzyme (Black) Deep shed without Enzyme (Black Only wash (Tubular) Only wash (Open) Double dyeing (Face & Back)

Finishing Charge of Different Fabrics: Name of fabric process 1. 2. 3. 4. 5. 6.

Slitting only Stenter only Compacting only Stenter + Compacting Stenter + Compacting+ wash Tube Compacting

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

(Tk) 09 30 16 16 16 16 17 30 25 80 100 22-25 Charge per kg (Tk) 35 30 85 75 110 ) 95 25 45 115 Charge per kg(Tk) 5 25 15 35 50 10


Production cost of fabric=$6. 15 Fabric price (with 25% margin) =$7.79 Fabric consumption! doz. = (Body length + Sleeve length) x Chest length x 2 x GSM x12 /10000000 Garments specification: Body length78 cm Sleeve length=33 cm Chest length=62 cm GSM=210 Fabric consumption! doz. ((78+33) x62x2x210x12}/ 10000000 3.469 kg Fabric consumption doze (with 10% wastage) 3.816 kg Body fabric cost / doz. =$(7.79x 3.8 16) = $29.73 Cost of collar& cuff â&#x20AC;&#x2122;doz = $ 4.00 Cost of Trims=$ 2.25 Cost of Trims (with 5% Process loss) = $2.36 Production Cost of Garments/ doz $36.09 Garments 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 achieving good profit and good profit is not possible without skillful costing. In ONE COMPOSITE MILLS LTD There are some skillful personnel to do this job. Consumers of Product: ONE COMPOSITE MILLS LTD is a 100% export oriented industry. All the goods produced in this industry are exported into various foreign countries. Name of the Buyer: Buyer 1) Walmart 2) Ricalewis 3) Texebo 4) Low land fashion 5) Mpl 6) Makyes 7) Imap Export S.P.A 8) Fareâ&#x20AC;?st 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 product label are given bellow: Main label

Care label

Size label

Not provided

Not provided

Not provided


Package Size & Label Market: Package size & label differs from buyer to buyer. The Package size & label are prepared according to the buyer requirements. Normally the following package sizes are used:60 x 40 x 40 cm. 58x33x44143 /42 cm. 58x33x25cm. 58x33x 13/16/18 cm. Importing Countries: There are some countries which are importing goods from ONE COMPOSITE MILLS LTD. Which are given below• United State of America • England • Germany • Europe • Europe Union • Swazer land Manpower of Marketing: Marketing plays a vital role in the field of displaying / showing the goods criteria of the products to the buyer & to communicate with the buyer. There are about 20 people in the marketing 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 of garments marketing the dealings with the buyer is a very important factor. ONE COMPOSITE MILLS LTD. mainly senior marketing officers, merchandiser & higher officials deal with the buyer. There are some fixed buyers of the industry. The buyers give their orders continuously all over the year. The marketing officers & the merchandisers communicate with the buying houses to collect the orders. 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 summary: i) Market search


ii) Market development iii) Customer’s motivation iv) Production follow up v) Technical assistance of customer Dealing with the buyer & convince the buyer is the main duty of marketing officer. A marketing officer also has some other duties. The main duties & responsibilities of a marketing 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. Merchandising Garment merchandising is an intricate and detail oriented job. If it can be done properly can be very rewarding. On the country, if it is done with lack of knowledge, insufficient skill and thorouglmess, it can be destructive. In the ONE COMPOSITE MILLS LTD, very skilled and experienced personnel run the merchandising section. After receiving an order, the merchandiser with the help of pattern master calculates the total consumption of fabric. Then according to the cost detail sheet and the price mentioned by the buyer costing is done. After the price is negotiated with the buyer order is placed to the suppliers of raw material and accessories. The manufacturing factory as per the requirement suppliers the fabric and a ledger is maintained regularly to assess the production status. The accessories such as label, button, zipper, sewing thread, packing materials are collected from outside [sometime mentioned by the buyer] through back-to-back L/Cs. The merchandising department also looks for the sources for procuring yams to produce fabric. Merchandising section monitors the production status regularly and ensures timely delivery of the shipment. Job responsibilities of Merchandising Team: Job responsibilities of Merchandising Team DEVELOPMENT 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 capacity situation. 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.

SAMPLING 03  Updating production development tern reg. different sample requirement of buyer at various stage (sales man, fit , sz set, pp sample etc)  Coordinating all fabric + trims which are required for sampling purpose.  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 lab dips / 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 a style.  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 on time 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 on time delivery.  Liaise 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.


 Developing 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  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 Maintains the development file. General correspondence with buyer and suppliers. Critical correspondence with buyer and suppliers Weekly updates for buyer, such as audit schedule, production

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

MEETING ONE COMPOSITE MILLS LTD. has a well learned marketing & merchandising team. They always communicate with the buyers. ONE COMPOSITE MILLS LTD. has some fixed buyers. The marketing section also looks the quality & quantity buyers. Conclusion: Mill is settled with utility to give all convenient supports to the productions for twenty-four hours. 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 authority full & found all nian, 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  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 mlc stoppage time should be analyzed and minimized. The maintenance should be carried out when the mic is out of action (wherever possible) and routine  maintenance should be carried out regularly.  There should be a yarn dyeing project.


ď&#x192;&#x2DC; Sitting arrangement of production officers should be improved. ď&#x192;&#x2DC; There should be identity card for INTERNSHIP students. Then they can avoid some hazardous situation.


One Composite Mills Pvt Ltd (Wet Processing Technology)