industrial attachment of uttara knitting & dyeing ltd

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INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTUttara Knitting & Dyeing Ltd.

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CHAPTER – I

PROJECT DESCRIPTION

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CHAPTER – I

1. Name of the company: Uttara Knitting & Dyeing Ltd.

2. Status : Private Ltd. company

3. Type : 100% Export oriented composite knitdyeing industry

4. Year of establishment : 1997

5. Location : South Pansail, Zirani bazaar, GazipurSadar, Gazipur

6. Address :Factory : South Pansail, Zirani bazaar, Gazipur

Sadar, Gazipur

Head Office : 39, Dilkusha C/A, Dhaka - 1000

7. Sponsor : Late. Md. Moklesur Rahman

8. Product mix : 100% cotton, 100% polyester, Chiefvalue

cotton, P/C

9. Annual production capacity 1800 tons

10. Project cost 22 crs (Initial), 50 crs (Present)

11. History of the project development1994 – Establishment of the industry at Tongi with 8 Knitting

m/c.1997 – Shifted in Zirany, Gazipur Sadar, BKSP with 24 knitting

m/c(rib – 3, S/J - 21)

1997 – Installment of 7 Dyeing m/c1997 – Installment of 6 Flat Collar m/c2000 – Installment of 3 rib m/c2003 – Installment of 4 Dyeing m/c (Bangla)2004 – Installment of the 2 Sample Dyeing m/c (5 kg, 25 kg)2004 – Installment of 3 Pai Lung m/c

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12. Different departments :To run the factory smoothly, there are some department in the

factory . They are given bellow:-KNITTING SECTION: Knitting Inspection

DYEING SECTION Batch section Dye house Dyeing lab. Quality control Finishing

MAINTENANCE Electrical Mechanical

ACCOUNTS & COMMERCIAL SECTION

ADMIN SECTION Time section Cleaning Security Store

13. Total area of the industry : 30 acres

14. Area of the plant : 20 acres

REMARKS:Uttara Knitting & Dyeing Ltd. is a well established Knit Composite Industry. Theindustry stands by the side of BKSP. The area is sufficient for the industry. Butits drainage system is not very good. There is no system for effluent treatment.

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ChemicalStore

Q.C.&Lab

Office

Store

DeliveryFabricStore

Dyeingmanager

MixingRoom

ProductionOfficer

Tensionless dryer

Softener

Calator

Soft set -2

SteamSet m/c 2

Soft set -1

SteamSet m/c 1

compactor

Hydroextractor

Batch Section

Batch Turner

Tumble Dryer

Finished fabricstore

DyeStore

DrainSteamWater

FINISHING SECTION

DYEING FLOORN

S

EW

Dyeing m/c (1 – 15)

LAYOUT OF UKDL

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UKDL

BKSP

EPZ - I

EPZ - II

BAIPAIL

ASHULIABAZAR

UTTARA

AIRPORT

MOHAKHALI

CTET

FIG: LOCATION OF UKDL

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CHAPTER – II

MANPOWER MANAGEMENT

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UTTARA KNITTING & DYEING LTD.JIRANI BAZAR, GAZIPUR SADAR, GAZIPUR

ORGANOGRAMSl.No.

Marketing Commercial A/C &store

ProductionDyeing

ProductionKnit

Quality Utility Administration

01 General Manager02 DGM DGM DGM DGM03 AGM AGM AGM AGM (Factory)04 Manager Manager Manager Manager

(Dyeing)Manager

(Knit)Manager Manager Manager

(Admin)05 Assist

managerAssist

managerCost

AccountantAssistantManager

AssistantManager

AssistantManager

ElectricalEngineer

Administration Officer

06 Sr.Executive

Sr.Executive

Sr.Executive

Sr. Prod.Engineer

Sr. Prod.Officer

QC officer MechanicalEngineer

Sr.Executive

Admin07 Executive Executive Executive Production

EngineerAsst.

ProductionEngineer

AssistantQC Officer

Sub.AssistantEngineer

ExecutiveAdmin

08 Jr.Executive

Jr.Executive

Jr.Executive

Asst. Prod.Officer

Shift In-charge

QC In-charge

Forman Asst. OfficerAdmin

09 Assistant Assistant AccountsAssistant

Lab. Chemist ProductionClark

Sr. QCSupervisor

Supervisor SecurityOfficer

10 Cashier Sr. Lab.Assistant

Sr.Supervisor

QCSupervisor

AssistantSupervisor

ComputerOperator

11 Purchaseofficer

Lab. Assistant Supervisor AssistantQC

Supervisor

Sr. Fitter OfficeAssistant/Time Keeper

12 Sr. Storeofficer

Report Clerk AssistantSupervisor

QC Fitter AssistantTime

Keeper13 Store

officerBatch

InchargeTr.

SupervisorAssistant

QCAssistant

FitterTypist

14 Asst. StoreOfficer

FinishIncharge

Fitter Tr. QC Electrician TelephoneOperator

15 St. StoreKeeper

Froman AssistantFitter

Tr. AssistantQC

AssistantElectrician

DeliverySupervisor

16 StoreKeeper

Sr. Supervisor Operator QC Man BoilerOperator

Peon

17 Asst StoreKeeper

Supervisor AssistantOperator

BoilerAssistant

Driver

18 StoreAssistant

AssistantSupervisor

Tr. Operator GeneratorOperator

Gardener

19 HelperStore

Tr. Supervisor Tr. AssistantOperator

CompressorOperator

Loader

20 Tr. Asst.Supervisor

Helper Asst.Operator

Cleaner

21 Sr. Operator W.T.P.Attendant

Painter

22 Operator Tr. Operator Sweeper23 Asst. Operator Helper24 Tr. Operator25 Assistant Tr.

Operator26 Helper

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MANAGEMENT SYSTEM:

Intercom telephone Fax Written

letters & Oral

SHIFT CHANGE:There are two shifts in this industry. So the shifts are changed atevery 12 hours

RESPONSIBILITIES OF PRODUCTION OFFICER:I. To give dyeing program slip.2. To match production sample with target shade.3. To collect production sample lot sample matching next production,4. To observe dyed fabric during finishing running & also afterfinishing.5. To identity disputed fabrics & report to P.M/G.M. for necessaryactions.6. To discuss with P.M about overall production if necessary.7. To sign the store requisition & delivery challan in the absenceof P.M.8. Also to execute overall floor works.9. To maintain loading'/unloading khata.10. Any other assignment given by higher authority.

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JOB DESCRIPTION OF PRODUCTION OFFICER:REPORT TO: Sr. Production Officer

JOB SUMMARY: To plan, execute & follows up the production activities &. control thequality production with related activities.

DUTIES & RESPONSIBILITIES: Overall supervision of dyeing, finishing production. Batch preparation & pH I chock. Dyes & chemical requisition issue & check. Write Fabrics loading & unloading time from m/c Program making, sample checking, colour measurement Control the supervisors, operator, ass. operator and helper

ofdyeing m/c.

And also any other over work as & when required by themanagement.

JOB DESCRIPTION OF Sr. PRODUCTION OFFICER:REPORT TO: A.G.M. (production)

JOB SUMMARY: To plan. execute & follows up the production activities & control thequality production with related activities.

DUTIES & RESPONSIBILITIES: Overall supervision of dyeing, finishing production. Checks the sensitive parameters of different machine for

smooth dyeing Checks the different log books of different areas & report

to management Checks out the plan to control the best output from

supervisors & workers. To trained up& motive the subordinates how to improve

the quality production. Control the supervisor, operator, Asstt. Operator & helper

of dyeing. Maintenance of machine & equipment Any other works &

when required by the management

REMARKS:

The man power management system of Uttara Knitting & Dyeing Ltd. is well arranged.Every officer & stuff are responsible for their duty. But there are only five textile engineersin the industry.

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CHAPTER – IIII

MACHINE DESCRIPTION

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DYEING FLOORDYEING MACHINES:In Uttara Knit Dyeing Ltd.. There are 14 dyeing machines. Among them 9 machines arewinch dyeing machines, 3 are H.T. dyeing machines and 4 sample dyeing machines. All themachines are from same company and country. The description and specifications of themachine are given below-

Name of the machine : Jet Dyeing MachineBrand Name : FukuokaManufacturing country: JapanCapacity : 400 KgYear of manufacturing: 1995Specification :

No of nozzle: 2Pressure/nozzle: 0.5 barMotor :

Winch motor – 2Pump motor – 1Stirring motor – None

OPERATION PROCESS:a. Preparation:

1. Turn on power on main panel2. Open valve for cooling water of main pump3. Check stream, water & air

+ Steam pressure : 5 – 6 kg/cm2 G+ Water pressure : 1.2 – 2 kg/cm2 G+ Air pressure : 5 – 7 kg/cm2 G

4. Adjustment of feeding valve as per production item & capacity

b. Putting fabric into the machine:

1. Select water supply level2. Supply water automatically by pushing ‘turn on’ button and stop by ‘turn off’ button.3. Take up edge of fabric to fabric gate through guide of the reel4. Put edge of fabric to nozzle5. Start main pump and put whole fabric with adjusting feeding by valve upto remaining

2 -3 meters fabric end6. Stop main pump and pull up 2 -3 meters of fabric edge by stick7. Joint both ends of fabric8. Start main pump & reel to circulate whole fabric and adjust torque of speed9. Make sure if fabric circulation is normal, then close the door of the gate, (Check again

reel speed)

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C. Operation:

1. Close the door2. In-put the pattern on programme controller3. Mix dyeing stuff & chemical in dyeing-mixing tank and pour it with using pouring

pump by adjusting feeding valve, after poring, feeding valve shall be closed4. Switch ‘run’ on programme setting device5. Automatic operation

1) Select the switch of water supply to ‘automatic’ on main panel2) Push the button of automatic operation, then automatically operation will go

through heating, holding, cooling, washing as per programming. Put ‘stop’button when finishing buzzer will ring

3) Open the door and take out fabric

Caution:

1. Before operation:(1) Check the power (Voltage/hz) wrong Voltage / Hz will cause to brake motor,

meter etc(2) Check air pressure(3) Clean inside of tube before dyeing(4) Set the meter correctly as per dyeing method(5) Check every valves

2. Starting operation:(1) Check closing the door perfectly(2) Set pressure below 1 kg / cm3 by watching pressure meter(3) When temperature will be over more than 800C, do not forget item (1) & (2)(4) Do not start pump when tube is empty(5) Put definitely cooling water before starting operation because pump & reel is

made for cool water3. During operation

(1) Check if meter is working correctly during operation(2) Check if any strange vibration(3) Check if any strange sound of pumping(4) Check if pressure in the tube is too high(5) Check if temperature in the tube meet programming(6) Start pump when feeding steam & cooling water(7) Check if reel is working correct under high temperature & high pressure

4. Nozzle installationSet nozzle base into nozzle-casing and install nozzle by turning it clock wise.After install nozzle, turn it one round by anti-clock wise to make 2 mm gap. The gap onnozzle shall be adjusted by kind of fabric

5. After operation:(1) Before opening the door, check if air pressure of inside the tube is 0 kg/cm2

and temperature of inside the tube is between 800-900C if the pressure is stillremained or temperature is more than 800C, it is very dangerous to open thedoor

(2) Temperature inside the tube shall be under 800C for manual draining

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(3) Turn off the power after operation and close the valve6. Maintenance:

(1) Keep cleaning seal packing of the door and surface to touch the packing to beprevented from dust and hurting

(2) Keep electric portion, pump and control panel not to be wet by water(3) Keep tight valve shaft seal ground packing of each valve by tightening

sometime(4) Check valve seat part of air valve & drain valve sometime(5) Keep tight each volt(6) Make often oiling rotating part(7) Inspect mechanical seal according to manual of pump(8) Keep adding grease & oil in pump bearing part according to manual of pump(9) Inspect sometime if safety valve is working correctly(10) Inspect sometime if steam trap is working correctly(11) Inspect meters of pressure and temperature

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Soft water pipe

Jet mechanism

Winch

Steam pipe

Water pipe Ledfilter

motor pump

drain pump motor

Automatic High Pressure Dyeing Machine

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TOTAL MACHINE CAPACITY

SL NO M/C TYPE NO. OFMACHINE

CATALOGUECAPACITY IN(KG)

ACTUALCAPACITY

ORIGIN OFMACHINE

01HIGH TEMPERATURESAMPLE DYEING M/C(JET DYEING)

01 20 20

FUKUOKAIRONWORKS,JAPAN

02 HIGH TEMPERATURE (JET)SAMPLE DYEING M/C 01 20 20 JAPAN

03 H/T (JET) DYEING M/C 01 60 60 JAPAN








11 ATMOSPHERIC DYEING M/C 01 400 310 JAPAN






17 SAMPLE DYEING M/C 01 10 10 BANGLADESH

18 SAMPLE DYEING M/C 01 15 15 BANGLADESH

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MACHINERIES OF THE DYEING LAB:The dyeing lap of the UKDL is not so developed. The description of the machineries of thedyeing lab are given bellow-

Laboratory facilities & equipments: Light box Electric balance Iron Sample dyeing m/c Lab dip m/c GSM tester Washing m/c PH tester Dryer

Light box: Visual assessment of color by reflectance & transmission Mainly used for shade matching Four types of light source are used Sometime it may be more such as TL84, CWD etc Metamerism of the fabric is checked

Brand Name Model Manufacturing countryVITIVIDE CAC-60 U.K.

Types of light source which is used in the m/c is given below-Symbol Full meaning FunctionsUV Ultra violet Used for white color

matchingF Fluorescent light Check the metamerism of

the fabricTL84 Tube light DoL D65 Artificial day light Used for color matching

Crock meter:Feature:

Mainly used for rubbing fastness Rub may be wet and dry

Brand name Model Mgf. Country Serial no.GUVEN SURTME Turkey S-9011

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Electric balance:Features:

Weight of the fabric and dyes and chemical is measured digitally which give goodresult in weighting

Used for accurate measurement Maximum weight that can be perfectly measured is 121 gm and minimum weight

which can be measured perfectly is 1.001 gm Accuracy 0.001 gm

Brand Name Company Model CountrySartorius James H. Heal &

Co. LtdBL310 UK

IRON:Feature:

Used for drying the sample Wet sample is placed between the two white fabric and temperature and pressure is

given A dial is provided indication the different temperature marked on tits upper surface

and gives accurate temperature for cootn, silk, wool etc. which is adjustedmanually.

SAMPLE DYEING MACHINE:There are three sample dyeing m/c in the laboratory, which features are described below inbrief

Solvent – GlycerinModel – HRNo: 3800M/c type Brand name Company Country

RAPID LABROTEX.CO TAIPE (TAIWAN)

Sample dyeing m/c:Feature: Sample can be dyed above 1000C, 1300C or more Glycerin bath is used 18 holders are providing in this machine

Main parts of the machine: Program set panel Glycerin bath Holder Holder carrier

Controlling point: Time Temperature Rotation speed Auto stop

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Type of fabric processed: COTTON AND POLYESTER

GSM Tester:Feature: Used to measure GSM for gray, dyed and finished fabric One GSM tester is in finishing section and another GSM tester is in Knitting

Section 100 Cm2 cut sample is weighted by electric balance 3 and given value of in gm.

Multiplied by 100 is the GSM of fabric, Say, 100 cm2 sample weight in 1.9 gmthat means its GSM is 180

Washing machine: All the washing condition and parameter can be controlled Model – RS-12MS Temp 1200C Solvent – water + glycerin

m/c no Brand name Company Country1. INDESIT INDESIT Italy

Wash fastness machine:It also used as a dyeing machine. Specification is unknown

Hot air rapid drying oven:Country – TaiwanComponent – Timer, Temperature indication meter

MACHINARIES OF THE FINISHING SECTION:Dewatering machine:

Feature: Used to remove excess water after pretreatment and dyeing Delivered fabric is crease free state Before squeezing ballon is formed with the help of compressed air passing by a

nozzle It can control the diameter of fabric and GSM and shrinkage by over feeding

mechanism To impart soft finish to the fabric

m/c no Brand name Country Production Company1 (modern) ABcalator Sweden Airtex

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

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Utilities:1. Electricity2. Processed air (to form the tube fabric into ballon with a view to remove crease)

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

CALENDER M/C:Name : SoftsetSpeed : 100 m /min

20-30 m / minOrigin : Korea

Functions:1. To calendar fabric2. To reduce G.S.M.

STREAM SETTING M/C:Name : KY0D0 DENKIOrigin : U.S.ASpeed : 60 m / min

Functions:1. To remove crease mark2. To reduce G.S.M of fabric

HYDROEXTRACTOR M/C:Name : NGAISHINGModel : NS 2542Serial : 158Company : NGAISHING DevelopmentOrigin : HongkongFunction:

1. To extract water from fabric

DRYER:Tension less dryerModel : MFG NO-0445Company : LK & LH CO. LTDOrigin : TaiwanSpeed : 10 – 20 m/min

Functions:1. To dry the fabric with help of steam

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COMPECTOR M/C:Brand : Parnit – II Delta Plus CompactorM/c number : BM-9529Company : Tubular Textile Ltd/Origin : U.S.A.

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Control Point :- Water pressure 2.5 lb- Air pressure 4 lb- Steam pressure 6 lb

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

Main parts of the machine:1. Heating chamber2. Blower (8)3. Synthetic blanket as a conveyor,4. Folder5. Exhaust fan

Heating system: Steam

Utility:1. Steam2. Electricity (to run the m/c)3. Compressed air (to spread the fire)

REMARKS:The average machineries in this factory are more or less same compared to the other

knit dyeing factories but the dyeing machineries are very much different from the otherfactories.

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CHAPTER – IV

RAW MATERIALS

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RAW MATERIALS:In Uttara Knitting & Dyeing Ltd., the raw materials used for production are –

1. Grey2. Dyes3. Chemicals

1. Grey fabrics:Following types of grey fabrics are dyed-

a. Single jerseyb. Single jersey with lycrac. Interlockd. Lacostee. Yarn dyed fabricsf. Ribg. Lycra ribh. 1 x 1 rib & othersi. Collar & cuffj. Polyester fabrics

Sources:The required grey fabric is produce in the industry

Chemicals Country01. Hostapol JU Thailand02. Rocowet RDA Germany03. NaOH China, India04. Na2CO3 China05. Defoamer SF Taiwan06. Stab SML Thailand07. H2O2 Belgium08. Cibafluid-C Singapore09. A. Acid Taiwan, India10. Ladiquest – 1097 Thailand11. Drimazin- E2R Thailand12. Rlf - 349 Germany13. Glanber salt India / China14. NaCl Bangladesh15. Decol – SN

RFLGermanySingapore

16. VNFECO

SingaporeThailand

17. Softerer [NI catalyst] Taiwan18. Enzyme Germany

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Dyes CountrySolazol TaiwanRemazol GermanyReactron IndiaReactive IndiaTerasil Switzerland

Materials consumed:ADD: MANUFACTURING EXPENSES WT. KGS @BDT.Knitting 610.0 13.49Dyeing 610.0 33.55Compacting 610.0 2.12

UTTARA KNITTING DYEING LTD. IMPORTED YARN PRICING THROUGH L/C:PARTY NAME YARN

CATEGORYRATE $(KG)

RATE (Tk. /KG)

QUANTITY(KGS)

Shameem Spinning 20s/1 CVC 2.70 158 400.00Shameem Spinning 30s/1 CVC 2.80 163 500.00Padma Textile Mills 30s/1 CVC 3.00 175 3628.80Square Textile Mills 24s/1 Comd 2.95 172 850.00Square Textile Mills 12s/1 Kard 2.05 120 500.00Square Textile Mills 10s/1 Kard 1.65 96 1850.00Prime Composite Mills 32s/1 Comd 2.95 172 2550.00Arief Knitspin Ltd 20s/1 Kard 2.58 151 2000.00Arief Knitspin Ltd 26s/1 Kard 2.62 153 2000.00Arief Knitspin Ltd 30s/1 Kard 2.62 153 3250.00Prime Composite Mills 32S/1 Comd 2.95 172 22500.00Arief Knitspin Ltd 24S/1 Comd 3.02 176 10000.00Arief Knitspin Ltd 34S/1 Comd 3.25 190 20000.00Shamsuddin Spinning 24S/1 Comd 3.00 175 6700.00Shamsuddin Spinning 26S/1 Comd 3.00 175 4350.00Arief Knitspin Ltd 20S/1 Comd 3.00 175 1500.00Saiham Textile Millsltd.

30s/1 Kard 2.55 149 661.84

Shamsuddin Spinning 30s/1 Comd 3.05 178 1150.00Shamsuddin Spinning 26s/1 Comd 3.00 175 1800.00Prime Composite mills 20s/1 Kard 2.40 140 1400.00Prime Composite mills 24s/1 Comd 2.85 166 1900.00Prime Composite mills 26s/1 Kard 2.82 165 650.00Prime Composite mills 30s/1 Kard 2.82 165 350.00Hanif Spinning Mills 28s/1 Comd 3.05 178 3800.00Square Textile Mills 26s/1 Comd 2.95 172 500.00Square Textile Mills 24s/1 Kard 2.50 146 500.00Square Textile Mills 10s/1 Kard 1.65 96 600.00Shameem Spinning 30s/1 CVC 2.80 163 1600.00Square Textile Mills 30s/1 Comd 3.00 175 1000.00

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CHEMICALS AVERAGE RATE (Tk / KG)ACETIC ACID 69.33DEFORMER SF/ALVATEX FFC 161.86BLUTON BVB 238.00BLUTON K2 236.00BLEACHING POWDER 109.00CAUSTIC SODA 17.00COMMON SALT 6.45GLOBER SALT 8.00H2O2 (50%) 20.35GEIZYME PR 140.79SODIUM HYDROSULPHITE 39.06SODA ASH 11.00SODIUM SULPHITE 22.00SODIUM CHLORIDE 60.00CIVAFLUIDE C 99.00HOSTAPOL – J – U 96.00LADIQUEST – 1097 129.03STABILIZER SF 86.05SOFTNER CS 118.22DEKOL SN 132.00

DYES AVERAGE RATEREACTIVE BLACK-5 129.29SULPHER BLACK 90.61REMA BLUE - BB 2245.89REACTIVE ORANGE – 16 459.50REMA YELLOW RR-GR 757.83REMA RED –RR – GR 757.01REMA RED H-38 780.00SOLO TURQUISE –BRIE 400% 525.50REACTIVE YELLOW 160 428.83TERASIL BLUE 3RL-02 1774.00TERASIL BLUE BGE -01 1370.00TERASIL RED F –B 3916.00REACTIVE BLUE BB 1319.00REACTIVE BLUE GG 688.50

REMARKS:UKDL uses best quality raw materials. It produces fabrics from best quality yarn. They

uses the best quality dyes like REMAZOL, REACTRON, REACTIVE , TERACIL etc.During the time of using dyestuff they give importance upon the quality of dyes than the priceof the dyes and chemicals.

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CHAPTER – V

PRODUCTION PLANNINGSEQUENCE

& OPERATIONS

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PRODUCTION PLANNING, SEQUENCE AND OPERATIONS:

PRODUCTION PARAMETERS:a. pH:

- During H2O2 bleaching pH 9.2 – 12- During reactive dyeing pH 10.5 – 12.5- During disperse dyeing pH 4.5 – 6.0

b. Temperature:

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

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

c. Time:

- For scouring 60-90 mins- For reactive dyeing 60-90 mins- For disperse dyeing 60-90 mins

d. M:L ratio:

- For reactive dyeing M:L ration maintained beween 1 : 7.5 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- PCLF (detergents) added & washing continued at 800C for 20 mins- Cold washing

Scouring-bleaching:

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

temperature reaches at 500C- When the temperature reaches at 600C then stabilizer is added- Then H2O2 is added- Temperature is then raised to 900C and the process is then carried out for 60-90 mins

depending on the requirements

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- The liquors are then drained- Then cold wash at 300-400C, hot wash at 700-800C and acid wash at 600-700C is done

Dyeing:

- After acid wash all liquors are drained out- Required amount of water is taken- Then leveling agents, anti-creasing agents, de-foaming agents are added according to

the requirement- Steam pipes are on & after 10-15 mins dyes are added- Salts are added after another 30 mins- Then soda ash after another 30 mins- Then the temperature is raised slowly up to the mark- The process is carried on and samples are taken after every 30-40 mins to match with

the target shade. It continues until shade matching.- If the sample is matched, then the liquors drained out- Then cold wash at 300-400C, hot wash at 700-800C, acid wash at 600-700C is done- Then softener is added at 400C for 20-30 mins- Fixer is applied for deep shade only before adding softener

Re-dyeing:When shade is not matched then fabric is treated again in dyeing machine for shade matchingis known as re-dyeing.Generally, re-dyeing is done if the shade is deeper than the target shade. It may occur whenthe fabrics absorb one or two colors more or less. One re-dyeing process is described below.

- Drain the let off solution- Hot wash at 700-800C- Acid wash at 600-700C(600 for light shade & 700 for deep shade).- Soda ash washes at 900-1000C for 60mins to reduce the depth of shade.- Acid wash at 600C.- Addition to required dyestuffs.- Salt addition.- Soda ash addition.- Other operations are same as previous described dyeing operations.

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PRODUCTION FLOW CHART:

Scouring Scouring H2O2

& bleaching hot killer A. acid950C1 hr 15 m salt dye soda

leveling 700C600C enzyme Hot wash agent

45 – 60 min40 min

matlcold wash

400C

Dyeing curve of 100% cotton fabric with reactive dye

Production flow chart for 100% cotton↓

Grey fabric loading↓

Scouring & Bleaching at 95oC for 1 hour↓

Scou g HO + (95oC x 15’)↓

H2O2 killer [invotex PC or gazyme PC]↓

A.Acid↓

Enzyme [pH 4 – 4.5, temp 60oC for 40’-60’]↓

Hot wash↓

Levelling [Ladiquest 1097]↓

DyeingSaltColorSoda

↓A. Acid

↓Hot wash [Decol SN, RSK, RFL]

↓Fixing [VNF, ECO]

↓Softener [LCF, Non ionic]

↓Unload

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CVC DYEING SEQUENCE:

Perergent + Artioreasomg agent at 800C for 20'↓

cad wash↓

A.Acid [pH 4-4.5]↓

Levelling agent + Antioreasomg agent↓

Buffering agent [jinlab RFL]↓

Color at 130o

50'

↓↓ ↓If OK If not oK↓ ↓Bath Drain temp 1300

↓ ↓½ scouring If OK↓ ↓Cotton dyeing sequence Bath drain

↓½ scouring↓Cotton dyeing sequence

material

400C

800C

Detergent +Anticreasing agent

20’Cold wash

Leveling &buffering agent

600C

dye

1300C 50’

A. Acid

½ scourig

950C salt SodaR. dye

Cold wash &unload

600C 50’

DYEING CURVE OF PC / CVC FABRIC WITH REACTIVE / DISPERSE DYES

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DYEING SEQUENCE FOR WHITE:

Scouring + bleaching, 950

↓Blutton´ 50'

↓15'Sample test

↓Water drain

↓Hot (without chem.: at 800C for 20')

↓A.cAcid

↓↓ ↓If OK If not oK↓ ↓Sequester Softener↓ ↓Softner Unload↓Unload

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STANDARD RECIPE OF SCOURING& BLEACHING OF UKDL

SCOURING & BLEACHING:

DEEP SHADE LIGHT SHADE

01. ALBATEX FFC : 0.15 G/L : 0.15 G/L

02. LADIQUEST 1097 : 0.25 G/L : 0.25 G/L

03. CIBAFUUIDE C : 0.50 G/L : 0.50 G/L

04. HOSTAPOL JU : 2.00 G/L : 2.00 G/L

05. CAUSTIC SODA : 2.50 G/L : 2.00 G/L

06. SODA ASH : 2.50 G/L : 2.00 G/L

07. STABILIZER SF. : 0.35 G/L : 0.30 G/L

08. H2O2 (50%) : 3.50 G/L : 3.00 G/L

09. ACETIC ACID : 1.00 G/L : 1.00 G/L

10. INVATEX PC : 0.30 G/L : 0.25 G/L

LEVELLING:

01. CIVAFLUDIE c : 0.50 G/L : 0.50 G/L

02. LADIQUEST 1097 : 0.80 G/L : 0.60 G/L

(FOR LYCRA S/J CIBAFLUIDE C : 0.70 G/L)

LEVELLING: FOR TURQUISE BLUE, R-BLACK, ROYEL COLOUR

01. CIBAFLUIDE C : 0.70 G/L

02. LADIQUEST 1097 : 1.00 G/L

03. E2R : 0.50 G/L

[ FOR WHITE SHADE ]

H2O2 ( 50% ) : ( 4.00 G/L - 7.00 G/L)

Page no: 34

White Dyeing Recipe For (100% Cotton)Buyer Name : Farnoorr M : L = 1 : 8Order No : Cross line Mtl wt. = 100 kgBatch No : 19100 Water = 800 LiterFabric Type : (1 * 1) Rib Fab dia. = 42 inchG. S. M. : 200 – 210 Colour = White

Serial No Name Dosing (g/l) Quantity Remarks

01 Hostapol JU 0.20 160 gm

02 Cibafluide-C 0.20 160 gm

03 Albatex – FFC 0.20 160 gm

04 Cibafluide – C 0.73 584 gm

05 Hostapol JU 1.20 960 gm

06 Sequester – K 1.00 800 gm

07 Caustec Soada 2.25 1.80 Kg

08 Soda Ash 1.00 800 gm

09 Stabilizer SF .30 240 gm

10 H2O2 4.00 3.20 Kg

11 BLUETONE – BVB 0.21 % 210 gm 950 C , 60 min

12 Acetic Acid 0.60 480 gm

13 Sequester – K 0.40 320 gm

14 Softener (Non - Ionic) 1.50 1.20 Kg

Prepared by : ………………… Checked by : …………………………..Dyeing Incharge : ……………. Production Manager : …………………..

Page no: 35

Colour Dyeing Recipe (100% Cotton)With Reactive Dye

Buyer Name : D. S. L M : L = 1 : 8Order No : Cross line Mtl wt. = 100 kgBatch No : 19100 Water = 800 LiterFabric Type : S / J Fab dia. = 42 inchG. S. M. : 160 – 170 Colour = Navy

Serial No Name Dosing (g/l) Quantity Remarks01 Hostapol JU 2.00 1.60 kg02 Ladiquest 1097 0.40 320 gm03 Albatex – FFC 0.15 120 gm04 Cibafluide – C 0.50 400 gm05 Stabilizer SF 0.50 400 gm06 Soda Ash 2.50 3.60 kg07 Caustec Soada 3.00 2.40 Kg08 H2O2 4.00 3.20 Kg09 Acetic Acid 1.00 800 gm10 Invatex PC 0.15 120 gm

11 Cibafluider – C 0.50 400 gm12 Ladiquest 1097 0.80 640 gm

13 Reactive S Yellow F3R 0.33 % 330 gm14 Reactive S Red F3B 0.79 % 790 gm15 Reactive Black – 5 4.20 % 4.20 kg

16 Salt 62.00 49.60 kg17 Soda Ash 20.00 16 kg18 RFL 0.80 640 gm19 A. Acid 1.00 800 gm20 Softner (Non Ionic) 1.00 800 gm

Scouring Scouring H2O2

& bleaching hot killer A. acid950C1 hr 15 m salt dye soda

leveling 700C600C enzyme Hot wash agent

45 – 60 min40 min

matlcold wash

400C

Dyeing curve of 100% cotton fabric with reactive dye

Page no: 36

REMARKS:

UKDL strictly follow the production parameters like the time, temperature, M:L ratio

pH etc. As they do some difficult shade, it takes more time for the production of the batch.

Because of the trolley shortage and generator failure, the production process is sometime

hampered. Considering these limitations, the production officer and the Sr. Production Officer

try their best to reduce the production time.

Page no: 37

CHAPTER – VI

QUALITY ASSURANCE

Page no: 38

Q. C. DEPARTMENT

QUALITY POLICY:It is the policy of UKDL to produce quality dyed knit fabrics that meet or exceed

customers expectations & needs. To implement this policy the top management of UKDL iscommitted to provide adequate resources in terms of good raw materials and trained personnel& continually improve / upgrade its processes and systems.

QUALITY OBJECTIVES: Overall material/product loss (Level of rejection) for the company during the

production process (in a year) shall not exceed 1.5 % Defects during dyeing & knitting operations to reduced by 10% by the Jan ‘03 Process capability shall be maximized by maximizing the m/c breakdown time. M/c

breakdown time should be reduced to 20 % form its current status/position by the mid2003.

A quality procedure manual in line with the requirement of ISO9001 shall bedeveloped and implemented by August 2002.

To ensure better work environment for the personnel working in the organization.

MACHINES: Wash Fastness Tester Light fastness tester Rubbing fastness tester Electronic balance G.S.M. cutter Fabric inspection table Light box Shrinkage (%) meter

INSPECTION AREA: Shade match of fabric G.S.M. Fabric diameter Shrinkage (%)

Length wise Width wise

Fiber type Wash fastness Light fastness Rubbing fastness Faults

Dyeing faults Knitting faults

Page no: 39

FAULTS ARE FOUND IN QC DEPERTMENT:Knitting faults:

Hole Slub Thick place Thin place Neps Stripe Missing yarn Contamination

Light Medium Deep

Dyeing faults: Uneven shade Running shade In fastness property

Finishing faults: GSM variation Spirality Shrinkage control

Length wise

Page no: 40

QUALITY ASSURANCE SYSTEM

QUALITY ASSURANCE PROCEDURE: Uttara Knitting & Dyeing Ltd. assures the quality of their products in

the following three steps: In laboratory In Dyeing section & 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 If matching is OK, then it is sent to the

buyer for approval. If buyer approves the sample then bulk

production.

In dyeing section: After approval form the buyer, sample dyeing is done in dyeing

m/c in dyeing shed & again matched with the approved sample If result is OK. then balk production, During dyeing, samples are taken until accurate shade matching.

The interval may be 30-40 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: Correctly dyed, after treated & matched fabrics are allowed for

finishing 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

Page no: 41

List of Equipments:Machineries & equipment used :

Spectrophotometer with software (Datacolor) Colour light box Sample dyeing machine (2) Lab. Dip Iron Electric Balance Crock meter Washing m/c GSM Tester PH meter

Quality standard:Uttara Knitting & Dyeing Ltd. follows the quality standard: ISO-9001. 2000,

REMARKS:Uttara Knitting & Dyeing Ltd. always aware about the quality of the product.The quality of the product is always approved by the buyer. They follows thequality standard: ISO 9001: 2000, Uttara Knitting & Dyeing Ltd. is wellequipped for checking the quality of the ptoduct.. They sent the qualityreport to the buyer time to time/ batch to batch.

Page no: 42

CHAPTER – VII

MAINTENANCE

Page no: 43

MAINTENANCEMaintenanace of Machinery:Maintenance of machinery is very essential mechanical effort for achievingsmooth running of different machines. Maintenance is a process by whichequipment is looked afterin such a way that trouble free. Services andincreased machine life can be ensured and specific product qualityrequired by the customers is sustained. On time maintenance increasem/c lifetime & ensures tuouble free services.

In Uttra Knitting & Dyeing Ltd. 2 types of maintenanceare done:

1. Break down maintenance2. Routine maintenance

1. Break down Maintenance: Break down maintenance is doneinstantly when problem arises in machine. In this case, repairs aremade after the equipment is out of order and it cannot perform itsnormal functions.

2. Routine Maintenance: After a particular little the machines arecleaned & reordered, that is routine or schedule maintenance. PPCdoes it once in a month. Schedule maintenance varies, time in time& also depends on situation according to types of machines, becausemaintenance is directly related to production.

Most of the time, all the screws, nuts, bolts & levers are checked,lubrication is also done. Workers inform about the problem areas of themachines. Depending on their information. maintenance is done,Maintainers analyses the machine records & take steps according torequirements.

Maintenance

Routine Maintenance Break Down Maintenance

Mechanical Maintenance Electrical Maintenance Mechanical Maintenance Electrical Maintenance

Page no: 44

MAINTENANCE PROCEDURE:

During maintenance procedure following points should be checked.

Checklist of different parts:

Maintenance: MechanicalMachine: Dyeing Machines

Sl.No. Item need to be checked & Serviced

1 Crease the winch bearing.

2 Complete cleaning of machine

3 Cleaning of drain valves, replace seals if required

4 Check air supply filter, regulators, and auto drain seals

5 Clean filters element and blow out

6 Greasing of Unloading Roller Bearings.

7 Checking of oil level and bolts of Unloading Roller Gearbox.

8 Checking of unloading roller coupling and packing.

9 Checking and cleaning (if required) of Min Vessel Level Indicator

10 Check the oil level of pump bearing and refill if requird.

11 Check the function of heat and cool modulating valves

12 Check all belts and belt tension

13 Check all door seals

Maintenance: MechanicalMachine: Lab dyeing m/c.

Sl. No. Item need to be checked & Serviced

1 Check rotating main shaft bearing.

2 Check cooling water inlet and outlet nose and nose clips.

3 Check cooling fans

4 Check driving bells and pulleys.

Page no: 45

Maintenance : MechanicalMachine : Lab dyeing m/c.

Sl. No. Items need to be checked & Serviced1 Check & clean fluff and dirt at all motor fan covers2 Check all motors terminals3 Check min panels (by using compressed air)4 Check panel cooling fan & clean it filter5 Clean main pump inverter and its cooling fan6 Check all circuit breaker, magnetic contractors and relays7 Check current setting of all circuit breaker & motor over loads.8 Visual checking of all power & control cables9 Check DC drive of reel motors10 Check all pressure switches11 Check calibration of main vessel & all additional tank12 Check all pneumatic solenoids13 Check calibration of heating/cooling. Modulating value14 Check setting of tangle sensor.15 Check setting & operation of lid safety switches16 Check all emergency Switches17 Check all indicating lamps18 Check all on/off switches19 Check all signal isolators20 Check key pad & display of controller21 Check proximity switches

The following tasks are generally done during maintenance:

Inspections & check ups Lubrications Planning & scheduling Record analysis Training of the maintenance crew Collection or purchase of spares

Page no: 46

Maintenance work to the different machines:

BOILER MAINTENANCE SCHEDULE:Daily: Check gas pressure Maintain log sheet Chemical dosing

Weekly: Check all steam line Fire quality of boiler

Monthly: Check all steam line Fire quality of boiler Gas consumption report Burner clean

Quarterly: Burner clean Economizer clean Feed tank clean Chemical tank clean Sight glass clean

Half yearly: Burner clean Feed tank clean Chemical tank clean Economizer clean Replace gasket Replace valve Check gas line & filter & pressure

Yearly: Overhauling of boiler Chemical cleaning of boiler Safety valve test Economizer clean Feed tank clean Chemical tank clean Burner clean Check safety valve setting Replace valve & gasket Boiler inspection by authority

Page no: 47

Dyeing m/c maintenance ScheduleDaily: Check belt tension Check steam or water system & air supply Check chemical pump Machine clean

Weekly: Bearing & belt check Check leakage of air, steam & Water line Greasing bearing points Add gland packing at pump

Monthly: Greasing bearing points Replace bearing points (if required) Gaskrt check Clean steam trap Lubricating all chemical pump

Quarterly: Replace belts Repairing of pulley, shaft & bearing housing Painting m/c & pipe line Clean steam trap Replace seals (if leakage) Change gasket of steam of water lines

Half yearly: Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing

Half yearly: Replace belts Repairing pulley, shaft & bearing housing Painting m/c, pipe line Replace seals Machine body repairing

Yearly: Machine overhauling

Page no: 48

Hydro extractor Maintenance

Daily: Machine clean Belt checking

Weekly: M/c clean Belt clean Greasing & lubricating of all points

Monthly: M/c clean Check gear oil quality

Quaterly: Change of gear oil Belt change

Half yearly: Change of gear oil Belt change (if required)


Page no: 49

TENSIONLESS DRYER MAINTENANCE

Daily: Check belt tension Check steam supply & air system Machine clean

Weekly: Check fabric drying quality Greasing bearing points Clean airfilter & regulator

Monthly: Clean radiator & m/c cabinet Greasing bearing points Clean air filter and regulator

Quarterly: Replace belt Replace gear oil Duct clean

Half yearly: Check roller condition Greasing & lubricating all points


Page no: 50

TUMBLER DRYER MAINTENANCE:Daily: Check belt Steam leakage area M/c clean

Weekly: Heat exchange clean Greasing & lubricating of all points Belt check M/c clean

Monthly: Filter clean Steam trap clean

Quarterly: Replace belt Replace gear oil Duct clean Gasket & valve change

Half yearly: Gasket & valve change


Page no: 51

SOFT SET M/C MAINTENANCE:

Daily: Check belt tension Check Steam supply & air system M/c clean

Weekly: Check fabric quality Greasing bearing points

Monthly: Greasing bearing points Clean air filter & regulator Clean steam trap

Quarterly: Replace belts Replace gear oil Painting m/c & pipeline of the total system Replace seals

Half yearly: Check roller condition Greasing & lubricating of all points Check bearing condition


Page no: 52

MAINTENANCE TOOLS/EQUIPMENTS & THEIR FUNCTIONS:

Maintenance tools/equipments Functions1. Adjustable wrench Used for setting nut & bolts2. Pipe Spanner For pipe fitting3.Spanner Fixed Spanner for nut & bolts fitting4.Socket spanner Handle system for nut & bolt fitting5. hammer To apply load where required6. Screw driver To release any screw7. Punch Used to fit any worn out shaft8. Lock opener To open the clip of bearing9. Hack saw To cut any metallic thing10. Outside calipers To measure outside dia11. Inside calipers To measure inside dia12. Slide calipers To measure very small dia13. Vernier scale To measure very small dia14. Chain ton To lift heavy load15. Welding machine To join metallic parts16. Grinding machine To make the smooth fabrics17. Tester To test electric circuit18. Pliers To grip anything & cut anything19. Avometer/Voltmeter To measure voltage20. Steel tape To measure length, width & height21. Chisel To cut any metal22. Gasket cutter For gasket cutting23. File To smooth the rough surface

REMARKS:

The maintenance department of UKDL is well equipped. It has sufficientmaintenance manpower including mechanical and electrical engineers. They do themaintenance of the m/cs during the Eid vacation. Otherwise, they do the breakdownmaintenance. To increase the lifetime of the machineries and ensure the properrunning of the machinery.

Page no: 53

CHAPTER – VIII

UTILITY

Page no: 54

WATER TREATMENT PLANT:(Water Softening Method – Base Exchange Process)

TechnicalDetails

Raw water tank Softener tank Soft watertank

Brine tane

Size Length - 40´Width - 20´Height - 15´

Diameter – 6´Height - 15´

Diameter - 20´Height - 20´

Salt reqd:190kg/day/tankRegenerationtime 1.30 hr

Capacity 360 Ton 45 Cubicmeter/hour/tank

180 Ton

Source Natural sourceDeep tubewell

R.W.T S.T. Salt price10tk/kg

Project cost Total Project Cost : 113 Lacks

AIR COMPRESSOR:An air compressor is a m/c to compress the air and to raise its pressure. The air compressorsucks air from the atmosphere, compresses it and delivers the same under in high pressure to astorage vessel. From a storage vessel, it may be conveyed by the pipeline to a place where thesupply of compressed air required.

Utility:1. Air2. Mobil3. Electricity

1. U3 – Com - 02Company : VESPACountry : TaiwanType : Piston type

Component:- Motor- Piston- Compressed a- Oil drain plug

U3 – Com – O2Country : EnglandType : Screw type

Component:- Radiator- Separator- Air filter- Oil filter- Motor- Screw

Page no: 55

BOILER:Specifications:

1. Type : Fire Tube Boiler2. Brand Name : Omnical, Germany3. Type No. : DDH 15.0 – 104. Serial No. : 187095. Year of manufacturing : 19966. Max. Working pressure gauge : 10 bar7. Max Temperature : 1830 C8. Max heat capacity : 3.25 MW9. Water content up to ‘NW’ : 9.62 cubic meter10. Max steam out put : 5.0 ton/hr11. Gas pressure in line : 1 bar12. Gas pressure (in boiler) : 010 bar13. Gas consumption : 34 cubic meter/day14. Steam pressure : 7.5 bar15. Steam header pressure : 120 PSI16. Blow down line : 4 times/day17. Soft water supply pipe dia : 1 inch18. Establishment cost : 60 lacks

Page no: 56

ElectricityElectricity is supplied by: Generator – 1

- Oil consumption – 25 lit/hr- Capacity - 250 KVA

Generator – 2- Oil consumption – 35 lit/hr- Capacity - 350 KVA

REBElectricity consumption – 50KW/day(A substation of voltage control – 1100 KV)

Utility cost:01. Gas bill (Titas) : 7-8 lacs / month02. Electricity Bill (REB) : 8-9 lacs / month03. Others : 5-6 lacs / month

Remarks:In UKDL all utilities that require are available for sufficient production.

Page no: 57

CHAPTER – IX

STORE &INVENTORY CONTROL

Page no: 58

CHAPTER-IX

STORE & INVENTORY CONTROL

INVENTORY SYSTEM FOR RAW MATERIAL:In Uttara Knitting & Dyeing Ltd. there are different inventory systems for different rawmaterials.

GREY FABRICS STORE:All the grey fabrics arc stored in the fabric store, near the batch section. Different typesof fabrics arc listed in the sheet according to the fabric types, quantity &consumer’s requirements. Fabrics GSM, shrinkage, diameter & other properties arealso taken into consideration. The batches are prepared by taking the required fabricsfrom the grey store. At present the grey fabrics store of Uttara Knitting & Dyeing Ltd.containing the following types of fabrics-

Single jersey 1 x 1 Rib 2 x 2 Rib 2 x 1 Rib Fleece Melange.. Pique Single jersey (with lycra attachment) 1 x 1 Rib (with lycra attachment)

Dyes & Chemicals Store:There is a different time for dyes & chemicals_ Various types of dyes & chemicals arcstored here according to the dyes & chemical company.Different types of dyes & chemicals are listed in a sheet. In the sheet the stored quantity of dyes &chemicals are also included. Everyday the sheet is updated & a copy of this sheet is supplied to theAGM (production), Dye house & lab section.

Spares:In Uttara Knitting & Dyeing Ltd. required amount of spares of different machines are

Page no: 59

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

Finished goods:Uttara Knitting & Dyeing Ltd. supplies its finished dyed fabrics to its garments section So.dyed finished fabrics are stored for short time in the finishing section. All the deliveredfabrics are noted on the tally khata according to the lot no, quantity, fabrics diameter,buyers name, color & considering other technical parameters.

Others:There is a central store at Uttara Knitting & Dyeing Ltd. In that store the various typesof forms, papers, stationary & other necessary goods are kept.

REMARKS:Uttara Knitting & Dyeing Ltd. has individual stores for raw materials, finished goods etc. the sotreof dyestuff & chemicals arc not so clean. There is no enough space to store the finishedgoods. It requires to increase the store area.

Page no: 60

CHAPTER – X

COST ANALYSIS

Page no: 61

COSTING OF THE PRODUCT

The following points are considered for costing any dyed product in UKDL1. Total dyes & chemical cost2. Total utility cost3. Salary4. Payment5. Transport cost6. Lunch7. Entertainment cost8. Miscellaneous cost9. Government cash incentive

AVERAGE PRODUCTION COST:1. White production : 200,000 kg * 5 hr = 1000,000 kg-hr2. Colour production : 130,000 kg * 11 hr = 1430,000 kg-hr3. Total wash : 70,000 kg * 3 hr = 210,000 kg-hr4. PC & CVC : 20,000 kg * 18 hr = 360,000 kg-hr

Total production : 3000,000 kg – hrTotal overhead cost : 30000,000 /=

Average production cost per kg-hr : Total overhead cost / Total kg-hr= 30000,000 / 3000,000= 10 /=

REMARKS:This are not all the costing information. Some other costing information are described in theprevious chapters.

Page no: 62

CHAPTER – XI

MARKETING ACTIVITIES

Page no: 63

MARKETING ACTIVITIESCONSUMERS OF PRODUCT:Uttara Knit Dyeing Ltd. is a 100% export oriented industry. All the goods produced in thisindustry are exported into various foreign countries. Name of the main buyers are givenbelow-

(A) L/C BUYER:01. PULL & BEAR02. DSL.03. COTTON HOME LTD.04. WLL LORD.05. PELICAN RESOURCE LTD.06. FUTURE CLOTHING LTD07. TOPSTAR SPROTSWEAR LTD.08. GILL TREADING CORPORATION09. SOUTHERN LTD.10. FORNOOR GARMENTS LTD.11. SHSHALI HOSIERY & FASHION LTD.12. UTTARA KNITWEARS LTD.

(B) SUB CONTRACT BUYER:01. FRIENDS WORLD COMPOSITE LTD.02. PURPLE APPARELS LTD.03. EXHO TEX LTD.04. OEKO TEX LTD.05. MOSTAFA APPARELS LTD.06. JOINTEX KNITWEARS LTD.07. WEATERN STORE LTD.08. HAQUE & SONS LTD.09. K.R.C. COMPOSITE10. STANDRED TRADING LTD.11. NASRIN TEX LTD.12. FAMILIAR LIMITED.

Local market:Uttara Knitting and Dyeing Ltd. is not 100% export oriented industry. They have some localbuyer and they also work by sub-contact.

Importing countries:There are some countries which are importing goods from Uttara Knitting & Dyeing Ltd. Thename of the countries are given below- Spain Germany Denmark Europe Denmark Europe Union United State of America

Page no: 64

Manpower of marketing:Marketing plays a vital role in the field of displaying / showing the goods criteria of theproducts to the buyer & to communicate with the buyer. There are about 15 people in themarketing section of the industry.

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

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

In Uttara Knitting & Dyeing Ltd. mainly senior marketing officers, merchandiser &higher officials deal with the buyer. There are some fixed buyers of the industry. The buyersgive their orders continuously all over the year. The marketing officers & the merchandiserscommunicate with the buying houses to collect the orders.

By both side understanding the rate & the order quantity are fixed.

Duties & responsibilities of marketing officer: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 amarketing officer are given bellow- To prepare cost sheet by dealing with the buyer To take different steps by discussing with the high officials & merchandisers To maintain a regular & good relationship between commercial officer &

merchandisers To maintain a communication with the buyers and buying houses Communicate with better criteria of the products

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

REMARKS:Uttara Knitting & Dyeing Ltd. has a well learned marketing & merchandising team. Theyalways communicate with the buyers. Uttara Knitting & Dyeing Ltd. has some fixed buyers.The marketing section also looks the quality & quantity buyers.

Page no: 65

CHAPTER – XII

CONCLUSION

Page no: 66

The UKDL is a well-planned versatile project. The administrations,management, chain of command – all are well organized. They are devotedto satisfy the customer by their activities. However, some of the point we wantto mention for the good of UKDL .

SOME SUGGESTIONS:- During the transport of the fabric in the dyeing floor and also during

the loading of the m/c, fabrics are soiled for the contact with floor.This makes the fabric/part of the fabric dirty. It may require morescouring/bleaching agent or may create stain making it faulty.

- The dyeing floor is watery most of the time: it should be cleaned allthe time.

- The illumination of the dyeing shade should be enhanced. It mayexert the worker fatigue ness.

- More skilled labour should be used in a project as UKDL. Many timethe dosing pipelines are clogged due to the careless dosing ofchemicals.

- The m/c stoppage time should be analyzed and minimized. Themaintenance should be carried out when the m/c is out of action(wherever possible)

Page no: 67

LIMITATIONS OF THE REPORT:- Because of secrecy act, the data on costing and marketing

activities has not been supplied & hence this report excludes thesechapters.

- We had a very limited time. In spite of our willing to study moredetails it was not possible to do so.

- Some of the points in different chapter are not described as thesewere not available.

- The whole process is not possible to bind in such a small frame as thisreport, hence our effort spent on summarizing them.

LastlyWhat special in this report is that the information, data & description

very much subjective & practical. So, one can easily have an idea about thewhole dyeing unit of UKDL at a single look on it.

The newcomer can use this report for further detailed study or can knowUKDL without much work. But what should be remembered the chemical,some process steps may be modified within the period this papers goes to thereaders.

industrial attachment of uttara knitting & dyeing ltd

Engineering

manager manager manager

dyeing mc bangla

sample dyeing mc

knitting section

general manager

knitting mc rib

rib mc

steam set mc