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ACKNOELEDGEMENTAt first my gratefulness goes to Almighty Allah to give me strength and ability to

complete the industrial training and this report. You have made my life more beautiful. Mayyour name be exalted, honored and glorified.

Now I wish to take this excellent opportunity to think a lot of people who have assisted andinspired me in the completion of my training period.

Md. Asif ossain, Manager !".#$, TEXEUROP (BD) LTD. to whom I am extremelyindebted for his tremendous support and guidance throughout my training period. %eingworked with him I have not only earned valuable knowledge but was also inspired by hisinnovativeness which helped enrich my experience to a greater extent. is ideas and way ofworking was truly remarkable.

I also express my gratitude to Mis&'amrunnahar (umi, )ecturer Europeain University ofBangladesh(EUB) for his support.

I would like to thank the management of the TEXEUROP (BD) LTD. for giving me theopportunity to do the industrial training successfully and also their valuable suggestions. Mydeepest appreciation goes to Md. (hahidulAlamMo*umder, +eneral Manager !dyeing$,TEXEUROP (BD) LTD. for his permission to conduct my industrial training without whichit would be uncompleted. he generous support is greatly appreciated. I would also like thank

-roduction officer, senior production officer, Assistant dyeing manager, Assistant +eneralmanager and other officials of exeurop!%$ )td. for helping me to complete industrialtraining successfully. My gratitude also goes to all the employees of exeurop !%$ )td. fortheir sincere co/operation, support and valuable advices.

)ast but not least, thanks go to my precious family for their never ending love and inspire atevery stages of my life. 0ithout their continuous support I reali*e that would not be a personI am right now.

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1 !O"TE"T#

#A-12 I)1 -A+1 N3.

45 Introduction 6

47 -ro8ect escription 9/:

46 Manpower Management ;/56

49 Machine escription 59/95

4< 2aw Materials 97/9:

4= -roduction -lanning (e>uences ? 3perations 9;/@9

4@ "uality Assurance (ystem @


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he term BtextileC derived from the )atin word DtextilesE and the France word DtexereE,meaning Bto weaveC, and it originally referred only to woven fabrics. It has, however, cometo include fabrics produced by other methods. hus threads, cords ropes, braids, lace,embroidery, nets and fabrics made by weaving, knitting, bonding, felting or tufting aretextiles. (ome definitions of the term textile would also include those products obtained bythe papermaking principle that have many of the properties associated with conventionalfabrics. In addition to clothing and home furnishing, textiles are used for such industrial

products as filters to air conditioners, life rafts, conveyor belts, tents, automobile tires,swimming costumes, safety helmet and ventilators.

From fiber to fabric, exeurop !%$ )td. is truly integrated undertaking. he exeurop !%$)td. has the capability to offer a complete product range for the export textile markets. hegoal of exeurop !%$ )td. is to become the preferred partner for sourcing high >uality

fabrics and clothing from %angladesh with highly advanced technology and an emphasis ondeveloping local human resources. exeurop !%$ )td. has the potential to make animportant contribution to the nationEs growing readymade garments export sector.

he nation behind the existing structure and future expansion of exeurop !%$ )td. is tocapture value/added at each stage of the textile manufacturing process. espite %angladeshEslack of indigenous cotton production capability, exeurop !%$ )td. has leveraged%angladeshEs labor cost advanced and export competitiveness to the maximum.

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1 LO!$T%O"&

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Gogra, Hoydebpur,+a*ipur, %angladesh.el& ::4/7/;7=5;:=, ;7=5;::,;7=5;;6,;7=75=6/9,;7=7@45/7, Fax& ::4/7/;7=5


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Te4europ (BD) Ltd. has been established with the ob8ective and vision to satisfy the needs of75st century of worldwide knit apparels markets from one stop service being committed to3ne/ time elivery, "uality Assurance, -rice Affordability and (ocial Accountability.%asically Pante4 gar-entsfactory was the mother textile at Narayangon8 of Te4europ (BD)Ltd. From which the factory was expanded with collaboration of 1uropean partner.he pro8ect is located in vogra8oydevpur under the district of +a*ipur, about 7< km distancefrom the a*rat(ah8alal !2&$ International Airport haka, %angladesh. A well/developed2oad #ommunication is there to reach the factory from the Airport as well as from the haka#ity.

1 D%//ERE"T DEP$RT0E"T#&

a) '"%TT%", #E!T%O"&

1 'nitting* Inspection

) D.E%", #E!T%O"&

1 %atch section* ye house+ yeing lab.5 "uality control6 Finishing

) ,$R0E"T# #E!T%O"&

1 Merchandising* #A+ #utting5 (ample6 (ewing Floor7 ".#. ept.8 -ackaging.

d) 0$%"TE"$"!E #E!T%O"&

1 1lectrical* Mechanical

e) #TORE #E!T%O"&

1 +eneral (tore* Accessories (tore1 #UPPORT%", DEP$RT0E"T#&

a$ -ersonnel administrationb$ 2

c$ Marketingd$ -rocurement

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e$ Finance and accountingf$ (ecurity department

0$OR !U#TO0ER#&

1 (. 3liver* -oly #oncept+ American 1agle5 +erry 0eber6 (/-olo7 A((AN8 om ailor9 # ? A: )erros1; 1)1GA111 Mustang Heans

!ERT%/%!$T%O"#&

P2.#%!$L %"/R$#TRU!TURE&

he mill is built in such a way that there is possibility for further expansion of the mill. hestructure such as mill, office buildings, record rooms, guardrooms ? dining room etc. are

made of solid hard concrete ? brick mtls. he main set up for mLcs are built of corrugated

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iron ? iron sheet, transparent hard plastics with enough ventilation ? scope for passing light? air.Total area of the industry : 12500 sq Meter

Factory land area : 10000 sq. Meter

Building : 8 Storied.

Floor sace !"nitting# : 5000 SFT

Floor sace !$yeing % Finishing# : 20&000 SFT

RE0$R'#&

exeurop !%$ )td. is a modern textile industry. 1very facility of a modern textile mill existsin this factory. It has a no. of renowned buyers especially at 1urope. (o, exeurop !%$ )td.is getting popular throughout the textile sectors and its buyers.

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OR,$"O,R$0#

1 OR,$"O,R$0 O/ 0$"PO


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irector!-roduction$

+M!yeing$

+M!3peration$

A+M!yeing$

Manager!"uality$

Manager!'nitting$

Manager!Maintenance$

+Mmaintenance A+Mgarments

ManagerMerchandising

Manager

(r. MerchandiserHr. Merchandiser

Asst.Lrainee Merchandiser

Asst.Manager

Asst. Manager Asst.Manager

Asst.Manager

Manager#uttingL(ewing

(enior -.3. Incharge (enior -.3. 3fficer

(upervisor-.3

3perator

3perator 3perator 3perator echnician

ifferent elpers

0$"$,E0E"T #.#TE0

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1 %"TER"$L !O00U"%!$T%O" #.#TE0&

1 Intercom telephone* 0ritten letters+ Fax5 3ral6 #ell -hone7 #2%/T !2$",E&

here are three shifts in this factory and each shift is of eight hours. (hift is changed after aweek on (aturday.

(hift #hange for worker of (ecurity&' Shift ( 0):00 ( 1*:00

B Shift ( 1*:00 ( 22:00+ Shift ( 22:00 ( 0):00

,eneral shift ( 0-:00 ( 18:00

1 RE#PO"#%B%L%T%E# O/ PRODU!T%O" O//%!ER&

From getting an order of upper level all responsibilities are on the production officers.hey work with a troop of operators, helpers, fitters etc. to finish the production in due time.In the meantime production officers bear all ha*ards, problems. hey have to explain to themanager for any type of production hamper. (o, all production activities and its success

depend on the production officers.

1 o $lign-ent of PO = #PO&

Hob title& -roduction officer ? (enior -roduction officer2eport to& -roduction ManagerPurpose&

1 o control shift according to the plan made by the production manager* erritory& yeing section !ma8or$ %atching and Finishing section !minor$

Role >ithin the organi?ation&

2esponsible for own shift production with a good >uality and minimum time.

Environ-ent&

-roduction officer has to work under huge stress. e has to work in acute heat under physical? mental pressure. Also he has to work in acute heat all the year round.

o Desription of Prodution Offier&

2eport o& (r. production officer

uties ? 2esponsibilities&1 3verall supervision of dyeing, finishing production.

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* %atch preparation ? - check.+ yes ? chemical re>uisition issue ? check.5 0rite fabrics loading ? loading time from mLc.6 -rogram making, sample checking, color management.7 #ontrol the supervisors, operator, asst. operator ? helpers of dyeing mLc.8 And also any other work as ? when re>uired by the management.

o Desription of #r Prodution Offier&

2eport o& -.M !production$Hob (ummary&o plan, execute ? follows up the production activities ? control the >uality production withrelated activities.

uties ? 2esponsibilities&1 3verall supervision of dyeing, finishing production.* #hecks the different log books of different areas ? report to management.+ #hecks the sensitive parameters of different machine for smooth dyeing.5 #hecks out the plan to control the best output from supervisor ? workers.6 o trained up ? motive the subordinates how to improve the >uality production.7 Maintenance of machine ? e>uipment. Any other works? when re>uired by the

management.8 #ontrol the supervisors, operator, asst. operator ? helpers of dyeing mLc.

1 RE0$R'#&

-roduction runs with the help of mechanical fitters. For any kind of mechanical faultof any machine they fix and work under technical in/charge. -roduction officerEs takesaccount of daily production by running after the two supervisors and workers so on.

1 %"TRODU!T%O"&

exeurop !%$ ). is an integrated computeri*ed company. It has total 74 dyeing machines

among of them 54 machines are known as sample dyeing machine on the basis of theirproduction capacity. he machines are controlled by high skilled operators. 3n the other hand'nitting section contains 5: machines, among of them 56 are circular knitting machine andanother < are flat bed machines.

'"%TT%", 0$!2%"E DE#!R%PT%O"

Proess re@uire-ents&

In exeurop !%$ )td. three types of machines are used for producing and inspecting knitted

fabrics.hese are&/

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1# +ircular nitting /achine !Single% $oule ersey Machine#.

2# Flat nitting Machine !+u % +ollar#.

3# Faric insection /achine

And the whole knitting section is divided in four sections,5. #ircular knitting section7. Flat knitting section6. Fabric inspection section9. (tore sectionTotal no of -ahine at a glane&

ML# ype Number of Machine +rand otal(ingle 8ersey 4@ 6:

ML#

2ib 4ill Tape #etion&

ML# No. ype %rand Model 3rigin ape 0idth45 0arping mLc ong +uan 0M#/647 #hina

47 will tape mLc ong +uan 'YF/:L64 #hina46 will tape mLc ong +uan 'YF/:L64 #hina49 will tape mLc ong +uan 'YF/:L64 #hina

1 !loth %nspetion&

In cloth inspection section one machines is available. (pecification of these machines is givenbelow.

ype & #loth Inspection MachineManufacturer name & *u fabric Inspection

#ountry & hailandModel No & ;44.65

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/ig& /ari %nspetion 0A!

1 %asic element of knitting&

* Needle.

+ (inker.

5 #am.

6 Types of needle

4n general there are three tyes of needles.1 Bearded needle.

* atch needle.

+ +o/ound needle.

$ording to the Butt position Lath needle are four types&

1 3ne butt latch needle

* wo butt latch needle

+ hree butt latch needle

5 Four butt latch needle

1 !$0&

#ams are the devices which convert the rotary mLc drive into a suitable reciprocating action

for the needles or other elements.

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ypes of cam& wo type of cam

1 1ngineering cam 'nit cam

* 'nitting cam Miss camuck cam

/untion of !$0&he function of cam is as follows&

1 o produce motion to needles.

* o drive the needles.

+ Formation of loops.

!n"e#$his is secondary primary knitting element. It is a thin metal plate with an individual andcollective action approximate at right angles from the hook side between ad8oining needles.

%&n'(!on of s!n"e#$

4t /ay one or /ore of the follo6ing functions deendent uon the/achines nitting action and consequent siner shae and /o7e/ent.

T)e f&n'(!ons of !n"e# *#e$

1 oo for/ation.

1 olding do6n.

1 "nocing o7er. Siner

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1 3thers 1>uipments sed In 'nitting (ection&

* +(M cutter

+ 1lectronic balance

1 Ter-s and definition of Cnitting&

!ourseO A hori*ontal row of loops formed by the needles during one knitting cycle


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7 Needle

8 #am box

9 #am? sinker: G" -ulley

1; %ase plate

11 ake up roller

1* %ody

1+ Auto stopper

!reel& 0hich is used to place the yarn cone, from where the yarn is supplied to mLc,

through pipe.

.arn ,uide& 0hich is used to guide the yarn, Yarn guide is necessary for maintaining

proper tension on yarn during kitting.

.arn Tensioned& Yarn tensioned is re>uiring to proper gripping of yarn by needle.

/eeder& Feeder is directly related to the production. 1.g. if no. of feeder is high then

production will be high and vice versa.

!ylinder& #ylinder is an important part of knitting mLc through which needles are set.uring selection of knitting mLc for specific types of knitting cylinder gauge is an important

parameter.

"eedle& he main part of knitting mLc is needle, without needle it is impossible to knit

garments. In knitting mLc there are many types of needle may be used, like letch needle,

bearded needle, compound needle but latch needle are very popular in knitting.

!a- o4& #am box is used to hold the cam according to the fabric design. 'nitting cams

are arranged according to the design, e.g. arrangement of knit, tuck ? miss cam.#inCer& (inker is essential for knitting garments. (inker is used to hold ? support the thread

during the loop formation. In knitting different shape of sinker is used.

3D Pulley& G" pulley is very important in maintaining proper stitch length.

G" pulley is positive then increase stitch length and decrease +(M. G" pulley is

negative then decrease stitch length and increase +(M.

Base plate& %ase plate is circular shaped body, on which cylinder is situated.

TaCeup roller& ake/up roller is used to take the cloth by roller.

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1 Typial Cnitting alulations&

The alulations >hih are fre@uently used in the Cnitting setion are disussed elo>&

1 ,auge (,)&Number of needles per inch.

* Total needles&Machine diameterP +augeP6.95=.

+ /eeders of #ingle ersey& Machine diameterP6.

5 /eeders of Doule ersey&Machine diameterP7.

6 "on teh !alulation of #ingle ersey&

7 "on teh !alulation of Doule ersey&

1 Prodution !alulation (Cilogra-s)&

Prodution for-ula&

'gLhour

1xample& )et,

ia. Q 67R

+auge Q 79

2-M Q 5:

Yarn count Q 64sL5

Feeder Q 574

() Q 7.:ue solution that usesthe knowledge of the experts in your company to help you manage dyeing recipes and entire

processes. It automatically creates or specifies the best production recipe for any color, dyedon a specific fabric and for a particular customer. It manages hundreds of different productionrecipes by relevant dyeing re>uirements.

MA#IN1 (-1#IFI#AI3N&(tandard features include the following&

1 -ulsed xenon light source* Multiple aperture si*es to accommodate samples of different si*es+ Automated specular port

3ptional features including the following&1 Automated aperture detection* Automated *oom lens+ Automated, ad8ustable ultra/violet filters for measuring fluorescent samples5 Ad8ustable G Filter

6 3ption ransmission 3ption7 Gertical Mount 3ption

EletrialAEnviron-ental Re@uire-ents

-ower & :< to 7=9 GA#, 9@ to =6 *, :4 GA peak, 6< GA typical$solute Operating Environ-ent


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(%& 5.5 or higher

Fig& elta -ass in ata #olor Fig& ata #olor Machine

Dyeing pot&7


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%rand & F?-3rigin & #hina

Ladip -A +&

#apacity & 79 pots !9


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/ig& Environ-ental Te-perature


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6 tility sed& Air, 0ater, 1lectricity.7 Main points&

8 (peed & 544 mLmin.!For single 8ersey fabric line speed is maintained as < mLmin.For other fabric line speed is maintained as 5 mLmin.$

1 -roduction capacity& @ tonsLday

/ig& #litting -A

;+Open s@uee?er&

BianoF %taly

0ain parts&1 (>uee*e roller!dewatering$* 3ver feeding roller!to delivers as per feed$+ Folding device!to delivers the fabric in folded form$

5 (oftener tray.!to impart soft finish$

Utilities used&

1 1lectricity.* #ompressed air.

-adder pressure& 9.uee*er.+ eatering unit.

5 (tretching unit!for ad8usting dia.$6 5st tank to remove dust, hairy fiber etc.

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7 7nd tank to apply different chemical finishes like flame retardant, softener, fixer.

8 (peed& :4 mLmin!max$9 -ressure of 5st padder & 6: -ressure of 7nd padder & 9/uirements.

1 Ratio Bet>een #alt = #oda aording to shade I &

For All #olors(hade (altL(oda

[.4; 54L7

.54/.74 5


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.94/.:4 7


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+arments esign or (ketch !Manually or #omputeri*ed$

\

%asic %lock !Manually or #omputeri*ed$

\

0orking -attern !%y Machine$

\

(ample +arments !Manually$

\

-roblem of -roduction or -roduction 2elated Matter

\

#osting\ (end to %uyer

\

Approved (ample

\

-roduction -attern !%y and or #omputer$

1 Briefly Disuss&

Design or #Ceth&

It is nothing but one kind of engineering art including all measurement of particular

style.

Basi BloC&

It is an individual component of garmentswithout any design or style.


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-roduction related problems should be eliminated in this step.

$pproved #a-ple&

he sample which is approved by buyer is called approved sample.

#end to Buyer&

0hen all process are done, then the garments are sent to buyer.

Prodution Pattern&

o make pattern for a particular style with net dimension along with allowance.

/ators Upon uence through which garments aremanufactured.

] Design A #Ceth&

In the garment manufacturing the first step is designing the sketch for the dresses that have tobe prepared. For this purpose the designer first draw several rough sketches in the sketchbook. he designer does not go for details at this moment but he rather let his creativity flowon the paper and he draws many sketches. )ater these sketches are analy*ed by a panel of

designers. hey finally select few out of them. hese few sketches are rendered in detailseparately or in the form of a single collection. he designer also draws working drawingsalong with the sketch. 0orking drawings are flat drawing of the sketch and it helppatternmakerin understanding the patterns involved in the construction.

] Pattern Design&

he pattern maker now develop first pattern for the designs in any one standard si*e. his ismade by pattern drafting method and the purpose of making this pattern is to create thesample garment for test fit.

] #a-ple 0aCing&

he first patterns are sent to the sewing unit for assembling them into garment. his isusually stitched on calico or muslin which is an inferior >uality of fabric and it reduces cost.

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his sample is constructed to analy*e the pattern fit and design too. After the sample garmentis stitched it is reviewed by a panel of designers, pattern makers and sewing specialists. If anychanges have to be made they are made at this time.

1 uality !ontrol /lo> !hart&

Yarn receiving

(ample 'nitting

%atching

yeing !#heck shade ? Faults of dyeing$

ewatering ? ntwisting

rying !#heck diameter, -retreatment, (hrinkage (pirality and +(M$

#ompacting

Final inspection

If sample 3' go for bulk production

1 uality !ontrol in ,rey /ari %nspetion&

(ome -oints Are Needed o Maintain For igh "uality Fabric&a$ %rought good >uality yarn.

b$ Machines are oiled and greased accordingly.c$ +.(.M, (titch length, ensions are controlled accurately.d$ Machines are cleaned every shift and servicing is done after a month.e$ +rey Fabrics are checked by 9 point grading system.

)ist of 1>uipments&In this factory this is the list of e>uipments to assure >uality&/5$ Inspection mLc ^ 57$ (cissors6$ 1lectronic balance9$ +(M cutter


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uality $ssurane Proedure&

5$ %ody ? 2ib Inspection&All rolls are kept in front of the inspection mLc time to time and are inspected over theinspection mLc visually in a pre/set speed against light. For any ma8or or minor faults likethick/thin, bare mark, fall out, contamination, fly, holes, oil lines, needle line, slubsetc arerecorded in inspection report to classify the fabric based on the four point system.

7$ #ollar ? #uff Inspectionollar? cuff are inspected visually under the light box, any ma8or or minor faulty collarLcufflike having wrong ply, hole, needle line, slubs, wrong design, first round problem etc.

properly counted and recorded.

1 uality #tandard&

exeurop!%$)td. maintains the I(3& ;447 standard in case of >uality. hey also posses(+( ?3ekotex certificate herefore, the four point system is followed to inspect the body ?rib fabric. he defects found and points given against are recorded in the inspection sheet.Following table shows the four point grading system followed by inspection atexeurop!%$)td.

Four point grading system

(i*e of defects -enalty6 inches or less 5 point3ver 6 inch but not over = inch 7 point3ver = inch but not over ; inch 6 point3ver ; inch 9 point

ole [5 inch 7 pointsole _5 inch 9 points

he following formula is used for determining pointsL544 s>. yds. in a roll of a fabric&/-ointsL544 s>. yds. Q !4.4:K2oll pointsKA.+(M$ L 2oll wt. in 'g

+rading calculation based on -oints&-oints +radep to 54 points A54/74 %74/64 #64/ 94 Above 94 2e8ect

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Following faults and results are shows common body and rib faults and response byinspection section at exeurop!%$)td.&/

ReJetion riteria for ody = ris

No. Faults 2esponse5. Needle mark Ma8or needle line is re8ected7. (tripe Ma8or needle line is re8ected6. %arre mark 2e8ected9. #ontamination ? fly Approved for color but for whiteshed 5

point is assigned


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56. hick/thin 2e8ect59. 0rong tube 2e8ect

1 uality !ontrol in Dyeing $nd /inishing&

he exeurop!%$)td assures the >uality of the products of dyeing section in the followingthree steps&5. In laboratory7. In yeing section ?6. In Finishing (ection-rocedures are described below.

%n laoratory&

1 (watch card from buyer according to their re>uirement* 2ecipe prediction for sample dyeing+ (ample dyeing until matching with swatch card5 Fastness ? other tests of the fabric or yarn are done here.

%n dyeing setion&

1 According to the buyerEs sample, sample dyeing is done in sample dyeing machine in

dyeing shed ? again matched with the approved sample.* If result is 3', then bulk production.+ uring dyeing, samples are taken until accurate shade matching.5 he interval may be 64/94 minutes.6 After dyeing sample is collected after softening matching is done. )ast of all, sample

is collected after fixation ? matched.7 hen allowed the fabrics to be finished.

%n finishing setion&

1 %y using a series of finishing machines correct width, softness ? appearance aremaintained according to re>uirements.

* hen sampling is done for several times to test +(M, (hrinkage ? fastness properties.Finally fabric is inspected ? prepared for delivery.

uality #tandard&

exeurop!%$)td follows the >uality standard& I(3/;447&7444, It also possess (+(andoekoex certificate. (o it maintains (+( and 3ekoex re>uirements.

List of E@uip-ents&In the "uality Assurance epartment the followings e>uipment are used /

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1 '12N 1lectronic %alance* Iron+ Ahiba Nuance )ab. ip yeing Machine5 igital -ipette6 #reda ryer7 2ota 0ash8 #rock Meter9 Incubator: (pectra -hotometer with software !ata #olor$1; - meter11 +(M cutter

1 Tests

here are two types of tests are done in "uality Assurance epartment. hey are `B5. -hysical ests7. #hemical ests

Physial Tests&

1 +(M test* (hrinkage test+ (pirality test5 Abrasion resistance

6 )ycra determination7 #rease resistance

!he-ial Tests&

1 Fastness to washing* Fastness to light+ Fastness to actual laundering5 Fastness to water6 Fastness to -erspiration

1 /ari %nspetion&

he inspection of fabric is a procedure by which the defects of fabric are identified and fabricis classified according to degree or intensity of defects. he fabric inspection is done for bothgrey and finished fabric.

,rey /ari %nspetion&

+rey fabric inspection is performed according to 9/point system.

/inished /ari %nspetion&

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9 point numbering system is followed for finished fabric inspection. efects found in thefinal inspection&5. neven shade7. 3il spot6. Neps9. #rease markuality.7. and feels on fabric surface6. neven on fabric surface9. 2unning shade on fold to fold.uired +(M56. Needle mark or slit mark59. -in mark on fabric surface5uality79. (uidedLpiece finish >uality7


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(2IN'A+1 1( #A)#)AI3N&

%efore wash/After wash(hrinkage Q W 544 %efore wash#pirality test alulation&

( Q !(5(7$ L 7(pirality Q !(L )$K544. (uppose,(5 Q he right side distance of the specimen from the stitch line after wash.(7 Q he left side distance of the specimen from the stitch line after wash. ) Q )ength beforewash

1 Re-arCs&

he exeurop!%$)td always aware about the >uality of the product. he >uality of theproduct is always approved by the buyer. hey follow the >uality standard& I(3 / ;447&7444,(+( ?3ekotex re>uirements. he exeurop!%$)td is well e>uipped for checking the>uality of the product. hey sent the >uality report to the buyer time to timeLbatch to batch.

Maintenance is considered as important as other engineering functions. It makes responsiblefor provision of a condition of machines, buildings and services that will permit uninterruptedimplementation of plans re>uiring their use.

1 OJetives Of 0aintenane&

1 o keep the factory/plants, e>uipment, machine tools etc. in an optimum workingconditions.

* o ensure specified accuracy to products and time schedule of delivery to customers.+ o keep the down time of machines to the minimum thus to have control over the

production program.5 o keep the production cycle within the stipulated range.6 o modify the machine tools to meet the augmented need for production.

7 o improve productivity of existing machine tools and to avoid sinking of additionalcapital.

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8 o reduce the maintenance costs as for as possible thereby leading to a reduction infactory overheads.

9 o prolong the useful life of the factory, plant and machinery, while retaining theiracceptable level of accuracy of performance thus avoiding or propounding incurringof heavy capital expenditure involved in their replacement.

1 0aintenane of 0ahinery&

Preventive -aintenane&

-reventive maintenance is a predetermined routine actively to ensure on timeinspectionLchecking of facilities to uncover conditions that may lead to production breakdowns or harmful description.

BreaCdo>n -aintenane&

In this case repairs are made after the e>uipment is out of order ? it cannot perform itsnormal functions.

Routine -aintenane&

Maintenance of different machines are prepared by expert engineer of maintenance

department. Normally in case of dyeing machine Maintenance after 64 days completechecking of different important parts are done.

Eono-i !onsideration of 0aintenane&

1 It is very profitable activity ? ensures maximum productivity at minimum costing.* It improves product >uality.+ It ensures less time to produce a specific product.5 It improves machine accuracy.6 It maintains a long life of the machine.7 No chance of back order.

0aintenane /lo> !hart&

2ead of 0aintenane

Tehniian

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$ssistant

0anpo>er #etUp for 0aintenane

A (hift = AM / 7 -M% (hift 7 -M / 54 -M+eneral (hift ;AM / = -M

1 /U"!T%O"# O/ 0$%"TE"$"!E PER#O""EL&

%nspetion or !heCUps&

1 E4ternal inspetions& 0atching and detecting defects form abnormal sound,vibration, heat, smoke etc. when machine is in operation.

1 %nternal inspetions& Inspection of parts such as gears, bushes, bearings, tolerancesin the parts etc. when machine is under pre/planned shutdowns.

1 %nspetions of i-portant -ahines&Machines, which can disrupt whole of theproduction, are delicate and re>uire much time for the repair. Attentions are given forinspection of these machines and schedule for inspection, cleaning lubrication aredone rigidly.

* %nspetions of ordinary -ahines& Fre>uency of inspection of ordinary machines iskept as low as they do not affect the production.

Luriation&Mechanical components like gears, bearings, bushes and other friction surfacesetc. +ive good performance for long periods when they are systematically lubricated.(ystematic lubrication means the application of right type of lubricants at the right time, atright place and in right >uantity. For lubrication, a lubrication schedule should be preparedand that should be followed strictly. ere lubrication is done whenever is needed.

Planning and sheduling&1very preventive maintenance work should be pre/planned indetail on the basis of the analysis done on the past records. A scheduled programmed thus

prepared should be followed strictly. hus programmed should be in detail specifying thepoint/re>uiring daily, weekly, monthly, and half yearly or yearly attention.

Reords and analysis& +ood record keeping is essential for good maintenance, as it helps in

for casting maintenance. For this purpose following records are generally maintained&

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1 3peration manual* Maintenance and instruction manual+ istory #ards and istory 2egisters5 (pares -rocurement 2egisters6 (pare -rocurement 2egister7 Inspection 2egister8 )og books9 efect 2egister etc.

Training of 0aintenane personnel&For the success of maintenance a sound training isessential for the maintenance personnel. ence the technicians and supervisors are trained tocarry out maintenance, inspection and repaired in a systematic way.

#torage of #pare Parts& (ometimes machine remains idle for want of spare parts forconsiderable time and thus it affects considerable loss of production. ence it is essential tokeep the spare parts so as to avoid loss of production.

The follo>ing tasCs are generally d on e du ring -aintenane&

1 Inspections ? check ups* )ubrications

+ -lanning ? scheduling5 2ecord analysis6 raining of the maintenance crew7 #ollection or purchase of spares

1 0aintenane shedule of the different -ahines&

Boiler 0aintenane #hedule&

Daily&

1 #heck gas pressure* Maintain log sheet+ #hemical dosing

uality of boiler

0onthly&

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1 #heck all steam line* Fire >uality of boiler+ +as consumption report5 %urner clean

uarterly&

1 %urner clean* 1conomi*er clean+ Feed tank clean5 #hemical tank clean6 (ight glass clean

2alf yearly&

1 %urner clean

* Feed tank clean+ #hemical tank clean5 1conomi*er clean6 2eplace gasket7 2eplace valve8 #heck gas line ? filter ? pressure

.early&

1 3verhauling of boiler

* #hemical cleaning of boiler+ (afety valve test5 1conomi*er clean6 Feed tank clean7 #hemical tank clean8 %urner clean9 #heck safety valve setting: 2eplace valve ? gasket1; %oiler inspection by authority

Dyeing -A -aintenane #hedule

Daily&

1 #heck belt tension* #heck steam or water system ? air supply+ #heck chemical pump5 Machine clean


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5 Add gland packing at pump

0onthly&

1 +reasing bearing points* 2eplace bearing points !if re>uired$+ +asket check5 #lean steam trap6 )ubricating all chemical pump

uarterly&

1 2eplace belts* 2epairing of pulley, shaft ? bearing housing+ -ainting mLc ? pipe line

5 #lean steam trap6 2eplace seals !if leakage$7 #hange gasket of steam of water lines

2alf yearly&

1 2eplace belts* 2epairing pulley, shaft ? bearing housing+ -ainting mLc, pipe line5 2eplace seals

6 Machine body repairing.early&

1 Machine overhauling

2ydro e4trator 0aintenane shedule&

Daily&

1 Machine clean* %elt checking

uality

uarterly&1 #hange of gear oil

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* %elt change

2alf yearly&

1 #hange of gear oil* %elt change !if re>uired$

.early&


Tensionless Dryer 0aintenane #hedule&

Daily&

1 #heck belt tension* #heck steam supply ? air system

+ Machine clean

uality* +reasing bearing points+ #lean air filter ? regulator

0onthly&

1 #lean radiator ? mLc cabinet

* +reasing bearing points+ #lean air filter and regulator

uarterly&

1 2eplace belt* 2eplace gear oil+ uct clean

2alf yearly&

1 #heck roller condition* +reasing ? lubricating all points

.early&


Tu-le Dryer 0aintenane shedule&

Daily&

1 #heck belt

* (team leakage area+ MLc clean

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2alf yearly&

1 #heck roller condition* +reasing ? lubricating of all points+ #heck bearing condition

.early&


1 Re-arCs&

he maintenance department of exeurop! %$ )td. is well e>uipped. It has sufficient

maintenance manpower including mechanical and electrical engineers. hey do themaintenance of the mLc during the 1id vacation. 3therwise, they do the breakdownmaintenance. o increase the lifetime of the machineries and ensure the proper runningof the machinery.

-roduction and profit are closely related. In order to get >uality final product it needs freshraw materials as well as effective manpower and machinery in good condition. tility incon8ugation with the three MEs plays an important role to maximi*e the production as well asthe profit.

1 ,$#&

he source of +as is IA( +A( ).he gas is supplied to gas generator or different section !%oiler/ for heating water$ from themain line of the IA( +A( ).

1 !O#T O/ D%//ERE"T UT%L%T%E#&

Eletriity ost&

21% Q6.: ' L '0/2+as generator Q 5.:4 ' L '0/2

,as ost&

9.;9 kLm for boiler6.== kLm for generator9.< kLm for domestic purpose

#tea- ost&

9.64 k. per kg fabric.

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1 T2E E//LUE"T TRE$T0E"T PL$"T&

he exeurop !%$ )td. has well organi*ed 1ffluent treatment plant. Normally the effluentgenerated from different sections of a textile mill must be treated before they are dischargedto environment. Garious chemicals ? physical means are introduced for this purpose. heeffluent treatment plant in exeurop !%$ )td is chemical biological combination process.

OJets&

his process is provided for treating the effluents of dyeing, printing, finishing, weaving? thus allow to discharge effluent as per by 0orld %ank dept. of environment of %angladesh.

#apacity & 94 tonsL hr.

#ost & k. = L )ittre54 lac % spend per month in 1-.

Re@uire-ent of disharge effluent as per


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/ otal dissolved solids/ #olor/ -

Typial Output of the Plant&

2aw effluent color %lackLdeep purple2aw effluent p 54reated effluent color )ight greenishreated 1ffluent p =/=.uali*ation ank

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Flash mixing ank

Flocculation tank

ube settler tank/5

p correction channel

%acteria reactor/5

%acteria reactor/7

ube settler tank/7

Filter feed sump

p #heck

(ludge of ube settler

(ludge thickening plant

#entrifuge platform.

1 Re-arCs&

As the new pro8ect exeurop !%$ )td, but it has vast utility systems. here is a skillmanpower group of engineers and other technical staffs to look after these utility services.hey have to remain aware of solution on a great sense of responsibility for any type of

problem due to utility supply.

%ntrodution &

Inventory is planning and execution involves participation by most of the fundamental

segment of business sales, production, purchase, finance and accounting. Inventory is a wider

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sense is defined as any idle resource of an enterprise however it is semi/finished packingspares and other stocked in order to meet an expected demand or distribution.

1 OBE!T%3E# O/ %"3E"TOR. !O"TROL&

5$ Financial activities&a$ o save amount of investment

b$ o know the cash position7$ -roperty -rotection&

a$ -reventable wasteb$ Insurable damagec$ nauthori*ed use

6$ 3perating&

a$ o obtain the best overall balance between production and inventory carrying cost.b$ o minimi*e lossesc$ o avoid stock out and to keep inventory holding costs in costs in balance.

(cope of Inventory #ontrol&/ 2aw materials

1 yes store.* 3ther chemicals.+ +rey fabrics.

/ Finished fabric./ (pare parts./ +eneral store&

1 #apital e>uipment.* Accessories.+ (tationary.5 Maintenance parts.

/re@ueny of %nventory Update&

5. Monthly inventory control7. Annual inventory control

%"3E"TOR. PRO!EDURE

1 %in #ard

* (tore 2e>uisition+ (tore )edger Account

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5 aily Inspection ? -ackage 2eport6 Monthly (tock ? #onsumption 2eport7 Monthly )L# wise elivery 2eport8 2eceived elivery ? %alance (tock

1 %nventory !ontrol #yste- for Ra> 0aterials&

Dye store = other he-ials store

1 %oth of these are received by the store in charge.* First he sends these to >uality in/charge for inspection. If they are found to be of

re>uired >uality then they are taken to store by the storekeeper.+ (tore in/charge supplies these when re>uired and records the date, type of material,

>uantity and section in which supplied, in his register book.

,rey fari store

1 +rey fabric is usually stored in another storeroom, which is separate from dyeingshade.

* +rey fabric is first sent to the "# department for >uality assurance and then taken tothe storeroom.

+ +rey fabric is received by fabric store in/charge.5 e supplies the fabric as per re>uirement and records the date, type of material,


At present the grey fabrics store of exeurop !%$ ). containing the following types offabrics/1 (ingle 8ersey.* 5x5 2ib.+ 7x7 2ib.5 7x5 2ib.6 Mlange.7 -i>ue.8 (ingle 8ersey !with )ycra attachment$9 5x5 2ib !with )ycra attachment$ etc.: (ingle lacost1; ouble lacost11 Fleece1* erry Fleece1+ Interlock15 0afel

#tages of ,rey /ari %nventory !ontrol&

1 After knitting production.* +rey inspection.

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+ 0arehouse.5 %atch preparation.6 ye house.

%nventory !ontrol #yste- for /inished fari&

1 Finished fabric from the compactor or stenter goes to inspection team. ereinspection is done by a four points system.

* 2e>uired +(M, width !diameter$, shrinkage, spirality, wash fastness, rubbing fastnessetc are tested from the lab before packaging.

+ After finishing the fabric is kept in package before their transfer to the garmentsdepartment.

5 It is controlled by the finishing in/charge who keeps a list of total finished product. e

also keeps a list of delivery products.6 e supplies the fabric as per re>uirement and records the date, type of material,


#tages of /inished /ari %nventory !ontrol&

1 Finishing section.* After final inspection.+ 0arehouse.

Others&

here is a central store at exeurop !%$ )td. In that store the various types of forms, papersstationary ? other necessary goods are kept.

%nventory !ontrol #yste- for #pare Parts&

1 (pare store officer keeps the spare parts in store and makes a list of spare parts.* If the spare parts are little in stock he gives re>uisition to maintenance manager.+ Maintenance manager gives re>uisition to head office. ead office imports spare parts

or buys from local market as per re>uirement.5 As new spare parts arrive to store officer, he receives and catalogues them.6 e supplies the spare parts as per re>uirement and records the date, type of material,


1 Re-arCs&

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exeurop!%$)td. has individual stores for raw materials, finished goods and spare parts.he store of dyestuff and chemicals are not so clean. here is not enough space to store thefinished goods. It re>uires increasing the store area.

1 %ntrodution&

#osting system mainly describes how the cost of the final product is fixed by thecompanyLbeneficiary. (o #osting is a process by which the setting price of a product iscalculated. It is a very important task for a factory which runs for business purposes. And it isalso strictly followed in the exeurop !%$ )td. #osting of the products considering the rawmaterials expenditure, salary and wages of officers and workers, distributions andadvertisement expenses etc. All direct and indirect expenses are needed to be consideredduring costing. It is determined by a team of accountants with advice and consultancy of

executive director.

he following points are considered for costing any dyed product in exeurop !%$ )td.

1 otal cost of yarn* #ost of fabric -roduction+ otal dyes ? chemical cost5 otal utility cost

6 (alary7 -ayment8 ransport cost9 Miscellaneous cost: +overnment cash incentive

Prie of the Produt&

+enerally price of product is determined by the re>uired profit adding to the total expenses.(o,-rice of productsQ !irect expenses Indirect expenses Factory 3verhead$ profit-rice 2ange of ifferent -roducts&/(hirt Q 4.@< / 9.


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/ari na-e!harge per Cg (TC)

5. (ingle Hersey 4;7. )ycra (ingle Hersey 646. (ingle locust 5=9. ouble lacost 5=


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yed fabric cost Q =.54-acking cost Q 4.4uite impossible to achieve 544 success but as a whole this industrial training was asatisfactory one and once again wed would like to thank the authority of exeurop !%$ )td.as well as our honorable teachers far their altruistic help and advice. 0e are fortunate enoughthat we have got an opportunity to have training in this mill. uring the training period wehave received enough co/operation and association from the authority and found all

personnel. All stuffs and officers were very sincere and devoted their duties to achieve theirgoal.

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