Industrial attachment of hams washing & dyeing ltd.

Industrial Attachment Report of 56HAMS WASHING & DYEING LTD.

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTHAMS WASHING & DYEING LTD.


Chapter 1In t roduct ion

As a part of course curriculum of Bangladesh College of Textile Engineering &

Technology we were send for industrial attachment for two months starting from 17th June 2006

to 17th August 2006 to HAMS Washing & Dyeing Ltd. During the attachment we worked as a

trainee textile engineer and had to attend the official working days in general working times i.e.

9 am to 5 pm.

AIM AND OBJECTIVES OF INDUSTRIAL ATTACHMENT

To enhance our University learning experience through involvement in industrial and

commercial field, thus enabling us to relate theoretical concepts with practical situations;

To develop our ability to evaluate issues and situations critically and propose well

considered options and solutions;

To develop and enhance our professional awareness and communication skills;

To provide experiences that will enable us to achieve a breadth of understanding that will

form a framework or agenda for our final year of study.


The experience offered by industrial training varies. However, by the end of the

placement we were expected to have substantially met most or all of the following objectives:

Undertaken problem solving activities in the workplace;

Further developed my communication skills;

Shown the ability to accept responsibility, work independently, manage my own time

and schedule my work;

Understood the constraints of a formal working environment and the benefits of team

work;

Appreciated the relevance of my academic work and have applied this to new situations;

Used new tools and techniques to supplement those covered on my scheme of study;

Acquired the experience to understand, discuss and evaluate the professional issues

relating to textile engineering.

Gained an understanding of which final year courses will provide the best foundation for

my int ended career.

SUPERVISION DURING THE INDUSTRIAL ATTACHMENT

During our industrial attachment we were overseen by our industrial tutor. We kept a log

of our activities during my industrial attachment in a diary supplied from our institute, which

was re-checked and signed by our industrial tutor.

We were also visited by our academic professionals of different departments whom

discussed about our progress with our industrial tutor. Thus we had the opportunity to learn from

our academic tutors in a practical field.

A routine was maintained to meet with our head of department. Once in every 15 days

we met with our head of department and discussed about solutions of some problems that we

had in the industry.


Chapter 2Overv iew of the Indust ry

This chapter contains general overview of the industry where we have carried out the

industrial attachment.

OVERVIEW

Company Name: M/S HAMS WASHING & DYEING LTD.

Company Nature: Privet Limited Company

Established Date: September, 1998

Location: Tejgaon Industrial Area, Dhaka

Project Cost: 57.04 Cror Tk.

Total area: 20,000 Square Feet (approx.)

Man-power: 200

Business field: Readymade Garments Washing & Dyeing

Main product: Denim long pant, short pant, overall skirt, cotton sweater .

Manufacturing capacity: 2000 Dozens/Day

Types of wash:

o Garments Wash o Acid Wash

o Heavy Garments Wash o Bio Wash

o Pigment Wash o Bleach Wash

o Sand Blasting / Spray Blasting o Stone Wash

o Tinting Wash o Deep Dye

o Stone Enzyme Wash o Tie Dye

o Sand Wash o Silicon Wash

o Enzyme-Silicon Wash o Whickering


Local Buying House:

Washing Capacity:

o Dye & Tint 12000 PCs/day

o Enzyme Wash 15000 PCs/day

o Bleach Wash 20000 PCs/day

o Enzyme Stone Wash 16000 PCs/day

o Pigment Wash 25000 PCs/day

o Garments Wash 40000 PCs/day

o Enzyme Silicon Wash 25000 PCs/day

o Avg. All type of Wash 22000-23000 PCs/day

Major customers:

o Jc-penny

o Primark

o Vermukt

o Walmart

o K-Mart

o Route-66

o Li & Fung (BD Ltd.) o Linmark

o Nor Wester o ABA Group

o Pelican Resources inc. o Auchan

o Lindex o Texel Ltd.

o Jecepenny o NASSA

o DAC Pacific o Tex-EBO

o Epic Designers


o Fashion Traders

o Auchan

Sales & Marketing policy: Improvement through Research and

development for better marketing.

Banks: Premier Bank Ltd. Gulshan Branch

National bank.

Address: 190, Tejgaon I/A, Dhaka-1208, Bangladesh

Telephone: 9885674, 9886406(off.) 8814365, 8814923(fac.)

Fax: 880-2-9881067

e-mail: [email protected]

Web: www.hamsgroup.com

Different departments: Sample section, Washing & Dyeing section, Drying

section, Sand Blasting section, Quality assurance section, Laboratory, Storage section.

Sister Concern: HAMS Fashion Bijoy (Pvt.) Ltd.

HAMS Fashions Ltd. Fashion-2000 Ltd.

Pacific Label Ltd.

HISTORY

Md. Shafiqur Rahman, founder & managing director of this company, is a textile

engineer himself who provided service for five year in garments washing and dyeing sector. In

September 1998 with five local made garments washing and dyeing machine he launched M/S

HAMS WASHING & DYEING LTD. The commitment was “TO MAINTAIN QUALITY AND

TO DELIVER TIMELY” and still strongly believes it.

Within five years the industry earned good reputation in garments washing & dyeing

sector. Now HAMS WASHING & DYEING LTD. is one of the leading garments washing &


dyeing industry in Bangladesh.

The industry is now equipped with modern washing & dyeing machines. The total

numbers of machine are three times than the initial set up.

Chapter 3Man power Management

The company includes over 150 employees with some highly skilled personnel. Most of

the staffs are self-motivated and hard working.

ORGANOGRAM

MAN POWER-ADMINISTRATION:

SL.No. Designation

No. ofPost

Gender Qualification Local Foreignexpert

1 Managing Director 1 Male B.Sc. in TextileTechnology

2 Director(admin) 1 Male Bachelor

3 Director(production) 1 Male B.Sc. in TextileTechnology

4 Director(marketing) 1 Male Bachelor

ORGANOGRAM-ADMINISTRATION:

Managing Director

Director (Admin.)

Manager (Account) Manager (Admin.) Manager (Compliance)


ORGANOGRAM-PRODUCTION:

Managing

Director

Director

(Production)

Production

Manager

Asst. production

manager

Supervisor

(Washing)

Supervisor

(Dyeing)

Supervisor

(Drying)

Supervisor

(Sand

Blasting)

Machine OperatorMachine

Operator

Machine

Operator

Machine

Operator

Assistant

Operator

Assistant

Operator

Assistant

Operator

Assistant

Operator


ORGANOGRAM-QUALITY CONTROL:

Production Manager

Super Visor (Quality)

Assistant (Quality)


ORGANOGRAM LABORATORY:

Production Manager

Machine Operator

(Sample washing machine)

Assistant

(Laboratory)

Machine Operator

(Sample drying machine)

Assistant Operator Assistant Operator

ORGANOGRAM MAINTENANCE:

Production manager

Supervisor

(Maintenance)

Technician

Assistant

ORGANOGRAM FINANCE:

Director (Finance)

Accountant

Asst. Accountant


MANAGEMENT

Management system: Vertical type

Figure: Symbolic representation of vertical type management system.

Shift Change: 12 hours shift (two shifts per day).

Responsibilities of Production Manager:

To give washing & dyeing slip.

To match production sample with target sample.

To collect production sample for sample matching for next production.

To identify disputed garments & report to director.

Also execute overall floor works.

To maintain loading & unloading record.

Any other assignment given by higher authority.


Chapter 4Machine Descr ip t ion

There are three (3) sample washing machines and fifteen (15) industrial machines in

washing section, seven (7) guns in sand blasting section, one (1) sample drying and twelve (12)

industrial drying machines in drying section, four (4) hydro extractors in hydro extraction

section. There is a modern sample washing machine, a modern industrial washing machine in

washing section and a modern hydro extractor in hydro extraction section. The industry is in the

process of upgrading it’s existing machines. Specifications of some incoming machines are also

given in this chapter.

GARMENTS WASHING & DYEING MACHINES

SAMPLE WASHING MACHINES

No. of machines: 03

Manufacturing company: Bengal Heavy Electric Engineering.

Manufacturing country: Bangladesh.

Features:

° Single door design for general washing, sample washing.

° Machine body and essential parts are made of stainless steel.

° Preset front and backward rotation.

° Conventional machine.

Specifications:

° Capacity: 30 kg

° Inner Cylinder: 28”X34”

° Thickness of inner drum: 3mm

° Outer Cylinder: 34”X40”

° Motor (HP): 1HP, 0.75KW

° Power Consumption: 2.3 Amp

° Steam Consumption: 2 HP, 31 Kg

° Water Inlet: 2”, 1 way in.

° Steam Inlet: 1”, 1 way in.


° Water Discharge: 3”, 1 way out.

INDUSTRIAL WASHING MACHINES

No. of machines: 10



Features:




Specifications:

° Capacity: 200 kg

° Inner Cylinder: 42”X88”

° Thickness of inner drum: 3mm

° Outer Cylinder: 54”X960”

° Motor (HP): 10HP, 7.5KW

° Power Consumption: 17 Amp

° Steam Consumption: 15 HP, 230 Kg

° Water Inlet: 2”, 2 ways in.

° Steam Inlet: 1”, 2 ways in.

° Water Discharge: 3”, 2 ways out

MORDERN SAMPLE WASHING MACHINES

No. of machines: 01

Manufacturing company: STEFAB INDIA LIMITED

Model no: LXS 35.

Manufacturing country: India.

Features:

° Single door, front-loading, open pocket.


° Automatic timed. Auto reverse. Automatic 5 water level & auto digital

temperature control.

° Electric solenoid water & steam valves.


° Non-clog motorised drain valve.

° Full electric protection.

Specifications:

° Capacity: 35 kg (Dry: Wet =1:10)

° Inner cylinder: 950 mm dial X 500mm

° Wash motor: 0.75 KW

° Extract speed: 200 RPM

° Main door opening: 500 mm dial

° Water connection consumption: 25 mm dial, 120 litres.

° Drain: 75 mm dial, 1 way out

° Steam connection consumption: 15 mm dial, 25 Kg/hr.

° Electric heating: 12 KW

° Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H)

MORDERN INDUSTRIAL WASHING MACHINES

No. of machines: 01

Manufacturing company: STEFAB INDIA LIMITED,

Model no: LXS 280.


Features:








Specifications:

° Capacity: 280 kg (1:10)






° Inspection door opening: 300 mm dial


° Drain: 115 mm dial, 2 ways out


° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.


HYDRO EXTRACTORS

No. of machines: 03

Manufacturing company: Tongxin Ltd.

Manufacturing country: China.

Features:

° Due to its solid constructions it can be positioned onto firm floorings to operate.

° It has excellent electrical layout in prevention of electricity leakage, shock, which

is important in wet conditions in the operations.

° Machine operations are made easy, with convenient start-stop operations for

maximum efficiency.

° The inner stainless steel is well balanced, thus achieving longer life span and

assuming energy efficiency of machine.

° Shock absorbers are well paced in the three suspension points to reduce

vibrations.

° Stainless steel constructions in major parts ensure durability.

Specifications:

° Model no: SHE-42° Capacity: 280 LBS° Inner cylinder: 1067dial X 419mm° Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H).° Wash motor: 7.5 KW° Extract speed: 860 RPM


MODERN HYDRO EXTRACTORS

No. of machines: 01



Features:

° Full stainless steel outer drum and inner basket. Strong welded construction.

Basket can be dismantled without dismantling outer casing. Electrically

interlocked top lid stops the machine when opened. Three position drain

connection. Outer casing mounted on heavy galvanised plate base frame. Long

rust free life and strength.

° Direct drive. Basket is directly mounted on to a specially designed high torque

heavy-duty motor resting on spigot of the base frame with built-in rubber buffer

cushion for self-balancing. No v-belts, no speed loss, quick self-balancing.

Noiseless & vibration less operation.

° Automatic timed. Automatic DC injection for braking. Safety devices against

single phasing reverse phasing & motor overload. Great convenience & safety.

No foot pedals, no levers, no brake liners, no maintenance.

Specifications:

° Model no: HX 50

° Capacity: 80 Kg

° Inner cylinder: 1000dial X 300mm

° Volume: 235 Litres

° Basket speed: 750 R.P.M.


° Drain: 75 mm dial



SAMPLE DRYING MACHINES

No. of machines: 01



Features:

° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body

not painted. Long rust free life and sheen.

° Built in solvent filter housed in the top tank receives soiled from the base tank

through a powerful centrifugal pump which pushes the soiled solvent through

several fine mesh cylindrical filters for reuse. Maximum recovery of clean

solvent.

° Low spin extract. Separate motors for dryclean & extract. Vibrationless during

extraction. Low spin extract makes articles lighter to unload. No solvent dripping.

No wastage of solvent.

° Automatic timed. Auto reverse. Full electrical protection against single phasing

& motor overload. Operator’s convenience & machine safety. Efficient cleaning.

Specifications:

° Capacity: 18 Kg

° Basket size: 700 mm (dial) X 470 mm


° Dry clean motor: 0.37 KW

° Extract motor: 1.5 KW

° Extract speed: 220 rpm

° Loading door opening: 400 mm (dial)

° Base tank capacity: 250 Litres

° Filter tank capacity: 250 Litres

° Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H)


INDUSTRIAL DRYING MACHINES

No. of machines: 11



Features:

° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body

painted.

° Low spin extract. Vibration less during extraction. Low spin extract makes

articles lighter to unload.

° Automatic timed. Full electrical protection against single phasing & motor

overload. Operator’s convenience & machine safety. Efficient cleaning.

Specifications:

° Capacity: 35 Kg

° Basket size: 950 mm (dial) X 500mm


° Dry clean motor: 0.75 KW

° Extract speed: 200 rpm

° Loading door opening: 500mm (dial)

° Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H)


INCOMING MACHINES

INDUSTRIAL WASHING PROCESSING & DYEING MACHINES

No. of machines: 06

Manufacturing company: STEFAB INDIAL LIMITED,


Features:








Specifications:

° Capacity: 280 kg (1:10)





° Inspection door opening: 300 mm dial


° Drain: 115 mm dial, 2 ways out


° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.



HYDRO EXTRACTOR MACHINE:

No. of machines: 01



Features:

° Full stainless steel outer drum and inner basket. Strong welded construction.

Basket can be dismantled without dismantling outer casing. Electrically

interlocked top lid stops the machine when opened. Three position drain

connection. Outer casing mounted on heavy galvanised plate base frame. Long

rust free life and strength.

° Direct drive. Basket is directly mounted on to a specially designed high torque

heavy-duty motor resting on spigot of the base frame with built-in rubber buffer

cushion for self-balancing. No v-belts, no speed loss, quick self-balancing.

Noiseless & vibration less operation.

° Automatic timed. Automatic DC injection for braking. Safety devices against

single phasing reverse phasing & motor overload. Great convenience & safety.

No foot pedals, no levers, no brake liners, no maintenance.

Specifications:

° Model no: HX 50

° Capacity: 80 Kg

° Inner cylinder: 1000dial X 300mm


° Basket speed: 750 R.P.M.


° Drain: 75 mm dial



GARMENTS SAND-BLASTING MACHINES

INDUSTRIAL SAND-BLASTIG GUNS

No. of machines: 07

Manufacturing company: Made in China

Features:




Specifications:

° Model: SBT-650

° Capacity: 200 Litres

° Dimension: 800mm X 1000mm X 1250mm

° Sand contains: 200 Kg

OTHER COMPONENTS/ACCESSORIES

No. of cabinets: 07

Hopper (for controlling dust in cabinets): 02

Helmet: 07 Pcs

Musk: 07 Pcs

Gloves: 07 pairs.

Air preserver-1, capacity of 2000 c.c.

Air preserver-2, capacity of 900 c.c.


OTHER MACHINES Spray machines: 03 Nos.Manufacturing country: Hong Kong Compressor: 03 Nos.

Two compressors with same following specifications.o Brand: ELGIo Capacity: 10 Jule/Baro Made in INDIA

One compressor with following specifications:o Brand: OSDo Made in ITALYo Includes Change Overo MCCBo Capacity: 10 Jule/Bar

Boiler:Brand name: SaccaManufacturer: Made in ITALYProduction capacity: 1.5 Tons/Hr.Pressure: 7.5 Jule Bar (5.0 Bar used)Supply system: Automatic Pressure control.

Chimney: 50 Feet with 12-inch diameter.

Generator

Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"

production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI)

alternators. All alternators are three phase, four pole, single bearing, synchronous type,

cosj=0.8, 50Hz.

Water supply pump: 03 Nos.

02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse

Power.

01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power.

REMARKS


No live industry can keep place with the advance of technology without continuous

renewal & transformation of its production facilities. Existing equipments must be kept on the

defensive, compelled always to justify its tenure against the challenge of new & more modern

machines. If any piece of existing equipment fails to meet this challenge, it must be displaced,

regardless of its age or condition & regardless of whether it is physically “worn out”.

Keeping the above in view, this industry is always replacing its existing machines in

order to increase productivity & improve quality.

Chapter 5Raw mate r ia ls

Different sections of the industry require raw materials i.e. chemicals of various types in

different quantity. Most of the chemicals are purchased locally. A few are imported directly.

RAW MATERIALS USED IN GARMENTS WASHING

Caustic Soda (NaOH)

° Type : Alkali

° Unit price : Taka 24 per Kg

° Source : Bangladesh

° Uses : Neutralize acidic materials, saponify glycerides (waxes

and oils), solubilize silicate

° Monthly requirements: 4050 kg (approximately)

Soda Ash (Na2CO3)

° Type : Alkali

° Unit price : Taka 14 per kg

° Source : China

° Uses : Used to alkaline the solution/medium. Control PH



Wetting agent:

° Type : Combination of Detergent & Surfactant



° Uses : Emulsify oils, fats and waxes; remove oil-stains; suspend

materials after they have been removed. Reduce surface

tension & minimize inter facial tensions.



Anti-back

° Type : Anti back staining agent


° Source : India, China

° Uses : Prevent back staining


Acetic Acid

° Type : Organic acid


° Source : Korea

° Uses : Used to make solution/medium acidic. Control PH


Sodium Hypo Chloride (NaOCl)

° Type : Oxidizing agent


° Source : India, China

° Uses : Used to uniform lightening of the colour of the indigo or

sulphur dyed garments in bleach wash.


Bleaching Powder [Ca (OCl)Cl]

° Type : Oxidizing agent

° Unit price : Taka 21 per kg (KCI, 33% Chlorine), Taka 105 per kg

(Japan, 65% Chlorine)

° Source : India

° Uses : Used to decolouration of fabric

° Monthly requirements: 3590 kg (KCI), 142 (Japan) (approximately)

Enzyme

° Type : Enzyme

° Unit price : Taka 300 per kg (liquid), Taka 400 per kg (powder)

° Source : China

° Uses : Used to breaks down the long starch molecular chain into

smaller sections, that can be easily washed from the


garments.

° Monthly requirements: 1500 kg (liquid), 1000 kg (powder) (approximately)

Peumic Stone

° Type : Washing stone

° Unit price : Taka 280 per bag (25 kg)

° Source : China

° Uses : It is used to have an abrasion/irregular-fading effect of

stone on garment.

° Monthly requirements: 200 bags (approximately)

Silicon

° Type : Softener


° Source : Korea

° Uses : Creates the fabric surface oily/ used for lubrication


Softener Flax

° Type : Softener


° Source : Korea

° Uses : Soften fabric handling


Potassium Permanganate

° Type : Decolouration agent

° Unit price : Taka 80 to 370 per kg

° Source : India, Bangladesh

° Uses : Used to decolouration of fabric

° Monthly requirements: Locally purchased when required.

Sodium Meta bi Sulphate

° Type : De-chlorination agent


° Source : China

° Uses : Used to neutralize activity of chlorine on fabric/solution


Peroxide (H2O2)

° Type : Oxidising agent


° Source : Korea

° Uses : OH- ions destroy the colouring material and improve

whiteness


Common Salt

° Type : Salt

° Unit price : Taka12 per kg


° Uses : Used as electrolyte for solution, improves shining of

fabric.


RAW MATERIALS USED IN GARMENTS DYEING

The following raw materials are used in garments dyeing in addition to some of the raw

materials already listed above.

Dyestuff

o Type : Direct dye

o Unit price: Taka 300-1200 per Kg

o Source: China, Switzerland.

o Use: Cotton & Viscose garments dyeing.

o Monthly requirements: Depends on ordered quantity.

o Type: Reactive dye

o Unit price: Taka 275-850 per Kg.

o Source: China, Switzerland.

o Use : Cotton & Viscose garments dyeing.



o Type : Pigment dye

o Unit price: Taka 300-500 per Kg

o Source: Switzerland.

o Use: Cotton & Viscose garments dyeing.


Glauber salt

o Type : Salt

o Unit price: Taka 14 per Kg

o Source: China.

o Use: Levelling agent.


Fixing Agent



o Use: Colour fixation.


Dispersing agent



o Use: Assists in the process of particle size reduction of dye.


REMARKS

The monthly requirements of raw materials vary depending on the type of washing &

ordered quantity. Sometimes the price of the materials also varies due to the availability of the

materials in the market.


Chapter 6Product ion Planning, Sequences & Opera t ions

Production process consist of different types of washing methods such as normal wash,

bleach wash, stone wash, acid wash, enzyme wash, super white wash, dirty wash etc and dyeing

methods with reactive, direct, sulphur etc dyes are done. Recently sandblast and chemical

sprayer added to the production process.

PRODUCTION FLOW CHART OF GARMENTS WASHING

Batching

Pre-treatment

Washing

Hydro Extraction

Drying

Quality Control

Storage


PRODUCTION FLOW CHART OF GARMENTS DYEING

Batching

Pre-treatment

Dyeing

Sample Check

Hydro Extraction

Drying

Quality Control

Storage


PROCESS TECHNIQUE OF SOME WASHING & GARMENTS DYEING METHODS

ENZYME-BLEACH WASH WITH TINTING:

Batch 60 PCs. Liquor 400 Litre

Step 01 Water is added (400 Lt)

Desizing Garments are added

Machine started running

500 gm Soda Ash added

500 gm Caustic Soda added

200 gm Bio. D added

Steam to raise temp 60°C

Process time 25 minutes

Drop liquor

Wash down twice



Enzyme Wash Machine started running

200 ml liquid, 400 gm powder

type Enzyme added

150 ml Acetic Acid Added

200 gm Anti back added

10 Kg Peumic Stone added



Drop liquor


Bleaching Machine started running

4 Kg KCI (35% Cl2) added





Drop liquor


Neutral Wash Machine started running

500 gm Hypo sulphide added



Drop liquor


Tinting Machine started running


0.02% Direct Brown GTL &

0.01% Direct Black V-200 added

4 Kg Salt added



Check Shade

Drop the liquor

Step 06 Garments are then taken out

Drying Hydro extracted

Send to dryer for drying of garments.

ACID WASH

Batch 100 PCs.Liquor 500

Litre







200 gm Bio. D added



Drop liquor

Wash down twice


Normal

Wash


Steam to raise temperature 40°C


Drop liquor


Take out the garments

Hydro extract the garments

Dry the garments

Step 03Load the pre-treated & dried

garments in another washing machine

Acid Wash Machine started running

Add stones soaked with potassium per magnate

double the volume of garments

Continue machine running for 7 minutes

Unload the garments from the machine

Step 04Load the garments into another washing

machine

Neutral

Wash

Water is added (500 Lt)



1.5 Kg detergent is added



Drop liquor


Neutral

Wash


500 ml Auxalic Acid added


Check Shade

Drop the liquor

Garments are then taken out

Hydro extracted


Send to dryer for drying of garments.

COTTON GARMENTS DYEING PROCESS (Sample Dyeing)

Batch 1.4 KgLiquor

14 Litre






100 gm Bio. D added


Process time 45~60 minutes

Drop liquor


Hot Wash





Drop liquor

Step 03

Scouring &

Bleaching

Water is added 14 litre

Start machine running

Added 1 litre H2O2

50 gm Stabiliser added



100 gm Bio-D added

Process temp 80° C



Drop the liquor


Hot Wash Machine started running



Drop liquor


Neutral Wash Machine started running

200 ml Acetic Acid added


Drop the liquor


Dyeing Start machine running


560 gm Salt is added

Reactive dye (T. Blue. G) - 0.2% &

Drimerine – Blue K2RL-0.03% is added

20% Soda Ash is added

Processing temp 80° C

Processing time 60 minutes

Drop the liquor


Washing Machine started running

1 % Detergent is added



Drop liquor

Again Add water of 14 litre



Drop liquor

Unload the Garments

Hydro extractor

Drying


PRODUCTION REPORTS

Date: 08.11.2004

Sl.No.

Name ofBuyer

Name ofGarments

Order/Style no.

Types ofProcess

Totalreceived

(pcs)

DeliveryAmount

(pcs)

Balance(pcs)

1 Snoopy UtahWashing

Sand Blast 17745 14899 2846

2 Snoopy Yoke Design G-21 Sand Blast +Bleach

4129 778 3351

3 CareeFour

TusukaFashion

100341/2 Rewash 5100 3576 1524

4 Etam Aba Fashion Enzyme Silicon 18935 15127 3808

5 CareeFour

Aba Fashion Enzyme Silicon 19576 15679 3897

6 Etam Export Knit 6094619 Enzyme Silicon 8696 8124 572

7 Texel Sportx Gmts. 100093 Enzyme + Dyed 7990 7191 99

8 Texel Sportx Gmts. 100093 Enzyme Wash 7628 5500 2128

9 Primark Universal 52510 Sand Blast +Dyed

1200 1200

10 RN Sha ShaGmts.

1161R Sand Blast +Dyed

5793 3767 2029

11 RN Sha ShaGmts.

8488 Sand Blast +Enzyme

2934 798 2136

12 NorWester

Leader Gmts. 25021XZ

Sand Blast +Enzyme

7404 2932 3122

13 NorWester

Leader Gmts. 25027XZ

Sand Blast +Enzyme

5903 1500 4633

14 NorWester

FasnoorGmts.

25069XZ

Enzyme Silicon 5155 4506 649

15 NorWester

Tamanna Ltd. 25074/75 Silicon Wash 4527 3769 758

Grand Total 3275


Chapter 7Maintenance

Maintenance is considered as important as other engineering functions. It makes

responsible for provision of a condition of machines, buildings and services that will permit

uninterrupted implementation of plans requiring their use.

OBJECTIVES OF MAINTENANCE:

To keep the factory-plants, equipments, machine tools etc. in an optimum working

conditions.

To ensure specified accuracy to products and time schedule of delivery to customers.

To keep the down time of machines to the minimum thus to have control over the

production program.

To keep the production cycle with in the stipulated range.

To modify the machine tools to meet the augmented need for production.

Degree of maintenance effort.

Total cost

Labour & Overhead

Cost of spares &maintenance

Cost of down time

Cost of downin efficient operation

>

To improve productivity of existing machine tools and to avoid sinking of additional

capital.

To reduce the maintenance costs as for as possible thereby leading to a reduction in

factory overheads.

To prolong the useful life of the factory, plant and machinery, while retaining their

acceptable level of accuracy of performance thus avoiding or prosponding incurring of

heavy capital expenditure involved in their replacement.


ECONOMIC CONSIDERATION OF MAINTENANCE

It is very profitable activity & ensures maximum productivity at minimum costing.

It improves product quality.

It ensures less time to produce a specific product.

It improves machine accuracy.

It maintains a long life of the machine.

No chance of back order.

MAINTENANCE FLOW CHART

Head of Maintenance

Technician

Assistant

FUNCTIONS OF MAINTENANCE PERSONNEL

Inspection or Check-Ups:

° External inspections: Watching and detecting defects form abnormal sound,

vibration, heat, smoke etc when machine is in operation.

° Internal inspections: Inspection of parts such as gears, bushes, bearings,

tolerances in the parts etc. when machine is under pre-planned shutdowns.

° Inspections of important machines: Machines, which can disrupt whole of the

production, are delicate and require much time for the repair. Attentions are given

for inspection of these machines and schedule for inspection, cleaning lubrication

are done rigidly.

° Inspections of ordinary machines: Frequency of inspection of ordinary

machines is kept as low as they do not affect the production.


Lubrication: Mechanical components like gears, bearings, bushes and other friction

surfaces etc. give good performance for long periods when they are systematically

lubricated. Systematic lubrication means the application of right type of lubricants at the

right time, at right place and in right quantity. For lubrication, a lubrication schedule

should be prepared and that should be followed strictly. Here lubrication is done

whenever is needed.

Planning and scheduling: Every preventive maintenance work should be pre-planned

in detail on the basis of the analysis done on the past records. A scheduled programme

thus prepared should be followed strictly. Thus programme should be in detail specifying

the point-requiring daily, weekly, monthly, half yearly or yearly attention.

Records and analysis: Good record keeping is essential for good maintenance, as it

helps in for casting maintenance. For this purpose following records are generally

maintained:

° Operation manual

° Maintenance and instruction manual

° History Cards and History Registers

° Spares Procurement Registers

° Spare Procurement Register

° Inspection Register

° Log books

° Defect Register etc.

Training of Maintenance personnel: For the success of maintenance a sound

training is essential for the maintenance personnel. Hence the technicians and

supervisors are trained to carry out maintenance, inspection and repaired in a systematic

way.

Storage of Spare Parts: Sometimes machine remains idle for want of spare parts for

considerable time and thus it affects considerable loss of production. Hence it is essential

to keep the spare parts so as to avoid loss of production.


Maintenance practices are made from the following ways:

Capital replacement: capital replacement is undertaken if analysis reveals that the

retention of equipment no more remains an economical proposition.

Provision of stand-by-capacity: Stand by capacity is often provided for items of

equipment that we are critical to production. It is sometimes an economical maintenance

practice to install such spare capacity to be put into operation while the original unit is

under repair or is over-hauled.

Break-down maintenance: Break-down maintenance practice allows a machine or

any other facility to run without much of routine attention, till it actually breaks down to

be then put back into commission.

Scheduled maintenance: Scheduled maintenance system provides for inspection,

overhaul lubrication, and servicing of certain machines at predetermined dates. Over-

hauling of machines, cleaning of tanks and white washing of buildings is normally done

in this manner.

Planned maintenance: Planned maintenance visualise the work contained in a future

job determines the best method to be adopted and skills required for its execution;

estimates the time, material and costs involved assigning jobs to individuals;

programmes the work to specific time periods on the basis of priority and after

ascertaining production requirements; arranges for availability of material tools and man-

power and for release of machines in time.

Preventive maintenance: It consists of routine actions taken in a planned manner to

prevent breakdowns and to ensure operational accuracy to the extent it is economically

and practically possible to do so.


MAINTENANCE TOOLS & THEIR FUNCTIONS

Tools Nos. Specifications UsesMeasuring Tape 02 Both British and Metric system

measurement.Mostly used for linearmeasurement

Hammer 01 It is just a weighted head and ahandle that directs its course.

The Hammer is very simplestriking tool.

Screw Driver (flattype)

02 10” steel shank, with flat blade andplastic handle.

To loosen or tighten screws.

Screw Driver(Phillips head)

01 8” steel shank, with star blade andplastic handle.

To loosen or tighten screws

Pliers 01Nose Pliers 01

Wrench (Lockingadjustable)

02 For exerting a twisting strainin turning bolt & nuts

Wrench (Pipe) 03Wrench (Doublehead open end)

06

WrenchHacksaw Adjustable frame Used to saw metalChisels (cold, flatpoint)

01 Made of good grade tool steel Used for cutting or chippingmetals.

Table vice 01FileMobil Gun 01Wielding Machine 01Hand GrindingMachine

01

Fixed Grinder 01Hand drill 01


Chapter 8Uti l i ty Serv ices

Man, Machine and Material, the three main things that can accelerate the production, if it

is used in proper and organized way. In the Industry, UTILITY plays an important role in case

of production. Production and profit are closely related. In order to get a quality-finished

product, it needs fresh raw materials as well as effective manpower and machinery in good

working condition. Utility is closely related to the three M's plays a vital role to maximize the

production as well as profit.

FUNCTIONS OF UTILITY

Utility ensures power supply by generator.

Utility ensures water supply by pump.

It ensures steam by boiler.

It ensures compressed air handling by vacuum planning system.

It provides fuel and gas supply.

It provides workshop facilities.

AVAILABLE UTILITIES

The following utility facilities are available at HAMS WASHING & DYEING LTD.

Water.

Steam.

Electricity.

Gas.

Compressed air.

Covered Van for Transportation.


SOURCES OF UTILITIES

Water: Own Supply (Pump)

Steam: Own supply (Boiler)

Electricity: Generator & PDB

Gas: Titas Gas Transmission & Distribution Co. Ltd.

Compressed Air: Own supply (Air compressor)

CAPACITY & OTHER TECHNICAL DETAILS

WATER: Water is supplied by pump. Pump supplies water on the basis of pressure.

Pump pressure ranges 0-10 bar. The pump is operated at 2-4-bar pressure. 3 motors are

used for uniform water supply. These are automatic on-off system motor. When the

pressure is reduced to the desired level (2 bars) then the motor is turned on. Similarly

when the pressure is above the desired level (4 bars) then the motor is turned off. So, it

has variable water supply capacity & supplies water as required.

The water, which is used for cooling, is brought to a tank & again supply by a pump.

There are 3 deep tube wells used in this project. Water is directly used in washing &

dyeing & other subsequent process.

02 PCs. Deep Tube wells are submersible, Made in ITALY, BG brand with 30 Horse

Power.

01 PC. Deep Tube well is submersible, Sigma branded, Made in ITALY with 42 Horse

Power.

STEAM: Heat generation is a very important factor for washing and dyeing process.

Steam is a very efficient & easy way to transfer heat. There is a boiler to generate steam.

By pipe line the generated steam is supplied to the washing and dyeing machines &

where it is necessary. The boiler has the capacity to generate steam 1.5 Tons/Hr.

Technical details about the boiler:


Boilers function is to transfer the heat produced by the combustion of fuel (gas) to water

and ultimately to generate steam.

Brand name: Sacca

Manufacturer: Made in ITALY

Production capacity: 1.5 Tons/Hr.

Pressure: 7.5 Jules Bar (5.0 Bar used)

Supply system: Automatic Pressure control.

Chimney: 50 Feet with 12-inch diameter.

ELECTRICITY: It is totally impossible to continue the production without electricity.

A frequent supply of electricity is very essential for soundless production. Here all the

machines in washing and dyeing section are provided electricity by the govt. electricity

with own standby generator of the industry.

Technical Details about the Generator:-

Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"

production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI)

alternators. All alternators are three phase, four pole, single bearing, synchronous type,

cosj=0.8, 50Hz.

Model Rated power Voltage Alter-nator

Diesel enginespecification

Dimensions Weight

KVA KW V LxWxH cm KgE275VM 275 220 400/230 MA "VOLVO" TWD1210G,

6 cyl., turbocharg 300x110x192 2400

Electric Substation:

o 500 KVA Transformer (11 KV to 440 KV)

Brand: Power man

Three phase

Rated power: 500 KVA

Standard: Bs-171

Class: A

Rated Frequency: 50 Hz

Type of cooling: ONAN


AMBIENT Temperature: 50°C

Duty: Continuous.

Voltage: 11000 Volt (HT) 415 (LT)

Rated Current: [HT - 26] [LT - 695] AMP

Vector group Dyn – 11

Impedance Voltage: 0.5%

Total Weight: 179 Kg

Lift able Weight: 990 Kg

Oil Weight: 610 Kg

Winding Temperature: 55°C

Manufacturing Year: 2003

Made in Bangladesh.

o High Tension Switch.

o Switch Gear

Brand: Power Man

Voltage: 415 Volt, 50 Hz

Phase: 3 Phase, 1 Neutral

Incoming: 800 AMP

MCCB/ACB

Made in Bangladesh

o ACB (Air-Circuit-Breaker)

Brand: SPARK Energy

Model: OSLO 6E

o MCCB (Magnetic Contact Current Circuit Breaker)

o PFI (Power Factor Improvement Plant, 6 step auto control)

Brand: Power man

Rating: 200 KV

Voltage: 415V, 50 Hz

o Change Over

o Bash Bar Panel Board.

Compressor: Two compressors with same following specifications.

o Brand: ELGI

o Capacity: 10 Jule/Bar


o Made in INDIA

One compressor with following specifications:

o Brand: OSD

o Made in ITALY

o Includes Change Over

o MCCB

o Capacity: 10 Jule/Bar

Air Condition:

o Exhaust Fan: 03 Nos.

o Air Cooler: 02 Nos.

Fire Fighting Tools:

o Washing section: 10 Nos. Fire Extinguisher

Air Dryer:

o For Compressor: 3 Nos.

Cover Van:

o 3 Cover Van used to carry garments.

Gas: The company gets natural gas from Titas Gas Transmission & Distribution Co. Ltd.

Capacity of gas line is variable ie. line able to supply gas according to the requirements.

COST OF UTILITIES

Water: Own supply (Pump)

Electricity Required- 46 KW/Hr. Cost 5 TK/KW.

Steam: Own Supply (Boiler)

Gas required: 670 Meter3/Hr. Cost 5.60 TK/ Meter3 (Aprox.)

Compressed Air: Own Supply (Air compressor)

REMARKS

There is problem with water supply in the company. The supply of water is not

sufficient, which create problem in washing and dyeing. The quality of water is not up to the

level. The hardness & presence of iron in water is high. A water treatment plant is very essential


to continue the production without disturb & to increase the production.

The generator of the industry is too old to supply the electricity fluently. Sometimes it

trip without any warning. So, it’s necessary to have a new generator for the industry.

The boiler also very old to maintain it high bar pressure. It should be replaced with

modern boiler for better service.

Chapter 9Store & Inventory Control

In HAMS WASHING & DYEING LTD. there are different inventory systems for

different raw materials and finished materials.

DYE & CHEMICAL STORE

There is a different store for dyes & chemicals. Various types of dyes & chemicals are

stored 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 the GM (production), Dye house & lab section.

SPARE STORE

In HAMS WASHING AND DYEING LTD. required amount of spears of different

machines are stored in the mechanical storeroom. All the spears are listed in a sheet, which is

controlled by the mechanical & maintenance personnel. Spares are arranged in the storeroom

according to their size, quantity & requirements. There are shelves in the storeroom to keep the

small spare parts.

FINISHED PRODUCT STORE

HAMS WASHING AND 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 delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics

diameter, buyer’s name, colour& considering other technical parameters.


OTHERS STORE

There is a central store at HAMS WASHING AND DYEING LTD. In that store the

various types of forms, papers, stationary & other necessary goods are kept.

Chapter 10Cost ana lys i s

Cost analysis is a crucial step for any business organization, specially if it is amanufacturing company. Here cost analysis is done in conventional method.

SAMPLE COST ANALYSIS

Issue Date: 10-07-2004 Buyer: Nassa – Pinacle Po-Style-Ref. : 21051 Type of Garments: Denim Long Pant Type of Wash: Enzyme/ Bleach/ Tint Quantity/ Machine: 60 PCs. Weight of Total Garments: 62 Kg.

Process Chemicals Quantity Temp Time Total

Desizing Caustic Soda 500 gm 12 /=Soda Ash 500 gm 60°C 15 min 7 /=Bio. D 400 gm 25 /=

Enzyme Wash Enzyme Powder 400 gm 152 /=Enzyme Liquid 200 gm 48 /=Anti Back Staining 200 gm 40°C 55-60 min 25 /=Acetic Acid 100 gm 7 /=Stone ½ bag 212 /=

Bleaching Bleaching (Japan) 500 gm 50°C 6-8 min 46 /=Neutral Wash Hypo Sulphide 500 gm Cold 5 min 9 /=Peroxide H2O2 500 gm 50°C 10 min 18 /=

Bio. D 100 gm 12 /=Tinting Dir Brown GTL 20gm 14 /=

Dir Yellow 2 gm 50°C 20 min 2 /=Salt 4 Kg 28 /=

Total Chemical Cost= 617/=

Add 10% Wastage = 678/=

Per Dozen = 135.6/=


Chemical Cost in USD/Doz = 2.47/=

Overhead Cost USD/Doz = 1.5/=

Total Cost USD/Doz = 3.97/= ~ 4.00/=

Profit USD/ Doz = 0.75/=

Final Cost USD/Doz = 4.75/=

Chapter 11Conc lus ion

As a ready made garments washing and dyeing sector, HAMS WASHING & DYEING

LTD. is excellent among the industries of Bangladesh. Garments washing and dyeing sector

comprise varieties of machineries. It is still completely running position.

The Management system of the factory is quite well too. All the personnel of the factory

are co-operative and friendly with us. The security system is very good too.

In the training period, we were introduced as a member of the factory. For that, they gave

us all kind of facilities and scope for learning about washing and dyeing production and

machineries.

Above all the industrial attachment has given us new ideas for practical life.

Industrial attachment of hams washing & dyeing ltd.

Engineering

Transcript of Industrial attachment of hams washing & dyeing ltd.