Intern-Report-Yasmin-full-and-final (1)

Intern report on Yasmin Spinning Mills Ltd.

Yasmin Spinning Mills Ltd

( A concern of Noman group)

Mawna, Gazipur.

Industrial Training report on YASMIN SPINNING MILLS LTD.


Acknowledgement

This industrial training has been a very enriching experience for us as it has given us the

chance to face & get exposed to the real world outside the classroom. We are thankful to

Almighty for enabling us to complete the industrial training smoothly and successfully.

Our industrial training was carried out at Yasmin Spinning Mills Ltd., a concern of Noman

Group, located at Mawna, Gazipur.

Firstly, we would like to express our sincere & immense gratitude to our respected supervisor

Siyam Quddus Khan for his enthusiastic co-operation and constant supervision during the

industrial training at Yasmin Spinning Mills Ltd.

Prof. Dr. Ahmed Jalal Uddin, Head, Department of Textile Engineering, Ahsanullah

University of Science & Technology, gave us his valuable advice and official permission for

internship at Yasmin Spinning Mills Ltd. where we conducted this training, so we are grateful

to him.

We are also indebted to other teachers of our department for providing the base of our textile

engineering knowledge for last 4 years through teaching various courses.

Mr. AKM Majed, General Manager, Yasmin Spinning Mills Ltd. provided us with all

necessary support during our industrial training. We express our heartfelt thanks to him.

Moreover, Mr. Mirza Murtoza Karim, DGM (production), Yasmin Spinning Mills Ltd.,

gave us accurate course of action & instruction during training. We are very thankful to him

as without his guidelines we cannot carried out our training and project work appropriately

and significantly.

We express our special thanks to all the official staffs of Yasmin Spinning Mills Ltd. for their

love, co-operation, support & services which they offered during our training period. Finally

we express our thanks to the authorities of Noman Group of Industries for giving us the

official permission for industrial training.


Chapter: 1

Introduction


Industrial training refers to work experience done during the program of study that is relevant

to professional development prior to graduation. The main objectives of Industrial Training

are:

To gain a first-hand experience working as an engineering student,

To apply the technical knowledge and engineering methods to a real-life situation,

To work with other engineering professionals,

To gain experience what it is like to work in a professional organization,

To increase technical, interpersonal and communication skills, both oral and written,

To observe interactions of engineers with other professional groups,

In addition, it can help students to gain their self-confidence and discover their own

ability. It can also be a preparation or a preview to working environment later in

future. At the same time, industrial training can also nurture a student‘s leadership

ability and responsibility to perform or execute the given task. Besides of that, the

student will be more disciplined to follow rules and regulations when conducting

industrial training. They would be trained for proper schedule planning and time

management. This situation will foster responsibility and independent thinking into

students.

We got an opportunity to complete 8-week long industrial training in Yasmin Spinning Mills

Ltd. (YSML) a concern of Noman Group. Our industrial training started in May 12, 2016 and

ended in July 15, 2016. As there were different departments in factory, our 8 weeks long

program was sub-divided into following categories to get us acquainted with all of them-

2 weeks in Production Department.

2 weeks in Quality Control Department.

2 weeks in Maintenance Department.

1 week in Utility and Electrical Department.

1 week in Administration Department.


Chapter: 2

Factory Profile


2.1: Background of Noman Group:

Noman group is a family business which was established in the year of 1986 by Md. Nurul

Islam. Noman Group started its journey with a vision of establishing itself as the largest

textile manufacturer in the world. With sustained growth over the years and an ever-

expanding list of international clientele, it has solidified its position as a leading vertically

integrated textile group in Bangladesh

2.2: Subsidiaries of Noman Group:

Ismail Spinning Mills Ltd

Noman Spinning Mills Ltd

Sufia Cotton Mills Ltd

Talha Spinning Mills Ltd

Yasmin Spinning Mills Ltd

Zaber Spinning Mills Ltd

Zubair Spinning Mills Ltd

Saad Saan Textile Mills Ltd

Noman Weaving Mills Ltd

Noman Textile Mills Ltd

Noman Composite Textile Ltd

Ismail Textile Mills Ltd

Talha Fabrics Ltd

Zarba Textile Mills Ltd

Artex Fabrics Ltd

Marium Textile Mills Ltd

Sufia Fabrics Ltd

Noman Fashion Fabrics Ltd

Noman Home Textile Mills Ltd

Ismail Anjuman Ara Fabrics Ltd

Talha Texpro Ltd

Noman Fashions Ltd

Zaber & Zubair Accessories Ltd


2.3: General information about Yasmin Spinning Mills Ltd:

Name of the Factory Yasmin Spinning Mills Ltd (YSML), an enterprise of Noman

Group of Industries.

Chairman Md. Nurul Islam

Managing Director A.S.M. Rafiqul Islam

General Manager A.K.M. Majed.

Type Spinning mill

Head Office Adamjee Court (4th Floor), 115-120 Motijhel, Dhaka -1000.

Sponsor Islami Bank Bangladesh Ltd.

Factory Location Beraidarchala, Sreepur, Gazipur.

2.4: Overview on Yasmin Spinning Mills Ltd.:

Nature of the company Private Limited Company.

Number of spindles

installed (Ring Section)

74352 (Unit-1= 42096 &

Unit-2= 32256)

Product Mix Ring Spun Yarn: -Polyester-cotton blend yarn, Lycra (U-1)

- 100% cotton yarn.(U-2)

Count Range 8-80 Ne

Production capacity 18 tons/day (U-1) & 14 tons/day (U-2)

Production capacity

achievement

87%

Establishment 1 April, 2008

Manpower 1580

Male Employee 474

Female Employee 1106

Total area of land 5,22,720 square feet

Total area of space 2,57,262 square feet

Production Floor space 2,13,057 square feet

First Aid box 13

Fire Extinguisher 513


2.5: Different Departments:

Production Department.

Quality Control and Assurance Department.

Maintenance Department.

Utility Department

Store Department

Administration Department

Marketing and Sales and Department.

Commercial Department.

Fire hose cabinet 62

Power Supply Gas generator

No. of first aider 66

No. of fire fighter 284

No. of Dinning 4

Medical service Available at 24 hours a day

Accommodation Facility Available for officers‘ family, male and female employees.


2.6: Factory Location:

The factory plant of Yasmin Spinning Mills Limited was setup to Beraidarchala, Mawna,

Sreepur at Gazipur, near about Mawna and beside the link road which connected with the

Dhaka-Mymensing high way on about 36 bigha of land. Here is the map of the location of

YSML.

Figure: Map of YSML

Figure: Google Earth view of YSML


2.7: Factory layout:


2.8: Layout plan of unit-1:


2.9: Layout plan of unit-2:


Chapter: 3

Human Resource Management


3.1: Organogram:

Organogram is a plan that gives the names and job titles of all staff in an organization or

department, showing how they are connected to each other. The organogram of Yasmin

Spinning Mills Ltd. is given below:

Figure: Organogram of Yasmin Spinning Mills Ltd.


3.2: Manpower setup:

Production department

Serial No. Designation Current Manpower Approved Manpower

1 DGM production 1 1

2 Production manager 0 1

3 Assistant production manager 0 1

4 Senior production officer 0 1

5 Production officer 12 14

6 Assistant production officer 14 15

7 Management & information

system officer

1 1

8 Production clerk 18 20

9 Supervisor 19 20

10 Worker 530 560

Total 595 636

Quality control department

Serial No. Designation Current manpower Approved manpower

1 AGM 0 1

2 Manager 1 1

3 Assistant manager 1 2

4 Sr. quality control officer 0 2

5 Quality control officer 1 2

6 Asst. quality control officer 4 4

7 Lab assistant 8 8

8 Lab boy/girl 6 6

Total 21 26


Maintenance Department


1 A.G.M. 0 1

2 Manager 1 1

3 Maintenance officer 2 4

4 Assistant maintenance officer 4 4

5 Head fitter 4 4

6 Senior fitter 6 6

7 Assistant fitter 27 30

8 Helper 36 36

Total 80 86

Administration Department


1 Manager (admin) 1 1

2 Admin officer 1 2

3 Asst. Admin officer 2 2

4 Accounts manager 1 1

5 Accounts officer 1 1

6 Time keeper 3 4

7 Executive security 1 1

8 Security inspector 3 3

9 Security guard 27 27

10 Pc operator 1 1

11 Imam 1 1

12 Driver 4 4

13 Peon 6 6

14 Sweeper / Gardener 4+6=10 12

Total 62 66


Utility Department

Generator &

Maintenance

Designation Current manpower Approved manpower

AGM 0 1

Engineer 0 1

Asst. Engineer 0 1

Sub-asst. Engineer 4 4

Operator + helper 8 2+6

Electrical Engineer 1 1

Sub-asst. engineer 2 4

Electrician 4 6

Helper + Loop cleaner 8 8

Work Shop Head fitter 2 2

Helper 6 6

AC/Chil/Boi/EGB Engineer 1 1

Sub. Assistant engineer 2 2

H.fitter + Fitter 3+2 3+2

Op + Ass.op 2+4 2+4

Helper 9 9

Heat setting Op + Helper 2+4 2+4

Total 64 71

Medical Department


1 Medical officer 1 1

2 Medical asst. 0 1

3 Nurse 0 1

Total 1 3


Store Department


1 Manager 1 1

2 Asst. Manager 0 0

3 Store officer 0 1

4 Asst. Store officer 1 1

5 Store keeper 2 2

6 Store asst. 7 7

Total 11 12

3.3: Job responsibilities of officers:

a) Senior production officer and Production officer:

Name: Rejaul Bari, Sifat Kibria.

Job responsibilities:

Production monitoring of blow room to finishing ensuring the achievement of target

production.

To cheek count wise and lot wise process parameter from blow room to finishing.

To take the charge from the outgoing shift and hand over the charge to the incoming

shift.

To control unusable wastage in every stage from Blow room to Finishing.

To allow leave of workers & subordinate supervising staffs in systematic way.

To supervise performance evaluation.

To check attendance.

To control count mixing, lot mixing of sliver, roving yarn and mixing / Bale

management of raw cotton.

To cheek count wise and lot wise process parameter from Blow room to finishing

against standard value.

To maintain doff ticket and control of doffing time in ring section.


b) Quality manager, Deputy quality manager, quality control officer:

Name: Mahfuzur Rahman, Abdul Hannan, Anwar Hossain.


To maintain the quality and process parameters of the yarn production process.

To plan and monitor the daily activities of quality department.

To ensure the proper training and motivation of QCA officers and supervisor, lab

assistance etc. up to date to G.M. regularly about the production process as well as the

yarn quality.

c) Maintenance manager:

Name: Ataur Rahman


To ensure all machine safety devices.

Machine maintenance schedule development.

d) Maintenance officer:

Name: Akter Hossain


Maintenance of chiller, boiler, AC plant etc.

Operating and controlling.

Machine selection and install.

Humidity setting.


e) Maintenance engineer:

Name: Shahed Hossain


Operation and maintenance.

Monthly maintenance schedule.

Local and foreign indents.

f) Admin manager:

Name: Mizanur Rahman


To recruit labor by ensuring that there is no any child or forced labor.

Punishment and appeal, harassment and abuse – to deal with these matters.

To keep payroll and attendance record.

To manage overtime, working hour, wages, breaks, leave, benefits etc.

g) Admin officer:

Name: Enamul Haque


Responsible person for overall IWAY Implementation, review, reporting and

corrective action.

Internal audit and HR management.

h) Manager of store:

Name: Abdul Kader


Total storage management of raw material, yarn, chemical etc.

Waste management.


Chapter: 4

Raw materials


A raw material is the basic material from which a good product is manufactured or made.

Raw material is goods or products which are used in manufacturing or unprocessed products

which are used in the creation of some final product. For example, fibres are raw materials to

make yarn.

4.1 Types and sources of raw material: (Fibres)

There are different types of fibres used to produce yarns of various qualities. Those fibres are

coming from different origin and region. Some fibres types and their origin are given below:

Cotton

Brand Name Origin Staple Length Average MIC

CIS Uzbekistan, Tajikistan 28-32mm 4.6

Chad Africa 29-30mm 3.8

Malawi Africa 26-30mm 4.5

Cameron Africa 28-30mm 3.5

Polyester

Origin Staple Length Average denier

China 32-35mm 1.4

Thailand 30-36mm 1.5

Other raw materials:

Paper cone

Sticker

Polyethylene bag

Polypropylene bag etc.


4.2: Information about a bale:

Binding material used for bales Steel wire

Bale size Height: 59 cm, Length: 95 cm, Width: 80 cm

Bale weight 230 kg

Tare weight 2.6 kg

Bale loading & unloading system It is done by FORKLIFT

Capacity of raw cotton godown 8000 bales

Bales used in per lay down 48 bales

Bales consumption/day 90 bales

4.3: Contaminations of raw cotton:

Dirty cotton Piece of plastic

White cloth piece Black cotton

White thread Polypropylene piece

Colored cloth piece Broken seeds

Colored thread Wooden piece

Leaf Jute

Feather Hair & Wool

4.4: Bale management on YSML:

Bale management is a process of inventory control and selection of bales of fibres according

to their properties and also to mix the fibres homogeneously to get consistent production and

quality of yarn. For bale management, all of the bale samples are tested and bales with almost

similar category are arranged for homogeneous mixing.

The procedure of bale management followed in YSML is:

Step-1: Bales provided by the vendor, are received in the plant, and identification number is

given on each bale. Sample from each bale are taken for testing (Uster HVI). A number is

added to each to each bale according to similarities. Then the bales are stored in storehouse.


Step-2: A report is prepared based on the MIC value from the tested samples like the

following example:

MIC-wise bale distribution

MIC 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9

Bales 36 288 413 701 125 180 16 19 Total-1780

Step-3: Range of MIC values are selected for specific count of yarn.

Step-4: Quality Control Department prepares a table for the bales of similar category to be

mixed.

Step-5: Bales are then transferred to blow room line, placed horizontally.


Chapter: 5

Production


5.1: Process flow charts of ring spinning yarn production:

Combed yarn is more precise than card yarn. To produce carded yarn needs fewer steps to

follow to make a yarn than the combed yarn. The main purpose of combed yarn

manufacturing is to create a yarn which is highly finer and highly qualified and combed yarn

is most precious, finer and thinner than the carded yarn. The flow charts of carded and

combed yarn are here:

a) Flow chart for carded yarn:

Blow-room

Carding

Breaker Draw Frame

Finisher Draw Frame

Simplex

Ring Frame

Winding

Yarn Conditioning

Packaging


b)Flow chart for combed yarn:

Blow-room

Carding

Pre -comb Drawing

Lap former

Combing

Post-comb Drawing

Simplex

Ring Frame

Winding

Yarn Conditioning

Packaging


5.2: Machines sequence & descriptions of blow room:

5.2.1: Flow chart of blow room machines of unit-1:


5.2.2: Machine descriptions of blow room of unit-1:

a) Waste opener:

Figure: Maxim bale opener

b) Uniflock:

Figure: Uniflock

Manufacturing Company Rieter

Model B 2/2

Manufacturing Year 1978

Country of Origin Switzerland

No of beater 3

Beater Type Pin type-2, wire type-1

Production 60 kg/h

Installed power 6kVA

Working width 750mm

Opening roller 9.8inch

Net weight 1450kg


Model A 1/2



Production rate

1400kh/h(cotton),

1000kg/h(MMF)

Installed power 14.6kVA

Net weight 2605kg

Channel length 10-50m


c) Uniclean:

Figure: Uniclean

d) Unimix:

Figure: Unimix


Model B 10



Production Up to 1200kg/h


Working width 1600m

Cleaning cylinder 750mm dia

Speed 480-960rpm

Length 2205mm

Height 1040mm

Weight 1180kg


Model B 7/BR



Output 800kg/h

Storage capacity 300-400kg

Active buffer 250kg

Working width 1200mm

Weight 3505kg


Feed air 1-1.2 m^3/s

No of chamber 8


e) Uniflex:

Figure: Uniflex

g) Mono-cylinder cleaner:

Figure: Mono-cylinder cleaner


Model B 5/5



Production capacity up to 600kg/h

Installed power 16 kVA

Working width 1200mm

Cleaning cylinder 400mm dia

Speed 500-1300rpm

Weight 2000kg

No of beater 1


Model B 4/1



No of beater 1


h) Loptex:

Figure: Loptex

i) Dustex:

Figure: Dustex

Manufacturing Company Loptex Italia S. R. L.

Model Optosonic Tandem

Country of Origin Italy

Maximum production rate Up to 800 Kg/h

Installed power 2.2 KW

Compressed air supply 6-8bar

Dimensions

Height 2450mm

Width 1700 mm

Depth 1200 mm

Weight 860 Kg

Manufacturing Company Trützschler

Model SP-DX


Country of Origin Germany

Production rate 800kg/h

Installed power 0.8KW


j) Rotopic:

Figure: Rotopic

k) Tuftomat:

Figure: Tuftomat


Model B 2/3



No of beater 3

Beater Type Pin type-2, wire type-1

Production 3 to 65 kg/h


Working width 760mm

Opening roller 9.8inch

Net weight 1500kg


Model TO-T1



No of opening roller 1



5.2.3: Flow chart of blow room machines of unit-2:

Blendomat

Condenser

SP-FM

Cl-P

MX-I6

CL-C1

Loptex

SP-FP

Condenser


5.2.4: Machine descriptions of blow room of unit-2:

a) Blendomat:

Figure: Blendomat

b) Condenser:

Figure: Condenser


Model BO-A 2300



`Material plucking pressure 950 pa

Capacity Up to 1650 kg/hr

Plucking depth 5 mm

Frame width 2300 mm

Material lay down length 27 meter

Height 2900 mm

No. of bales per side 45

Max. bale height 1700 mm




Back suction 50pa

Waste suction Max 200pa

Material pressure 1050pa


c) SP-EM: (Electric & metal parts separator)

Figure: SP-EM

d) Pre-cleaner: (CL-P)

Figure: Pre-cleaner








Grid bar setting 4.0/4.0º

Beater speed 660rpm

Roller rpm 800

Waste suction 500pa


e) Integrated multimixer: (MX-I6)

Figure: Integrated multimixer

f) Post-cleaner: (CL-C1)

Figure: Post-cleaner




Opening roller rpm 800

Number of chambers 6

Chamber width 500mm





Beater speed 582

Roller rpm 660


g) Loptex:

Figure: Loptex

h) SP-FP: (Foreign particle separator)

Figure: SP-FP

Accessories of blow room:

Item Name Quantity Item Name Quantity

Bale Trolley 06 Helmet 04

Wastage Carrier Trolley 04 Bale Cleaner 06

Bale Cutter 05 Crowbar 04

Manufacturing Company Loptex Italia S.R.L.

Model Optosonic Tandem

Country of Origin Italy

Maximum production rate Up to 800 Kg/h

Installed power 2.2 KW

Compressed air supply 6-8bar

Dimensions

Height 2450mm

Width 1700 mm

Depth 1200 mm

Weight 860 Kg




Opening roller rpm 590


5.2.5: Production parameters of blow room:

RIETER Line:

Production rate (100%) = 750 kg/hr

Efficiency = 95%

TRÜTZSCHLER Line:

Production rate (100%) = 1000 kg/hr

Efficiency = 95%

5.3: Carding Machine:

Carding maybe defined as the reduction of an entangled mass of fibers to a filmy web

working between two closely spaced, relatively moving surface clothed with sharp wire

points. The carding is the heart of spinning and well card is half of spun demonstrate the

immense significance of carding for the final result of the spinning operation. The importance

of carding is still greater where new spinning systems are concerned.

The Objectives of Carding are:

Neps removal,

Fibre individualization and slightly straightening including parallelization,

Web formation,

Cleaning of heavy particles by stripping and carding action.

5.3.1: Cotton carding machine specification and description:

There are three types of cotton carding machines found in YSML.

i. Rieter card C-50,

ii. Rieter card C-60,

iii. Trützschler TC-03.


i) Rieter card C-50:

Figure: Rieter C-50

ii) Rieter card C-60:

Figure: Rieter C-60

iii) Trützschler TC-03:

Figure: Trützschler TC-03

Model C 50


Country of origin Switzerland

Manufacturing company Rieter

Model C 60




Model TC-03


Country of origin Germany

Manufacturing

company

Trützschler GmbH

& Co. KG.


Parameters of carding machines:

Technical data &

settings C-50 C-60 TC-03

No. of machines 04 05 14

Feed roller diameter 127 mm 127 mm 100 mm

Taker in diameter 254 mm 254 mm 172.5 mm

Taker in speed 930-2200 rpm 935-2306 rpm 1162 -2392 rpm

Taker in PPSI 120, 10 º 120, 10 º

1) 34, 10º

2) 163, 10º

3) 210, 10º

Cylinder diameter 1290 mm 840 mm 1287 mm

Cylinder speed 600-900 rpm 600- 900 rpm 561 rpm

Cylinder PPSI 950, 40º 950, 40º 950, 40º

No of flats 104 79 84

No. of flats in

carding action 25 25 30

Flat speed 342 mm/min 342 mm/min 320 mm/mi

Flat PPSI 520-550, 5º 520-550, 5º 525-600, 5º

Doffer diameter 510 mm 680 mm 700 mm

Doffer speed Depends on delivery Depends on delivery Depends on delivery

Doffer PPSI 367, 30º 367, 30º 483, 30º

Delivery roller

diameter 80 mm, 80 mm 80 mm, 80 mm 80 mm, 80 mm

Delivery roller speed 192 m/min 192 m/min 210 m/min


5.3.2: Polyester carding machine specification and description:

Crosrol:

Figure: Crosrol Card

Parameters of Polyester Card:

Delivery speed 90 m/min

Feed roller diameter 127mm

Taker in diameter 254 mm

Taker in speed 800 rpm

Taker in PPSI 130, angle 5º

Cylinder diameter 1270 mm

Cylinder speed 570 rpm

Cylinder PPSI 745, angle 20º

Doffer diameter 508 mm

Doffer speed Depends on delivery

Doffer PPSI 367, angle 30º

Delivery roller diameter 80 mm,80 mm

Calendar roller diameter 60 mm, 60 mm

Flat speed Depends on cylinder (Max 290 mm/min)

No of flat 85 (on action 30 flats)

Top flat PPSI 480, angle 5º

Model M8658


Country of origin China

Manufacturing

company

Shanghai Crosrol

Pacific Machinery

Co. Ltd.


5.4: Breaker Draw Frame:

The carded sliver is fed in the Breaker Draw Frame. In YSML 8 (eight) card sliver cans are

fed in each Breaker Draw frame. The more no. of doublings give more removeal of

irregularity. If the number of doubling increases, the number of drafting also increased. But

more draft leads more unevenness in the drawn sliver. So optimum doubling should be

maintained. There are two types of BDF in YSML:

i) DX-8:

Figure: DX-8 Breaker Draw Frame

ii) DX-7A:

Figure: DX-7A Breaker Draw Frame

Model DX-8


Country of origin Japan

Manufacturing company Toyota

Model DX-7A





Parameters of breaker draw frame:

Technical Data and settings DX-7A DX-8

Drafting system 3 over 3 5 over 4

No. of head 2 2

Roller weighting system Spring loaded Spring loaded

Cot roller shore hardness 83‘ (Carded)

65‘ (Combed)

83‘ (Carded)

65‘ (Combed)

Bottom roller diameter

f-35 mm

m-35 mm

b- 35 mm

Front roller - 40 mm

2nd roller - 35.795 mm

3nd

roller -35 mm

Back roller - 35 mm

Top roller diameter


Middle roller - 34 mm

Back roller- 38 mm


2nd

roller -38 mm

3rd

roller - 34 mm

4th roller - 38 mm

Back roller -38 mm

Bottom roller gauge Front zone - 40 mm

Back zone - 45 mm

Front roller - 76.9 mm

Middle roller -76.4 mm

Back roller - 81 mm

Delivery speed 450 m/min 500 m/min

Sliver 345-400 grain/6yd 390 grain/6yd

Trumpet size 3.8/4.2 mm 3.8 mm

Present of auto leveler No No

No of doubling 5-6 5-6

No of machine 13 10


5.5: Lap Former:

In YSML, Lap former is used to produce combed yarn. Good laps are important for

satisfactory combing. Lap former produces faultless lap sheet from slivers by distributing the

fiber evenly the whole lap width.

Figure: Unilap

Parameters of unilap machine:

No. of doubling 26 (max -28)

Delivery speed Depends on delivery (100 m/m)

Drafting system 3 over 3

Top roller diameter 39 mm

Top roller size 39 (d)×26 (t)×300 (l)

Bottom roller dia 30 mm

Bottom roller size 30 (d)×26 (t)×300 (l)

Lap diameter 650 mm (max)

Total lap length 250 m

Full lap weight 19 kg

Lap width 300mm

Pressure on drafting zone 5bars (on each roller)

Top roller hardness 83º

Total draft 1.455

Roller gauge Front: 42mm

Back: 34mm

Model E -16





5.6: Comber:

For high quality yarn, an extra process is introduced called combing. Combed sliver has

constituted with higher length of fibres because of removal of short fibres. The objectives of

combing machine:

It influences the yarn quality like yarn evenness, strength, cleanness, smoothness,

visual appearance.

Removes short fiber.

Finally forms of a combed sliver with necessary cohesive force.

Figure: Comber

Parameters of comber machine:

No of machine 14

No of head 8

Machine speed 345-450 nips/min

Delivery gr/6yd 416

Delivery hank 0.12

Total draft 14.25

Back draft 1.37

M/C efficiency 80-90%


Can size 600 mm dia and 1200 mm height

Full lap dia 550×300mm

Model E -65





Feed/nip 4.7 mm

Feed roller dia 30 mm

Delivery bottom roller dia 25.5 mm

Delivery top roller dia 45mm

Noil% 16-17.5%

Auto stop motion yes

Auto doffing yes

Problem indicating lamp system yes

Top front detaching R/r dia 24.5 mm

Top back detaching R/r dia 24.5 mm

Bottom front detaching R/r dia 25.5 mm

Bottom back detaching R/r dia 25.5mm

Detaching roller hardness 62º

Delivery roller hardness 83º

Detaching roller pressure 3.5 bars

Suction pressure 800 pa

Pneumatic pressure 6 bars

Roller gauge Front to middle: 3 mm

Middle to back: 6 mm

Roller setting Front to middle: 44 mm

Middle to back: 50 mm

Top comb 2026

Circular comb 8016


5.7: Finisher draw frame:

This machine is used both for card and combed yarn. The card and combed sliver both are fed

to the finisher draw frame. If any fault is occurred in this process it cannot be removing in the

further process. The main deference of finisher draw frame to breaker draw frame is the auto

leveler. If sliver mass variation is occurred then it averages out the mass variation. The auto

leveler can remove maximum about ±25% variation. There are two types of FDF in YSML:

i) DX-8LT:

Figure: DX-8LT finisher draw frame

ii) DX-7ALT:

Figure: DX-7ALT finisher draw frame

Model DX-8LT




Model DX-7ALT





Parameters of finisher draw frame:

Parameters DX7A LT DX8 LT


No. of head 2 2

Roller weighting system Spring loaded Spring loaded

Cot roller shore hardness 83º (Carded)

65º (Combed)

83º (Carded)

65º (Combed)

Bottom roller diameter



Back roller - 35 mm


2nd roller - 35.795 mm

3nd

roller - 35 mm

Back roller - 35 mm

Top roller diameter



Back roller - 38 mm


2nd

roller - 38 mm

3rd

roller - 34 mm

4th roller - 38 mm

Back roller - 38 mm

Bottom roller gauge Front roller - 40 mm

Back roller - 45 mm

Front roller - 76.9 mm

Middle roller -76.4 mm

Back roller - 81 mm

Delivery speed 450 m/min 600 m/min

Sliver 330-400 grain/6yd 416 grain/6yd

Trumpet size 3.5 mm 3.5 mm

Creel roller diameter 70 mm 70 mm

No of doubling: 7-8 7-8

Pneumatic pressure 120 bar 140 bar

Presence of auto leveler Yes Yes


5.8: Simplex:

The finisher draw frame slivers are fed to the simplex. The sliver is extended and small

amount of twist is inserted. This twist only helps to hold the fiber during winding of roving

and unwinding of slivers.

Figure: Simplex

Parameters of simplex:


No of machine 18 (Unit-1 : 12, Unit-2 : 09)

No. of spindle 120

Spindle gauge 220 mm

Roving hank 0.9-1.10

Roving TPI 1.15-1.22

Total draft 7.54-8.97

Auto stop motion Yes

Problem indicating lamp system Yes

Arm pressure 15-15-20-12 kg(green)

Top apron size 37×39.8×1 mm

Bottom apron size 38.8×39.8×1.4 mm

Top clearer cloth size 680 (l)×3(t)×40(w) mm

Bottom clearer cloth size 510(l)×160(w)×3(t) mm

Flyer speed 600-1500 rpm

Model FL-100





Top roller + cradle hardness 83º

Spacer size

White- 3.5mm

Black-4.5mm

Beige- 5.5mm

Green- 6.5mm

Blue-8.4mm

Brown-11.3mm

Ash-4mm

5.9: Ring frame:

The roving is fed into the ring frame to produce yarn. The necessary amount of draft is also

needed. The twist is inserted to improve the strength but excessive twist may decrease the

strength. The traveler is mainly inserted for imparting the twist. The ring bobbins are doffed

automatically. There are two types of machines are seen in YSML:

i) JINGWEI ( Suessen, EliTE® Compact set) & (conventional):

Figure: Jingwei ring frame Figure: Elite compact spinning system

ii)Howa:

Model F1520

Manufacturing year 2007(Compact), 2008 (Conventional)

Country of origin China

Manufacturing company JINGWEI ( Suessen, EliTE®Compactset),

JINGWEI conventional


Figure: Howa ring frame

Parameters of ring frame:

Parameters JINGWEI ( Suessen, EliTE

®

Compact set)& (conventional)

Howa

No of machines Unit -2: 64 (Compact) & unit-1:

20 (Conventional) 24


No of spindle per

machine

Compact- 504

Conventional-912 & 1008 960 & 912

Spindle speed 16500-20000 rpm 14500-15000 rpm

Roving stand

Compact-504 Extra-72

Conventional 912 & 1008

Extra- 142

960 & 912

Extra- 140

Top apron size 37×28×1.1 mm 37×28×1.1 mm

Bottom apron size 82.9×28×1.1 mm 82.9×30×1.1 mm

Bottom roller gauge

F-44 mm, B-52mm (compact)

F-45mm, B-55mm

(conventional)

F-44mm, B-64mm

Bottom roller diameter 27-27-27 mm 25-27-25 mm

Angle of drafting zone 45º 45º

Model UA33G

Manufacturing year 1991


Manufacturing company Howa


Wooden roller size 111×42×42 mm 111×42×42 mm

Spindle gauge 70 mm 75 mm

Ring bobbin length 200 mm 210 mm

Ring bobbin diameter Top- 19.5 mm

Bottom -25mm

Top- 22 mm

Bottom- 27 mm

Cradle type OH 2022 OH 2022

Spacer type & size

Red- 2 mm

Yellow- 2.2 mm

Violet- 2.5 mm

White- 2.8 mm

Red- 2 mm

Yellow- 2.2 mm

Violet- 2.5 mm

White- 2.8 mm

Traveller clearer gauge 2.2 mm 2.2-2.5 mm

Weighting system Pneumatic Spring loaded

Ring cup 38-40 mm 38-40 mm

Spindle tape size 2630×11×.6 mm 2870×11×.6 mm

Shore hardness 63º A 63º A

Doffing Manual Manual

Traveller manufacturer KANAI (JAPAN),

BRACKER (GERMANY)

KANAI (JAPAN),

BRACKER(GERMANY)

Count range 10- 60 Ne 10- 60 Ne

Spindle Speed 17000-18200 15000-1650

Total Draft 58.56 36.21


5.10: Winding section:

The Auto coner machine is used to make the yarn cone package from ring cops. During

winding, a yarn clearer device is placed onto each drum head of the auto coner machine

which detects the faulty parts of yarn. Then the faulty part is cut & a splicer joins it.

Pneumatic splicer is used here and Loepfe Yarn Master and Quantum-2 are used as yarn

clearer.

Figure: Process Coner

Process parameters:

Winding heads 60

Drum diameter 100 mm

Tensioning device Tensor Disc

Yarn speed 1200 ~1550m/min

Splicing system Pneumatic

Finished package wt. 1.9-2.2kg

Electronic clearer USTER Quantum-2, LOEPFE Yarn Master

Magazine 9 bobbin feed

Cutter Ceramic

Traverse length 108-152 mm

Drum type Pac21(Ø100)

2.0-2.5 w

Model 21-C



Manufacturing company Muratec


5.11: Heat setting:

Xorella is used to insert the twist permanently and add standard moisture. It has a chamber

where the yarn is subjected to proper temperature and pressure. Heat setting increases the

strength of yarn.

Figure: Heat setting

Process parameters:

Temperature Time

Cotton Cycle-1 65ºC 5 min

Cycle-2 70ºC 15 min

Lycra Cycle-1 70ºC 5 min

Cycle-2 75ºC 15 min

Model XS-R/DIA.

1800×3200



Manufacturing company FONG‘s

Engineering


5.12: Packaging section:

Figure: Packaging section

Package label:

Package label contains following information:

Yarn count

Types of yarn

Code no.

Lot no.

Factory name.

Date of making yarn.

Weight in kg

Measurement of packing bag:

Length of packing bag =37‖

Height of Packing bag =48‖ .

Bag weight = 51.3kg

A bag contains 24 cones.

Each cone contains 2.04 kg yarn.


Chapter: 6

Quality Control


6.1 Quality control system:

The quality control department is assigned to maintain consistently uniform quality of the

material in process and various stages of its manufacturing. Yasmin Spinning Mills Ltd. is

more about concern about quality. In this factory quality assurance is more preferred than

quality control, but both are in advancement.

After collecting fiber, sliver, roving, yarn from different m/c, they are needed to be inspected

or assured required quality by the quality inspectors as if there were no big production

hampered and no complain from the buyers.

6.2: Plan of quality department:

Raw cotton analysis.

CV% & deviation control of gr/yd and count.

Setting parameter control (B/R, Card setting, Roller gauge, Draft, TPI, Speed, Yarn

clearer etc.).

Optimum quality (CVm%, Thin, Thick, Neps, H%, Tenacity, Elongation, CSP).

Wastage control (B/R to finishing).

Machine fault find out by machine audit and rectification by responsible department

(B/R to Finishing).

Operation control (m/c, floor cleaning, material handling, lot change, count change

and housekeeping etc.).

Manpower training (market demand, operation, wastage/quality control, Work

procedure, housekeeping and safety).

Yarn performance report (Observation market feedback report).

Continual improvement by R&D.


6.3: List of testing equipment and their manufacturer and model no:

M/c name Manufacturer Model no No of machine

Lea strength tester MAG, INDIA YO261 1

USTER auto sorter 5 Switzerland XS603SDR 2

Auto wrap 10 MAG, INDIA YO121 3

Auto winder (Board

winder)

MAG, INDIA MAG-Y0881 2

USTER® AFIS PRO-2 USA AFIS PRO-2 1

HVI USA HVI 1000 1

USTER TESTER-5 Switzerland YGO41 2

Wrap reel MAG,INDIA Ele wrap-10 3

Dry bulb hygrometer Zeal, England 2

6.4: Machine description:

Lea strength tester:

Function: A lea strength tester measures the strength of one lea

yarn. One lea means 120 yards. Strength is a measure of the steady

force necessary to break a material and is measured in pound. The

m/c works in constant rate of extension.

Figure: Lea strength tester


USTER auto sorter 5:

Function: USTER auto sorter‘s function is to weigh certain

lengths of skeins and give English count (Ne) of yarns.

Figure: USTER auto sorter 5

Auto wrap 10:

Function: An auto wrap reel is an automatic

device for measuring yarn and making it into

hanks of a standard size. The reel is of a standard

size and its revolutions are counted as the yarn is

wrapped around it. A set number of revolutions

will be used so that the hank is of a standard size

— a skein or a lea. A skein of cotton would be

80 turns on a reel of 54 inches circumference,

making 120 yards.

Figure: Auto wrap 10

Auto board winder:

Function: To wind sample yarn onto tapper

board for visual assessment of the appearance

of the sample yarn.

Figure: Auto board winder


Wrap reel:

Function: A wrap reel is a device for measuring yarn

and making it into hanks of a standard size. The reel is

of a standard size and its revolutions are counted as the

yarn is wrapped around it. A set number of revolutions

will be used so that the hank is of a standard size — a

skein or a lea. A skein of cotton would be 80 turns on a

reel of 54 inches circumference, making 120 yards.

Figure: Wrap reel

USTER AFIS PRO-2:

(Advanced Fibre Information System)

This instrument is widely used instrument for neps

measurement. This equipment has three modules.

NC Module (Nep classification)

L & M Module (Length and Maturity)

Trash Module

Figure: USTER AFIS PRO-2

Functions: To measure following fiber properties-

-Nep (Cnt/gm), Nep (μm), SCN (Cnt/gm), SCN (μm), L(w) (mm), L(w) (%CV), SFC(w) (mm),

SFC(n) (%<12.7), UQL(w) (mm), L(n) (mm), L(n) (%CV), IFC (%), Maturity ratio.


HVI:

(High Volume Instrument) This equipment

is used mainly for bale management. This

equipment contains three modules. They are:

-Micronaire,

-Color and trash,

-Length and strength.

Figure: HVI

Functions: To measure MIC, Maturity, UHML, SCI, Length, Amt, Uniformity, Strength,

Short Fiber Index, Elongation, Moisture, Rd, +b, Color grade, Trash Content, Trash Area,

Trash Grade, UV.

USTER tester 5:

Function: It is used to measure the

unevenness of mass (Um%), co-efficient of

variation of mass (CVm%), hairiness,

imperfection index (IPI), thick- and thin

places, neps etc. of yarns, rovings and

slivers.

Principles of Uster evenness tester are

capacitive principle and optical principle.

Figure: USTER tester 5


Dry and wet bulb hygrometer:

Function: A hygrometer is an instrument used for measuring

the moisture content in the atmosphere.

Humidity measurement instruments usually rely on

measurements of some other quantity such as temperature,

pressure, mass or a mechanical or electrical change in a

substance as moisture is absorbed. By calibration and

calculation, these measured quantities can lead to a

measurement of humidity.

Figure: Dry and wet bulb hygrometer

6.5: Wastage information:

Section For 100% Cotton For PC or CVC

Blowroom Up to 4% (Dropping-2) 2.5%

Carding Up to 6% (Dropping-1) 3.5%

Breaker drawframe 0.5% 0.5%

Lap former 1%

Comber 15%-16.5%

Finisher drawframe 0.5% 0.5%

Simplex 1% 1%

Ring 2.5% 1.5%

Winding 0.35% 0.35%


6.6: Chemical analysis for fiber composition determination:

A 0.5 to 1.0 gm of blend sample is taken, carefully weighed, and kept it in a flask.

70% Sulphuric acid + 30% water solution is added into the flask.

In refrigerator or cold water bath, the flask is kept for 30 min.

Then it is filtered, whatever is left is polyester as cotton dissolves into 70% Sulphuric

acid.

The polyester is washed thoroughly.

It is dried by iron, cooled and weighted to find the percentage of polyester.

6.7: Growth test report:

Fibre growth analysis reports for 30/1CW (Chad, Lot no-70) and 40/1 CW (Cameroon, Lot

no-58) is given bellow:

Raw

cotto

n

Card

mat

Cardi

ng

Pre

comb

drawi

ng

Unila

p

Com

ber

Post

comb

drawi

ng

Simp

lexRing

Process Stages 15.8 16.3 15.9 14.9 15.9 7.5 8.1 8 14

0

2

4

6

8

10

12

14

16

18

Len

gth

in

crea

se in

mm

SFC(n)%<12.7


Raw

cotton

Card

mat

Cardin

g

Preco

mb

drawin

g

UnilapComb

er

Post

comb

drawin

g

Simple

xRing

Length increased 0 -0.9 -0.5 -0.1 -0.7 0.3 0.6 1.3 -1.2

-1.5

-1

-0.5

0

0.5

1

1.5

Len

gth

in

crease

/decrea

se in

mm

Length increased

Mixin

gBDT

T.V.

Fan -1

Staend

BR -

CO

CL-PT.V.

Fan -2

M.X.-

1

C.L.C

1

SP-F

M

T.V.

Fan-3

Card

mat

SCN -11.7 15.79 -50 12.5 14.29 -38.8 40 -13.3 17.65 -42.8

Nep 28.24 -2.87 -27.8 21.81 3.98 -10.7 -23.6 17.88 -42.4 -5.7

-100

-80

-60

-40

-20

0

20

40

Nep

gen

era

tion

/rem

ova

l %

Nep Generating%


Chapter: 7

Maintenance


7.1: Maintenance:

Maintenance is the combination of all technical and associated administrative actions

intended to retain an item in, or restore it to, a state in which it can perform its required

function. Many companies are seeking to gain competitive advantage with respect to cost,

quality, and service and on-time deliveries. The effect of maintenance on these variables has

prompted increased attention to the maintenance area as an integral part of productivity

improvement. Maintenance is rapidly evolving into a major contributor to the performance

and profitability of manufacturing systems.

Objectives of maintenance:

Minimizing the loss of productive time because of equipment failure.

Minimizing the repair time and repair cost.

Minimizing the loss due to production stoppages.

Prolonging the life of capital assets by minimizing the rate of wear and tear.

To keep all productive assets in good working conditions.

To minimize accidents through regular inspection and repair of safety devices.

To minimize the total maintenance cost which includes the cost of repair, cost of

preventive maintenance and inventory carrying costs, due to spare parts inventory.

To improve the quality of products and to improve productivity.

7.2: Maintenance of machineries:

Maintenance

Preventive Maintenance

Electrical Maintenance

Mechanical Maintenance

Break Down Maintenance

Electrical Maintenance

Mechanical Maintenance


Preventive maintenance:

Preventive maintenance is the care and servicing by personnel for the purpose of maintaining

equipment and facilities in satisfactory operating condition by providing for systematic

inspection, detection and correction of incipient failures either before they occur or before

they develop into major defects. This type includes maintenance of machine parts like gear

changing.

Break down maintenance:

Break down Maintenance is maintenance performed on equipment that has broken down. It is

based on a breakdown maintenance trigger.

7.3: Maintenance points:

S.N. Items need to be checked & serviced

1. Check and tightening all motor terminals.

2. Check and clean pressure sensor and tightening terminals

3. Check and clean the interfacing and data cables.

4. Check and tightening the proximity switch terminals.

5. Inspection, cleaning and tightening all the terminals in the panel.

6. Check and tightening limit switch, safety door guard and the emergency switch.

7. Functional test of the fiber, sliver, roving and yarn detector.


7.4: Machineries used for maintenance:

The list of machineries used in Yasmin Spinning Mills Ltd. is given below-

Carding

Grinding machine

Mounting machine

Berkolizing machine

Brush cleaning machine etc.

Draw frame, lap former, comber

Long cot grinding machine

Flyer washing machine

Grinding machine etc.

Ring frame

Cot grinding machine

Cot mounting machine

Berkolizing machine

Spindle oil change machine etc.

7.5: Machine maintenance schedule:

7.5.1: Maintenance for blowroom:

Operations Frequency

Cleaning of dust and collected fly from the m/c Daily

Cleaning of motor air intake screens Daily

Cleaning of flat belts, v-belts and sprockets Every 7 days

Cleaning the brush roller Every 7 days

Checking the condition & tension of flat belt & chain drives. Every 7 days

Oil change in gear motors Every 30 days

Lubrication works of bearing of supporting shaft and tension

pulley.

Every 15 days

Cleaning of fiber accumulating from the grid bars and the pins of

the beaters.

Every 7 days

Cleaning of the intake grill of the fan cover of the driving motor.

Every 15 days


7.5.2: Maintenance for carding:


General cleaning of machinery by the operator. Daily

Checking of stop motion switches Daily

Checking of belt tension and condition Daily

Ampere rating of motor Every 7 days

Checking of doffer to cylinder driving gears Every 30 days

Full setting/re-setting Every 30 days

Dismounting and cleaning of feed coupling plates and web units Every 30 days

Checking of auto leveler Every 30 days

Checking the condition of wire of cylinder, T-in doffer and flat

combs

Every 30 days

Checking the gauge of feed plate to feed roller Every 30 days

Checking the gauge of feed plate to feed roller Every 30 days

Checking the gauge of taker -in to cylinder Every 30 days

Checking the gauge cylinder to doffer Every 30 days

Under casings setting Every 30 days

Checking of trumpet, calendar roller & gears Every 30 days

Checking the bearings & motor shafts Every 30 days

Wire replacement of cylinder, doffer & f1ats. Every I5-18 months

Wire replacement of taker in According to order of

Q.C.

Replacement of flat stripping comb According to order of

Q.C


7.5.3: Maintenance for drawframe:


General cleaning of machine by operator Daily

Cleaning of top roller cots with suitable solvent Daily

Checking the drive/motion of clearer cloth, clearer pad, positive

drive comb, can change drive

Daily

Checking the function of oil pump of outer side, gear end side,

filling the oil in oil tank

Daily

Function of stop motion limit switches etc. Daily

Greasing the top bushes having bearings Every 7 days

Roller gauge checking/resetting Every 30 days

Pressure checking/resetting Every 30 days

Cleaning the bottom fluted roller with wire brushes Every 30 days

Cleaning and polishing of coiler and brush Every 30 days

Lubricating/greasing of the creel roller drivers Every 30 days

Tightening of the loose nuts, bolts, allan screws etc. Every 30 days

Checking the condition of trumpets, sliver guides, clearer tubes

yokes, air pipes grease nipples etc.

Every 30 days

Checking of timing belt tension Every 30 days

Backlash checking of machine gears Every 30 days

Checking the eccentricity of top and bottom roller (if needed) Every 30 days

Oil change Every 60-90 days

To roller cots buffing/grinding Every 60-90 days

Replacement of top roller cots and end bushes. Every 360 days


7.5.4: Maintenance for lapformer:


General cleaning of creel part and drafting part by the operator. Daily

Function of limit switches, photo switches etc. Daily

Top roller cot treatment / greasing Every 30 days

Gauge checking/resting Every 30 days

Over hauling of pneumatic unit Every 30 days

Cleaning and plashing of silver table, calendar rollers etc. Every 30 days

Cleaning and plashing of silver table, calendar rollers etc. Every 30 days

Greasing the ball/needle bearings shell roller bearings open gear. Every 30 days

Top roller cot buffing/grinding and pressure setting. Every 90 days

Replacement of top roller cots Every 360 days

7.5.5: Maintenance for comber:


Cleaning of nip Jaws Every 7 days

Cleaning and straightening of cylinder needles and top combers Every 7 days

Topping the oil tank Every 7 days

Check functioning of limit switches, stop motions etc. Every 7 days

Top roller cots treatment greasing Every 30 days

Gauge checking/ resetting Every 30 days

Greasing/lubricating the top detaching Every 30 days

Checking and tightening of nuts, bolt Every 30 days


Checking of bottom fluted roller with bushes Every 30 days

Top roller cot buffing/grinding Every 90 days

Replacement of top roller cots Every 360 days

Replacement of top comb brackets, top comb strips, brushes. Every 360 days

Reversing of brush Every 180 days

7.5.6: Maintenance for simplex:



Check functioning of oil pump Daily

Topping of oil Every 15 days

Building motion setting Every 30 days

Top roller cot treatment/greasing Every 30 days

Roller gauge checking/resetting Every 30 days

Centering/alignment the sliver guide, collector and condenser in

relation to cot.

Every 30 days

Alignment of bottom apron tensioning pulley W.R.I. knurled

roller.

Every 30 days

Checking & tightening of loose nuts blots etc. Every 30 days

Pressure checking/resetting Every 30 days

Top roller cot grinding Every 30 days

Lubricating oil change Every 60-90 days

Replacement of top roller cots Every 60-90 days

Greasing the top roller arbor Every 360 days


7.5.7: Maintenance for ring frame:

Operation Frequency


Checking of oil pump Daily

Checking of push-bottom & motor amperes Every 7 Days

Refilling of oil Every 7 Days

Tension of V-belts and spindle tapes Every 7 Days

Checking of gears & gear meshing Every 20 days

Inverter checking A/C (input & output), D.C Every 20 days

Top roller cots treatment / greasing Every 36 days

Checking of spindle and lappet Every 36 days

Checking of ring rail parallelism Every 36 days

Checking of ring cup block gauge Every 36 days

Building motion setting Every 36 days

Roller gauge checking / resetting Every 36 days

Pressure checking / resting Every 36 days

Bottom roller turning (If required) Every 36 days

Checking of traverse motion, top & bottom rollers/top etc. Every 36 days

Greasing of all bearings, open gears etc. Every 36 days

Checking & tightening of loose nuts, bolts etc. Every 36 days

Top roller cots buffing / grinding Every 90 days

Spindle oil change Every 90 days

Lubricating oil change Every 90 days


7.5.8: Maintenance for winding:

Operation Frequency

Checking and removal of blow cleaner waste Daily

General cleaning of blower motor, filter shaft, motor filter control

box, clipper filters

Daily

Measuring head checking Every 7 Days

All micro switch checking Every 7 Days

Gauge checking/resetting Every 7 Days

Drum checking Every 30 Days

Checking of splicing unit Every 30 Days

Spray lubricant for cutters Every 30 Days

Checking of cone sensors Every 30 Days

Spray grease for drive gears/spindle oil for cam shafts Every 30 Days

Checking of drum bearing, splicing bearings, blower shaft

bearings

Every 90 Days

Checking of drum brakes, shutter cutters, cassette type joint gears,

reduction gears

Every 180 Days


Chapter: 8

Utility


In Yasmin Spinning Mill the available utility services are:

Generator Chiller

Electrical & Electronics A/C Plant

Boiler Compressor

8.1 Generator:

Unit-01

M/c Name Model Brand

Name

Country of

origin

Manufacturing

year Quantity

Generator VPH 7100

GSID Waukesha USA 2000 3

Generator VHP 3604

GSID Waukesha USA 2003 1

Generator 5904 GSID

W/ESM Waukesha USA 2005 1

Water pump

(Generator cooling) KSB India 2003 5

Water softener 40 M3/H Bangladesh 2000 2

Generator specification:

Figure: Generator

Type Gas generator

Efficiency 68%

Frequency 50 Hz

Total capacity

1100 ×3 = 3300KW

750×1 = 750KW

980×1 = 980KW


Electrical panel:

M/c Name Brand Country of

origin

Manufacturing

year Quantity

Synchronizing bus bar 9600A Siemens Germany 2001 1

Power factor improvement

plant Siemens Germany 2002 4

LT panel (New)

12001X1,2000X2 Siemens Germany 2003 2

LT panel (Old) 3200X2 Nilson Australia 1978 2

Generator load distribution:

Section Total load (KW)

Blow room 82

Carding 262

D.S.C. 123

Ring 1644

Finishing 72

A/C 892

Compressor 182

Chiller 554

Boiler 489

Generator 160


Unit-02

M/c Name Model Brand Country of

origin

Manufacturing

year Quantity

Generator G-3516 Caterpiller USA 2007 4

Generator control

panel Unilib Singapore 2007 4

Generator specification:

Figure: Generator

Electrical panel:

M/c Name Brand Country of

origin

Manufacturing

year

Quantity

LT-Panel (4000AMPS) Siemens Germany 2007 1



PFI-Panel (500KVAR) Siemens Germany 2007 1



BDT (3200AMPS) Siemens Germany 2007 1

BDT (3200AMPS) Siemens Germany 2007 1

Type Gas generator

Total capacity 1030 KW (each)

Frequency 50 HZ

Efficiency 70%


Generator load distribution:

Section Total load (KW)

Blow room 72

Carding 193

D.S.C. 112

Ring 1464

Finishing 54

A/C 788

Compressor 152

Chiller 450

Boiler 427

Generator 130

8.2: Boiler:

M/c Name Model Country of

origin

Manufacturing

year

Quantity

Schneider Kessel Berlin WHR-33230/10 Germany 2007 1

Schneider Kessel Berlin WHR-2785/10 Germany 2007 1

Boiler specification:

Figure: Boiler

Volume 5770 litres

Type Fire tube boiler

Temperature 400 C

Function To produce steam and the steam of

boiler is used for chiller.

Total capacity 3.23 ton/hr

2.94 ton/hr


8.3: Cooling tower:

Unit-1

M/c Name Model Country of origin Manufacturing

year

Quantity

Cooling tower 500RT CTA 500 VK Malaysia 2004 8

Cooling tower 350RT Sun 350 Thailand 2007 3

Unit-2


origin

Manufacturing

year

Quantity

Cooling tower 687 m^3/h STA-800SUN Thailand 2007 8

Cooling tower 624 m^3/h 200RT Thailand 2007 4

Figure: Cooling tower


8.4: Chiller:


origin

Manufacturing

year Quantity

Absorption chiller Prochil LSH- 040 Korea 2007 3

Absorption chiller LWM – 048 Korea 2007 1

Thermex hot water

chiller

SG 6MC India 1

Thermex drive chiller SD 30A TC India 1

Centrifugal chiller LDR -07 OS 1

Parameters of chiller:

Parameters LSH – 040 LWM – 048:

Cooling capacity 360 USRT 400 USRT

Heating source type Steam Hot water

Chilled water flow rate 214 m^3/hr 241.9 m^3/hr

Chilled water temp. 13º-8ºC 32‘-37c

Cooling water flow rate 388.7 m^3/hr 588.3

Figure: Chiller


8.5: Compressor:

M/c Name Model Country

of origin

Manufacturing

year

Quantity

Hitachi Screw air compressor OSP - 55SA1 Japan 2005 4 (Unit 01)

Hitachi Screw air compressor OSP- 55SA1 Japan 2007 4 (Unit 02)

Air dryer HDR- 55AE Japan 2006 4 (Unit 01)

Air dryer HDR- 55AE Japan 2007 4 (Unit 02)

Parameters of compressor:

Power consumption for a compressor 60 KW/Pcs

voltage 41 V

Frequency 50 HZ

Capacity 13.6m/min

Normal pressure 5.5 bar

Pressure after compressed 8.6 bar

Figure: Compressor


8.6: AC plant:

M/c name Model Country of

origin

Manufacturing

Year

Quantity

LUWA completer A/C plant DG 05 Switzerland 2010 5 (Unit1)

LUWA completer A/C plant DG 05 Switzerland 2007 4 (Unit2)

A/C plant controls the relative humidity in different section during processing of yarn. The

most effective way to humidify a textile plant is to use a compressed air & water spray

system. Air humidity is measured as ‗‘Relative Humidity‖. It is defined as the amount of

water in a sample of air compared to the maximum amount of water the air can hold at the

same specific temperature. It‘s expressed in a form of ―0 to 100‖.

Cold air can hold less moisture than warm air, therefore the humidity of air is relative to its

temperature. For example a sample of air at 10ºc can hold less moisture than the same sample

of air at 20ºc. Even with the same amount of water present in both samples, the warmer

sample has a lower relative humidity as it can potentially hold more moisture than the cold air

sample. The properties like dimensions, weight, tensile strength, elastic recovery, electrical

resistance, rigidity etc. of all textile fiber whether natural or synthetic are influence by

moisture regain.

Air conditioning is the process of treating air also as to control simultaneously its

temperature, humidity, cleanliness and distribution to meet the requirements of "conditioned

space". An air conditioning system may use heating, cooling, humidifying, de-humidifying

and filtering units of combination of these depending upon the outside weather.

The capacity of an air conditioning system is directly proportional to the heat load in the

system. The heat load consists of internal heat which is almost constant for textile mills and

transmission heat which varies from time to time and season.

The maximum heat load, which occurs during summer afternoons, determines the capacity of

air conditioning required for a department of the maximum heat load, roof heat load accounts

25% to 30%. Air conditioning plants are installed to maintain correct ambient condition for

spinning process to work smoothly. Norms of temperature and relative humidity for textile

mills are established through controlled experiments in laboratories and mills.


Relative humidity and temperature in different section:

Section RH Temp

Blow room 46±2% 30ºC

Ring section 50±2% 27ºC

Preparatory 48±2% 30ºC

Finishing 68±2% 28ºC

Air exchange rate:

Blow room 12.8/hr

Carding 44.1/hr

Draw frame, lap former, comber 9.8/hr

Simplex 11.2/hr

Ring 47/hr

Finishing 33.4/hr


Chapter: 9

Store and Inventory


9.1: Inventory control:

Store is the place where every type of raw materials, spares, finished goods are kept in proper

system. Inventory control means the accurate calculation of every type of raw materials,

spares, wastages and finished goods time to time. Inventory control is necessary-

To know about the required amount of raw material,

To be continued the production process,

To find out the profit or loss of a company,

Stock and stock value for consumption measuring etc.

9.2: Sections of store:

YSML store consist of five sections:

Store

Raw material

Finished goods

Wastage cotton

Spare parts

General storage


Inventory system for raw material:

Raw materials partially received from production planning & directly from head

office.

Material receiving & inspection report (MRIR) is prepared. Received quantity is

mentioned and noted down.

Submitted to Q.C. department. Some are OK & few rejected.

Entry of data of goods.

Goods are arranged according to OK or rejected group.

As per requisition materials supplied & this record are noted down.

All the raw cotton is stored in godown, near the blow room section.

Inventory System for spare parts:

In this mills required amount of spears of different machine are stored in mechanical store

room. All the spears are listed in a sheet which is controlled mechanical and maintenance

personal. Spears are arranged in store room according their size, quantity and requirements.

There are selves in store room to keep small spear parts.

Inventory system for finished goods:

YSML supplies its finished yarn to different fabric manufacturing industry. So package yarns

are stored for short time in the finishing section. All the delivered yarns are noted on tally

khata according to lot no, count, quantity, buyer‘s name and other technical parameter.

Inventory system for waste cotton:

There is a waste cotton godown where hard waste and soft waste are stored. Dropping-1,

dorpping-2, flat strip, noils, bonda waste etc are sorted and stored as per as their usability.


Inventory system for general store:

In general store, there stored-

Capital equipments.

Accessories.

Stationary.

Maintenance parts etc.

All the particulars are labeled and the records of them are noted in record book.

9.3: Inventory procedure:

Store requisition

Store ledger account

Daily inspection & package report

Monthly stock & consumption report

Monthly L/C wise delivery report

Received delivery & balance stock


Chapter: 10

Administration, HRD, Account, First

aid and Fire fighting


10.1: Administration:

Administration department plays a vital role in manufacturing industry. It controls/maintains

and looks after all the task of all departments in industry. It communicates with different

department in regarding company‘s target. It is said that, well administration is half success

and well management is the fame of company.

Administration is like a network which spread information, gather information, collect data,

recruit employee & worker, well distribution, try to improve the company‘s environment,

improve skill by arranging training and so on. Objective and tasks are:

To control/maintain and look after,

To recruit the manpower,

To improve environment of industry,

To communicate with owner of the company, local, politician, legal adviser, if face

any unexpected problem,

To ensure the security of properties and employees inside the factory,

To arrange training for improving skill,

To motivate employees and workers and aware about rules and regulations of

industry.

10.2: HRD department:

Human Resource Development department provides the facilities of employees and workers

in industry. This is also called facilitator department. Tasks of HDR are:

Need to arrange training program for manpower development.

To act as a bridge / catalyst / facilitator.

To co-operate with other departments as per their requirements.

10.3: Accounts:

All the financial activities are done by Accounts department. This department is responsible

of any transaction, pay wages, account receivable and payable, to inform to owner, make

monthly sheet and yearly sheet and so on.


10.4: First aid:

First aid means primary treatment of any injury. It may be done by doctor, nurse, expert of

medicine and others. The main tasks of first aid team are:

To ensure primary treatment

To provide necessary medicine

To aware of workers about first aid

To check up workers health

To send injured to general hospital if need

To give proper treatment & medicine

To call ambulance for serious injured.

There are 13 first aid boxes present in the factory and 66 first aiders are present.

10.5: Fire fighting:

Team:

YSML have a trained team who can straight forwardly fight against any type of fire exposure.

Every one of this team is endow with a distinct costume and requisite equipment to stand

before the fire hazard.

There are 284 fire fighters present in YSML.

Equipment:

YSML installed a modernized fire hydrant system covering the entire area of the factory. Fire

extinguishers of CO2 and ABC gas powder are available in every section of the factory. A

fire can rapidly spare in a spinning mill if it cannot be control. Cotton ignited very fast. The

worker and other related person are always ready for any kind of accident with their modern

equipment.


Fire extinguisher:

There are 4 kinds of fire:

A class – Solid fire (Cotton, fiber, bamboo, wood etc.)

B class – Liquid fire (Diesel, petrol, octane etc.)

C class – Gas fire

E class – Electric

And there are four kinds of fire extinguisher:

ABCE (It can be used in all kinds of fire)

DCP (Dry chemical powder)

CO2 (For electrical fire)

Water type

Foam type

Here, in YSML, there are 513 fire extinguishers, 370 of these are dry powder, 32 of these are

water type, and 9 of these are foam type. There are 63 fire house cabinets present in YSML.


Chapter: 11

Marketing strategy and cost analysis


11.1 Consumers of product:

YSML follows In-house consumption sales system. It means that it sells its product within

the weaving factories of Noman group of industries like,

Sufia Fabrics Ltd.

Noman Fabrics Ltd.

Noman Weaving Mills Ltd.

Noman Fashion Fabrics Ltd.

Talha Fabrics Ltd.

Saad Saan Apparels Ltd.

Zaber & Zubaer Fabrics Ltd.

It also sells yarn to different kind of export oriented factories like,

HR Textile Ltd.

Jointex Knitwear Ltd.

KAC Fashion Ltd.

Meghna Knit Composite Ltd

Apex Knitwear.

GMS Group.

P.A Knit Composite Ltd.

Epilion Knitwear Ltd. etc.

11.2: Local market:

YSML produces only export quality yarn. This company does not sell yarn in local market.

11.3: Importing country:

Raw cotton is imported mainly from Uzbekistan, Tajikistan, Chad, Cameroon, Mali, and

Zimbabwe.


11.4: Exporting country:

Yasmin Spinning Mills Ltd. does not export yarn directly. They sell yarn to the various

export oriented factory. And after the factories make knitted garments & dyed fabric, then the

final products are exported.

11.5: 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 Yasmin

Spinning Mills Ltd., mainly senior marketing officers & higher officials deal with the buyer.

There are some fixed buyers of the industry. The buyers give their orders continuously all

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

A well defined marketing strategy has the following characteristics:

Good quality,

Low price or competitive price,

Prompt service,

Good commitment.

11.6: Cost analysis:

The management of YSML does not provide any information regarding these to the outsiders

as per their managerial policies.


Chapter: 12

Conclusion


This training program is an excellent opportunity for us to get to the ground level and

experience the things that we would have never gained through going straight into a job. We

are grateful to Yasmin Spinning Mills Ltd. for giving us this wonderful opportunity. The

main objective of the industrial training is to provide an opportunity to identify, observe and

practice how engineering is applied in the real industry. It is not only to get experience on

technical practices but also to observe management practices and to interact with fellow

workers. It is easy to work with sophisticated machines, but not with people. The only chance

that undergraduates can have this experience is the industrial training period and we got the

maximum out of that experience. Also we learnt the way of work in an organization, the

importance of being punctual, the importance of maximum commitment, and the importance

of team spirit. We have gained lots of knowledge and experience needed to be successful in a

great engineering challenge, as Engineering is after all a challenge, not a job.

We must say we are fortunate enough to enjoy the opportunity to be trained in a factory like

the Yasmin Spinning Mills Ltd. Its excellent working atmosphere, orderly mannered

production process, advanced technology in production and quality control lab and most

importantly its friendly behaved executives made our journey encouraging, interesting and

smoother.

To motivate, every employee and worker is given the incentive from the factory. When they

face any kind of problems, the management always stands for their welfare. One thing that

made YSML unique is their payment on right time in every month.

At the end, we like to thank the directors and employees of YSML for their support and

encouragement during our training period. By dint of that we have enriched our depth of

knowledge on practical. We believe YSML will hold its name and fame in future too.

We wish Yasmin Spinning Mills Ltd. all success.

Intern-Report-Yasmin-full-and-final (1)

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