Operations Final Slides

7/31/2019 Operations Final Slides

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Submitted By:

Adam Zia

Khurram Yar Javed

RehmanAkram

Saba Javed Hayat

Samar Shoaib

SHAHRAJ FABRICS LIMITED

FABRICPROCESSING UNIT

Process Design and Quality Management


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Company Profile


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Introduction

Weaving

Processing

StitchingVertically Integrated

Sales: US$45 Million

Local Sales: Local Buyers, ArmyInternational Sales: USA, EU, Chi


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Machinery

Weaving

250 Air-Jet Shuttle less Looms Woven Fabric Width Range: 31 160 Inches Capacity: 2 3 Million / Linear Meter Month

Processing

Bleach, Dye, Print, Finish Capacity: 3 Million Meter / Month

Stitching

250 Stitching Machines 4 Quilting Machines Capacity: 2 Million Sheet Sets and 100,000 Sets Bed / Month


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FabricTypes

Soap Washed

Bleached

Dyed

Printed

Peach Finish

Crease Resistant

Water Repellant

Mercerized

Anti Bacterial


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Production Process


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ProductionFlow Chart

PhysicalInspection ofRaw Material

Singeing

De-sizing

Bleaching

Mercurizing

Dyeing Printing

Finishing

Folding


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Step 2: Singeing

Flame

GasHeavyFabric

90 C

Light Fabric

45 C

FabricRefinement

Guiders

Fiber Brushing

Gas Heaters

Oxygenated Air

Burns flawed Fibers

Upper Limit

120 Meters / Min

Average

100 Meters / Min

Lower Limited

90 Meters / Min


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Step 3: DE-SIZING PROCESS

Heating fabric over hotoxygenated air stream

De-sizing Box Starch removed throughenzymes

Cloth passed throughsqueezing machine

where linear squeezing

and compressing underhydraulic pressure is

done

Cloth framed onhydraulic rotation

machine which makes 10rotations in a minute


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Step 4: BLEACHING AND MERCERIZINGPROCESS

Rinsing-PreWashing

The frames loadedon the J box andcloth sent through aset of 3 pre-washers andsqueezers.

First washer tries toachieve maximumtemperature of 90to 95 degrees asfabric temperatureis low.

Cloth then fed tothe hydraulicpressure squeezerin which vacuum iscreated andsuckers take outimpurities from the

fabric

BleachingProcess

Cloth fed into agiant steaming unit.

Unit containshydrogen peroxide,caustic catalyst,

stabilizer, de-ironizing agent andwetting agent.

Steamer has atemperature of 100to 102 degrees dueto both saturatedand dry steam.

Usually 200gramcloth takes 15 to 18minutes beforedyeing process canstart.

Rinsing PostWashers

The cloth sentagain to analternate series offive washers andfive squeezers.

First washertemperature is 85to 90 degrees

Cloth is thenpassed on to bi-conduction dryers.Where it is driedthrough contactwith steam filleddryers

MercerizingProcess

PH neutralizedbefore the dyeingprocess. The fabricmoisturized at avery fast pace.

Caustic of relevantstrength

Passes againthrough a series ofpost washers andsqueezers toremove caustic.

PH is neutralized

Cloth dried byconduction


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Step 5: DYEING PROCESS

In the thermo-dyingmachine,white clothframe isloaded on theJ-box .

DyeingProcess

Fabric dried indryingchamber.

It contains afluid which isheated byinfrared waves

DryingProcess

Polyester isremoved fromthe fabric

Then sent intothe steamer

Padding,Steamin

g andWashing

Cloth driedin Teflondryers

For shadetesting, sentto the lab

DryingProcess


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Step 6: FINISHING PROCESS

StanterMachine

Finishing Width

completion

Winding

Dying


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Step 7: PRINTING PROCESS

ComputerizedDesign Repeat

Pattern

ScreenProduction

Printing Folding


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Computerized Design Repeat Pattern Screen Production

Printing

Folding


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QUALITY ASSURANCE

ISO 9001

ISO 2008

ISO 14000

SA 8000


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Quality Policy guidelines at Shahraj

fabrics includes:

Quality assurance

Regular monitoring of customers requirement and expectations.

Clients satisfaction

Compliance of legal and regulatory environment

Timely delivery/ shipment

Minimize wastage

Employees professional competence, constant grooming and development

Striving for excellence


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Quality testing at Shahraj fabrics


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Water spray test

Conducted to find out water pick up rate in fabric.

A sample of the fabric is cut and secured at the start of thetest.

A beaker with 250ml of water is placed on the top of thefabric.

The beaker dispels water at a constant rate for 25 seconds.

If the criteria for water resistance is met then the roll of fabricis passes, if not then it goes back to get waterproofing.


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Lab Test for light fastness and

color

The light fastness test is used to determine the color fastnessof any type of dyed and printed materials against day light.

In this test a sample is exposed to a mercury blindedtungsten lamp inside a chamber.

This test checks for the resistance of the fabric to fading dueto exposure to sunlight.

A sample of the fabric is put into the machine and then anultra bright light is exposed to the fabric.

At the end of the test the fading of the fabric is reviewed


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Perspiration Tester

The perspirometer isused to check thefading in fabric .

A sample is dippedin either water or an

alkaline solutionand then rested to

absorb the liquid.

The stacks are thenplaced under two

stainless steelplates.

After the test thefabric is checked for

the change in colorand the degree ofstaining.


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Martindale Abrasion Test

The abrasiontest is used to

find out theabrasion

resistance ofall types of

fabrics.

The abrasionresistance ismeasured bysubjecting thesample to a

rubbing motion

This test findsout theresistive

capabilities ofvarious typesof materials.

The materialsare then

evaluatedthrough directcomparison to

actualsamples or thelap assistant

checks it.


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Digital balance is usedto measure the coloraccording to customerspecifications.

The accuracy is in line

with the internationalstandards

Digital Balance

Thespectrophotometer is

used to measure thecolor density of thedye used in the fabric

The machinemeasures the dyemixture solutions in

order to control thecolor and to measurethe density of dyeused in the fabric.

Spectrophotometertest


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Recommendations

Improve the working environment as well ascleaniness

Improve inspection methods of rawmaterials

Improve upon chemical waste disposal

Demand forecast should be done to achievefull capacity utilization.

Organize the departments according toprocess flow

Operations Final Slides

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