Viyellatex Group

8/12/2019 Viyellatex Group

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ACKNOWLEDGEMENT:

We are extremely delighted to express our indebtedness and deepest sense of

gratitude to our supervisor Md. Dewan Mahbub Kamran(Sr.Executive,

Dyeing).for his able guidance, untiring efforts, stimulating influence andvaluable comments during the training period .

We would like to offer sincere thank to the DGM (Dyeing) Engr. Md. Shamim

Rahmanfor his invaluable suggestions regarding this training period.

The authority of the VIYELLATEX GROUP who gave us the opportunity to

complete our industrial attachment with great success is remembered with

honor. Thanks are due to all Engineers, officers, technicians, employees, stuffs,

all section in-charges for their cordial behavior. We are really lucky that we have

gotten such helping hand without whom, this attachment could not be completed.

We also like to thank Dr. Shah Mohammad Fatah-ur-Rahman, department of

Wet Processing Technology for his encouragement, valuable suggestion, and for

the completion of this Industrial attachment successfully.

Last but not least, thanks goes to my precious family for their never-ending

support and loves in every stages of my life which has motivated me to do such

type work.

I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page 4


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EXECUTIVE SUMMARY

The internationally recognized Buyers or clients are looking for those countries

for producing their apparel products where different types of mills have

established as a one stop source for the global apparel market, satisfy and

meet customer's expectation by developing and providing products andservices on time, which offer value in terms of Quality, Price, Safety &

Environmental impact. And also assure complete compliance with the

international quality standards and also to provide the employees

internationally acceptable working condition/standards. In Bangladesh, there are

different types of Textile Industry those are producing high quality textile and

apparel product. VIYELLATEX GROUPis one of them.

VIYELLATEX GROUPis a Knit Composite Garments, having all state of the

art facilities with the annual turnover US$ 106.6 Million (2006-2007). They have

different types of Knitting, Dyeing, Cutting, Sewing, and Finishing machinessupplied by mostly Germany, Japan, Taiwan, China, U.K, U.S.A, Singapore, etc.

which are very latest. It has high production where 30 Metric tons of dyed and

finished fabrics are produced per day. The production is controlled by technical

persons. All of the decision makers of production sector in VIYELLATEX

GROUPare textiles graduates. All the chemicals and dyes use for dyeing and

finishing are well branded.

They produce their product for their buyer and client those are coming from

international market like U.K, Sweden, Netherland, France, U.S.A, Germany

and Spain. Their customer profile is big and top end such as Esprit, M&S, S-

Oliver, Puma, G-star, Gap, Tesco and Grew waver etc. They follow all the system

for their machines maintenance so production can not hamper.

In this report, we have tried to give some information about VIYELLATEX

GROUP and we have observed that VIYELLATEX GROUP produce high

quality fabric and fulfill the special requirements from the different types of

buyers by following different internationally recommended standard method.



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INTRODUCTION

The industrial attachment is the process, which builds understanding,

skills and attitude of the performer, which improves his knowledge in boosting

productivity and services. University education provides us vast theoreticalknowledge as well as more practical attachment, in despite of all these industrial

attachment helps us to be familiar with technical support of modern machinery,

skillness about various processing stages.

By means of practical knowledge its not possible to apply the theoretical

knowledge in the practical field. For any technical education, practical experience

is almost equal important in association with the theoretical knowledge.

It also provides us sufficient practical knowledge about production

management, work study, efficiency, industrial management, purchasing, utilityand maintenance of machinery and their operation techniques etc. the above

mentioned can not be achieved successfully by means of theoretical knowledge

only. This is why it should be accomplished with practical knowledge in which it

is based on. Industrial attachment makes us reliable to be accustomed with the

industrial atmosphere and improve courage and inspiration to take self

responsibility.

Textile education cant be completed without industrial training. Because

this industrial training minimizes the gap between theoretical and practical

knowledge and make us accustomed to industrial environment. I got anopportunity to complete two-months long industrial training at VIYELLATEX

GROUP, which is a 100% export-oriented composite Knit Dyeing Industry. It has

well planned & equipped fabric dyeing-finishing and garments units in addition

to facilitate knitting and knitwear manufacturing. .



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TABLE OF CONTENT



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GENERAL INFORMATIONABOUTTHE FACTORY

Name of Company : VIYELLATEX GROUP.

Factory: VIYELLATEX GROUP.

297 Khortoil, Tongi,

Gazipur-1712.,Dhaka

Bangladesh.

Tel : 880-2-9813001, Ext: 110

Fax : 880-2-9811400

http//www.viyellatexgroup.com

VIYELLATEX LTD. is a well establishe !"it #$%&$site i"'st(). The i"'st()

sta"s $" i"'st(ial a(ea $* +a,i&'(. VIYELLATEX GROUP. is a +($'& $* C$%&a"ies-Vi)ella s&i""i"g- Y$'"g$"es *ashi$" LTD. Vi)ella !"itti"g a" )ei"g/ VIYELLATEX

LTD. is g$i"g t$ &($0e its $w" sta"a( ab$'t &($'#t 1'alit) i" w$(l %a(!et as the) !"$w

that thei( (e&'tati$" e&e"s $" its 1'alit). VIYELLATEX LTD. is a &($*itable &($2e#t a"

#$"t(ib'tes the e#$"$%) $* $'( #$'"t().



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PROJECT DESCRIPTION

Name of the Company : VIYELLATEX GROUP

Status : Private Ltd. Company

Type : 100% Export oriented composite knit DyeingYear of establishment : 2001

year of starting production : 2002

Location : Gazipura, Tongi

Address:

Factory: 297, Khortoli, Tongi, Gazipur-1712

Head Office : 297, Khortoli, Tongi, Gazipur-1712

Tel : No: 88192812Fax No: 880-2-8810445

E-mail: www.viyellatexgroup.com

Sponsors :Mr. Rezaul Hasnat

Product Mix

100% cotton

100% polyester

Spun

Filament

Nylon

Chief Value Cotton (CVC)

Polyester Cotton (PC)

Grey melange (15% Voscose 85% cotton)

10% Voscose 90% cotton

Ash melange (1% Viscose 99% cotton)

http://www.viyellatexgroup.com/http://www.viyellatexgroup.com/


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Different Departments of VIYELLATEX knit dyeing composite

unit

a) knitting Section:

Knitting

Inspection

b) Dyeing section:

Batch section

Dye house

Dyeing lab.

Quality control

Finishing

c) Garments section:

Merchandising

Sample

Cutting Section

Sewing Section

Finishing Section

d) Maintenance section:

Electrical

Mechanical

e) Store Section

f) Administration Section

g) Security Section

h) Marketing Section

i) Production Planning & Control

j) Human Resource & Development Section



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Departments Structure of Knitting Section

D+M 3 A+M

Ma"age( 3Asst. Ma"age( P($'#ti$" 5 Pla"6786 Ma"age(3

Te#h"i#al6 Asst. Ma"age(796

S(. E:e#'ti0e P($'#ti$"- Pla" 5 Sa%&le6786

S(. ;eee(3;eee(76

Asst. ;eee(746

S(. S'&e(0is$(3S'&e(0is$(7?6 Sa%&le S'&e(0is$(786 Neele Ma"7@6

S(. O&e(at$(3O&e(at$(9@>6 Sa%&le Asst.7>6

Se(0i#i"g Ma"7?6

Asst. O&e(at$(@@6

Se(0i#i"g Hel&e(7?6

P($'#ti$" Hel&e(896

Ma"age( 3 Asst. Ma"age( St$(e6796

S(. E:e#'ti0e 3 E:e#'ti0e 786

=(. E:e#'ti0e Ya("6786 =(. E:e#'ti0e +(e) ;ab(i#67@6

St$(e Asst.Ya("67@6 St$(e Asst.+(e) ;ab(i#67


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KNITTING:

KNITTING IS THE PROCESS OF PRODUCING A FABRIC BY FORMING

A SERIES OF CONNECTED LOOPS FROM A SERIES OF YARN. IN THIS

METHOD FABRIC IS PRODUCED BY INTERMESHING OF LOOPS.

KNITTING TYPES:

warp knitting: each loop in the horizontal direction is made from a

different thread and the number of threads used to produce such a fabric is at

least equal to the number of loops in a horizontal row.

Weft knitting:a horizontal row of loops can be made using one thread andthe thread runs in horizontal direction.



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Raw Material for Knitting

The raw material for knitting is the yarn. Different types of yarn of wide range of

count are used. In yarn store section we had the chance to know about different

yarns of different count used in \/IYELLA TEX knitting. We also have knowndifferent yarn manufacturer/suppliers name for this knitting section i.e. sources

of yarn. Both carded and combed yarn is used for knitting.

Cotton 24S, 26s,30S, 32S,34S,40S

Polyester 75D, lO0D

=

Spandex yarn 20D,40D, 70D

Grey Mlange (C 24S,26S

Ecru Mlange (C-85% V-15%) 24S,26S,28S

Anthra Mlange (C-65% V-35%) 24S,26S,28S

PC (65%Polyester & 35% cotton)24S,26S,28S,30S

CVC 24S,26S,28S,30S



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Knitting section is divided in four sections,

1. Inspection section

2. Flat knitting section

3. Circular Knitting section

4. Store section

I. Cloth Inspection Section:

In cloth inspection section two machines are available. Specification of those

machines is given below

Type Cloth Inspection Machine

Manufacturer name Uzu fabric Inspection

County Thailand

Model No. UZ 900.31

2. Flat Knitting Section:

Generally collar, cuff of knitted garments is produced in this section. In this

section there are 25 flat knitting machines. all of them are same type and also

have same specification. The specification of all machines is given below:

Type Automatic Flat knitting machine

Manufacturer namePrecision Fukuhara Works Ltd.

Country JapanModel No. \l-100

Gauge G14

3. Circular Knitting Section:

This section contains 72 circular knitting machines. Circular knitting machines

are of different types, made by different manufacturer and also have different

specifications. In this section body fabric for knitted garments is produced. Thedifferent specifications of different machines are given one after another

4. Store section:

In this section knitted fabric and yarns are stored.



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Automatic Flat Bed M/C

Automatic Flat Bed M/C



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Machine List of Knitting Section in Viyellatex :

Machine name Machine Quantity

Circular Knitting(Single jersey) m/c 32

Circular Knitting(Rib) m/c 18

Engineering Stripe m/c 08

V-bed Knitting m/c 26

Grey Fabric Inspection m/c 03

Specification of Circular Knitting Machine:



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PROCESS FLOW CHART FOR KNITTING

YARN IN PACKAGE FORM

PLACE THE YARN PACKAGE IN THE CREEL

FEEDING THE YARN

SET THE M/C AS PER DESIGN &GSM

KNITTING

WITHDRAW THE ROLLED FABRIC AND WEIGHTING

INSPECTION

NUMBERING

FAULTS, CAUSES & THEIR REMEDIES IN KNITTING:

1. Hole Mark

Causes:

Holes are the results of yarn breakage or yarn cracks.

During loop formation the yarn breaks in the rejoin of the needle hook.

If the yarn count is not correct on regarding structure, gauge, course and

density.

Badly knot or splicing.

Yarn feeder badly set.

Remedies:

Yarn strength must be sufficient to withstand the stretch as well as

uniform. Use proper count of yarn.

Correctly set of yarn feeder.

Knot should be given properly.

2. Needle Mark

Causes:



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When a needle breaks down then needle mark comes along the fabrics.

If a needle or needle hook is slightly bends then needle mark comes on the

fabrics.

Remedies:

Needle should be straight as well as from broken latch.

3. Sinker Mark

Causes:

When sinker corrode due to abrasion then some times can not hold a new

loop as a result sinker mark comes.

If sinker head bend then sinker mark comes.

Remedies:

Sinker should be changed.

4. Star

Causes:

Yarn tension variation during production.

Buckling of the needle latch.

Low G.S.M fabric production.

Remedies: Maintain same Yarn tension during production.

Use good conditioned needles.

5. Drop Stitches

Causes:

Defective needle.

If yarn is not properly fed during loop formation i.e. not properly laid on to

the needle hook.

Take-down mechanism too loose.

Insufficient yarn tension.

Badly set yarn feeder.

Remedies:

Needle should be straight & well.

Proper feeding of yarn during loop formation.

Correct take up of the fabric & correct fabric tension.



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Yarn tension should be properly.

6. Oil stain

Causes:

When oil lick through the needle trick then it pass on the fabrics and make

a line.

Remedies:

Ensure that oil does not pass on the fabrics.

Well maintenance as well as proper oiling.

7. Rust stain

Causes:

If any rust on the machine parts.

Remedies:

If any rust on the machine parts then clean it.

Proper maintenance as well as proper oiling.

8. Pin hole

Causes:

Due to break down or bend of the latch, pin hole may come in the fabric.

Remedies:

Change the needle

9. Grease stain

Causes:

Improper greasing

Excess greasing

Remedies:

Proper greasing as well as proper maintenance

10. Cloth fall- out

Causes:



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Cloth fall- out can occur after a drop stitch especially when an empty

needle with an empty needle with closed latch runs into the yarn feeder

and remove the yarn out of the hook of the following needles.

Remedies:

Make sure all the latches of needle are closed with feeding yarn after a

drop stitch.

11. Barre:

A fault in weft knitted fabric appearing as light or dark course wise

(width wise) Stripe.

Causes:

This fault comes from yarn fault.

If different micro near value of fiber content in yarn.

Different lusture, dye affinity of fiber content in yarn.

During spinning different similar classes of fiber is mixed specially in

carded yarn & these fibers have similar characteristics.

In draw fame different similar classes sliver is mixed and make one sliver.

Remedies:

We can use this fabric in white color.

12. Fly dust:

Causes:

In knitting section too much lint is flying to and fro that are created from

yarn due to low twist as well as yarn friction. This lint may adhere or

attaches to the fabric surface tightly during knit fabric production.

Remedies:

Blowing air for cleaning and different parts after a certain period of time.

By cleaning the floor continuously. By using ducting system for cleaning too much lint in the floor.

Over all ensure that lint does not attach to the fabric.

13. Yarn contamination



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Causes:

If yarn contains foreign fiber then it remains in the fabric even after

finishing,

If lot, count mixing occurs.

Remedies:

By avoiding lot, count mixing.

Fault less spinning.

14. Yarn Faults:

Neps.

Slubs.

Yarn count variations.

Thick/Thin place in yarn.

Hairiness.



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Batching is the process to get ready the fabrics which should be dyed and

processed for a particular lot of a particular order.

Function or Purpose of Batch Section

B To receive the grey fabric roll from knitting section or other source.

B Turn the grey fabric if require.

B To prepare the batch of fabric for dyeing according to the following

criteria

Order sheet (Received from buyer)

Dyeing shade (color or white, light or dark)

M/C capacity

M/C available

Type of fabrics(100% cotton, PE, PC, CVC)

Emergency

B To send the grey fabric to the dyeing floor with batch card.B To keep records for every previous dyeing.

Proper batching criteria

B To use maximum capacity of existing dyeing m/c.

B To minimize the washing time or preparation time & m/c stoppage

time.

B To keep the no. of batch as less as possible for same shade.

B To use a particular m/c for dyeing same shade.

Batch management

Primarily batching is done by dyeing manager taking the above

criteria under consideration. Batch section in charge receives this primary batch

plan from dyeing manager. Some time planning is adjusted according to m/c

condition or emergency.



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Machines in batch section

M/c quantity: 02

M/c Specification:

Machine Name : Air turning m/c

M/c No : 01

Brand Name : Taida

Origin : China

M/c Speed : 300-500m/minModel : DF 200

Max up clothing : 150 kg

Company :Shandong Taida Dyeing & Finishing

Machinery Co.Ltd

Machine Name : Air turning m/c

M/c No : 02

Brand Name : Taida

Origin : China

M/c Speed : 300-500m/min

Model : DF 200

Max up clothing : 150 kg

Company :Shandong Taida Dyeing & Finishing

Machinery Co.Ltd.



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I N D U S T R I A L A T T A C H M E N T O N V I Y E L L A T E X Page @>


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LABORATORY

LABORATORY MACHINERIES WITH ITS SPECIFICATION

1. Tearing Strength Tester:

Brand Name :Elmatear

Origin : U.K

2. Button Strength Tester:

Brand Name : Titan

Origin : U.K

Max.Pressure: 10 bar

Capacity : 3000N

3.Bursting Strength Tester:

Brand Name : TruBurst

Origin : U.K

4. Pilling Resistant Tester:

Brand Name : Impulse

Origin : U.K

5. Sprectra Flash:

Brand Name : Data Color

Origin : U.S.A

Test Name: Colorfastness to Washing, Dry cleaning.Name of the m/c : Rota a!h

Origin : U.K

Test Method :ISO105-C06, ISO105-D02

Test Name: Dimensional Stability, Spirality, Appearance after washing.

Name of the m/c : Eltrolux wascator.

Origin : U.K

Test Method : ISO 6330, ISO 26330



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Test Name : Shrinkage Test.

Name of the m/c : Eltrolux

Origin : U.K

Test Name : Color Fastness to Wash Test.Name of the m/c : Gyro wash

Origin : U.K

Test Method : ISO 105-C06

Lab Dip m/c:

No.of m/c: 02

M/C NO- 01 Brand name : Ahiba Nuance Lab Dip Dyeing m/c

Origin : U.S.A

M/C NO- 02

Brad name : Ahiba Nuance Lab Dip Dyeing m/c

Origin : U.S.A

Color Matching Cabinet (Light box):

No. of Light Box: 02

Light Box no: 01

Brand : Spectralight-111

Origin : U.S.A

Light Source:

Day Light (D-65)

Cool White

Horizon

UV

TL-84

A (F11-10 degree)



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Light Box no: 02

Brand : Verivide

Origin : U.K

Light Source: Day Light (D-65)

UV

TL-84

A (F11-10 degree)

Laboratoryis the heart of dyeing Industry. An efficient laboratory can increase

the efficiency of dyeing. So, laboratory in-charge is sometimes called pilot. Before

bulk production a sample is sent to buyer for approval. Laboratory supplies the

recipe to the floor.

Purpose of Laboratory:

Get color approval from buyer.

Recipe supply to the floor.

Shade correction.

Minimize the deviation between bulk and laboratory.

Laboratory line:

Standard sample:

At first recipe % of standard sample is measured by CCM (computer color

matching) system.

Laboratory Trial:

Then by taking those recipe laboratory officers produce laboratory trial and

match with standard according to buyer requirement.

Approved Sample:



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Then sample swatch, which is matched with the standard, is send to buyer for

approval.

Off-Line Tests:Off-Line tests for finished fabrics are divided into two groups. These are as

follows:

Physical tests

Chemical tests

Scope for Quality control, quality assurance and testing

1 Testing lab

2. Machine auditing system

3.A good training system

4. Excellent analytical back up

5. Technical expertise

QUALITY ASSURANCE SYSTEM

The Quality assurance Department is assigned to maintain consistently

uniform quality of the material in process and various stages of its

manufacturing.VIYELLATEX LTD is more about concern about quality. In this

factory quality assurance is more preferred than quality control, but both are in

advancement.

Objects of Quality Control:

1. Research.

2. Selection of raw materials.

3. Process control.

4. Process development.

5. Product testing.

6. Specification test



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Quality management system in viyellatex:

Online Quality control:

There are two types of online quality control. These are as follows:B

Raw material control:

Raw material control means control the quality of raw materials (e.g.- Quality of

Grey fabric, Dyes, Chemicals and Auxiliary)

Process control:

Process control means the selection of right process and controlling of some

parameters. Such as PH, Water hardness, water volume, Temperature, Reel

Speed, Pump pressure, etc.

Online Tests:

Dyed fabric.

Shade check.

Wash fastness.

Water fastness.

Crocking fastness.

Off-Line Tests:

Off-Line tests for finished fabrics are divided into two groups. These are as

follows:

Physical tests

Chemical tests

Physical Tests:

GSM of Fabric.

QA

On-Line Off-Line



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Abrasion resistance / Pilling.

Dimensional stability test.

Spirality test.

Color fastness to rubbing test (Dry / Wet).

Bursting strength test (For Knitted fabric).

Tensile Strength test (For Woven fabric).

Chemical Tests:

Color Fastness to washing.

Color Fastness to light.

Color Fastness to heat.

Color Fastness to actual laundering

Color Fastness to Chlorinated water.

Color Fastness to water spotting.

Color Fastness to perspiration.

Color Fastness to Seawater.

Flammability test.

Fibre analysis. PHtest.

Spray test (water repellency).

Phenolic yellowing.

RESPOSIBILITY OF OFF-LINE QUALITY CONTROL:

To check the following things:

Inspection of fabric in the inspection M/C under 4-point system.

Yarn count and lot no.

Buyer.

Design.

Stitch length of grey fabric.



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Shade of grey fabric with in one order.

RESPOSIBILITY OF ON LINE QUALITY CONTROL

To check the following things:

M/C Dia/Gauge

Buyer

Design

Grey fabric GSN & Stitch Length

Yarn count & Lot no

Yarn whether approved or not by Q.C. Department

Finished dia & grey dia.

Fabric quality checking under 4-point system.

RESPONSIBILITY OF IN CHARGE OF QUALITY CONTROL

Making report.

Supervise the grey Q.C.

Check machine is running according to program or not

Check program can meet the requirement. Which is mentioned in the

order sheet or not.

Check yarn is approved by Q.C.or not.

RESPONSIBILITY OF THE FINISHING Q.C.

Finishing Q.C. (shade):



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After unloading from dyeing cut small piece, check shade with

std/approved lab dip/production sample & previous production batch (if

any).

Then instruction to finishing for finish by mentioning specific temperature

in dryer.

After finish again cut sample & check same way like before at dry state.

Keep the record of every lot after dry & after finished state.

If any batch is not OK at any stage then make the re-process card for

dyeing.

If any batch is closer to standard but not exactly pass with standard, then

make trial for that batch in finishing to make it OK.

Maintain the resister of all batches.

Check the shade of Body to Rib, Body to Collar & Cuff.

In charge:

Supervise the trainee Q.C. & Q.C.

Make report every day.

Cross check whatever shade already checked by Q.C.

Q.C. (Finishing):

Make the R2R continuity of each dye lot by cutting small piece from each

roll of dye lot.

Inspect 30-40 % of each dye lot under 4-point inspection system & report

accordingly.

If found any problem then re-inspect 100% of that dye lot and make report

& re-process card (if re-process able) for dyeing. If it is knitting faults then

immediately inform to officer asking decision.

Check the evenness of a dye lot by checking R2R continuity.

Check the shade of body to rib, body to collar & cuff.

In charge:

Monitor the all Q.C.S (finishing) work including shade Q.C.

Take decision when asking advise from his subordinate.

Make daily problematic batch report.

Make daily production report.

Maintain resister khata.



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Make daily batch re-process job card.

RESPOSIBILITY OF QUALITY ASSURANCE MANAGER:

Responsible for all quality matter of fabric.

Yarn selection.

Monitoring product development.

Organize Laboratory.

Control grey and finished fabric inspection under 4- point system.

!cumentati!n a"ter s#ade c#ec$ !" e%ery &!t.



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Quality Assurance Procedure

1) Body & Rib Inspection:

All rolls are kept in front of the inspection m/c time to time and are inspectedover the inspection m/c visually in a pre-set speed against light. For any major or

minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil

lines, needle line, stubs etc are recorded in inspection report to classify the fabric

based on the four point system.

2) Collar cuff Inspection:

Collar& cuff are inspected visually under the tight box, any major or minor faulty

collar/cuff like having wrong ply, hole, needle line, stubs, wrong design, first

round problem etc properly counted and recorded.

Quality Standard:

VIYELLA TEX Ltd. maintains the ISO: 9002 standard in case of quality.

Therefore the four point system is followed to inspect the body & rib fabric. The

defects found and points given against are recorded in the inspection sheet.Following table shows the four point grading system followed by inspection at

VIYELLA TEX Ltd.

Four point grading system

Size of defects Penalty

3 inches or less 1 point

Over3 inch but not over 6 inch

2 point

Over 6 inch but not over 9 inch 3 point

Over 9 inch 4 point



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Following table shows common body and rib faults and response by inspection

section at VIYELLA TEX Ltd.

Acceptance CalculationFactory: Roll yardage (A) Total points founds(B)

Formula : X100 =points per 100 yard

Classification:

40 points =A type

41-60 =B type

61-80 =C type

Above 8Opoin = Reject

Tests

There are two types of tests are done in Quality Assurance Department. They are

1. Physical Tests

2. Chemical Tests

Physical Tests:

Yarn Grade

GSM test

Shrinkage test

Spirality test

Tensile strength

Abrasion resistance

Button Strength Testing

Lycra% determination

Crease resistance



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Chemical Tests:

Fastness to washing.

Fastness to light

Fastness to actual laundering

Fastness to sea water

Fastness to water

Fastness to perspiration



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O"#ano#"am of Dye$n# %ect$on:

C.E.O 4;ab(i#6

+.M 3 D.+.M 3 A.+.M 4796

Ma"age( 4796

Assista"t Ma"age( 4786

Se"i$( E:e#'ti0e 47@6

E:e#'ti0e 47@6

P($'#ti$" O**i#e( 47@6

Se"i$( S'&e(0is$(

S'&e(0is$( 3 =(. S'&e(0is$(

P($'#ti$" O&e(at$(

P($'#ti$" Hel&e(



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Responsibility of production officer

o Overall supervision of dyeing & finishing.

o Dyes & chemicals requisition issue & check.

o Program making, sample checking color measurement.

o Control the supervisors operators & helpers of machines.

o To give dye-line or the program slip according to daily production

plan, batch preparation & PHcheck.

o To rectify the finished fabric which rejected from quality control

department

o To check daily production report.

o To study dye & chemicals nature delivery by the manufacture &

applied them correctly to the production to get best product

Job Description:

Title: Production officer.

Dept: DyeingReport to: Senior production officer.

Job summary:To plan execute & follow up the production activities

& control the quality production with related activities.

Title: Senior production officer.

Dept: Dyeing.

Report to: Dyeing manager.

Job summary: To plan execute & follow up the production

activities & control the quality production with related activities.

Duties & Responsibilities :

Overall supervision of dyeing, finishing production.

Checks the different log books of different areas & report to management.

Checks the sensitive parameters of different machine for smooth dyeing.

Checks out the plan to control the best output from supervisor & workers.

To trained up & motive the subordinates how to improve the quality

production.

Maintenance of machine & equipment. Any other works & when required

by the management. Control the supervisors, operator, asst. operator & helpers of dyeingm/c.

REMARKS:

The manpower management systemVIYELLATEX GROUP is well arranged.

Every officers & stuffs are responsible for their duty. But there are only six



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textile engineers in the industry 11 for dyeing & 1 for Finishing. It is sufficient

for Finishing). It is sufficient for fluent production. The efficiency of the \\orker

should be increased for more quality production.

Raw materials for dyeing

Raw materials used in the dyeing section are:

1.Grey fabrics

2. Dyes

3. Chemicals.

Grey fabrics

Following types of gray fabrics are dyed in ViyellaTex:

Single jersey

Single jersey with lycra

Polo pique

Back Pique

Single lacoste

Double Lacoste

Fleece

Rib

Rib with lycra

11 rib



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FLOW CHART FOR DYEING

BATCHING

SELECT M/C NO.

FABRIC LOADING

SELECT PRODUCTION PROGRAMME

PRETREATMENT

SELECT RECIPE FOR DYEING

RECIPE CONFIRMED BY DM/PO

DYEING

POST TREATMENT

UNLOAD



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Finishing:

Textile finishing, in a restricted sense, is the term used for a series of processes

to which all bleached, dyed, printed and certain grey fabrics are subjected before

they are put on the market. In fact, finishing includes the final treatment of

every kind of fabric made from every kind of fiber

Objective of finishing:

Improving the appearance Luster, whiteness, etc

Improving the feel,which depends on the handle of the material and its

softness , suppleness ,fullness, etc.

Wearing qualities, none soiling, anticrease, antishrink, comfort, etc.

Special properties required for particular uses water proofing,flame

proofing, etc.

Covering of the faults in the original cloth.

Increasing the weight of the cloth.

Types of finishing:

1) Chemical finishing:a) Chemical reaction of auxiliaries with fibers.

b) Application of the handle modifying products/additives.2) Mechanical finishing:

Mechanical treatment with machines

Finishing effects:

Easy - care

Crease recovery.

Dimensional stability.

Good abrasion resistance.

Improved tear strength.

Good sew ability



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Soft or stiff handle.

Shine or luster



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Departments Structure of Finishing Section:

E:e#'ti0e Di(e#t$( E.D6

Ma"age( 3 Asst.Ma"age(

S(. P(i"#i&le $**i#e( P.O6

;i"ishe ;ab(i# ;i"ishe C$lla( 3 C'**

S(. S'&e(0is$( 3 S'&e(0is$( 3

O" li"e S)ste% O** li"e s)ste% =(. S'&e(0is$(

S(. S'&e(0is$( 3 S'&e(0is$( S(. S'&e(0is$( 3 S'&e(0is$( 'alit) C$"t($lle(

3 =(. S'&e(0is$( 3 =(. S'&e(0is$(

Asst. 'alit) C$"t($lle(

'alit) C$"t($lle( 'alit) C$"t($lle(

Asst. 'alit) C$"t($lle( Asst. 'alit) C$"t($lle(



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Flow chart of finishing section :

Finishing Section

O&e" *ab(i# T'be *ab(i#

Slitti"g %a#hi"e Dewate(i"g %a#hi"e

Ste"te(i"g D()i"g Ma#hi"e

C$%&a#ti"g%a#hi"e

T'be #$%&a#ti"g%a#hi"e

;i"alI"s&e#ti$"

;i"ali"s&e#ti$"



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Process Flow Chart of Final Inspection :(Q.A.D)

After completing finishing process here firstly check the shade as per buyer

standard with dimensional stability from lab.

Secondly check dia / width fabric weight or G.S.M

Thirdly check fabric surface or appearance as per buyer standard.

The every roll with every meter check as per four (04) point system.

Make a report.

If OK then ready for delivery.

If not OK then identify the fault.

If it is knitting fault then inform the knitting department by job card and mail, &requested the fabric for replacement.

If it is dyeing fault & If make sure that it is reprocess able then give job card to

dyeing department correction. And if is not reprocess able then reject the fabric &

inform the dyeing department to replace the rejected quantity.



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Sample Development :

Sample is the prototype or model o the garment, upon what the buyer can decide

on how and whiter to confirm the order or not.

Organ gram of sample department :

There are about 175 total employees working in the Viyellatex Group sample

department including executives and workers. There are also some supervisors

and coordinators to stimulate and take care the sample job. Let us see the

Departments Structure below to know more about the sample department

Manager

Patten Master Officer/Coordinator Officer. QC

Pattern asst. Fabric Coordinator QC/AQC

Sample man Folding Man

Accessories Issue Man

Cutter man

Iron Man

Purchase/Marketing man

Sample Asst.

Sample Input man

Sample Operator



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Sampling Process Flowchart :

Receiving Tec Pak from buyer (Via Merchandiser)

CAD & Pattern Making (Styling & Measurement)

Sample Making

Approval Failed

Size Setting (One Development Stage) Re Sample Making

Evaluation the Sample

Pre Production Meeting (Decides on when to produce) Sending Sample

to the Cutting Section

Grading of sample Market Making Production stats

Sending sample to the buyer Approval Grading of Sample

Brief Description of the Sampling Processes:

1. Tec Pack Receiving: This is the firs stage of the sampling processes. In

this stage Tec Pack or the technical pack is received from the buyer, via

merchandiser. Tec pack contains all the specifications to produce a garment.2. CAD & Pattern Making: In this stage pattern is made through CAD.

Sometimes pattern is made manually, but CAD is more popular and easy.

Computer-aided design (CAD) is the use of computer technology for the

design of objects, real or virtual. The design of geometric models for object

shapes, in particular, is often called computer-aided geometric design

(CAGD).However CAD often involves more than lust shapes. As in the manual

drafting of technical and engineering drawings, the output of CAD often must



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convey also symbolic information such as materials, processes. dimensions,

and tolerances, according to application-specific conventions. CAD may be

used to design curves and figures in two-dimensional (2D) space; or curves,

surfaces, or solids in three-dimensional (3D) objects. Viyellatex pattern

section uses OptiTex CAD software for pattern making.

3. Sample Making: Sample making is the ultimate goal of this department.

After making the pattern, the sample is made by using the pattern set.

4. Size Setting: After making the sample, size is set according to the Tec

Pack. If there is any fault, the sample is redone

5. Pre Production (PP) Meeting: after the buyer has inspected the sample,

a preproduction meeting is called. In this meeting buyer or his agent,

merchandiser, sample manager. all remain present. They decide on how to

and when to start the production. If the decision Okayed. the sample is ready

to go for final production.

6. Grading of Sample: After finalizing the sample. grading is done to separate

the samples and patterns from each others.

7. Marker After grading the samples. the design is inputted into the marker

software. This software specifies how to set the pattern in the actual fabric.

By using the marking software efficiently, fabric can be saved. Viyellatex uses

Gerbar Garment Technology (GGT) for marker making.

8. Cutting: After making the pattern is delivered to the cutting unit and the

fabric is cut for final production.



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DEPARTMENTS STRUCTURE

CEO

COO

DGM

EXECUTIVE

PRODUCTION OFFICER

SUPERVISOR

SHIFTSUPERVISOR QUALITY SUPERVISOR STORE

SUPERVISOR OPERATOR Q.I STORE

STUFF

HELPER

LOADER



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EMBROIDERY

DEPARTMENTS STRUCTURE OF EMBROIDERY

CO (Embroidery)

Embroidery manager

Assistant manager (designer)

Supervisor ( A.Q.C) Sample man

Q.I senior operator

Helper Helper

Senior operator

Assistant operator

Frame men

M/c men

Helper

Iron men

Embroidery Machine Specification

Electronic multi-head automatic Embroidery M/C

Brand: Tajima

Country: Japan

Model: TFGn-920

No. of head: 20

No. of Needle per head: 9

No. of Embroidery M/C: 7 M/Cs for Bulk production: 1 M/C for Sample

Machine RPM= maximum 950



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Maintenance

Maintenance is a procedure by which we can maintain active functioning in

operation according to the behavior and utility of a particular element. Machine,

buildings and other facilities are subjected to deterioration due to their use and

exposure to environmental condition. Process of deterioration, if unchecked.culminates in rendering these service facilities unserviceable and brings them to

a standstill. In Industry, therefore has no choice but to attend them from time to

time to repair and recondition them so as to elongate their life to the extent it is

economically and physically possible to do so. In engineering, we use this

terminology for maintaining smooth and uninterrupted performance of machines,

tools and metallurgical characteristics in practical uses

Objective of maintenance:

To keep the factory plants, equipments, machine tools in an optimum

working condition.

To ensure specified accuracy to product and time schedule of delivery to

customer.

To keep the downtime of machines to the minimum thuds to have control

over the production program.

To keep the production cycle within the stipulated range.

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

Three types of maintenance are performed in Viyellatex

Group.

1. Preventive Maintenance.

2. Routine/ Schedule Maintenance.

3. Breakdown Maintenance.

Preventive Maintenance: Preventive maintenance is a predetermined

routine actively to ensure on time inspection checking of facilities to uncoverconditions that may lead to production break downs or harmful description.These

actions are performed to prevent or reduce consequences of failures .

Schedule maintenance: Maintenance of different machines are prepared

by expert engineer of maintenance department. It is time-based maintenance and

pre-planned to perform on machine and equipments Normally in case of dyeing

machine maintenance after 30 days complete checking of different important



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parts are done.

Breakdown maintenance:In this type of maintenance when the machine

remains stop that time the maintenance is done.



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CONCLUSION :

Fe ha0e #$%&lete $'( i"'st(ial atta#h%e"t s'##ess*'ll) b) the g(a#e $* Allah.

Industrial attachment sends us to the expected destiny of practical

life. The completion of the two months Industrial attachment at VIYELLATEX

GROUP, we have got the impression that factory is one of the most modern

export oriented knit composite complex in Bangladesh. Though it was established

only a few years ago, it has earned very good reputations for its best

performance over many other export oriented textile mills.

During our training period, talking with the clients of this mill we

knew that the mill is fulfilling the countrys best export oriented white finished

fabric as well as very good colored fabric due to its modern machinery & good

management system.

Mill is settled with utility to give all convenient supports to the

productions for twenty-four hours. It had self-power generator system to satisfy

total power consumptions of the mill.

We are enough fortunate that we have got an opportunity of having a

training in this mill. During the training period we are received co-operation and

association from the authority full & found all man, machines & materials on

appreciable working condition. .\ll stuffs & officers were very sincere & devoted

their duties to achieve their goal.

There are some suggestions from us within our limited knowledge

Some Suggestions:

The dyeing floor is watery most of the time: it should be cleaned all the

time.

To increase overall efficiency, more skilled labor should be used in a

project.

The m/c stoppage time should be analyzed and minimized.

The maintenance should be carried out when the m/c is out of action

(wherever possible) and routine maintenance should be carried outregularly.

There should be a yarn dyeing project.

Sitting arrangement of production officers should be improved.



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Lastly:

We tried our best to gather all necessary information but it is true that within

this short period it is quite impossible to achieve 100% success but as a whole

this industrial training was a satisfactory one and once again wed would like to

thank the authority of VIYELLATEX GROUP. as well as our honorableteachers far their altruistic help and advice. We are fortunate enough that we

have got an opportunity to have training in this mill. During the training period

we have received enough co-operation and association from the authority and

found all personnel. All stuffs and officers were very sincere and devoted their

duties to achieve their goal.

Viyellatex Group

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