We would also like to express our utmost gratitude to the officials of Amazing Fashions Limited who have helped us and given their valuable time and provided us with the most relevant information on the basis of which we have prepared this report. Due to some limitation of the factory, we have found shop section, cutting section, sewing section, finishing section and maintenance section, cost section washing section. With the help of my supervisor, we have acquired the knowledge of handling an order, the production procedure and the control procedure to maintain the quality of these orders.
CHAPTER-1
EXECUTIVE SUMMARY
Executive Summary
Industrial connection is the process, which builds the understanding, skills and attitude of the performer, which improve one's knowledge for increased productivity and services. This report is arranged based on the Industrial Appendix on Amazing Manufacturing Technology (Deformation, Dyeing, Sizing, Weaving, Finishing, Inspection, Planning and Research and Development). Here in this report we present various working procedures for the production of Amazing of the industry.
CHAPTER-2
INFORMATION ABOUT FACTORY
Factory Profile
Amazing Fashions Ltd
Amazing Fashions has a high-tech finishing and mercerizing setup along with stenter and coated finishing to create premium finishes. Amazing Fashions produces its own yarns from its own spinning mill with capacity of 44 tons daily, with all stages of in-house capability; Amazing Fashions goes vertical in both Amazing and Woven. Amazing Fashions produces yarns from its own Spinning Mill with a capacity of 44 tons per day.
CHAPTER-3
MACHINE IDENTIFICATION
Ball Warping
Slasher Dyeing
Rope Dyeing
LCB : Long Chain Beam
SIZING
WEAVING
Machine Parts of Singeing
CHAPTER-4
PRODUCTION SEQUENCE AND OPERATION
Flow Chart of Amazing Production
Part-1
Direct Warping, Ball warping, long chain beamer)
Direct Warping
Types of Creels
These are V-shaped spindles with actively flowing yarn packets on the outside of the V and full yarn packets placed on the inside of the V. When the liquid packets are emptied, the yarn spools on the spindle rotate so that the empty packets are moved to the inside of the spindle for supplement. Empty pack positions are then replaced with new full packs while the warper is running.
Magazine Creels
The new thread ends must be pulled forward and properly threaded into the machine.
Direct warping process flow chart
Yarn Suppliers
Package Length
Time Study
Direct warping machine parts name
Ball warping process flow chart
Yarn supplier
Fault of Ball Warping
Long chain beamer (LCB)
The upward movement of the rope releases the ropes before they approach the beamer head and releases the rope from the rest of the rope in the can.
Lcb important parts
LCB Problems
Part-2(dyeing & sizing) Dyeing
Slasher / Sheet Dyeing
The passage of flow of yarns in slasher dyeing is shown below
Pre Treatment
Washing
Dyeing (Indigo blue dye)
Drying
Accumulator
Sizing
Advantages of Slasher / Sheet Dyeing
Advantages
Color Dyeing Arrangement
Indigo dye recipe
Sulpher Dye Recipe
Dyeing Fault
At MIL, 40 ropes are simultaneously fed into the rope dyeing machine through various guides and a tensioning arrangement in the spindle area to be first fed into the cleaning box. The level of this bath is controlled by a ruler, which, when lowered to a certain level (manually present), together with the liquid level, opens a value for the addition of caustic liquid from the main tank. There are eight dye baths and their number depends on the type of dye to be made. Addition of dye liquid and other auxiliaries is done with different dosing pumps like DYSTAR. Liquids circulate between the used dye baths in other pumps, as they are connected to each other.
After exiting each dye box, the filaments are filled, the pressure is highest in the first and last dye box which is 55psi and the intermediate one 40-50psi. The ropes pass after filling around a no. After that, the ropes pass through the washing box of five, where hot washing, cold washing and neutralization are carried out. Sometimes softener treatment is also given in one of the washing boxes. The temperature of the entire wash box is controlled through the control panel by means of a thermostat.
There are three rows of vertical drying cylinder ranges each with twelve post-wash cylinders. Each column is equipped with a steam trap. The temperature is controlled by the electronic control panel. The ropes are guided by the respective guide m/c, delivery rollers and guide tubes which wrap the ropes in the big can.
The passage of yarn in rope dyeing is as follows
Recipe Calculation
Dyeing Result
Machine Problem
Sizing
Objectives of Sizing
Types of Sizing
Heavy sizing: when the size pick up % is above 40 % then it is called heavy sizing
Disadvantages of Sizing
Flow Chart for Sizing of Warp Yarn
Sizing Chemicals
Sizing Faults Causes
Part -3 Weaving Weaving
Classification of Weaving Machine
Shuttle Weaving
Projectile Weaving
Rapier Weaving
Rapier weaving machines can be of two types
Air Jet Weaving
Water Jet Weaving
Basic Weaving Mechanism
Primary Motion
The upper layer is called the upper pour line, and the lower layer is called the lower pour line. The type of closed sheds where the leveling of the warp yarns is done at the bottom/top line of casting is called bottom closed shed or top closed cage depending on the leveling position. Similarly, the type of shed where the warp threads are made flush with the centerline of the casting is called a closed-center shed.
In a center closed shed, the base yarns needed to make the top line of the shed move up, while the base yarns needed to make the bottom line of the shed move down. The schematic diagrams of the closed shed at the bottom and the closed shed in the middle are shown in Figure 4. The advantage of the closed shed at the bottom is to achieve a high coverage factor at the expense of high energy consumption and wear of the weaving parts.
The bottom/top closed shed is not suitable for high speed weaving, because more time is needed to change the shed. High speed weaving can be achieved by means of a central closed mesh due to less tension in the warp yarns compared to a closed top/bottom mesh. Power consumption and wear are also less in a centrally closed house compared to a bottom/top closed house.
In half-open tee-off, as shown in Figure 4, the stationary bottom line is maintained, but the warp threads of the top tee-off line are lowered to the bottom or raised in one motion.
Secondary Motion
The fitting of a newly inserted pick on a piece of fabric is called tapping. The drop of the fabric is an imaginary line that shows the tip of the woven fabric. After the fabric is made, it is necessary to drop the base yarn for continuous weaving.
The warp threads are delivered in sheet form from the weaver beam installed at the back of the loom. The launch motion was controlled by dead weight called lingos, but nowadays the speed of this motion is controlled using load cell and servo motor. The control panel sends instructions to the servo motor to adjust the speed in order to release the warping sheet.
The fabric is wound onto a roller located at the front of the loom, called the take-up roller. Here, it is important to note that the length of the fabric is always smaller than the length of the warp due to shrinkage of the warp. The take-up roller is connected to the servo motors via worm and worm gear pairs.
The pick-up system is equipped with an electrical sensor to control the surface speed of the pick-up roller to ensure the required number of catches per unit length.
Auxiliary Motion
The woven cloth must be wrapped on a specific package after beating. All warp yarns must pass through an individual thread with a special slanted shape called a dropper. The completion of the electrical circuit sends the instruction to the servo motor to stop through the control panel.
A weft stop motion is used to stop the loom in case of weft breakage. In modern looms, two types of weft stop movements are mainly used, namely piezoelectric electronic weft stop sensor and optical sensors. The piezoelectric impact stop sensor is designed for rapier and projectile looms, while the optical sensors are specifically made for air jet looms.
The piezoelectric sensor is made of smart materials, which works on the principle that vibration produces electrical charges. In normal operation of the loom, electrical charges are produced with low amplitude due to less vibration; however, when the tissue fibers break, a surge is created which results in high amplitude electrical charges. In air jet looms, the optical stop weft movement sensor serves two purposes, namely, it stops the loom if the weft threads are broken and stops the loom if the weft threads are moved too far forward.
Weft Feeler 1 senses the absence of weft threads and stops the loom, while Weft Feeler 2 senses the presence of thread and stops the loom.
Amazing Fashions Weaving
Other auxiliary motions are warp tension compensation motion, tissue tension control motion, automatic pick up motion, tissue mixing motion, tissue holding motion, pull and shorten motion, warp protection motion, tissue replenishment movement and temple movement.
Weaving Design
Weft Count
Wastages
Various Types Reed Used
Cam Setting
Weaving Faults
Selvedges
Machine Parts Name
Batcher roller 3. Reed
Slay sword 5. FD-1
Gripper receiver belt 10. Monitor
Take up roller 12. Pressure roller
Air treatment plant
Warning lamp 17. Catch cord bobbin
Yarn guide roller 20. Ring frame
Overhead cleaner 26. Pre-winder
Finishing
Finishing
Benefits of Finishing
To improve the wear quality of the fabric by controlling shrink resistance, creasing resistance, warp, bow, etc.
Classification of Finishing
Semi-permanent finishes: Usually withstand multiple washes or dry cleans, and many can be removed in a home laundry or dry clean. Temporary Finishes: Removed or significantly reduced when the product is first washed or dry cleaned.
Singeing Machine
Benefits of Singeing
Machine parameter
Special Checkpoints
Cleaning Area of Singeing
Osthoff Singeing Parameter According to GSM
Sanforizing Machine
Benefits of Sanforizing
Machine Parts Sanforizing
Machine Parameters Sanforizing
Process Parameters of Sanforizing
So after completion of the move it should be zero (0). The quality of the fabric decreases due to skew problems. If you choose more or less than the requirements, the fabric will come back for refinishing. The letters pH stand for "power of hydrogen," and the numerical value is defined as the negative base-10 logarithm of the molar concentration of hydrogen ions.
Stenter Machine Machine parts of stenter
Function of Stenter
Process Parameter of Stenter Machine
De-sizing
Benefits of de sizing
Machine Parts of Desizing
Process Parameter of De-sizing
Chemical Recipe of De-sizing
Cleaning Area of De-Sizing
Mercerizing
Benefits of Mercerizing
Machine parts of Mercerize
Process Parameter of Mercerize
Chemical Recipe of Mercerize
Chemical Area of Mercerize Machine
Special Care of Mercerize
Over Dyeing
Bleaching
Inspection
Inspection
Objectives
Fabric Inspection Method
4-Points System
Procedure of 4-Points System
These machines are designed so that rolls of fabric can be mounted behind the inspection table under sufficient light and rolled again when they leave the table. Inspection machinery is either a power driver or the inspector pulls the material over the inspection table. Some machines are equipped to measure the length of each roll of fabric (meters/yards).
Fabric defects point values based on the following
Calculations of Result
List of defects in woven fabric is given bellow
Testing
Testing
Test Name
Apparatus
Conditioning
Preparation
Marking
Pairs of standards in the same direction in the direction should be spaced approximately 120 mm apart.
Machine Cycle
Washing Temperature
Measurement
Calculation
Yarn and Chemical quality checking before production
Lab Q.A - (Testing) - Activities system
The testing Facilities Available in HDL lab
Amazing Washing
Process of Amazing Washing
Different Types of Washing Vault
CHAPTER-5 MAINTENANCE
Mechanical store
Schedule maintenance
Dyeing Machines maintenance
Sizing maintenance
Weaving machine maintenance
Finishing maintenance
CHAPTER-6
STORE OR INVENTORY SYSTEM
Inventory
Type of Inventory in HDL
CHAPTER-7
MARKETING ACTIVITIES
Definition
Flow chart of marketing
Activities of Marketing
Duties and Responsibilities
CHAPTER-8
UTILITY SERVICE
Introduction
There is a pond in Integra Apparels (Bangladesh) Ltd which is also used as a secondary water source. A large underground water reservoir is also present to meet the demand in case of fire and any kind of emergency.
CHAPTER-9
INDUSTRAIL ENGINEERING AND PLANNING
Introduction
Work Flow Chart of R & D Section
Conclusion
