Industrial attachment HAMS washing & dyeing Ltd
Chapter-1
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Industrial attachment HAMS washing & dyeing Ltd
In troduc t ion
As a part of course curriculum of Bangladesh University of Textiles, we were send for
industrial attachment for two months starting from 1st July 2012 to 31st August, 2012 to
HAMS Washing & Dyeing Ltd. During the attachment we worked as a trainee textile
engineer and had to attend the official working days in general working times i.e. 9 am to 5
pm.
AIM AND OBJECTIVES OF INDUSTRIAL ATTACHMENT
To enhance our University learning experience through involvement in industrial and
commercial field, thus enabling us to relate theoretical concepts with practical
situations;
To develop our ability to evaluate issues and situations critically and propose well
considered options and solutions;
To develop and enhance our professional awareness and communication skills;
To provide experiences that will enable us to achieve a breadth of understanding that
will form a framework or agenda for our final year of study.
The experience offered by industrial training varies. However, by the end of the
placement we were expected to have substantially met most or all of the following
objectives:
Undertaken problem solving activities in the workplace;
Further developed my communication skills;
Shown the ability to accept responsibility, work independently, manage my own time
and schedule my work;
Understood the constraints of a formal working environment and the benefits of team
work;
Appreciated the relevance of my academic work and have applied this to new
situations;
Used new tools and techniques to supplement those covered on my scheme of study;
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Industrial attachment HAMS washing & dyeing Ltd
Acquired the experience to understand, discuss and evaluate the professional issues
relating to textile engineering.
Gained an understanding of which final year courses will provide the best foundation
for my int ended career.
SUPERVISION DURING THE INDUSTRIAL ATTACHMENT
During our industrial attachment we were overseen by our industrial tutor. We kept a
log of our activities during my industrial attachment in a diary supplied from our institute,
which was re-checked and signed by our industrial tutor.
We were also visited by our academic professionals of different departments whom
discussed about our progress with our industrial tutor. Thus we had the opportunity to learn
from our academic tutors in a practical field.
A routine was maintained to meet with our head of department. Once in every 15
days we met with our head of department and discussed about solutions of some problems
that we had in the industry.
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Industrial attachment HAMS washing & dyeing Ltd
Chapter-2
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Industrial attachment HAMS washing & dyeing Ltd
Projec t Descr ip t ion
This chapter contains general overview of the industry where we have carried out the
industrial attachment.
OVERVIEW
Company Name: M/S HAMS WASHING & DYEING LTD.
Company Nature: Privet Limited Company
Established Date: September, 1998
Location: Tejgaon Industrial Area, Dhaka
Project Cost: 57.04 Cror Tk.
Total area: 20,000 Square Feet (approx.)
Man-power: 350
Business field: Readymade Garments Washing & Dyeing
Main product: Denim long pant, short pant, overall skirt, cotton
sweater .
Manufacturing capacity: 2000 Dozens/Day
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Industrial attachment HAMS washing & dyeing Ltd
Layout Plan of Washing Section
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Industrial attachment HAMS washing & dyeing Ltd
o Garments Wash o Acid Wash
o Heavy Garments Wash o Bio Wash
o Pigment Wash o Bleach Wash
o Sand Blasting / Spray Blasting o Stone Wash
o Tinting Wash o Deep Dye
o Stone Enzyme Wash o Tie Dye
o Sand Wash o Silicon Wash
o Enzyme-Silicon Wash o Whickering
Types of wash:
Local Buying House:
Washing Capacity:
o Dye & Tint 12000 PCs/day
o Enzyme Wash 15000 PCs/day
o Bleach Wash 20000 PCs/day
o Enzyme Stone Wash 16000 PCs/day
o Pigment Wash 25000 PCs/day
o Garments Wash 40000 PCs/day
o Enzyme Silicon Wash 25000 PCs/day
o Avg. All type of Wash 22000-23000 PCs/day
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o Li & Fung (BD Ltd.) o Linmark
o Nor Wester o ABA Group
o Pelican Resources inc. o Auchan
o Lindex o Texel Ltd.
o JC Penny o NASSA
o DAC Pacific o Tex-EBO
o Epic Designers
Industrial attachment HAMS washing & dyeing Ltd
Major customers:
o JC-Penny
o Primark
o Vermukt
o Walmart
o K-Mart
o Route-66
o Fashion Traders
o Auchan
Product or , Item:
1. Washing of Denim gmts
2. Washing of Knit gmts
3. Washing of sample gmts
4. Different types of Dry wash.
Sales & Marketing policy: Improvement through Research and
development for better marketing.
Banks: 1. Premier Bank Ltd. Gulshan Branch
2. National bank.
Address: 190, Tejgaon I/A, Dhaka-1208, Bangladesh
Telephone: 9885674, 9886406(off.) 8814365, 8814923(fac.)
Fax: 880-2-9881067
e-mail: [email protected]
Web: www.hamsgroup.com
Different departments: Sample section, Washing & Dyeing section, Drying
section, Sand Blasting section, Quality assurance section, Laboratory, Storage
section.
Sister Concern: HAMS Fashion Bijoy (Pvt.) Ltd.
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Industrial attachment HAMS washing & dyeing Ltd
HAMS Fashions Ltd. Fashion-2000 Ltd.
Pacific Label Ltd.
HISTORY
Md. Shafiqur Rahman, founder & managing director of this company, is a textile
engineer himself who provided service for five year in garments washing and dyeing sector.
In September 1998 with five local made garments washing and dyeing machine he launched
M/S HAMS WASHING & DYEING LTD. The commitment was “TO MAINTAIN
QUALITY AND TO DELIVER TIMELY” and still strongly believes it.
REMARKS:
Within five years the industry earned good reputation in garments washing & dyeing
sector. Now HAMS WASHING & DYEING LTD. is one of the leading garments washing
& dyeing industry in Bangladesh.
The industry is now equipped with modern washing & dyeing machines. The total
numbers of machine are three times than the initial set up.
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Industrial attachment HAMS washing & dyeing Ltd
Chapter-3
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Industrial attachment HAMS washing & dyeing Ltd
Man power Management
The company includes over 150 employees with some highly skilled personnel. Most
of the staffs are self-motivated and hard working.
ORGANOGRAM
MAN POWER-ADMINISTRATION:
SL. No.
Designation
No. of Post
Gender Qualification LocalForeign expert
1 Managing Director 1 MaleB.Sc. in Textile
Technology
2 Director(admin) 1 Male Bachelor
3 Director(production) 1 MaleB.Sc. in Textile
Technology
4 Director(marketing) 1 Male Bachelor
ORGANOGRAM-ADMINISTRATION:
Managing
Director
Director (Admin.)
Manager
(Account)Manager (Admin.) Manager (Compliance)
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Industrial attachment HAMS washing & dyeing Ltd
ORGANOGRAM-PRODUCTION:
Managing
Director
Director
(Production)
Production
Manager
Asst. production
manager
Supervisor
(Washing)
Supervisor
(Dyeing)
Supervisor
(Drying)
Supervisor
(Sand
Blasting)
Machine OperatorMachine
Operator
Machine
Operator
Machine
Operator
Assistant
Operator
Assistant
Operator
Assistant
Operator
Assistant
Operator
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Industrial attachment HAMS washing & dyeing Ltd
ORGANOGRAM-QUALITY CONTROL:
Production Manager
Super Visor
(Quality)
Assistant (Quality)
ORGANOGRAM LABORATORY:
Production Manager
Machine Operator
(Sample washing
machine)
Assistant
(Laboratory)
Machine Operator
(Sample drying machine)
Assistant Operator Assistant Operator
ORGANOGRAM MAINTENANCE:
Production manager
Supervisor
(Maintenance)
Technician
Assistant
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Industrial attachment HAMS washing & dyeing Ltd
ORGANOGRAM FINANCE:
Director (Finance)
Accountant
Asst. Accountant
Shift Change: 12 hours shift (two shifts per day).
Responsibilities of Production Manager:
To give washing & dyeing slip.
To match production sample with target sample.
To collect production sample for sample matching for next production.
To identify disputed garments & report to director.
Also execute overall floor works.
To maintain loading & unloading record.
Any other assignment given by higher authority.
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Industrial attachment HAMS washing & dyeing Ltd
Chapter-4
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Industrial attachment HAMS washing & dyeing Ltd
Machine Descr ip t ion
There are three (3) sample washing machines and fifteen (15) industrial machines in
washing section, seven (7) guns in sand blasting section, one (1) sample drying and twelve
(12) industrial drying machines in drying section, four (4) hydro extractors in hydro
extraction section. There is a modern sample washing machine, a modern industrial washing
machine in washing section and a modern hydro extractor in hydro extraction section. The
industry is in the process of upgrading it’s existing machines. Specifications of some
incoming machines are also given in this chapter.
GARMENTS WASHING & DYEING MACHINES
SAMPLE WASHING MACHINES
No. of machines: 03
Specifications:
° Capacity: 30 kg
° Inner Cylinder: 28”X34”
° Thickness of inner drum: 3mm
° Outer Cylinder: 34”X40”
° Motor (HP): 1HP, 0.75KW
° Power Consumption: 2.3 Amp
° Steam Consumption: 2 HP, 31 Kg
° Water Inlet: 2”, 1 way in.
° Steam Inlet: 1”, 1 way in.
Water Discharge: 3”, 1 way out.
Manufacturing company: Bengal Heavy Electric Engineering.
Manufacturing country: Bangladesh.
Features:
° Single door design for general washing, sample washing.
° Machine body and essential parts are made of stainless steel.
° Preset front and backward rotation.
° Conventional machine.
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Industrial attachment HAMS washing & dyeing Ltd
INDUSTRIAL WASHING MACHINES
No. of machines: 10
Specifications:
° Capacity: 200 kg
° Inner Cylinder: 42”X88”
° Thickness of inner drum: 3mm
° Outer Cylinder: 54”X960”
° Motor (HP): 10HP, 7.5KW
° Power Consumption: 17 Amp
° Steam Consumption: 15 HP, 230 Kg
° Water Inlet: 2”, 2 ways in.
° Steam Inlet: 1”, 2 ways in.
° Water Discharge: 3”, 2 ways out
Manufacturing company: Bengal Heavy Electric Engineering.
Manufacturing country: Bangladesh.
Features:
° Single door design for general washing, sample washing.
° Machine body and essential parts are made of stainless steel.
° Preset front and backward rotation.
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Industrial attachment HAMS washing & dyeing Ltd
Fig: side loading washing m/c (vertial)
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Industrial attachment HAMS washing & dyeing Ltd
MORDERN SAMPLE WASHING MACHINES
No. of machines: 01
Specifications:
° Capacity: 35 kg (Dry: Wet =1:10)
° Inner cylinder: 950 mm dial X 500mm
° Wash motor: 0.75 KW
° Extract speed: 200 RPM
° Main door opening: 500 mm dial
° Water connection consumption: 25 mm dial, 120 litres.
° Drain: 75 mm dial, 1 way out
° Steam connection consumption: 15 mm dial, 25 Kg/hr.
° Electric heating: 12 KW
° Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H)
Manufacturing company: STEFAB INDIA LIMITED
Model no: LXS 35.
Manufacturing country: India.
Features:
° Single door, front-loading, open pocket.
° Machine body and essential parts are made of stainless steel.
° Automatic timed. Auto reverse. Automatic 5 water level & auto digital
temperature control.
° Electric solenoid water & steam valves.
° Non-clog motorised drain valve.
° Full electric protection.
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Industrial attachment HAMS washing & dyeing Ltd
MORDERN INDUSTRIAL WASHING MACHINES
No. of machines: 01
Specifications:
° Capacity: 280 kg (1:10)
° Inner cylinder: 1750 mm dial X 1180mm
° Wash motor: 7.5 KW
° Extract speed: 130 RPM
° Main door opening: 1000 mm dial
° Inspection door opening: 300 mm dial
° Water connection consumption: 50 mm dial, 960 litres.
° Drain: 115 mm dial, 2 ways out
° Steam connection consumption: 25 mm dial, 200 Kg/hr.
° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.
° Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H)
Manufacturing company: STEFAB INDIA LIMITED,
Model no: LXS 280.
Manufacturing country: India.
Features:
° Single door, front-loading, open pocket.
° Machine body and essential parts are made of stainless steel.
° Automatic timed. Auto reverse. Automatic 5 water level & auto digital
temperature control.
° Electric solenoid water & steam valves.
° Non-clog motorised drain valve.
° Full electric protection.
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Industrial attachment HAMS washing & dyeing Ltd
Fig: Front loading washing m/c (horizontal)
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Industrial attachment HAMS washing & dyeing Ltd
HYDRO EXTRACTORS
No. of machines: 03
Manufacturing company: Tongxin Ltd.
Manufacturing country: China.
Features:
° Due to its solid constructions it can be positioned onto firm floorings to
operate.
° It has excellent electrical layout in prevention of electricity leakage, shock,
which is important in wet conditions in the operations.
° Machine operations are made easy, with convenient start-stop operations for
maximum efficiency.
° The inner stainless steel is well balanced, thus achieving longer life span and
assuming energy efficiency of machine.
° Shock absorbers are well paced in the three suspension points to reduce
vibrations.
° Stainless steel constructions in major parts ensure durability.
Specifications:
° Model no: SHE-42° Capacity: 280 LBS° Inner cylinder: 1067dial X 419mm° Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H). ° Wash motor: 7.5 KW° Extract speed: 860 RPM
MODERN HYDRO EXTRACTORS
No. of machines: 01
Manufacturing company: STEFAB INDIA LIMITED,
Manufacturing country: India.
Features:
° Full stainless steel outer drum and inner basket. Strong welded construction.
Basket can be dismantled without dismantling outer casing. Electrically
interlocked top lid stops the machine when opened. Three position drain
connection. Outer casing mounted on heavy galvanised plate base frame.
Long rust free life and strength.
° Direct drive. Basket is directly mounted on to a specially designed high
torque heavy-duty motor resting on spigot of the base frame with built-in
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Industrial attachment HAMS washing & dyeing Ltd
rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick self-
balancing. Noiseless & vibration less operation.
° Automatic timed. Automatic DC injection for braking. Safety devices against
single phasing reverse phasing & motor overload. Great convenience &
safety. No foot pedals, no levers, no brake liners, no maintenance.
Specifications:
° Model no: HX 50
° Capacity: 80 Kg
° Inner cylinder: 1000dial X 300mm
° Volume: 235 Litres
° Basket speed: 750 R.P.M.
° Wash motor: 7.5 KW
° Drain: 75 mm dial
° Overall dimension: 1250mm(W) X 1550mm(D) X 1150mm(H)
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Industrial attachment HAMS washing & dyeing Ltd
Fig: Hydro extractor m/c
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Industrial attachment HAMS washing & dyeing Ltd
SAMPLE DRYING MACHINES
No. of machines: 01
Specifications:
° Capacity: 18 Kg
° Basket size: 700 mm (dial) X 470 mm
° Volume: 180 Litres
° Dry clean motor: 0.37 KW
° Extract motor: 1.5 KW
° Extract speed: 220 rpm
° Loading door opening: 400 mm (dial)
° Base tank capacity: 250 Litres
° Filter tank capacity: 250 Litres
° Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H)
Manufacturing company: STEFAB INDIA LIMITED,
Manufacturing country: India.
Features:
° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer
body not painted. Long rust free life and sheen.
° Built in solvent filter housed in the top tank receives soiled from the base tank
through a powerful centrifugal pump which pushes the soiled solvent through
several fine mesh cylindrical filters for reuse. Maximum recovery of clean
solvent.
° Low spin extract. Separate motors for dryclean & extract. Vibrationless
during extraction. Low spin extract makes articles lighter to unload. No
solvent dripping. No wastage of solvent.
° Automatic timed. Auto reverse. Full electrical protection against single
phasing & motor overload. Operator’s convenience & machine safety.
Efficient cleaning.
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Industrial attachment HAMS washing & dyeing Ltd
Fig: Gas dryer
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Industrial attachment HAMS washing & dyeing Ltd
INDUSTRIAL DRYING MACHINES
No. of machines: 11
Specifications:
° Capacity: 35 Kg
° Basket size: 950 mm (dial) X 500mm
° Volume: 350 Litres
° Dry clean motor: 0.75 KW
° Extract speed: 200 rpm
° Loading door opening: 500mm (dial)
° Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H)
Manufacturing company: Bengal Heavy Electric Engineering.
Manufacturing country: Bangladesh.
Features:
° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer
body painted.
° Low spin extract. Vibration less during extraction. Low spin extract makes
articles lighter to unload.
° Automatic timed. Full electrical protection against single phasing & motor
overload. Operator’s convenience & machine safety. Efficient cleaning.
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Industrial attachment HAMS washing & dyeing Ltd
INDUSTRIAL WASHING PROCESSING & DYEING MACHINES No. of machines: 06
Specifications:
° Capacity: 280 kg (1:10)
° Inner cylinder: 1750 mm dial X 1180mm
° Wash motor: 7.5 KW
° Extract speed: 130 RPM
° Main door opening: 1000 mm dial
° Inspection door opening: 300 mm dial
° Water connection consumption: 50 mm dial, 960 litres.
° Drain: 115 mm dial, 2 ways out
° Steam connection consumption: 25 mm dial, 200 Kg/hr.
° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.
° Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H)
Manufacturing company: STEFAB INDIAL LIMITED,
Manufacturing country: India.
Features:
° Single door, front-loading, open pocket.
° Machine body and essential parts are made of stainless steel.
° Automatic timed. Auto reverse. Automatic 5 water level & auto digital
temperature control.
° Electric solenoid water & steam valves.
° Non-clog motorised drain valve.
° Full electric protection.
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Industrial attachment HAMS washing & dyeing Ltd
HYDRO EXTRACTOR MACHINE:
No. of machines: 01
Specifications:
° Model no: HX 50
° Capacity: 80 Kg
° Inner cylinder: 1000dial X 300mm
° Volume: 235 Litres
° Basket speed: 750 R.P.M.
° Wash motor: 7.5 KW
° Drain: 75 mm dial
° Overall dimension: 1250mm(W) X 1550mm(D) X 1150mm(H)
Manufacturing company: STEFAB INDIA LIMITED,
Manufacturing country: India.
Features:
° Full stainless steel outer drum and inner basket. Strong welded construction.
Basket can be dismantled without dismantling outer casing. Electrically
interlocked top lid stops the machine when opened. Three position drain
connection. Outer casing mounted on heavy galvanised plate base frame.
Long rust free life and strength.
° Direct drive. Basket is directly mounted on to a specially designed high
torque heavy-duty motor resting on spigot of the base frame with built-in
rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick self-
balancing. Noiseless & vibration less operation.
° Automatic timed. Automatic DC injection for braking. Safety devices against
single phasing reverse phasing & motor overload. Great convenience &
safety. No foot pedals, no levers, no brake liners, no maintenance.
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Industrial attachment HAMS washing & dyeing Ltd
INDUSTRIAL SAND-BLASTIG GUNS No. of machines: 07
Specifications:
° Model: SBT-650
° Capacity: 200 Litres
° Dimension: 800mm X 1000mm X 1250mm
° Sand contains: 200 Kg
Manufacturing company: Made in China
Features:
° Single door design for general washing, sample washing.
° Machine body and essential parts are made of stainless steel.
° Preset front and backward rotation.
OTHER COMPONENTS/ACCESSORIES
No. of cabinets: 07
Hopper (for controlling dust in cabinets): 02
Helmet: 07 Pcs
Musk: 07 Pcs
Gloves: 07 pairs.
Air preserver-1, capacity of 2000 c.c.
Air preserver-2, capacity of 900 c.c.
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GARMENTS SAND-BLASTING MACHINES
Industrial attachment HAMS washing & dyeing Ltd
Spray machines: 03 Nos.
Manufacturing country: Hong Kong
Compressor: 03 Nos.
Two compressors with same following specifications.
o Brand: ELGI
o Capacity: 10 Jule/Bar
o Made in INDIA
One compressor with following specifications:
o Brand: OSD
o Made in ITALY
o Includes Change Over
o MCCB
o Capacity: 10 Jule/Bar
Boiler:
Brand name: Sacca
Manufacturer: Made in ITALY
Production capacity: 1.5 Tons/Hr.
Pressure: 7.5 Jule Bar (5.0 Bar used)
Supply system: Automatic Pressure control.
Chimney: 50 Feet with 12-inch diameter.
Generator
Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"
production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA),
"SINCRO"(SI) alternators. All alternators are three phase, four pole, single bearing,
synchronous type, cosj=0.8, 50Hz.
Water supply pump: 03 Nos.
02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse
Power.
01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power.
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OTHER MACHINES
Industrial attachment HAMS washing & dyeing Ltd
REMARKS
No live industry can keep place with the advance of technology without continuous
renewal & transformation of its production facilities. Existing equipments must be kept on
the defensive, compelled always to justify its tenure against the challenge of new & more
modern machines. If any piece of existing equipment fails to meet this challenge, it must be
displaced, regardless of its age or condition & regardless of whether it is physically “worn
out”.
Keeping the above in view, this industry is always replacing its existing machines in
order to increase productivity & improve quality.
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Industrial attachment HAMS washing & dyeing Ltd
Chapter-5
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Industrial attachment HAMS washing & dyeing Ltd
Raw mater ia l s
Different sections of the industry require raw materials i.e. chemicals of various
types in different quantity. Most of the chemicals are purchased locally. A few are imported
directly.
RAW MATERIALS USED IN GARMENTS WASHING
Caustic Soda (NaOH)
° Type : Alkali
° Unit price : Taka 24 per Kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : (Neutralize acidic materials, saponify glycerides
(waxes and oils), solubilize silicate
° Monthly requirements: 4050 kg (approximately)
Soda Ash (Na2CO3)
° Type : Alkali
° Unit price : Taka 14 per kg
° Source : Dystar ( Singapore ) / Clariant ( Germany )
° Uses : Used to alkaline the solution/medium. Control PH
° Monthly requirements: 2000 kg (approximately)
Wetting agent:
° Type : Combination of Detergent & Surfactant
° Unit price : Taka 150 per kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Emulsify oils, fats and waxes; remove oil-stains;
Suspend materials after they have been removed.
Reduce surface tension & minimize inter facial
tensions.
° Monthly requirements: 2000 kg (approximately) Anti-back
° Type : Anti back staining agent
° Unit price : Taka 175 per kg
° Source : India, China
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Industrial attachment HAMS washing & dyeing Ltd
° Uses : Prevent back staining
° Monthly requirements: 2000 kg (approximately)
Acetic Acid
° Type : Organic acid
° Unit price : Taka 70 per kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Used to make solution/medium acidic. Control PH
° Monthly requirements: 1000 kg (approximately)
Sodium Hypo Chloride (NaOCl)
° Type : Oxidizing agent
° Unit price : Taka 18 per kg
° Source : India, China
° Uses : Used to uniform lightening of the colour of the indigo
or sulphur dyed garments in bleach wash.
° Monthly requirements: 1500 kg (approximately)
Bleaching Powder [Ca (OCl)Cl]
° Type : Oxidizing agent
° Unit price : Taka 21 per kg (KCI, 33% Chlorine), Taka 105 per kg
(Japan, 65% Chlorine)
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Used to decolouration of fabric
° Monthly requirements: 3590 kg (KCI), 142 (Japan) (approximately)
Enzyme
° Type : Enzyme
° Unit price : Taka 300 per kg (liquid), Taka 400 per kg (powder)
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Used to breaks down the long starch molecular chain
into smaller sections, that can be easily washed from
garments.
° Monthly requirements: 1500 kg (liquid), 1000 kg (powder) (approximately)
Silicon
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Industrial attachment HAMS washing & dyeing Ltd
° Type : Softener
° Unit price : Taka 130 per kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Creates the fabric surface oily/ used for lubrication
° Monthly requirements: 500 kg (approximately)
Softener Flax
° Type : Softener
° Unit price : Taka 105 per kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Soften fabric handling
° Monthly requirements: 500 kg (approximately)
Potassium Permanganate
° Type : Decolouration agent
° Unit price : Taka 80 to 370 per kg
° Source : India, Bangladesh
° Uses : Used to decolouration of fabric
° Monthly requirements: Locally purchased when required.
Sodium Meta bi Sulphate
° Type : De-chlorination agent
° Unit price : Taka 28 per kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Used to neutralize activity of chlorine on
fabric/solution
° Monthly requirements: 475 kg (approximately)
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Industrial attachment HAMS washing & dyeing Ltd
Peroxide (H2O2)
° Type : Oxidising agent
° Unit price : Taka 35 per kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : OH- ions destroy the colouring material and improve
whiteness
° Monthly requirements: 1000 kg (approximately)
Common Salt
° Type : Salt
° Unit price : Taka12 per kg
° Source : Clariant ( Switzerland ) / Dystar ( Germany )
° Uses : Used as electrolyte for solution, improves shining of
fabric.
° Monthly requirements: 2200 kg (approximately)
RAW MATERIALS USED IN GARMENTS DYEING
The following raw materials are used in garments dyeing in addition to some of the
raw materials already listed above.
Dyestuff
o Type : Direct dye
o Unit price: Taka 300-1200 per Kg
o Source: Clariant ( Switzerland ) / Dystar ( Germany )
o Use: Cotton & Viscose garments dyeing.
o Monthly requirements: Depends on ordered quantity.
o Type: Reactive dye
o Unit price: Taka 275-850 per Kg.
o Source: Clariant ( Switzerland ) / Dystar ( Germany )
o Use : Cotton & Viscose garments dyeing.
o Monthly requirements: Depends on ordered quantity.
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Industrial attachment HAMS washing & dyeing Ltd
o Type : Pigment dye
o Unit price: Taka 300-500 per Kg
o Source: Clariant ( Switzerland ) / Dystar ( Germany )
o Use: Cotton & Viscose garments dyeing.
o Monthly requirements: Depends on ordered quantity.
Glauber salt
o Type : Salt
o Unit price: Taka 14 per Kg
o Source: Bangladesh
o Use: Levelling agent.
o Monthly requirements: Depends on ordered quantity.
Fixing Agent
o Unit price: Taka 500 per Kg
o Source: Clariant ( Switzerland ) / Dystar ( Germany )
o Use: Colour fixation.
o Monthly requirements: Depends on ordered quantity.
Dispersing agent
o Unit price: Taka 500 per Kg
o Source: Clariant ( Switzerland ) / Dystar ( Germany )
o Use: Assists in the process of particle size reduction of dye.
o Monthly requirements: Depends on ordered quantity.
REMARKS
The monthly requirements of raw materials vary depending on the type of washing &
ordered quantity. Sometimes the price of the materials also varies due to the availability of
the materials in the market.
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Chapter-6
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Produc t ion P lann ing , Sequences & Opera t ions
Production process consist of different types of washing methods such as normal
wash, bleach wash, stone wash, acid wash, enzyme wash, super white wash, dirty wash etc
and dyeing methods with reactive, direct, sulphur etc dyes are done. Recently sandblast and
chemical sprayer added to the production process.
PRODUCTION FLOW CHART OF GARMENTS WASHING
Batching
Pre-treatment
Washing
Hydro
Extraction
Drying
Quality Control
Storage
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PRODUCTION FLOW CHART OF GARMENTS DYEING
Batching
Pre-treatment
Dyeing
Sample Check
Hydro
Extraction
Drying
Quality Control
Storage
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PROCESS TECHNIQUE OF SOME WASHING & GARMENTS DYEING METHODS
NORMAL WASH:
Batch 60 PCs. Liquor 400 Litre
Step 01 Water is added (400 Lt)
Desizing
Garments are added
Machine started running
200 gm Detergent added
Temperature raise to 60°C
Time 5-10 minutes
Drop the liquor
Add water and cold wash
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Step 02 Water is added (400 Lt)
Softening
Garments are added
Machine started running
240 gm Softener added
Temperature Cold
Time 5-10 minutes
Drop the liquor
Unlaod garments on trolley
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Step 03Load the garments on m/c
Hydro
Extracting
R.P.M 700-900
Time 3-5 minutes
Unload the garments on trolley
Unload the garments
Trolley
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Step 04 Load the garments on dryer m/c
Drying
Temp 60- 70°C
Time 40-50 minutes
Time 10-15 minutes for cold dry
Unload the garments
Quality checking
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ENZYME-BLEACH WASH WITH TINTING:
Batch 60 PCs. Liquor 400 Litre
Step 01 Water is added (400 Lt)
Desizing
Garments are added
Machine started running
500 gm Soda Ash added
500 gm Caustic Soda added
200 gm Bio. D added
Steam to raise temp 60°C
Process time 25 minutes
Drop liquor
Wash down twice
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Step 02 Water is added (400 Lt)
Enzyme Wash
Machine started running
200 ml liquid, 400 gm powder
type Enzyme added
150 ml Acetic Acid Added
200 gm Anti back added
10 Kg Peumic Stone added
Steam to raise temp 50°C
Process time 60 minutes
Drop liquor
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Step 03 Water is added (400 Lt)
Bleaching
Machine started running
4 Kg KCI (35% Cl2) added
500 gm Soda Ash added
Steam to raise temp 60°C
Process time 10 minutes
Drop liquor
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Step 04 Water is added (400 Lt)
Neutral Wash
Machine started running
500 gm Hypo sulphide added
Steam to raise temp 45°C
Process time 10 minutes
Drop liquor
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Step 05 Water is added (400 Lt)
Tinting
Machine started running
0.02% Direct Brown GTL &
0.01% Direct Black V-200 added
4 Kg Salt added
Steam to raise temp 70°C
Process time 20 minutes
Check Shade
Drop the liquor
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Step 06 Garments are then taken out
Drying
Hydro extracted
Send to dryer for drying of
garments.
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CAUSTIC WASH:
Batch 60 PCs. Liquor 400 Litre
Step 01 Water is added (400 Lt)
Desizing
Garments are added
Machine started running
320 gm Detergent added
320gm Caustic soda added
Temperature raise to 60°C
Time 20-60 minutes
Drop the liquor
Add water and cold wash
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Add water 300 lit
Temperature cold
Acetic acid 150gm added
Time 5 minutes
Step 02Neutral wash
Step 02 Water is added (400 Lt)
Softening
Garments are added
Machine started running
240 gm Softener added
200gm Acetic acid added
160gm silicon softener added
Temperature Cold
Time 15 minutes
Drop the liquor
Unlaod garments on trolley
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Step 03 Load the garments on m/c
Hydro
Extracting
R.P.M 700-900
Time 3-5 minutes
Unload the garments on trolley
Step 04 Load the garments on dryer m/c
Drying
Temp 60- 70°C
Time 40-50 minutes
Time 10-15 minutes for cold dry
Unload the garments
Quality checking
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PIGMENT WASH:
Batch 60 PCs. Liquor 400 Litre
Step 01 Water is added (400 Lt)
Desizing
Garments are added
Machine started running
320 gm Detergent added
320gm Caustic soda added
600gm Soda ash added
Temperature raise to 60°C
Time 20-60 minutes
Drop the liquor
Add water and cold wash
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Step 02 Water is added (400 Lt)
Softening
Garments are added
Machine started running
240 gm Softener added
200gm Acetic acid added
160gm silicon softener added
Temperature Cold
Time 15 minutes
Drop the liquor
Unlaod garments on trolley
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Step 03 Load the garments on m/c
Hydro
Extracting
R.P.M 700-900
Time 3-5 minutes
Unload the garments on trolley
Step 04 Load the garments on dryer m/c
Drying
Temp 60- 70°C
Time 40-50 minutes
Time 10-15 minutes for cold dry
Unload the garments
Quality checking
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ACID WASH
Batch 100 PCs.Liquor 500
Litre
Step 01 Water is added (500 Lt)
Desizing
Garments are added
Machine started running
400 gm Soda Ash added
400 gm Caustic Soda added
200 gm Bio. D added
Steam to raise temp 60°C
Process time 20 minutes
Drop liquor
Wash down twice
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Step 02 Water is added (500 Lt)
Normal
Wash
Machine started running
Steam to raise temperature 40°C
Process time 5 minutes
Drop liquor
Take out the garments
Hydro extract the garments
Dry the garments
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Step 03Load the pre-treated & dried
garments in another washing machine
Acid Wash
Machine started running
Add stones soaked with potassium per magnate
double the volume of garments
Continue machine running for 7 minutes
Unload the garments from the machine
Step 04Load the garments into another washing
machine
Neutral
Wash
Water is added (500 Lt)
Machine started running
1.5 Kg detergent is added
Steam to raise temp 50°C
Process time 15 minutes
Drop liquor
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Step 05 Water is added (500 Lt)
Neutral
Wash
Machine started running
500 ml Auxalic Acid added
Process time 5 minutes
Check Shade
Drop the liquor
Garments are then taken out
Hydro extracted
Send to dryer for drying of garments.
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COTTON GARMENTS DYEING PROCESS (Sample Dyeing)
Batch 1.4 KgLiquor
14 Litre
Step 01 Water is added (14 Lt)
Desizing
Garments are added
Machine started running
500 gm Soda Ash added
500 gm Caustic Soda added
100 gm Bio. D added
Steam to raise temp 80°C
Process time 45~60 minutes
Drop liquor
Step 02 Water is added (14 Lt)
Hot Wash
Machine started running
Steam to raise temperature 50°C
Process time 5 minutes
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Drop liquor
Step 03
Scouring &
Bleaching
Water is added 14 litre
Start machine running
Added 1 litre H2O2
50 gm Stabiliser added
150 gm Soda Ash added
250 gm Caustic Soda added
100 gm Bio-D added
Process temp 80° C
Process time 90 minutes
Drop the liquor
Step 04 Water is added (14 Lt)
Hot Wash
Machine started running
Steam to raise temperature 50°C
Process time 5 minutes
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Drop liquor
Step 05 Water is added (14 Lt)
Neutral Wash
Machine started running
200 ml Acetic Acid added
Process time 5 minutes
Drop the liquor
Step 06 Water is added (14 Lt)
Dyeing
Start machine running
560 gm Salt is added
Reactive dye (T. Blue. G) - 0.2% &
Drimerine – Blue K2RL-0.03% is added
20% Soda Ash is added
Processing temp 80° C
Processing time 60 minutes
Drop the liquor
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Step 07 Water is added (14 Lt)
Washing
Machine started running
1 % Detergent is added
Steam to raise temperature 50°C
Process time 10 minutes
Drop liquor
Again Add water of 14 litre
Process time 5 minutes
Drop liquor
Unload the Garments
Hydro extractor
Drying
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Dry process
Hand scraping Sand blasting Whiskering Grinding Destroy P.P spray Resin application Wrinkle (permanent) Overall wrinkle Laser draw
Hand Scraping:Hand scraping is generally being done in rigid form of garments to get distress look. Locations can be front thigh & back seat or it can be over all as per standard. Emery paper is being used to scrape the garments in particular placement & design.Emery paper comes in different number generally starts from 40 till 600 and above, higher the number finer the emery paper, lower the coarseness of the paper. In garments industry from 220, 320& 400 numbers papers are most popular & widely used.The most important factor is to select right number of paper according to the fabric strength & intensity need. Scraping can be done on inflated rubber ballons for better effect (horizonta or vertical its up to operators convinence),even it can done plain wooden board of garments size & hand pressure should be uniform in order to get better results.Sand BlastingSand blasting is recently popular dry process. It is a mechanical process by which we can fadding effect/old looking effect on heavy garments like denim, twill etc by the action of aluminium oxide which looks like sand. Sand blasting is applied on specific area of a garments.Sand blasting is performed with combine the wash like bleach wash, enzyme wash,normal wash, stone wash & tinting/over dyeing.
Process of sand blasting: The garments to be sand blasted are placed on the bed in a closed chamber Aluminium oxide is very hard, fine, sharp. Aluminium oxide through by gun with dry air to perform sand blasted action. The gun has a switch to start and stop the flow of aluminium oxide. The flow of aluminium oxide on fabric is done at an angle 10-20 degree. Higher the blowing angle higher the fadding effect. Sand blasting is a hazardous process and its area is isolated from other producion
areas. Producion per gun per hour varies from 25-50 garments, depending on the area. After prodution chemical treatment are required as per buyer requirements.
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Operator should wear protective wear includes glass,helmet,gloves,uniform,masks etc.
Whiskering: We need a rubber board. Design should be placed on rubber board. Then the board is placed inside the garments Hand rubbing is done on the upper side of the garments. After wash design produced. It may be rectangular or circular. Wet wash is must.
Grinding:Grinding is done on pocket edges & bottom hems edges by running against abrasion surface or stone to achieve worn out effect. Many different make of machines & pen grinding tools are avilable in the market which runs with pneumatic system.
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Destroy:One o the most popular distressing effect currently. Destruction is an art which makes denim look unique and used. To make destruction pen type stone tools being used in mid of wash process to apply on desired area. It can also be achieved by cutting it through knife the warp yarns & keep the weft yarn as is to show white thread. Holes can also be made by cutting weft & warp yarns. These are manual processes & every garments will look unique & different than others.
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P.P Spray:PP spray is done on denim garments to achieve local abraded area to appear whiter than back ground indigo color shade. This can be applied by spray gun or by towel dipped into pp solution & rubbed on desired area followed by neutralization in wet wash process. This process sone in rigid after doing hand scrape or in the middle of the wash. Doing after bleach or enzyme cycle will give more natural & whiteb effect than doing in rigid form. There are many additives that can be added in order achieve desired intensity and out look.The same way bleach solution can also be spray or rubbed on the garments on desired area. But this process is more complicated & neeed high skilled operator to execute it followed by immediate neutralization.There are many parameter to control during pp spray or bleach spray……… spray gun pressure, width of spray,flow and way of spraying.
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Resin Application:Resin being used for achieving 3D effect,rigid look,etc. this process can be done by spraying or dipping the garments into resin ,catalyst,silicone,PU solutionin right combination according to the fabric strength & desired effect needeed.After aplication of resin solution in right proportion,make manual desinig as needed on the thigh hip & back knee area to get 3D effect. After making it , it should be dried with hot press or by hairb dryer & then must be cured in woven at right temperature , time as mentined in resin product manual.
Permanent wrinkle:This is one of the most popular dry process recently and being done on front thigh, front knee, back knee. Resin is applied on the required area where wrinkle is to be done. Then garments is squeezed by machine or by hand and clip is placed on the dsign to keep in riginal design. Then garments with the resin is kept in woven for half an hour for permanency of wrinkle. Next wet is done as per buyer demand.
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Laser Draw:Wrinkle effect or burn out effect is produced by laser ray. If the production area of wrinkle is more than laser draw is done on the required area of the garmnets. The effect is produced by burning out the fibre of garments surface. The system is controlled by computer. The required design is kept inside computer. There is a chamber where garments are placed to get the required effect. There is also a switch controlled by oprator to controll laser draw and to get desired design on desired area.
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PRODUCTION REPORTS
Date:05.08.2012
Sl. No.
Name ofBuyer
Name ofGarments
Order/Style no.
Types ofProcess
Total received
(pcs)
DeliveryAmount
(pcs)
Balance (pcs)
1 Snoopy Utah Washing
Sand Blast 17745 14899 2846
2 Snoopy Yoke Design G-21 Sand Blast + Bleach
4129 778 3351
3 Caree Four
Tusuka Fashion
100341/2 Rewash 5100 3576 1524
4 Etam Aba Fashion Enzyme Silicon 18935 15127 3808
5 Caree Four
Aba Fashion Enzyme Silicon 19576 15679 3897
6 Etam Export Knit 6094619 Enzyme Silicon 8696 8124 572
7 Texel Sportx Gmts. 100093 Enzyme + Dyed 7990 7191 99
8 Texel Sportx Gmts. 100093 Enzyme Wash 7628 5500 2128
9 Primark Universal 52510 Sand Blast + Dyed
1200 1200
10 RN Sha Sha Gmts.
1161R Sand Blast + Dyed
5793 3767 2029
11 RN Sha Sha Gmts.
8488 Sand Blast + Enzyme
2934 798 2136
12 Nor Wester
Leader Gmts. 25021XZ
Sand Blast + Enzyme
7404 2932 3122
13 Nor Wester
Leader Gmts. 25027XZ
Sand Blast + Enzyme
5903 1500 4633
14 Nor Wester
Fasnoor Gmts.
25069XZ
Enzyme Silicon 5155 4506 649
15 Nor Wester
Tamanna Ltd. 25074/75 Silicon Wash 4527 3769 758
Grand Total 3275
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Chapter-7
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Maintenance is considered as important as other engineering functions. It makes responsible
for provision of a condition of machines, buildings and services that will permit
uninterrupted implementation of plans requiring their use.
OBJECTIVES OF MAINTENANCE:
To keep the factory-plants, equipments, machine tools etc. in an optimum working
conditions.
To ensure specified accuracy to products and time schedule of delivery to customers.
To keep the down time of machines to the minimum thus to have control over the
production program.
To keep the production cycle with in the stipulated range.
To modify the machine tools to meet the augmented need for production.
To improve productivity of existing machine tools and to avoid sinking of additional
capital.
To reduce the maintenance costs as for as possible thereby leading to a reduction in
factory overheads.
To prolong the useful life of the factory, plant and machinery, while retaining their
acceptable level of accuracy of performance thus avoiding or prosponding incurring
of heavy capital expenditure involved in their replacement.
ECONOMIC CONSIDERATION OF MAINTENANCE
It is very profitable activity & ensures maximum productivity at minimum costing.
It improves product quality.
It ensures less time to produce a specific product.
It improves machine accuracy.
It maintains a long life of the machine.
No chance of back order.
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M a i n t e n a n c e
Industrial attachment HAMS washing & dyeing Ltd
MAINTENANCE FLOW CHART
Head of
Maintenance
Technician
Assistant
FUNCTIONS OF MAINTENANCE PERSONNEL
Inspection or Check-Ups:
° External inspections: Watching and detecting defects form abnormal sound,
vibration, heat, smoke etc when machine is in operation.
° Internal inspections: Inspection of parts such as gears, bushes, bearings,
tolerances in the parts etc. when machine is under pre-planned shutdowns.
° Inspections of important machines: Machines, which can disrupt whole of
the production, are delicate and require much time for the repair. Attentions
are given for inspection of these machines and schedule for inspection,
cleaning lubrication are done rigidly.
° Inspections of ordinary machines: Frequency of inspection of ordinary
machines is kept as low as they do not affect the production.
Lubrication: Mechanical components like gears, bearings, bushes and other friction
surfaces etc. give good performance for long periods when they are systematically
lubricated. Systematic lubrication means the application of right type of lubricants at
the right time, at right place and in right quantity. For lubrication, a lubrication
schedule should be prepared and that should be followed strictly. Here lubrication is
done whenever is needed.
Planning and scheduling: Every preventive maintenance work should be pre-planned
in detail on the basis of the analysis done on the past records. A scheduled programme
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thus prepared should be followed strictly. Thus programme should be in detail specifying
the point-requiring daily, weekly, monthly, half yearly or yearly attention.
Records and analysis: Good record keeping is essential for good maintenance, as it
helps in for casting maintenance. For this purpose following records are generally
maintained:
° Operation manual
° Maintenance and instruction manual
° History Cards and History Registers
° Spares Procurement Registers
° Spare Procurement Register
° Inspection Register
° Log books
° Defect Register etc.
Training of Maintenance personnel: For the success of maintenance a sound
training is essential for the maintenance personnel. Hence the technicians and
supervisors are trained to carry out maintenance, inspection and repaired in a
systematic way.
Storage of Spare Parts: Sometimes machine remains idle for want of spare parts for
considerable time and thus it affects considerable loss of production. Hence it is
essential to keep the spare parts so as to avoid loss of production.
Maintenance practices are made from the following ways:
Capital replacement: capital replacement is undertaken if analysis reveals that the
retention of equipment no more remains an economical proposition.
Provision of stand-by-capacity: Stand by capacity is often provided for items of
equipment that we are critical to production. It is sometimes an economical
maintenance practice to install such spare capacity to be put into operation while the
original unit is under repair or is over-hauled.
Break-down maintenance: Break-down maintenance practice allows a machine or
any other facility to run without much of routine attention, till it actually breaks down
to be then put back into commission.
Scheduled maintenance: Scheduled maintenance system provides for inspection,
overhaul lubrication, and servicing of certain machines at predetermined dates. Over-
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hauling of machines, cleaning of tanks and white washing of buildings is normally
done in this manner.
Planned maintenance: Planned maintenance visualise the work contained in a
future job determines the best method to be adopted and skills required for its
execution; estimates the time, material and costs involved assigning jobs to
individuals; programmes the work to specific time periods on the basis of priority
and after ascertaining production requirements; arranges for availability of material
tools and man-power and for release of machines in time.
Preventive maintenance: It consists of routine actions taken in a planned manner to
prevent breakdowns and to ensure operational accuracy to the extent it is
economically and practically possible to do so.
MAINTENANCE TOOLS & THEIR FUNCTIONS
Tools Nos. Specifications UsesMeasuring Tape 02 Both British and Metric system
measurement.Mostly used for linear measurement
Hammer 01 It is just a weighted head and a handle that directs its course.
The Hammer is very simple striking tool.
Screw Driver (flat type)
02 10” steel shank, with flat blade and plastic handle.
To loosen or tighten screws.
Screw Driver (Phillips head)
01 8” steel shank, with star blade and plastic handle.
To loosen or tighten screws
Pliers 01Nose Pliers 01
Wrench (Locking adjustable)
02 For exerting a twisting strain in turning bolt & nuts
Wrench (Pipe) 03Wrench (Double head open end)
06
Wrench Hacksaw Adjustable frame Used to saw metalChisels (cold, flat point)
01 Made of good grade tool steel Used for cutting or chipping metals.
Table vice 01FileMobil Gun 01Wielding Machine 01Hand Grinding Machine
01
Fixed Grinder 01
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Hand drill 01
Chapter-8
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U t i l i t y S e r v i c e s
Man, Machine and Material, the three main things that can accelerate the production,
if it is used in proper and organized way. In the Industry, UTILITY plays an important role
in case of production. Production and profit are closely related. In order to get a quality-
finished product, it needs fresh raw materials as well as effective manpower and machinery
in good working condition. Utility is closely related to the three M's plays a vital role to
maximize the production as well as profit.
FUNCTIONS OF UTILITY
Utility ensures power supply by generator.
Utility ensures water supply by pump.
It ensures steam by boiler.
It ensures compressed air handling by vacuum planning system.
It provides fuel and gas supply.
It provides workshop facilities.
AVAILABLE UTILITIES
The following utility facilities are available at HAMS WASHING & DYEING LTD.
Water.
Steam.
Electricity.
Gas.
Compressed air.
Covered Van for Transportation.
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SOURCES OF UTILITIES
Water: Own Supply (Pump)
Steam: Own supply (Boiler)
Electricity: Generator & PDB
Gas: Titas Gas Transmission & Distribution Co. Ltd.
Compressed Air: Own supply (Air compressor)
CAPACITY & OTHER TECHNICAL DETAILS
WATER: Water is supplied by pump. Pump supplies water on the basis of pressure.
Pump pressure ranges 0-10 bar. The pump is operated at 2-4-bar pressure. 3 motors
are used for uniform water supply. These are automatic on-off system motor. When
the pressure is reduced to the desired level (2 bars) then the motor is turned on.
Similarly when the pressure is above the desired level (4 bars) then the motor is
turned off. So, it has variable water supply capacity & supplies water as required.
The water, which is used for cooling, is brought to a tank & again supply by a pump.
There are 3 deep tube wells used in this project. Water is directly used in washing &
dyeing & other subsequent process.
02 PCs. Deep Tube wells are submersible, Made in ITALY, BG brand with 30 Horse
Power.
01 PC. Deep Tube well is submersible, Sigma branded, Made in ITALY with 42
Horse Power.
STEAM: Heat generation is a very important factor for washing and dyeing process.
Steam is a very efficient & easy way to transfer heat. There is a boiler to generate
steam. By pipe line the generated steam is supplied to the washing and dyeing
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machines & where it is necessary. The boiler has the capacity to generate steam 1.5
Tons/Hr.
Technical details about the boiler:
Boilers function is to transfer the heat produced by the combustion of fuel (gas) to
water and ultimately to generate steam.
Brand name: Sacca
Manufacturer: Made in ITALY
Production capacity: 1.5 Tons/Hr.
Pressure: 7.5 Jules Bar (5.0 Bar used)
Supply system: Automatic Pressure control.
Chimney: 50 Feet with 12-inch diameter.
ELECTRICITY: It is totally impossible to continue the production without
electricity. A frequent supply of electricity is very essential for soundless production.
Here all the machines in washing and dyeing section are provided electricity by the
govt. electricity with own standby generator of the industry.
Technical Details about the Generator:-
Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"
production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA),
"SINCRO"(SI) alternators. All alternators are three phase, four pole, single bearing,
synchronous type, cosj=0.8, 50Hz.
Model Rated power Voltage Alter-nator
Diesel enginespecification
Dimensions Weight
KVA KW V LxWxH cm KgE275VM 275 220 400/230 MA "VOLVO" TWD1210G,
6 cyl., turbocharg300x110x192
2400
Electric Substation:
o 500 KVA Transformer (11 KV to 440 KV)
Brand: Power man
Three phase
Rated power: 500 KVA
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Standard: Bs-171
Class: A
Rated Frequency: 50 Hz
Type of cooling: ONAN
AMBIENT Temperature: 50°C
Duty: Continuous.
Voltage: 11000 Volt (HT) 415 (LT)
Rated Current: [HT - 26] [LT - 695] AMP
Vector group Dyn – 11
Impedance Voltage: 0.5%
Total Weight: 179 Kg
Lift able Weight: 990 Kg
Oil Weight: 610 Kg
Winding Temperature: 55°C
Manufacturing Year: 2003
Made in Bangladesh.
o High Tension Switch.
o Switch Gear
Brand: Power Man
Voltage: 415 Volt, 50 Hz
Phase: 3 Phase, 1 Neutral
Incoming: 800 AMP
MCCB/ACB
Made in Bangladesh
o ACB (Air-Circuit-Breaker)
Brand: SPARK Energy
Model: OSLO 6E
o MCCB (Magnetic Contact Current Circuit Breaker)
o PFI (Power Factor Improvement Plant, 6 step auto control)
Brand: Power man
Rating: 200 KV
Voltage: 415V, 50 Hz
o Change Over
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o Bash Bar Panel Board.
Compressor: Two compressors with same following specifications.
o Brand: ELGI
o Capacity: 10 Jule/Bar
o Made in INDIA
One compressor with following specifications:
o Brand: OSD
o Made in ITALY
o Includes Change Over
o MCCB
o Capacity: 10 Jule/Bar
Air Condition:
o Exhaust Fan: 03 Nos.
o Air Cooler: 02 Nos.
Fire Fighting Tools:
o Washing section: 10 Nos. Fire Extinguisher
Air Dryer:
o For Compressor: 3 Nos.
Cover Van:
o 3 Cover Van used to carry garments.
Gas: The company gets natural gas from Titas Gas Transmission & Distribution Co.
Ltd. Capacity of gas line is variable ie. line able to supply gas according to the
requirements.
COST OF UTILITIES
Water: Own supply (Pump)
Electricity Required- 46 KW/Hr. Cost 5 TK/KW.
Steam: Own Supply (Boiler)
Gas required: 670 Meter3/Hr. Cost 5.60 TK/ Meter3 (Aprox.)
Compressed Air: Own Supply (Air compressor)
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REMARKS
There is problem with water supply in the company. The supply of water is not
sufficient, which create problem in washing and dyeing. The quality of water is not up to the
level. The hardness & presence of iron in water is high. A water treatment plant is very
essential to continue the production without disturb & to increase the production.
The generator of the industry is too old to supply the electricity fluently. Sometimes
it trip without any warning. So, it’s necessary to have a new generator for the industry.
The boiler also very old to maintain it high bar pressure. It should be replaced
with modern boiler for better service.
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Chapter-9
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S t o r e & I n v e n t o r y C o n t r o l
In HAMS WASHING & DYEING LTD. there are different inventory systems for
different raw materials and finished materials.
DYE & CHEMICAL STORE
There is a different store for dyes & chemicals. Various types of dyes & chemicals
are stored here according to the dyes & chemical company.
Different types of dyes & chemicals are listed in a sheet. In the sheet the stored
quantity of dyes & chemicals are also included. Everyday the sheet is updated & a copy of
this sheet is supplied to the GM (production), Dye house & lab section.
SPARE STORE
In HAMS WASHING AND DYEING LTD. required amount of spears of different
machines are stored in the mechanical storeroom. All the spears are listed in a sheet, which
is controlled by the mechanical & maintenance personnel. Spares are arranged in the
storeroom according to their size, quantity & requirements. There are shelves in the
storeroom to keep the small spare parts.
FINISHED PRODUCT STORE
HAMS WASHING AND DYEING LTD. supplies its finished dyed fabrics to its
garments section. So, dyed finished fabrics are stored for short time in the finishing section.
All the delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics
diameter, buyer’s name, colour& considering other technical parameters.
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OTHERS STORE
There is a central store at HAMS WASHING AND DYEING LTD. In that store the various
types of forms, papers, stationary & other necessary goods are kept.
Chapter -10
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Cost analysis is a crucial step for any business organization, specially if it is a manufacturing company. Here cost analysis is done in conventional method. SAMPLE COST ANALYSIS
Issue Date: 10-07-2004 Buyer: Nassa – Pinacle Po-Style-Ref. : 21051 Type of Garments: Denim Long Pant Type of Wash: Enzyme/ Bleach/ Tint Quantity/ Machine: 60 PCs. Weight of Total Garments: 62 Kg.
Process Chemicals Quantity Temp Time Total
Desizing Caustic Soda 500 gm 12 /=Soda Ash 500 gm 60°C 15 min 7 /=Bio. D 400 gm 25 /=
Enzyme Wash Enzyme Powder 400 gm 152 /=Enzyme Liquid 200 gm 48 /=Anti Back Staining 200 gm 40°C 55-60 min 25 /=Acetic Acid 100 gm 7 /=Stone ½ bag 212 /=
Bleaching Bleaching (Japan) 500 gm 50°C 6-8 min 46 /=Neutral Wash Hypo Sulphide 500 gm Cold 5 min 9 /=
Peroxide H2O2 500 gm 50°C 10 min 18 /=Bio. D 100 gm 12 /=
Tinting Dir Brown GTL 20gm 14 /=Dir Yellow 2 gm 50°C 20 min 2 /=Salt 4 Kg 28 /=
Total Chemical Cost= 617/=Add 10% Wastage = 678/=
Per Dozen = 135.6/=Chemical Cost in USD/Doz = 2.47/=
Overhead Cost USD/Doz = 1.5/=Total Cost USD/Doz = 3.97/= ~ 4.00/=
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C o s t a n a l y s i s
Industrial attachment HAMS washing & dyeing Ltd
Profit USD/ Doz = 0.75/=
Final Cost USD/Doz = 4.75/=
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Chapter -11
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M a r k e t i n g A c t i v i t i e s
MARKETING:
Marketing plays a vital role in the field of displaying/showing the good criteria
of the products to the buyer & to communicate with the buyer .there about 30 people in the
marketing section of the industry .
Marketing Strategy :Marketing strategy is a very important factors to sale the products to the
buyers If the marketing strategy Is not so developed it will be very hard to reach the goal In
case of garments marketing the dealings with the buyer is a very important factor.In one
Washing & Dyeing Mainly senior marketing officers ,merchandisers & higher officials deal
with the buyer There are some fixed buyers of the industry. The buyers give their orders
continuously all over the year. The marketing officers & by both side understanding The rate
& the order quantity are fixed.
DUTIES & RESPONSIBILITIES OF MARKETING OFFICERS
Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A
marketing officer has some also other duties The main duties & responsibilities of a
marketing officer are given below :
• To prepare cost sheet by dealing with buyer .
• To take different steps by discussing with the high officials & merchandisers .
• To maintain a regular & good relationship between commercial officers &
merchandisers
• To maintain a regular communication with the buyers & buying houses .
• Communicate with the new buyers .
• Display the better criteria of the products .
Actually the responsibilities & duties of marketing officer begins from getting order of
buyer & ends after receiving goods by the buyer So he should be always smart energetic
& sincere.
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CONSUMER OF THE PRODUCT
HAMS Washing & Dyeing Ltd. is a 100% export oriented industry. All the goods
produce in this industry are exported to various country .
Product Label:
Product label differs from fabric to fabric. The product labels are prepared according to
the quality & the buyer requirements .
LOCAL MARKET
HAMS Washing & Dyeing Ltd is a 100% export oriented industry. All the goods
produced in this industry are exported into various foreign countries . So, goods are not
supplied into local market.
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 case of garments marketing the dealings with the buyer is a very important
factor .
In HAMS Washing & Dyeing Ltd. mainly senior marketing officers ,
merchandiser & higher officials deal with the buyer . There are some fixed buyers of
the industry. The buyers give their orders continuously all over the year . The
marketing officers & the merchandisers communicate with the buying houses to
collect the orders .
By both side understanding the rate & the order quantity are fixed .
REMARKS
HAMS Washing & Dyeing Ltd has a well learned marketing & merchandising team. They always communicate with the buyers HAMS Washing & Dyeing Ltd has some fixed buyers The marketing section also looks for the quality & quantity of buyers .
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Chapter-12
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Compliance
Compliance:Compliance is undertaking activities or establishing practices or policies in accordance with the requirements or expectations of an external body such as ILO,ISO,WARP,ETI etc and international buyer.
Benefits for business:
Putting company values into action. Enhancing company reputation. Improve company requirement. Better supply chain management and performance.
Benefits for workers
Educating the worker to avail a better life style. More awareness about quality Better job satisfaction will be developing.
Benefits for investor and customer: Identification of product made ethically Clear and credible assurance for ethical purchasing.
The return will be greater on less investmentCompliance with the law.
1. Fire Training:• At least 20 percent of factory personnel are trained in fire safety
and emergency evacuation.• Certificates and pictures of fire safety and emergency evacuation
training are maintained.• Factory holds fire emergency drills regularly.• For factories with high turnover, fire drills are held more frequently.• Factory trains new employees in fire drill procedures.
2. Fire alarm:• Factory has fire alarm system that is audible throughout entire facility.• Fire alarm has a distinct sound from other notice systems.• Alarm is tested regularly in coordination with fire drills.• Factory trains all new employees about alarm system sound
and procedures.
3. Emergency Exits:• Factory has at least two emergency exits per floor in buildings
with less than 1000 workers.• At least three exits exist per floor in buildings with more than 1,000 workers.
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• Factory ensures that the maximum travel distance to an emergency exit is200 feet or 60 meters for unsprinklered industrial buildings.
• Exit doors are at least 28 inches, 71 cm or 2.3 feet and have a width adequate for the number of persons it must accommodate.
• Exit doors are not unlocked and do not have locks that require special operation.• Door should open outwards.• Emergency signs are visible for 30m and use letters at least 18cm high.
Also, signs have bright colors are illuminated or have a photo luminescent front panel.
• Battery operated exit signs are checked regularly and batteries are replaced.
4. Emergency exit routes:
• As referenced above, factory posts diagrams/maps of emergency exit routes at various locations throughout the factory.
• All exit routes are at leastl 12cm wide.• Exit routes are not obstructed by equipment, materials, product,
etc. and are regularly checked.• Two exit routes exist on opposite sides of the factory.
5. Emergency lighting:• Factory has emergency lighting for all stair ways and where
needed on exit routes.• Lighting will last for at least 90 minutes.• Factory regularity checks test-button and replace batteries immediately if
needed on emergency lighting systems.
6. Electrical Wiring:• Electrical cords in the factory and dormitories are in good
condition and properlyencased to prevent shorting or fire.
• Electrical equipment is grounded to prevent injury and or fire.
• Electrical cords are not found in damp areas of in standing water. • Electrical wiring does not obstruct aisles unless they are securely taped to the
floor in a manner that does not create additional hazard
7. Lighting:• Factory uses a light meter to take periodic measurements of light
levels in the factory and keeps a record of light levels in various work areas.
• Factory has minimum illumination of 30 foot-candles (300 Lux) in work areas.• Factory has minimum illumination of 5 foot-candles (50 Lux) in corridors utilized as emergency routes.
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8. Ventilation:• Factory has adequate ventilation system in work areas where
chemicals are handled and where there are significant dusts or metal particles.
• Factory has ventilation system present in enclosed spaces where heat-generating equipment is operated.
9. Hazardous Chemicals or Materials:• Factory stores chemicals in separate area, which is equipped with
appropriate fire extinguishers, safety signs, and ventilation, instructions on handling or disposal, and personal protective equipment for personnel.
• Factory is familiar with all chemicals on site and the potential health effects.• Explore opportunities for hazardous chemical/material
minimization and document changes made
10. Medical Care:• Factory has a medical clinic available on-site or in close
proximity to address basic health and injury needs.• Factory has a system in place to address severe injuries.• Factory maintains copies of licenses for all applicable medical personnel.• A record of injuries is maintained at the factory to focus on how
injuries can be reduced.
11. First Aid:• Factory has one properly stocked first aid kit available for every 100 employees.• Factory maintain standard first aid kits that includes basic supplies, a
kit for blood borne pathogens protections, an emergency log, and a first aid guide in the local language.
• First aid stations are posted with a first aid sign.• The first aid kit is inspected regularly and restocked when needed.• Factory trains at least 10 percent of personnel in basic first aid.• Records are maintained for employees seeking first aid to
track injury/illness as well as remedy.
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Responsibilities & Duties Of Compliance Team of “ HAMS Washing and Dyeing Ltd ”
1. To floor visit at least thrice a day.2. To ensure workers fire safety, fire prevention, fire equipment, health & safety &
comfortable environment at work place.
3. To aware the workers about personal protective equipment.
4. To receive grievance, complain, demand & suggestion from the workers & after
receiving the issue discuss with related persons & local management immediately.
5. Try to find out emotional problem of an employee. The problem may be work
related or personal or family which affects his/her work performance.
6. To provided supportive counseling the sick worker for medicinal support on the
worker’s requests, complain or situational demand.
7. Try to make aware the existing workers about by company provided all facilities
8. Necessity of compliance.
9. To perform when social compliance audit.
10. To follow up aisle mark free, fire extinguisher no blocked, emergency exit free, fire
equipment free, stair free from carton in the floor
11. To check all production related register if any date mentioned of holiday or not.
12. To conduct orientation program for newly appointed worker.
13. Try to motivate & make them conversant with the company objective, rules &
regulations, buyer code of conduct & local laws.
14. To briefing the employees about all facilities of company, mandatory safety
instruction including all “do’s & Don’ts”.
15. To make aware the employees about leave procedure, maternity benefits, working
hour & over time system according to local laws.
16. To make aware the employees about personal health & hygiene, HIV/ AIDS/STD.
17. To conduct awareness programs the pregnant workers about safe motherhood
18. To ensure that no employee each maltreated mentally or physically abused & they
should be treated with respect & dignity.
19. And any other work assigned by the Management.
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Chapter-13
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ETP (EFFLUENT TREATMENT PLANT)
E T P - E ff l u e nt T r e a t m e nt p l ant
Capacity of ETP : 30,000 Litres
W o r k i ng P r o c e du r e :
We use different type of chemical, detergent, which is mixed with water & also mixed different types of fiber, that pollute our environment.
Wastewater contains both organic & inorganic chemical. The inorganic constituents are present in the carriage water & increase because of water use. In the case of industrial wastewater, inorganic are highly present & physio-chemical treatment has to be employed to maintain desirable water quantity.
We treatment the wastewater by using modern technology & decontaminate water & the drag out which is not harmful for our environment. The process by which wastewater treatment is occurred to obtain pure water to kept our environment free from pollution that process is known as ETP (Effluent Treatment Plant).
By using ETP we are getting the result of distillation water is 6”-8”.
W a s t e w a t er c ha m b e r : Firstly the waste water which is mixed with different types of chemical& detergent used for washing in the factory is stored in the waste water chamber.
E ff l u e n t Tran s f er P u mp : There is a Effluent transfer pump connected with this chamber for the treatment of waste water which is connected with three other chambers. Two of them are chemicals & another one is lime. Chemical pumps are called Alum pump & Poly Electrolyte pump & the Lime is called the waste water pump.
P l o y - E l ec t ro l y t e C h e m i c a l pu m p : The chemical pump which is poly electrolyte, in this chamber250gm poly electrolyte is mixed with 1000 litter of pure water.
Al u m C h e m i c a l pu m p : In the Alum chemical pump 5kg Alum is mixed with 1000 litter of pure water.
L i m e w a s t e w a t er pu m p : And in the Lime waste water pump 1kg lime is mixed with 100 litter of pure water.
After mixing with Alum & poly electrolyte & also mixing with lime the waste water is
purified. By flowing through these three pumps like Alum, Poly electrolyte & lime waste
water becomespurified, then this purified water is preserved in the preserver.
P r ese r v e r : the treated water which is preserved in the preserver pass through the treated water drain outline & the sediment is stored in the lower portion of the preserver.
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B l o w do w n c ha m b e r : There is a blow down line connected with the lower portion of the preserver 7 sediment pass through this blow down line to the blow down chamber. This blow down chamber is connected with the suction chamber with three valves.
S u c ti o n c ha m b e r : Sediment water from the blow down chamber comes to the suction chamber. After purifying in this chamber the purifying water flows to the drain out chamber & then discharge to the sewer
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Chapter-14
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C o n c l u s i o n
As a ready made garments washing and dyeing sector, HAMS WASHING &
DYEING LTD. is excellent among the industries of Bangladesh. Garments washing and
dyeing sector comprise varieties of machineries. It is still completely running position.
The Management system of the factory is quite well too. All the personnel of the
factory are co-operative and friendly with us. The security system is very good too.
In the training period, we were introduced as a member of the factory. For that, they
gave us all kind of facilities and scope for learning about washing and dyeing production and
machineries.
Above all the industrial attachment has given us new ideas for practical life.
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