kal printing final 2016
TRANSCRIPT
KAL PRINTING UNIT TECHNICAL PROFILE
Knit Asia Limited
Outline
• Space utilization
• Machine summary
• Capacity
• Organogram
• Production flowchart
• Buyer name
• Category of printing
• Quality defect trend
• Expose room
• Color kitchen
• Color sub store
• Stretching process
• Coating process
•Curing process•Basic area of improvement•My study & observation•Problem findings•Solving
KAL-Printing Section Space Utilization
Printing ( Sft )
Total Floor Area 8,250
2 nos Auto machine used @300sft 600 2 nos Manual table used @404sft 808Fusing Machine used 400
Office area+ color mixing room+ store used 1066 QA and others used 533
Total Head Count 65
Utility
Compressor Pre req 7 kg
Power Req (KW) 43.5
05/03/23
4
Mac
hine
Sum
mar
yKAL printing Unit -2 MC Summary (Shafipur)
SN
Present MC Specifications Present Machine Status
MC Using Model
Using Brand &
Made country
Machine SpecificationIn-Hand
Total MC
Out of Order MC
In-Hand Total
Usable MC
1 Auto printing Sportsman M&R
10 Head, 8-color Max Image size-20’’X20’’
Compressed air Req-100psi,Power req- 3.3KW
1 0 1
Auto printing Sportsman M&R
6 Head, 5-colorMax Image size-20’’X20’’
Compressed air Req-100psi,Power req- 3.9KW
1 0 1
2 Conveyer Dryer Sprint 2000 M&R
Power- 380V, 16amp, 3-phase, Manifold pre-3.2,
BTU/Hr-40000-300000 1 0 1
3 Exposer Table local local 11 pcs light tube 1 0 1
4 Pad Printing B-100 Inkcups
Ink cup size- 90mmImage size- 80mm
Speed one color- 720-2100(IPH)Power- 110V/10amp
Compressed air req- 80psi
1 0 1
Total 5 0 5
Printing Section: Capacity
Production Area Avg Capacity Total Daily Capacity
Table 02 Nos(one-color) 34,000 pcs/day44,000 pcs/day
Machine 02 nos (Multi-color) 10000 pcs/day
Month Production pcs
Sub-Con Pcs Remarks
January 214516February 160508March 186569April 185279May 133426June 516462July 669243August 782579September 373579October 349698
Printing Organogram
Sample coordinator
Expose Man DesignerColor Master
Supervisor Expose Assistant
Operator
Layer man
Dryer Man
Input-output man
QA InspectorColor
Assistant
Loader
Wash Man
Designation PresentManager 1
QA Officer 1Color master 1
Designer 1Asst. In-Charge 1
Supervisor 4QA Inspector 6Exposer Man 1
Operator 18Helper 31Total 65
Production Manager
QA OfficerPrint In-Charge
Printing production Flowchart
Design Making Price Quotation
Screen making & Expose design
Sample Development
Color Making
Sample submit
Sample Approval
Monthly Production Plan
Sample Making
Dyes & Chemical Requisition
Art Work Receive
Fabric Receive
Bulk Fabric Receive
Bulk Production Start
Bulk Production Delivery
05/03/23
Printing Production CapacityProduction (Pcs)
M/C or Table Production Pcs/hr/op
No of operators/
shiftHourly Daily@60% of
observed time Weekly Monthly
Printing Table-1 (One color) 240 5 1200 17,280 1,03,680 4,14,720
Printing Table-2(One color) 240 5 1200 17,280 1,03,680 4,14,720
Auto Machine-1(Multi color) 120 3 360 5,184 31,104 1,24,416
Auto Machine-2(Multi color) 120 3 360 5,184 31,104 1,24,416
Total Output 18 3,120 44,928 2,69,568 10,78,272
Buyer Name
1. LIDL2. ZARA3. MATALON4. UNDIZ5. DACATHOLON6. MORRISON7. PRIMARK8. KIK9. LPP10.MANGO11.BTR12.NOI SOULITION13.ARENA14.AEROPOSTALE15.K-MART16.US POLO17.WOOL WORTH18.JEAN FRITZ19.GKAY STATE20.C.V21.NEXT22.NEWYORKER23.CARTEX24.ZAZA25.SRG26.ADMIRAL27.ELLESSE28.FILA
Category of printing
Rubber DischargeSolventSemi-RubberFoilGlitterEmboss
(Puff) Plastisol
High density
Water/ Pigment Flock
Gel print
Reflective
Reactive
High density
Gel print
Photo print
Photo Print
Water base Rubber base
Foil Glitter base
PUFF Semi-Rubber
Plastisol Discharge
Quality defect trend in 2016 1. Spot(rubber and plastisol
base)2. Size & grading mistake3. Dirty(water base) 4. Crack (plastisol base)
Customer wise error / defects Buyer Problem type
1. LIDL 1. Spot, 2. Size-mistake, 3. Broken Print, 4. Color missing, 5. Color sticky, 6. Bundle mistake, 7. Print side
2. PRIMARK 1. Spot, 2. Size-mistake, 3. Bundle mistake, 4. Print side
3. UNDIZ 1. Spot, 2. Color Bleeding, 3. Color pass, 4. Print side
4. MATALAN 1. Spot, 2. Print side, 3. Grading Mistake, 4. Puff Uneven
5. ZARA 1. Spot, 2. size mistake, 3. color missing, 4. wrong placement
6. KIK 1. spot, 2. color crack, 3. shade variation, 4. gap
7. SRG 1. Spot
Customer wise error / defects Buyer Problem type
8. K-MART 1. Spot, 2. gap, 3. print crack, 4. dirty spot, 5. over lapping
9. MORRISON 1. Spot, 2. dirty, 3. print gap
10. DECATHOLAN 1. Spot, 2. gap, 3. uneven shade
11.MANGO 1. Spot, 2. size mistake
12. LPP 1. Spot, 2. color missing, 3. color gap
13. BTR 1. Spot, 2. color missing, 3. color crack
14. WOOL WORTH 1. Spot, 2. color missing, 3. gap, 4. print side
15. JEANS FIRTZ 1. Spot, 2. size mistake, 3. color missing
Expose RoomStrength
1. Skilled manpower2. Individual dedication to
their responsibility
Weakness
1. Need advanced exposer machine.
2. Damage light must be replaced.
3. Film should be kept in basket
4. Walls should be repaired and repainted
5. Window should be fully replaced by closed wall
6. Need advanced screen chemical attaching machine instead of manual system at present.
7. Sliding door should be placed
Damage exposer light
Open window
Film storage
Damage wall
Open door of exposer room should be replaced with sliding
dark glass door
Wash RoomStrength
Operator perfectly done the screen wash.
Weakness
1. Walls are dirty, need paint
2. Wash basin should be placed outside of the building, near drain,
3. Need high pressure nozzle to clean the screen,
4. Eye wash need to modify
Dirty exposer room
Dirty wash basin
Incorrect eye wash facility
Need High pressure nozzle
• Recommendation
Stretching machine
• Recommendation
Color KitchenStrength
1. color Master knowledge is good,
2. Quick and efficient work force
Weakness1. SOP to be developed by sample
preparation practical work , this can be done by recording the steps immediately after making the chemical mixture . Mixing ratio to be finalized by a team discussion and revalidation . Thus controlled SOP will be finalized.
2. Chemical handling process should be developed, should be introduce mixing machine instead of manual system.
3. Double door is needed
4. Walls should be painted
5. Unnecessary items should be cleaned from the room
6. Record keeping area not sufficient, need shelf,
7. Room should free of dust, need protection in top of the room from where dust are coming.
Color Chemical without Expire date
Dust in the color mixing room
Dirty behind the white cloth of the window
Damage light in the floor
Dirty wall in the color mixing room
Door exit blocked
Recommendation
1. Instead of colored box, we need to use transparent box.
2. Personal protective equipment must be use all time.
Existing Opaque color mixing box
Recommended Transparent color
mixing box
Existing Insufficient space for
record keeping
Recommended file keeping shelf
Recommended Color mixing machine
Existing Manual Color mixing
Color Sub StoreStrength
Chemical are keeping buyer wise.
Weakness
1. Unused basket should be removed from store
2. Remove cloths and make the room free from dust- need overhead cover to reduce dust
3. Weighing machine should be cleaned regularly
4. Use sliding door to reduce dust.
Damage light
Dirty in the upper wall area
Open door
Unused items
Recommendation
Existing weighing machine
Recommended clean with big table
Office AreaStrength
Skilled designer
Weakness
1. Need to repair broken chairs
2. Need shelf for keeping printing records
Damage Chair Need Shelf
Recommendation Need shelf for record keeping
Printing Table-1 & 2Strength
Samples as well as production is doing nicely.
Skilled workforce
Weakness
1. Broken glasses to be repaired or replaced to increase productivity.
2. Need standard racks for storing the screen.
3. Pattern should be kept in boxes and buyer wise systematically,
Broken Glasses
Existing racks to keep screen
Recommended rack
Existing pattern rack Recommended pattern rack
To increase productivity place one big and one
small panels in one table
Next development - One operator multi color can be make which will
reduce head count
Existing work procedure
Existing production table
Auto Printing Machine-1 & 2Strength
Machines are running nicely.
Advanced printing process can be done up to 10-color.
Weakness
1. One damage head should be repaired
2. Two flash dryer should be repaired
Damage flash dryer
Improper work procedure Standard procedure of working
Dryer machineStrength
Efficiency is okay.
Weakness
1. Need to repair belts.2. Speed controller need to
repair.
Damage dryer Belt
Improper work procedure
Damage speed controller
Recommendation Dryer machine belt and speed
controller need to be corrected as early as possible.
SampleStrength
Skilled workforce exist.
Weakness
1. Need expertise in printing sample.
2. Flock print technology need to developed in future.
Quality TableStrength
Skilled Quality inspector
Weakness Reporting system should be improved.
Recommendation Daily quality report should be checked
and take corrective actions to reduce defect.
Idle Pad printing machine
Pad Printing machineStrength
modern high speed quality printing is possible
Weakness Need to commissioning the machine
Printing Section Picture tour
Knit Asia Limited
Operators taking lunch in the production floor
Damage hanging fan
Flammable material in production floor
Flammable and toxic chemical use in production
floor
Mosquito net on M&R machine
Store material must be removed from printing section
Water drinking area
Knit Asia Limited
Unclean drinking water area
Stretching Process Findings & Standard
Stretching Process Findings & Standard
Coating Process Findings & Standard
Coating Process Findings & Standard
Coating Process Findings & Standard
Curing Process Findings & Standard
Machines and other necessary instrument for Printing Item name
QuantityEstimated price
1. Exposer machine 1 pc USD$5,000
2. High pressure hose pipe 10 pc
3. Color mixing machine 1 pc USD$2,000
4. Record keeping shelf 4 pcs USD$100X4= USE$400
5. Screen making instrument 2 pc
6. Transparent boxes for ink 500 pcs
7. Large Basket for film keeping(36X21X50cm) 20 pcs USD$1X20= USD$20
8. Sliding door 3 pcs
9. Temporary roof 3 rooms
10. Recommended screen keeping racks 10 pcs
11. Recommended pattern keeping rack 3 pcs
12. Multi color manual rotating table 3 pcs USD$1200X3 = USD$3600
13. Repair of Printing table 90 ft USED$5X90 = USD$450
Basic Area Of Improvement with Urgency Exposer & wash room 1.Damage lights on exposer machine to be replaced
Color Mixing room 1.Uniform for chemical handling operators.2.SOP composition of sample developing chemical should be written immediately after making chemical.3.Record keeping area not sufficient, need shelf,4.Room should free of dust, need protection in top of the room where dust are coming.
Printing chemical Store room 1.Training & development with practical sessions 2.MSDS for all chemical MUST hang on store .3.Other section item remove from Printing section.
Production & development1.Daily production report(mandatory) 2.Daily Quality report (Mandatory)3.Daily production target need to fix one day before.4.Screen making process should be develop for correct screen tension.5.Screen keeping racks to be increase. 6.Training for the operators to develop skill.7.Printing table MUST be repaired to increase productivity.
Production on table 1.Hourly target and production monitor by management immediately. This is one of the root cause of low productivity.
Auto printing machine and dryer 1.Immediately trained up operators or recruit because 6000 pcs/day production loss due to skilled operator shortage.2.Repair Dryer machine’s speed controller.
Attached technical appendix
My study & observation
Human Resource Accounting(HRA)Type of employees Persons Grade Avg. gross Education Avg. Age Exprence District
Sr. Machine OP. 1 G-03 7362 V 27 8 Tangail
Operator & QI 16 G-04 6939 VIII -HSC 27 4 North bengal
Jr. Operator 1 G-05 6042 V 34 3 North bengal
General Operator 6 G-06 6132 V 31 5 Tangail
Helper 29 G-07 5540 V 38 3 North bengal
Staff (Supervisor) 5 MGT 12792 VII 28 11 Tangail
Shafiqul Islam 1 MGT 55000 BSS (Pass) 40 11 Tangail
Md. Zillur Rahman 1 MGT 29000 BA (Pass) 37 5 Nogaon
Md. Nazmul Hoque (Emon) 1 MGT 22000 HSC 37 1 Jamalpur
Saiful Islam 1 MGT 29705 VIII 27 11 Tangail
Ataur Rahman 1 MGT 20500 SSC 38 4 Jamalpur
Loader 2 S-04 6940 V 38 4 North bengal 65 8553 34 6
Overall Process Flowchart
Design Published
Preparation of the Screen Board (Hand Made)
Expose Design (Traditional)
Art Film
Using Hand Coated
Prepare Screen Design (Performing Screen Wash by normal water Flow)
Color Kitchen (Mixing the Color
Manually)
Printing Process (Buyer’s
Requirement)
Auto Printing (Auto Machine)
Manual Printing (Handling by Manpower)
Steps for Operation
• Step 1 : Preparation of the Screen Board• Step 2 : Coating Process• Step 3 : Design Process• Step 4 : Color Kitchen• Step 5 : Criteria of Printing• Step 6 : Quality Assurance
Stepwise Process Flowchart
Making the Screen Board
Frame making
New frame Old frame Old machine frame- reuse for 2-3 times
Old screen coated by bar remover
Wash by water flow
Dry
Remove the old mesh
Clean the frame
Dry
Adhesive on the frame & dry
Clean the frame
Dry
Adhesive on the frame & dry
Put the mesh on the frame
Stretch the mesh
Adhesive on the frame & dry
Cut the outside of mesh
Ready to use
Design Process
Color Room
No
Yes
Received Artwork
Check color standard & chemical
Check fabric quality
Select the color for required fabric
Mix the color
Prepare the color combination
Check color shade on fabric
Is it ok? Adjust the recipe
Keep record of mixing recipe
Send to print sample
Color Room
Problem Analysis
• Cause – Effect Analysis ( Fish-Bone Diagram )• Pareto Chart Analysis• Root – Cause Analysis
Cause – Effect Analysis
MAN MACHINE
METHODS MATERIAL MANAGEMENT
Lack of Decision
Lack of System
Not Clean Properly
Lack of Observation
Random Screen Preparation
Improper Machine Setup
Lack of Preventive Maintenance
Unavailability of Proper Machine
Dryer Belt Damage Compressor Failure
Improper Power Sourcing
Frequent Design Change
Improper Mesh Selection
Scheduling Problem
Unknown Production Time
Not Proper Dryer
Improper Planning
Dot Missing
Damaged Screen
Curved Frame
Color Matching Problem
Lack of Sufficient Useable Material
Poor Conservation of Color Ignorance Problem
Improper Training
Lack of Worker Motivation
Frequent Order Change
Pareto Chart AnalysisIdentification of Problem(1st – 13th December, 2016)
Problem Frequency Cumulative cumulative %
Screen not keeping proper place 9 9 12.0
Not proper screen tension 7 16 21.33
Random screen preparation 10 26 34.67
Frame curved 1 27 36.0
Wrong color combination 6 33 44.0
Wrong mesh selection 3 36 48.0
Serial mistake / Design mistake 3 39 52.0
Not proper gumming 2 41 54.67
Design revise 6 47 62.67
Not proper drying 17 64 85.33
Screen shot without pattern 1 65 86.67
Lack of decisions 6 71 94.67
Others 4 75 100
Pareto Chart Analysis
Solving & Improvements
Improvements SN
Price ref 2 USD
Thailand
Items need to purchase to remove the CAP 1 Price ref 1 USD
china
1 Stretching machine,Mass binding machine
1 5000 7400
2 Tension meter, Screen tension checking machine 1 200 750
3 Automatic coating Machine, Screen coated machine 1 16000 20250
4 High pressure hose jet 10 200 5 Color mixing machine small ( 10 liter ) 1 2000
6 Shelf for file, transparent boxes for ink , large basket for film keeping( 36x21x50 cm),
Lot 400
7 Multi color manual rotating table 3 3600 8 Sliding door , roof 3 sets 500 9. Screen keeping racks, pattern keeping rack , Lot 600
10. Repair of printing table ( emergency ) with tempered glass 90 ft 450
11. Expose Machine/unit with dryer, Design expose and coated frame rack
550013280
12. Installation and commissioning, painting , lighting , decoration Lot 1000
13. Conveyer belt repair of Dryer machine 1 1000
14. Digital Thickness meter 1 200
Grand total 36650 USD , 29 lacs BDT
Miscellaneous Improvements
• Screen wash table• All walls are painted by white color (lime stone)• Screen frame rack- large (Buyer wise production)• Notice board• Multiple color for entrance wall• Attached (color sub store + color kitchen) & extend
to ceiling with A/C room• Rack arrangement in color kitchen• Expose room should have dark environment(no
window is needed)
Miscellaneous Improvements
• Need sample table• Worker requirement – (2 sample man+ 3 helper);
Auto machine– (2 operator+6 helper); Color kitchen – (1 helper)