liberty textile (project proposal)
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INDUS INSTITUTE OF HIGHER EDUCATION.
M.B.A – IV (EVENING)
• SUBJECT : BUSINESS RESEARCH
SUBMITTED TO: MR.
PROJECT:
RESEARCH PROPOSAL Proposal to study on Steam consumption
• SUBMITTED BY:
ZAHOOR AHMAD.
TABLE OF CONTENTS
Acknowledgment .............................................................................. .1Executive summary................................................................................2Problem statement ...................................................... 3Project goals.....................................................................................4Project time line.............................................................................5Motivation....................................................................5Back ground..............................................................................................6Introduction of Liberty Textile mills...........................................................................................6Types of energy used in textile industry..............................................................................................8Progress in relative field...............................................................................................10Importance of Boiler.......................................................................................13Identification of problems and its justification...........................................................................14Research method.....................................................................................15
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
ACKNOWLEDGEMENT:
“The hardest steel goes through the hottest furnace”
The same was the case with us. We faced many problems when we started the work
on Report. There was no any information about our research. But, we are greatly
thankful to Al Mighty Allah for enable us to get successfully through our
Responsibilities.
Very warm and special tanks to our respected teacher “Mr.Rana Tariq”
We also thank to
DYEING HOUSE MANAGER “BABAR KHAN”
ALL DYEING MANAGERS
ALL SENIOR MACHINE CHEMIST
And all whole technician of “LIBERTY TEXTILE MILLS”.
Who gives us a lot of information and pay full attention? And give real dedication
and devotion kindly for us.
Sir we thank full yours ability of extracting the very best out of us. For your
Patience and perseverance, and also for acknowledgement the efforts made by us
during the whole semester.
Thank you sir, God Bless You
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
EXECUTIVE SUMMARY
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
Problem Statement
The purpose of this proposal is to outline the need for a project that analyze the
Use of steam in textile industry. This project will seek answer the following
Question.
What is the use of steam in textile?
How can we reduce the steam consumption during process?
Is this step can able to cut down the cost of production?
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
PROJECT GOALS
The result of this project will be suggest to reduce the production cost by reducing
Consumption of steam by use of better steam management and technology.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
PROJECT TIME LINE
The project will be completed according following schedule,
Initial research complete 2nd Class
Follow up research 3rd Class
Interviews/Questioner Completed 4th To 8th Class
Analysis of date completed 9th and 10th Class
Final report draft 11t Class
Final presentation submit 12th Class
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
MOTIVATION:
Textile industry has a lion share in export of Pakistan, and these days in industry in
Troubles Because of high energy charges, in addition shortage of electricity , gas,
and water have depend the problem. Exports are also suffering due to high
Production cost then other competitor’s countries.
As we know that steam is one of the main source of dyeing and printing process and
Generate by gas and water through boiler.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
BACK GROUND:
This conservation of energy is an essential step we can all take towards overcoming
the mounting problem of the world wide energy crises and environment
degradation.
In particular, developing countries are interested to increase their awareness on the
inefficient power generation and energy usage in their countries. However, usually
only limited information sources on the rational use of energy are available,\.The
know-how on modern energy saving and conservation technologies should ,
therefore , be disseminated to governments and industrial managers, as well as to
Engineers and operators at the plant level in developing countries. It is particularly
important that they acquire practical knowledge of the currently available energy
conservation technologies and techniques.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
INTRODUCTION OF LIBERTY TEXTILE MILLS
Liberty Mills Limited, located in the industrial heart of Karachi, Pakistan,
was established in 1964. From humble beginning it is today one of the
largest textile processing and production unit in Karachi, Pakistan with a
production capacity of about 500,000 square meters of fabric per day. The
whole production is exported directly and indirectly to customers which
include vendors of internationally recognized brands, departmental stores
and mail order firms.
Liberty Mills Limited is an ISO 9001:2000, OE 100 and OEKO TEX Standard
100 Certified companies. Upgrading the quality of our products and
services, personnel, equipment and infrastructure is an ongoing feature of
our operation.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
TYPES OF ENERGY USED IN THE TEXTILE INDUSTRY
In general , energy in the textile industry is mostly used in the forms of
electricity, as a common power source for machinery, cooling and
temperature control system , lighting office equipment , etc; oil as a fuel for
boilers which generate steam; liquefied petroleum gas; coal ; and city gas.
Table 1 compares the energy consumption shares of various specialized
technical fields and it can be seen that energy consumption is relatively
high in the fields of dyeing and finishing ,fiber production , spinning,
weaving and clothing manufacturing.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
Specialized Technical Field
Fuel Electricity Total Share
Fiber production 32,551 21,498 54,049 21.0%
Spinning 3,224 44,262 47,480 18.4
Twisting 219 1,660 1,879 0.7
Textured-yam production 120 1,543 1,663 0.6
Weaving 4,467 24,848 29,315 11.4
Knitting 4,059 11,709 15,858 6.1
Dyeing 37,661 28,412 66,073 25.0
Clothing manufacturing 8,240 15,420 23,660 9.2
Others 5,959 12,000 17,959 7.0
Total 96,500 161,442 257,942 100.0
Note: Calculated from the Tabulated Industrial Statistics (Industry Volume)
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
In 90’s UNIDO organized a Regional Meeting on Energy
Consumption as well as an Export Group Meeting on Energy Conservation in small
and medium scale industries for Asian countries. During these meetings , it was
Brought out that, for some energy intensive industries , saving up to 10% could be
Achieved through basic housekeeping improvements,
Such as auditing and energy management. The rational use energy calls for a broad
Application of energy conservation technologies in the various industrial sector
Where energy is wasted. One of these energy intensive industrial sectors to be
Consider to improve efficiency through the introduction of modern energy
Conservation technologies is the textile industry.
“In the textile industry, appreciable amount of energy could be saved or conserved
By regulating the temperature in the steam pipes , adjusting the air/fuel ratio in the
boilers, and installing heat exchangers using warm waste water.”
Currently, UNIDO, with the financial support of Japanese Government, is carrying
out a regional programmed on the promotion and application of energy saving
Technologies in selected Asian developing countries. This program aims at
adopting
these innovative energy conservation technologies, to the conditions of develop
countries. In this programmed, we are considering that the transfer of these
technologies could be achieved throgh
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
A: Conducting surveys of energy usage and efficiency at the plant level.
B: Preparing manual on energy management and energy conservation / saving
Technologies, based on the findings of the above surveys;
C: Presenting and discussing the manual at seminars held for government
officials, Representatives of industries, plant managers and engineers;
D: Disseminating the manuals to other developing countries for their proper
utilization and application by the industrial sector.
INDUS INSTITUTE OF HIGHER EDUCATION PROJECT PROPOSAL
IMPORTANCE OF BOILER
As we know steam generate by boiler. Water, gas and electricity are the main raw
material of steam. If boiler is working efficiently there raw material use in very
Uncomely than generation of steam and if boiler is not work effecienlly their steam
Generation process become costly because heavy amount of gas and electricity use
During this process and amount of steam generate very pour. So, role of boiler and
Selection of boiler play a very important role in conservation of energy.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
PROBLEM IDENTIFICATION
During visit of “LIBERTY TEXTILE MILL” we discover that steam waist on
Following ways;
PROBLEM:
1: Steam lines are not in proper ways.
JUSTIFICATION:
If we re-arrange the steam lines we can reduce the wastage of steam.
PROBLEM:
2: High neglected attitude of machine staff concern steam line leakage.
JUSTIFICATION:
If machine staff inform about leakages it will be control.
PROBLEM:
3: Mechanical and electrical staff attitude also seems be very negative.
JUSTIFICATION: Maintenance staff works with loyalty. It can be helpful to minimize the leakage.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
PROBLEM:
4: Sensor and actuating valve often not working properly.
JUSTIFICATION: Sensor and actuating valve should be monitor because it control over all steam
consumption.
PROBLEM:
5: Fabric moisture is less than required moisture.
JUSTIFICATION: We can reduce steam consumption, if we put dryer temperature according
fabric.
PROBLEM:
6: Water chamber temperature also more than required temperature.
JUSTIFICATION:
We can also reduce steam consumption by putting water chamber temperature
according manually.
INDUS INSTITUTE OF HIGHER EDUCATION
PROJECT PROPOSAL
RESEARCH METHOD
We did our research by filling questionnaire to the employees of “LIBERTY
TEXTILES MILLS” (Dyeing unit) .We categories our questionnaire sample in 3
Categories. The Question mode of questionnaire is investigative.
1: TOP LEVEL MANAGEMENT
We get filled 7 questionnaire sample by dyeing house manager , dyeing manager,
And assistant dyeing managers.
2: MIDDLE LEVEL MANAGEMENT
We get filled 17 questionnaire sample by supervisor and senior machine chemist.
3: LOWER LEVEL MANAGEMENT
We get filled 16 questionnaire sample by machine chemist and assistant machine
Chemist.
Question -1
Ever the company study on the wastage of steam
Management Level All the Time
Some Time
Never No Idea
Top Management 7
Middle Management 13 4
Lower Management 4 8 1 3
Total 24 12 1 3
Conclusion : 60% All the time agreed that management study on wastage of steam while 30%
some time 2.5% never and 7.5% have no idea.
Question -3
Management is satisfied with the design of steam consumption system
Management Level All the Time
Some Time
Never No Idea
Top Management 1 5 1
Middle Management 4 12 1
Lower Management 2 9 5
Total 7 26 7
Conclusion : 65% employee believe that management some time satisfied with design of steam
consumption while 17.5 with all the time and 17.5 have no idea
Question - 4
Ever you realized that company need to redesign the system of streamlines or other areas where steam is in use
Management Level All the Time
Some Time
Never No Idea
Top Management 5 2
Middle Management 9 8 1
Lower Management 5 4 5
Total 19 14 1 5
Conclusuin : 47.5% employees belive that company realised to redesign the steam system while
35% belive with some time 2.5 realised never and 12.5% have no idea
Question -5
If company studded on it so, management introduced any system to reduce the consumption of system
Management Level All the Time
Some Time
Never No Idea
Top Management 5 2
Middle Management 11 6
Lower Management 4 11 1
Total 20 19 1
Conclusion : 50% belive that company improved system to reduce the consumption while 47.5
believe on some time 2.5 think never.
Question - 6
Have the system is implemented
Management Level All the Time
Some Time
Never No Idea
Top Management 5 2
Middle Management 13 4
Lower Management 6 8 1 1
Total 24 14 1 1
Conclusion : 60% employees believes that system have been implemented 35% says some time
2.5% think never and 2.5 have no idea
Question - 7
Interest of company to improve boiler efficiency in consultation with the consultants
Management Level All the Time
Some Time
Never No Idea
Top Management 7
Middle Management 5 5 7
Lower Management 3 13
Total 12 8 20
Conclusion : 50% have no idea about boiler efficiency while 30% believe all the time 20% believe
with some time.
Question - 8
Trend of management about training and development
Management Level All the Time
Some Time
Never No Idea
Top Management 4 3
Middle Management 3 14
Lower Management 16
Total 4 6 30
Conclusion : 10% says all the time 15% think some time75% have no idea
Question - 9
Management supplies of related material/literature to the machine staff about the use of new technology on steam
Management Level All the Time
Some Time
Never No Idea
Top Management 7
Middle Management 17
Lower Management 16
Total 30
Conclusion : 100% employees says no literature is being provided to machine staff
Question - 10
Machine staff is informed about less or excess stem consumption than production
Management Level All the Time
Some Time
Never No Idea
Top Management 7
Middle Management 17
Lower Management 16
Total 30
Conclusion : 100% employees believed never
Question -11
Logbook/history data is maintaining for individual machine on daily basis and it is shared with all concerned.
CONCLUSION: 45% says all the time, while 53% says some time
Question -12
Management LevelAll the Time
Some Time
Never No Idea
Top Management 7
Middle Management 7 10
Lower Management 4 12
Total 18 22
Appraisal or punishment system to staff is existing and implementing
CONCLUSION:97% employees says never know while only 2.5% says all the time.
Management LevelAll the Time
Some Time
Never No Idea
Top Management 7
Middle Management 1 16
Lower Management 16
Total 1 39
Question -13Company staff having technical skills
CONCLUSION: 72.5% all the time while 22.5% are some times.
Management LevelAll the Time
Some Time
Never No Idea
Top Management 7
Middle Management 12 5
Lower Management 10 4 1
Total 29 9 1
Question -14Machine staffs are aware about the moisture required for different fabric on different process.
CONCLUSION:40% says all the time,47.5% says some time,7.5%says never and 5%don’t know.
Management LevelAll the Time
Some Time
Never No Idea
Top Management 5 2
Middle Management 7 10
Lower Management 4 7 3 2
Total 16 19 3 2
Question -15
Machine staffs are aware about the temperature of different areas of machine required for different process.
CONCLUSION:97.5%employees agree to alla the time while 2.5% say never
Question -16
Management LevelAll the Time
Some Time
Never No Idea
Top Management 7
Middle Management 17
Lower Management 15 1
Total 39 1
Existing staff is capable to handle the issues and complaints about the steam leakages.
CONCLUSION: 97.5% employees agree to all the time and 2.5% says never.
Management LevelAll the Time
Some Time
Never No Idea
Top Management 7
Middle Management 17
Lower Management 15 1
Total 39 1
Question -17
Response of machine staff if any error is formed in parameters.
CONCLUSION:25% employee agree to all the time , while 75% says some time.
Question -18
Management LevelAll the Time
Some Time
Never No Idea
Top Management 7
Middle Management 4 13
Lower Management 6 10
Total 10 30
Yours efforts are apprized by the management for the process
CONCLUSION:12.5% says all the time , 25% says some time while 62.5% agree to never.
Question -19
Management LevelAll the Time
Some Time
Never No Idea
Top Management 4 2 1
Middle Management 1 6 10
Lower Management 2 14
Total 5 10 25
Supervisor’s trend for feed book of employee/machine staff how they are performing towards achieving the result expected
CONCLUSION:15%employee agree all the time , 65% say to some time while 20% says to never.
Question -20
Management LevelAll the Time
Some Time
Never No Idea
Top Management 3 3 1
Middle Management 2 14 1
Lower Management 1 9 6 3
Total 6 26 8 3
They monitor the safety valves
CONCLUSION: 47.5% employee agree to all the time 50% don’t know while 2.5% says never.
Management LevelAll the Time
Some Time
Never No Idea
Top Management 7
Middle Management 10 7
Lower Management 2 1 13
Total 19 1 20