Professional Documents
Culture Documents
UNIVERSITY
OF
TEXTILES
Mohammad Sultan
Lecturer,Dept of Yarn Manufacturing
Engineering
Bangladesh University Of Textiles
Submitted by
NAME
Yasin Al Faysal
Md: Abdul Hamid
STUDENT ID
2011-1-100
2011-1-261
ACKNOWLEDGEMENT
We are very fortunate that we were well-supported and cooperated at
all points during our industrial attachment training in R.K.
SPINNING MILLS LIMITED. It is high time to express our gratitude
to all related with our training session. First of all we are grateful to
Prof. Mashud Ahmed(Vice Chancellor,Bangladesh University of
Textiles).Our heartiest thanks goes to our honorable teacher Dr.
Hosne Ara Begum (Associate Professor and Head, Department of
Yarn Manufacturing Engineering) , Md. Reajul Islam (Lecturer)
along with supervisor Md Sultan(Lecturer) for arranging our mill
training with convenience. We also express our heartiest gratitude to
our training supervisors B.M Selim Ahmed (QM), Keshob
Mazumder (Sr.QC).Their thoughtful advices, logical directions and
relentless efforts have made it possible to implement the training
faithfully.
Md Fazlul Hoque,Assistant General Manager of the R.K.
SPINNING MILLS LTD. who gave us the opportunity to complete
our industrial training with great success is remembered with honor
over here. Special thanks goes to Mr. Nuruzzaman, Manager
(Production) as well as supervising officer of our training session,
who arranged the training session with a systematic schedule and
provide us all sort of help.
Finally we place our sincere acknowledgement to all those officers,
staffs and technicians for their cordial behavior and helpful support to
gather the necessary information during the training period.
CONTENTS
Chapter1
1.1
1.2
1.c
1.d
1.e
1.f
1.g
1.h
1.i
Chapter2
2.a
2.b
2.c
2.d
2.e
2.f
2.g
Chapter3
3.a
3.b
3.c
3.d
3.e
3.f
3.g
3.h
3.i
3.j
Chapter4
4.a
4.b
PROJECT DESCRIPTION
Pag
Company Profile
Shift Classification
Machines in the mill
Origin of the machines, tools and
equipments
Product mix
Production Capacity
Different Departments
Physical infrastructures
Stuff facilities
MANPOWER MANAGEMENT
5
5
6
6
Manpower setup
Officers and stuffs
Workers rights and privileges
Point of compliances
Major duties of production officer
Nature and scope
Management Information system{MIS}
MACHINE DESCRIPTION
6
6
6
7
7
4.c
4.d
Chapter5
5.a
5.b
5.c
5.d
5.e
Chapter6
6.a
6.b
Chapter7
7.a
7.b
7.c
7.d
7.e
Chapter8
8.a
8.b
8.c
8.d
8.e
8.f
8.g
8.h
Chapter9
9.a
9.b
9.c
Chapter10
10.a
10.b
10.c
Chapter-
Units
Power generator
A/c plant
Chiller
Compressor
Fire fighting system
Power supply and consumption
Humidification plant
STORE AND INVENTORY
CONTROL
Raw Materials
Finished yarn
Engineering stocks
COST ANALYSIS
Types of cost
Product cost
Formula of various cost
MARKETING ACTIVITIES
4
11
Brand name,Buyers of the
products,competitors
CONCLUSION
Chapter12
Chapter-1
PROJECT DESCRIPTION
R.K. Spinning Mills limited
1.1 Company Profile:
Production Start
Spinning System
Capacity
100 Acres
Production/day
80%
Head office
:
:
:
6 am to 2 pm
2 pm to 10 pm
10 pm to 6 am
= 02
= 22
= 14
= 11
= 45
= 12
= 01
Brand:TRUTZSCHLER
Brand:TRUTZSCHLER
Brand:TOYOTA
Brand: TOYOTA
Brand:TOYOTA
Brand:MURATEC
Brand:CONTEXXOR
Japan
China
Germany &
Switzerland
: Carded yarn.
: Under Construction.
Total spindle
45000 R.K.
18000 A.B.R
Count range
Ne 20 to 40
Production capacity(Tons/day)
24
10
Production Department
Quality control and assurance department
Maintenance department
Utility department
Power generation department
Store Department
Security Department
Chapter-2
MANPOWER
MANAGEMENT
2.1 Manpower setup:
Name of department
600
22
50
672
318
990
62
63
21
146
SALARIES
1
2
3
4
5
5000
4500
4200
4000
3800
Nil
Nil
Nil
Nil
Nil
Free
Free
Free
Free
Free
TRANSPORT
MONEY
Nil
Nil
Nil
Nil
Nil
TOTAL
5000
4500
4200
4000
3800
7
6
7
8
9
10
3500
3100
2700
2300
1600
Nil
Nil
Nil
Nil
Nil
Free
Free
Free
Free
Free
Nil
Nil
Nil
Nil
Nil
3500
3100
2700
2300
1600
Total Salaries=Main Salaries +House rent money+ Treatment money+ Transport money.
Main salaries X 2
03. Overtime per hour=
26 days X 8 hours
= 10tk
04. Salaries and wages should be paid= within 7th days for the next month.
05. Working schedule:
a) General shift
b) A shift
c) B shift
e) Working hour
f) Over time
g) Weekly holyday
06. Holiday:
a) For occasion
b) Normal holiday
c) Vacation for illness
d) Weekly holiday
25. To check the production report prepared by assistant officer at the end of the shift. If
production isnt achieved as per target create pressure on worker.
26. At last hand over the shift with all information to the coming shift and leave the
section.
PURPOSE:
Territory:
Environment:
Production officer has to work under huge stress. He has to work in acute heat under
physical and mental pressure. Also he has to work in acute heat all the year round.
Tasks:
a) Areas for development
Responsible for training the production people to get maximum and quality output
from them.
b) Control
He has to control the production and the people according to the plan to get the
optimum efficiency.
c) Organizing
He watches over the process of spinning and introduces required system it needed for
quality produced during spinning.
d) Re-viewing
Production officer review the activities of shift in charge and supervisors every month
according to the production manager order.
e) Planning
Production officer has to plan in all the sections for the smooth flow of production. He
has to distribute the work of the worker for balancing their work.
f) Administration
10
He checks daily and monthly production report including reprocess of dyeing section
as well as the daily production report.
g) Leadership
He made the worker to give their best by inspiring and motivating. He commit
himself to the company and faster that same kind of commitment in his followers. He knows
their strengths, weakness, hope and goals. He demonstrates strength of character by their
word and actions.
h) Management contact
The jobholder consults with production manager in matter of production planning and
work distribution of the people. He also consults with quality assurance manager in case of
quality falls as well as the production quality for the individual buyers.
11
Chapter-3
MACHINE DESCRIPTION
Layout of Ring Spinning Unit
12
:1
: A-11
: Trutzschler
: 2005
: Germany
: 12m/min
: 1700mm
: 50-60 Hz
: 110V~400V
: 1800kg/hr (in 1 assortment)
: cotton
:1
: B-11
: Trutzschler
: 2005
: Germany
:5
14
:8
: 50~60Hz
: 110V~400V
Production
: 1000kg
:2
: B-70
: Trutzschler
: 2005
: Germany
: 50Hz
: 415V
: Up to800kg/hr
: cotton
: Six
: 350-400kg
: 1200mm
: 7700mm
: 1510mm
:2
: B-60
: Trutzschler
: 2002/2005
: Germany
: 50Hz
: 400V
: 600kg/hr
: cotton
: 1.0
: 1200mm
: 400mm dia
: 500 to 1300 rpm
:1
15
Integrated Mixer(MI 6)
Cleanomat(CLC-1)
Foreign Part Separatore(SFP)
Cleaning intensity:
Range: 1to 10
std. R.H. is a must .As auto mixing is available, a proper mixing and opening of material is
obtained. The overall performance of the Blow Room is good
3.2.1Introduction:
Carding is the heart of spinning .The card line available in is equipped with chute feed
system,high speed machines suitable for constant production at a high rate. In order to
produce both card and combed yarn simultaneously the card line is divided in to two parts
including DK903 and TC03
17
Particulars obtained:
Total no of machines
Output
: 22
: card sliver
Specification:
Model
Manufacturer
Year of manufacturing
Country of origin
Production capacity
Sliver weight
Flat speed
Sliver length per can
Sliver hank
No of licker in
Licker in speed
Cylinder dia
Cylinder rpm
No of flat
Machine height
Machine weight
Total draft
Opening roller speed
Delivery speed
Can dia
Can height
Can content
: TC-03
: Trutzschler
: 2005
: Germany
: 150m/min (variation)
: 92.5 grs/yd
: 0.33 m/min
: 6870m
: 0.11 Ne
: 03
: 1904rpm
: 51 inch
: 850
: 79(total), 24(in action), 55(out of action).
: 1845mm
: 6200kg (without can coiler)
: 109
: 837rpm
: 254m/min
: 36 inch
: 1200mm
: 45kg
Feeding zone.
Cleaning zone. (Taker - in)
Carding zone.
Sliver formation.
18
: 04
Specification:
Model
: DX-8
Manufacturer
Year of manufacturing
Country of origin
Drafting System
Doubling
Sliver length per can
Delivery speed
Drafting zone pressure control
Cot roller dia
Feed sliver weight
Delivery sliver weight
: Toyota
: 2005
: Japan
: 3 over 3
:6
: 5000m
: 700m/min
: Hard pressure
: 38mm
: 75grain/yard
: 75grains/yard
: 7
Specification:
Model
Manufacturer
Year of manufacturing
Country of origin
Drafting system
Doubling
Delivery speed
Can capacity
Draft range
:DX-10
: Toyota
: 2005
: Japan
: 4 over 3
: 6(maximum 8)
: 560 rpm
: 2500m
: 5.17-6.83
20
Lap Former
Specification:
No. of m/c
Company
Manufacturing Year
Country of origin
Model no.
No. of doubling
Delivery speed
Drafting system
Front roller dia
Back roller dia
Lap dia
Delivery length
Lap weight
Lap width
Spool dia
Top roller hardness
:02
: Rieter
:2005
: Switzerland
:E-32
:26 (maxm -28)
:120 m/min
:3 over 3
:39 mm
:32 mm
:650 mm (maxm)
:230 mm
:20 kg
:300 mm
:200 mm
:83 shore
3.5 Comber
21
Fig: Comber
Comber
Manufacturer
:RIETER
Country of origin
:Switzerland
Mode
:E-65
No of m/c
:10
No of head
:8
Delivery speed
:345-450 nips/min
M/C efficiency
:80-90%
Drafting system
:3 over 3
Can size
:(25 mm*600 mm*1200 mm)
Feed/nip
:4.7 mm
Noil%
:8-25%
Auto stop motion
: Yes
Auto doffing
: Yes
Lap dia
550 mm
Lap length
230 mm
Lap weight
:80 gm/m
Spool dia
:200 mm
Problem indicating lamp system: Yes
Delivery per m/c
One
Roller dia:
Top
Top
Bottom
Bottom
24.5 mm
24.5 mm
25 mm
25 mm
o Front-35 mm
o Middle-27 mm
o Back-27 mm
Total draft:9.12-25.12
Signal system: Yellow(Can change)
Roller hardness:Front-76,middle-80,back-80 (shore)
Roller gauge:
Front to middle: 41 mm
Middle to back: 44mm
Power consumption for comber:3.79kw
23
Particulars Obtained:
No of simplex
: 12
Specification:
Model
Manufacturer
Year of manufacturing
Country of origin
Drafting system
Sliver hank
Drafting roller dia
Bottom apron thickness
Top apron length
No of Spindle
Bobbin contain
Flyer revolution
Bobbin length
Pressure Arm: Model PK- 1500
:FL-100
: Toyota
: 2004
: Japan
: 4 Over 4
: .7-10 .5
: 28.5 mm
: 1.4 mm
: 37 mm
: 120
: 120
: 1180 rpm
: 2054m
Meanings
For roving breakage
For doffing
For sliver breakage
Auto stop indication by light
24
Particulars obtained:
Number of ring frame
: 45
Machine specification:
Model
Manufacturer
Year of manufacturing
Country of origin
Spindle speed
No of spindle per machine
Drafting system
Ring cup dia
Pneumatic suction
:RX-10
: Toyota
: 2005
: Japan
: 20000 r.p.m
: 1004
: 3 over 3
: 40 mm
: Yes
25
: 14 lbs
Apron brand
Top apron origin
Top apron size
:Accotex
: Kureha, Japan
: (37*27.8*1.0) mm
: Accotex, Germany
:( 36.9*30*1.1) mm
(Length x Width x Thickness)
: Precitex, India
: (19*30*28) mm
: c type
Yarn count(Ne)
20
24
26
30
34
Roller dia:
Front roller
Middle roller
Back roller
: 27 mm
: 27 mm
: 27 mm
Roller pressure:
Back roller
Middle roller
Front roller
: 2-2.3 bar
: 2-2.3 bar
: 2-2.3 bar
3.8Winding section
Particulars obtained:
No. of machines
: 12
Machine specification:
Model
Manufacturer
Year of manufacturing
Country of origin
No of drums per machine
Speed range
Groups of per machine
Package length
Package mass
: Savio
: 2007
: Italy
: 64
: 800~2000 m/min
: Max 4
: 25000 m
: 2.5 Kg
Electronic clearer:
The electronic clearer is a standard feature of the Autoconer but is not made by SAVIO.
Information on functions, setting and operation can be obtained from the respective
manufacturers Uster-Quantum2 and Loepfe.
:2
Machine specification:
Model
Rotor model
Rotor Dia
Rotor Speed
Rotor angle
Rotor groove dia
Rotor groove angle
Rotor bearing
Naval
No of Head
Opening roller dia
Opening roller speed
: RIETER-BT-903
: A22-R-CHAH
: 40/48 mm
: 65000rpm
: 45 degree
: 51,41 mm
: 45 degree
: Brand-kinex,RD(slovakia)
Model no.73-1-50
: Ribbed type(ceramic),Model:CR7-CH
: 192
: 74mm
: 7000rpm
Chapter-4
RAW MATERIALS
28
The factory has used the following cottons in the past years:
Serial no
Country of origin
Micronaire
01
Australia
4.58
02
USA
4.63
03
ZIMBABWE
4.18
04
UGANDA
4.1
05
INDIA
4.8
06
UZBEKISTAN
4.5
Australia
India
CIS
Uganda
1.5
.75
.90
1
Country
Cotton Corporation
Cotton Club
Queensland Cotton
OLAM
GHANDHI Cotton
Bangladesh
Bangladesh
Australia
Singapore
India
Chapter-5
30
Yarn
count
Roving
hank
Total
draft
Break
draft
TPI
Spacer
color
Space
mm
Carded
20
28
30
40
50
0.70
0.70
0.07
1.25
1.25
29.16
40.02
42.30
54.80
40.55
1.19
1.19
1.19
1.19
1.19
19.51
20.15
20.24
23.60
30.81
White
Cream
Cream
Chocolate
Chocolate
3.75
3.00
3.00
2.50
2.50
Trav
eler
No
01
2/0
2/0
4/0
6/0
Spee
d
14000
14000
14500
14000
15500
Y.T.
factor
Cops
filling
mm
4.32
4.23
3.66
3.69
4.32
43
45
45
44
50
Total spindles
45000
18000 (ABR)
Count range
10Ne to 50Ne
10Ne to 50Ne
Production capacity
22 Tons/day
The colour grade comes into consideration.colour of cotton can be the followings
White
Light spotted
31
Spotted
Yellowish
Tinged
Mainly to have good end product white,light spotted and rarely spotted are used.then i will
have to consider the maturity of fibres and check out if there is any kind of dead fibres in
it.then the strength of the fibres should also be checked.the short fibre index is also an
important fact.it should also be taken care of.
So these are the facts i will have to consider for going into a successful bale management for
consistent quality.Here i have made a bale management report for 33 bales given in the
below.
Step 1 :Bales provided by the vendor, are received in the plant, and identification no. is given
on each bale, sample is taken from each of the bale for testing, a number is added to each
similar to each bales. The bales are sackedin the store house.
Step 2 :Then 100% of the bale samples are tested on the HVI machine.
Step 3 : A status report is prepared based on MIC value of the tested sample.
Step 4 :Range of MIC values are selected for specific count of yarn. Generally it is formed
4.0 to 4.5
Step 5 :Production department prepares a table for the bales of similar category to be mixed.
Step 6 :Bales are then transferred to the blow room line, places horizontally on the mouth of
bale plucker.
1
A=1
4.2
B=4
4.3
C=7
4.4
D=8
4.5
E=6
4.6
F=4
4.7
H=2
4.8
L=1
4.9
10
11
Bale weight
Suppliers Bale No.
CIS Ronda.
CIS pervi.
American pima
Sudan
Zambian
Mixing man
Cleaning man
A.P.O
Total
: 04
: 02
: 01
:07
Type
Price
Source
Annual requirement
: CIS
: 60 to 85 cents/ Ib
: Uzbekistan, Tajikistan
: (95 X 365) bales.
33
Winding
Chapter-6
Quality Assurance
System
6.1 QUALITY ASSURANCE :
Quality Control
Department
OFF LINE
ROUTINE TEST
ON
LINE
: WIRA
: 5-SKRM-36
: UK
: To measure the length of yarn.
.
6.2.2 Yarn Strength Tester:
Manufacturer
Model
Country
Function
: PREMIER
: Tensomaxx 7000
: India
: To measure the RKM of yarn.
: USTER
: Premier art
: Switzerland
: Determination of
Micronaire Value
Color
Trash %
Length
34
Strength
Uniformity
Elongation
Moisture regain %
: USTER
: AFIS PRO 2
: Switzerland
: Determination of raw cottons nep, Trash,Maturity ratio.
: Determination of sliver neps, Trash.
: USTER
: Uster Tester 7000
: India
: Determination of the following faults in the
Imperfection (Thick, Thin, Neps)
Unevenness ( U %, CV% & Diagram)
Hairiness & CV% of hairiness.
3.57
3.69
3.91
3.80
3.74
CVm %
4.48
4.61
4.92
4.75
4.69
CVm
%{1m}
1.86
1.80
1.57
1.81
1.71
CVm
%{3m}
1.11
1.04
1.06
1.36
1.14
index
2.89
2.98
3.18
3.07
3.03
Rel cnt
%
1.8
1.1
-1.1
-1.7
0.0
<5
For Yarn:
(Pkg from Auto coner)
Nr
U
%
CVm
%
Index
1/1
1/2
Thin
-50%
/km
0.0
10.0
Thick
+50
%
/km
112.5
117.5
Neps H
+200
%
/km
435.0 8.48
475.0 9.04
sh
Rel
Cnt
%
1.93
2.09
.7
-0.8
35
2/1
2/2
Mean
CV
Max
Min
USP01
0.0
2.5
301
1.77
1.77
1.89
-1.5
1.6
0.0
10.0
0.0
<5
9.04
7.95
73
1.6
-1.5
: WIRA
: DE 5
: UK
: Determination of yarn T.P.I.
Raw cotton is tested from HVI spectrum m/c 100% raw cotton is tested here.
Carded sliver & Draw frame and combed sliver are also tested here by Uster
evenness tester.
Roving & Yarn are tested by Uster evenness tester & Uster AFIS Pro.
Yarn from Winding m/c are tested here randomly.
Strength of yarn is tested by single yarn strength tester.
6.4 Comments:
In R.K. spinning Mills Ltd, they have modern and time quality machineries for production
and then quality control department is strong. They maintain a good quality of production by
process control. I came to know that they are bringing modern testing machinery like Uster,
HVI etc. for high quality control.
36
Chapter-7
Maintenance
7.1.1 Maintenance points in blow room:
MACHINE NAME
Blendomat
Maxi-flo
Securomat
MPM
MAINTENANCE POINTS
Chasis
Take off Unit
Take off roller
WORK TO BE DONE
Clean properly by compressed air.
Clean properly by compressed air.
Check & clean properly by compressed
air.
Retainer roller
Check & clean properly by compressed
air.
Conveyor belt
Check & clean properly by compressed
air.
Sensor
Lenses to be cleaned by soft cloth.
Control cabinet
Clean by skilled person.
Cleaning cylinder
Properly clean & check any damage.
Cleaning grid
Check any damage & position.
Airlock cylinder
Check & clean properly.
Gear and drive motor
Clean properly.
Sensor
Lenses to be cleaned by soft cloth.
Chamber
Clean properly by compressed air.
Upright lattice
Properly clean & check any damage.
Blending roller
Properly clean & check any damage.
Take off roller
Properly clean & check any damage.
Sensor
Lenses to be cleaned by soft cloth.
V-belt and pulley
Clean, check belt & chain tension.
Lamellar chute
Cleaned by soft cloth &compressed air.
Perforated roller
Check & clean properly by compressed
air.
Opening
and
cleaning Properly clean & check any damage.
cylinder
37
Clenomat
Waste opener B 2/5
Mono cylinder
B 4/1
Mix bale opener
B
Cleaning grid
Gear and drive motor
Sensor
Tube Light
CCD camera
Sensor
Upright lattice
V-belt and pulley
Beater
Upright lattice
V-belt and pulley
Sensor
:After 7 to 10 days
: From 8 a.m. to 5 p.m.
:3
:7
Schedule maintenance
Preventive maintenance
7.1.6Maintenance procedure:
At the beginning of the maintenance operation, all the covers of the machines are
opened and the machine is cleaned with a cloth internallythis is called as general cleaning.
Inside the machine the conveyor belt tension (if present) is checked and wooden lattice is also
cleaned and conveyor belt is cleaned if needed. Jam in the two sides of spiked lattice is
opened and under cover of spiked lattice is opened and cleaned. Jam in the sides of the
bearing house of evener roller, cleaner roller with oils orlubricants as instructed by the
manufacturer. China box is checked and jamis cleaned if necessary. M/C parts are checked
conveniently and or changed if necessary.
Blendomat
: Every month
Action
Inspect for sign of damage
Ensure clean
Inspect and clean cowl plate grille
Check condition
Ensure clean
Action
Check condition of the teeth
V-belt drive check
Duplex drive chain-chain tension
Duplex drive chain-chain tension
Drive belt check tension
: One year
Action
Replenish lubricant using shell
Alvania-3 or equipment
Do
Action
Duplex drive chain-chain tension
Duplex drive chain lubricant using, gear box
check oil levels and replenish if necessary.
Duplex drive chain to roller lubricating used.
39
MAINTENANCE POINTS
WORK TO BE DONE
Aero feed
Opening roller
Lap roller
Feed roller
Licker in
Flat
All Flat belts
Doffer
Card C 51
Detaching roller
Cross roller
Delivery roller
Calendar roller
Pneumatic system
All suction points
Cylinder
Control cabinet
Gauge
Coiler
40
Maintenance points
Frequency
2 weeks
2 weeks
2 weeks
2 weeks
2 weeks
3 months
2 weeks
6 months
3 months
2 weeks
6 months
3 months
3 months
6 months
WORK TO BE DONE
Outer surface
Drafting zone
MAINTENANCE AREA
Gear box
Electrical parts
Nut-Bolt
Bottom roller
make
41
perfect
adjust if required.
Suction system
Can changer
Gear
Drafting zone
Gear box
Electrical parts
Nut-Bolt
Belt tension and condition
Suction system
MAINTENANCE POINTS
WORK TO BE DONE
Can changer
Gear
Drafting zone
Gear box
Electrical parts
Nut-Bolt
Belt tension and condition
Suction system
Can changer
MAINTENANCE POINTS
WORK TO BE DONE
Life time
6-8 years
3-4 years
10 years
6 years
6 years
aprons are opened with jet powder and then acid treatment is done. Collector,condenser,
sliver guide, top and bottom cleaner, roller beam, roller stand, top arm, lifter rack, building
part creel part and each flyer and bobbin rail cover are cleaned. At the last every nuts and
bolts are checked. Thus routine maintenance in the simplex machine is carried out.
Back side
MAINTENANCE POINTS
WORK TO BE DONE
Creel
Sensor
Balancing spring and chain.
Creel chain
Rack groove
Grease level in the grease
pump.
Top and bottom roller
Condenser assembly
Traverse bar and sliver guide.
Neck bearing of bottom roller.
Drafting zone
Cradle unit
Pressure arm
Top and bottom apron
Yarn clearer
Flyer rail
Flyer cap
Flyer and its gear
Bobbin rail
Shaft
Bobbin rail and seal
Outer surface
Auto doffing
MAINTENANCE POINTS
Cog belt tension
Bottom apron tension bracket
Tape tension roller condition.
All type of timing belt condition
for head stock & tail stock.
ROBO doff, lifting rod, drive
Brushes of servo discs
Cot roller
Cradle
Top & bottom apron
Spindle & spindle break
Pneumatic line, mono meter &
pressure regulator
Pressure hose condition
Gripper membranes condition
Filter box, filter cloth, seal of filter
drum.
Suction tubes gauge 1mm
Sensors
Ring cup, balloon control ring &
lappet guide.
Ring rail, lappet bar setting gauge.
WORK TO BE DONE
Cleaning & checking condition if required.
Cleaning & checking condition if required.
Cleaning & checking condition if required.
Cleaning & checking condition if required.
INTERVAL
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
30 days.
240 days
30 days.
30 days.
120 days.
120 days.
120 days.
90 days.
730 days.
365 days.
730 days.
730 days.
45
Splice unit
Tension device
Cradle holder
Magazine
MAINTENANCE POINTS
WORK TO BE DONE
Waxing shaft
Pressure fork
Yarn trap
Guide plate
Splice cutter
Prism and its cover
Untwist nozzle
Clamping guide
Feeder arm
Rubber sleeve
Sensor
Cuter
Lower end sensor
Package adapter
Sliding part (cradle)
Cradle sensor
Circular magazine
Chute door
Elector
Bobbin peg
Tensioning device
Conveyor belt
Deflection roller
Lubrication schedule:
-6 months
- 3 months
-1 month
-2 months
: 6 months
: 6 months
: 6 months
: 3 months
: 1 month
: 1 month
47
Chapter- 8
Utility Services
The utility department undertakes the following units:
Power generator
A/C plant
Waste collection plant
Chiller boiler
Workshop service
Water treatment & water supply
Civil works
Fire fighting system
:5
: JGS320GNL
:JENBACHER
:Austria
:2000
:Gas engine
:1500
:20
:370 liter
:14.5 psi
:6000KW
48
SSL:
No of generators
Model
Manufacturer
Country of origin
Year of manufacture
Engine type
Engine rpm
No of cylinder
Cylinder volume
Line pressure
Capacity
:3
:JGS320
:JENBACHER
:Austria
:2006
:Gas engine
:1500
:20
:370 liter
:10 psi
:1064KW
49
Air washer
Return Air floor grills
Return Air trenches
Exhaust damper
Fresh air damper
Supply air ducts and grills
Face and bypass dampers on the air washer
Control panel for Automatic control the RH and Temperature
The fresh air come from outside, air is sucked by fan. Then the air humidified in the washer
room. In the washer room air and water is mixing then it supply by nozzle through the supply
air fan. Supply air fan supply the cooling air through the supply air grills on the floor.
The invisible dusts are sucked through the air floor grills. The invisible waste is separate by
filter and fresh air sucked by return air. Then the air is circulating again in the washer room. It
is continuous process.
The humidity and temperature controlling depend on the machine performance, machine life
and on personnel.
A/C plant is most needed for textile industries mainly spinning shed. If A/C plant will run
smoothly then the operators will feel comfortable and performance will be optimum.
Otherwise all these will suffer.
50
tensile strength, elastic recovery, electrical resistance, rigidity etc of all textile fibre whether
natural or synthetic are influenced by moisture regain.
Moisture regain is the ratio of the moisture bone-dry weight of the material expressed as
percentage.
Many properties of textile materials vary considerably with moisture regain, which in turn is
affected by the ambient Relative Humidity (RH) and Temperature. If a dry textile material is
placed in a room with a particular set of ambient conditions, it absorbs moisture and in course
of lime, attains equilibrium.
Some physical properties of textile materials which is affected by RH is given below:
Strength of COTTON goes up when R.H.% goes up
Strength of VISCOSE goes down when R.H.% goes up
Elongation% goes up with increased R.H.% for most textile fibers
The tendency for generation of static electricity due to friction decreases as RH goes
up
At higher levels of RH, there is also a tendency of the fibers to stick together
Temperature alone does not have a great effect on the fibers. However the temperature
dictates the amount of moisture the air will hold in suspension and therefore, temperature and
humidity must be considered together.
RELATIVE HUMIDITY
DEPARTMENT:
Section
R.H%
Blowroom
Carding
Comber
Simplex
Ring
Autoconer
Rotor
49.6
54.5
55.0
60.2
58.3
63.0
59.8
&
TEMPERATURE
Temperature
C
38.5
37.9
37.5
37.7
38.0
39.0
39.1
FOR
DIFFERENT
F
101.3
100.22
99.5
99.86
100.4
102.2
102.38
8.3 Chiller:
The main purpose of chiller is to supply chilled water to the A/C plant. Here three chiller in
R.K.
: 02
: THW LT/42, THW LT16
: Thermax
: India
51
Capacity
245.2 RT
245.2 RT
245.2 RT
245.2 RT
245.2 RT
159.4 RT
588.5 RT
Capacity
437 RT
425 RT
160 RT
Total=1022 RT
8.4 Compressor:
In spinning factory, compressed air is necessary for operation of various machines. Moreover
it is also used for different cleaning purpose. The compressed air is providing by different
compressed machine. SRSL and SSL consist of following compressor machine.
No of machine
Manufacturer
Year of manufacturing
Country of origin
Type
Total capacity
Pressure capacity
:5
: Atlas capco, Motivair
: 2001
: England, Belgium
: Screw Type
: 346 m3/min
: 10 bar max
factory. External and internal fire fighting group are always ready to action. Some worker are
well training, they can take any action against the fire. Some time worker practice to quickly
out from the factory during fire alarm is start, it is help to make any action against fire and
reduce any kind of injury.
Number of fire fighters:
Shift
P/A
P/B
16
P/C
Fire extinguisher:
FIRE EXTINGUISHER NAME
ABC POWER BOX
CO2
FOAM
EXIT BOX
HOSE CABINET BOX
SMOKE DETECTOR
FIRE ALARM
06
05
05
03
04
Boiler Section:
Boiler:Create Steam for Chiller by generator exhaust.
Safety against fire hazard:
Particular obtained:
Automatic fire door:
One pair between Blow room and pre-spinning
One pair between Blow pre-spinning and spinning
One pair between spinning and finishing
Firefighting equipment:
53
Section
Blow room
Pre spinning
Spinning
Yarn finishing
Power sub stating
Store & godown
Generator House
Total
No of fire existing
6
13
20
5
3
3
2
52
No of water drum
5
9
4
4
22
:2
:1
:2
:1
Generator
: DESA
:
No. of generator: 5
Manufacturer: Caterpillar, U.S.A
Model No: M- 3516
R.P.M: 1500
Capacity of each generator: 1025KW.
Existing power producing capacity:
o Generator 1 670KW
o Generator 2 590KW
o Generator 3 650KW
o Generator 4 550KW
o Generator 3 650KW
DESA Line:
Particulars obtained:
Manufacturer: Singapore
54
Remarks:
R.K.spinning mills Ltd. tries to maintain proper humidity required for different sections. So
fewer problems is occurred in processing materials from back to finishing section. There is no
system for temperature controlling slightly by controlling the humidity.
CHAPTER-9
In case of raw cotton inventory, QCA department sampling every bale and numbering
the bale according to micronaire value.
2. Finished yarn inventory:
Different lots of finished yarn given to the from the production department by
Transfer Memo. The store produces its daily monthly production report based on the
yarns are delivered to order of the marketing department, the yarns are delivered to
the buyers.
3. Wastage yarn inventory:
Different wastage produces from different department. Such as hard waste, pneumafil,
FS, dropping etc they are measured every day and transferred to store same
procedure.
4. Spare parts and materials inventory:
Different type machine parts are stored in the store. When any kind of machine parts
broken, damage etc then this machine parts collect from store.
SPR No.
56
MRR No.
Chalan No.
User name Ref.
Number
1
2
1
Gender
Male
Male
Male
Qualification
B.Com
M.A & B.A
B.Com
Remarks:
R.K. spinning mills Ltd. tries to maintain proper stock report required for different sections.
So fewer problems is occurred in processing materials from back to finishing section. The
store department & inventory control system of this mill is well organized.
CHAPTER-10
Cost Analysis
Manufacturing cost.
Selling cost.
Marketing cost.
10.2Product cost:
L/C price
C & F value
Landing cost
Transport cost
Carrying, Loading& Unloading cost.
** Conversion cost:
Wastage cost.
Machine cost.
Machine depreciation change.
Fuel cost.
Lubricant cost.
Electricity cost.
Spares cost.
Manpower cost.
Salary & Wages.
Bank interest.
Establishment cost.
Paper cone.
H.D.P.E bag (High density poly ethylene).
P.P bag / Hosiery bag/ Cartoon.
Lebel.
Jute twine / wrapping.
** Packing cost:
Selling price:
Selling price depends on the following costs:
58
CHAPTER-11
Marketing
Activities
Brand name:
59
Competitors:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Square textile
Shamim textile
Ages cotton
Akij textile
Thermax textile
Sayham textile
Nasa textile
Shirin textile
Al-Haj Karim textile
Conclusion
Conclusion
Technical education and its adoption in practical field we involved inextricably, without the
implementation of the knowledge gathered in technical education its success bound to suffer.
Therefore, this eight weeks long industrial as a partial fulfillment of our B.Sc textile
engineering course helped us to accomplish the gap between the theoretical and practical
knowledge by providing an elementary idea about industrial environment processing
machines, tools, equipments production system and maintenance, administration and
management system.
Our selected R.K.SPINNING MILLS LIMITED may be regarded as the pioneer if
modern spinning mills in our country. It was established a few years ago with latest model of
different machineries with in a very short time it earned name and fame at home and abroad
for its quality in production and administrative facilities. It is now not only providing knitted
yarn to the local market, fabric mils but also exporting them to foreign countries at a
satisfactory level. It mainly uses online process control and its quality control department
helped us to achieve a profound knowledge about spinning mills production sequence
maintenance. Quality control & assurance as well as its organization structure.
We tried our best to gather all necessary information but it is true that within this short
period it is quiet impossible to achieve 100% success but as a whole this industry training
was a satisfactory one again we should like to thank the authority of R.K. SPINNING MILLS
LIMITED as well as honorable teachers for their altruistic help and advice.
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