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PABNA TEXTILE ENGINEERING COLLEGE

SALGARIA , PABNA

INDUSTRIAL ATTACHMENT REPORT


FROM 28TH SEPTEMBER TO 30 NOVEMBER

THE DELTA SPINNING MILLS LTD.


Zarun(South) Kashimpur, Gazipur,

SUPERVISING TEACHER

MD. AHMED ALI

CI

PABNATEXTILE ENGINEERING COLLEGE

SALGARIA , PABNA

PREPARED BY
HADIULLAH RAHAMAN
B.sc. in Textile Engineering(1st batch)
ROLL NO. : 070043

REG. NO. : 4512

SESSION: 2006-2007

1
INDEX
1. Acknowledgement-------------------------------------------------------------
-- 02
2. Introduction----------------------------------------------------------------------
- 03
3. General
Information------------------------------------------------------------- 04
4. Location of
mill------------------------------------------------------------------- 05
5. Lay out of
ring-------------------------------------------------------------------- 06
6. Lay out
rotor---------------------------------------------------------------------- 07
7. Organ gram of
factory----------------------------------------------------------08-10
8. Manpower of
organization-----------------------------------------------------11
9. Name of departmental
head---------------------------------------------------12
10. Process flow chart of the
mill--------------------------------------------------13
11. Raw material
used----------------------------------------------------------------14
12. Spin
plan----------------------------------------------------------------------------15
13. Machines & equipments
------------------------------------------------------16-27
14. Wastage of different
section---------------------------------------------------28
15. Process
sequence-----------------------------------------------------------------29-32
16. Quality management
system--------------------------------------------------33
17. Lab
Equipments------------------------------------------------------------------33
18. Scope of quality assurance and
testing-------------------------------------34-36
19. Bale
Management----------------------------------------------------------------37
20. Quality
Standards----------------------------------------------------------------37
21. Information about slub
yarn---------------------------------------------------38
22. Maintenance of
Machinery----------------------------------------------------39-51
23. Utility
Department--------------------------------------------------------------52-57

2
24. HR &
Admin----------------------------------------------------------------------58-59
25. Inventory
system----------------------------------------------------------------60-61
26. Marketing
Information----------------------------------------------------------62
27. L/C opening
system-------------------------------------------------------------63
28. Involvement in Social
Development-----------------------------------------64
29. Conclusion----------------------------------------------------------------
----------65

We were very fortunate to carry out our industrial attachment


training at
The Delta Spinning Mills Ltd. So, at this point we would like to
express our
gratitude to everyone related . First of all our heartiest thanks to
our Training
Supervisor Md.Ahmed Ali, Chief Instructor of Yarn Spinning
Department of PTEC; Special thanks to Md.Bokhtiar Rahman,
Chief Instructor of the Department of Garments Technology of
PTEC for arranging our Industrial Attachment at The Delta
Spinning Mills Ltd. It is their logical guideline, constant
inspiration, necessary instruction and proper supervision that
have helped us to complete the training successfully.

3
We also express our heartiest gratitude to the authority of The
Delta Spinning Mills Ltd. Special thanks goes to Engr. Md.
Tariqul Islam, Deputy
General Manager of QA; Engr. Md. Moshiur Rahman, DGM of
production, Anjan Chowdhury, PM of production for supervising
our training in a
systematic schedule and all sort of help.

Finally we place our sincere acknowledgment to all those


officers, staffs
and technicians of The Delta Spinning Mills Ltd. who have helped us
to
overcome different problems in different situation that have made a
Successful completion of our training.

4
The Delta Spinning Mills Ltd. is a well reputed spinning mill
in Bangladesh. It is the sister concern of The Delta Group. The area
of mill is about 26 acres. It is fully 100% export oriented spinning
mill. It is located in Zorun South, Konabari, Gazipur. The Mill is
established in 2006. The owner of this mill is Engr. Faruq Hossain.
The Delta Spinning Mill is ISO certified by ISO 9001:2008.

The Delta Spinning Mills Ltd. is a truly undertaking. The


Spinning Devision has the capability to offer a complete product
range for the 100% export quality yarn to EU & American market.
The goal of the Spinning Division is to become the preferred partner
for sourcing high quality value added yarn from Bangladesh. With
an emphasis on developing local human resource, the Spinning
Division has the potential to make an important contribution to the
nation’s growing RMG export sector.

5
Name Of the Mill: The Delta Spinning Mills Ltd.
Zarun(South) Kashimpur,
Gazipur, Bangladesh.

Head Office: House# 389, Road# 6


DOHS Baridhara, Dhaka – 1206.
Phone: 880-2-8813636-7, 8824092
Fax: 880-2-8840263
E-mail: info@tdsml.net

Date of Establishment:

Ring Unit: 2006


Rotor Unit: 2008

Production Capacity:

Total Production
Unit Spindles Count Capacity
Range (MT/day)
Ring 42,336 Ne 7 to 40
s s
approx
28~32
Rotor 960 Ne 12 to s
approx
20s 3~4

Location of the Mill:

Mymensing- Dhaka road

Ch
6
ow
ras
ta

Cotton
Club
Ch
an Kasimpur
dra
Ro
ad
Delta
composit
e

Delta
Delta Blended
Accessori
yarn

The Delta
Spinning Mills
Ltd.

Kashimpu
r Jail

Layout Plan of Ring Unit:

7
Raw Cotton Carding Back Process Auto Coner
Godown Machine Ring Section

8
Draw Frame

9
Blow Room Carding Machine
Lay-out Plan of Rotor unit:
Rotor Machine A/C Plant
Organogram of the Factory:
Departmentwise:

Design of Organization
Chairman and
MD

Commercial
Director
All Departmental
Heads

Second
man

Officer
and Office
Staff

Production Department Organogram

DGM Production
Manager
Production

Shift in Charge

APO
HR AndWorke
Admin Organogram
r
10
Head of HR and
Admin

Security Medical
Officer Officer
Executiv
e
Supervis
or Assistant
Officer
and Office
Guard staff

Quality Department Organogram

DGM Quality

Executive

Officer

Lab Assistant

Lab Boy
Maintenance Department Organogram

DGM Utility
11
Executive
Maintenance
Officer

Worker

Utility Department Organogram

DGM Utility

Manager Manager E and Senior Engr. Assistant Engr. A/C


Generator E CBC

Assistant Worker
Worker Worker
Engr.

12
List of workers of different department

Department Category Number of


workers
Electrical Maintenance 16
Blow room 80
Carding &
Card shop
Maintenance Draw frame 15
Comber &
Simplex
Ring Frame 40
Winding 40
Chiller, Boiler, Cooling 13
Tower & Pump
Utility A/C Plant, Compressor 15
Power Generation & 15
Distribution
Workshop 15
Mixing & Blow room 45
Carding and 71
Preparatory section
Production Ring section 160
Winding Section 100
Packing Section 50
Research & 7
Development section
Production 86
Rotor Unit Maintenance 10
Utility 9
Total Workers 877

Total workers 877


Total Staff 60
Total Officers 52
Grand total of 989
manpower

Name of the owners & Departmental Head:

13
 Chairman – Engr. Faruq Hossain
 Director Commercial – Md. Shahidul Alam
 DGM Production – Engr. Moshiur Rahman
 DGM Quality – Engr. Tariqul Islam
 DGM Utility – Engr. Abul Kased
 DGM Maintenance – Engr. Abul Kased(temporary)
 DGM Marketing – Md. Shah Jamal
 GM Finance –Md. Ruhul Amin
 Manager Store – Md. Kamal Molla
 Manager HR& Admin – Md. Abdul Khaleq

Sponsored by Islami Bank Bangladesh Ltd.

Total Floor Space:

Total floor space is 1,31,000 square feet.

Vision:

The visions of The Delta Spinning Mills Ltd are –

# To provide an efficient back-linkage support for the


ready-made garments industry in Bangladesh by
producing export quality cotton hosiery yarn.
# To provide sufficient monetary profit to the Group.

# To train and develop skilled manpower for the industry.

# To reduce the employment problem in Bangladesh by


creating
employment opportunities.

14
Process Flow Chart of The Delta
Spinning mill:
Bale Management (Mixing)

Unifloc-A11

Uniclean-B11

Unimix-B70 Unimix-B70

Uniflex-B60 Uniflex-B60

Vision Shield-ED35 Vision Shield-ED35

Condensor- Condensor-A21

Karded Process Carding-C60


Combed Process

Breaker Drawing-SB- Precomb Drawing-SB-

Unilap-
E32
Comber-
Finisher Drawing-RSB-
Postcomb Drawing-RSB-

Simplex-FL-100,FL-

Ring-RX240,K44,BT-
702
Winding-Muratec-
Yarn
Packin Conditioning
g
15
Raw Material Used:

Raw material is a vital factor for the productivity, quality and


profitability
of a factory. As The Delta Spinning Mills Ltd is a cotton spinning mill, its
main
raw material is cotton. As cotton is not grown in our country, all of
these
cotton are imported from foreign countries. The factory has used the
following cottons in the past years:

Australian cotton, America, India, CIS, Thailand, Zimbabwe,


Turki,
Syria, Chad, Egypt, China, South pacific cotton etc.

The factory requires around 35 Metric Tons of raw cotton per day.

For the rotor unit, around 30 % to 40% virgin cotton and 60%
wastage of the ring unit is used as raw material. A mixing ratio is as
follows –

Virgin Cotton (CIS) – 40% – 2400kg


Noil – 35% – 2100kg
Pneumafil – 10% – 600kg
Dropping-1 – 15% – 900kg

Total – 100% – 6000kg

Raw Material Inventory:

16
The factory consists of a Raw Cotton Godown. It can store up to
7000 cotton bales of 220kg each. That means it can store around 1500
Metric Tons of raw cotton at a time.
Spin Plan
100% Karded Yarn

Mac Spinning Schedule Production Schedule


hine
Type Deli Util Cou D T. Spee TPI Cal Pr Prac Wa Total Actu Total
s ver i nt/ o M. d cula od tical ste produ l no. m/c
of y zat Han u ted uc prod % ction of reqd.
m/c unit ion k/ bl pro tio uctio reqd. m/c
per % Kte in duc n n/m/ (Kg/d
m/c x g tion Eff c(Kg ay)
/m/ i% /day
c(K )
g/d
ay)
Windi 72 10 28 1600 18.5 349 70 244 0.6 20000 8.17 8
ng 2 2 7 8
Ring 100 10 28 3. 1600 18.5 672 96 645 2.5 20120 31.2 31
Fram 8 1 7 0 2 0
e
Simpl 144 10 0.7 1100 1.05 434 75 325 0.5 20623 6.33 6
ex 5 5 4 8
Finis 1 98 5.3 8 650 496 85 421 0.5 20726 4.92 5
her 1 7
D/F
Brea 2 99 5.3 6 650 496 85 421 0.2 20830 4.94 5
ker 1 7
D/F
Card 1 10 6 195 168 95 160 6 20871 13.0 13
0 5 1 4
Blow 4 22124
room
Total
Raw 14. 230
mate 3 09
rial
reqd.

17
As stated earlier, the factory consists of two lines. One is the Ring
line and
the other is the Rotor line. A short description about the machineries of
these
lines are given in below :-

Blow Room:

The blow room consists of :-

Unifloc :
Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ A11
Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter
Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Switzerland
Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006

18
No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 02(1 for ring and
other for rotor)
Production capacity‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 1400 kg/hr

Uniclean :
Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐B11, B12 (Ring,
rotor)
Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter
Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland
Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006
No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐02 (Ring and
Rotor)

19
Production capacity‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1200kg/hr,1400kg/hr(ring,Rotor)

Unimix:
Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐B70,B71
(Ring,Rotor)
Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter
Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland
Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006,2008
No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐03 (2
ring+1rotor)
Production capacity‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐800 kg/hr

20
Uniflex :

Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐B60
Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter
Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland

21
Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006,2008
No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐05 (4ring+1rotor)
Production capacity‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐600kg/hr

Vision shield :

Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ED-35
Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Jossi
Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland
Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006,2008
No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐04 (only for ring)

Condensor :

22
Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐A21
Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter
Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland
Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006,2008
No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐05 (4 ring+ 1
rotor)

Carding :

Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐C60
Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter
Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland

23
Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006,2008
No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐23 (19 for ring
and 4 for rotor)
Production capacity------------------------70 kg/hr,100 kg/hr
(70 kg
for ring and
100 kg for rotor)

Breaker Drawing:

Model-----------------------------------------SB-D-40
Brand------------------------------------------Rieter
Country of origin----------------------------Switzerland
Year of manufacture-----------------------2006
No. of m/c------------------------------------8
24
Production capacity------------------------707 m/min

Unilap :
Model-----------------------------------------E 32
Brand------------------------------------------Rieter
Country of origin----------------------------Switzerland
Year of manufacture-----------------------2006
No. of m/c------------------------------------3
Production capacity------------------------97 m/min

25
Combing:
Model-----------------------------------------E 65
Brand------------------------------------------Rieter
Country of origin----------------------------Switzerland
Year of manufacture-----------------------2006,2008
No. of m/c------------------------------------15
Production capacity------------------------46 kg/hr

Finisher Drawing:
Model-----------------------------------------RSB-D40
Brand------------------------------------------Rieter
Country of origin----------------------------Switzerland
Year of manufacture-----------------------2006
No. of m/c------------------------------------9 (6 for ring line
and 3 for
rotor
line)
Production capacity------------------------657 m/min

26
Simplex :
Model-----------------------------------------FL-200, FL-100
Brand------------------------------------------Toyota( Both
model)
Country of origin----------------------------Japan
Year of manufacture-----------------------2008,2006
No. of m/c------------------------------------10 (FL-200 2
pieces)
Production capacity------------------------27 m/min

Ring Frame:
Model-----------------------------------------K 44+, RX-240,
BT-702
Brand------------------------------------------Rieter,
Toyota,Rieter
Country of origin----------------------------Switzerland,
Japan, India
Year of manufacture-----------------------2008,2006
No. of m/c------------------------------------(5+31+6)=42
Production capacity------------------------180 GPSS

27
Winding :
Model-----------------------------------------Uster Quantum-
2, 21C
Brand------------------------------------------Savio, Muaratec
Country of origin----------------------------Italy, Japan
Year of manufacture-----------------------2008, 2006
No. of m/c------------------------------------14 (4+10)
Production capacity------------------------1600 m/min

28
Conditioning :
No. of m/c : 01
Model : 1200 kg
Brand : Seizer
Country of origin : India
Year of manufacturing : 1996

Rotor :
Model-----------------------------------------BT-923
Brand------------------------------------------Rieter
Country of origin----------------------------Switzerland
Year of manufacture-----------------------2008
No. of m/c-----------------------------------03
Production capacity------------------------650 kg/shift

29
Wastes produced at different production
process:

Blow Room (4-5%) : Droppin-1, Droppin-2


Fine dust

Carding (5-6%) : Flat strip


Licker-in

Drawing (0.5%) : Filter Waste, Sliver waste


Sweeping dust

Lap Former (0.5%) : Sliver waste, Lap waste

Comber (10-20%) : Lap


Sweep
Noil

Simplex (0.5%) : Sliver


Roving
Apron Clearer waste
Sweep waste

Ring Frame (3%) : Roving ,wooden roller clearer,


Bonda,Soft waste,
Pneumafil ,
Sweeping .

Winding (0.5%) : Hard Waste


Sweeping
Invisible waste

Rotor : Pneuma dust


Hard waste
Sliver waste
Soft waste

30
Blow Room :

The cotton comes in compact bale form, which are not suitable for
processing. So it have to be opened, cleaned and made free of
contamination
before processing. To obtain consistent parameters throughout the
process,
the cotton have to be mixed uniformly. All these tasks are carried out
in the
blow room. At first the Unifloc plucks raw cotton in lump form and
sends these to Uniclean through air transportation for coarse cleaning.
After the heavy particles being removed, the cotton is blended and
mixed in the Unimix. Then it is taken for fine cleaning in Uniflex. After
that the material is scanned for contamination and made free of it by
Vision shield. These machines use optical and sonic principles for
detection of contamination. Then they are de-dusted in the machine
Conensor and sent to the carding machine for further processing via
chute line.

Carding:

The carding machine mainly removes the Neps, short fibers and
remaining
impurities in the cotton fiber and forms carded sliver. Mainly impurities
are
removed at the taker in and the neps and short fibers are removed by
action
between the cylinder and flat. It is called the heart of cotton spinning
because
the quality of a cotton spinning mill is greatly dependent upon the
performance of the carding machine. The card slivers are delivered in
card
sliver cans which are then fed to the breaker drawing frame.

31
Breaker / Pre-comb Draw Frame:

In the breaker draw frame 5 to 6 carded sliver cans are fed at a


time and are
drafted to one drawn sliver. By this, the fibers in the sliver becomes
more
oriented, parallelized and the irregularity of the strand decreases.
Produced
drawn sliver cans are then either fed to the finisher if it is card process
or fed
to the lap former if it is combed process.

Lap Former:

For combing, the material have to be presented to the comber


machine is a
lap form. So to convert the slivers into mini laps, the lap former is
used. Here
23 to 24 drawn sliver cans are doubled and drafted together to form
lap. The
lap is then fed to the comber machine.

Comber:

The comber machine mainly combs out the lap and removes any
kind of
neps, short fiber or other impurities present in it. It also parallelizes the
strand
to the maximum degree. As a result the yarn produced from this sliver
possesses better quality and aesthetic properties. The produced
combed sliver
is then fed to the finisher / post-comb drawing machine.

32
Finisher / Post-comb Drawing Frame:

The finisher is the last machine where the irregularities in the


strand can be
modified easily and any fault after this will pass on to the yarn. So this
machine is of great importance. That is why this machine is equipped
with an
auto-leveler. The auto-leveler continuously scans the incoming slivers
and
increases or decreases the draft in the drafting zone to minimize any
thick or
thin place. 7 to 8 breaker or comber sliver cans are fed together. This
machine
is monitored continuously and carefully. The produced finisher sliver
cans
are then fed to the simplex machine.

Simplex:

In the ring frame, if the yarn is produced directly form sliver, then a
very
high amount of draft will be necessary, which will be un-manageable.
That is
why the material is gradually drafted and an intermediate strand
named
roving is produced. A slight amount of twist is also inserted in the
roving to
ensure breakage free winding and unwinding of it on the roving
bobbin. Then
the rovings are fed to the ring frame.

33
Ring Frame:

In the ring frame, finally the yarn is produced by drafting the roving.
Here
twist is inserted in the yarn to obtain required strength. Twist is
inserted by
means of ring traveller. The number of turns that the spindle rotates at
one
revolution of the front roller is the number of twist that are inserted on
the
unit length of yarn. Then the yarn are wound on ring bobbins. When
the
bobbins are full, they are doffed from the machine automatically by
SCD
(Stationary Cone Doffer) mechanism.

Auto Coner:

The auto coner is a machine for automatic winding of yarn on cross


wound
34
packages. The yarn is wound on paper cones. It represents an
autonomous,
compact winding machine, which is equipped with a splicer and
electronic
yarn clearer in each winding unit. The EYC continuous scans the yarn
for
faults using either capacitative or optical principle or both. When a
fault is
found then it cuts it out. Then a upper and lower arm catches the yarn
and
brings the two ends to the splicer where they are joined together. The
joining
is done by means of compressed air. Thus the finished cones are
produced
which are then heat set and packed in required form of packaging.

Heat Setting Machine:

Heat setting is mainly done to stabilize the twist in the twisted yarn,
reduce hairiness and increase the moisture content in the yarn
packages. The yarn cones are arranged on trolleys. Maximum 6
trolleys can be fed to the machine. After that the machine door is
closed. Then vacuum is created inside the machine and water at 550C
is sprayed inside the chamber. Due to negative pressure, the water
becomes steam. There the yarn packages are heat set in the steam for
45 minutes. Then they are brought out and sent for packing.

Rotor Machine:

In the rotor machine, the yarn is produced directly from sliver. The
sliver is
opened into individual sliver in the opening unit and then individualized
fibers are deposited in rotor groove. From there they are bounded
around an
open end of yarn and thus rotor yarn is formed. The produced yarn is
directly
wound on a paper cone package. So here the simplex and auto coner
is not
required.
35
In The Delta Spinning Mills, responsibility of quality management is
carried
out by the Quality Assurance Department Lab. The lab is lead by the
DGM of
QA . The lab carries out tests on materials at every stage of processing
starting from the raw cotton to finished yarn. By this they provide the
assurance of obtaining consistent quality throughout the process and
in the finished yarn. A brief description about the lab and its quality
management process is given in the later section.

Lab Equipments:
Manufactu
Seri Name of the Model rer Year of Purpose
al Machine & Manufact
Country of ure
Origin
1 USTER® 4-SE Zellweger 2006 To test
Evenness Tester Switzerland evenness,
imperfection and
hairiness of yarn
and other
strands such as
roving and
sliver.
2 USTER® PR503 Zellweger 2006 To test count of
Tensionjet– 4 Delta Switzerland yarn directly
Range

3 USTER® AFIS- AFIS Zellweger 2006 To test Neps,


PRO PRO Uster length and
USA maturity related
properties of
cotton fibers

4 USTER® HVI HVI – Zellweger 2006 To test


Spectru Uster important
m USA parameters of
cotton fiber.
USTER® 754 Zellweger 2006 To test strength
5 Stelometer Uster and elongation
Germany of cotton fiber

36
Zweigle To measure
6 Electronic TEM1 Germany 2006 moisture content
Moisture Meter of textile
materials

Scope of quality assurance and testing:

Here the task of quality control starts from the raw material. At first
when
the raw cotton arrives, the lab boys collect samples from each bale and
give
respective numbers to each bale. Then the samples are tested in H.V.I.
machine. From the obtained results, the bales are categorized in
suitable categories for bale management and stored in the warehouse.
Then the raw cotton is fed to the blow room through the bale
management system. The bale management system is a vital task of
the QA department and will be described separately in later portion.

In blow-room, the fibers are opened and cleaned by beaters. Here if


over
beating takes place then there is a chance of fiber damage. So, the QA
department tests cotton sample before and after every beating
position to
check the cleaning efficiency and fiber damaging. From there,
necessary
actions are taken. Different wastes that are collected at the fiber
deposition
plant of blow room are also studied to assure proper removal of trash
particles as well as least possible wastage of cotton fiber. Also the QA
department monitors the setting and performance of the
contamination
separator of the blow room.

37
In the carding machine the Ktex of the produced sliver is checked
once
per shift. The performance of the carding is evaluated by testing m/c
and
sliver of the carding in USTER-5 and AFIS. From there the Neps
Removal
Efficiency, SFCw, SFCn, UQL etc are seen to evaluate its performance
and
necessity of gauge change, grinding and wire change of cylinder,
licker-in and
flat is determined. The card sliver is tested in USTER-5 once
per shift to test its Unevenness (U%) and coefficient of variation of
mass
(CV%).

In breaker draw frame, mainly the grain/yd of sliver is tested once


per
shift. Other than this also the sliver is tested in USTER-5 to
determine the length of the fibers in strand to set the proper roller
gauge in
the roller drafting zone. The breaker sliver is tested once per shift in
USTER-5
to determine its Unevenness (U%) and coefficient of variation of mass
(CV%).

In lap former, the lap thickness is measured mainly.

The Comber is a very crucial machine. Its performance plays a vital


role on
the quality of the combed yarn. So, the performance of the comber is
assessed
by testing the material before and after it. From there the nep removal
efficiency of the machine is determined. Also the noil is tested to see
whether

38
long fibers are being wasted during the processing. From there, the
necessary
changes in the setting of the machine is carried out. The grain/yd of
combed
sliver is checked once per shift. The combed sliver is also tested once
per shift
in USTER-5 to determine U%, CV% etc and any periodic faults from the
spectrogram.

The finisher draw frame is a very vital machine in respect of quality


control. As it is the last machine fitted with an auto leveler, it is the last
step
where the mass variation of sliver can be maintained. For this here the
grain/yd of sliver is checked at every hour. If the variation of the
finisher
sliver can be controlled, then there will be less variation and
imperfection in
the yarn. Also the calibration of the auto-leveler is done when
necessary by
the QA department. The finisher sliver is tested once per shift in
USTER-5
to determine its U%, CVm%, CV3m% and to see whether there is any
periodic fault from the spectrogram.

In case of testing of carding, breaker draw frame and finisher draw


frame,
a schedule is maintained so that all the machines are tested within a
fixed
period of time.

In simplex, the hank is mainly tested once per shift. Also the roving
is
tested in the USTER-5. A schedule is maintained so that all the spindles
of simplex machines are tested over a period of time.

39
The yarn of ring frame, rotor machine and auto-coner are tested to
determine their count. This test is carried out at each shift for each
count and
lot. Testing is carried out in USTER-5 Tester in the same manner to
determine the U%, CV%, Relative count, +50% thick places, -50% thin
places, +200% Neps (ring yarn), Imperfection index, hairiness,
standard deviation of hairiness, periodic faults etc. From there
necessary actions are taken to eliminate or reduce the faults. The CSP
(Count Strength Product) of the yarn are also tested to determine the
bundle yarn strength which is very important for knitted fabric. The TPI
(Twist Per Inch) of yarn is tested at the beginning of each lot.

The setting of drafting gear in drawing frame, simplex and ring


frame is
given by the QA department and is implemented then by the
maintenance
department. The QA department on the basis of trial and experiment
does
the selection of proper roller gauge and spacer in the drafting zone of
simplex
and ring frame. Also the setting of the EYC (Electronic Yarn Clearer) is
determined by the QA department. This ensures that most of the faults
that
are present in the yarn are cut out during winding on paper cone and
fault
free yarn are delivered to the customer.

The moisture content in the yarn packages after heat setting are
also tested
by the QA department. Thus the proper time of heat setting can be
maintained to deliver yarn with required amount of moisture content.

Bale Management:

Bale management is the judicious selection of cotton bales in the


laydown in order to obtain consistent quality as well as economic

40
spinning performance. For this at first samples are collected from
100% bales. The samples are tested in HVI and from there, the bales
are categorized. The categorization is done on the basis of different
fiber properties. Here it is done on the basis of Mic and chrome (+b)
value. At first all the bales are categorized. Then from there they gives
the list of bales for each lay-down of required number of bales. The
average fiber properties from lay down to lay-down is kept constant.
The list is sent to the warehouse. From there the store personnel
procures the bales according to the category and send a list of the ID.
No. of the bales. Then the QA personnel again checks whether these
bales fulfill the requirements. Then from there the lay-down plan is
prepared. During preparing it, one thing should be kept in mind that
bales of same categories should not be placed right next to each other.
Then according to the lay-down plan the bales are arranged under the
bale plucker.

Quality Standards:
In The Delta Spinning Mills Ltd, they maintain their whole process in
a way so that the finished yarns as well as all the processing strands
comply with the
quality standards. In the QA lab, always the standard temperature
(27±2°C) and Relative Humidity (65%) is maintained.

41
The Delta Spinning Mills produce one kinds of yarn called slub yarn.
Slub yarn is one kind of yarn which contain irregularity in a uniform
distance. A model parameter of slub yarn is given below :-

Length Length Wide Initial Wide Final


Minimum Maximum (mm) (mm)
(mm) (mm)
Pause 110 380 1.0 1.0
Length
Ramp 10 10 1.0 1.6
Slub Length 45 65 1.6 1.6
Ramp 10 10 1.6 1.0

Pause Length Ramp

Slub Length

Maintenance of Machinery
42
All the textile machinery both process and related ones are high
performance
machinery and they have to maintained well to ensure their high
performance
and efficiency. Also proper maintenance ensures their long operating
life. The
following types of maintenance are carried out in the factory –

# Schedule Maintenance: Here mainly all the machines are


checked
on the basis of a fixed schedule of time. Different machine
parts are
opened, cleaned, lubricated, gauged and replaced if
necessary.

# Predictive Maintenance: This type includes maintenance


of machine
parts on the basis of suspicion that they consists problem and
will
cause greater problem in future. It also includes the gear
changes that
are done to adjust count, ktex etc of machinery and
overhauling.

# Breakdown Maintenance: When a machine stops due to


failure of
machine parts, then it is called machine breakdown. The
maintenance
that is done to repair and make it ready to run is called
breakdown
maintenance.

43
The points that are checked during the maintenance of
different machines as well as different lubricating points are
given in the following section –

Blow-room:

Maintenance Points:

Machine Maintenance Point Work to be Done


Name
Fan Impeller Checking .
Unifloc A11 Inside Swivel Tower unit Cleaning.

Take-off Roller/Retracting Cleaning and Checking.


Roller/Swivel Flaps
Covering belts/Ducts Cleaning, Checking and
Tension.
All types of Belts/Rollers Cleaning, Checking and
Tension.
All drive Chain Cleaning, Checking,
Tension and Oiling.
Guard Checking.

Gear Motor of Retracting Check Oil Level.


Rollers
Tooth Segments Checking.
Brake Lift Drive Check Oil Level.
Sealing Strips (Lock Roller) Cleaning
UniClean Grid Bar Cleaning
B11/B12 Inside of Drum and Grid Cleaning
adjustment
Perforated sheet for dust Cleaning, Checking,
extraction Adjusting

44
V-Belt for Drum Drive Tension
Lock rollerdrive chain Cleaning,Checking
Inner part of the spike feed Cleaning
lattice
Unimix All types belts Checking, Tension
B-70/B-71 All drive Chain Cleaning, checking,
tension, Oiling
Separating vanes, Exhaust air Cleaning
chambers
Storage section inner chamber Cleaning
Rivets & spikes of spiked feed Cleaning, checking
latice
Roller Checking

Conveyor belt Checking, Cleaning

Closing flap & spike feed Checking

Spike feed lattice bearing Checking


Cotton filter Tension

All Gear box Check oil level

Stripping roller checking

Lamella chute Cleaning


All drive chain Checking, Cleaning,
Uniflex B-60 Oiling
Saw tooth roller Checking, Cleaning
Grid Bar Checking, Cleaning
All Seals Checking
Drum seal Checking

Stripper Cleaning, Checking


All types belt Cleaning , Checking,
Condenser
Tension
A-21
Perforated drum inside or Cleaning
outside
All bearing checking
Take off roller Cleaning

Outside the m/c Cleaning

45
Material in , out and exhaust Checking,Cleaning
line

Lubrication Points

Machine Lubricating Lubricants Intervals


Points
Unifloc-A11 All roller chain Mobil Gear 632 or Chain 25 to 45
Spary Hotemp 2000 Days
Spary
Unimix B-70 All roller chain Mobil Gear 632 or Chain 25 to 45
Spary Hotemp 2000 Days
Spary
Uniflex B-60 All roller chain Mobil Gear 632 or Chain 25 to 45
Spary Hotemp 2000 Days
Spary
Uniclean B-11 Chain of lock Mobil Gear 632 or Chain 25 to 45
roller Spary Hotemp 2000 Days
Spary

Carding:

Maintenance Points:

SL Maintenance Point Work to be done


NO.
01. Carding element Cleaning
02. All bearing condition checking
03. Flat to cylinder setting Checking
04. Front auto leveler surroundings Tension,Cleaning
05. Cylinder inside Cleaning
06. Cylinder gasket Checking
07. Stripping knife Checking
08. Can turntable Cleaning
09. Card clothing condition Checking
10. All suction points Checking, Cleaning

46
11. Detaching unit Cleaning
12. Chute Cleaning
13. All types belts Tension, Checking
14. Flat drive belt Tension

Lubrication Points:-

SL Lubricating Point Suggested Intervals


NO. Lubricating
01. Cylinder bearing Grease EP-2 (10-14) months
02. Bearing of the card Grease EP-2 (10-14) months
flats,cleaning brush and
cleaning comb
03. Card flat drive Kluber plex (10-14) months
BEM34-132

Unilap:
Maintenance points:

Maintenan Maintenance Points Work to be done


ce Area
Table Top cleaning device & bottom Clean and check its
calendar cleaning device physical condition
Mote knives, waste suction pipes Clean and check
Suction Unit suction properly
Filter Clean and check
condition
Sliver feed Sliver guide, guide rolls Clean properly and
frame check setting
Drafting Top & bottom rollers , tension bar Clean, check gauge
system and reset if
required
Drive units All belts and chains Clean, check
tension, greasing
and apply grease if
required
Safety Safety switch, pneumatic switch Check functioning
device

47
Lubrication Drafting gear box, main gear box Check oil level and
and all greasing point put oil if required,
also check greasing
Gear Units Setting gear Clean and check
gear meshing,
vibration, abnormal
sound etc.
Lap guide plate Clean and check
Lapping unit condition
Condenser roller Clean properly
Electrical Motor, electronic board, limit To be cleaned and
function switch, proximity switch etc. checked by
electrical persons.
Nut and bolt Drafting gear box, main gear box, Tightness check
lap roller drum, lap plate etc. and make correct if
required.
Trolley Trolley wheel, pneumatic system Clean the wheel
and the outer
surface

Comber:

Maintenance Points:

Maintenanc Maintenance Points Work to be done


e Area
Feed table, trumpet, calendar Clean and check
roller, table funnel condition, adjust if
required
Top combs, clearer rolls and Clean and check
flats, bearing of the bottom condition, adjust if
roller, circular comb, filter, required
Delivery Unit spring assemblies
Nipper, nipper lever on in-feed Clean and check
side, circular comb brush condition, adjust if
required
Feeding throats, feed roller, Clean and check
nipper lips, top detaching condition and gauge,
roller, fleece guide plates, top adjust if required
delivery roller, lap plate
Draft system Stripper, Top and bottom roller Clean properly, check
physical condition

48
Belt tension Timing belt, flat belt, V-belt Clean all the belt,
and condition check tension and
adjust if required
Setting and condition of top Gauge check and
comb, circular comb brush adjust if required
Gauge points Roller, nipper feed plate, Gauge check and
nipper gauge, bottom adjust if required
detaching roller gauge
Machine Side Outer surface of the machine Clean properly
and condition
Oil level in gear box Check oil level and
Gear Box apply oil if necessary
All gear Check gear condition,
correct if required
Can changer Chain tension on turn table Clean and check
condition, adjust if
required

Bearing, bush of the top Clean and check,


detaching roller grease if required
Drafting roller, strip nipper Clean and check,
Greasing frame, lower delivery and table grease if required
points calendar
Batt tension roll axles and Clean and check,
other greasing points grease if required
Nut-Bolts Top comber nipper, circular Check tightness and
comb, top roller pressure, make correct if
main gear box, index wheel, all required.
pulley, can wheel, coiler wheel,
lap feed plate, lap roller nut-
bolt.
Electrical Motor, motor fan, photo-cell, Check and clean by
parts limit switch, electronic board, electrical person
connection cable

Finisher Draw Frame:

Maintenance Points:

Maintenanc Maintenance Points Work to be done


49
e Area
Auto leveler Funnel, scanning roller, Clean and check their
contact roller, gatherer, nail condition, make
and stripper correct if required
Top & bottom roller Clean and check its
gauge, reset if
Drafting Zone required.
Pressure bar, round guide bar, Clean properly, check
top roller, weighing frame, physical condition
funnel, condenser, trumpet,
coiler
Suction Filter box, filter screen, fan Clean properly and
system blade check filters and blade
condition.
Can Plate Clean and check that
it works correctly
Gear Clean, check meshing
Can changer condition, vibration,
abnormal noise etc.
Power cylinder Clean and check that
it is working correctly.
Belt tension Flat belt, V-belt, timing belt Clean all the belt,
and condition check tension &
adjust.
Gear box Planetary gear box Check oil level and put
oil if required
Nut-Bolt Top roller lock, pulley nut-bolt, Check tightness and
creel nut-bolt, drafting zone make perfect
nut-bolt tightness
Electrical Motor, fan, limit switch, Clean and check by
parts proximity switch, creel light electrical persons
barrier
Outer Surface Outer surface of the whole Clean properly
machine

Simplex:
Maintenance Points:
Maintenanc Maintenance Points Work to be done
e Area
Creel Clean and check
bearing condition
Balancing spring and chain Clean and check
greasing

50
CWC Clean and check belt
Back Side tension and condition
Creel chain Clean and check
greasing
Grease level in the grease Check grease level and
pump apply grease if required,
Check grease pump
Photo cell Clean by soft cloth
Rack groove Clean and check
greasing
Belt tension and its condition Check and adjust if
necessary
Lifter gear box, main gear Check oil level and filter
box and put oil if required
Gear setting Check gear meshing,
GE head observe vibration,
sound etc.
Bearing and greasing point Check bearing
condition, vibration and
sound, check greasing
and apply grease if
required
All nuts and bolts Check tightness and
make it correct if
required
Sensor Clean all the sensor
OE Head with soft cloth.
Blanching chain Clean and check
greasing
Traverse bar and sliver guide Clean, check setting
Top & bottom roller Clean, gauge check and
adjust if required
Condenser assembly Clean, check assembly
and make correct if
necessary
Top & bottom clearer cloth Clean, check condition
Neck bearing of bottom roller Clean, check cover
Drafting Zone missing or broken,
nipple missing or
broken, replace if
required
Cradle unit Clean and check
functioning and wear
and tear
Pressure arm Check height gauge and
re-adjust if required

51
Top & bottom apron Clean properly with
suitable detergent,
check condition for
replacement
Bobbin Rail & Seal Open the cover, Clean it
& check the gear
Flyer rail & condition
Bobbin rail Flyer cap Clean and set properly
Flyer and its gear Clean, check gear
meshing condition
Shaft Clean and check
condition
Outer surface Outer surface of the machine Clean the outer surface
properly

Ring Frame (RX-240):

Maintenance points:

SL Maintenance Points Work to be done


NO.
01. Top cot roller and cradle Cleaning
02. Travers track of roving guide Checking, Adjusting
03. Gear Bearings Checking
04. Top and bottom apron Cleaning
05. Teeth surface of all gears at head stock Cleaning, Checking
06. Mesh clearance of the gears Checking
07. Fluted roller bearings Checking
08. Bottom fluted roller Cleaning
09. Suction tube Checking, Adjusting
10. Top & bottom apron Washing
11. Gauge of traveler Checking, Adjusting
12. Spindle blade Checking
13. Ring rail height gauge Checking, Adjusting
14. Top roller gauge Checking, Adjusting
15. Ring rail position gauge Checking, Adjusting

52
16. Balloon control ring center Checking, Adjusting

17. Top roller arm pressure gauge Checking, Adjusting


18. Lappet rail height gauge Checking, Adjusting
19. Filter box Checking

Lubrication Points :-

SL Lubricating Point Suggested Interval


NO. Lubricants
01. Tim pulley shaft bearing Mobilux EP-2 (05-07) Months
02. GE gearing Mobil gear oil (05-07) Months
632
03. Spindle bolster Mobile velocite (05-07) Months
oil 6
04. Drive shaft bearing Mobilux EP-2 (05-07) Months
05. Tape tension pulley bearing Molilith SHC-100 (05-07) Months
06. Screw shaft lifting gear Mobilux EP-2 (05-07) Months
AUTO DOFFER
07. Spar gear in the gear box Mobilux EP-2 (05-07) Months
08. Screw shaft in the power Mobilux EP-2 (05-07) Months
cylinder
09. Taper roller bearing in the Mobilux EP-2 (05-07) Months
power cylinder
10. Crank lever bracket Mobilux EP-2 (05-07) Months

53
54
Auto Coner:

Maintenance Points:

Maintena Maintenance Work to be done


nce Area Point
Waxing shaft Cleaning and checking any
damaged(cut)
Waxing Pressure fork Cleaning and checking any
Device damaged(cut)
Locking flap Remove the yarn accumulation and
cleaning
Yarn trap Remove the yarn accumulation
Guide Plate Cleaning the wax properly
Splice cutter Cleaning and apply R.S. – 400
Prism and its Cleaning the prism by compressed air
cover
Splice Unit Untwist nozzle Clean/wash by petrol & brush,
checking the position
Clamping guide Cleaning by cloth
Pointer Checking the position of similarity
Feeder arm Checking the position
Rubber sleeve Cleaning
Tension Sensor (Tension) Cleaning carefully and adjust if
Device required
Cutter Cleaning and apply RS-400 spray
Lower end Cleaning the sensing area
sensor
Package adapter Check for unobstructed rotation
Cradle Sliding part Cleaning and apply silicon oil
Holder (cradle)
Cradle sensor Check its cover and screw
Circular Dis-assy, check, clean and refixing
magazine
Magazine Chute door Cleaning, centering check
Ejector Cleaning & movement check
Bobbin peg Cleaning
Deflection roller Remove loose yarn ends from the
Conveyor deflection rollers
belt Tensioning Remove cover from the belt
Device tensioning device of the conveyor belt
and remove yarn laps / jam if required
Rail Cleaning
OHTC Filter Cleaning by compressed air
Shifter Cleaning and put one drop silicon oil
55
Suction end and Head stock Cleaning the fly waste from head
stock and suction device compartment

Suction arm Checking (adjust if required)


Cradle vibration Checking (adjust if required)
Paper cone to Checking (adjust if required)
drum
Checking Bobbin peg Checking (adjust if required)
and centering
Gauging Dust collection Checking (adjust the alignment if
assym. (OHTC) required)
EYC Checking the sensitivity
All kinds of nut & Nut-bolt checking, tightening if
bolt required

Lubrication Points:

Lubrication Points Used Lubricants Intervals


Lubricate the RH package adapter Silicon oil (S-1000) 1 month
Apply the maintenance spray (RS- Maintenance spray 1 month
400) on both splice cutter and lower RS-400
yarn cutter
Lubricate the LH package adapter Shell Alvania 4 months
grease – R2
Lubricate the RH package adapter Kluberplex BE 32- 1 year
222
Lubricate the suction drive motor Shell Alvania 4 months
grease – R2
Lubricate all internal rotating parts Lithium grease 4 months
containingMos2 /
Molykote spray
Lubricate all bearing points of the Lithium grease 8 months
gear containingMos2 /
Molykote spray
All toothed wheel and toothed Shell Alvania 8 months
segment of central housing grease – R2
Lubricate the yarn guide drum Shell Alvania 2.5 years
grease – R2

56
Utility Department

The utility department undertakes the following units –


o Power generation.
o A/C Plant.
o Fibre Deposit Area
o Chiller Boiler.
o Water supply
o Fire fighting system.
o Yarn Conditioning Plant
o Compressor

Power Generation:
The factory generates its own power from natural gas. It has six
generators of 1145 KW each. The generator’s specification are as
follows-

No of generators : 6
Model : G-3516 B
Manufacturer : Caterpillar
Country of Origin : U.S.A.
Compression ratio (Air : Gas) : 11.7 : 1
Engine Type : 4stroke engine
Engine rpm : 1500
Total Plant Capacity : 6.87 MW
Power Transmission By : BBT
Starting Motor rpm : 1500
Ext. rpm : 65000
Year of Manufacture : 2006

57
A/C Plant:

The factory consists 4 A/C plants. These are for back process,

ring unit, finishing unit and rotor unit. The main task of A/C plant is to
maintain

specific humidity in the factory shed. For this it circulates the inside air.
The

air is sucked through return ducts, humidified in the water house and
again

supplied through supply dampers. Outside air is mixed to some ration


if

necessary. The temperature can also be controlled if cool water is


sprayed in

the water house. The following RH. Conditions are maintained in the
floor –

Back process 48 to 55%


Ring unit 48 to 52%
Finishing unit 60 to 65%
Rotor unit 60 to 65%

The A/C plants of ring unit are of LTG and those of rotor unit are of
Best

Air. The main impact of humidity and temperature controlling is on the

machine performance, machine life and on personnel. Under favorable

58
condition, the machines will run smoothly and their lifetime will also

increase. Also the operators will feel comfortable and their


performance will

be optimum. Otherwise all these will suffer.

Chiller :

The main purpose of chiller is to supply chilled water to the A/C


plant. Here
there are three chillers .

Hot water chiller


Model : LWM-W067
Cooling Capacity : 520 µsRT
Heating Source : Hot Water
Serial No. :
060101104800201C
Manufacturer : LS
Country of origin : South Korea
Year of Manufacture : 2006

Steam Fired chiller


Model : LSH-W 070S
Cooling Capacity : 630 µsRT
Heating Source : Steam
Serial No. :
060101104800101C
Manufacturer : LS
Country of origin : South Korea
Year of Manufacture : 2006

Gas Fired chiller


Model : LDF-S070S
Cooling Capacity : 650 µsRT
Heating Source : Gas
Serial No. :
060101104800301H
59
Manufacturer : LS
Country of origin : South Korea
Year of Manufacture : 2006

Total Capacity of Chiller is 1800 µsRT

The hot water chiller runs on the hot jacket water from the generator.
The steam
fired chiller runs on steam produced using exhaust gas of the
generators.

Temperature maintained within the mills shade is as follows:

Back Side : 26 to 30˚C


Ring : 28 to 30˚C
Winding : 26 to 30˚C
Rotor : 26 to 30˚C

Boiler:

In Delta Spinning Mill boiler is used to generate steam. This steam


is used in chiller. Boiler specification is given below:-

Model : WHR-4250/10
Brand : Schneider-Kessel
Berlin
Year of Manufacture : 2006
Steam Capacity : 4.25 t/h
No. of m/c :1
Maximum working pressure : 10 bar

60
Compressor:

In spinning factory, compressed air is necessary for operating of


various
machines. Moreover it is also used for different cleaning purpose. The
task of
compressed air supply is carried out by compressor machine. The
factory
consists of the following compressor machines –

No of machine :3
Model : L-55
Country of origin : Germany.
Year of Manufacture : 2006
Type : Screw Type
Capacity : 3000
Pressure capacity : 10 bar max.

Yarn Conditioning Plant :

In yarn conditioning plant yarn is used to stabilize the twist.


Sometimes here give some weight into yarn. YCP specification is given
below:-
No. of m/c : 01
Model : 1200 kg
Brand : Seizer
Country of origin : India
Year of manufacturing : 1996

61
IMPORTANCE OF RH AND TEMPERATURE:

The atmospheric conditions with respect to temperature and humidity


play very important role in the manufacturing process of textile yarns.
The properties like dimensions, weight, tensile strength, elastic
recovery, electrical resistance, rigidity etc. of all textile fiber whether
natural or synthetic are influenced by Moisture Regain.
Moisture regain is the ratio of the moisture to the bone-dry weight of
the material expressed as a 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 time, attains an 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

o Elongation % goes up with increased R.H.% for most textile


fibers
o the tendency for generation of static electricity due to friction
decreases as RH goes up
o 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
62
suspension and , therefore, temperature and humidity must be
considered together.

ISO Standard # 139 defines Standard Atmospheric Conditions :


• Temperature of 68° ± 4°F (20±2° C)
• Relative humidity of 65% ± 2%

Fire Fighting System :

Cotton fiber catches and spreads fire very fast. So any kind of
accidents

related to fire generation can turn into a devastating calamity in a


cotton

spinning mill. That is why the factory has a well equipped fire fighting
system.

Water lines are spread though-out the factory. Water is pumped by


means of the main fire fighting pump. Other than this, there is also a
jockey pump which maintains the water pressure through-out the pipe
line.
Also there are extinguisher of both CO2 and ABC powder type. A
skilled team
of fire fighters always remain alert within the factory. Fire drills also
take place regularly.

HR and Admin Department


Definition of HR and Admin :

The policies and practices one needs to carry out the people or
human resource aspects of a management position including,
recruiting, screening, training, rewarding and appring. This is HR or

63
Human Resource. The main object of HR is to make a man into
resource.
Admin administrate the all department. Admin department
does the appointment, labour welfare, labour department,
recommendation, staffing etc.
Two types recruiting system:-
I. Internal
II. External
In Delta Spinning Mills viva board consists of minimum 3 person. They
are :-
I. HR Head
II. Departmental Head
III. 3rd Person

Leave Days of Delta Spinning


Mill
According to labour law 1 year leave days of the mills given below :-

Name of Leave How many days Overtime


Week end leave 52 days No
Casual leave 10 days No
Medical leave 14 days No
Earn leave 16 days Over time will be
given
Festival leave 11 days Over time will be
given

According to 26 days working days over time calculation :-

Overtime=Basic/208 * 2 * Hours

64
Salary

The entry level salary of the production worker is 2200 taka.


The entry level salary of the quality lab assistant is also 2200 taka.
The entry level salary of the maintenance worker is 2500 taka.
But the entry level salary of the officers such as APO, PO, Executive are

Negotiable.

Inventory System:
The inventory system can be divided into four major types:

1. Raw cotton inventory.


2. Wastage cotton inventory.
3. Finished yarn inventory.
4. Spare parts and materials inventory.

The inventory in maintained in First in First out system. When the


store

receive some goods, they write a note about it in the received khata
and inform

the concerned department about it. The concerned department then


inspects the
65
goods and approve those if are satisfactory. Then the MRR (Material
Receiving

Report) is made. Then BIN card for that particular item is made which
contains

its name, part no, card no, amount and other necessary informations.
Then the

material is stored in the store. In case of raw cotton after sampling and

numbering the bales, they are stored in the raw cotton godown.

If any department requires any item, they prepare a requisition slip


(SR) for

that particular item and send it to store. The store then checks its
availability and

delivers as required.
The daily production of finished yarn of different lots are given to
the store

form the production department by means of a “Transfer Memo”. The


store

produces its daily and monthly production report based on it. Then
according to

the order of the marketing department, the yarns are delivered to the
buyers.

Also the different wastes produced from different department are


measured and

handed over to the store in the same procedure.

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Inventory Procedure :
# Bin Card
# Store Requisition
# Store Ledger Account
# Daily Inspection & Package Report
# Monthly Stock & Consumption Report
# Monthly L/C wise Delivery Report
# Received Delivery & Balance.

Marketing Information:

The marketing activities of The Delta Spinning Mills are carried out
from the

corporate head office. The marketing activities are shortly described in


the

following portion –

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At first market research and survey is carried out. The customer’s
wants are

specified and also the other products available in the market are
studied. Then

samples are made and delivered to different customers for approval.


When

approved, a Proforma Invoice containing product quantity, validity,


count etc

are given to the customer. Then the customer open L/C. Then
depending on the

customers urgency, the production plan is made and the factory begins

production according to it. Then Delivery Order is made and delivery of


yarn is

carried out to the customers according to it.


Then documentation is done according to L/C. The documents
include Bill of

exchange, delivery chalan, Commercial Invoice and Packing list. The


bill of

exchange and the delivery chalan is acknowledged by authorized


person from

buyer’s side. The buyer also issues an Inspection Certificate (IC) if the
goods

fulfill the requirement. Then Copy of these documents as pe L/C are


submitted

to the bank. The bank the then endorses the Bill of Exchange and
delivery chalan

68
& forwards these to the buyer’s bank. Then the buyer’s bank gives a
maturity

date. The whole correspondence is done in terms of USD. Then at the


end of

maturity period, the amount is received in the bank account according


to the

L/C.

L/C OPENING FLOW CHART


Requirement of material with
specification

To inform about requirement to the head of the


management

Management will search for the


requirement

Various company response with those


specification

The management will select some


offers

Then discussion will held among two


management

Management will sign the agreement with the selected company or


agencies

Then negotiation will take place among management and


agencies

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Submission of the final
PI

Bank will open L/C

Customers:

• Delta Composite
• Pacific Denim
• Hamim
• Royal Denim
• Astro Knitware
• Alim Tex
• Fariha Knitware
• Metro Knitting & Dyeing
• Babyllon Group (Aboni Textiles Ltd.)

After Sales Service:

• Maintain the relation with the buyer.


• Respond to any quality complain.
• Ask for further order.

Involvement in Social Development:

The Delta Spinning Mill provides primary medical services to all its
workers
and staff by maintaining a two bed health care center operated by an
M.B.B.S.

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doctor. It also organizes an Annual Internal Sports Program for all its
staff.

It also allows training programs and industrial visit programs for the
students of different textile educational institutes.

Technical education and its adoption in practical field are involved


inseparably. Without the implementation of the knowledge gathered in
technical
education, its success is bound to suffer. Therefore, this two months
long
industrial attachment training, as a partial fulfillment of our B. Sc. in
textile
technology course helped us to accomplish the gap between the
theoretical and
practical knowledge by providing an elementary idea about industrial
environment, processing machines, tools, quality management, quality
equipments, production system, maintenance, administration and
management
system.

The Delta Spinning Mills Ltd is such an well equipped, well staffed,
well
planned, well organized and well administrated mill that it has become
a role
model for all the industries in Bangladesh. Other than producing export
quality
cotton hosiery yarn, it is also developing a skilled manpower which is
very
important and fruitful for the Textile Industry in Bangladesh.

We tried our best to utilize our training program by collecting all the
71
knowledge and information. But were not 100% successful due to
shortage of
time. But all our success is well contributed by our teachers and the
staff of
TDSML. For all these we would like to thank them all from the deepest
corner of
our heart and hope that all these will be greatly helpful for our
professional life.

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