Industrial Attachment Report

BANGLADESH
UNIVERSITY
OF
TEXTILES
INDUSTRIAL ATTACHMENT REPORT

OF
R.K. SPINNING MILLS LTD

(From 16th may to 16th July)
Supervised By:
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
Layout Plans of 1st and 2nd floor

Blow room section
Carding section
Drawing section
Lap former
Comber
Simplex section
Ring section
Winding section
Finishing section
RAW MATERIALS
Raw materials used
Raw materials procurement
3
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-
Price of the raw cotton

Raw cotton suppliers
PRODUCTION PLANNING,SEQUENCE AND
OPERATIONS
Production Parameters
Production Capacity
Concept of Bale management
Process of Bale management
Process sequence
QUALITY ASSURANCE
SYSTEM
Quality assurance procedure
Testing Equipments
MAINTENANCE
Maintenance
Maintenance
Maintenance
,simplex
Maintenance
Maintenance
points in Blow room line

in Carding section
of comber,draw frame
in Ring section
of Autoconer
UTILITY SERVICES
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:
Name of the mill
R.K. Spinning Limited.
Location of the mill
Godnyle ,Chowdhuribari, Narayonganj.
Type of the mill
100% Cotton Spinning Mill.
Production Start
Spinning System
One type-Ring Spinning
Capacity
45000 (Ring spindles)
Total land area
100 Acres
Production/day
Ring yarn-22 tons
Production capacity achievement
80%
Head office
5th Floor, House # 2, Road #21,Gulshan
On 1st March 2007
1.2 Shift Classification:

A-shift
B-shift
C-shift
:
:
:
6 am to 2 pm
2 pm to 10 pm
10 pm to 6 am
1.3 Machines in the mill:

No. of Blow Room line
No. of Carding
No. of Draw Frame
No. of Simplex
No. of Ring
No. of winding m/cs
No. of Conditioner
= 02
= 22
= 14
= 11
= 45
= 12
= 01
Brand:TRUTZSCHLER
Brand:TRUTZSCHLER
Brand:TOYOTA
Brand: TOYOTA
Brand:TOYOTA
Brand:MURATEC
Brand:CONTEXXOR
1.4 Origin of machinery, tools and equipments:
Japan
China
Germany &
Switzerland
1.5 Product Mix:

RING YARN
ROTOR YARN
: Carded yarn.
: Under Construction.
1.6 Production Capacity:

UNIT
Ring yarn
Total spindle
45000 R.K.
18000 A.B.R
Count range
Ne 20 to 40
Production capacity(Tons/day)
24
10
1.7 Different Departments:
Production Department
Quality control and assurance department
Maintenance department
Utility department
Power generation department
Store Department
Security Department
1.8 Physical Infrastructure:

R.K. spinning mill is organized into three major parts factory, sales and procurement (S&P)
department and Finance department and Account department of which the factory consists of
five departments namely Production, Maintenance, Quality control & Assurance,
Administration and Information technology.
1.9 Stuff facilities:

Residence and Food facilities for the entire officer.
Chapter-2
MANPOWER
MANAGEMENT
2.1 Manpower setup:
Name of department
R.K. Spinning Mill
Total worker for production department

Total worker for utility department
Total worker for maintenance department
Grand total worker of unit-1
Workers of unit-2
Grand total of workers
600
22
50
672
318
990
2.2 Officer and staffs:

Name of Department
R.K. Spinning Mill
Total officer(with ED+ASO)

Total staff
Security Personnel
Grand total of officer and staffs
62
63
21
146
So the total no. of worker with officers and staffs is 1136

2.3 Worker rights and privileges:
01. Wages statement for workers:
GRADE
SALARIES
HOUSE RENT TREATMENT
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
: 9 am to 5 am (lunch time 1 pm to 2 pm)

: 6 am to 2 pm.
: 2 pm to 10 pm.
: 8 hours per day, 48 hours per week.
: 2 hours per day, 12 hours per week.
: Friday or any day in a week.
: 11 days.
: 10 days.
: 14 days
: 1 day.
2.4 Point of compliance:

01. Training of workers (Syllabus and training program):
a) IWAY
b) Fire
c) First aid
d) Machine safety
e) Electrical safety
f) PPE
g) Labor law rights and privilege
h) Dangerous operation.
02. Fire fighting evacuation:
a) Extinguisher
b) Team
c) Evacuation plan
d) Fire drill
e) Alarm
f) Records keeping.
8
03. First aid:

a) Box
b) Medicine
c) Team.
04. Toilet
05. Drinking water
06. Noise level
07. Safety instruction on machine safety devices
08. Compensation and benefit
09. Working hour and weekly holidays
10. Harassment abuse and disciplinary practices
11. Issue of appointment latter.
12. Grievance police and welfare.
13. Personal file and list of workers with date of birth.
14. Attendance registers and card (Shift wise).
2.5 Major duties and responsibility of production officer:

1. smooth running of the section.
2. Make the junior officers understand how to operate the whole production process.
3. All of the junior officers and workers of his shift keep themselves busy to their duties
under his supervision.
4. Always ask his officers what steps they have to taken for the betterment of the factory.
5. Check the worker setting to the machine. In case of worker shortage in a particular
machine and fill up gap deputing worker from another section.
6. Collection of necessary information and instruction from the previous shift for the To
control production process and quality parameters of the machine.
7. To ensure target production of each machine with appropriate quality.
8. To control the workers so that they can operate the machine as per instruction.
9. In case of machine breakdown he has try best to start it as early as possible.
10. Secure conventional rules and regulation inside of the factory.
11. To arrange necessary punishment for the worker if they violet discipline.
12. Ensure cleanliness of all machine and floor.
13. Ensure use of proper dress, waste bag, cleaning stick of the worker.
14. To keep eyes on worker to minimize machine down time.
15. Ensure sorting of contamination and heavy particle from the lay down.
16. Ensure use of waste sliver and pneumafil in the in the Blow room.
17. Prevent lot, count mixing in different production stage.
18. Checking of machine setting, drafting zone cleaning.
19. To train up the learners.
20. To take necessary steps to reduce soft wastage.
21. In case of any problem regarding production, maintenance etc. take decision when the
high officials are not available in the section.
22. To keep the workers always busy with their duty so that they dont get time for
unnecessary gossip.
23. Checking of sticker, defective cone, and package weight in finishing avoiding mixing.
24. Sometimes he works himself through different machine if necessary.
9
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:
To control shift according to the plan made by the production manager.
Territory:
Production section (major)

Quality control section& maintenance section (minor)
Nature and scope:

Role within the organization:
Responsible for own shift production with good quality and minimum time.
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.
2.7 Management Information system (MIS):

Management information system (MIS) is very important for any production process which
helps the management to get correct information about productivity of different machine,
machine efficiency, idle spindle, end breaks, product quality, process parameter i.e. hank,
count, T.P.I. wastage % doffing time, creeping time, CV %, thick, thin, neps, etc. which are
necessary to make correct decisions and take the correct course of acting it is clearly essential
that they should not be confused by superfluous information, hampered by delayed
information or mislead by confusing information.
11
Chapter-3
MACHINE DESCRIPTION
Layout of Ring Spinning Unit
12
BLOW ROOM SECTION:

3.1 Blow Room Line
Introduction:
The Blow Room is the first processing stage in Yarn Manufacturing Process. Starting with
bale management it performs the opening, cleaning, dust removal, sometimes blending and
accelerates even feed of the material to the card. The Blow Room section is obviously
sophisticated one, equipped with modern machines, which are suitable to go for quality
production. In order to produce carded yarn, combed yarn and rotor yarn the Blow Room
section is divided into parts or lines referred to as ring line.
3.1.1 Machines available in Blow Room section:

1. Blendomat machine
2. Maxi-flo machine
3. Securomat machine
4 .MPM machine
5. Clenomat machine
Two types of detector are available. These are
1. Metal detector
2. Fire detector
Fig: Blow Room Section

13
01. Blendomat machine:

No of machine
Model
Manufacturer
Year of manufacturing
Country of origin
Traverse drive speed
Take of depth
Main frequency
Use of electricity
Production
Material used
02. Maxi-flo machine:

No of machine
Model
Manufacturer
Country of origin
Cleaning intensity
: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
Relative waste amount

Main frequency
Use of electricity
:8
: 50~60Hz
: 110V~400V
Production
: 1000kg
03. Securomat machine:

No of machine
Model
Manufacturer
Country of origin
Main frequency
Use of electricity
Production
Material used
Blending chamber
Storage capacity
Working width
Length
Width
Height
: 4000mm
04. MPM machine:
No of machine
Model
Manufacturer
Country of origin
Main frequency
Use of electricity
Production
Material used
Cleaning intensity
Working width
Cleaning cylinder
Speed
Relative waste amount
: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
3.1.2Blow room line for Ring Yarn (Trutzschler line ):

Blendomat (BDT)
Securomat(Sc)
Precleaner(CLP)
15
Integrated Mixer(MI 6)
Cleanomat(CLC-1)
Foreign Part Separatore(SFP)
3.1.2 Beating points:

Major beating points: 2
i. Maxi-flo
ii. MPM
Minor beating points:

i. Waste opener B2/5
Dust collection system:

i. Air suction system
Mixing system in Blow room:

I. Completely auto mixing system
Delivery system towards the card line:

I. Chute feed system
Beater r.p.m setting:

Beater is set according to cleaning intensity and relative amount of waste.
Cleaning intensity:
Range: 1to 10
Relative amount of waste:

i. Range: 1 to 10
ii. Grid bar setting wider: 10 (maximum)
iii. Grid bar setting closer: 1 (minimum)
3.1.3Comments on blow room:

The blow room section of R.K.Spinning Mills Ltd is equipped with modern machinery.
Production rate is also satisfactory. But it should be noted that this spinning deals with 100%
cotton only, used to produce knitted yarn. As a result it consists only to Blow Room lines,
which does not exhibit any variations and complexity in machine sequence as well as in
operational procedures as it would be seen in a mill producing blended yarn. For different
count of yarn, weight should be varied. But in R.K. Spinning Mills Ltd, It is not carried out;
waste extraction percentage is not measured regularly. In Blow Room section, maintaining a
16
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 Carding Section:
Fig : Carding Machine
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
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
3.2.2 Regulating action for constant feeding to the card:

To get a constant & uniform feed to the card, two methods are implemented. In the first
case the volume of the mat is input to the control panel of the card mechanism, which
regulates the feed to the card by servo- motor. The motor speed increases or decreases
according to the volume of the incoming material to the card m/c so that a constant feed
volume is obtained.
3.2.3 No of operating zone
Feeding zone.
Cleaning zone. (Taker - in)
Carding zone.
Sliver formation.
18
3.3The Drawing section
Fig: Draw Frame

3.3.1 Introduction:
The drawing frame is an essential machine in any spinning mill. The drawing section of R.K.
Spinning mills Ltd. consists of ten draw frames. Drawing provides elongation of sliver,
therefore more parallel and oriented fiber arrangement in the sliver is obtained. The purpose
of drawing is to reduce soft large mass of fibers into the final usual yarn size and also to
reduce trash and neps.
19
3.3.2 Breaker Draw frame:

No of machine
: 04
Specification:
Model
: DX-8
Manufacturer
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
3.3.3 Finisher Draw frame:

No of machine
: 7
Specification:
Model
Manufacturer
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
3.3.4 Comments on drawing section:

Humidity in drawing section cannot be controlled always. As a result of it roller lapping may
be occurred which causes defective in production. This section is kept in running condition
maximum time to ensure the feed material of next process.
20
3.4 Lap Former
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
Front detaching R/r dia

Back detaching R/r dia
Front detaching R/r dia
Back detaching R/r dia
24.5 mm
24.5 mm
25 mm
25 mm
Draw box roller dia:

22
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
3.6 The Simplex Section
FIG: Simplex Machine

3.6.1 Introduction:
The Simplex section provides an important part in ring spinning process. It is the final
operation procedure in the back process producing roving, a continuous slightly twisted stand
of fibres, which is fed directly to the ring frame to produce yarn. The function of roving
frame is drafting the sliver from draw frame, increasing a little amount of twist & then
winding the roving in a taper shaped bobbin , which facilities easy with drawn during feeding
to the ring frame. R.K. SPINNING MILLS LTD. consists of 10 modern simplex machines
with sophisticated regulating motion, ready to provide materials to 77 Ring Frame.
23
Particulars Obtained:
No of simplex
: 12
Specification:
Model
Manufacturer
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
3.6.2 Diameter of different rollers:

Roller type
Front roller
2nd roller
3rd roller
Back roller
Top roller dia

28
28
28
28
Bottom roller dia(mm)

28.5
28.5
28.5
28.5
3.6.3 Signal system:

Color
Red
Green
Yellow
White
Meanings
For roving breakage
For doffing
For sliver breakage
Auto stop indication by light
3.6.4 Comments on simplex section:

Different colors of bobbin are used for different counts. So there is no possibility of mixing of
different count roving. Sometimes sliver breakage occurs mainly due to lake of supervision,
which can be indicated easily.
24
3.7 The Ring Section
Fig: Ring Frame

3.7.1 Introduction:
Ring frame section is the last section in a spinning mill producing ring yarn. The R.K.
Spinning Mills Limited consists of 45 ring frames providing 45000 spindles. All the ring
frames are modern once with auto doffing and auto stop motion.
Number of ring frame
: 45
Machine specification:
Model
Manufacturer
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
Pressure in drafting zone
: 14 lbs
Apron brand
Top apron origin
Top apron size
:Accotex
: Kureha, Japan
: (37*27.8*1.0) mm
Bottom apron origin

Bottom apron size
: Accotex, Germany
:( 36.9*30*1.1) mm
(Length x Width x Thickness)
: Precitex, India
: (19*30*28) mm
Origin of cot roller

Cot roller size
(Inner dia*Outer dia*Width)
Traveller type
Traveller no.
Traveller no
1
1/0
2/0
3/0
4/0
: 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
3.7.2 Comments on ring section:

In this section, the humidity plant controls humidity but temperature cannot be fully
controlled. Sometimes temperature is increases in such a high rate that it creates an
unbearable situation for the workers and the officers. The end breakage rate is low for the
proper maintenance and modern machineries. So the production is quite satisfactory.
3.8Winding section
No. of machines
: 12
Model
:Savio Polar, Savio Orion

26
Manufacturer
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.
Comments on winding section:

In this section, the humidity plant controls humidity but temperature cannot be fully
controlled. Sometimes temperature is increases in such a high rate that it creates an
unbearable situation for the workers and the officers. The end breakage rate is low for the
proper maintenance and modern machinery. So the production is quite satisfactory
3.9 Rotor Spinning

Particulars Obtined
No. Of machines
:2
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
3.9 Finishing Section

3.9.1 Introduction:
Yarn bobbins which are to be supplied to mark should under go the following operations:
Yarn bobbin
Heat section
27
Cone winding (Package form)

Packing
(Carton)
Storing
3.9.2 Heat setting or Twist setting:

For the heat setting, one room is provided and required temperature and humidity are
supplied to the room. And the package of yarn placed on the creel for the specified time by
this process heat setting / twist setting is done.
Chapter-4
RAW MATERIALS
28
4.1 Raw Material Used:

Productivity, quality and profitability all are depend on raw materials. Raw material is main
factor in every factory. R.K. spinning mills Ltd, only cotton yarn is produce. As cotton is not
grown in our country, so all of this cotton are imported from foreign countries. R.K.spinning
mills has used several types of cotton, which are imported different countries.
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
4.2 Raw material procurement:

R.K. spinning mill runs on 100% imported raw cotton. R.K. mill mainly uses Shanker-6,
India J-34 raw cotton from India, CIS (Commonwealth Independent States) raw cotton from
Uzbekistan. The cotton is bought on credit from India & Uzbekistan.
At first the cotton is booked. The price of the cotton depends on it pick. After the price and
other terms and condition are set, it is brought by transport through Benapol port.
After shipping, it requires around 27-35 days to rich Chittagong port. The cotton has to be
inspected before or after shipping. But if it is inspected in Uzbekistan, then it is cost around
6000-7000 USD. So it is inspected in Chittagong which cost around 2000 USD.
The cotton has to be inspected before and after transporting. After the cotton lands on
Benapol port it is checked for weight and moisture content. If any irregularity is found in
weight of the material, then monetary claims from the port after being cleared from the port
by C&F agents. Then it is transported to the factory by trucks.
4.3 Price of the raw cotton:

Name
Price(Rate $ per Lbs)

29
Australia
India
CIS
Uganda
1.5
.75
.90
1
4.4 Raw cotton suppliers:

Supplier`s Name
Country
Cotton Corporation
Cotton Club
Queensland Cotton
OLAM
GHANDHI Cotton
Bangladesh
Bangladesh
Australia
Singapore
India
Chapter-5
Production Planning &

Sequences &
Operations
30
5.1 Production Parameters:

Yarn
type
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
5.2 Production Capacity:

Unit
Ring yarn
Total spindles
45000
18000 (ABR)
Count range
10Ne to 50Ne
10Ne to 50Ne
Production capacity
22 Tons/day
5.3 Concept of Bale Management:

Bale Management is a process of inventory control and selection of bales of fibres according
to their properties and also to mix the fibres homogeneously to get consistent production and
quality of yarn. For bale management, all of the bale samples are tested and bales with almost
similar category are arranged for homogeneous mixing.
5.4 Procedure of Bale Management:

.Bale management is one of the important task for going into production of good quality
yarn.so it must be done properly.An specific spinning mill has to do it regularly by keeping
the quality consistent. Bale management is done to
Have proper blending of fibres of different grade.
Have a proper average of Mic value of fibres.normally it is kept in a range of 4.3-4.6
Make the fibres ready for the next processes.
Have a proper mixing of fibres of different length.
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
Avg mic: 4.51
10
11
5.5 Information found on a Bale:

Gin No.
Lot No.
32
Bale weight
Suppliers Bale No.
5.6 Binding Material for Bales:

Steel wire, Polyester strap etc.
No. of Binders : 6 to 8
5.7 Types of Raw cotton used:
CIS Ronda.
CIS pervi.
American pima
Sudan
Zambian
5.8 Manpower available in mixing section:
Mixing man
Cleaning man
A.P.O
Total
: 04
: 02
: 01
:07
5.9 Raw materials:
Type
Price
Source
Annual requirement
: CIS
: 60 to 85 cents/ Ib
: Uzbekistan, Tajikistan
: (95 X 365) bales.
5.10 Production flow chart:

Carded yarn
Blow Room
Carding
Drawing
Simplex
Ring frame
33
Winding
Chapter-6
Quality Assurance
System
6.1 QUALITY ASSURANCE :
Quality Control
Department
OFF LINE
ROUTINE TEST
ON
LINE
6.2 Information about testing equipment:

6.2.1Wrap Reel:
Manufacturer
Model
Country
Function
: 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.
6.2.3 HVI1000 (High volume instrument) Tester:

Manufacturer
Model
Country
Function
: USTER
: Premier art
: Switzerland
: Determination of
Micronaire Value
Color
Trash %
Length
34
Strength
Uniformity
Elongation
Moisture regain %
6.2.4 AFIS(Advance Fiber Information System):

Manufacturer
Model
Country
Function
: USTER
: AFIS PRO 2
: Switzerland
: Determination of raw cottons nep, Trash,Maturity ratio.
: Determination of sliver neps, Trash.
6.2.5 Uster Evenness Tester:

Manufacturer
Model
Country
Function
Yarn, roving and sliver.
: USTER
: Uster Tester 7000
: India
: Determination of the following faults in the
Imperfection (Thick, Thin, Neps)
Unevenness ( U %, CV% & Diagram)
Hairiness & CV% of hairiness.
Reports of USTER Tester is given below

For Roving :
U%
1
2
3
4
Mea
n
CV%
USP
01
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
11.28 14.39 1.38

11.71 14.85 1.42
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
11.21 14.25 1.37

11.05 14.06 1.35
11.31 14.39 1.38
0.0
2.5
301
112.5 307.5 7.99

122.5 297.5 7.95
116.3 393.8 8.36
1.77
1.77
1.89
-1.5
1.6
0.0
11.71 14.95 1.42

11.05 14.06 1.35
10
10.0
0.0
<5
122.6 475.0 9.04

112.5 297.5 7.95
9
54
>95
9.04
7.95
73
1.6
-1.5
6.2.6 Digital Twist Tester:

Manufacturer
Model
Country
Function
: WIRA
: DE 5
: UK
: Determination of yarn T.P.I.
6.2.7 Optical yarn reader:

Manufacturer
: Capio
Model
: OYR 1513
Country
: Italy
Function
: To measuring slub dia, length
&distance between two slub.
6.3 Quality assurance procedure:
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.
Check & clean properly by compressed
air.
Retainer roller
air.
Conveyor belt
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
Chamber
Upright lattice
Blending roller
Take off roller
Sensor
V-belt and pulley
Clean, check belt & chain tension.
Lamellar chute
Cleaned by soft cloth &compressed air.
Perforated roller
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
Check any damage & position.

Clean properly.
Clean by soft cloth.
Upright lattice
V-belt and pulley
Sensor

7.1.2 Maintenance carried in blow room:

Periodic maintenance
Maintenance Period
:After 7 to 10 days
: From 8 a.m. to 5 p.m.
7.1.3 No of men in maintenance of blow room to carding machine are ten

Maintenance assistance
Maintenance helper
:3
:7
Schedule maintenance
Preventive maintenance
: After two weeks

: 1 month or 3 month.
7.1.4 Maintenance tools for blow room to carding machine:

Adjustable range
Screw driver
Hammer
Spanner etc.
1 month, 3 month, 6 month, 1 year, 1 and a half year.
Duration of maintenance for carding machine
: 2.5 to 3 hrs.
Duration of maintenance for blow room
: 3.5 to 4 hrs.
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.
7.1.7 Examples of maintenance procedure instructed by the manufacturer:

38
Name of the machine

Maintenance and Lubricating schedule
Item
Plucker roller
Head slewing
Traverse
Flexible pipe
Internal structure comb
Blendomat
: Every month
Action
Inspect for sign of damage
Ensure clean
Inspect and clean cowl plate grille
Check condition
Ensure clean
Maintenance and Lubricating schedule: Six month

Item
Plucker roller
Plucker roller drivers
Head lifting drive
Head slew drive
Transport fan drive
Action
Check condition of the teeth
V-belt drive check
Duplex drive chain-chain tension
Drive belt check tension
Maintenance and Lubricating schedule

Item
Bearing for plucker rollers
Cutting head
Tower support head
: One year
Action
Replenish lubricant using shell
Alvania-3 or equipment
Do
Lubrication of head drive unit:

Mobil synthetic oil ED62/230 viscosity class VG680 or equivalent.
Lubrication of head slewing drive unit:
Shell BP mineral oil viscosity class VG220 or equivalent.
Lubrication of traverse drive unit:
Shell BP mineral oil viscosity class VG220 or equivalent.
Name of the machine: Securomat

Maintenance and Lubricating schedule: Every three month.
Item
Variable speed for feed rollers
Variable speed for beater rollers
Conveyor belts
Action
Duplex drive chain lubricant using, gear box
check oil levels and replenish if necessary.
Duplex drive chain to roller lubricating used.
39
7.2 Maintenance check list of carding m/c:

MAINTENANCE
AREA
MAINTENANCE POINTS
WORK TO BE DONE
Aero feed
Check and clean.

Check and clean.
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
Check and clean.

Check and clean.
Check and clean.
Clean properly & check sharpness
of the wire.
Clean, check tension & adjust if
required.
of the wire.
Check and clean.
Check and clean.
Check and clean.
Check and clean.
Clean & check function.
Clean & check condition.
of the wire.
Clean properly.
Feed roller to licker- Check gauge & adjust if

in
required
Check gauge & adjust if required
Licker-in to cylinder
Cylinder to doffer
Cylinder to flat
Doffer to striping
roller
Coiler calendar roller
Rotary plate for can
40
Drive for rotary can

plate
Can changer
Maintenance points

Frequency
Suction points and hoses

Interior of the coiler
Detaching unit
Check the doffer
Clean flats reversing points & the space
Inside the flats
Empty condenser
Check the tension & condition of the belts
Check the condition of the flat bar
Clean & check carding profiler
Check the tension of the flat belt
Cylinder inside & Cylinder gasket
Check the stripping knives
Check the bottom of the coiler & coiler tube
Check setting
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
7.3Maintenance of draw frame, comber & simplex:
Nine people are involved in D, C, S maintenance.

Number of maintenance assistant 4
Number of maintenance helper 5
Schedule maintenance After 2 weeks
Preventive maintenance 1 month, 2 month, 3 month
Maintenance check list of Breaker drawing:

MAINTENANCE POINTS
WORK TO BE DONE
Outer surface
Outer surface of the whole machine

Clean properly check its condition.
Drafting zone
Pressure bar, dead weight, condenser,

trumpet.
Top roller
MAINTENANCE AREA
Gear box
Planetary gear box
Cleaning by washing powder &

grinding after 5000 hour.
Clean & check its gauge, reset if
required.
Check oil level & put oil if required.
Electrical parts
Motor, fan, creel light barrier
Clean & check by electrical person.
Nut-Bolt
Top roller lock, pulley nut-bolt, creel

nut-bolt, drafting zone nut-bolt.
Check tightness &

tightness if required.
Belt tension and condition
Flat belt, V-belt, timing belt
Clean the entire belt, check tension
Bottom roller
make
41
perfect
adjust if required.
Suction system
Can changer
Filter box, filter screen, fan blade.

Can plate
Power cylinder
Clean properly filters & blade condition.

Clean & check meshing condition,
vibration, abnormal noise etc.
Gear
7.4 Maintenance procedure of lap former:

At first, the gear box is opened and grease is applied to all gears. Top and bottom rollers are
opened and cleaned with sprit. Top roller, feed roller, calendar roller, sliver table, sliver guide,
counter shaft, conveyer belt, guide roller, lap plate, lap drum, bobbin box, bobbin feeder,
creel parts are cleaned . In all the bearings and gearings of the above parts lubrication is
carried out. All the nuts and bolts are checked. If any parts of the m/c are damaged, it is either
changed or repaired. Then the whole m/c is set sincerely and the m/c is started experimentally
to watch if the m/c is running smoothly.
7.5 Maintenance procedure of draw frame:

First gear box is opened and clean finally with cloth. Then grease is applied to gears.
Roller part is opened and cleaned with sprit. In all the bearing of cover is opened and cleaned.
In the bearing gears, grease is applied. All the settings, nuts and bolts are checked. If
necessary any parts of the machine can be changed.
Maintenance check list of Breaker drawing:

MAINTENANCE AREA
Outer surface
Drafting zone
Gear box
Electrical parts
Nut-Bolt
Suction system
MAINTENANCE POINTS
WORK TO BE DONE
Outer surface of the whole

machine
Pressure bar, dead weight,
condenser, trumpet.
Top roller
Clean properly by compressed

air.
Clean properly check its
condition.
Cleaning by washing powder
& grinding after 5000 hour.
Bottom roller
Clean & check its gauge, reset
if required.
Planetary gear box
Check oil level & put oil if
required.
Motor, fan, creel light barrier
Clean & check by electrical
person.
Top roller lock, pulley nut- Check tightness & make
bolt, creel nut-bolt, drafting perfect tightness if required.
zone nut-bolt.
Flat belt, V-belt, timing belt
Clean all the belt, check
tension adjust if required.
Filter box, filter screen, fan Clean properly filters & blade
blade.
condition.
Can plate
Power cylinder
42
Can changer
Clean & check meshing

condition, vibration, abnormal
noise etc.
Gear
Maintenance check list of Finisher Drawing:

MAINTENANCE AREA
Outer surface
Auto leveler
Drafting zone
Gear box
Electrical parts
Nut-Bolt
Suction system
Can changer
MAINTENANCE POINTS
WORK TO BE DONE
Outer surface of the whole Clean properly by compressed

machine
air.
Funnel, scanning roller, contact Clean & check their condition
roller
adjusts if required.
Pressure bar, dead weight, Clean & check their condition
condenser, trumpet
adjusts if required.
Top roller
Clean by washing powder &
grinding after 500 hour.
Bottom roller
Clean check its gauge, reset if
required
Planetary gear box
Check oil level put oil if
required.
Motor, fan, creel light barrier.
Clean & check by electrical
person.
Top roller lock, pulley nut-bolt, Check tightness & make perfect
Creel nut-bolt, drafting zone nut- tightness if required.
bolt.
Flat belt, V-belt, timing belt.
Clean the entire belt, check
tension& adjust if required.
Filter belt, filter screen, fan blade Clean properly & filters &
blade condition.
Can plate
Clean & check properly.
Power cylinder
Clean & check properly.
Gear
Clean & check meshing
condition, vibration, abnormal
noise etc.
Spares parts life:

Parts
Cots
Belts
Timing belts
Cans
Bearing
Life time
6-8 years
3-4 years
10 years
6 years
6 years
7.6 Maintenance procedure of simplex:

At first the machine is opened and a general cleaning is done. Greasing is done to all outer
bearings. Gear box is opened according to the authorized booklet of the machine. Top and
bottom rollers are opened and cleaned with spirit and then acid treatment is done. Cotton
43
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.
Maintenance checklist of Simplex:

MAINTENANCE AREA
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
Clean & check bearing condition.

Clean by soft cloth.
Clean & check greasing.
Check grease level & apply
grease if required.
Clean & gauge check & adjust if
required.
Clean & check assembly & adjust
if required.
Clean & check setting.
Clean & check & replace if
required.
Clean & check & replace if
required.
Check height gauge & readjust if
required.
Clean properly by detergent &
replace if required.
Clean by brush replace if
required.
Clean set properly.
Clean & check gear-meshing
condition.
Clean & check the gear
condition.
Clean the outer surface properly.
Auto doffing system is clean by
compressed air.
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
Outer surface of the machine

Auto doffing in machine.
7.7 Maintenance procedure for Ring frame:

First machine cover is opened. All the top aprons and bottom aprons are opened with Surf
ultra. Here acid treatment is done. It is also cleaned with ammonia. In all the middle bearing,
necessary amount of grease is applied. Ring plate is taken down and all the ring caps are
cleaned with corium 97. After cleaning all the gears, sufficient amount with corium 97.
If any part of machine is damaged or rough, it is changed or repaired. In this way, all the
works of maintenance is done successfully.
Maintenance checklist of Ring frame:

44
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.
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.
Spinning traveler cleaner gauge

Auto doffer, beam & conveyor
belt centre
Roller eccentricity & bearing
condition check (back & middle
roller)
Front roller eccentricity, bearing
condition
Driving shaft eccentricity &
bearing condition check
Machine leveling

120 days.
90 days.
730 days.
365 days.
730 days.
730 days.
Maintenance of ring frame:

Twenty three persons are involved in ring frame maintenance
No of maintenance assistants -6
Grade-1 = 2
Grade-2=4
No of maintenance helper-17
Schedule maintenance : after one month
Cleaning, checking and lubrication are included in ring frame maintenance
Lubrication schedule: 6 months (spindle oil), grease (driving shaft), 1 year (gear oil),
1 month (bottom roller).
45
7.8 Maintenance checklist of Autoconer:

MAINTENANC
E AREA
Waxing device
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
Cleaning & checking any damaged (cut)

Cleaning & checking any damaged (cut)
Remove the yarn accumulation
Cleaning the wax properly
Cleaning and apply RS-400
Cleaning the prism by compressed air
Clean/wash by petrol & brush, checking
the position
Cleaning by cloth
Checking the position
Cleaning and checking
Cleaning carefully & adjust if required
Cleaning and apply RS-400
Cleaning the sensing area
Check for unobstructed rotation
Cleaning and apply silicon oil
Check its cover and screw
Check, clean and re-fixing.
Cleaning and centering check.
Cleaning and movement check.
Cleaning.
Remove cover from the belt tensioning
device of the conveyor belt & remove yarn
jam if required.
Remove loose yarn ends from the
deflection rollers.
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
Maintenance procedure for Autoconer:

Ten persons are involved for winding m/c maintenance
No of maintenance assistant-3
Grade-1=1
Grade-2=2
No of maintenance helper -7
Schedule maintenance is done for winding m/c
60 drums consist in a winding m/c
Every day except Friday 12 drums maintenance
maintenance schedule for a winding m/c
:45 days
Frequency of each drum maintenance
: 45 days
Cleaning, checking, lubricating is done in winding m/c maintenance.
46
Lubrication schedule:
Sliding part of gamo, cradle

Driving part inside winding unit
Winding unit outside cam drives and cassette type gear
Line shaft driving chain
Bearing centre for (right side)
Bearing centre for(left side)
Line shaft gear motor
Cam shaft bearing
Blower shaft
Cassette type joint gear cover
-6 months
- 3 months
-1 month
-2 months
: 6 months
: 6 months
: 6 months
: 3 months
: 1 month
: 1 month
7.9 List of Maintenance equipments for general purpose:

1. Dial gauge
2. Tightening tools
3. Thickness gauge
4. Straightening gauge
5. Grease pump
6. Stropping pliers
7. Spring piece for level plate
8. Bobbin rail jack
9. Weight gauge
10. Plumb bubs
11. Carding gauge.
liker in
12. Outside calipers
13. Roller setting gauge
14. L- key
15. Ring spanner.
16. Spindle gauge
17. Double end spanner
18. Soft hammer.
: used measure roller eccentricity.

: used to tight bottom roller.
: to measure thickness.
: used to measure straightness of bottom roller after joining.
: use to apply grease.
: to open or close the ring.
: for leveling parts of m/cs.
: use to level the bobbin rail.
: use to adjust top arm pressure.
: use to alignment of the bobbin wheel.
:Used to measure the distances among doffer,cylinder &
: use to measure the dia.
: use set roller to roller distance.
: use to open lock guard of m/cs.
: use to set spindle at the center of the ring.
: use to open the nut bolts.
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
8.1 Power generator:

R.K. SPINNING MILLS LTD. generates its own power from natural gas. It has five
generators in SRSL & three generators in SSL. The generators specifications are as follows:
SRSL:
No of generators
Model
Manufacturer
Country of origin
Year of manufacture
Engine type
Engine rpm
No of cylinder
Cylinder volume
Line pressure
Capacity
: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
8.2 A/C plant:

The factory consists of five A/C plants in SRSL and the two A/C plant in SSL.
The A/C plant in R.K. for
Blow room
Carding
Simplex
Rotor
Ring
The manufacture of A/C plant for R.K.is BESTAIR.
The main task of A/C plant is to maintain specific humidity in the factory shed, for this it
circulates the cooling air. A/C plant without chilling helps to maintain only the RH% without
much difficulty. They can be classified generally as either unitary or central station. Central
system is the most widely used system in the textile industry.
The systems principal components are
1. Air moving devices-fans
2. Mixing devices for air and washer i.e. Air washers.
Air moving devices are always two types,
1. Return Air fans
2. Supply Air fans
The return air fans return the air to the plant room from where it may circulate or exhausted
in the mill.
The supply air fans-supply air to the mill from plant room.
Air washer is a device for intimately mixing water and air. The mixing water and air supply
by nozzle.
The following components are a must in a A/C plants:
Return Air and Supply Air fans
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.
Supply & Return Air Capacity:

Section
Carding
Drawing
Lap former
Comber
Simplex
Ring
Auto coner
Rotor
Supply Air Capacity

74000 CMH
70000 CMH
70000 CMH
70000 CMH
50000 CMH
452000 CHM
70000 CMH
106000 CMH
Return Air Capacity

17180 CMH
237820 CMH
237820 CMH
237820 CMH
46700 CMH
436640 CMH
67900 CMH
100020 CMH
Number of Air Change Cycle per hour:

Section
Carding
Drawing
Lap former
Comber
Simplex
Ring
Autoconer
Rotor
Air Change Rate/ Hr

29.7
11.9
11.9
11.9
11.8
40.4
20.8
27.3
IMPORTANCE OF RH AND TEMPERATURE:

The atmospheric conditions with respect to temperature and humidity play very important
part in the manufacturing process of textile yarns. The properties like dimensions, weight,
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.
Types of Chiller in this mill:

1. Steam fire Chiller
2. Hot water Chiller
Hot water chiller
No of chiller
Model
Manufacture
Country of origin
: 02
: THW LT/42, THW LT16
: Thermax
: India
51
Year of manufacture: 2000

Steam fired chiller
Manufacture
: Thermax
No of chiller
: 01
Model
: EW 770 V
Country of origin
: India
Year of manufacture: 2000
REQUIRED COOLING LOAD

Section
Carding
Drawing
Lap former
Comber
Simplex
Ring
Autoconer
CAPACITY OF CHILLER
SRSL
Name
Steam fired chiller (1)
Hot water chiller(2)
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
Country of origin
Type
Total capacity
Pressure capacity
:5
: Atlas capco, Motivair
: 2001
: England, Belgium
: Screw Type
: 346 m3/min
: 10 bar max
8.5 Fire fighting system:

Cotton fibre 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 way the
factory has a well equipped fire fighting system. Water lines are spread throughout the
52
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
R.K. Spinning Mill

16
16
P/B
16
P/C
Fire extinguisher:
FIRE EXTINGUISHER NAME
ABC POWER BOX
R.K. Spinning Mill

24
10
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
Water in each bucket

10
10
8
8
36
Hose pipe points:
North west of blow room

South west of blow room
Simples gate generator
East of yarn finishing section
:2
:1
:2
:1
8.6 Power supply & consumption
Main power source

Substitute line
Generator
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:
Substation:Jarun, Konabari, Gazipur.

Supply: 1415 volts.
No. of step down transformer: 3
Transformer capacity: 1500KVA
No. of low tension distribution board: 14
Fluctuation: 2-5%
8.7 Humidification plant
Manufacturer: Singapore
54
Total No. of m/c: 5

Machine presentation:
- For back process: 1
- For ring section : 2
- For finishing section: 1
- Comber: 1
No. of air change (Filtration): 30 times per hour.

Air spreading system: By different duel line.
Relative humidity in different section:

Back process : 45%
Ring section: 52%
Finishing section: 65%
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
Store & Inventory control

9.1 Raw materials:
Import processing by head office.

Physical received by stock spare LC or invoice as bale or Kg.
The raw materials are provided for lay down according to lay down plane given
from Q.C Department.
The inventory systems are divided into four groups:
1. Raw cotton inventory
2. Finisher yarn inventory
3. Wastage yarn inventory
4. Spare parts and materials inventory
The inventory is maintained in first in first out system. When the store keeper receive some
goods, they write a note in the receive book. They also inform inventory related department.
Then the department made MRR (Material Receiving Report). They made BIN card which
contain its name, amount and other necessary information. Then the material stored in the
store.
If any department requires any item, they prepare a SR (Requisition Slip) for the particular
item and send it to store. The store then checks its availability and delivers as required.
1. Raw cotton inventory:
55
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.
9.2 Finished Yarn:
Received from production department.

Delivered to the customers.
Count, Lot/ LC.
9.3 Engineering stock/ spares:
All kinds of spare parts are received and stock maintained.

At first received by reporting system.
Stock purchase requiting (SPR)
Material receiving report (MRR)
Posting to bin card
Issue
Balance position.
** Gate pass is required for receiving or delivering.

Quality certified:
SPR No.
56
MRR No.
Chalan No.
User name Ref.
Manpower summary of store department:

Position
Store officer
Store assistance
Office assistance
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
10.1 Types of cost:
There are three types of cost:
Manufacturing cost.
Selling cost.
Marketing cost.
10.2Product cost:
Product cost consists of the following costs:

** Cost of raw material:
L/C price
C & F value
Landing cost
Transport cost
Carrying, Loading& Unloading cost.
** Conversion cost:
Bale management cost.

57
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:
10.3 Formula of various costs:

Marketing cost = (Manufacturing cost +Selling cost + Distribution cost.)
Selling cost
= (Manufacturing cost + certain amount of profit.)
Gross profit
= (Selling cost Manufacturing cost.)
Net profit
= Gross profit (Bank charge + All sorts of Taxes.)
Selling price:
Selling price depends on the following costs:
( 60- 70)% Raw material cost.

( 2- 2.5)% Spares cost.
( 12- 17)% financial charge.
( 3- 10)% Wages cost.
( 3- 4)% Electricity cost.
( 1.3- 2)% Packing cost.
58
CHAPTER-11
Marketing
Activities
Brand name:
1. R.K. spinningMills Ltd

Buyer of the product:
1. Denim:
Hamim denim ltd
Pacific denim ltd
Chittagong denim ltd
Royal denim ltd
Sinha denim ltd
2. Textile:
Sinha yarn dyeing ltd
Sinha knitting ltd
Adnan textile ltd
Asian textile ltd
Dacca dyeing ltd
Radiance group
Regent textile ltd
Mascot group
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
Buyers compliance: IKEA (IWAY)
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.
60
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BANGLADESH

INDUSTRIAL ATTACHMENT REPORT

R.K. SPINNING MILLS LTD

Layout Plans of 1st and 2nd floor

Price of the raw cotton

points in Blow room line

Name of the mill

R.K. Spinning Limited.

Location of the mill

Godnyle ,Chowdhuribari, Narayonganj.

Type of the mill

100% Cotton Spinning Mill.

One type-Ring Spinning

45000 (Ring spindles)

Total land area

Ring yarn-22 tons

Production capacity achievement

5th Floor, House # 2, Road #21,Gulshan

On 1st March 2007

1.2 Shift Classification:

1.3 Machines in the mill:

1.4 Origin of machinery, tools and equipments:

1.5 Product Mix:

1.6 Production Capacity:

1.7 Different Departments:

1.8 Physical Infrastructure:

1.9 Stuff facilities:

R.K. Spinning Mill

Total worker for production department

2.2 Officer and staffs:

R.K. Spinning Mill

Total officer(with ED+ASO)

So the total no. of worker with officers and staffs is 1136

HOUSE RENT TREATMENT

: 9 am to 5 am (lunch time 1 pm to 2 pm)

2.4 Point of compliance:

03. First aid:

2.5 Major duties and responsibility of production officer:

To control shift according to the plan made by the production manager.

Production section (major)

Nature and scope:

2.7 Management Information system (MIS):

BLOW ROOM SECTION:

3.1.1 Machines available in Blow Room section:

Fig: Blow Room Section

01. Blendomat machine:

02. Maxi-flo machine:

Relative waste amount

03. Securomat machine:

3.1.2Blow room line for Ring Yarn (Trutzschler line ):

3.1.2 Beating points:

Minor beating points:

Dust collection system:

Mixing system in Blow room:

Delivery system towards the card line:

Beater r.p.m setting:

Relative amount of waste:

3.1.3Comments on blow room:

3.2 Carding Section:

Fig : Carding Machine

3.2.2 Regulating action for constant feeding to the card:

3.2.3 No of operating zone

3.3The Drawing section