Industrial Attachment on Masco Industries Ltd (Part 3) - Assignment Point
Industrial Attachment on Masco Industries Ltd (Part 3)
Subject: Organizational Behavior | Topics:

CHAPTER-9

QUALITY MANAGEMENT SYSTEM:

Quality Assurance:

The Quality assurance department is assigned to maintain consistently uniform quality of the material in process and various stages of its manufacturing. Masco Industries  Ltd. is more about concern about quality. In this factory quality assurance is more preferred than quality control but both are in advancement.

After collecting fabric rolls from different machine they are needed to be inspect or assured required quality by the quality inspectors as if there no big production hampered and no complain from the buyers. Here are the details about it.

 Objects of Quality Control:

i) Research

ii) Selection of raw materials.

iii) Process control.

iv) Process development.

v) Product testing.

vi) Specification test

Quality Control in Grey fabric Inspection:

Some points are needed to maintain for high quality fabric

i) Brought good quality yarn

ii) Machines are oiled greased according.

iii) GSM, Stitch length, Tensions are controlled accurately.

iv) Machine are cleaned every day and servicing is done a month.

v) Grey fabrics are check by four points system.

QUALITY ASSURANCE PROCEDURE IN GREY FABRIC:

 Body & rib inspection:

All rolls are kept in front of the inspection m/c time to time and are inspected over the inspection m/c visually in a pre-set speed against light. For any major or minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil lines, needle line, slubs etc are recorded in inspection report to classify the fabric based on the four point system.

 Collar & cuff inspection:

Collar & cuff are inspected visually under the light box, any major or minor fault in collar/cuff like having wrong ply, hole, needle line, slubs, wrong design, first round problem etc properly counted and recorded.

QUALITY STANDARD:

Masco maintains the ISO: 9001:2000 standards in case of quality. Therefore, the four point system is followed to inspect the body & rib fabric. The defects found and points given against are recorded in the inspection sheet. Following table shows the four point grading system followed by inspection at MASCO….

Four point grading system

Size of defects

Penalty

3 inches or less

1 point

Over 3 inch but not over 6 inch

2 point

Over 6 inch but not over 9 inch

3 point

Over 9 inch

4 point

 Following table shows common body and rib faults and response by inspection section at Masco industries Ltd.

No.Faults Response
01Needle markMajor needle line is rejected
02StripeMajor needle line is rejected
03Barre markRejected
04Slubs1 point
05Thick thin placeRejected
06Pin hole1 point
07Wrong designReject
08Mixed Yarn1 point
09Sinker markRejected
10Missing YarnUse 4 point
11HolesUse 4 point
12Oil lineUse 4 point
13ChemicalUse 4 point
14Crease lineUse 4 point

 Following table shows common collar & cuff fault and response taken by inspection section at Masco Industries Ltd.

No.Faults Response
01Needle lineRejected
02StripeRejected
03SlubsReject
04Thick thin placeRejected
05Wrong designReject
06Mixed YarnReject
07Sinker markRejected
08Missing YarnRejected
09HolesRejected
10Oil lineRejected
11Crease lineRejected
12Wrong plyReject

 Factory: Roll Yardage (A)

Total points founds (B)

Formula: B/AX100= points per yard

Classification:

= 40 points = A type

41-60 = B type

61-80 = C type

Above 80 points = Reject

Quality control in Dyeing and Finishing:

Masco Industries Ltd. assures the quality of the products of dyeing section in the following three steps:

Off-line Tests:

All the Off-line tests for finished fabrics can be grouped as follows,

1) Physical test

  • GSM
  • Spirality test
  • Shrinkage test
  • Pilling test

2) Chemical test or Color fastness test

  • Fastness to perspiration.
  • Fastness to water
  • Fastness to rubbing and crocking.
  • Fastness to wash.
  • Fastness to light.

On-Line Tests:

1) For Pretreatment –

  • pH test.
  • Absorbency test.
  • Fabric width measure.
  • Whiteness test.
  • Water quality test.

2) For Dyeing –

  • Shade matching check.
  • pH check.
  • Wash fastness Check.
  • GSM checking

3)  Machine checking.

Procedures are described below:

In laboratory:

  • swatch card from Buyer according to their requirements
  • Recipe prediction for sample dyeing
  • Sample dyeing until matching with swatch card
  • Fastness& other tests of the fabric or yarn are done here.

In Dyeing section:

According to the buyers sample dyeing is done in sample dyeing machine in dyeing shed & again matched with the approved sample.

  • If results OK then bulk production.
  • During dyeing samples are taken until accurate shade matching. The interval may be 30-40 minutes
  • After dyeing sample is collected after softening matching is done
  • Last of all samples is collected after fixation& matched.
  • Then allowed the fabrics to be finished.

In finishing section:

  • By using a series of finishing machines correct width softness & appearance are maintain according to requirements.
  • Then sampling is done for several times to test GSM, Shrinkage& fastness properties.
  • Finally fabric is inspected & prepared for delivery.

Process Flow Chart of Final Inspection :(Q.A.D)

After completing finishing process here firstly check the shade as per buyer standard with dimensional stability from lab.

Secondly check dia / width fabric weight or G.S.M

Thirdly check fabric surface or appearance as per buyer standard.

The every roll with every meter check as per four (04) point system.

Make a report.

If OK then ready for delivery.

If not OK then identify the fault.

If it is knitting fault then inform the knitting department by job card and mail, & requested the fabric for replacement.

If it is dyeing fault & If make sure that it is reprocess able then give job card to dyeing department correction. And if is not reprocess able then reject the fabric & inform the dyeing department to replace the rejected quantity.

FAULTCAUSEREMIDIES
HOLEDUE TO YARN BREAKAGE AND YARN FAULTUSE GOOD QUALITY OF YARN
RUB MARKIF THE DUST OF ENZYME IS NOT CLEAN PROPERLYFLOW CONTINUOUS AIR TO FABRIC DURING COMPACTING
OIL STAINOIL STICK ON FABRIC FROM NEEDLE, SINKER OR CYLINDERUSE SOLUBLE OIL AND KEEP THE M/CS CLEAN
DYE STAINDYES POWDER FALLS ON TO THE WET FABRICSSTORE THE FABRICS BY COVERING
WATER SPOTSBEFORE INSPECTION IF FABRIC STORED IN WET FLOORBY WASHING AND STORE FABRIC IN DRY PLACE
FLY YARNDIFFERENT TYPES OF YARN MIXED DURING KNITTINGCOVER THE KNITTING M/C DURING KNITTING
YARN CONTAMINATIONDIFFERENT DUST OR SLUBS MIXED DURING KNITTINGKEEP THE M/C AREA CLEAN
SOFTENER SPOTIF SOFTENER IS USED UNDER 45ºCUSE SOFTENER UNDER REQUIRED TEMP.
PATCHESIF SODA IS NOT USED PROPERLYUSE SODA PROPERLY
HAIRYIF THE ENZYME WASH IS NOT PROPERLY DONEGIVE ENZYME WASH PROPERLY
NEEDLE LINEFOR FAULTY NEEDLEREPLACE THE FAULTY NEEDLE
DEAD COTTONFOR IMMATURE FIBREUSE YARN OF MATURED FIBRE
CREASE MARKFOR THERMAL SHOCK, UNEVEN NOZZLEPRESSURE AND BAD QUALITY LEVELLING AGENTINCREASE DYEBATH TEMP. SLOWLY,MAINTAIN NOZZLE PRESSURE AND USE GOOD QUALITY LEVELLING AGENT

SCOPE OF QUALITY CONTROL AND TESTING:

The scope of quality control testing in MASCO. is good. It has the following ability for quality control & testing,

   Perspiration tester.

   Spectrophotometer.

   Data color

   Washing machine.

   Dry

   Rota wash.

   Observer

SOME TEST PROCEDURE:

Color fastness to rubbing (wet & dry)

Procedure:

           *Rubbing cloth: Take rubbing cloth at 5*5cm size.

*Sample size : Take the specimen at 14*5cm at wales & course wise.

Put the rubbing cloth on to the grain & stag by steel wire & run 10 times manually & asses the rubbing cloth with gray scale.

Place the rubbing cloth on the water & socked & squeeze.Place the wet rubbing cloth on to the grain & stag with stainless steel wire & run 10 min. manually. Then asses the rubbing cloth by  scale for wet rubbing.

* H&M —-Dry rubbing

*  All others buyer —- Dry and wet rubbing

Result :    

*Dry rubbing —-  4-504-5

*Wet rubbing —-

Color fastness to washing.(ISO/05-CO6)

Procedure:

Size of specimen : Cut sample & multifibre at 10*2cm then stitch.

Detergent : 4g/l PCLF detergent  + 1g/l sodium per borate put in distilled water & colled at 20*c & measure pH(where necessary)

Run the program in the following way:-

Test no.    Temp.*C      Liq.volume ml       Time min.     Steel balls      Adjust pH

C2S          60*C                   50                       30                    25           10.5+_ .1

Rinse the sample twice with cold water.

Dry at 60*c by hanging or by flat iron pressing but temp. should not less more than 150*c.

 Result:

Color change: 4-5

Staining        : 4-5

Color change: 4-5

Staining        4-5:

Shrinkage & spirality test.

Buyer’s requirements :

Template size : 50cm & 35cm    , 25.5cm &18cm(use after quick wash)

Shrinkage:   length wise— 5%

Width wise—-5%

Spirality :    Left    ——-   5%

Right ——–  5%

 Procedure :

At first take two ply of fabric & put the template(50cm) on to the fabric.The template has 8 holes.Both length & width wise the template holes can measured 35cm at 3 places.Then we mark the 8 holes by permanent marker & also at the edges of the template.

Then sewn the fabric & it is given washing m/c run at 60*c for 60min.with water .After that dry the sample & then measurement the fabric.

( only for H & M buyer used 4 rinse + 4 spin )

Spin speed — 500rpm

Drum speed—500rpm

Calculation:

#Shrinkage:

Length wise :

After wash – Before wash

=    ———————————-×100

Before wash

34.5-35

=  ————— ×100

35

= -1.4%

Width wise :

After wash – Before wash

=   ———————————-×100

Before wash

34.7-35

=  ————— ×100

35

= – .8%

Measurement of Spirality:

Working procedure:

1.Two layer of (21” X 21”) sample is cut.

2.Then stitch the layers.

3.Then wash the sample 60º C at 30 minutes.

4. Then tumble dry the sample.

5. Then measured the sample following way:

D1                                                          D2

1st Side                                                     2nd side

Where,

L = Length of sample.

D1, D2 = Distance of seam movement.

Calculation:

Left side + Right side

=  —————————- ×100

2

—————————

Length ( Width for H&M)

Spirality % =   (D1+D2 ) ¸L    * 100

2

                                            .8+0

                                      =—————×100

                                               2

                                          ————-

                                              49.5

                                             = .8%

Maximum 5% allowed after washing.

Color fastness to water ( ISO105 EO1& EO2)

Sample size : Cut the specimen & multifibre at 10×2cm & sewn together.

Solution       :  Wet in distilled water at room temp. & socked.

Place it in acrylic resin plates & put the wt. on to the plates.

Keep it in oven & keep the temp. at 37+_ 2°c for 4hrs.

Open the specimen & dry it in the air hot exceeding 60°c.

Asses the staining & shade change  with gray scale.

Result:

Color change –   4-5

Staining —–   4-5

Color change — 4-5

Staining   ——  4-5

Color fastness to perspiration  Alkaline & Acid solution.:

 Method: ISO 105 E04

1)  Procedure: Cut the specimen & multifibre at 10×2cm & sewn together.

2)   Prepare solution :

Alkaline Solution :

# 0.5g/l of 1-histadine mono hydrochloride monohydrate

#   5g/l  of sodium chloride

This solution is brought to pH -8 with 0.1 mole/l caustic solution.

Acid  solution  :

# 0.5 g/l of 1-histadine monohydrochloride monohydrate

# 5g/l of sodium chloride.

# 2.2 g/l of sodium dihydrogen orthophosphate dyhydrate.

This solution is brought to pH-5.5 with 0.1 mole/l caustic solution.

 3)  M : L =  1 : 50

4)  Wet the specimen in flat dish containing  acid &  alkaline solution & keep for 30min. Then take the specimen & squeeze the excess solution by two glass rods.

5)  Put the specimen in to the acrylic resin plates & put wt. on the plates.

6)  Keep it in the woven at 37°c +_ 2°C for 4hrs.

7)  Open the specimen 7 multifibre & dry separately in the air temp. not exceeding 60°C.

8) Access the staining & shade change with grey scale.

 Result:

 Alkaline:

Peacock blue: color change—4

Staining —     4

Acid:

Blue :             color change—3-4

Staining  — 4

PH Test:

Procedure:

Take 2gm sample fabrics and cut into small pieces . Then put it conical flax with 100cc water.Then shake it 15 min , then place it in a shaker m/c for 1 hour. Then check PH by PH meter .

Results:

Texsebo:

Others buyer:

GSM TEST:

GSM is the most important factor. There is a GSM cutter. The sample cut by this is weighted in the electronic balance. The reading (in gm ) from the balance is multiplied by 100 to get the value of GSM.

Finished Fabric Inspection Report (4 Point system):

Final Inspection Report:

RESPOSIBILITIES OF OFF LINE Q.C.

To check the following things :

  • Inspection of fabric in the inspection M/C under 4-point system .
  • Yarn count and lot no .
  • Buyer .
  • Design .
  • Stitch length of grey fabric .
  • Shade of grey fabric with in one order .

RESPOSIBILITIES OF ON LINE Q.C.

To check the following things :

·         M/C Dia/Gauge

  • Buyer
  • Design
  • Grey fabric GSN & Stitch Length
  • Yarn count & Lot no
  • Yarn whether approved or not by Q.C. Department
  • Finished dia & grey dia .
  • Fabric quality checking under 4-point system .

RESPONSIBILITIES OF IN CHARGE Q.C.

  • Making  report .
  • Supervise the grey Q.C.
  • Check machine is running according to program or not
  • Check program can meet the requirement . Which is    mentioned in the order sheet or     not .
  • Check yarn is approved by Q.C. or not .

RESPOSIBILITY OF THE FINISHING Q.C.

Finishing Q.C. (shade): 

  • After unloading from dyeing cut cut small piece , check shade with std/approved lab dip/production sample & previous production batch (if any) .
  • Then instruction to finishing for finish by mentioning specific temperature in dryer .
  • After finish again cut sample & check same way like before at dry state .
  • Keep the record of every lot after dry & after finished state .
  • If any batch is not OK at any stage then make the re-process card for dyeing .
  • If any batch is closer to standard but not exactly pass with standard , then make trial for that batch in finishing to make it OK .
  • Maintain the resister of all batch .
  • Check the shade of Body to Rib , Body to Collar & Cuff .

In charge :

(1)    Supervise the trainee Q.C. & Q.C.

Make report every day .

Cross check whatever shade already checked by Q.C.

Q.C. (Finishing) :

  • Make the R2R continuity of each dye lot by cutting  small piece from each roll of dye lot .
  • Inspect 30-40 % of each dye lot under 4-point inspection system & report accordingly .
  • If found any problem then re-inspect 100% of that dye lot and make report & re-process card (if re-process able) for dyeing . If it is knitting faults then immediately inform to officer asking decision .
  • Check the evenness of a dye lot by checking R2R continuity .
  • Check the shade of body to rib , body to collar & cuff .

In charge :

  • Monitor the all Q.C.’S (finishing) work including shade Q.C.
  • Take decision when asking advise from his subordinate .
  • Make daily problematic batch report .
  • Make daily production report .
  • Maintain resister khata .
  • Make daily batch re-process job card .

RESPOSIBILITY OF QUALITY ASSURANCE MANAGER :

(1)   Responsible for all quality matter of fabric .

(2)   Yarn selection .

(3)   Monitoring product development .

(4)   Organize Laboratory .

(5)   Control grey and finished fabric inspection under 4- point inspection system (6)   Documentation of each dye lot after checking shade .

CHAPTER- 10

WASTE MANAGEMENT SYSTEM

Effluent Treatment Plant (ETP):

The effluent generated from different sections of a textile industry must be treated before they are discharged to the environment. Various chemicals and physical means are introduced for this purpose.

Capacity          :           100m3/ hr

Cost                 :           Tk. 2.5 / m3

Process Flow chart of Biological Effluent Treatment Plant:

The major sources of liquid discharge are:

  • Scouring
  • Bleaching
  • Dyeing
  • Washing

Dye Waste Content:

  • Carbon, nitrogen, phosphorus

Bleaching:

  • Dilute hypochlorite solution
  • H2O2

Raw Materials:

  1. Main raw material:
  • Cotton yarn
  • Mixed yarn
  • Dyes
  • Chemicals
  1. Dye includes:
  • Reactive dye
  • Disperse dye
  1. Chemical Includes:
  • Detergent
  • Soda ash
  • Caustic soda
  • H2O2
  • Stabilizer
  • Acetic acid

Function of different Unit of Biological Effluent Treatment Plant (E T P):

♦Screening unit: It works like a filter. By filtering waste water, it removes threads, pieces of fabrics, small metal pieces etc. In this unit a rotating brush is used for clean the pores if screen. The brush rotates periodically.

♦ Storage and Homogenization tank: Different waste water from varies process is stored and makes a homogeneous mixture by mixing different concentration of waste water.

♦ Neutralization tank: Neutralization of waste water is performed by dosing 98% H2SO4 as required to control the PH Of waste water PH range 6.5 to 7.5.

♦ Distribution tank: It distributes the water to the biological oxidation tank. Continuous aeration is supplied here. Antifoam is dosed here to control the foaming in the oxidation tank.

♦ Biological oxidation tank: It is the heart of E T P. The entire harmful chemicals are damaged here by breaking their bonds. This is done by bacteria. To ensure the proper function work and growth of bacteria, few conditions must be maintained.

○Temperature                 : 35º to 37º C

○ PH      (Maximum)     : 6.5

○ Dissolved oxygen       : 4 PPM

♦ Sedimentation Tank / Biological feeding tank: Treated water is overflowed here from oxidation tank. De-colorant is used here to destroy the color of waste water.

♦ Settling tank / Sedimentation Basin: A tank or basin in which waste water is held for a period of time, during which the heavier solids settle to the bottom and the lighter material will floats to the water surface. In this tank sludge is immersed and the harmless water is discharge to ponds, Land, river etc.

♦ Sludge Thickener: Sludge taken here from clarifier. Polyelectrolyte is dosed coagulate the sludge. After one hour of Polyelectrolyte dosing aeration is stopped and fresh water discharge to drain when sludge is taken. The thickened sludge is transferred to the sludge thickener bed.

♦ Sludge Thickener bed: Here sludge is dried which is used as good fertilizer as well as fuel of brick field. Sludge is dried under the sunlight.

 Required Chemical of Biological E T P:

H2SO4:

Function: Neutralize the waste water controlling the PH. It is auto dispensed in the neutralization tank.

Polyelectrolyte:

Function: Used for sedimentation / sludge coagulation and also killing bacteria.

Antifoaming Agent:

Function: Used for reduction / controlling foam. It is used auto / manually in the distribution tank.

De-colorant:

Function: Used for removing color. It is used auto / manually in the sedimentation feeding tank.

Sodium Hypochlorite:

Function: It is used to kill the harmful bacteria. It is used in the biological oxidation tank.

Standard water quality for dye house

Minimum Standard

Permissible concentration

Color

Colorless

Smell

No bad smell

Water hardness

<  5o

PH value

7.8 Neutral

Dissolved solid

< 150 mg/l

Inorganic salt

< 500 mg/l

Iron (Fe)

< 0.1 mg/l

Manganese (Mn)

< 0.01 mg/l

Copper (Cu)

< 0.005 mg/l

Nitrate (NO3)

< 50 mg/l

Nitrite (NO2)

< 5 mg/l

Chlorine

< 0.1 mg/l

Filterable solids

< 50 mg/l

Ammonia

< 0.5 mg/l

 Hardness Check

The hardness should be checked after every 6hrs. It should be checked by the hardness test kits. The using hardness test kits are Hanna Instrument, made in  Italy. If hardness is going to be 0.2 on the syringe scale, then have to do the regeneration process.

The characteristics of waste water assumed at Masco Industries Limited as follows :

  • PH = 11
  • BOD = 300 mg/l
  • COD = 200 mg/l
  • Suspended solid = 200 mg/l
  • Color = dark

Final treated quality of Masco Industries Limited discharge is

  • PH = 6.9
  • BOD = 35 mg/l
  • COD = 170 mg/l
  • Suspended solid = 50 mg/l
  • Color = Colorless

BSTI’S standard :

  • Ph = 6.9
  • BOD = 50mg/l
  • COD = 200 mg/l
  • Suspended solid = 150 mg/l
  • Color = Light brownish

Remarks: Waste water from processing industries e g. Dyeing , Printing , Finishing and washing causes great harmful effect on our environmental, As a result agricultural land loses its fertility, natural water becomes polluted aquatic life is destructive and crops are damages.

So, it is important to maintain the ETP. It costs less, along with it will save 100 of lives outside the factory and will also contribute to save our environment from being polluted.

A little cost but a huge benefit.

CHAPTER-11

MAINTENANCE SECTION

Maintenance

Maintenance:

                       Maintenance is a procedure by which we can maintain active functioning in operation according to the behavior and utility of a particular element. Machine, buildings and other facilities are subjected to deterioration, if unchecked. Culminates in rendering these service facilities unserviceable and brings them to a stand still. In industry, therefore has no choice but to attend them from time to time to repair and recondition them so as to elongate their life to the extent it is economically and physically possible to do so. In engineering, we use this terminology for maintaining smooth and uninterrupted performance of machines, tools and metallurgical characteristics in practical uses.

 Objectives of Maintenance:

  • To keep the factory pants, equipments, machine tools in an optimum working condition.
  • To ensure specified accuracy to product and time schedule of delivery to customer.
  • To keep the downtime of machines to the minimum thus to have control over the production program.
  • To keep the production cycle within the stipulated range.
  • To modify the machine tools to meet the need for production.

Three types of maintenance are performed in Masco Industries Limited:

  1. Preventive Maintenance.
  2. Routine /  Scheduled Maintenance.
  3. Breakdown Maintenance.

Preventive Maintenance:

Preventive Maintenance is a predetermined routine activity to ensure on time inspection or checking of facilities to uncover conditions that may lead to Production   break downs or harmful depreciation. These actions are performed to prevent or reduce consequences of failure.

 Schedule Maintenance:

Maintenance of different machines are prepared by expert engineer of maintenance department. It is time- based maintenance and pre-planned to perform on machine and equipments. Normally in case of dyeing machine maintenance after 30 days complete checking of different important parts are done.

Break down Maintenance:

In this case, repairs made after the equipment is out of order and it can not perform its normal functions.

 Flow chart of maintenance

Problem occurred

Operator

Supervisor

Production officer

Maintenance officer

Solution

Checking Parameters:

SL NO.

Items need to be Checked & Serviced

1.

Check and tightening all motor terminals.

2.

Check and clean pressure sensor and tightening terminals.

3.

Clean the ventilation fans of panel board and circular fan on top machine.

4.

Check and clean the interfacing and data cables.

5.

Inspection, cleaning and tightening all the terminals in the panel.

6.

Check and tightening limit switch, safety door guard and emergency.

7.

Check and tightening the proximity switch terminals.

8.

Functional test of the yarn detector.

SL NO.

Items need to be Checked & Serviced

1.

Check and tightening all motor terminals and clean the motor (30 days).

2.

Check activity of wide and sensor and pneumatic regulator.

3.

Check and clean pressure sensor and tightening terminals.

4.

Check  the A/C ventilation fans of panel board.

5.

Check the fan and the heat sink of the inverters in the panel board.

6.

Check and tightening the ledge sensors.

7.

Check and tightening the photo sensor terminals.

8.

Check and tightening the safety light barrier and tightening terminals.

9.

Inspection, cleaning and tightening all the terminals in the panel.

10.

Check and tightening limit switch, safety door guard and emergency switch

 Check list of different Parts

Maintenance: Mechanical

Machine: Dyeing machine

SL NO.

Items need to be Checked & Serviced

1.

Clean the m/c bearing.

2.

Complete cleaning of machine.

3.

Cleaning of drain valves, replace seals if required.

4.

Check air supply filters, regulators auto drain seals.

5.

Check filters element and blow out.

6.

Greasing of unloading roller bearing.

7.

Checking of oil level and bolts of unloading roller, gearbox.

8.

Checking of unloading roller coupling and packing.

9.

Checking & cleaning (if required) of main vessel level indicator.

10.

Check the oil level of pump bearing and refill if required.

11.

Check the function of heat and cool modulation valves

12.

Check all door seals.

 Maintenance: Electrical                   

Machine: Dyeing Machine

SL NO.

Items need to be Checked & Serviced

1.

Check & clean fluff and dirt at all motor fan covers.

2.

Check all motor’s terminals

3.

Check main panels (by using compressed air)

4.

Check panel cooling fan & clean its filter

5.

Clean main pump inverter and its cooling fan.

6.

Check all circuit breaker, magnetic conductors and relays.

7.

Check current setting of all circuit breaker & motor over load.

8.

Visual checking of all power & control cables.

9.

Check calibration of main vessel & all addition tank

10.

Check all pneumatic solenoids

11.

Check calibration of heating/ cooling modulation value

12.

Check setting of tangle sensor

13.

Check setting & operation of lid safety switches

14.

Check all emergency switches

15.

Check all indicating lamps

16.

Check all on/off switches

17.

Check all signal isolators

 Maintenance in Dyeing Department

Dyeing department contains the following machines:

  1. Winch machine (HTP)
  2. Atmospheric machine

Following check should be done in these machines:

  • Motor
  • Motor driving wheel
  • Feeding system
  • Delivery system
  • Heating system
  • Electric wiring system
  • Electric control system
  • Drainage system

Maintenance in Finishing Department

Finishing department contains the following machines:

  1. Raising machine
  2. Stenter
  3. Compactor
  4. Calendaring machine
  5. Sudded maching
  6. Dryer

Following maintenance check should be done in these machines:

  • Brush roller
  • Raising cylinder
  • Motor
  • Rubber belt
  • Feeding & delivery system
  • Electric control panel
  • Stenter machine clip

Maintenance in Utility Department

Utility department contains the following machines:

  1. Gas Boiler
  2. Generator
  3. Air Compressor
  4. Air Conditioner

Following maintenance check should be done in these machines:

  • Boiler gas burner
  • Boiler filter
  • Water filter
  • Boiler blow down
  • Heating arrangement
  • Boiler pressure control system
  • Different parts of generator
  • Gas feeding system
  • Exhaust system
  • Filter
  • Compressor moisture management system
  • Air duct & conditioning of air

Maintenance in Drying Section

Drying system is very important for producing the moisture free dry fabric. If moisture present in the fabric after drying then it creates difficulties in good conditioning of the fabric & it downgrades the quality. So drying system should be proper. The main responsibility of the maintenance department to check up regularly the steam pipe, steam pressure valve, drying cylinder, motor related to rotation purpose etc.

 Lubrication System

A good lubrication program should be chalked out in different parts of the machine for finding   the best possible output from the machine. For this purpose a right lubricant is applied in the right place at the right quantity at the right time. Maintenance department should make the chart for lubrication program for each machine & this must be followed strictly.

Maintenance work to the different machines:

Boiler maintenance schedule:

Daily:

  • Check gas pressure
  • Maintain log sheet
  • Chemical dosing

Weekly:

  • Check all steam line
  • Fire quantity of boiler

Monthly:

  • Check all steam line
  • Fire quantity of boiler
  • Gas consumption report
  • Burner clean

Quarterly:

  • Burner clean
  • Economizer clean
  • Feed tank clean
  • Chemical tank clean
  • Sight glass clean

Half yearly:

  • Burner clean
  • Feed tank clean
  • Chemical tank clean
  • Economizer clean
  • Replace valve
  • Check gas line & filter & pressure

Yearly:

  • Overhauling of boiler
  • Chemical cleaning of boiler
  • Safety valve test
  • Economizer clean
  • Feed tank clean
  • Chemical tank clean
  • Burner clean
  • Check safety valve setting
  • Replace valve & gasket
  • Boiler inspection by authority

Dyeing machine maintenance schedule

Daily:

  • Check belt tension
  • Check steam or water system & air supply
  • Check chemical pump
  • Machine clean

Weekly:

  • Bearing & belt check
  • Check leakage of air, steam & water line
  • Greasing bearing points
  • Add gland packing at pump

Monthly:

  • Greasing bearing points
  • Replace bearing points (if required)
  • Gas kit check
  • Clean steam trap
  • Lubrication all chemical pump

Quarterly:

  • Replace belts
  • Repairing of pulley, shaft& bearing housing
  • Painting m/c & pipe line
  • Clean steam trap
  • Replace seals ( if leakage)
  • Change gasket of steam of water lines

Half Yearly:

  • Replace belts
  • Repairing pulley, shaft & bearing housing
  • Painting m/c, pipe line
  • Replace seals

Yearly:

  • Machine overhauling

Maintenance Tools & Equipments and their functions:

1. Combination tools (Spanner)

Function: Tightening & Loosening of Nuts & bolts

2. Socket Ratchet set

Function: Tightening of Nuts & bolts

3. Slide Range

Function: Tightening & Loosening of Nuts & bolts

4. Pliers

Function: Tightening & Loosening of Nuts & bolts

5. Pipe threat Cutting Tools

Function: To Cut the threat in Pipe.

6. Bearing Puller

Function: To assist the Opening of bearing from shaft.

7. Pipe Range

Function:  Tightening & Loosening of Pipe Joint

8. Pipe Cutting Tools

Function: For Pipe Cutting.

9. Hole Punch

Function: Punching the hole.

10. Divider

Function: For circle marking on metal & wood

11. Easy Opener

Function: To open the broken head bolt

12. Heavy Scissor 

Function: Cutting of gasket & steel sheet.

13. Oil Can

Function: Oiling of moving Parts.

14. Drill M/C and Drill bit.

Function: For Drilling.

15. Grease Gum.

Function: For greasing of moving Parts of M/C.

16. Girding M/C

Function: For grinding & Cutting of mild steel.

17. Welding M/C

Function: For welding & Cutting.

18. File

Function: For Smoothing the Surface.

19. Hammer

Function: For Scaling & right angling.

20. Hacksaw blade.

Function: For metal Cutting.

21. Handsaw (wood)

Function: For wood Cutting.

22. Grinding Stone.

Function: For smooth finishing

Remarks:

Maintenance of  m/c’s are very essential to prolong the m/c life and good maintenance is important. It is necessary to check that, whether all routine maintenance is done regularly and properly. Otherwise efficiency of the machines will be reduced.

CHAPTER- 12

UTILITY SERVICE

Utility Service:

The utilities are Masco Industries Ltd.:

  • Water
  • Gas
  • Electricity
  • Compressed air
  • Steam
  • Water:

Source of water is deep tube well.

Production capacities are – 100000 liter/day

Electricity:

Gas generator is used for supplying electricity for dyeing, knitting, office of the Masco Industries Ltd.

Total power produced by gas generator- 1030kw/hr.

Specification of Gas generator is given below:

Technical DetailsGas Generator
BrandKaukesha
CountryUSA
Capacity1125 KVA
Technical DetailsGas Generator
BrandPerkins
CountryUK
Capacity500  KVA

Compressed Air:

Compressed air is produced by air compressor.

There are three air compressors for producing compressed air.

Specification of the air compressor is given below:

Technical DetailsAir Compressor
BrandAtlas copco
originBelgium
capacity10 bar

 Boiler:

Technical DetailsAir Compressor
BrandCleaver Brooks
originUSA
capacity6.3 ton

 

 

Technical DetailsAir Compressor
BrandCleaver Brooks
originUSA
capacity9.3  ton

 

 

Gas:

 The source of Gas is TITAS LTD.

The gas is supplied to gas generator or different section from the main line of the TITAS GAS LTD.

Source of Utility:

  • Electricity: PDB & Generator
  • Steam: Boiler
  • Water: Pump
  • Compressed air: compressor
  • Gas: TITAS GAS LTD.

 Remarks:

As the biggest project the CPM Composite Knit (pvt.) Ltd. so the best utility system. There is a skill manpower group of Engineer and other technical staffs to look after these utility services.

CHAPTER- 13

STORE & INVENTORY CONTROL

Inventory Control:

Store is the place where every type of raw materials, spares, finished goods are kept in proper system. Inventory control means the calculation and data of every type of raw materials spares and finished goods in time to time store for inventory control are necessary , because-

i)        To know about the required amount of raw material

ii)      To know about the job no which would be processed?

iii)    To be continued the production process

iv)    To find out the profit or loss a company.

v)      Stock and stock value for consumption measuring.

Frequency of inventory Update:

-Monthly inventory control

-Annual inventory control

Scope of Inventory Control:

-Raw materials

* Dyes store

* Other chemicals

* Grey fabric

– Finished fabric.

– Spare parts

– General store

* Capital equipment

* Accessories.

* Maintenance parts

The type of inventory carried in this mill is as follows :

  • Grey Fabric                                             : Imported/Own factory.
  • Dyes and Chemicals                                : Important.
  • Spare parts and Consumables               : Local/Imported.
  • Packing materials                                    : Local/Imported.
  • Finished fabrics                                       : Good/Reject.

The prime responsibility for the inventory management function in the company including the estimation of consumption quantities of raw materials over the forecast period and initiation of a purchase requisition keeping in view quantities is transit and an order and the adequacy as otherwise of material coverage during lead time is as follows :

The Procurement Department is responsible primarily for the sourcing of raw material.

The flow chart of requisition of raw materials is as follows:

Inventory System for Raw Materials:

  • Raw materials partially received from production planning & directly from head office.
  • Material receiving & inspection report is prepared. Receive quality is mentioned and noted down.
  • Submitted to Q.C department some are ok 7 few rejected.
  • Entry of data of goods in Datatec.
  • Department gives store requisition to wear house.
  • As per requisition materials supplied and this record are noted down.

Grey Fabric Store:

All the grey fabrics are stored in the fabric near the section. Different types of fabric are listed in the sheet according to fabric types, quality, and consumer’s requirement. Fabrics GSM, Shrinkage, diameter other Properties are also taken into consideration. The batches are prepared by   required fabrics from grey store.

Stages of Grey Fabric Inventory control:

  1. After Knitting Production.
  2. Grey inspection.
  3. Warehouse.
  4. Batch preparation.
  5. Dye house

Dyes and Chemicals:

There is a different store for dyes and chemicals. Varies types of dyes and chemicals are store here according to dyes and chemicals companies. Different types of dyes and chemicals are listed in a sheet. Dyes and chemicals are also including. Every day the sheet is update. And a copy of this sheet is supplied to the dyeing manager dye house and lab section.

Spares:

In MASCO Industries Ltd. required amount of the spears of different machines are stored in the mechanical store room. All the spears listed in a sheet which is controlled by the mechanical & maintenance personal. Spears are arranged in the store room according to size quality and requirements. There are shelves in the store room to keep the small spears.

Finished Goods:

MASCO Industries Ltd. Suppliers it’s finished dyed fabrics to its garments section. So dyed finished fabrics are stored for short time in the finishing section. All the delivered fabrics are noted on the tally khata according to the lot no. quality, fabrics diameter, buyer’s name, Color & considering technical parameters.

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.

Remarks:

MASCO Industries Ltd. has individual stores for raw materials finished goods etc. there are not enough space to store the finished goods. It requires increasing the store area. In this factory the store for inventory control is satisfactory.

CHAPTER- 14

COST ANALYSIS

Costing:

Costing is a process by which the setting price of products is calculated. It is a very important task for a factory which runs for business purpose. It is also strictly followed in the Masco Industries Ltd. Costing of the products considering the raw materials expenditure salary, and wage of the officers and workers, distributions and advertisement expense etc. all direct and indirect expense is done in this factory.

Costing system mainly describes how the cost of the final product is fixed by the company/beneficial. According to buyer/customers requirement at first the fabric is collected from local and foreign suppliers. Then it is calculated how much dyestuff and chemical is required to the end of the processing of that specific fabric .After that, the final cost is fixed including some profit. Then the unit price is offered to the buyer for approves it.

Costing of the product is done by the consideration of the following factors:

  • Amount raw materials consumed.
  • Direct Labour
  • Indirect Labour
  • Factory Cost
  • Officer and administrative cost
  • Sales and distribution cost
  • Profit, etc.

Costing of the product:

The following points are considered for costing any dyed product in Masco Industries Ltd.

Total dyes and chemical

  1. Total utility cost
  2. Salary
  3. payment
  4. Transport
  5. Lunch
  6. Miscellaneous cost
  7. Government cash incentive.

Price of the product:

Generally price of the product is determined by the required profit adding to the total expenses. So

Price of the products= (Direct expense + indirect expenses + Factory overhead) + Required profit.

Knitting Charge of different fabrics:

Se. NoFabric nameCharge per kg   (TK)
01Single jersey09
02Single jersey with Lycra30
03Single Locust pk16
04Double lacost16
05Single PK16
06Double Pk16
07Rib17
08Rib with lycra30
09Interlock25
10Auto striper80
11Fleece25

 Dyeing charge if different Fabrics:

Name of fabric processCharge per kg (Tk)
White with Enzyme35
Avg. color with Enzyme90
Deep shade with Enzyme105
Only Wash40

Finishing Charge of Different Fabrics:

Sl.NoName of Fabrics ProcessCharge per kg (Tk)
01Slitting Only05
02Stenter Only25
03Compacting15

Remarks:

Costing is very important for a productive factory. Without proper costing all production curriculums will go to vain. Because a factory reach to its goal without achieving good profit and good profit it not possible without skillful costing. MASCO Industries Ltd. is some skillful personal to do this job.

CHAPTER-15

MARKETING ACTIVITIES

Consumer of the products:

MASCO Industries Ltd. is a 100% export oriented industries. All the goods produced in this factory are exported into various foreign countries.

Product Label:

Product Level differs from buyer to buyer. The product labels are prepared according to the fabric criteria and the buyer requirements.

Package size& Label market:

Package size& label differs from buyer to buyer. The package size & label are

Prepared according to the buyer requirements.

Important countries:

There are some countries which are importing goods from in this factory. Which are given below:

  • U.S.A
  • England
  • Germany
  • Europe
  • Europe Union

Present Buyers:

  • New Wave (Sweden)
  • Umbro (UK)
  • Aldi (Germany)
  • Zara (Spain)
  • Stradivarius (Spain)
  • Bershka (Spain)
  • Big Star (Poland)
  • TK International (Germany)
  • Lonsdale (UK)
Countries of Exports:A) Germany
C) Sweden
E) Italy
G) United Kingdom
I) Poland
K) Austria
M) Belgium
B) Spain
D) The Netherlands
F) France
H) Norway
J) Finland
L) Denmark

Countries of Imports:A) Hong Kong
B) China
C) Korea
D) Thailand
E) Taiwan

Marketing Information :

            The declining retail sales and the losses shows by big retailer’s worldwide and consequent drop in order in the world wide garment industry proved to be a major challenge to our marketing efforts and strategy. The very fact that in spite of the factors mentioned earlier masco maintained more or less the sales of last year showing a fall on only 3.32% is a credit to their marketing. In an uncertain world market, masco doubled their efforts with our design team leading the way ; they increased their calls as the customers & looked for ways to add new ones also. Having established a strong relationship with H & M and becoming one of their core suppliers, masco targeted Europe & Australia also and made in roads there. masco added new and dynamic designers to the existing team & can proudly say that their spring and autumn collections were hailed as some of the best to be presented. These meetings boosted the confidence of existing buyers and attracted new customers. masco continued with their strategy to market value added products like dyed fabrics with special finishes. This is reflected in the increase in average price per linear meter.

MASCO now in a strong position to take on the challenge of WTO in the end of 2004 when quotes will be abolished and only those company’s with a reputation for innovative, creativity and reliability and the ones having strong strategic relationships and business alliances will survive and benefit.

Buyer’s Compliance :

The factory is full compliance with ILO and Bangladesh Labour Law. Their company policy is as follows :

  • No child labour.
  • No forced labour.
  • Transport facilities for worker.
  • Hours of work.
  • Voluntary over time.
  • Intervals for rest.
  • Weekly holidays.
  • Annual leave.
  • Festival holidays & leaves with bonus.
  • Maternity protection.
  • Worker’s welfare committee.
  • Mineral drinking water.
  • Sanitary facilities.
  • First aid box.
  • Canteen services.
  • Day care centre.
  • Health care activities for the worker & employ company doctor.
  • Fire extinguisher each & every floor & conduct fire drill at least 12 times a year. We are giving a top priority on prevention of fire and eventual evacuation.
  • Other safety department (no discrimination).
  • Compensation cases department.
  • The development of compliance programmer.
  • Environmental developer.
  • Smoking free zone.

Manpower of Marking:

Marketing plays a vital role in the field of displaying /showing the goods criteria products to the buyer & to communicate with the buyer. There are about 15 people marketing section of the factory.

Duties & Responsibilities of marketing officer:

Job summary:

  1. Market search
  2. Market development
  3. Customer’s motivation
  4. Production follow up
  5. Technical assistance of customer.

Dealing with the buyer & convenience the buyer is the main duty of the marketing officer. A marketing officer also has some others duties. The main duties & responsibilities of a marketing officer are given bellow;

  • To prepare cost sheet by dealing with the buyer.
  • To take different step by discussing with the high officials 7 merchandisers.
  • To maintain a regular & good relationship between commercial officer& merchandisers.
  • Communicate with better criteria of the products.

Actually the responsibilities & duties of marketing officers begins from getting order of buyer & ends after receiving foods by the buyer. So he should be always smart energetic sincere.

CHAPTER- 16

CONCLUTION

We have completed our industrial attachment successfully by the grace of Allah.

Industrial attachment sends us to the expected destiny of practical life. The completion of the two months Industrial attachment at MASCO INDUSTRIES Ltd, we have got the impression that factory is one of the most modern export oriented knit composite complex in Bangladesh. Though it was established only a few year‘s ago, it has earned  very good reputations for its best performance over many other export oriented textile mills.

During our training period, talking with the clients of this mill we knew that the mill is fulfilling the country‘s best export oriented white finished fabric as well as very good colored fabric due to its modern machinery & good management system.

Mill is settled with utility to give all convenient supports to the productions for twenty-four hours. It had self-power generator system to satisfy total power consumptions of the mill.

We are enough fortunate that we have got an opportunity of having a training in this mill. During the training period we are received co-operation and association from the authority full & found all man, machines & materials on appreciable working condition. .\ll stuffs & officers were very sincere & devoted their duties to achieve their goal.

There are some suggestions from us within our limited knowledge

 Some Suggestions:

  Knitting production needs to increase as well as technical persons need to be employed there.

   More skilled labor should be used in a project and the overall efficiency will increase.

   Dyeing floor should keep always neat and clean. It kept wet after unloading the fabric from the dyeing machine specially, for Athena. Water must be swept time to time.

   During the transport of the fabric and during the loading of the m/c, fabrics get soiled due to their drawing over the floor. This makes the fabric/part of the fabric dirty. It may require more scouring/bleaching agent or may create stain.

   Due to the pressure of higher production some times machine operators do not maintain accurate time according to the actual process so that less quality product is produced and may reject. So our suggestion is to increase machine and reduce the pressure on the operator.

   Should increase understanding between the top level personal and floor level personal.

   Finishing section need to be enlarged well as more technical persons need to be employed there.

   The m/c stoppage time should be analyzed and minimized. The maintenance should be carried out when the m/c is out of action (Wherever possible) and routine maintenance should be carried out regularly.

   In knitting and finishing section every workers should use mask to make protect them from fly. Otherwise the exhaust air system should be more effective.

   Workers are not interested to wear their gown & hand gloves.

   In the Laboratory there is no technical person, a textile engineer may be employed here.

  There is shortage of proper light in the dyeing and finishing floor, specially, when smoke is produced from dryer and stenter. Proper lighting should be provided in the floor.

  In Laboratory, only one sample dyeing machine is used. The rest two are out of order. So, if this activate one is in problem then the lab dip process may be hampered. So, another lab dip dyeing machine may be purchase to reduce the load of current one.

   The spectrophotometer is virus affected. This must be quarantine immediately.

   The person at the top level of a department must take good care of the trainees & he should provide all kinds of support to them.

Limitations of the report:

  Because of secrecy act, the data on costing and marketing activities have not been supplied.

  We had a very limited time. In spite of our willing to study more it was not possible to do so

  Some points in different chapters are not included as these were not available.

  It is not possible to hold the whole thing of a textile industry in such a small frame as this report. So, try our hard to summarize all the information that we are provided.

Lastly:

We tried our best to gather all necessary information but it is true that within this short period it is quite impossible to achieve 100% success but as a whole this industrial training was a satisfactory one and once again wed would like to thank the authority of Masco Industries Ltd. as well as our honorable teachers far their altruistic help and advice. We are fortunate enough that we have got an opportunity to have training in this mill. During the training period we have received enough co-operation and association from the authority and found all personnel. All stuffs and officers were very sincere and devoted their duties to achieve their goal.

Masco Industries Ltd

Some are parts:

Industrial Attachment on Masco Industries Ltd (Part 1)

Industrial Attachment on Masco Industries Ltd (Part 2)

Industrial Attachment on Masco Industries Ltd (Part 3)

 

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