1

CHAPTER-1
PROJECT DESCRIPTION

Reedisha Knitex Ltd. an 100% export oriented composite knit textile unit
established with the commitment to care the Global needs for knit and casual clothing.
The project has employed the State-of-Art technology in its very pieces of investments.
Aiming at the context of the changing Global demand pattern, international environment
on trade specially the withdrawal of quota system and GSP and the availability of
craftsmanship in the country, the project encompassed the knitting, dyeing and
processing of fabrics and ready-made Garments production to be available from one stop
service.
The project is a new and one established in 2003, but the manpower
engaged in the projects to carry out the day to day business are all highly skilled, purely
professional, vastly experienced. The unique combination of organized Managerial and
Technical term in one hand and latest, advanced and balanced technology on the other
hand made the project one of the top to be referred in this field in the country. The best
use of continuous development of Human Resources by providing them International
Standard Environment and equal opportunity is the keys for achieving comprehensive
competence in all the level Organizational Hierarchy.

Reedisha Knitex Ltd. has been established with the objective and vision
to cater the needs of 21st century of world wide knit apparels markets from one stop
service being committed to One-time Delivery, Quality Assurance, Price Affordability
and Social Accountability.
The project is located in Dhanua, Sreepur under the district of Gazipur,
about 50 km distance from the International Airport Dhaka, Bangladesh. A well
developed Road Communication is there to reach the factory from the Airport as well as
from the Dhaka City. The head office of the project is Located in the heart of Dhaka City
in Tejgoan Industrial Area.

 Name of the mill : REEDISHA KNITEX LTD..

 Type :100% export oriented composite knit textile unit.
 Year of establishment : 2003.
 Status : PRIVATE company Ltd.
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LOCATION PLANT OF THE FACTORY

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Address :
Factory address: Head office:

Reedisha Knitex Ltd. 36 Shaheed Tajuddin Ahmed Sarani

Dhanua,Nayanpur, Tejgaon Industrial Area , Dhaka-1208.

Gazipur. Tel: 9897816, 9897817-20.

Tel : 0173-013126. Fax: 880-2-8826086.

Fax: 0173-013127.

 Sponsor : KOHINOOR GROUP of company LTD.

Product mix:

a) Knitted grey fabrics : Plain single Jersey, Heavy jersey, Polo pique,

Lacoste, Rib & Interlock double jersey, Drop needle, 2/3 Thread fleece( Brushed/

Unbrushed), Stripe fabric, French terry, Collar & cuff etc.

100% cotton, 15% viscose + 85% cotton,10% viscose + 90% cotton, 30%

viscose + 70% cotton, 100% polyester, Spandex etc.

b) Knit Garments: T-shirt, polo shirt, sweat shirt, Golf shirt, cardigan,

Jogging suit, Short/ Trouser, Legging, Children wears & Fashion dress etc.
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 Annual production capacity:

Production capacity: 7 tons/day (Knitting).

Production actual: 3.5 tons/day.

Production capacity:12 tons/day (dyeing).

Actual Production: 8-10 tons/day.

Production capacity: 40,000 pcs/day (Garments)

Actual Production: 30,000 pcs/day.

Final product name: Long sleeve/ Short sleeve T-shirt, Polo shirt, Ladies wear,

Sports

Wear, Tank tops, Kids wear, Trouser, Pants, Jacket, Children

Wear etc.

 Project cost : 60 crore Tk.

 Project area : 1,52,204 sq.ft.
 Total manpower at a glance : 1200.
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 Different departments :
1.Production oriented department :

Knitting.

Batching.

Pretreatment.

Dyeing lab.

Dyeing floor.

Chemical house.

Finishing.

Quality control.

Finished ware house.

Maintenance.

Utility.

2. Supporting department :

Procurement.

 Marketing.

 HRD.

 Finance & accounting.

Personnel administration.

 Securit
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Physical infrastructure:

Physical infrastructure of REEDISHA KNITEX LTD. is a simple one. It is fabricated

by steel structure, somewhere it is R.C.C & brick wall structure.

 Building floor area :

Dyeing building =27,328 sq.ft.

Dyeing R.C.C GF =2,352 sq.ft.
Utility section =9,146 sq.ft.
Chemical godown =5,445 sq.ft.
Salt godown =1,320 sq.ft.
Knitting building =31,500 sq.ft.
Rest house =7,830 sq.ft.
Guard house =4,360 sq.ft.
Wastage godown = 5,151 sq.ft.

 Remarks :

Reedisha Knitex Ltd. is a member concern of Kohinoor Group of companies, a

leading house & Commerce in Bangladesh,having printing & packaging Industry,
paper manufacturing unit,country wide network of color film processing laboratory
units, representing world famous Fuji color Film products, personal,hygiene products
manufacturing & real estate development etc.
 7

CHAPTER –II
MAN-POWER MANAGEMENT
MAN-POWER ORGANOGRAM OF ADMISISTRATION
↓
Managing Director (Md.Rezaul Karim).
↓
Director (Md. Abul Khair Bhuyan )
↓
Sr. Vice-President (Md. Hasan Imam)
↓
A. General Manager (Kazi Farukuzzaman)

MANPOWER ORGANOGRAM OF PRODUCTION

Knitting manager Dyeing manager

↓ ↓ Garments manager
Production officer-01 Asst. Manager
↓ ↓ ↓
Incharge-02 Sr. prod.Officer-3 Prod. Manager
↓ ↓ ↓
Fitter man-04 Prod. Officer-2 A.P. Manager
↓ ↓ ↓
Supervisor-03 Sr. Operator-05 Incharge-05
↓ ↓ ↓
Operator-34 Operator-45 Supervisor-14
↓ ↓ ↓
Helper-17 Helper-45 Line chief-24
Supervisor collar -01
↓ ↓
Operator (collar)-04 Operator-500
Helper(collar)-04 ↓
worker-300
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MANAGEMENT SYSTEM:

KNITTING SECTION:
Two in charge one is sample & other is production.
Two fitters for each shift.
One skilled supervisor for each shift.
One skilled operator and one unskilled helper
for each knitting machine.

SHIFT CHANGE:
There are two shifts in this factory and each shift is of twelve hours. Shift is
changed after a week on Saturday.
a)Day shift: From 8 AM – 8PM
b)Night shift: From 8 PM – 8AM

RESPONSIBILITIES OF PRODUCTION OFFICER:

From getting an order of upper level all responsibilities are on the production
officers. They work with a troop of operators, helpers, fitters etc. to finish the production
in due time. In the meantime production officers bear all hazards, problems. They have to
explain to the manager for any type of production hamper. So, all production activities
and its success depend on the production officers.

JOB DESCRIPTION:
SENIOR PRODUCTION OFFICER:
In a knitting factory a senior production officer plays a great role in production
and man power management who are production related. Here we enlist the duties of
senior production officer:
1) Follow up knitting production,
2) Regular observation of knitting floor,
3) Prepare knitting order status regularly,
4) Maintain the quality of the product,
5) To help the senior prod. Officer & co-operate with others for fulfilling the
required destination.
PRODUCTION OFFICER:
Production officer is the right hand of senior production officer and he is directly
related with production manpower and informs senior production officer time to time.
Here are his listed duties:-
1) Follow up overall knitting production,
2) Decide every m/c utilization during production,
3) Recruit new labor,
4) To inform the authority on the overall knitting prod. and make it financial
profitable,
5) Regular m/c maintenance,
6)Maintain sub-contract order
7)Help knitting manager & also guide the junior officers of the section, etc.
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REMARKS:
Production runs with the help of mechanical fitters. For any kind of
mechanical fault of any machine they fix and work under technical in-charge. Production
officers’ takes account of daily production by running after the two supervisors and
workers so on.
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Chapter-III
Machine description

Process definition:
Knitting is the interlocking or interlooping of one or more yarns
through a series of loop. The length wise columns of stitches, corresponding to the warp
in woven fabrics, are called WALES, the cross wise rows of stitches, corresponding to
the filling in fabrics are known as COURSES. Filling knits (weft knit) are those fabrics in
which the courses are composed of a single strand of yarns, while warp knits are those in
which the Wales are composed of single strands of yarns. Gauge corresponds to the yarn
count in a knitted fabric, and is defined as the number of needles or yarns in ½ inches of
the fabrics. Higher the gauge, the more compact and fine the fabrics.

Process requirements:
In Reedisha Knitex Ltd. two types of machines are used for producing knitted fabrics.
These are:-
1) Circular knitting machine (Single& Double Jersey Machine).
2) Flat knitting Machine (Cuff & Collar).

MACHINE AT A GLANCE:

M/C TYPE M/C NAME TOTAL M/C NO.

SINGLE JERSEY 08
CIRCULAR INTERLOCK 03
RIB 03
3-THREAD FLEECE 03
AUTO STRIPER 02
FLAT CUFF & COLLAR 11
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SPECIFICATION OF CIRCULAR KNITTING MACHINE

PLAIN SINGLE JERSEY MACHINE

ORIZINE: MAYER & CIE.
MADE IN GERMANY
SPECIFICATION
M/C NO. 03 04 05 09 10 11 12 16
CYLINDER DIA 30 20 18 20 26 26 24 30
(”)
FEEDERS NO. 48 63 59 63 59 74 72 96
GAUGE 24 24 24 24 24 24 24 24
NEEDLES NO. 2261 1508 1357 1508 1960 1960 1810 2261
MODEL NO. MV- MV- MV- Relanit- Relanit- Relanit- MV- Relanit-
4-3.2 4-3.2 4-3.2 3.2 3.2 3.2 4-3.2 3.2

DOUBLE JERSEY (RIB) MACHINE

ORIZINE: MAYER & CIE.
MADE IN GERMANY
SPECIFICATION
M/C NO. 06 13 14
CYLINDER DIA (”) 36 30 30
FEEDERS NO. 74 62 62
GAUGE 18 18 18
.MODEL NO. INOVIT-2.0QC FV-2.0 FV-2.0

NEEDLES NO. 2*2016 2*1680 2*1680

DOUBLE JERSEY (INTERLOCK) MACHINE

ORIZINE: MAYER & CIA.
MADE IN GERMANY

SPECIFICATION
M/C NO. 07 08 15
CYLINDER DIA (”) 30 30 30
FEEDERS NO. 96 96 96
GAUGE 22 22 22
NEEDLES NO. 4145 4145 4145
MODEL OV 3.2QC OV 3.2QC OV 3.2QC
ORIZINE: YEAR CHINA MACHINERY CO. LTD.
MADE IN TAIWA
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3-THREAD FLEECE MACHINE

SPECIFICATION
M/C NO. 17 18 19
CYLINDER DIA (”) 30 30 30
FEEDERS NO. 90 90 90
GAUGE 20 20 20
NEEDLES NO. 1884 1884 1884
MODEL IC. FLH IC. FLH IC. FLH

AUTO STRIPER MACHINE (SINGLE JERSEY)

ORIZINE: MAYER & CIA.
MADE IN GERMANY

SPECIFICATION
M/C NO. 01 02
CYLINDER DIA (”) 30 30
FEEDERS NO. 48 48
GAUGE 24 24
NEEDLES NO. 2268 2268
MODEL Relanit-1.6R Relanit-1.6R
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FLAT KNITTING MACHINE:

For cuff and collar this factory has three types flat bed knitting machine. One fully
automatic and other is semi-jacquard and jacquard both of the machines are made in
Taiwan and Japan. These machines are kept separate from the circular machine.

SPECIFICATION OF FLAT KNITTING MACHINE:

M/C ORIZINE COUNTRY MODEL M/C GAUGE M/C

NO. NO. width TYPE
01 MASTSUYA JAPAN M -100 40 ˝ 14 Fully
CORPORATION auto.
02 MASTSUYA JAPAN M -100 40 ˝ 14 Fully
CORPORATION auto
03 SUOHWAN CO. LTD. TAIWAN 712 52 ˝ 14 Fully
auto
04 SUOHWAN CO. LTD TAIWAN 712 52 ˝ 14 Fully
auto
05 SUOHWAN CO. LTD TAIWAN 712 52 ˝ 14 Fully
auto
06 MASTSUYA JAPAN M -100 40 ˝ 14 Fully
CORPORATION auto
07 MASTSUYA JAPAN M -100 40 ˝ 14 Fully
CORPORATION auto
08 SUOHWAN CO. LTD TAIWAN 201 52 ˝ 14 Jacquard
09 SUOHWAN CO. LTD TAIWAN 201 52 ˝ 14 Jacquard
10 MATSUYA IND.LTD. JAPAN MG-172SJ 52 ˝ 14 Semi-
Jacquard
11 MATSUYA IND. LTD JAPAN MG-172SJ 52 ˝ 14 semi-
Jacquard

LAY-OUT PLAN OF KNITTING & FLAT BED SECTION

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9 8

11 10

SUCTION ROOM 3 7
STORE TOILET
2 6

1 FLAT BED M/C

DOOR

19 18 17 16 15 14 13

12 11 10 9 8 7 6

5 4 3
 M/c. Gauge – needle/inch (varies according to diameter)
 Needle Type – Latch
 Needle bed type – Single cylinder, Double cylinder, Cylinder &
Dial long or short needles for cylinder and dial.
 Two principle operations exist:
1. English system – Where the cams and yarns strands revolve by needle
2 and fabric take down is stationary.
1
2 American system – Where the FOR
OFFICE
needles and fabric take down revolves
by cams and yarn strands are stationary.
KNITTING SECTION
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THE PROPERTIES OF RB FABRICS AND SINGLE JERSEY OR

PLAIN FABRIC AND MACHINE

Plain fabric and m/c Rib fabric and m/c

1. Face side and Back side of fabric are 1. Face side and Backside of fabric are
different same.
2. Less expensive 2. Expensive
3. Lighter fabric 3. Heavier fabric.
4. Produce by S/J m/c. 4. Produce by Double Jersey m/c.
5. The m/c. contains no Dial. 5. The m/c. contains Dial.
6. The m/c. contains Sinker 6. The m/c. contains no Sinker
7. The m/c. contains one set of needle 7. The m/c. contains two set of needle
8. Extensibility: 8. Extensibility:
a) Length wise – 10 to 20% c) Length wise – 50 to 80% (for 11
b) Width wise – 30 to 40% rib)
d) Width wise – 30 to 45% (for 11
rib)
9. Thickness & Warmth: 9. Thickness & Warmth:
Thicker and wormier than plain Much thicker and wormier than plain
woven made from same yarn. woven made from same yarn.
10. Curling: 10. Curling:
Tendency to curl No tendency to curl
11. End use: 11. End use:
Ladies stocking, fine cardigan, men Socks, cuffs, warm outerwear, under
and ladies dresses, sweater etc. wear etc.
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IMPORTANT PARTS PER MACHINE:

Name of parts Number per machine

MPF Magnet 90
Knot catcher 90
Eye pot 90
Hose pipe 02
Needle fault detector 15
Oil nozzle 21
Oil pipe 21
Air flashing nozzle 30
0Air flashing pipe 30
Fabric detector 02
Main switch 01
Fabric light 01
Take down light 02
Oil & air pressure 02

IMOPORTANT EQUIPMENT OF CIRCULAR KNITTING M/C:

1. START/STOP/INCH BUTTONS:
Complete set of easily accessible start/stop/inch buttons at top in each leg.
2. RATCHET LEVER:
Permit hand movement of the M/C.
3. AUTO STOP MOTION:
Automatic three stages 24v yarn motion, positive feed tapes & knitting
zone. Indicator lamps are on individual stop motions & on the main
control panel. While the yarn is broken we can find the location which is
broken as well as to repair, meanwhile the motor can brake and stop
operation at once to keep the security of M/C.

4. FREE STANDING SIDE CREEL:

With an active reserve package for each feed.

5. AUTO–COUNTER
Two shift revolution with display counter with predetermined stop, to
settle freely the weight or yardage of fabric.
6. VARIABLE SPEED DRIVE WITH M/C BRAKE:
Transistor inverter provided for free controlled, the process of “V.s.
motor-drive” from slow operation to normal operation is quite & fast brake to prevent
damages in case of needles or yarn breakage.
7. FABRIC TAKE-UP SYSTEM:
With variable speed control by a belt drive set can be adjusted the speed for
different course of fabric-constant and uniform fabric tension.
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8. SAFETY GUARD SWITCH:

Machine cannot be started with guards open; this guard have reinforced
fiberglass window for easy fabric inspection.

9. AUTO LUBRICATION:
The automatic central pressurized oil sprayer can be adjusted at cycling
time and quantity to make cylinder, dial, sinker ring’s cam, needles and sinkers lubricated
enough, besides it has the function cooling and clearing.

10. AUTO-LINE REMOVAL SYSTEMS:

Three fans on each rotating arm for clearing off any dust of creel and knitting zone.

STUDY ON AUTO STRIPER MACHINE:

This is one kind of single jersey machine. This has 48
feeders and each feeder contains four fingers and each finger receives different color of
yarn according to design of stripe. So we can use 192 different types of yarn in this
machine. We can produce horizontal stripe of fabric in this machine and any repeat size
is possible to produce. At first program is input in the control unit of the machine
according to fabric design. The stripe of the fabric is done by mechanical selection of
yarn by the machine and for this reason it is also called engineering striper.

PROGRAM SETTING OF THE MACHINE:

To produce stripe fabric a pre-determine design is set in the
machine control unit. The program setting of the machine is as follows-

Types of yarn No of courses Finger no. Total courses

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Sphere 56 1 56
White 13 4 69
Freshness 4 2 73
White 13 4 86
Beech 10 3 96
White 2 4 98
Sphere 3 1 101
White 5 4 106
Sphere 3 1 109
White 4 4 113
Sphere 9 1 122
White 8 4 130
Freshness 3 2 133
White 5 4 138
Freshness 3 2 141
White 5 4 146
Freshness 3 2 149
White 8 4 157
Beech 9 3 166
white 6 4 172
Freshness 15 2 187
White 3 4 190
Sphere 3 1 193
White 10 4 203
Beech 4 3 207
White 4 4 211
Sphere 3 1 214
White 4 4 218
Sphere 3 1 221
White 5 4 226

REMARKS: Reedisha Knitex Ltd. is a well planed factory. Every thing which is required
for good working condition is present here. But only water treatment plan is not available
which is harmful for the environment.
CHAPTER-IV
RAW MATERIALS
In knitting section, for knitting fabrics only yarn is used as raw materials. There are
different types of yarns are used as raw materials in this factory. These are –
1. Cotton yarn:
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(A).Combed.
(B).Carded.
2. Polyester yarn:
(A). Normal.
(B).Micro.
3. CVC.
4. Grey mélange.
5. Anther mélange /Ecro melange.
6. Spandex (Lycra).
7. Different types of colored yarns for Auto-striper.
PRICE OF RAW MATERIALS:
Price of yarn varies mill to mill and as different count. Here, we
collect a price sheet of overall price for all the spinning mills of home and abroad of
different count from merchandizing section:

PRICE AND SOURCE OF RAW MATERIALS:

Yarn Types. Yarn Count Source of Yarn Price of Yarn

100% Cotton, Combed. 40/s Shinha Tex $ 3.55/kg
100% Cotton, Carded. 40/s Rahmat Tex $ 2.90/kg
100%Cotton, Combed. 34/s Akij Tex $ 3.08/kg
100%Cotton, Carded. 34/s Shamim Tex $ 2.70/kg
100% Cotton, Carded. 32/s Shamim Tex $ 2.56/kg
100% Cotton, Carded. 30/s Akij Tex $ 2.55/kg
100%Cotton, Combed. 30/s Akij Tex $ 2.95/kg
100%Cotton, Combed 30/s Keya Tex $ 3.00/kg
100%Cotton, Combed. 26/s Akij Tex $ 2.90/kg
100% Cotton, Carded. 26/s Keya Tex $ 2.45/kg
100% Cotton, Carded. 24/s Akij Tex $ 2.45/kg
100%Cotton, Combed. 24/s Akij Tex $ 2.85/kg
100%Cotton, Combed 20/s Keya Tex $ 2.90/kg
Grey mélange(85% Cotton 34/s Shamim Tex $ 3.05/kg
+15% viscose)
Grey mélange (”) 26/s Shamim Tex $ 2.85/kg
Spandex ( Lycra) 20/d Korea,Chine&Taiwan $ 08-18/kg

Another source of raw materials is as follows-

Jamuna Spg. Mill Ltd,

Paradise Spg. Mill Ltd
Utha Spg. Mill Ltd
Amber Spg. Mill Ltd
J.K Spg. Mill Ltd
 20

Cotton concern Spg. Mill Ltd

Square Spg. Mill Ltd
Talha Spg. Mill Ltd
Malek Spg. Mill Ltd
Prim Spg. Mill Ltd
Arif Spg. Mill Ltd
Vardhman Spg Mill Ltd(Indian)
TT Spg. Mill Ltd (Indian)
Youth Spg. Mill Ltd
ST cotex(Indian)
Ginni Spg. Mill Ltd(Indian)
Kader Synthex Ltd

ANNUAL REQUIREMENT:
This factory required 1400 to 1500 tons yarn per year.

REMARKS:
REEDISHA KNITEX Ltd. is a big buyer of local spinning mills. In
this factory maximum raw materials are collect from local Spinning Mills and it is very
beneficial for our economy. This factory collects Spandex yarn from foreign country.

CHAPTER-V
PRODUCTION PLANNING, SEQUENCE & OPERATION:

PRODUCTION PARAMETERS:
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Machine Diameter.
Machine rpm (revolution per minute);
No. of feeds or feeders in use;
Machine Gauge;
Count of yarn;
Required time (M/C running time);
Machine running efficiency.

DESCRIPTION OF PRODUCTION PROCESS:

In every mill, there maintains a sequences in production processing.
It is also followed in this mill where I was in industrial attachment. The process
sequences are in list below:
1) Firstly, knitting manager gets a production sheet from merchandisers as
accordance as consumer requirements. Then he informs or orders senior production
officer about it.

2) Senior production officer informs technical in charge and knows about m/c
in which the production will be running.

3) Technical in charge calls for leader of mechanical fitter troops, they two
take decision about m/c for production considering m/c condition, production capacity,
maintenance complexity etc.

4) Production officer with experienced mechanical fitter adjusts required stitch

length and grey GSM (gram per square meter) for required final GSM.

5) Supervisor check daily production regularity and make operators conscious

about finishing in due time.

6) Operators operate machine in highly attention as if there were no faults in

the fabrics. If he thinks or sure about any fabric fault, then he call for mechanical fitter in
duty. Mechanical fitter then fixes it if he can or he informs technical in-charge. He then
comes in spot.

7) After required production and final inspection in 4-point system, they are
sent in store section.
8) From store section, fabric sent batch section .

DAILY PRODUCTION REPORT:

Daily production report represents the amount of
production of each machine individually on a specific sheet of paper. This report also
represents how many machines are in running condition and stop. We collected a daily
production report sheet of a day from the factory.
 22

DAILY PRODUCTION REPORT OF REEDISHA KNITEX LTD:

M/c M/C Dia & Buyer Yarn Fabrics Production Qty(Kg) Total Remarks
no. GG A-Shift B-Shift (Qty)
01 30dia 24gg No order
02 30dia 24gg PBL 26 Dyed S/J 37 28 75
03 22dia 24gg Style Tex 32 Card S/J Lycra 98 94 192
04 20dia 24gg Maxi Tex 24 Card S/J 127 141 268
05 18dia 24gg Style Tex 32 Card S/J Lycra 68 71 139
06 36dia 18gg Design Tex 34 Card 1x1 Rib 195 161 356
07 30dia 22gg No order
08 30dia 22gg No order
09 30dia 24gg Piakash 34 Card S/J Lycra 140 152 292
10 26dia 24gg Piakash 34 Card S/J Lycra 92 124 216
11 26dia 24gg Fontana 24Comb S.LA. PK. 254 256 510
12 24dia 24gg Style Tex 34 Card S/J 129 131 260
13 30dia 18gg Piakash 26 Card 1x1 Rib 97 184 281
14 30dia 18gg Piakash 26 Card 1x1 Rib 195 189 384
15 30dia 22gg
16 30dia 24gg Square 26 Card S/J 288 285 573
17 30dia 20gg No order
18 30dia 20gg No order
19 30dia 20gg No order
Production Date: 31.10.04
Reporting Date: 01.11.04

PRODUCTION FLOW-CHARTS:

Executive director takes order from Buyer

|
Merchandiser estimates total amount of yarn of production
|
 23

Knitting manager gets production order sheet

|
Senior Production Officer ordered by K.M. and orders
Production officer and Technical in-charge.
|
Production officer fixes up stitch length and GSM
With mechanical fitter.
|
Definite operator operates machine in his full conscious and
Attention.
|
Mechanical fitter fixes machine if there is any m/c fault.
|
Supervisors keep daily production report and assure m/c is OK.
|
Fabric roll is checked by a troop of inspectors in inspection unit
and weighted.
|
Final product to the required amount is delivered to dyeing unit.

MONTHLY EFFICIENCY:

Daily production – 3500 kg. Approx.

Daily production capacity – 7000 kg. approx.
So, monthly production – 3500 *30 kg.
Monthly production capacity – 7000*30 kg.

So, Monthly production efficiency= (3500*30*100)/ (7000*30) %

=50%.

COUNT OF YARN FOR SPECIFIED FINISHED G.S.M:

FOR DOUBLE JERSEY (INTERLOCK)

Finish G.S.M. Count ( Ne)

Less than 130-145 30/s
145-160 28/s
160-175 26/s
175-190 24/s
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190-210 20/s

Finish G.S.M. Count (Ne)

160-180 34/s
180-200 30/s
200-220 28/s
220-235 26/s
235-245 24/s

FOR DOUBLE JERSEY (RIB)

Finish G.S.M. Count (Ne)

180-200 40/s
200-220 34/s
220-240 30/s
240-260 28/s
260-280 26/s

RELATION AMONG YARN COUNT, GAUGE, S.L, GREY GSM, FINISH GSM &
M/C DIA (ACCORDING TO EXPREMENT)

M/C Fabric Yarn Grey S.L. Finished Fabric M/c

G. Type. Count. GSM. GSM. width. dia.
28 S/J 30/1 CC 117-118 2.85 140 75” 30”
24 ST.B.PK. 28/1 PC 150-155 2.85 175-180 84” 30”
20 ST.B.PK. 20/1 CC 195-200 2.85 220 39” 30”
24 P.PK. 34/1 PC 125-130 2.85 160-165 78” 30”
24 B.PK. 26/1 KC 160-165 2.85 200 78” 30”
20 P.PK. 34/1 KC 150-152 2.85 175-180 78” 30”
20 J.PK. 26/1KC 180-182 2.85 230-235 78” 30”
28 S/J 40/1CC 145-150 2.85 170 60” 30”
LYCRA +5% 40D
LYCRA

FOR SINGLE JERSEY

PRODUCTION PER SHIFT FOR EACH MACHINE

Types of fabric Yarn Count Hours M/C R.P.M Wt. of fabric

Single Jersey 30/s 12 36 170kgs
Single Jersey 24/s 12 35 180kgs
Rib 30/s 12 25 200kgs
Rib 26/s 12 24 220kgs
Interlock 34/s 12 25 180kgs
 25

NECESSARY INFORMATION

1. G.S.M.:

It is technical term that indicates the weight of the fabric per square meter.

2. Changing of G.S.M.:

The GSM of the fabric is change by altering the position of the tension pulley. If
pulley moves towards the positive direction then the GSM is decrease and in the reverse
direction GSM will increase.

3. Points that should consider in case of g.s.m. changing:

i) VDQ (Variable Dia. Quality Control) pulley diameter.

ii) Yarn count.
iii) M/C gauge.
iv) Cam position
v) Take up motion

4. Factors that should be considered for changing of fabric design on:

i) Cam arrangement changing.

ii) Needle butt setting & needle dropping.
iii) Using of different colors in selected feeder.
iv) Using of jacquard mechanism.
v) Size of the loop shape

5. Recommendable points of a buyer:

i) Diameter of the fabric

ii) Design of the fabric
iii) GSM of the fabric
iv) Total wt. of the fabric
v) Yarn count
vi) Types of yarn
vii) Color of the fabric
viii) Finishing of fabric.
 26

ix) Handling & fastness property.

6. Gauge numbers that are usually seen in different m/c:

i) Incase of rib m/c. 16 to 18 G are normally used. But incase of improved

quality yarn 20G M/s are used in European country.
ii) Single jersey m/c is normally found 20, 24,28etc. Gauges.

7. Relation between yarn count and m/c gauge seen in different m/c.:

We know,
G2

Ne =-------------
18

Where, Ne = English Cotton Count

G = M/c. gauge.

WORKING PARTICULARS

1. Working hours: Two shift each of 12 hours.

# M/c cleaning and maintenance at the time of shift running

# M/c stoppage & cooling during shift changing for half an hour.

2. Type of fabric produced:

Single Jersey, Lycra Single Jersey, Single Lacoste, Double Lacoste, Single pique,
Double pique, Fleece, French Terry, Plain Rib, 2*2 Rib, 6*2 Rib, Plain Interlock, 8-lock
nit interlock,Lycra Rib, polo pique, , honeycomb, , waffle, mesh, Auto stripe fabric and
many others designed fabrics.

3. Needle breaks: 5 Nos. /day 13 machine.

Causes:
a. Irregularities in yarn (Thick place, neps & slubs)
b. Faulty needle latch.
c. Dirty machine condition.
d. Needle trick jamming.
e. Worn out needle trick.
f. High yarn tension.
g. Improper lubrication
h. Complexity of design
i. Use of more yarn in a feeder
 27

j. Negligence of operator
k. Wrong selection of machine gauge

Remedies:
a. Proper lubrication & cleaning of machine
b. Involvement of automation system
c. Application of schedule maintenance
d. Proper yarn & tension setting
e. Using of fault free yarn (high quality combed yarn)
f. Extra care during producing of complex design
g. Skill ness & awareness of operator
h. Correct selection of machine gauge for a specific fabric

4. Adjusting points of the knitting machine:

a) Feeder to needle (horizontal distance, 1 to 2 sinker thickness)

b) Feeder to needle (vertical distance, by feeder adjustment or by dia height
adjustment)
c) Dial to Cylinder distance.
d) Sinker groove to Cylinder groove.
e) Tension and loop length.(VDQ pulley diameter Adjustment)
f) Yarn tension adjustment (Tension control knob on cam box)
g) Adjustable speed in motor driving shaft.
h) Change pinion in take up roller to perform tension.
5. Auto stop motion in knitting machine:

a) Gate open
b) Needle breakage
c) Motor drive fault
d) Yarn breakage both
e) Fabric cut & falls down.
f) Oil & pressure air problem.
g) Completion of selected target.
h) Photo electric cell
i) Take up problem.

METHODS OF INCREASING PRODUCTION:

By the following methods the production can be increased –

1. By increasing m/c speed:

Higher the m/c speed faster the movement of needle and ultimately production
will be increased.
 28

2. By increasing the number of feeder:

If the number of feeder is increased in the circumference of cylinder, then the
number of courses will be increased in one revolution at a time.

3. By using machine of higher gauge:

The more the machine gauge, the more the production is. So by using machine of
higher gauge production can be increased.

4. By imposing automation in the m/c:

a) Quick starting & stopping for efficient driving system.
b) Automatic m/c lubrication system for smoother operation.
c) Photo electric fabric fault detector.

5. By imposing other developments:

a) Using creel-feeding system.
b) Applying yarn supply through plastic tube that eliminates the
possibilities of yarn damage.
c) Using yarn feed control device.
d) Using auto lint removal.

PRODUCTION CALCULATION:

1. Production/shift in kg at 100% efficiency:

RPM  No. of Feeder  No. of Needle  SL( mm)  60  12


10  2.54  36  840  2.2046  Yarn count
RPM  No. of Feeder  No. of Needle  SL(mm)

3527.80  Yarn count

2. Production/shift in meter:
 29

Course / min .

Course / cm
RPM  No. of Feeder  60  12  Efficiency

Course / cm  100

3. Fabric width in meter:

Total no. of wales


Wales / cm  100
Total no. of Needles knitting

Wales / cm  100

STITCH NOTATION, CAM ARRANGEMENT

&
NEEDLE REPEAT
OF
SOME KNITTED FABRIC

FABRIC NAME: SINGLE LACOST

1. Stitch Notation:

 30

     = Knit stitch 1 = 1 Butt Needle

     = Tuck stitch 2 = 2 Butt Needle
K = Knit cam 3 = 3 Butt Needle
    T = Tuck cam 4 = 4 Butt Needle
   
   

Fig. Looping diagram

2. Cam arrangement & Needle arrangement:

i) Using two track cams:

▲ ▲ ▲ T ▲ 1
▲ T ▲ ▲ ▲ 2

ii) Using three truck cams:

▲ ▲ ▲ T ▲ 1
▲ T ▲ ▲ ▲ 2
3
▲ ▲ ▲ T ▲
ii) Using four truck cams:

▲ ▲ ▲ T ▲ 1
▲ T ▲ ▲ ▲ 2
3
▲ ▲ ▲ T ▲
4
▲ T ▲ ▲ ▲

Fig.- Cam arrangement Fig.- Needle arrangement

 31

FABRIC NAME: DOUBLE LACOST

1. Stitch Notation:

     = Knit stitch 1 = 1 Butt Needle

     = Tuck stitch 2 = 2 Butt Needle
K = Knit cam 3 = 3 Butt Needle
    T = Tuck cam 4 = 4 Butt Needle
   
   
   
Fig. Looping diagram

2. Cam arrangement & Needle arrangement:

i) Using two track cams:

▲ ▲ ▲ ▲ T T 1
▲ T T ▲ ▲ ▲ 2

ii) Using three truck cams:

▲ ▲ ▲ ▲ T T 1
▲ T T ▲ ▲ ▲ 2
▲ T T ▲ ▲ ▲

ii) Using four truck cams:

▲ ▲ ▲ ▲ T T 1
▲ T T ▲ ▲ ▲
2
3
4
 32

▲ ▲ ▲ ▲ T T
▲ T T ▲ ▲ ▲

Fig.- Cam arrangement Fig.- Needle arrangement

FABRIC NAME: SINGLE JERSEY

1. Stitch Notation:

     = Knit stitch 1 = 1 Butt Needle

K = Knit cam 2 = 2 Butt Needle
   
3 = 3 Butt Needle
    4 = 4 Butt Needle
   
   
Fig. Looping diagram

2. Cam arrangement & Needle arrangement:

i) Using two track cams:

▲ ▲ ▲ ▲ ▲ 1
▲ ▲ ▲ ▲ ▲ 2

ii) Using three truck cams:

▲ ▲ ▲ ▲ ▲ 1
▲ ▲ ▲ ▲ ▲ 2
3
▲ ▲ ▲ ▲ ▲

ii) Using four truck cams:

1
▲ ▲ ▲ ▲ ▲ 2
▲ ▲ ▲ ▲ ▲ 3
4
 33

▲ ▲ ▲ ▲ ▲
▲ ▲ ▲ ▲ ▲

Fig.- Cam arrangement Fig.- Needle arrangement

Different fabric sample are given below:

34
 35

REMARKS:

As Reedisha Knitex Ltd. is not so big project; but its production quantity is not so small.
Production quantity varies as according as buyers demand. It gives approximately 110
ton production per month. In Bangladesh, there are a few mills which can produce such
quantity of knitted fabrics.
 36

CHAPTER-VI
QUALITY ASSURANCE SYSTEM
There is hardly any chance of any roll to be passed through
production or to any buyers by to by unchecked or disqualified. The inspectors are too
much experienced and they are aware of their duties and responsibilities. Factory
authority and the production officers are happy and satisfied with their works.

QUALITY ASSURANCE SYSTEM

 37

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

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

QUALITY ASSURANCE PROCEDURE:

Based on the sequence of grey inspection, the inspector serially numbers each
roll ensuring that all rolls having the knit card with complete details of the roll.

1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from
the cloth or batch roller and they are carried to inspection section by the helpers.

2) Almost four inspection workers are for every shift to check the fabric rolls.
For any kind of fault they are checked thoroughly. Skilled inspectors find them and
indicate them by the scissors in some cases.

3) Quality is specified on the basis of 4-points system. Here is the point

distribution for different kinds fault in this system:-

FOUR POINT GRADING SYSTEM

Size of defects Penalty
3 inches or less 1 point
Over three inch but not 6 inch 2 point
Over 6 inch but not 9 inch 3 point
Over 9 inch 4 point

THICK THIN DIRT, OIL SPOT, CONTAMINATION:

Up to 3’’ in length: 1 Pt
Up to 6’’ in length: 2 “
Up to 9’’ in length: 3 “
Up to 9’’ in length: 4 “

QUALITY Pts / per 100 square meter= (Total point * GSM)/ (Roll weight*10)

Quality inspectors seal on the fabric rolls as ‘CHECK-1’, ‘OK’ &

‘REJECT’ as according as quality classification.
 38

QUALITY CLASSIFICATION

1 2 3
<20 20-30 30>
OK ASK REJECT

LIST OF EQUIPMENTS:

In this factory ‘REEDISHA KNITEX LTD.’ this is the list of

equipments to assure quality:-

1) Inspection m/c # 1(For plain single jersey)

2) Inspection m/c #2 (For decorative single jersey as like as Lycra,
Lacoste, waffle, Fleece and all kind of double jersey as like as Rib, Interlock).
3) Scissors
4) Weight balance & Micro balance
5) GSM cutter
6) Seal (‘CHECK-1’, ‘OK’, ‘REJECT’.).

Fabric defects are given below:

39
 40

Rejection criteria for body & Rib: Following table shows common
body & rib faults and response by grey inspection section.

No. Faults Response

1. Needle marks Major needle line is rejected.

2. Stripe Major needle line is rejected.
3. Barre marks Rejected
4. Slubs 1 point
 41

5. Wrong design Rejected

6. Pin holes 1 point
7. Fly & contamination Acceptable for color but not for white
8. Sinker marks Do
9. Uneven tension Discuss with manager
10. Missing yarn Use 4 point
11. Crease line Do
12. Uneven tension Discuss with manager
13. Oil stripe/line Do
14. Thick-thin place Rejected
15. Mixed yarn Discuss with manager

Rejection criteria for collar & cuff: Following table shows common collar & cuff
faults and response taken by grey inspection section.

No. Faults Response

1. Wrong ply Reject

2. Hole Reject
3. Needle line Reject
4. Slubs Reject
5. Wrong design Reject
6. Wrong tripping Reject
7. Fly & contamination Acceptable for color but not for white
8. First round problem Reject
9. Uneven tension Discuss with manager
10. Missing yarn Reject
11. Crease line Reject
12. Rust line Reject
13. Oil stripe Reject
14. Thick-thin Reject
15. Wrong tube Reject

QUALITY STANDARD:

Here is the quality standard:-

1) Fabric width 7) Broken needle /2’’
2) Fabric length 8) Thick /thin yarn
 42

4) Slub 9) Barre/ Stripe

3) Fabric weight 10) Dirt
5) Hole 11) Oil
6) Needle / Sinker line 12) Press off

REMARKS:
There is hardly any chance of any roll to pass through production on to any buyers by to
by unchecked or disqualified. The inspections are too much experience and they are
aware about their duties and responsibilities. The factory authority and production related
personnel are happy and satisfied with their works

CHAPTER-VII
MAINTENANCE

Maintenance of machineries is very important for any type of industries and

it is a must for a knit composite mill. All machines and machines parts of knitting, dyeing
and garments are maintained with extreme care. Because production quality and quantity,
both depends on the maintenance with regularity. Reedisha Knitex Ltd. lead maintenance
with a troop of skilled mechanical fitters.

MAINTENANCE OF MACHINERY:
 43

In the knitting floor of Reedisha Knitex Ltd. all circular and flat knitting m/cs
are maintained regularly and as necessity requirements. Here, different type of
maintenance of machinery, which is taken, different time on the machineries.

TYPES OF MAINTENANCE: There are three types of maintenance which is taken in

Reedisha Knitex Ltd are as follows-
(1). Routine maintenance
(2).Unscheduled maintenance
(3). Scheduled maintenance

(1). Routine maintenance:

# during this maintenance production should be off.
#during this maintenance clearing should be done.
# during this maintenance setting should be checked & adjusted if should.
# during this maintenance oiling should be doing.
# It takes approximately 5-6 hrs.

(2) Unscheduled maintenance:

# it is done suddenly.
# during this maintenance production should be temporary off.
# It takes one day, but it depends on availabity of machine parts.

# scheduled maintenance.
# during this maintenance production should be temporary off.
# it takes half a day.

ROUTINE:
1) Daily Maintenance: Every machine is taken maintenance daily by the
operators during production. When a production is started by the operator after handing
over from previous shift operator, he takes a routine maintenance on the machine. He
cleans the machine, assures yarn is fed to all needles, cleans the eye pot of feeder,
memminger, signal lamp sensor etc. Before a while of a roll cut from batch or cloth
roller, operator cleans needles, cylinder base plate etc. All around of the machine are kept
neat and clean as if there is no dirt with yarn in the fabric.

2) Schedule/Routine Maintenance: Every machine has a schedule of

maintenance of 10 or 15 days. According to date, schedule maintenance is taken on the
machines. Operators are informed about the time of maintenance. After pre-estimated
production, they hand over the machine to the fitters. Thus, fitters assure all machines are
OK. for any time.

3) Break down maintenance: When product quality hampered and to complete

production in due time break down maintenance is taken. There are many faults seen in
the fabric during production due to needle, sinker, take down roller etc. Then operators
inform the mechanical fitters and they fix it.
 44

4) Restorative maintenance: Restorative maintenance is taken for design

change or new design development. According to advice or order of production officer, a
machine is fixed for new design and mechanical fitters rearrange cam and needle system.
Planned and preventive maintenance are not taken on the machineries in this mill.

MANPOWER SET UP FOR MAINTENANCE:

There are two shifts in this mill. Two groups of mechanical fitters for four
persons work for two shifts. Each group having a leader, a needle man and two assistant
fitters. Fitters work under the technical in charge for knitting section only. They all are
very efficient and hard working. They can fix any type of mechanical problem of
machines. No necessity happens to hire others from outside to fix machine maintenance.
There are electro-mechanical groups to work for electrical problem of machineries. They
work for overall factory.

Manpower set for different m/c maintenance:

# For single jersey m/c: 3-4 person/ hrs.
# For double jersey m/c: 7-8 person/ hrs

MAINTENANCE PROCEDURE:

1) For there is any mechanical fault of machine which is responsible for

production hamper, operator informs mechanical fitters in duty. Mechanical fitters come
and observe the problem firstly, and then they begin to fix it.

2) If mechanical fitters be unable to fix it, then they inform technical in-charge,
he then comes in spot and fix it.

3) For there is any electrical problem of machine or serious founding

mechanical problem, mechanical and electrical department are informed, they come and
fix the problem. They commence at work after informing of knitting manager. There are
two mechanical engineers in the department.

4) For restorative maintenance, senior production officer orders mechanical

fitters to fit required machine for cam and needle arrangement and other necessary
requirements in case of new design development.

Maintenance sequence of circular knitting machine

Power on/off
↓
MPF/Positive feeder current line off
↓
MPF belt out/loss
↓
Yarn cut
 45

↓
Fabric out by handle
↓
Cleaning and Oiling
↓
Cam box out
↓
Needle & sinker out
↓
Needle & sinker cleaning by oil
↓
Cam box cleaning by air

After opening & cleaning, m/c is leveled by using leveling meter and follows the reverse
process to ready the m/c.

MAINTENANCE TOOLS & THEIR FUNCTIONS:

S L No. Name of Tools Functions of maintenance Tools

01. L-Key Loosen and Tighten the screws.
02. Air Suctioner Cleans machine by suctioning.
03. Screw Driver To loosen and tighten the screws.
04. Dhali (Spanner) Loosen and Tighten nut and bolt etc.
05. Star Driver Screw unlocking.
06. Pliyers (Nose &Coarse) Tighten screws and nuts.
07. Cutting Pliers Cutting thin wire.
08. Pulley Key To loosen pulleys.
08. Pulley Key To loosen pulleys.
Remarks: This mill has a strong maintenance fitter’s troop to fix up all types problem.
Two groups of two shifts obey their duties responsibly and sincerely. With their different
tools or equipments they perform their duties skillfully.
CHAPTER-VIII
UTILITY SERVICES
Production and profit are closely related. In order to get quality final
product it needs fresh raw materials as well as effective manpower and machinery in
good condition. Utility in conjugation with the three M’s plays an important role to
maximize the production as well as the profit.
Utility ensures the followings:
Power supply (By Generator)
Water supply (By Pump), Hot water supply (by hot water tank).
Steam supply (By Boiler)
Compressed air (By A/C plant)
Exhaust air handling (By vacuum planning system)
Fuel & gas supply
 46

Workshop facility
Civil work
POWER SUPPLY:
Reedisha Knitex Ltd. has two generators for power supply to
ensure continuous dyeing & knitting operation and help to fulfill their target production.
One is gas generator & other is diesel generator. Both of this two generator gas generator
is widely used because of lower production cost of
Specification of generator ( 1 ) :
Types: Gas generator
Company: Gauscor.
Model: 560 SFGLD.
Country origin: Spain.
Capacity: 1170kv, 936kw,1717A.
Frequency: 50Hz
Fly Wheel RPM: 1500.
Cylinder no: 16
Pressure of gas: 0.7 bar.
Stork: 4
Cost of price: 02crore.
Types: Diesel generator
Company: Perkins
Model: P380EI.
Country origin: United Kingdom
Capacity: 380kv, 304kw.
Rated power: 330 kva
Maximum current: 264 kw,450A.
Frequency: 50 Hz
Fly Wheel RPM: 1500.

Gas Generator ( 2 ) :
Company:Waukasha, Model: VHP 7100G
Capacity: 600 kw, Speed: 1000 R P M, Voltage: 400 vol

WATER SUPPLY: There are two deep tubes well for supplying water in
the factory. This unit collects water from the under ground and here for hardness testing
common test i.e. shop testis followed. For dyeing section 05 ppm is maintain. This
collecting water is reserve in reserve tank and then supply everywhere in the factory. On
the other hand, there is water treatment plant use to oxidize water before supply. There
are two water conditioners in this factory.
Specification of water conditioner:
Country of origin: USA
Model no: ACC-SMR 300-2TW
Capacity: 300,00GRS/Tank
Presser: 100 PSI
 47

STEAM SUPPLY: In this factory, there is a boiler use to supply steam for
different operation where it is necessary.
Specification of boiler: Cleaver books
Model: CB700600150
Country: USA
Max. Pressure: 150(PSI)
Capacity: 9.5 tons
Frequency: 50 Hz
Volts: 400 , Temp. 300-350 C
Boiler motor: 20Hp
Supply: 10 tons/hrs
COMPRESSED AIR SUPPLY: There is a air compressor to
supply compressed air in the factory.
Specification of compressor:
No of compressor: 02
Origin: BOGE super tonic
Country: Germany
Model: DB 150.
Air pressure: 08 kg( For factory)
Max pressure: 25 kg
Air suck: 5.83m3/min

COST OF DIFFERENT UTILITIES:

Electricity cost:
REB =3.8 TK / KW-HR
Gas generator = 2.70 TK / KW-HR
Diesel generator = 6.50 TK / KW-HR
Gas cost:
4.94 Tk/m³ for boiler
3.66 Tk/m³ for generator
4.5 Tk/m³ for domestic purpose

Steam cost:
4.30 Tk. per kg fabric.

REMARKS:
As the biggest project the Reedisha Knitex Ltd, but it has vast utility systems.
There is a skill manpower group of engineers and other technical staffs to look after these
utility services. They have to remain aware of solution on a great sense of responsibility
for any type of problem due to utility supply.
 48

CHAPTER-IX
STORE & INVENTORY CONTROL

Inventory is planning and execution involves participation by most of the

fundamental segment of business sales, production, purchase, finance and accounting.
Inventory is a wider sense is defined as any idle resource of an enterprise how ever it is
semi-finished packing spares and other stocked in order to meet an expected demand or
distribution.
 49

OBJECTIVES OF INVENTORY CONTROL:

1) Financial activities:
a) To save amount of investment
b) To know the cash position
2) Property Protection:
a) Preventable waste
b) Insurable damage
c) Unauthorized use
3) Operating:
a) To obtain the best overall balance between production and
inventory carrying cost.
b) To minimize losses

c) To avoid stock out and to keep inventory holding costs in

costs in balance.

INVENTORY SYSTEMS:

For Raw Materials:

In this factory, Reedisha Knitex Limited, raw materials are yarn of
different type, different count and of different spinning mills of home and abroad. As
according to knitting section demand yarn is either imported or bought from spinning
mills and they are kept in the store for raw materials in accordance with type and count.
As like as polyester, cotton, lycra are kept separately and also to their count variation.
Inventory office keeps record of this raw materials amount, their usage and storage.

For Spares:
Different spares parts of knitting machines and other equipments are
kept in store as inventory so that there are no time and money losses while it is being
used. Here is the list of spare parts as inventory:
1) Needle detector
2) Fan
3) Air gun
4) MPF belt tensioning device
5) Air nozzle
6) Fabric spreader
 50

7) Fabric light
8) Compressor line + pipe
9) Air blower
10) Memminger
11) Oil Tank
12) Fabric roller
13) Inverter
14) Yarn Guide feeder
15) Oil Nozzle
16) Cam box
17) Magnet
18) VDQ pulley
19) Fan broker
20) Oil Meter cover
21) Oil plutonic
22) Air meter cover
23) Knot catcher
24) Feeder ring bolt

For Knitted Fabrics:

After knitting the fabrics are collected according to roll form. There is a
big store room beside knitting section in this factory and fabric rolls are stored here
according to fabric types and some specification is given to fabric rolls such as buyer
name, yarn count, lot no, fabric type, m/c no, fabric weight etc. Collars and cuffs are also
stored in this room. A store keeper always does this job successfully.

For Finished Goods:

Finished goods in this mill are the readymade garments. All garments
are being ready in the cartoon according to the piece numbers as buyers choose.
Cartoons are kept prepared one upon another for dispatch. Total no. of cartoons is
maintained by the inventory office for finished goods. And at last, they are sent to
dispatch after counting.

For Others:
Out of above types there are inventory systems for semi-finished goods
like as dyed fabrics, garments pattern pieces, markers, sewed goods, scrap, surplus,
absolute items, garments labels, packages etc.These goods are maintained by the
respective inventory control office different departments this knit-composite mill.

REMARKS:
Proper inventory control of raw materials, semi-finished goods, finished
goods and other miscellaneous goods lead smooth production. As REEDISHA KNITEX
LTD. follow the correct way of inventory control system, it can have a good and huge
production as it demands.
 51

CHAPTER -X
COST ANALYSIS
INTRODUCTION:
Costing is a process by which the setting price of a product is calculated. It is a
very important task for a factory which runs for business purposes.
And it is also strictly followed in the REEDISHA KNITEX LTD. Costing of the products
considering the raw materials expenditure, salary and wages of officers and workers,
distributions and advertisement expenses etc. all direct and indirect expenses is done in
 52

this factory. It is determined by a troop of accountants with advice and consultancy of

executive director.

PRICE OF THE PRODUCT:

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

Price of products= (Direct expenses + Indirect expenses + Factory

Overhead) + Required profit

PRICE RANGE OF DIFFERENT PRODUCTS:

T-Shirt = $0.75 - $4.50 /Pcs
Polo Shirt =$2.00 - $6.50 /Pcs
Kids Wear ==$0.75- $2.15 /Pcs

KNITTING CHARGE OF DIFFERENT FABRICS:

Fabric name Charge per kg(Tk)

Single Jersey 8-9
Single Jersey with Lycra 30-35
Single locust PK 16
Double lacost PK 16
Single PK 16
Double PK 16
Rib 12-17
Rib with Lycra 30
Interlock 18-22
Auto striper 80
Auto striper with Lycra 100
Fleece 22-25

DYEING CHARGE OF DIFFERENT FABRICS:

Name of fabric process Charge per kg(Tk)

White with Enzyme 45
White without Enzyme 35
Avg. color with Enzyme 85
Avg.color without Enzyme (Light& 75
med.)
Deep shed with Enzyme (Black) 120
Deep shed without Enzyme (Black) 95
Only wash (Tubular) 25
Only wash (Open) 45
 53

Double dyeing (Face & Back) 115

FINISHING CHARGE OF DIFFERENT FABRICS:

Name of fabric process Charge per kg(Tk)

Slitting only 5
Stenter only 25
Compacting only 15
Stenter + Compacting 35
Stenter + Compacting+ wash 50
Tube Compacting 10

COSTING OF THE PRODUCT:

Let price of yarn is $ 3.00/ kg.

Process loss of yarn for knitting (10%) = $0.30
Knitting fabric cost = $3.30
Cost of dyes & chemicals = $2.50
Process loss for dyeing (12%) = $0.30
Dyed fabric cost = $ 6.10
Packing cost = $0.05
Production cost of fabric=$6.15
Fabric price (with 25% margin) =$7.79
 54

Fabric consumption/ doz. = (Body length + Sleeve length +10) x Chest length x 2 x GSM
x12 /10000000

Garments specification:
Body length=78 cm
Sleeve length=33 cm
Chest length=62 cm
GSM=210
Fabric consumption/ doz. = {(78+33) x62x2x210x12}/ 10000000
= 3.469 kg
Fabric consumption/doze (with 10% wastage) = 3.816 kg

Body fabric cost / doz. =$(7.79x 3.816)

= $29.73
Cost of collar& cuff/doz = $ 4.00
Cost of Trims=$ 2.25
Cost of Trims (with 5% Process loss) = $2.36
Production Cost of Garments/ doz=$36.09
Garments Price/doz (with 25% Profit) =$45.12

REMARKS:
Costing is very important for a productive factory. Without proper costing all
production curriculums will go to vain. Because a factory cannot reach to its goal without
achieving good profit and good profit is not possible without skillful costing. In Reedisha
Knitex Ltd. There are some skillful personnel to do this job.

CHAPTER-XI
MARKETTING ACTIVITIES
INTRODUCTION:
Marketing activities are done in this mill, REEDISHA KNITEX LTD. by a
skillful team of marketing officers under the Executive Director. Here are the details of
marketing activities.

CONSUMER OF THE PRODUCTS:

The mill has a great number of renowned and international consumers. The
main consumers of this factory are European country such as Germany, France,
Netherlands, Denmark, Italy & England. Following are some regular consumers:
1) Tandem 9)Texco BD
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2) Style tex. 10)Acorn

3) I.C. Company. 11)Norp Knit
4)Jack Pot 12)OBS
13)Adidas
5) H&M
6) Walmart
7) Fashion concept
8) KIABI

PRODUCT LEBEL:
There are following labels used by this mill:
1) Care Label: It contains washing in hot or cold water, chemical
cleaning, drying conditions etc.
2) Size Label: It contains size of garments.
3) Composition Label: It contains the fabric composition of different
fiber type.
4) Decorative Label: Decoration is as buyer or consumer choice wise.

PACKAGE SIZE & LEBEL:

Most common sizes are
S - Small
M - Medium
L - Large
XL - Extra large
XLL - Very very large

LOCAL MARKET:
Reedisha Knitex Limited is 100% export oriented mill. So there is no local
market involved in it. But the knitting and dyeing & finishing section takes some sub-
contact for knitting and dyeing & finishing an amount of fabrics from their given yarn
and fabrics.
Duties & Responsibilities of Marketing Officer:

Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A
marketing officer also has some other duties. The main duties responsibilities of a marketing
officer are given below :-

 To prepare cost sheet by dealing with the buyer.

 To take different steps by discussing with the high officials & merchandisers.
 To maintain a regular & good relationship between commercial officer &
merchandisers.
 To maintain a regular communication with the buyer & buying houses.
 Communicate with the new buyers.
 Display the better criteria of the products.
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Remarks :- The marketing activities of this mill is so good. The marketing &
merchandising section is well organized

CHAPTER-XIII

CONCLUION

The industrial training gives us the opportunity to work in mills. It is an

experience of normal academic learning,
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This training gives us actual picture about man, machine, material, methods and
market. We have earned the direct knowledge about the raw materials, actual running
condition of the m/cs. Works technologist and administration.

This mill is a well planed with enough expansion facilities. Their exist are
wonderful employer and worker relation. Working environment for the labors is also
good.
During our training we visited administration section, store, boiler section,
generator room, compressor section etc. Everywhere we got cordial behavior from all
employees

Above all this training for 35 days in the Reedisha Knitex Ltd. Has give us a new
experience for practial life.

College of Textile Technology has given me the field to perform the industrial
attachment with Reedisha Knitex Ltd. This attachment seems to me as a bridge to
minimize the gap between theoretical and practical knowledge. Undoubtedly, this
attachment paved us the way to learn more about Textile Technology, industrial
practices, and industrial management and production process.
Besides this attachment gave us the first opportunity to work in an Industry and
acquainted us with the internal sight and sound of Textile Industries. I believe with all
these, the experience of the industrial attachment will help our future life as a Textile
Technologist