Zarun(South) Kashimpur, Gazipur,



PREPARED BY HADIULLAH RAHAMAN in Textile Engineering(1st batch)
ROLL NO. : 070043 REG. NO. : 4512

SESSION: 2006-2007


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

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

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


We also express our heartiest gratitude to the authority of The Delta Spinning Mills Ltd. Special thanks goes to Engr. Md. Tariqul Islam, Deputy General Manager of QA; Engr. Md. Moshiur Rahman, DGM of production, Anjan Chowdhury, PM of production for supervising our training in a systematic schedule and all sort of help. Finally we place our sincere acknowledgment to all those officers, staffs and technicians of The Delta Spinning Mills Ltd. who have helped us to overcome different problems in different situation that have made a Successful completion of our training.


The Delta Spinning Mills Ltd. is a well reputed spinning mill in Bangladesh. It is the sister concern of The Delta Group. The area of mill is about 26 acres. It is fully 100% export oriented spinning mill. It is located in Zorun South, Konabari, Gazipur. The Mill is established in 2006. The owner of this mill is Engr. Faruq Hossain. The Delta Spinning Mill is ISO certified by ISO 9001:2008. The Delta Spinning Mills Ltd. is a truly undertaking. The Spinning Devision has the capability to offer a complete product range for the 100% export quality yarn to EU & American market. The goal of the Spinning Division is to become the preferred partner for sourcing high quality value added yarn from Bangladesh. With an emphasis on developing local human resource, the Spinning Division has the potential to make an important contribution to the nation’s growing RMG export sector.


Name Of the Mill:

The Delta Spinning Mills Ltd. Zarun(South) Kashimpur, Gazipur, Bangladesh.

Head Office:

House# 389, Road# 6 DOHS Baridhara, Dhaka – 1206. Phone: 880-2-8813636-7, 8824092 Fax: 880-2-8840263 E-mail:

Date of Establishment: Ring Unit: 2006 Rotor Unit: 2008 Production Capacity:
Total Unit Spindles Count Range Production Capacity (MT/day)

Ring Rotor

42,336 960

Ne 7 to 40

approx 28~32 approx 3~4

Ne 12 to


Location of the Mill:
Mymensing- Dhaka road


ow ras ta Ch an dra Ro ad
Delta composit e Cotton Club


Delta Blended yarn The Delta Spinning Mills Ltd.

Delta Accessori

Kashimpu r Jail

Layout Plan of Ring Unit:


Raw Cotton Godown Ring Section

Carding Machine

Back Process

Auto Coner


Draw Frame Blow Room Carding Machine

Lay-out Plan of Rotor unit:


A/C Plant

Rotor Machine

Organogram of the Factory: Departmentwise:
Design of Organization Chairman and MD Commercial Director All Departmental Heads Second man Officer and Office Staff Production Department Organogram DGM Production Manager Production Shift in Charge APO HR And Admin Organogram Worke r 10

Head of HR and Admin

Security Officer Supervis or Guard

Executiv e Officer and Office staff

Medical Officer


Quality Department Organogram DGM Quality

Executive Officer Lab Assistant Lab Boy Maintenance Department Organogram DGM Utility 11

Executive Maintenance Officer Worker

Utility Department Organogram

DGM Utility

Manager Generator Worker

Manager E and E Assistant Engr.

Senior Engr. CBC Worker

Assistant Engr. A/C



List of workers of different department Department Category Electrical Maintenance Blow room Carding & Card shop Draw frame Comber & Simplex Ring Frame Winding Chiller, Boiler, Cooling Tower & Pump A/C Plant, Compressor Power Generation & Distribution Workshop Mixing & Blow room Carding and Preparatory section Ring section Winding Section Packing Section Research & Development section Production Maintenance Utility Total Workers 877 60 52 989 16 80 15 40 40 13 15 15 15 45 71 160 100 50 7 86 10 9 877 Number of workers




Rotor Unit

Total workers Total Staff Total Officers Grand total of manpower

Name of the owners & Departmental Head: 13

 Chairman  Director Commercial  DGM Production  DGM Quality  DGM Utility  DGM Maintenance  DGM Marketing  GM Finance  Manager Store  Manager HR& Admin

– Engr. Faruq Hossain – Md. Shahidul Alam – Engr. Moshiur Rahman – Engr. Tariqul Islam – Engr. Abul Kased – Engr. Abul Kased(temporary) – Md. Shah Jamal –Md. Ruhul Amin – Md. Kamal Molla – Md. Abdul Khaleq

Sponsored by Islami Bank Bangladesh Ltd. Total Floor Space: Total floor space is 1,31,000 square feet. Vision: The visions of The Delta Spinning Mills Ltd are – # To provide an efficient back-linkage support for the ready-made garments industry in Bangladesh by producing export quality cotton hosiery yarn. # To provide sufficient monetary profit to the Group. # To train and develop skilled manpower for the industry. # To reduce the employment problem in Bangladesh by creating employment opportunities.


Process Flow Chart of The Delta Spinning mill:
Bale Management (Mixing) Unifloc-A11 Uniclean-B11

Unimix-B70 Uniflex-B60 Vision Shield-ED35 Condensor-

Unimix-B70 Uniflex-B60 Vision Shield-ED35 Condensor-A21

Karded Process Combed Process Breaker Drawing-SB-


Precomb Drawing-SBUnilapE32 Comber-

Finisher Drawing-RSBSimplex-FL-100,FLRing-RX240,K44,BT702 Winding-MuratecPackin g

Postcomb Drawing-RSB-

Yarn Conditioning 15

Raw Material Used:
Raw material is a vital factor for the productivity, quality and profitability of a factory. As The Delta Spinning Mills Ltd is a cotton spinning mill, its main raw material is cotton. As cotton is not grown in our country, all of these cotton are imported from foreign countries. The factory has used the following cottons in the past years: Australian cotton, America, India, CIS, Thailand, Zimbabwe, Turki, Syria, Chad, Egypt, China, South pacific cotton etc. The factory requires around 35 Metric Tons of raw cotton per day.

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

Virgin Cotton (CIS) – 40% – 2400kg Noil – 35% – 2100kg Pneumafil – 10% – 600kg Dropping-1 – 15% – 900kg Total – 100% – 6000kg

Raw Material Inventory:

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

Spin Plan

100% Karded Yarn Mac hine Type s of m/c Spinning Schedule Deli ver y unit per m/c Util i zat ion % Cou nt/ Han k/ Kte x D T. o M. u bl in g Spee d TPI Cal cula ted pro duc tion /m/ c(K g/d ay) 349 7 672 434 4 496 1 496 1 168 5 Production Schedule Pr od uc tio n Eff i% Prac Wa tical ste prod % uctio n/m/ c(Kg /day ) 0.6 2.5 0.5 0.5 0.2 6 4 14. 3 Total produ ction reqd. (Kg/d ay) Actu l no. of m/c Total m/c reqd.

Windi ng Ring Fram e Simpl ex Finis her D/F Brea ker D/F Card Blow room Total Raw mate rial reqd.

72 100 8 144 1 2 1

10 2 10 1 10 5 98 99 10 0

28 28 0.7 5 5.3 5.3 6 3. 7

1600 1600 0 1100 8 6 650 650 195

18.5 2 18.5 2 1.05

70 244 8 96 645 75 325 8 85 421 7 85 421 7 95 160 1

20000 8.17 20120 31.2 0 20623 6.33 20726 4.92 20830 4.94 20871 13.0 4 22124

8 31 6 5 5 13

230 09


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

Blow Room:
The blow room consists of :-

Unifloc : Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ A11 Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Switzerland Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006 18

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

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


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

Unimix: Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐B70,B71 (Ring,Rotor) Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006,2008 No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐03 (2 ring+1rotor) Production capacity‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐800 kg/hr 20

Uniflex : Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐B60 Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland 21

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

Vision shield : Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ED-35 Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Jossi Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland Year of manufacture‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2006,2008 No. of m/c‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐04 (only for ring) Condensor : 22

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

Carding : Model‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐C60 Brand‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Rieter Country of origin‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Switzerland 23

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

Breaker Drawing: Model-----------------------------------------SB-D-40 Brand------------------------------------------Rieter Country of origin----------------------------Switzerland Year of manufacture-----------------------2006 No. of m/c------------------------------------8 24

Production capacity------------------------707 m/min

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


Combing: Model-----------------------------------------E 65 Brand------------------------------------------Rieter Country of origin----------------------------Switzerland Year of manufacture-----------------------2006,2008 No. of m/c------------------------------------15 Production capacity------------------------46 kg/hr Finisher Drawing: Model-----------------------------------------RSB-D40 Brand------------------------------------------Rieter Country of origin----------------------------Switzerland Year of manufacture-----------------------2006 No. of m/c------------------------------------9 (6 for ring line and 3 for rotor line) Production capacity------------------------657 m/min


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

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


Winding : Model-----------------------------------------Uster Quantum2, 21C Brand------------------------------------------Savio, Muaratec Country of origin----------------------------Italy, Japan Year of manufacture-----------------------2008, 2006 No. of m/c------------------------------------14 (4+10) Production capacity------------------------1600 m/min


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

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


Wastes produced at different production process:
Blow Room (4-5%) Carding (5-6%) Drawing (0.5%) Lap Former (0.5%) Comber (10-20%) : Droppin-1, Droppin-2 Fine dust : Flat strip Licker-in : Filter Waste, Sliver waste Sweeping dust : Sliver waste, Lap waste : Lap Sweep Noil : Sliver Roving Apron Clearer waste Sweep waste : Roving ,wooden roller clearer, Bonda,Soft waste, Pneumafil , Sweeping . : Hard Waste Sweeping Invisible waste : Pneuma dust Hard waste Sliver waste Soft waste

Simplex (0.5%)

Ring Frame (3%)

Winding (0.5%)



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

Carding: The carding machine mainly removes the Neps, short fibers and remaining impurities in the cotton fiber and forms carded sliver. Mainly impurities are removed at the taker in and the neps and short fibers are removed by action between the cylinder and flat. It is called the heart of cotton spinning because the quality of a cotton spinning mill is greatly dependent upon the performance of the carding machine. The card slivers are delivered in card sliver cans which are then fed to the breaker drawing frame. 31

Breaker / Pre-comb Draw Frame: In the breaker draw frame 5 to 6 carded sliver cans are fed at a time and are drafted to one drawn sliver. By this, the fibers in the sliver becomes more oriented, parallelized and the irregularity of the strand decreases. Produced drawn sliver cans are then either fed to the finisher if it is card process or fed to the lap former if it is combed process.

Lap Former: For combing, the material have to be presented to the comber machine is a lap form. So to convert the slivers into mini laps, the lap former is used. Here 23 to 24 drawn sliver cans are doubled and drafted together to form lap. The lap is then fed to the comber machine. Comber: The comber machine mainly combs out the lap and removes any kind of neps, short fiber or other impurities present in it. It also parallelizes the strand to the maximum degree. As a result the yarn produced from this sliver possesses better quality and aesthetic properties. The produced combed sliver is then fed to the finisher / post-comb drawing machine.


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

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


Ring Frame: In the ring frame, finally the yarn is produced by drafting the roving. Here twist is inserted in the yarn to obtain required strength. Twist is inserted by means of ring traveller. The number of turns that the spindle rotates at one revolution of the front roller is the number of twist that are inserted on the unit length of yarn. Then the yarn are wound on ring bobbins. When the bobbins are full, they are doffed from the machine automatically by SCD (Stationary Cone Doffer) mechanism. Auto Coner: The auto coner is a machine for automatic winding of yarn on cross wound 34

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

Heat Setting Machine: Heat setting is mainly done to stabilize the twist in the twisted yarn, reduce hairiness and increase the moisture content in the yarn packages. The yarn cones are arranged on trolleys. Maximum 6 trolleys can be fed to the machine. After that the machine door is closed. Then vacuum is created inside the machine and water at 550C is sprayed inside the chamber. Due to negative pressure, the water becomes steam. There the yarn packages are heat set in the steam for 45 minutes. Then they are brought out and sent for packing. Rotor Machine: In the rotor machine, the yarn is produced directly from sliver. The sliver is opened into individual sliver in the opening unit and then individualized fibers are deposited in rotor groove. From there they are bounded around an open end of yarn and thus rotor yarn is formed. The produced yarn is directly wound on a paper cone package. So here the simplex and auto coner is not required. 35

In The Delta Spinning Mills, responsibility of quality management is carried out by the Quality Assurance Department Lab. The lab is lead by the DGM of QA . The lab carries out tests on materials at every stage of processing starting from the raw cotton to finished yarn. By this they provide the assurance of obtaining consistent quality throughout the process and in the finished yarn. A brief description about the lab and its quality management process is given in the later section.

Lab Equipments:
Seri al 1 Name of the Machine USTER® Evenness Tester Model Manufactu rer & Country of Origin Zellweger Switzerland Year of Manufact ure 2006 Purpose




PR503 Delta Range AFIS PRO

Zellweger Switzerland Zellweger Uster USA


To test evenness, imperfection and hairiness of yarn and other strands such as roving and sliver. To test count of yarn directly To test Neps, length and maturity related properties of cotton fibers To test important parameters of cotton fiber. To test strength and elongation of cotton fiber





HVI – Spectru m 754

Zellweger Uster USA Zellweger Uster Germany



USTER® Stelometer




Electronic Moisture Meter


Zweigle Germany


To measure moisture content of textile materials

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

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

separator of the blow room.


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

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

In lap former, the lap thickness is measured mainly.

The Comber is a very crucial machine. Its performance plays a vital role on the quality of the combed yarn. So, the performance of the comber is assessed by testing the material before and after it. From there the nep removal efficiency of the machine is determined. Also the noil is tested to see whether 38

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

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

In case of testing of carding, breaker draw frame and finisher draw frame, a schedule is maintained so that all the machines are tested within a fixed period of time.

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


The yarn of ring frame, rotor machine and auto-coner are tested to determine their count. This test is carried out at each shift for each count and lot. Testing is carried out in USTER-5 Tester in the same manner to determine the U%, CV%, Relative count, +50% thick places, -50% thin places, +200% Neps (ring yarn), Imperfection index, hairiness, standard deviation of hairiness, periodic faults etc. From there necessary actions are taken to eliminate or reduce the faults. The CSP (Count Strength Product) of the yarn are also tested to determine the bundle yarn strength which is very important for knitted fabric. The TPI (Twist Per Inch) of yarn is tested at the beginning of each lot. The setting of drafting gear in drawing frame, simplex and ring frame is given by the QA department and is implemented then by the maintenance department. The QA department on the basis of trial and experiment does the selection of proper roller gauge and spacer in the drafting zone of simplex and ring frame. Also the setting of the EYC (Electronic Yarn Clearer) is determined by the QA department. This ensures that most of the faults that are present in the yarn are cut out during winding on paper cone and fault free yarn are delivered to the customer. The moisture content in the yarn packages after heat setting are also tested by the QA department. Thus the proper time of heat setting can be maintained to deliver yarn with required amount of moisture content.

Bale Management:
Bale management is the judicious selection of cotton bales in the laydown in order to obtain consistent quality as well as economic 40

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

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


The Delta Spinning Mills produce one kinds of yarn called slub yarn. Slub yarn is one kind of yarn which contain irregularity in a uniform distance. A model parameter of slub yarn is given below :Length Minimum (mm) 110 10 45 10 Length Maximum (mm) 380 10 65 10 Ramp Wide Initial (mm) 1.0 1.0 1.6 1.6 Wide Final (mm) 1.0 1.6 1.6 1.0

Pause Length Ramp Slub Length Ramp

Pause Length

Slub Length

Maintenance of Machinery

All the textile machinery both process and related ones are high performance machinery and they have to maintained well to ensure their high performance and efficiency. Also proper maintenance ensures their long operating life. The following types of maintenance are carried out in the factory – # Schedule Maintenance: Here mainly all the machines are checked on the basis of a fixed schedule of time. Different machine parts are opened, cleaned, lubricated, gauged and replaced if necessary. # Predictive Maintenance: This type includes maintenance of machine parts on the basis of suspicion that they consists problem and will cause greater problem in future. It also includes the gear changes that are done to adjust count, ktex etc of machinery and overhauling. # Breakdown Maintenance: When a machine stops due to failure of machine parts, then it is called machine breakdown. The maintenance that is done to repair and make it ready to run is called breakdown maintenance.


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

Maintenance Points: Machine Name Unifloc A11 Maintenance Point Fan Impeller Inside Swivel Tower unit Take-off Roller/Retracting Roller/Swivel Flaps Covering belts/Ducts All types of Belts/Rollers All drive Chain Guard Gear Motor of Retracting Rollers Tooth Segments Brake Lift Drive Sealing Strips (Lock Roller) Grid Bar Inside of Drum and Grid adjustment Perforated sheet for dust extraction Work to be Done Checking . Cleaning. Cleaning and Checking. Cleaning, Checking and Tension. Cleaning, Checking and Tension. Cleaning, Checking, Tension and Oiling. Checking. Check Oil Level. Checking. Check Oil Level. Cleaning Cleaning Cleaning Cleaning, Checking, Adjusting 44

UniClean B11/B12

V-Belt for Drum Drive Lock rollerdrive chain Inner part of the spike feed lattice All types belts All drive Chain Separating vanes, Exhaust air chambers Storage section inner chamber Rivets & spikes of spiked feed latice Roller Conveyor belt Closing flap & spike feed Spike feed lattice bearing Cotton filter All Gear box Stripping roller Lamella chute All drive chain Saw tooth roller Grid Bar All Seals Drum seal Stripper Condenser A-21 All types belt Perforated drum inside or outside All bearing Take off roller Outside the m/c

Tension Cleaning,Checking Cleaning Checking, Tension Cleaning, checking, tension, Oiling Cleaning Cleaning Cleaning, checking Checking Checking, Cleaning Checking Checking Tension Check oil level checking Cleaning Checking, Cleaning, Oiling Checking, Cleaning Checking, Cleaning Checking Checking Cleaning, Checking Cleaning , Checking, Tension Cleaning checking Cleaning Cleaning 45

Unimix B-70/B-71

Uniflex B-60

Material in , out and exhaust line


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

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


11. 12. 13. 14.

Detaching unit Chute All types belts Flat drive belt

Cleaning Cleaning Tension, Checking Tension

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

Maintenance points: Maintenan ce Area Table calendar Suction Unit Filter Sliver feed frame Drafting system Drive units Sliver guide, guide rolls Top & bottom rollers , tension bar All belts and chains Maintenance Points Top cleaning device & bottom cleaning device Mote knives, waste suction pipes Work to be done Clean and check its physical condition Clean and check suction properly Clean and check condition Clean properly and check setting Clean, check gauge and reset if required Clean, check tension, greasing and apply grease if required Check functioning 47

Safety device

Safety switch, pneumatic switch

Lubrication Gear Units

Drafting gear box, main gear box and all greasing point Setting gear

Lap guide plate Lapping unit Electrical function Condenser roller Motor, electronic board, limit switch, proximity switch etc.

Nut and bolt Drafting gear box, main gear box, lap roller drum, lap plate etc. Trolley Trolley wheel, pneumatic system

Check oil level and put oil if required, also check greasing Clean and check gear meshing, vibration, abnormal sound etc. Clean and check condition Clean properly To be cleaned and checked by electrical persons. Tightness check and make correct if required. Clean the wheel and the outer surface


Maintenance Points: Maintenanc e Area Maintenance Points Feed table, trumpet, calendar roller, table funnel Top combs, clearer rolls and flats, bearing of the bottom roller, circular comb, filter, spring assemblies Nipper, nipper lever on in-feed side, circular comb brush Feeding throats, feed roller, nipper lips, top detaching roller, fleece guide plates, top delivery roller, lap plate Stripper, Top and bottom roller Work to be done Clean and check condition, adjust if required Clean and check condition, adjust if required Clean and check condition, adjust if required Clean and check condition and gauge, adjust if required Clean properly, check physical condition 48

Delivery Unit

Draft system

Belt tension and condition

Timing belt, flat belt, V-belt Setting and condition of top comb, circular comb brush Roller, nipper feed plate, nipper gauge, bottom detaching roller gauge Outer surface of the machine and condition Oil level in gear box All gear

Gauge points Machine Side Gear Box Can changer

Clean all the belt, check tension and adjust if required Gauge check and adjust if required Gauge check and adjust if required Clean properly Check oil level and apply oil if necessary Check gear condition, correct if required Clean and check condition, adjust if required

Chain tension on turn table

Greasing points Nut-Bolts

Electrical parts

Bearing, bush of the top detaching roller Drafting roller, strip nipper frame, lower delivery and table calendar Batt tension roll axles and other greasing points Top comber nipper, circular comb, top roller pressure, main gear box, index wheel, all pulley, can wheel, coiler wheel, lap feed plate, lap roller nutbolt. Motor, motor fan, photo-cell, limit switch, electronic board, connection cable

Clean and check, grease if required Clean and check, grease if required Clean and check, grease if required Check tightness and make correct if required.

Check and clean by electrical person

Finisher Draw Frame:
Maintenance Points: Maintenanc Maintenance Points Work to be done 49

e Area Auto leveler

Funnel, scanning roller, contact roller, gatherer, nail and stripper Top & bottom roller Pressure bar, round guide bar, top roller, weighing frame, funnel, condenser, trumpet, coiler Filter box, filter screen, fan blade Can Plate

Drafting Zone

Clean and check their condition, make correct if required Clean and check its gauge, reset if required. Clean properly, check physical condition Clean properly and check filters and blade condition. Clean and check that it works correctly Clean, check meshing condition, vibration, abnormal noise etc. Clean and check that it is working correctly. Clean all the belt, check tension & adjust. Check oil level and put oil if required Check tightness and make perfect tightness Clean and check by electrical persons Clean properly

Suction system

Can changer

Gear Power cylinder

Belt tension and condition Gear box Nut-Bolt

Flat belt, V-belt, timing belt Planetary gear box

Top roller lock, pulley nut-bolt, creel nut-bolt, drafting zone nut-bolt Electrical Motor, fan, limit switch, parts proximity switch, creel light barrier Outer Surface Outer surface of the whole machine

Maintenance Points: Maintenanc Maintenance Points e Area Creel Balancing spring and chain Work to be done Clean and check bearing condition Clean and check greasing 50

Clean and check belt Back Side tension and condition Creel chain Clean and check greasing Grease level in the grease Check grease level and pump apply grease if required, Check grease pump Photo cell Clean by soft cloth Rack groove Clean and check greasing Belt tension and its condition Check and adjust if necessary Lifter gear box, main gear Check oil level and filter box and put oil if required Gear setting Check gear meshing, GE head observe vibration, sound etc. Bearing and greasing point Check bearing condition, vibration and sound, check greasing and apply grease if required All nuts and bolts Check tightness and make it correct if required Sensor Clean all the sensor OE Head with soft cloth. Blanching chain Clean and check greasing Traverse bar and sliver guide Clean, check setting Top & bottom roller Clean, gauge check and adjust if required Condenser assembly Clean, check assembly and make correct if necessary Top & bottom clearer cloth Clean, check condition Neck bearing of bottom roller Clean, check cover Drafting Zone missing or broken, nipple missing or broken, replace if required Cradle unit Clean and check functioning and wear and tear Pressure arm Check height gauge and re-adjust if required 51


Top & bottom apron

Bobbin Rail & Seal Flyer rail & Bobbin rail Flyer cap Flyer and its gear Shaft Outer surface Outer surface of the machine

Clean properly with suitable detergent, check condition for replacement Open the cover, Clean it & check the gear condition Clean and set properly Clean, check gear meshing condition Clean and check condition Clean the outer surface properly

Ring Frame (RX-240):
Maintenance points: SL NO. 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. Maintenance Points Top cot roller and cradle Travers track of roving guide Gear Bearings Top and bottom apron Teeth surface of all gears at head stock Mesh clearance of the gears Fluted roller bearings Bottom fluted roller Suction tube Top & bottom apron Gauge of traveler Spindle blade Ring rail height gauge Top roller gauge Ring rail position gauge Work to be done Cleaning Checking, Adjusting Checking Cleaning Cleaning, Checking Checking Checking Cleaning Checking, Adjusting Washing Checking, Adjusting Checking Checking, Adjusting Checking, Adjusting Checking, Adjusting 52

16. 17. 18. 19.

Balloon control ring center Top roller arm pressure gauge Lappet rail height gauge Filter box

Checking, Adjusting Checking, Adjusting Checking, Adjusting Checking

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



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

Splice Unit

Tension Device

Cradle Holder


Conveyor belt


Suction end and Head stock

Cleaning the fly waste from head stock and suction device compartment Checking (adjust if required) Checking (adjust if required) Checking (adjust if required) Checking (adjust if required) Checking (adjust the alignment if required) Checking the sensitivity Nut-bolt checking, tightening if required

Checking and Gauging

Suction arm Cradle vibration Paper cone to drum Bobbin peg centering Dust collection assym. (OHTC) EYC All kinds of nut & bolt

Lubrication Points: Lubrication Points Lubricate the RH package adapter Apply the maintenance spray (RS400) on both splice cutter and lower yarn cutter Lubricate the LH package adapter Lubricate the RH package adapter Lubricate the suction drive motor Lubricate all internal rotating parts Lubricate all bearing points of the gear All toothed wheel and toothed segment of central housing Lubricate the yarn guide drum Used Lubricants Silicon oil (S-1000) Maintenance spray RS-400 Shell Alvania grease – R2 Kluberplex BE 32222 Shell Alvania grease – R2 Lithium grease containingMos2 / Molykote spray Lithium grease containingMos2 / Molykote spray Shell Alvania grease – R2 Shell Alvania grease – R2 Intervals 1 month 1 month 4 months 1 year 4 months 4 months 8 months 8 months 2.5 years


Utility Department
The utility department undertakes the following units – o Power generation. o A/C Plant. o Fibre Deposit Area o Chiller Boiler. o Water supply o Fire fighting system. o Yarn Conditioning Plant o Compressor Power Generation: The factory generates its own power from natural gas. It has six generators of 1145 KW each. The generator’s specification are as follows-

No of generators Model Manufacturer Country of Origin Engine Type Engine rpm Total Plant Capacity Power Transmission By Starting Motor rpm Ext. rpm Year of Manufacture

: 6 : G-3516 B : Caterpillar : U.S.A. : 4stroke engine : 1500 : 6.87 MW : BBT : 1500 : 65000 : 2006

Compression ratio (Air : Gas) : 11.7 : 1


A/C Plant: The factory consists 4 A/C plants. These are for back process, ring unit, finishing unit and rotor unit. The main task of A/C plant is to maintain specific humidity in the factory shed. For this it circulates the inside air. The air is sucked through return ducts, humidified in the water house and again supplied through supply dampers. Outside air is mixed to some ration if necessary. The temperature can also be controlled if cool water is sprayed in the water house. The following RH. Conditions are maintained in the floor –

Back process Ring unit Finishing unit Rotor unit

48 48 60 60

to to to to

55% 52% 65% 65%

The A/C plants of ring unit are of LTG and those of rotor unit are of Best Air. The main impact of humidity and temperature controlling is on the machine performance, machine life and on personnel. Under favorable 58

condition, the machines will run smoothly and their lifetime will also increase. Also the operators will feel comfortable and their performance will be optimum. Otherwise all these will suffer.

Chiller : The main purpose of chiller is to supply chilled water to the A/C plant. Here there are three chillers . Hot water chiller Model Cooling Capacity Heating Source Serial No. 060101104800201C Manufacturer Country of origin Year of Manufacture Steam Fired chiller Model Cooling Capacity Heating Source Serial No. 060101104800101C Manufacturer Country of origin Year of Manufacture : LWM-W067 : 520 µsRT : Hot Water : : LS : South Korea : 2006

: LSH-W 070S : 630 µsRT : Steam : : LS : South Korea : 2006

Gas Fired chiller Model Cooling Capacity Heating Source Serial No. 060101104800301H

: LDF-S070S : 650 µsRT : Gas : 59

Manufacturer Country of origin Year of Manufacture Total Capacity of Chiller is 1800 µsRT

: LS : South Korea : 2006

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

Temperature maintained within the mills shade is as follows: Back Side Ring Winding Rotor : 26 to 30˚C : 28 to 30˚C : 26 to 30˚C : 26 to 30˚C

Boiler: In Delta Spinning Mill boiler is used to generate steam. This steam is used in chiller. Boiler specification is given below:Model Brand Berlin Year of Manufacture Steam Capacity No. of m/c Maximum working pressure : 2006 : 4.25 t/h :1 : 10 bar : WHR-4250/10 : Schneider-Kessel


Compressor: In spinning factory, compressed air is necessary for operating of various machines. Moreover it is also used for different cleaning purpose. The task of compressed air supply is carried out by compressor machine. The factory consists of the following compressor machines – No of machine Model Country of origin Year of Manufacture Type Capacity Pressure capacity :3 : : : : : : L-55 Germany. 2006 Screw Type 3000 10 bar max.

Yarn Conditioning Plant : In yarn conditioning plant yarn is used to stabilize the twist. Sometimes here give some weight into yarn. YCP specification is given below:No. of m/c : 01 Model : 1200 kg Brand : Seizer Country of origin : India Year of manufacturing : 1996


IMPORTANCE OF RH AND TEMPERATURE: The atmospheric conditions with respect to temperature and humidity play very important role in the manufacturing process of textile yarns. The properties like dimensions, weight, tensile strength, elastic recovery, electrical resistance, rigidity etc. of all textile fiber whether natural or synthetic are influenced by Moisture Regain. Moisture regain is the ratio of the moisture to the bone-dry weight of the material expressed as a percentage. Many properties of textile materials vary considerably with moisture regain, which in turn is affected by the ambient Relative Humidity (RH) and Temperature. If a dry textile material is placed in a room with a particular set of ambient conditions, it absorbs moisture and in course of time, attains an equilibrium. Some physical properties of textile materials which is affected by RH is given below: Strength of COTTON goes up when R.H.% goes up o Elongation % goes up with increased R.H.% for most textile fibers o the tendency for generation of static electricity due to friction decreases as RH goes up o At higher levels of RH , there is also a tendency of the fibers to stick together Temperature alone does not have a great effect on the fibers. However the temperature dictates the amount of moisture the air will hold in 62

suspension and , therefore, temperature and humidity must be considered together. ISO Standard # 139 defines Standard Atmospheric Conditions : • • Temperature of 68° ± 4°F (20±2° C) Relative humidity of 65% ± 2%

Fire Fighting System : Cotton fiber catches and spreads fire very fast. So any kind of accidents related to fire generation can turn into a devastating calamity in a cotton spinning mill. That is why the factory has a well equipped fire fighting system. Water lines are spread though-out the factory. Water is pumped by means of the main fire fighting pump. Other than this, there is also a jockey pump which maintains the water pressure through-out the pipe line. Also there are extinguisher of both CO2 and ABC powder type. A skilled team of fire fighters always remain alert within the factory. Fire drills also take place regularly.

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


Human Resource. The main object of HR is to make a man into resource. Admin administrate the all department. Admin department does the appointment, labour welfare, labour department, recommendation, staffing etc. Two types recruiting system:I. II. are :I. II. III. HR Head Departmental Head 3rd Person Internal External

In Delta Spinning Mills viva board consists of minimum 3 person. They

Leave Days of Delta Spinning Mill
According to labour law 1 year leave days of the mills given below :Name of Leave Week end leave Casual leave Medical leave Earn leave Festival leave How many days 52 days 10 days 14 days 16 days 11 days Overtime No No No Over time will be given Over time will be given According to 26 days working days over time calculation :Overtime=Basic/208 * 2 * Hours


The entry level salary of the production worker is

2200 taka. 2200 taka. 2500 taka.

The entry level salary of the quality lab assistant is also The entry level salary of the maintenance worker is

But the entry level salary of the officers such as APO, PO, Executive are


Inventory System:
The inventory system can be divided into four major types: 1. Raw cotton inventory. 2. Wastage cotton inventory. 3. Finished yarn inventory. 4. Spare parts and materials inventory. The inventory in maintained in First in First out system. When the store receive some goods, they write a note about it in the received khata and inform the concerned department about it. The concerned department then inspects the 65

goods and approve those if are satisfactory. Then the MRR (Material Receiving Report) is made. Then BIN card for that particular item is made which contains its name, part no, card no, amount and other necessary informations. Then the material is stored in the store. In case of raw cotton after sampling and numbering the bales, they are stored in the raw cotton godown. If any department requires any item, they prepare a requisition slip (SR) for that particular item and send it to store. The store then checks its availability and delivers as required. The daily production of finished yarn of different lots are given to the store form the production department by means of a “Transfer Memo”. The store produces its daily and monthly production report based on it. Then according to the order of the marketing department, the yarns are delivered to the buyers. Also the different wastes produced from different department are measured and handed over to the store in the same procedure.


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

Marketing Information:
The marketing activities of The Delta Spinning Mills are carried out from the corporate head office. The marketing activities are shortly described in the following portion –


At first market research and survey is carried out. The customer’s wants are specified and also the other products available in the market are studied. Then samples are made and delivered to different customers for approval. When approved, a Proforma Invoice containing product quantity, validity, count etc are given to the customer. Then the customer open L/C. Then depending on the customers urgency, the production plan is made and the factory begins production according to it. Then Delivery Order is made and delivery of yarn is carried out to the customers according to it. Then documentation is done according to L/C. The documents include Bill of exchange, delivery chalan, Commercial Invoice and Packing list. The bill of exchange and the delivery chalan is acknowledged by authorized person from buyer’s side. The buyer also issues an Inspection Certificate (IC) if the goods fulfill the requirement. Then Copy of these documents as pe L/C are submitted to the bank. The bank the then endorses the Bill of Exchange and delivery chalan 68

& forwards these to the buyer’s bank. Then the buyer’s bank gives a maturity date. The whole correspondence is done in terms of USD. Then at the end of maturity period, the amount is received in the bank account according to the L/C.

Requirement of material with specification To inform about requirement to the head of the management Management will search for the requirement Various company response with those specification The management will select some offers Then discussion will held among two management

Management will sign the agreement with the selected company or agencies

Then negotiation will take place among management and agencies


Submission of the final PI Bank will open L/C

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

After Sales Service: • • • Maintain the relation with the buyer. Respond to any quality complain. Ask for further order.

Involvement in Social Development:
The Delta Spinning Mill provides primary medical services to all its workers and staff by maintaining a two bed health care center operated by an M.B.B.S. 70

doctor. It also organizes an Annual Internal Sports Program for all its staff. It also allows training programs and industrial visit programs for the students of different textile educational institutes.

Technical education and its adoption in practical field are involved inseparably. Without the implementation of the knowledge gathered in technical education, its success is bound to suffer. Therefore, this two months long industrial attachment training, as a partial fulfillment of our B. Sc. in textile technology course helped us to accomplish the gap between the theoretical and practical knowledge by providing an elementary idea about industrial environment, processing machines, tools, quality management, quality equipments, production system, maintenance, administration and management system. The Delta Spinning Mills Ltd is such an well equipped, well staffed, well planned, well organized and well administrated mill that it has become a role model for all the industries in Bangladesh. Other than producing export quality cotton hosiery yarn, it is also developing a skilled manpower which is very important and fruitful for the Textile Industry in Bangladesh. We tried our best to utilize our training program by collecting all the 71

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


Sign up to vote on this title
UsefulNot useful