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AHSANULLAH UNIVERSITY OF

SCIENCE & TECHNOLOGY

Industrial Training Report


On Knitting at

Mondol Knitwears Limited


COURSE NO:

TEX-500

Supervised by
SHEIKH NAZMUL HOQUE
Lecturer, Department of Textile Technology

Submitted by
Mir Mahbub Alam
ID:06.01.06-146
Lutfor Rahman Shanzid
ID:06.01.06-105
4 TH YEAR 2 ND SEMESTER, FALL 2009

Department of Textile Technology.


Acknowledgement
At first we would like to express our gratitude to the almighty Allah, who has enabled us to complete
the industrial training for finishing the 4 years long courses.

Special thanks to Professor Dr.Mustafizur Rahman,Head, Department of Textile Technology, (AUST);


for his support & encouragement.
We are grateful to our training supervisor & respected teacher Mr.Sheikh Nazmul Hoque (Lecturer,
DTT,AUST) for his supervision regarding the industrial training.
We also give a thank to our project supervisor Mr.Sheikh Abdullah Shadid (Lecturer, DTT,AUST) for
his guidance.
We offer heartiest thanks to our all respected teacher of DTT, especially to all teachers of Fabric
Manufacturing Technology who advised & guided us on training by various way.
We are also grateful to Executive director of Mondol group & Manager of Mondol knitwears ltd. for
their support.
We also want to give thanks to all other people like knitting operator, QC operator, Production officer
& all worker of the knitting floor as well as the security division who were somehow related to help in
our training.

Table of content
Section

Topics

Contents

Page
number

Section 1
Section 2

Introduction
General information of
the factory

Introduction
Name, status, nature of
business, address,
sponsor, project
money, year of
establishment, year of
production, floor area,

7
9

Section 3

Section 4

Knitting Description

Yarn count for GSM

Section 5
Section 6

Machine profile
Machine & knitting
elements description

Section 7
Section 8

Tools & equipments


Fabric identification &
fault detection

Section 9
Section 10
Section 11

Maintenance
Utility services
Conclusion

contact person, turn


over, fabric mix,
production capacity,
daily & annual
production, different
departments, total
manpower, buyers, list
of machinery, power
system, data collection
date, location map
Process flow chart,
Generally used yarn &
their count,
Sources of yarn,
Product list of factory
Yarn count range for
different GSM
Machine profile
Photos of machine &
yarn, production card,
features of knitting
machine, yarn passes
sequence from creel to
feeder, function of
knitting elements
Tools & equipments
Sample analysis,
sample collected from
knitting floor,
comparison of weft
knitted structure, stitch
length measurement,
GSM control, quality
standard, production
calculation, fabric
faults & causes
Maintenance
Utility services
Achievements,
limitations, comments

15

19
23
29

40
45

58
61
65

List of tables
Table no.

Table name

Page no.
3

1
2
3.1, 3.2, 3.3,
4.1, 4.2, 4.3
5
6
7
8
9
10
11
12

List of machinery
Generally used yarn & their
count
Relation between GSM & count

12
17

Existing machine profile


Comparison between basic
structure of weft knitted fabric
Relation between GSM & SL
Four point grading system
Knitting faults
Air compressor specification
Alternator specification
Enginator

28
52

20, 21, 22

54
54
56
62
63
64

List of figures
Name of figures
S/J machine
Double jersey machine
Auto stripe machine
Cotton & polyester yarn
Lycra yarn
Circular knitting machine with different system

Page no.
30
31
33

Knitting elements:

Needle, sinker

35

Knit, tuck & miss cam

36

Cam box, ssVDQ pulley

37

MPF, oiling point

38

Air pipe, lycra feeding devices

39

Equipments:

Electronics balance, measuring tape, scissors

41

Tools:

Adjustable wrench

41

Double head spanner, Single head spanner, L-key

42

Allen key, pin setter, flat screw driver, hammer

43

Pliers

44

Different types of fabric


Knitting faults

46
55

List of abbreviation
abbreviation

elaboration

CKM
S/J
S/L
MKL
F. Terry
F.F lycra S/J
M/C or m/c
Fab.
GSM
SL
D
G or Gg
P/I or P/Int
75 D/72 F
mm
R&D
AUST
DTT
Avg.
No.
Strct
PS
VDQ
Fig
K
T
M
H
L
RPM

Circular Knitting Machine


Single Jersey
Single Lacost
Mondol Knitwears Limited
Fleece Terry
Full Feeder lycra Single Jersey
Machine
Fabric
Grams per Square Meter
Stitch Length in mm
Dia
Gauge
Plain Interlock
75 Denier /72 Filament
mili meter
Research & Development
Ahsanullah University of Science & Technology
Department of Textile Technology
Average
Number
Structure
Production Serial
Variable Dia Quality
Figure
Knit cam
Tuck cam
Miss cam
High butt needle
Low but needle
Revolution per Minute

TQ
Int. mesh

Target Quantity
Interlock mesh

Section:1

INTRODUCTION

INTRODUCTION

Industrial training is an important part for textile students for minimizing the gap between theoretical & practical
knowledge. For completing the 8 week long training, we were attached at Mondol Knitwears Ltd.,at
Kashimpur,Gazipur. From an industrial training vast knowledge can be achieved from the bulk production as well
as the production planning. In our training, we tried to receive more technical information from different views.
In this report we tried to point out our observation & learning in a small volume.

Section:2

GENERAL INFORMATION OF THE FACTORY

GENERAL INFORMATION OF THE FACTORY:


Mondol Knitwears Ltd. is a 100% export oriented sub-contracting knit fabric producing factory. It is a sister
concern of MONDOL Group.
1. Name of the Company:
Mondol Knitwear Ltd.
2. Status:
Private Ltd. Company
3. Nature of Business:
100% Export Oriented knit fabric
manufacturing
4. Address:
Factory:

Head Office:

5. Financed by:

6. Project Money:

Surabari, Kashimpur, Gazipur


Tel: (88-02)9289110-2, Ext-113
Fax: (088-02)8955005
E-mail: alamintex29th@gmail.com
Web: www.mondol.net
House #15 (9th & 10th Floor),
Siam tower,
Sector # 3,
Dhaka-Mymensingh Road
Uttara, Dhaka-1230, Bangladesh
Tel: (088-02) 8955000-3
Fax: (088-02) 8955005
E-mail: mondol@bd.online.com
Prime Bank Ltd.
Motijheel C\A, Dhaka-1000
Bangladesh
Tk. 1billion

7. Year of Establishment:

24 Dec 2006

8. Year of Production:

24 Dec 2006

9. Floor Area:

Total floor space is 53,500 SQFT.

10. Contact person:

Engr.Al-Amin Sheikh
Asst.Manager (Production)
Mob: 01716-671452
alamintex29th@gmail.com

Engr.Ishaque Hossain
Factory manager
Mob: 01713-314898
11. Turn Over:

2.50 billion

12. Fabric Mix:

Single Jersey
Pique
Single lacost
Double lacost
11 Rib
22 Rib
Drop needle
Lycra Rib
Thermal rib
Plain Interlock
Fleece
Terry Fleece
Lycra Single Jersey
100% Polyester
CVC (Chief Value Cotton)
Interlock mesh
Grey Melange
Eyelet

13. Production Capacity: 50 tons per day


14.Daily Production: 40 tons (avg.)
15.Annual Production: 14400 tons (approx.)
16. Different Departments:

a) Samples R & D Section


b) Knitting Section:
Knitting
Inspection
c) Maintenance Section:
Electrical
Mechanical
d) Store Section
e) Administration Section
f) Security Section
g) Marketing Section
h) Production Planning & Control

17. Total Manpower:


a) Knitting Section:
b) Utility Service:

475
15

18. Major Buyers & Exporting Country:


10

INSTYLE
MONTECARLO
JOB S.P.A
FRANK Q
DEPA S.R.L
BASKA
FRANSA
GOOATEX
B-YOUNG
BURGER KING
PTB SRL
4-YOU
TERRAVOVA
BENGLER
VEGOTEX
TRACK & GO
ESPIONAGE
EL & BI
JOMAS
FEUVERT

- Italy
- Spain
- Mexico
- Denmark
- Norway
- USA
- Denmark
- Italy
- Norway
- Spain
- Italy
- Denmark
- Italy
- Italy
-Belgium
- Italy
- Italy
- Italy
- Spain
- Spain

19. List of Machinery:


Table: 1

Machine category
Circular Normal CKM
Knitting ( without stripe)
Machin Auto stripe CKM
e
Flat bed Knitting machine

Total nos.
185

Grand total

261

24
52

Power system:
Gas Generator (1064 KW)
Diesel Generator (900Kw)
REB(Rural Electrification Board)
Compressor
Dryer
SDB(Sub Distribution Board)
20.Date of information collection:

: Jenbacher

: 01
: 01
: 01
: Worthington Creyssemsac : 05
: Worthington Creyssemsac : 05
: 11
June 05,2010.

11

12

Section:3

KNITTING DESCRIPTION

13

Knitting section

Knitting is the method of creating fabric by transforming continuous strands of yarn into a series of
interlocking loops, each row of such loops hanging from the one immediately preceding it. The basic
element of a knit fabric structure is the loop intermeshed with the loops adjacent to it on both sides &
above and below it.
Knitted fabrics are two types. One is weft & another is warp.MKL produces weft knit
fabrics.

Process flow chart of Knitting:


Yarn in cone form

Feeding the yarn cone in the creel

Feeding the yarn in the feeder via trip-tape positive feeding arrangement and tension device

Knitting
14


Withdraw the rolled fabric and weighting

Inspection

Numbering

Generally used yarn & their count:


Table: 2

Types of yarn

Count
20 , 22 , 24 , 26 , 28 , 30s, 32s, 34s, 40s
75D,150D
20D, 40D, 70D
24s, 26s, 30s
24s, 26s, 28s, 30s
24s, 26s, 28s, 30s
s

Cotton
Polyester
Lycra
Grey Mlange
PC (65% polyester & 35% cotton)
CVC

Sources of yarn ( for knitting):

Delta
Square
Badsah
Aman
Akbar
Prime
Protiva
Kamal
Thermax
Karim
JK
NZ
GPI
SN
15

Types of fabric knitted in MKL:


1) Single jersey
a)
b)
c)
d)
e)
f)
g)
h)
i)

Single jersey (Plain)


Single lacost
Double lacost
Pique
Fleece fabric
Terry fleece
Spandex jersey
Full feeder lycra S/J
Half feeder lycra S/J

2) Double jersey
a) Rib fabric
i. 1x1 Rib
ii. 2x1 Rib
iii.
Drop needle
iv. Thermal
b) Interlock fabric
i.
Plain interlock
ii.
Interlock mesh
iii.
Eyelet
3) Different types of collar & cuff

16

Section: 4

YARN COUNT RANGE FOR DIFFERENT GSM

17

Yarn Count Range For Different GSM:

From the m/c we have practically collected some data (table no. 4.1, 4.2, 4.3) on relation between GSM, SL &
Count. And from manager of the factory we collected data (table 3.1, 3.2, 3.3) only relation between GSM &
count. These are given below.

Table 3.1: For Single jersey:Fabric GSM(finished)


130 150
150 160
160 170
170 190
190 220

Yarn Count
30/1
28/1
26/1
24/1
20/1

Table 3.2: For Rib Fabric:Fabric GSM(finished)


160 180
180 200
200 220
220 240
240 260

Yarn Count
34/1
30/1
28/1
26/1
24/1

Table 3.3: For Interlock Fabric:Fabric GSM(finished)


190 240
210 240

Yarn Count
40/1
34/1
18

240 260
260 280
280 300

30/1
28/1
26/1

Table 4.1: For S/J

count
24/1

26/1

28/1

30/1

GSM (finished)

SL (mm)

180
17-180
175
160
160
160
150-155
160
160
nill

2.73
2.85
3
2.94
2.95
2.85
2.9
2.9
2.82
2.53

Dia(inch) x Gauge
34 x 24
34 x 24
23 x 24
34 x 24
30 x 24
30 x 24
25 x 24
24 x 24
24 x 24
22 x 24

150
160
160
160
160
160
160
160
150

2.78
2.7
2.67
2.7
2.7
2.7
2.7
2.75
2.8

30 x 24
32 x 24
36 x 24
32 x 24
24 x 24
30 x 24
30 x 24
32 x 24
32 x 24

140-145
140
145
140
140
140-145
150
150
150
140-145
140-145
140
145
145

2.75
2.7
2.62
2.7
2.96
2.75
2.75
2.75
2.75
2.75
2.78
2.75
2.72
2.72

19 x 24
19 x 24
19 x 24
19 x 24
19 x 24
23 x 24
22 x 24
23 x 24
24 x 24
29 x 24
24 x 24
24 x 24
24 x 24
29 x 24

Table 4.2: For Rib

Count

GSM(finished
)

SL (mm)

230

2.65

Fab. type

Dia (inch) x G
36 x 18
19

26/1
28/1
30/1
32/1
34/1
40/1

230
220
220-230
200
220
210
200
200
180
180
180
180
150-155

2.65
2.9
2.58
2.6
2.6
2.5
1.9
1.7
2.6
2.5
2.5
2.58
2.86
1.85

1 x 1 rib
1 x 1 rib
2 x 1 rib
1 x 1 rib

36 x 18
34 x 18
36 x 18
36 x 18

2 x 1 rib
1 x 1 rib
Stripe 1 x 1 rib
1 x 1 rib
1 x 1 rib
1 x 1 rib
Thermal rib

36 x 18

Fab.type

D(inch) x G

32 x 18
32 x 18

Table 4.3:For Interlock:

Count

34/1

75 D/72 F
75 D/72 F

GSM(finished
)

SL (mm)

200
200
210-220
210
210-220
145

1.78
1.7
3.7
1.58
3.07

P/Int

1.25
1.15

Eyelet

30 x 24
30 x 24
34 x 24
32 x 24
36 x 24
34 x 24

140

1.12
1.11

Int.Mesh

36 x 24

140

1.4
1.2

Int.Mesh

32 x 24

140-145

1.12
1.1

Int.Mesh

38 x 24

20

Section: 5

MACHINE PROFILE

21

22

23

24

25

Existing Machine profile


From the factory we collected upper (given) machine profile but all machines are not existing. The table of
existing machines which are collected from the floors are given below.
Table:5

Machine type

MASA
Jiunn long
Ssang yong
Fukuhara
Fukuhama
Ta-yu
Pai-lung
Circula
r
Total

Floo
r1

Floo
r2

Floo
r3

Floo
r4

Floo
r5

10
5
2

6
3
8
45

10
8

31

53

27

31

Floor 6
(auto stripe
floor)
Auto
Non
stripe
auto
stripe
3

21

21

4
8

16
6
29
7
10
59
82

24

33

209

7
10
6

24

17

Total

Flat bed
52

26

Section: 6

MACHINE & KNITTING ELEMENTS DESCRIPTION

Machine & Yarn

27

Single jersey machine

Double jersey machine

Auto stripe machine

Cotton & polyester yarn

28

Lycra yarn

Production card
We collected some production cards during the production. Sample of one card is given below.
M/C no. 107
Card ID: 55658
PS:491
T.Q: 880 kgs
Buyer: Abony
Order no. 002453
Party: Abony Textile Ltd.
Strct.: S/J
Dia: 33 inch
Gg: 24
Fab.D:71 inch (open)
Fab. GSM (finished):190
Color: Vert pique
Count
Type
22 Ne
comb

Brand
Akbar

Lot
10

S.L (m.m)
3.02

Features of Knitting Machine:


A knitting machine is an apparatus for applying mechanical movement either hand or power driven, to primary
knitting element in order to produce knitted structure from yarn. The machine incorporates and coordinates the
action of a number of mechanism and device each performing specific function, which contributes toward the
efficiency of the knitting action.
The main features of a knitting machine are given below:
The frame, normally free standing and either circular or other shape according to needle bed.
The machine control and drive system
29

The yarn supply system


The knitting system
The fabric take-down mechanism
The quality control system
The stop motion mechanism.
Main features of circular knitting machine
o CKM normally has rotating cylindrical needle bed(s)
o On CKM latch & compound needles are used
o For S/J machine, holding down sinkers are used
o Normally stationary angular cam systems are used for needle & sinker
o Stationary yarn feeders are used
o Yarn feeder guide is associated with its own set of knitting cam
o Machine gauge is normally used 5 to 40 needles per inch

Main features of flat bed knitting machine

Flat bed machine has two stationary needle beds


Latch needles are used
Angular cam system is used
Separate cam system for each needle bed
Machine gauge 3 to 18

30

Fig: Circular Knitting Machine with different system

Passes of Yarn in Circular knitting Machine:

Creel

Cone

Tube

Knot Catcher

Magnet Pressure

Sensor

Ceramic Eye Pot

Yarn Wheel

Guide

31

Sensor

Guide

Ceramic eye pot (Feeder Ring)

Feeder

FUNCTION OF KNITTING ELEMENTS:

NEEDLE
Needle is the primary knitting element. It is a thin metal bar.

Needle is used to produce a loop.

SINKER
Sinker is the second primary knitting element. It is a thin metal plate.

Functions of sinker are


Holding down
Knocking over
Loop formation.

32

KNITTING CAM
Cam is the device which converts rotary machine drive into a suitable reciprocation action for the needle.
Knitting cams (raising) are three types. These are:
i.
Knit cam
ii.
Tuck cam
iii.
Miss cam

KNIT CAM:

It is used to produce a knit loop.

TUCK CAM

It is used to produce a tuck loop.

MISS CAM

It is used to produce a miss loop.


33

CAM BOX:

Function of cam box is to set cam on the slider.

VDQ PULLEY:

VDQ pulley is used to control the GSM & SL.

MEMMINGER POSITIVE FEEDER:

34

It is used to apply positive feed of the yarn.

OILING POINT:

It is used to pass oil into the needle.

AIR PIPE:

35

It is used to flow air into the cam and needle.

LYCRA FEEDING DEVICE:

Lycra feeding device is used to apply positive feed of the spandex.

Section:7

TOOLS & EQUIPMENTS


36

Tools & equipments used in knitting section:


Different type of tools & equipments are used in knitting. Some of tools & equipments list & images are given
below.

Equipments:

Electronic balance
Scissors
Measuring tapes
GSM cutter
Inspection m/c

Fig: electronics balance

Fig: measuring tape


37

Fig: scissors

Tools:
For adjusting and or tightening or loosing different types of nuts & bolts some tools are used. These tools are:Adjustable wrench
Double head spanner
Single head spanner

Fig: Adjustable wrench

Fig: Double head spanner

Fig: Single head spanner

For fitting the cam box and other machine parts as well as tightening or loosening of nuts & bolts some L-keys
are used. These are:T-type L-key
I-type L-key
Allen key

38

Fig: Ttype L-key

Fig: I -type L-key

Fig: Allen key

To hold small machine parts Pinsetter is used.

Fig: pinsetter

To adjust different types of screw flat screw driver is used.

Fig: Flat screw driver

Hammer is used to beat metal parts.

39

Fig: Hammer

To hold machine parts, to cut metal wire & to set nut-bolts Multi pliers are used.

Fig: Multi-pliers

To cut metal wire cutting pliers are used

Fig: cutting pliers

To hold and set machine parts in thin or narrow space Long nose pliers is used.

Fig: Long nose pliers

40

Section:8

Fabric identification & their faults

SAMPLE ANALYSIS
41

SINGLE JERSEY PLAIN

Sample

Structure, Needle set-out and cam arrangement

POLO PIQUE

Sample

Structure, Needle set-out and cam arrangement

DOUBLE LACOST

42

sample

Structure, Needle and cam arrangement

11 RIB

sample

Dial
Cylinder
structure & cam arrangement

22 RIB

sample

43

Dial
Cylinder
Structure & cam arrangement

PLAIN INTERLOCK:

Structure & cam arrangement

Sample

Some sample collected from knitting floor


Sample name

Image(s)

44

S/L

Fleece

F.Terry

Eyelet

Int.mesh

45

Heavy S/J

F.F.Lycra S/J

Engineering stripe type

46

Comparison between basic structures of weft knitted


fabric:
In the table we have shown only three basic structures, purl structure is not shown because MKL does not
produce purl fabric.
Table:6

Plain

Rib

Interlock

Same on both sides

Unroving

Different on face &


back
Either end

Curling

Tendency to curl

No tendency to curl

Thickness &
warmth

Thicker & warmer


than plain woven
made from same yarn

Much thicker & warmer than


plain

Same on both
sides
Only from end
knitted last
No tendency to
curl
Very much
thicker &
warmer than
plain

Structure

Properties

Appearance

End-uses

Only from end knitted last

Ladies stockings, fine Socks, cuffs, waistbands,


cardigans, dresses,
collars,
base fabric for coating Underwear, knitwear.

Underwear,
shirts,
Suits,
sportswear,
Dresses.

47

STITCH LENGTH MEASUREMENT


STITCH LENGTH:
Stitch length combines in the form of course length & it influences the fabric
dimension & other properties including weight. Stitch length is the average length of
yarn in a knitted stitch; sometimes it is called loop length.
PRINCIPLE:
Stitch length is calculated from the total length of yarn taken in by one feeder during one revolution
(course length) divided by the number of needles knitting in the machine.
APPARATUS:
Counting glass, Fine Marking Pen
Scissors
Stainles steel ruler

TEST PROCEDURE:
Carefully mark a single wale line with the fine pen. Count 100 wales and mark the 100 th. Make
cuts along the wales about 1 cm each side of the marked wales.
Then we unrobed the yarn.
Now we measure yarn length between two marked points.
At last we divide yarn length by needle number.
Stitch length = course length/ total number of needle

GSM CONTROL
GSM means grams per square meter. It is one of the most important knitting
variable which need to be controlled to increase fabric quality.
48

We can control GSM by controlling the stitch length. The stitch length can be controlled
by the following ways By changing VDQ pulley diameter
By adjusting the Central stitch cam
If we increase dia of VDQ pulley then GSM decreases and vice versa.

Table:7:- Relation between GSM & SL


Dia of VDQ pulley
GSM
Rotating to positive
direction
Rotating to negative
direction

SL

Decrease

Increase

Increase

Decrease

Quality Standard
Most of the knitting factories follow 4-point grading system for quality standard. Though MKL is a 100% export
oriented sub-contracting factory but they do not follow any standard system like 4-point or 10-point
system.MKL standardize their products by checking of their skilled inspection team, visual inspection of every
product if any problem is occurred & negotiation with buyers. But some officials of MKL suggest 4-point
grading system with big problem in product; but it is rare case.
Table: 8

Four Point Grading System


Size Of Defects

Penalty

3 inches or less

1 point

Over 3 inch but not over 6 inch

2 point

Over 6 inch but not over 9 inch

3 point

Over 9 inch

4 point

49

Production Calculation
MKL follows the following formula for production calculation at 100% efficiency in kg per shift:-

0.000000593 x no. of needle x no. of feeder x SL x RPM


x 60 x 12
Ne

Faults and their causes in knitting:Table: 9

Defects

Causes

Sample
50

Star mark

Un-effectiveness or buckling
of latch of needle.
Low GSM.
Yarn tension variation.

Hole

Wrong stitch attachment.


Yarn breakage.
Yarn tension variation.
Defective needle.
Thick-thin place in the yarn.

Set-up

Yarn breakage.

Needle mark

Barrie

Oil mark

Drop stitches

Wheel free & belt free

Needles hook breakage.


Needle latch breakage.
Dirt in needle slot.
Needle line.
Improper cam setting.
Bad yarn.
Needle to loose or tight in
trick.
Count variation in same lot.
Lot mistake.
Low tensioned yarn.
Old produced yarn.
Faulty yarn.
Excess oil or grease use in
the machine.
Poor quality lubricant.
Mixing of lubricant.
Leakage in oiling system.
Faulty needle.
Wrong setting of yarn
feeder.
Improper yarn feeding.
Unlocking the wheel lock.
Raising the wheel to upper
collection.

Slubs

Poor yarn quality.


Poor air circulating system.
Fly formation of yarn.

Packy

Thicked yarn.

51

Black spot

Late servicing of m/c

Loop

Yarn tension variation.


Needle drop.
Low SL.

Yarn contra

Storage of dust during yarn


feeding.

Lycra drop

Wrong setting of needle.


Dusted yarn.

Lycra out

Breakage of yarn.
Dusted yarn.

GSM variation

Count variation

Design variation

Wrong setting of VDQ


pulley.
Wrong selection of yarn
count.
Tension variation in yarn.
Different count in same lot.
Different yarn quality in
same order.
Long storaged yarn.
Stripe variation in the
machine.
Wrong cam arrangement.

Section:9

MAINTENANCE
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Maintenance & servicing


Maintenance & servicing is the food of a knitting machine. Without maintenance a machine can not run
smoothly.

Maintenance:
Defination:
All actions essential in order to retain a product in or restoring it to a satisfactory operational condition.
Aims of a maintenance programme:
To maintain equipments at the maximum operating speed & production efficiency
To ensure the best possible level of quantity of the product
To minimize the idle time resulting from machinery breakdowns
To reduce to a minimum the cost of maintenance consistent with te above objectives
Maintenance system can be categorized into two types,
- Break down maintenance

Planned maintenance

Break down maintenance:

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In this system alternation is given to a m/c only when it breaks down. Un-planned system but finds favor of
course. But this system suffers from two main draw backs,
Deterioration in the quality of the product
Productivity loss increase gradually
Planned maintenance:
It is a scientific & technical approach. The basic principles are taken out of production on a time programming &
detailed scheduled work done so as to maintain their productive potential quantitatively & qualitatively until the
next servicing data.

Servicing:
In servicing point at MKL, most of the fitters, servicing men worke in the following ways:
- Open the belt of the MPF

Cut the yarn


Cut the fabric from the machine
Oiling to the needle
Run the m/c for 2-3 minutes
Stop the m/c & open the cam boxes
Remove the needles from cylinder & dial
Blow air to clean needle tricks
Clean whole machine by air
Wash needles & cams by lubricant
Check needles of dial & cylinder
Set cam boxes of dial & cylinder
Complete the yarn threading

During the servicing following m/c parts must be cleaned:


Needles
Sinkers
Sinker cam
Cam boxes
Full body
Cylinder & dial

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Section:10

UTILITY SERVICES

55

UTILITY SERVICES
Utility Services:In MKL, the following utility services are available. These are given below:
Water
Electricity
Gas
Compress air

Air Compressor:Specification of Air Compressor:


Table:10

Technical Data
No. of M/C
Manufacturer
Country of origin
Type
Reference
SI. No.

Compressor Data
05
Worthington C reyssensac
FRANCE
RLR60B7YD
6250315600
WCF250879

Bar maxm
m3/h

10
432
56

Kg
KW

975
45

v/ph/Hz

400/3/40

Gas Generator:There are two parts of Gas Generator. They are1) Alternator
2) Enginator

Specification of Alternator:
Table:11

Technical Data
Manufacturer name
Country of origin
Model
SI. No.
EMI
KVA
KW
PF
VOLTS
AMPS
Over speed
Rotation
Hz
RPM
PHASE
RATING
Date
AMB
ALT
EXC AMPS
TEMP. RISE
Enclosure
Weight
Insulation
STATOR CONN
Arrangement

Alternator Data
WAUKESHA ENGINE DRESSER INC.
USA
MTG846
CB5L5505
68604200
1125
900
0.8
240/415
1565
125 0/0
CCW
50
1000
3
PRIME
2006
40C
100 M
7.0
105C
1P-22
4763 Kg
H
WYE
P316099A

Engine control unit:


57

Input voltage:
Maxm current:
Maxm temperature:
Waukesha part no.:
ECU SI. No.:

12-36 VDC
0.7A
70C
740824B
1314

Specification of Enginator:
Table:12

Technical Data
Manufacturer name
Country of origin
Model No.
SI. No.
Date
Weight
RPM
PHASE
VOLTS
PE
Hz
DUTX
KW
KVA
AMPS
Maxm Site Attitude
Maxm Ambient Temp.
Performance Class

Enginator Data
WAUKESHA ENGINE DRESSER INC.
USA
VHP5904GSID
C-94890-901/1
2006
17650 Kg
1000
3
415/240
0.8
50
Continuous
900
1125
1565
5 meter
36C
No Overload Allowed

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

SOURCES OF UTILITY:
Electricity

: REB & Generator


58

Water

: Pump

Compressed air

: Compressor

Gas

: TITAS GAS LTD.

Section:11

CONCLUSION

59

Conclusion:In the conclusion point, we can discuss the conclusion in three sub-section like achievements, imitations &
comments.
Achievements:
In the industrial training we have learnt various things in more practically but our prime achievements are,
Being familiar with knit factory.
Being familiar with process sequence of knitting.
Gathering vast knowledge on fabric structure & design, GSM, SL, count.
Detecting & minimizing the fabric faults from technical point of view.
Knowing how the order is received & go to bulk production.
Learning on textile machineries & equipments.
Controlling & operation of industrial management.
Limitations:
We had faced a big problem from the officials of MKL; they did not want to help or supervise to the
private university students.
For ignoring to private university students, we could not collect various technical information from the
technically sound person.
Some of the points of different section are not included due to limitation of factory help.
Comments:
Though MKLs higher management did not offer full support for us, but we got a lot
of technical help, suggestions and informations from lower level of management &
stuffs. It was impossible for us to complete our training successfully without their
support. We got acclimatized with the industrial environment during this period.
Besides, it gives us the first opportunity to work in an industry.

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