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I here by acknowledge the great efforts done by the HR department of MTM mills. I appreciate all those instructors who managed to deliver lectures even they were packed by the work load. I will not forget to pay regards to all those persons who helped me learning about the processes and machines even they were not bound to tell me and guide me. There are piles of information available about all the processes and definitions involved in Spinning, Knitting, Processing and about the other production or managerial processes and departments. But, in this report I remain restricted to mention the knowledge that I have acquired from the MTM Mills only. In this report, I am not mentioning the recommendations or suggestions for further improvements, because I feel myself still in the process of socialization with the organization. Hopefully, I will be better able to suggest any thing by the completion of my three months’ training. I am in debt with Mr. Yasir Nazir, who believed in me and in my qualifications to make me a part of MTM. I am quite determined to contribute to the achievement of our vision and mission of becoming the world’s best organization. (Insha Allah) Thanks
Naeem Anjum (Management Trainee)
May 2, 2003.
Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Particulars Management and Departmental Hierarchy Production, Planning and Control ( PPC ) Spinning Department Knitting Department Processing Department - Lot Section Processing Department - Dyeing Processing Department - Finishing Processing Department - R & D Processing Department - Q.C. And Q. A. Human Resources Department Information Technology Department Material Management Department Admin Department Finance Department Apparel Division - Process Flow 2 Page Number 3 4 6 19 26 29 39 42 49 52 55 56 57 58 60
MANAGEMENT AND DEPARTMENTAL HIERARCH IN MTM
MTM Mills is consisted of the following departments; 123456789PPC Spinning Knitting Processing ( Dyeing , Finishing, R & d, and QC & QA ) HR IT Material Management Admin Finance
The Top Level Management is consisted of following hierarchy; CEO GM
The Middle Level Management is consisted of following hierarchy; Manager Deputy Manager Asst. Manager Sr. Officer Officer
The Lower Level Management is consisted of the following hierarchy mainly; Super visor Foreman Operator Helpers
Here is the flow of a PO in Mills.Planning: This division plans the whole PO with order specifications. a).e. i. The whole process in MTM mills is initiated with the placement of PO from Apparel to Mills division. PO PPC R&D Knitting Dyeing Finishing Dispatching PPC is involved at each level of PO in Mills. The PO is first placed in PPC department from where it is fed in the FMS ( Fabric Management System). work schedule. a). finishing and up till dispatching of fabric to customer (Apparel Division). its planning and controlling of production towards the right direction in and effective and efficient manner in given period. The three divisions of PPC work as follows.Planning b).Yarn: This division makes the availability of yarn in time before knitting gets started.Control c). time line for knitting. The actual customer of MTM mills division is the MTM apparel division. PLANNING AND CONTROL) It is obvious from the name of the department that this department is meant for production. The procedure followed for yarn procurement is as follows. This division is named by many people as Peeshay Peeshay Challo (PPC) due to its involvement in PO.Yarn. c). b).PPC (PRODUCTION. 4 . PPC department has been subdivided into three divisions.Control: This division actually looks after the PO time line execution for in time production and dispatching to customer. Now this PO is available to all concerned department in Mills. dyeing (Lot Making).
And the actual work of PPC starts after PO Parameters Approval Sheet by the R & D department. and quantity (PPC) Forwarded to Head Office Feed Back with time and vendor (H.PO PO Feeding in FMS (PPC) Approval Sheet (R &D) Yarn Demand Generation including the yarn count. The roll of R & D is very important because it defines the whole PO for knitting.O. quality (CRD/ CMB). and finishing according to customer Parameters and Requirement.) Received in Store (Store) Allocation to POs on Priority Bases (PPC) Availability of Yarn in POs in FMS.) Feed Back Fed in FMS (PPC) Receiving of Yarn (Store) Testing of Yarn (Q.C. 5 . dyeing.
Mixing Blow Room Carding Drawing and Simplex Ring Auto cone Packaging and Dispatching Along with these units there are four service departments in spinning. The process flow of converting cotton to yarn is as follows.SPINNING Spinning is the process of converting the raw cotton into end product yarn. A).Quality Control (Lab) Here is the elaboration of each process of spinning and role of service department. The wastage of this department is consisted of contamination and jute mainly.Maintenance with work shop B). Note:. The daily consumption of this department is 106 bales in total in three shifts of workers. The reason of lot making is that the cotton produced in different areas of Pakistan has different characteristics.AC with work shop D).Electrical with work shop C). The cotton is mixed in the form of lots. MIXING The purpose of this department in spinning is to mix the cotton brought from different areas and to remove the contaminations from the cotton.e. Mixing of cotton from different areas makes an even blend of these characteristics. Each lot consists of 70-74 bales brought from different areas. i. The spinning process is consisted of different units.The machines (with parts) used in the spinning process are explained under the heading of Maintenance. The machine used for this purpose is Auto Bale Plucker. 6 .
The weight of yarn in the sliver form is kept 58 grains per yard. The machine used for the fulfillment of this purpose is Crosrol MK. Each can is consisted of 4000-4500 yards of sliver. One is for the carded yarn and the other is for the combed yarn. Toyoda VC and Lap Former Toyoda SK4A machines are used for combing. 14-16 canes are filled in 8 hours by one machine. Toyoda CM 10. The wastage of this department is mainly consisted of trash and carded cotton. Each Lap is consisted of 50 yards and one yard of Lap has the weight of 14 once. Then it is converted into sliver and drafted for evenness. This department takes cotton as input and produces Laps of cotton as out put. Drawing Toyoda DYH 500 C. The breaker has the capacity of 130 canes per shift. The total weight is 22. Each cane has 18.20 kg. cleaning and lap forming of cotton for further process of spinning.20 kg with +/.5 kg in carding. It means 600-700 Laps per day are being produced. 16 kg in breaker and 14 kg weight in finisher. The wastage of this department is mainly consisted of trash and suspended particles. It takes half an hour to fill a cane.4. CARDING The purpose of this department is the conversion of laps made in the blow room into the sliver. the finisher has the capacity of 7 . DRAWING The purpose of this department is doubling and drafting of sliver. For combed yarn the silver is converted into laps once again by the lap former and then combed for separating noil (Cotton Fibers shorter than 1 inch).of 0. doubling and drafting of sliver. It takes 7-10 mint. AXE Flow Cleaner and Scuthcer. This machine has the capacity of 1000 canes per day in three shifts of workers daily. The machines used for the fulfillment of this purpose are Named as Multi mixer Bale Breaker. Drawing Toyoda DYH 2 C. to make 3 Laps.BLOW ROOM The objective of this department is opening. There are two paths available for sliver for further processing.
75 hanks and 15 yards of roving in combed have 0.66 Grains per yard in Breaker The wastage of this department is lap cut. the breaker comber has 370 meters per mint. and lap former has 110 meters of lap per 5 mint capacities. Ring machines Toyoda RY. The capacity of a spinning unit is measured in spindles. Its capacity is 30 machines having doff of 480 spindles of each machine. The machine used is Toyoda FL -16. 15 yards of roving in carded have the weight of 0. Pneuma fill is the wastage of this department mainly. twisting and winding of roving into yarn on bobbins. dropping.120 canes per shift and the lap former have the capacity of 240-245 laps per shift. SIMPLEX The purpose of this department is twisting and drafting of sliver to make roving. In smaller units the breaker carded has 350 meters per mint. RING This department is meant for drafting. noil and hard waste. .95 hanks. The weight of sliver is kept at each machine as. MTM has the spinning unit of 14400 spindles (480 spindles per machine).65 Grains per yard in Finisher . The capacity of this department is to input 120 canes per machine and out put 14-15 roving per cane. The waste of this department is consisted of roving cut and pneuma fill.4 are installed in this department of spinning. sliver cut. finisher carded has 700 meters per mint. finisher comber has 350 per mint. 8 .66 Grains per yard in Drawing . One bobbin has a weight of 65 grams with yarn and 55 grams without yarn.
checked under ultra violet rays and packed into bags.Corrective maintenance 2. MAINTENANACE Maintenance means to keep up the condition of the machine at its original specifications so that the machine performs to give its best efficiency and effectiveness.Predictive/ Proactive maintenance The approach that is being followed in MTM unit is a blend of corrective and preventive maintenance.Preventive maintenance 3. while each cone has a weight of 18901900 grams. thin. This department has the capacity of producing 750-8000 cones per day. neps. thin. Murat Mach Conner is used for this purpose. The machine parts Uster in old and LOEFE in new machines is used for sensing these faults and cutters cut these faults while the splicing unit G1 in old and G2 in new machines splice the two ends of yarn. These are as follows. Machines can be maintained by following different approaches. PACKAGING The yarn is moisturized. neps and contamination from the yarn and to rewind the yarn in the form of cones. A moisturizing machine is being installed in the packaging department. The wastage of this department is thick. 1. The capacity of this department is 300-325 bags per day while each bag has a weight of 100 ponds. 9 . color contamination and double yarn.AUTO CONE The main purpose of this department is to remove the thick.
1234567After failure or Preventive Check Depute Personal(s) Analysis of Fault Procedure to be followed Execution of procedure Job done Report / Record The above mentioned procedure of maintenance is not being followed in MTM.The standard procedure that should be followed to perform the maintenance activities is as follows.Beaters . Hers is the maintenance schedule being followed in MTM (Department Wise). 10 .Shooters .Condensers Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling AOOZD 3 in No. The machine used for this purpose is Name of M/C Auto Bale Plucker Having Parts .Lattices . The basic purpose of maintenance is to Reduce the downtime Reduce the maintenance Cost Reduce the average inventory (Store and Spares) Provide a guideline for respective procedure next time These purposes can be achieved y following the above mentioned procedure that will also help in the maintenance managers to implement the CMM. which actually needs the past history of faults and their remedies to take the next decision. MIXING The objective of mixing department is to blend the cotton brought from different areas and to open the pressed bales of cotton into fluffs.
Name of M/Cs VO1 HR6 VO2 Having Parts Porcupine Beaters Daily Checking and Oiling 1 in No. The machine parts that are due to be changed. BLOW ROOM After mixing cotton is brought into the blow room and stored in the sandwich form for 24 hours and then it is put into the following machine. 1 in No. are changed on regular basis.. Name of M/C Multi-Mixer Bale Breaker Having Parts Long Lattice Bottom feed lattice Spike lattice MBK Pockets Grid Bars Feeding Rollers Strippers Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling MBK-4 1 in No.Cutters Daily Checking and Oiling Daily Checking and Oiling One machine is kept standby while two machines remain in function.Strippers . Name of M/C AXI Flow Cleaner Having Parts Pockets Feeding Rollers Porcupine Beaters Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling 1 in No. 11 . 1 in No.
In Blow room the main problem or the main hindrance in performing the maintenance activities is the single line of material flow. The machine parts that are due to be changed are changed on regularly and timely intervals. 12 . CARDING The laps formed in the blow room are then brought into the carding. However.- Shooters Feeding Rollers Crushers Grid Bars Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Name of M/c Scutcher Scutcher Having Parts Scuthcer Pockets Shooters Porcupine Beaters Piano Motion Cone Drum Double Gauge Suction Fan Calender Rollers Lap Rods Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling TOYODA CHINA MADE 1 in No. periodic checks. Name of M/C CrosRol Having Parts Taker-in Cylinder Doffer Mounts flyer Brush Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling MK-4 24 in No. oiling and greasing is done to maintain the smooth running of machines. That is why it is not possible to overhaul a machine regularly. 1 in No.
- Top Set Coiler Box Daily Checking and Oiling Daily Checking and Oiling This department has a defined schedule of maintenance. Calendar is changed after 4 years. combed and converted into more purified form of slivers. a weekly oiling. drafted. 7 in No. One machine is overhauled daily. Taker in is changed after 9 months. Name of M/C Drawing Frames Drawing Frames Lap Former Comber Comber Having Parts Creels Drafting zones Auto Leveler Top Pressure Section Top Comber Flyer Coiler Box Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling TOYODA-DYH500C TOYODA-DYH2C TOYODA-SK4A CM10 VC250 7 in No. Machines are over hauled once in a month. 1 in No. Brush is changed after one year. DRAWING Sliver formed in carding is doubled. 2 in No. 13 . 1 in NO> Along with the regular daily checking and oiling. checking and greasing is done. Doffer wire and cylinder wires are grinded on regular basis and changed after every two year. SIMPLEX Sliver formed in the precious department is turned into ravings in this department with the help of following machines. A general check is also performed weekly. Top comber in Comber Machine is changed after 18 months.
Rubber cords are changed after one year. 14 ..RY4 30 in No. One machine is over hauled once in a week. Ring travelers are changed with in 4-7 days. Grinding of rubber cords is done on \regular basis. Rubber cords are changed after one year. Machines are weekly oiled and greased and overhauled once in a month.Name of M/C TOYODA Having Parts Drafting zone Coving Flyer Twister Shafts Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling FL-16 6 in No. Hardness of rollers tested weekly. RING The final shape of yarn is given to the roving in the ring department. Name of Machine Ring Having Parts Roving Guide Front and Back Rollers Wooden rollers Cradle and Apron Spindle and Spindle Traveler Pneumonias Pipe Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling TYODA.
Recommendations. P3. 15 . and it takes 3-4 months for a complete overhaul of a machine. In Ring department. P2. a machine is checked in three rounds.AUTO CONE Yarn is wounded on cones and checked for faults ( Thick. 50-60 % of maintenance cost is being incurred. Neps and Color Contamination) in this department. If we are to divert the manual maintenance system to CMM then we have to keep The Records of faults The Records of remedies The Store and Spare Records The expiry Dates of Machine Parts So that. P4 (Pressure Pipes) G1 and G2 (Splicing Units) Uster And LOFPFE (Sensors) Spindle Cutters Tension Assembly Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling Daily Checking and Oiling 6 in No. Thin. the computer may suggest us by analyzing the history records. Round wise maintenance is being followed in this department i.e. the actions to be performed. Name of M/C Murata Mach Coner Having Parts Adopter Cone Drum Suction Mouth Retie Mouth P1.
R. = Difference b/w Dry and Wet * 300 / Dry = Ans – 98. This is the responsibility of the AC department to keep the temperature and humidity. The relative humidity is calculated from dry and wet temperature by following formula. AIR CONDITIONING Temperature and humidity in the air does count a lot each department of spinning because it effects the count variation directly. The relative humidity of each department is checked after every half hour and controlled with help of supply of fresh or used air of unit with the help of supply and return fans. Supply Fans. This department is equipped with LUWA AC Plant. H. at the required levels.4 = Ans The temperature of each department is as follows.ELECTRICAL The electrical department is of great importance because each machine is run by electrically functioning motors and circuits. and Ducts. constant and same through out the year (All seasons). Return Fans. DRY Mixing Blow Room Carding Drawing Simplex Ring Auto Cone Packing Normal 102-104 F 100-102 F 80-90 F 80-90 F 90 F 90 F 70 F WET Normal 85-86 F 84-90 F 78-80 F 78-90 F 94 F 94 F 71 F 16 . Daily checking of machines is done by this department for avoiding any mishap and for constant supply of electricity in the whole spinning unit.
QUALITY CONTROL (LAB)
The purpose of this department is to ensure the quality from very start, cotton purchase, till the yarn packing and dispatching. Before purchasing the cotton following properties of cotton are checked. Fiber / Staple length MIC (Weight per unit length) Trash (Dead Leaves of Cotton) Moisture ( Water contents in Cotton) With fibro graph or VI 4000 With MIC Tester 4.2-5.2 accepted With Shirley Analyzer 100 g / Bale With Moisture Meter 8 % Accepted
After the process of spinning has started the QC has checks at each level. Count ( Hanks Per Pond or Count = 8.33*L/W) is checked by Auto sorter computer Program after Wrapping of slivers, roving and yarn. Sliver Roving Breaker Finisher Simplex (Hank Roving Test) 6 yards 15 yard 6 yard 6 yard 15 yard 8 Samples Three times a day 8 Samples Three times a day 8 Samples Three times a day 8 Samples Three times a day 4 Samples Once a day 4 Samples Once a day
Ring ( Strength check in Lea Form) 120 yard Packing
Checking of each cone in ultra violet rays.
Uster test is applied to check the U% (Unevenness of the Yarn) at the Uster Tester Machine. Tenso Rapid machine is used to check the strength and elongation of a single thread of yarn. Classimate machine is used to test all types of faults and making their graphs. TPI (Twist Per Inch = (TM) Twist Multi Pliers √ Count) can be checked on this Machine. The yarn can be classified into three types based on TPI and TM and these are as; - Hosiery Yarn - Warp Yarn - Weft Yarn Micronare is used to calculate the value of 1st, 2nd and 3rd pick Value.
We make blends of cotton with other materials like polyester and viscous to add more value while reducing cotton costs - CVC Cheap Value Cotton (CVC) is the blend of Polyester and Cotton in 40:60 Ratios. - CVS Cheap Value Synthetic (CVS) is the blend of Polyester and Viscous in 40:60 Ratios.
Yarn faults are as under Thick Thin Neps U % age Hairiness Slubs Contamination Baree
The spin plan for carded and combed yarn is a bit different because of difference in routs for both yarns. a)- Spin Plan for Carded Blow Room Carded Sliver Drawing Breaker Drawing Finisher Carded Roving 14 Once per yard of lap 58 Grains per yard 66 Grains per yard 65 Grains per yard 0.75 Hanks
b)- Spin Plan for Comber Drawing Lap Former Comber Comber Breaker Comber Finisher Simplex 58 Grains per yard 900 Grains per yard 66 Grains Per yard 65 Grains Per yard 65 Grains per yard 0.95 Hanks per yard
Only 10 – 20 % of total production of spinning is used for knitting in MT. The rest of the yarn is exported to different countries.
Knitting in a process of fabrication with the help of needles. Needles turn the yarn thread into loops and loops are interlaced by the sinkers or needles to make fabric. There are two types of knitting; 1- Warp Knitting 2- Weft Knitting
1- Warp Knitting:
in warp knitting no of yarn stings fed to machine are equal to the machine needles. Needles are fed yarn with beams. Sinkers are used for interlacing along with needles. The fabric produced so is Flat.
2- Weft Knitting:
Single yarn thread is fed to all needles to weft knitting machines. Feeders are used to fed the yarn to needles. The weft knitted fabric is produced by; Circular Knitting b)- Flat knitting The weft knitting machines are of two types; a)- Single Knit b)- double Knit a)- Single Knit: In single knit, the machines have - Single needle bed - Sinkers - Cylinders (Vertical Needles) Single knit fabrics include S/J S/PQ D/PQ D/PQ (H.C) 19
L. Feeder: 20 . = Length of computed Wales /no of Wales Increase in S. Is called course length. These can be counted vertically per unit of length. Stitch Length: Yarn used for making one loop is called S.Double Knit: In Double Knit the machines have Double Needle Bed Cylinder (Vertical Needles) Dial (Horizontal Needles) Double Knit fabrics include RIB 1*1 RIB 2*2 INTER LOCK WAFFLE Different Types of Fabric and Machine Parameters Wales: Vertical lines of loops in fabric are called Wales. These can be counted horizontally per unit length.- FLEECE b). can increase Dia from 1-2 inches.L. (CPI) Course Length: Length of yarn used in one round of fabric DIA. (WPI). Courses: Horizontal lines of loops in fabric are called as courses.L. S.
Count: Count means the count of yarn. of needles per inch of cylinder and dial is called the gauge of the machine.L. Stripe: 21 . ( TPI increases Shrinkage decreases and vice versa) ( S. Production is increased by increasing the feeders. Gauge: No. If gauge is increased. increases GSM decreases and vice versa) Shrinkage: Increase or decrease in width of fabric is named as shrinkage. and Quality of Fabric.The point at which yarn is fed to the machine is called feeder. Size: Size means the width of fabric.L. the quality of the fabric becomes fine and vice versa. Shrinkage depends upon the TPI of yarn S. (Hanks Per Pond).L. DIA: Dia is the diameter of the machine. ( S. Dia determines the width of fabric. It is measured in inches and depends upon the Dia of machine. It also controls the S. It is used for constant supply of yarn to machine.L. tight Shrinkage decreases and vice versa). MPF: Multiple feeding units made by CONI are the feeding units that feed yarn to machine. If count is decreased the GSM is increased and vice versa. Count effect the GSM of fabric. GSM is based on Gauge ( Gauge increases GSM Increases and vice versa) Count ( Count increases GSM decreases and vice versa) S. GSM: GSM is the grams per square meter of fabric.L.
CAM: CAM is a path engraved in metal in which needles move according to their Buds.3. It is made by feeding colored yarn at different feeders after specified intervals. Cylinder has the different diameters. Sinkers: Sinker is a part of machine that brings the yarn to the needle and drops the loop of yarn to make a stitch. Cylinder: Cylinder is the rounded part of machine that contains vertical grooves for carrying the needles. Auto Engineering Stripe: It is stripe made on computerized machines. Dial is also of different diameters and gauges.Stripe is the repeative band (Different color yarn) in fabric. Knit ( Needles make a full loop when pass through the knit) Tuck ( Needles make a half loop when pass through the tuck) Miss ( Needles make no loop when pass through the miss) 22 . The distance between two grooves is called pitch and the no of grooves (no of needles) per inch is named as gauge. Sinkers are used only in single knit machines. A CAM may have three kinds of paths to pass through (made by combining CAMMs). Dial: It is part if double knit machine that contains horizontal grooves for needles. Head Litch Buds Stem Increase in needles can increase in width of fabric while the Dia of machine is fixed. Four types of needles (named as needle no1. Needles: A needle has four parts.2.4 based on buds) combine to make a set of needles.
L. Take down winder also creates the Take Sown tension. S. RPM: It is the round / resolution per minute of cylinder or dial in knitting machines. Take Down Winder: Take winder is used to wind the fabric into rolls.Clearance 1.Knitting 3. Different types of fabric are produced at different rpm as follows.Knitting Co-ordination 2. of fabric. PROCESS OF FABRICATION There are three sub-departments of knitting in MTM. S/J Fleece Rib S/J (L) PQ 20-24 rpm 25-28 rpm 15-22 rpm 15-20 rpm 20-24 rpm RPM has to be reduced with lycra attachment with machine. The gears of master wheel effect the GSM.Master Pulley: Master pulley (wheel) controls the rpm of dial/cylinder/MPF. RPM of dial/cylinder effects the production quantity in plus of minus with increase or decrease respectively.Knitting Co-ordination: 23 . 1. which increases the distance between the Wales that ultimately effects the GSM. Lycra Attachment: It is a part of machine to feed lycra to feeders at a constant speed and stretch.
knit 2 and knit 3. And. SL and Count at required production from this formula. Rib.Knitting Co-ordination department is involved in communicating the. production capacity. KNITTING UNITS There are three units of circular knitting in MTM at present but new Units are under construction and soon machines will be installed in these units. no of feeders. and generating work orders according to machine type and capacity. parameters into the machine parameters as defined by the R & D. and machine parameters. The production capacity of each machine varies at different parameters of fabric and RPM of machine. PO R & D (Parameter Approvals) a).O. strings. twill tape. cuffs. Wastage: Wastage % age is different for In House and Out Source production.6 * count We can also calculate no of needles. / 117. These units are named as knit 1. It is also responsible for in house or out source knitting decision making depending upon the machine availability. Production of fabric (main body and trims including.L. time line.Out Source Contract Work Order Production Clearance At this time MTM is out sourcing more than 50 % of its total production of fabric. The general formula for calculating the machine capacity is as under. Production = no of needles * no of feeders * RPM * S. one unit is for flat knitting. collars. P. RPM.Out Source a). Out Source In House Stripe Trims 2% 1% 3-5 % 4-7 % 24 .In house b). There are more than 100 machines in these units including flat knit unit. etc) has the following flow.In House Work Orders Production Clearance b).
Yarn Faults b). Oil Spots Heavy Yarn Lint Hole Thin Yarn Tuck Stitch Knot Hole Drop Run Down Broken Needle Tape Down / Tape off of wheel Winding Hole Caused by Broken Needle MTM is producing 10 tons in house while out sourcing 12-15 tons. CLEARANCE The purpose of this department is to provide service to knitting units and fabric stores.Machine Faults Here are some faults that occur due to both above mentioned categories. 25 .Fabric Faults: Fabric faults are categorized in two groups a). The fabric produced in house or out sourced is cleared and documented when it arrives at MTM mills or from knitting units by the clearance department.
STEP ONE Machine allocation plan This is prepared on the Axel sheet. Category.to making section are here elaborated one by one. STEP TWO Greg fabric requisition After the availability of fabric in FMS lot section raises a requisition for grey fabric to store with parameters as followed. The steps involved in the procedure of . P. Fabric. Size/Width. STEP THREE Greyer Fabric Issue Fabric is issued by the store to lot section against the grey fabric requisition with details of following parameters. 26 . Col. This plan is prepared by the PPC department in which the dyeing and finishing paths of a PO are defined along with required parameters.O. . F.PROCESSING IN MTM Processing in MTM is consisted of Lot Section Dyeing Finishing R&D QC and QA LOT SECTION IN PROCESSING Lot section is responsible of making lots of fabric and issue these lots to the dyeing and finishing machines according to their capacity and machine allocation plans. Rolls and Weight. Req GSM.
GSM. F. Method. floor. Quantity and Clearance No. Lot NO. STEP FIVE The fabric received by the lot section is then divided into lots with parameters as followed. F. STEP SIX Lot Issued Then those lots of fabric are issued for dyeing and finishing on job Cords. GSM. GSM.R. STEP FOUR The fabric is received by the lot section along with specified parameters as mentioned above.width Sample Dyeing Finishing Pink paper Pink paper Blue paper Green paper White paper REPROCESS ISSUE Dyeing Finishing 27 Yellow paper . Job cards are different in colors according to issued process. Yarn Lot. Yarn Lot. Bar Code. P. Color.. Fabric. Bar Code. FRESH ISSUE Dyeing Finishing Tabular Op. S/W. Weight Qty. Size/ Width. GSM. These are as followed. Count. Weight. Purpose.O. Count.
28 . opening & stitching of roles into round form and Putting then into trellis is also the responsibility of lot section.Width Yellow paper Yellow paper Sample Dyeing Finishing Yellow paper Yellow paper Lot for reprocess are issued by weight section with difference in Bar Code or customer code. The Bar Code on Job Card and the worker’s card are scanned and then this lot is ready for dyeing & finishing (Either Fresh or Reprocess) Inventing .Tabular Op.
PRIMARY COLOR: There are three shades of primary colors. DYES: Dyes are the chemical agent that gives different shades on treatment with fabric.DYEING IN PROCESSING UNIT DYEING: Dyeing is a process to give shades (colors) to fabric . we define what is a color or shade. e.g. COLOUR: A color is a specified range of wave length omitted by an object when light ray are thrown at that object. Yellow + red = orange Yellow + red + blue = green Yellow + red + blue = black Yellow + red + blue = navy 29 . 12Primary colors Secondary colors First all. These dyes may be of different colors (shades) but these are mainly categorized into two groups of shades. 123Yellow Red Blue We can obtain any kind of color shade by mixing these three primary colors with different ratios.Different shades of colors are obtained by the treatment of fabric with different type of dyes.
123Eco Soft Roto steam Eco Soft Plus ECO SOFT: These are also called as environmental machines. these machines are used for Low temperature dyeing Full bleach Reactive We can say that these are used for (a) White (b) cotton dyeing 30 . This is done in the Dyeing Machines. but how we can treat both of these to obtain different shaded fabric. These are as followed. Turquoise Blue R (reddish) Blue BRF Khaki Royal Black B Now. Some are as followed. we have the colors & fabric.SECONDRY COLOR: There are also some secondary shades of colors which have been obtained by mixing the primary colors. DYEING MACHINES There are three types of dyeing machines in MTM which the process of Dyeing is being carried down.
is the brief summary of machines and there allocation in terms of machine. machine ports.High temperature .Soft Plus Eco.Used for blend dyeing (polyester) We can say that these are used for a) White b) Reactive dyeing & c) Disperse dyeing Here. Type.Soft Plus MACHINE PORTS MACHINE CAP L:R 2 300 1:7 2 300 1:7 3 450 1:7 3 450 1:7 3 400-500 1:7 3 400-500 1:7 4 600 1:6 4 600 1:6 5 800 1:7 2 250 1:6 1 120 Controlled 5 800 1:7 6 100 1:10 4 600 1:6 6 1000 1:10 1 4 4 35 600 600 Controlled 1:6 1:6 31 .Soft Plus Eco.Soft Plus Rotosteam Rotosteam Sampling Rotosteam Eco.Soft Plus Eco.ROTO STEAM & ECO SOFT PLUS: These types of machines are . machine capacity & liquor Ratio. MACHINE T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 MACHINE TYPE Ecosoft Ecosoft Ecosoft Ecosoft Rotosteam Rotosteam Eco.Soft Plus Sampling Eco.Soft Plus Eco.
Nozzle and Nozzle sizer: This is the part from where fabric is fed to the machine and Nozzle size is adjusted according to the heaviness of the fabric e.g. Steam valve: To control the temperature of the machine. Button Adjustments: 9 13 41 43 73 63 Side tank draining Side tank fresh water Hot water Fresh water loading Draining Wringing 5-6 1-2 32 . Side tank + Feeding Valve: Dyes and chemicals are fed to the machine from this part. Main Pump: To run the machine.Machine Parts: Here are some machine parts and their functionality. Main Drum: Where the dyeing process is actually performed. S/J Fleece Winch Motor: To rotate the fabric during the dyeing process.
second reading after loading the fabric. Two readings are taken from the level. Water level indicator: Water level indicators are attached with each machine on which the level of the water in the machine is indicated by a pointer on scale. S/J H/J or Fleece Pressure of port: The range of port pressure is from 0. Pressure of main pump: Dyes and chemicals are pumped and sprinkled in the machine through this pump. For example 1:7 or 1:6 Where 1 indicates the water in and 6 indicates the fabric. while motor speed varies for different fabrics as. 1234567Basic Dyeing ( For Wools) Pigment Dyeing ( For Garment’s lustrous Look) Acid dyeing ( For Acrylic apparel dyeing) Sulpher dyeing ( For rich black dyeing of cotton) Full bleach ( For white and wash) Polyester dyeing ( For cotton and Polyester Dyeing) Reactive dyeing ( For cotton dyeing) 33 . 150. first reading before loading the fabric.200 rpm TYPES OF DYEING There are different types of dyeing as followed.5 to 2 PSI and varies with heaviness of fabric. Motor speed: The winch motor speed on each port is kept constant with each other on a machine.DIFFERENT MACHINE PARAMETERS Liquor Ratio: The ratio between the water and fabric according to their masses in a machine is known as liquor ratio.180 rpm 150.
work order scan b.25 % of lot wt. The other three processes of dyeing are being carried down which are being elaborated here. Sando clean ( minor oil lines) 0. Delta clean (minor oil lines) 0.5 % of lot wt.De-oiling: Major oil lines. LOT MAKING AND ISSUEING FOR DYEING PPC department allocates the lots of fabric for dyeing according to machines capacities. a). Stainless 2000 (for severe oil lines) 1 % of Lot wt. Following chemicals are used.Full bleach: following chemicals and steps are involved as. - - - FULL BLEACH ( WHITE AND WASH) Full bleach is carried down in following steps. After receiving the fabric and lot allocation plan the lot making department issues lots for dyeing according to a.lab dip number c.machine code(bar code) Lots are received in dyeing on work order.worker card scan Lots are then loaded on machines in loops of fabric. oil spots and impurities are removed in this process.customer number d. Temp and Timing: 50 C for 20 mints b). Lots are received after the a. Jet clean Caustic soda Stabilizer Hydrogen peroxide Optical brighteners (Photince CXT or Leacophor) - 34 .The first four types of dyeing are not followed in MTM.machine number b.
De-oiling: Same as mentioned earlier defined in full bleach. H. Acetic Acid 2-2. Acetic Acid Draining Cold wash at Draining Off load 1. a).Neutralization: to neutralize the fabric at PH 7 the chemicals and process involved as. Under reduced pressure in acidic media at PH 5. The steps or procedures followed in polyester dyeing is as follows. In first step polyester is dyed and in second step cotton is dyed.5 % of lot wt At 50 C 35 C for for 2mint - - 10 mint PC DYEING PC is blend of polyester and cotton with the following ratios used in MTM.Disperse Dyeing: The steps followed are as.5 %of lot wt. P 20 30 35 : : : : C 80 70 65 that is why PC is dyed in two steps. b). Buffer 35 .Temp and Timing: Draining Hot wash at Draining Cold wash at 95 C 60-80 C 35 C for for for 45-60 mint 10 mint 10 mint - c).T dyeing Disperse dyeing is a high temperature dyeing at 135 C for 45 mint.
De-oiling: Same as already been defined in full bleach process.Half Bleach: the chemicals used in half bleach are as. Draining Reduction and cleaning Off load The second step cotton is dyed which is called Reactive Dyeing Process. Jet clean Caustic soda Stabilizers Hydrogen peroxide Temp and Timing: Draining Hot wash at Draining Cold wash at Draining 60-80 C 35 C 95 C for 10 mints. for 10 mints.Acetic Acid 36 . Skelton dyeing Draining (if shades matched) Cold wash at 35 C for 10 mints. It fixes the dye in fibers of polyester.- Ammonium sulfate is used as buffer. b). for 45 mints. Cooling up to 80-90 C Sample put in sulphuric acid to get polyester skeleton. 2% of lot wt. - - - c).Caustic Soda .Soda Ash (weak) .Neutralization: neutralization process is completed either by Alkali: Acid: . REACTIVE DYEING a).
Colors are fixed in this sequence RedBlueYellow Neutralization ( As already been defined above) f)..Pharmic Acid . Absorbency test is carried down on a sample of fabric ( Half Bleached and Neutralized) for further reactive dyeing process. e).Finishing Process: in finishing process of reactive dyeing following steps are taken. Caustic soda ( Only when Depth of color is required) Shade Check – First Shade after 15 mint Second Shade after 35 mints Third shade after 50 mints. PH Check ( PH of fabric should be at 7. The following steps are taken in reactive dyeing at 60 C.Absorbency test: The power of water to penetrate in the fabric is called as absorbency of the fabric. - - 37 . Rocco Line Chemical ( To decrease the rope marks) Color Adding Yellow % Green % WEIGHED AMOUNT Blue % Mixing of colors with water Either from Machine Or Fresh water a And this mixture is injected into machine through side tank. Anti Creasing agents / lubricants (To reduce the friction ) 1% of lot wt. Soda Ash ( to fix the colures) is fed in 30 mints. Soaping For removal of excessive dyes at 90C for 10 mint Draining Hot Wash at Draining 80 C For 10 mints. Common salt (it is added in 20-80 mint) for bonding of dye molecules with fabric fibers.Sulphuric Acid PH for wash and white is PH for dyeing is = 11-12 = 7 d).Reactive dyeing: This process is called reactive dyeing because the dye molecules react chemically with cellulose in this process.
- Cold wash at Softener Application 35 C For 10 mints. - - To give the fabric a better hand feel and the chemicals used for this purpose are as followed. Tubingal –UGS with acetic acid at PH 7 Temp and Timing: 50 C for 20 mints. Draining Off Load This was the whole process of dyeing carried down in MTM mills Division. 38 .
Width problem GSM problem Shrinkage Tourquing Bowing Calendar line Different finishing routs are being followed in MTM.Tubular c). And on the other hand these faults may happen in finishing process if this process is not handled carefully. These are as under a).Open Width Route: The open width route consists of following machines. On this machine the fabric is slit sidewise. Slitting Machine Dryer Compactor Slitting Machine: we have to slit it side wise depending up on the customer requirement. The speed of machine varies from 0 to 50meter /minute. 39 .Open width b). There are different kinds of problems that can be controlled in finishing process. Dryer: This machine is used to dry the fabric. Bianco. These faults are as under. Mild silicon and silicon softeners are applied in this machine.Tumble a). Slitter is used to cut the fabric into open form along with the slit line or drop needle line.FINISHING IN PROCESSING The processes of giving the desired look to the fabric and to prepare it for cutting is called as finishing. For this purpose a slitter machine. is used. to reduce its width and to apply the softener.
Squeezing (squeeze the water) . Raising is done for both the open and tubular fleece and peaching for the sewed fleece and single jersey fabric. to cover it.Overfeeding Santa Stretch machine is basically used to apply the softener and open the width up to the required level.Expansion .Wetting (water dipping) . single jersey.2 Chambers Dryer .Compactor: In Compactor machine the fabric is pressed and its shrinkage. The usual speed of the machine is 7. Instructions can be changed only by 40 .Fab cone .Squeezing (squeeze the softener) .Wetting (softener dipping) . Santa stretch (stretch machine) Santa shrink (dryer machine) . If fabric has different moisture then pickup of softener will also be different and color/shade variation should occur. overfeeding is necessary. These are the peaching and raising. width and bowing is controlled.Tubular Route: The tubular route consists of following machines. .Calender The steps involved are as under.5 meter/minute.4 Chambers Dryer Two Chambers dryer is steam operated and is computerized. Santa Shrink (dryer machine): There are two types of these machines . Programs feed according to the fabric type like. which are applied depending up on the customer requirement and kind of fabric. because during expansion and to get required width the length going to be short. b). Besides the above-mentioned open width route there are two other routes.De-twisting . While overfeeding is to feed more fabric behind the machine to get required length of fabric. fleece or interlock.
Each and every function in this machine is controlled automatically. Steam is working in tumble machine to shrink the fabric up to maximum limit. Tumble is done after semi drying & semi dry fabric is never entering into the compactor. The functions performed by the machine are to dry and shrink the fabric. c). 41 . 4 chambers dryer is manually gas operated and has no option to store different program and each program is feed according to fabric type.one touch according to the fabric. Santa Shrink is used for the dryness and shrinkage of the fabric up to the level where it can maximum shrinks. From here the fabric is transferred to the final quality inspection.Tumble Route: Tumble machine is for the shrinkage control further.
Samples are made and sent to customers according to their specifications.Energy costs c.R & D IN PROCESSING UNIT R & D department in processing is of great importance. It is also playing a role of co-ordination with merchandisers of apparel division. research work is done about the samples. Purpose of R & D: R & D is basically a service department which is providing service to knitting. It is also named as intensive care unit (ICU) of processing because many faults of fabric are repaired by reprocessing in this part. There are two sub departments in R&D 1. Reprocessing: Reprocessing portion of R & D plays an important role in the production. Dyeing and Finishing) COSTING IN R & D There are three factors accounted for costing a. Garments Order Lab R & D R & D Yarn demand Knitting Color recipe Different shades submitted to buyers Option Approved Recipe (lab Dip) Planning of lot Dyeing Sample Sample Approved Parameter Approvals Production ( Knitting.Sampling 2.Reprocessing Sampling: In sampling.Dyes + Chemicals b.Over heads 42 . dyeing and finishing. Process flow of R & D is as follows.
C AVG COST PER KG = A + B + C = ****** RS PROCESSING FUNCTION IN R & D R & D department is involved in two functions mainly. 1.a.Dyes and chemicals For example Caustic soda = **** RS Hydrogen per oxide = **** RS Red = **** RS Yellow = **** RS --------------------------------------------------Total Cost = ***** RS Total Cost / Lot Wt = b.Fabric Dyeing Fabric dyeing is related with large scale production in processing.Over Heads Over heads include Labor Maintenance Service Dept. = c. 43 . Depreciation ****** RS Cost / Kg --------.B ***** RS Cost / Kg -------.A Total Cost / Total Production= ******* RS Cost / KG -------.Piece Dyeing 2.Electrical Total Cost / Lot Wt. Here is the elaboration of processing in the textile.Energy There are two energy sources – Thermal .
Yellow By the combination of these primary colors.Red b).Brightness 3.Blue c).Tone 2.Hue There are three primary colors a).Textile Woven Yarn Dyeing Fabric Dyeing Processing R&D Knitting Piece Dyeing In Dyeing the basic thing to control is color shading. there can be made different shades of colors. The basic properties of color shades are as followed. Red Reddish Olive Yellowish Yellow Yellow Navy Bluish Reddish Purple Bluish Blue At the red point the tone will be reddish At the yellow point the tone will be yellowish At the blue point the tone will be bluish 44 . 1.
Following steps are involved in piece dyeing. the main function of R & D is Piece Dyeing.5%at 50C for30min .Draining . 45 .2. a). Grey Fabric Knitting Garment Stitching Scovering/ De-oiling >Detergent -1. in MTM.Common Salt Common salt works as a carrier of dye molecules from liquor to fabric.” e. This process is carried down at o Room Temp.Tumblers ( Finishing) Piece dyeing machines are of small production capacity.Hue: Hue can be defined as “ Color contribution” or “Concentration of Color.1. Here.Catenization with catenizing agent1.Piece Dyeing Machines ( Dyeing) b).5 % for 30 mint at 70 C >Draining >Hot wash >Draining >Cold Wash . PIECE DYEING There are two types of machines used for piece dyeing in R & D.Brightness: Brightness shows the color property of being Brighter Darker 3.g. a)Red Blue Total Hue 2% 1% 3% b)Red Blue Total Hue 4% 2% 6% Although the ratio of mixing the Red with the Blue is same in both cases but the hue of colors is different each time. which is elaborated here.
Dyes Stuff Addition Dye % vary depending upon the color shades at 60-90 C for 45 mint. Thiese and Gaston county machines are of light temperature.Binder Different dye stuffs have different modes of attachment with fabric. Here is the list of machines and their capacities. . Machine Name T11 T16 G1 G2 G3 G4 G5 G6 Capacity(KG) 120 35 150 150 100 35 35 35 46 Ports 1 1 2 2 2 1 1 1 .Draining . high pressure and with controlled liquor ratio.Hot Wash . Garment wash machines are also atmospheric with Max 95 C. . .o For 15 mint. Amounting to o 15-17 % depending upon the depth of shade. (Max Temp 135C) While winch machines are atmospheric machines with low temperature (95 C Max) and at least with 1:10 Liquor ratio for reactive dye stuffs.Cold Wash PIECE DYEING MACHINES There are three types of machines Gaston County Thiese Winch “G” “T” “W” Beside these machines there are two machines of garment wash “GW”. Chromopher( Coloring Group same in all dyes) Dye BridgingGroup (Different in All Dyes) Binder has the ability to fix dye molecules on fabric. Winch machines are mother of dyeing machines.
2. to give fabric a shiny look. 6.Stone wash: treatment of fabric with special stones in the GW for 2-6 hours. The Garment wash program is as followed. 5.Silk Wash: softener treatment to give fabric softening effect.Enzyme Wash: Special enzyme are used to treat fabric to give extra shine to it. 1.Sand Wash: Extra softness and shine is given to fabric in this type of wash. Garment wash program is carried down in “GW” machines. 4.Soda Wash: In soda wash treatment an old look is given to fabric. 3.Bleach Wash: 47 .W1 W2 W3 W4 W5 W6 W7 W8 W9 GW1 GW2 60 130 130 20 8 15 15 35 20 20 100 Open … … … … … … … … … … GARMENT WASH PROGRAM T add artificial look and characteristics garment wash program is carried on after stitching fabric into garments.
R & D is the department to produce fine and high quality production in MTM. Actually.Bleach wash is applied on fabric to produce color patches on fabric and uneven floor faintness on fabric. 48 .
L. 49 . The test applied in Lab are as follows. attaches bar codes and clearance no. b). To assure this thing MTM has two departments. which checks the fabric for faults. Where different kinds of test are applied according to the requirements of QC or QA.Stitch Length: Yarn consumed to make a loop of fabric is called as S. which audits the QC checked fabric and give a positive or negative opinion whether the fabric is according to the customer requirements or not.Quality Control Department b). a). It is quite difficult task to fulfill the customer requirements. there is a LAB in MTM. b).Quality Assurance Department a).L.GSM: Grams per Square inch is also calculated in LAB. = No. Grey Section. This department does not suggest any thing. S. which checks the finished and dyed fabric for faults according to 20 point system. It has two sections.QUALITY CONTROL AND QUALITY ASSURANCE Quality may be defined as the set and required parameters by the customer.Shrinkage: Length wise or Width wise relaxation or contraction of fabric is called as shrinkage.Quality Assurance Department: This department can be said as agent from the customer side.Quality Control Department: This is the department which can be said as an agent from MTM side which checks the required parameters and recommends solution at each level of process. LAB IN PROCESSING To assist both of these departments. a). of loops / yarn length c). Inline Section.
k). nylon and with any other synthetic fibers is checked by dissolving either component in the relevant acid. (PSI) l).Blend % age: Blend percentage of cotton with polyester.Burst Strength: Strength of fabric measured in Ponds per square inch.Dry and Wet Rubbing Test: Color bleeding of dyed fabric is checked on white fabric.9/w Where L is length in centimeters and W is weight in milligrams. viscous.Courses/ Wales Courses and Wales per inch are calculated with the help of eye glass. i).Light Fastness: Color fastness in the presence of day light or any other artificial lights is checked. m). f). 50 . j).d). h).Washing Fastness: Color fastness of dyed fabric is checked on a piece of white fabric while washed together.Scorching Test: Scorching mean color bleeding while dyed fabric is heated with white fabric (by ironing both fabrics together).Count: Hanks per pond are calculated as Count = L*5. g). e).Fabric Width: Fabric width is calculated with the help of scale.Perspiration: Color fastness with alkaline or acidic perspiration is checked.
o).Flam ability Test: Butane gas flam is used to test the flam ability of the fabric. Lab to Production = W*P/C Where W = Weight of Fabric P = Percentage of Color C = Concentration of Color / Dyes/ Chemicals 51 .PH Test: PH is tested after finishing process.n). The parameters of recipe approved by the LAB can be converted to Big quantities for large scale production as under. The PH should be 7 after finishing.Absorbency Test: After half bleach and neutralization in reactive dyeing the absorbency test is applied to check the water picking capacity or power of the fabric.Stretch and Recovery test: Resistance of fabric against the stretch is measured after stretching the fabric. q).Pilling Test: Pilling on fabric is checked after revolving fabric in a machine for 18000 cycles.Hot Wet Press: Dry and wet fabric is heated by the iron for 15 seconds and tested for fastness. p). t). r). s).Tourquing: De-shaping of fabric is checked after many or required washes.
Indoor Training Apprentices Trainee supervisors Trainee Operators Trainee Engineers Management Trainees Trainee Officers B.Recruitment: HR Department in MTM regarding recruitment is almost online up to the middle level management and has the following procedure. Approved strength in each department Invitation of vacant or new position applications Scrutinizing of applications.Compensation 52 .Out Door Training Training in institutions Meetings and reviews 3. 1234567Recruitment Training and Development Compensation Performance Appraisals Employee Welfare Rewards and Punishments Retiring and Termination Benefits 1.Training and Development: The training and development process in MTM is very strong and has following setup A.HR DEPARTMENT IN MTM HR department in MTM is involved in different types of human resource development and human resource development activities. Here are the activities of HR department in MTM. Test including intelligence and aptitude tests Interviews in panel form 2.
MTM has setup for workers as Market rate Overtime Incentives Vehicles Accommodation 4. Best performance results in good rewards in MTM.Performance Appraisals: Promotions in MTM have very fair methodology. Some of them are as follows.Rewards and Punishment: MTM gives in terms of rewards Appreciation Cash Prizes Promotions In MTM for the control purpose there are also punishments Disciplinary Actions Show cause notices Suspension Terminations Charge sheets Fines 5. Health insurance Social Security EOBI 5% of Profit Accommodation Transportation Canteen and Mess Leave Encashment 53 . 6. Personality and job related traits are evaluated at regular basis.Employee Welfare: There are many employee benefits policies being followed in MTM.
HR department in MTM is almost computerized and includes HRMS ( Human Resource Management System) GMS (Gate Management System) JMS ( Job Management System) (Yet to be Introduced) JOB Bank (Yet to be Introduced) 54 .7.Retiring and Termination: Gratuity and provident fund is being maintained for the retiring personals in MTM.
Most of the departments have been computerized except Finance Department. The systems developed by the IT Department includes.IT DEPARTMENT AT MTM MILLS DIVISION MTM is at Almost Pure Dot Com position and we can say that IT has been so much flourished in MTM that it will be difficult to survive for MTM without IT at this time. JMS JOB Bank AIS (Job Management System) ( For online Jobs applications) (Accounting Information System) 55 . HRMS GMS FMS (Human Resource Management System) (Gate Management System) (Fabric Management System) And they are planning now for the following systems at urgent bases.
Purchase Requisition Submitted to W/H Purchase Department Purchased Material Arrives at Mills Quality Inspection Goods Receipt Note Material Received in Store + Goods Receipt Not Store Issue Requisition Purchase Demand Checking Material Issued to Demanded Department. But in my opinion. Spinning ware house Yarn ware house Grey fabric ware house Rejection ware house Cotton waste ware house Dyes and chemical ware house Finished fabric ware house The process of material management involves the following steps. The stores that are maintained by this department are as follows. Knitting and Lot section Department along with ware house management. these conditions are the result of miss planning of PPC.MATERIAL MANAGEMNET DEPARTMENT IN MTM Material management to insure control the safety stock to insure the regular supply. The conditions of stocks at stores are miserable. 56 .
Construction. Accommodation.ADMIN DEPARTMENT IN MTM The admin department is managing the Security. Transportation. 57 . Mess and Cleaning and Sweeping. and Maintenance of premises.
which is named as finance department or I can say that it is only a part of accounts department not the finance department. Lahore).Daily Cotton Stock Report . Date Wise Yarn Receiving Detail Date Wise Yarn Returned from Outside Date Wise Yarn Returned to Outside Date Wise Grey Fabric Received from Party Date Wise Yarn Issuance Detail Dyeing: In the dyeing section. the reports prepared are as followed: Party wise receiving summary Party wise issuance summary Party wise production summary Party wise issuance summary 58 .FINANCE DEPARTMENT IN MTM In my opinion there is a stock and inventory controlling department at Mills division of MTM. This department has three sections. Knitting: In the knitting section following reports are prepared. and Accounts Officer (Head Office) for the submission to the Textile Commissioner (Bureau of Statistics. Accounts Manager (Head Office). Spinning Knitting Dyeing Spinning: Following reports are prepared in the spinning section: .Daily Yarn Stock Report .Daily Management Report This report is reported to the Finance Manager (Head Office and Mills).
above mentioned reports following documents are also maintained. Vouchers Bill for Daily Expenses Payment to Employees Collection and Deposit of Cash from Head Office 59 .Besides.
PPC merchandiser Communication with customer Proto Samples Fit Samples Size Samples Pre Production Approvals of Fabric. Lab Dips Order Received with Time Line Fabric PO Forwarded to Mills Fabric Arrives from Mills QC Checking Fabric Received in store Feeding in AMS Cutting Planning Fabric Requisition Job Cards Spread of Fabric in Layers QC and QA Checking Cutting According to Cutting Plan Bundling ( Roll To Roll & Lot Wise) Induction Stitching In line Inspection (QC & QA) Final Inspection Super Final Inspection (QC & QA) Packing and Packaging (Assorted or Solid. Color. 60 .PROCESS FLOW IN APPAREL DIVISION OF MTM Following steps are involved in all processes of apparel division. color wise or size wise) Dispatching to customer Thanks.
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