Internship in Textile Wet

Processing/ Garments etc

A report submitted as a partial fulfillment for the degree of B.Sc. Textile

Engineering

by
[Student’s Name Reg. #]
[Student’s Name Reg. #]

Session 2016-20

Submitted to
BZU College of Textile Engineering

Work done at
[Name of the mills/ industry with address]

Duration
[start date to end date]

Bahauddin Zakariya university

multan
[Important Note: Please make sure that when you finish your internship, you have
to submit the internship report to the department. In addition to what you have been
taught, if you find anything unusual in practice in mills, please mention that in your
report. At the completion of internship, you will be required to submit the report; a viva
shall be conducted from the report submitted. Also note that this report is worth zero
credit hour but without the submission of report and conduction of viva, you will not be
able to collect and clear degree.]

{Don’t include this page in your report}

 Internship Report Layout

The report consists of the following major sections:

1. Introduction of the organization

2. Technical knowledge learnt from the main production plant/unit related to the
subjects in curriculum and the standard practices being performed in the industry.
3. Services of all kinds required for the smooth production
4. All the supporting departments to run the business of the organization in
coordination with each other (including HR, Marketing, Accounts, Time Office).
5. Health & Safety and the social aspects of the industry
6. And finally a Feedback based on observations made during the internship
 Table of contents
a. Title page
b. Internship Report layout
c. Table of contents

Section-I
1. A brief introduction of the organization
1.1. History,
1.2. Owners,
1.3. Management hierarchy (managerial tree),
1.4. Mills layout of various departments,
1.5. Branches / sister companies,
1.6. Products / services/ businesses,
1.7. Specialty

Section-II

2. Technical Knowledge
2.1. Technical knowledge related to the subjects in curriculum
2.2. It may include: Various departments, machinery, processes, products, machine
settings, working procedures, machines parts, mechanism, methods, materials,
process and material flow, time studies etc
2.3. Research and Development (R & D)
2.4. Standards
2.4.1. ISO Quality Standards
2.4.2. ISO Management Standards
2.4.3. Testing Standards
2.4.4. ASTM standards
2.4.5. BSI Standards
2.5. Maintenance
2.5.1. Maintenance schedules
2.5.2. Cleaning schedules
 2.5.3. Overhaul schedules
2.5.4. Oiling / Greasing schedules

Section-III
3. Services
3.1. Conditioning
3.2. Compressors
3.3. Dryers
3.4. Cooling towers
3.5. Capacity of Conditioning system
3.6. Supply and return fans
3.7. Trenches
3.8. Chillers
3.9. Boilers (Steam production)
3.10. Steam
3.11. Water
3.12. Compressed air
3.13. Gas/ Fuel for engines
3.14. Generators (Power generation)
3.15. Power

Section-IV
4. Essential Supporting Departments
4.1. Human Resource Department (HRD)
4.1.1. Responsibilities/ duties / task being performed / authorities / etc
4.2. Accounts / Finance
4.2.1. Responsibilities/ duties / task being performed / authorities / etc
4.3. Purchase and Sales
4.3.1. Responsibilities/ duties / task being performed / authorities / etc
4.4. Marketing
4.4.1. Responsibilities/ duties / task being performed / authorities / etc
 4.5. Time Office and Pay
4.5.1. Responsibilities/ duties / task being performed / authorities / etc

Section-V
5. Health & Safety and Social Aspects
5.1. Health and Safety
5.1.1. Health awareness
5.1.2. First aid
5.1.3. Noise pollution protection
5.1.4. Water and chemical pollution
5.1.5. Air pollution protection
5.2. Social security systems
5.3. Accommodations:
5.3.1. Hostels
5.3.2. Housing colonies
5.4. Food:
5.4.1. Mess
5.4.2. Canteens
5.5. Security
5.6. Conclusion

Section-VI
6. Feedback
6.1. Strength: good aspects of the industry
6.2. Weaknesses: weak areas / deficiencies / observations
6.3. Suggestions
A Brief Introduction of the Organization/ Industry/ Mills:
[History, owners, management, mills layout, branches/ sister companies,
products/ services/ businesses, specialty with respect to product being made
or anything new to the readers]
 A Specimen of Internship Report
Note:
 The following is a specimen questionnaire for weaving
students mainly based on technical knowledge related to
curriculum (subjects).
 However the other relevant areas (mentioned in layout)
have to be covered in a similar way or as per requirement of
the topic/ knowledge area.
 Students of other technologies can copy the pattern and
modify it according to their technology.

Report on Weaving
(Subject Related Technical Knowledge)

Winding:
Winding Machine Particulars:

Table for Winding Machine Information Collection

Sr.
Maximum speed
No. of groves on
No. of magazine

#
Working speed
Manufacturer

No. of Heads

pockets
Model

drum
Year

1
2
3
Rewinding yarn coming from Warp/Weft?
______________________________________________________________________________
______________________________________________________________________________

Rewinded Yarn to be used for Warp/Weft?

______________________________________________________________________________
______________________________________________________________________________

Different counts being rewound in the mill:

______________________________________________________________________________
______________________________________________________________________________

How rewinding of two different fiber materials (mixing) are avoided?

______________________________________________________________________________
______________________________________________________________________________

How rewinding of two different counts are avoided(Count mixing)?

______________________________________________________________________________
______________________________________________________________________________

General Flow in winding process:

Hierarchy of winding section:

Hierarchy of workforce in the section:
1. No. of supervisors?
2. Winders?

How Efficiency of winding set is calculated?

______________________________________________________________________________
______________________________________________________________________________
 Warping:

Table for Warping Machine Information

Beam capacity & density

Comb movement
Flange diameter

Barrel diameter
Drum pressure
Creel Capacity

Spindle Pitch

Beam space
Creel angle

Wing angle

Drum size
Model

Speed
M/C #

Make

Type

1
2
3
4
5

Yarn Passage:
Make Passage of yarn through machine of all types of warping machines :

Working of different parts of creel:

Student should be able to answer these kinds of questions:
How thread break is indicated on the creel?
How broken yarn is noted and repaired?
What is the function of different tension devices available at creel and how their tension is
adjusted?

Working of different parts in head stock:

Student should be able to answer these kinds of questions:
How length of set is noted in the machine?
What different types of information are available on the headstock?

Basic working of air conditioning system in warping?

How waste is calculated in warping area?

How warp yarn quality testing is performed for one creel?

Stoppage analysis on warping?

Production & efficiency calculations?

Make a table for Maintenance schedules?

Set calculations:
Student should be able to perform set calculation of a running quality:

Table for Yarn Breakages on Warping Machine

Source of Yarn Fault (Material,
Sr.# Name of Yarn Break Identification
Spinning, Winding)
1

10

….
Sizing:
Table for Warping Machine Information
Sr.# Make Model Type Creel capacity
1
2
3
4
5

Beam Breaking system?

Different parts in size box?

Different types of ingredients used in sizing?

What is general Method of size recipe preparation?

Any specific observation in sizing?

Weaving Shed:

Table for Different types of looms with respect to weft insertion and shedding
systems
Shedding\Picking Air Jet Repair Projectile Shuttle Water Jet Other
systems
Models
Cam
Dobby 12
Dobby 16
Dobby 20
Dobby 24
Jacquard
Hydraulic
Others
Total =

Table for Different Types of Looms w.r.t Manufacturers

Manufacturer Air Jet Repair Projectile Shuttle Water Jet
Model
Sulzer
Picanol
Dornier
Tasudokoma
Toyoda
Others
Total =

Table for Average RPM of Different Machines w.r.t. Machine Widths

Width Air Jet Repair Projectile Shuttle Water Jet
Model
190 cm
250 cm
300 cm
340 cm
400 cm
other
Total =
Maximum and minimum rpm of machines = ______________________________________________________

Table for Different Machines Quantities w.r.t. Different Machine Widths

Width Air Jet Repair Projectile Shuttle Water Jet
Model
190 cm
250 cm
300 cm
340 cm
400 cm
other
Total =
 Table for Weave Design and Fabric Construction
Sr.# Fabric Reed Denting Body Body Selvedge Selvedge
Quality Dents/inch Ends/Dents Weave Frames Weave Frames

1
2
3
4
…
Table for Different types of Selvedge Types
Selvedge type Count/Number of Machine Installed with
Tuck-in
Half Leno
Full Leno
Fused Selvedge
Hair Pin
Selvedge
Total =

Table for Warp Knotting Time (minutes) of Different Widths of Machines

Observations\Machine 190 cm 250 cm 300 cm 340 cm 400 cm other
Widths
1
2
3
4
5
Total
Average

Table for Change in width/Warp density on different positions on Loom

Observations Width Required On Weaver’s On Reed On Cloth Roll
Beam
1
2
3
4
….

Table for different types of Lubrication on the Loom

Lubrication Name of The Type of Manufacturer of Name/Number
Point # Point Lubricant Lubricant of Lubricant
1
2
3
4
…

Table for Loom Mechanisms on Different Machines

Inter-Nozzle distance
Main Motor Min. M/C

False Selvedge Made

Warp Detector Type

Max. # of Frames
Weft Detectors
Observation #

Max. # of Weft
Manufacturer

Weft/repeat
Pick Finding
Name of the

Movement

Max. # of
Take-up

Feeders
Beat-up
Let-Off
Model

Types

by
1
2
3
4
5
6
7
8
…
Weaver’s Work Load:

Looms/Weaver = No. Machines / Weaving Shed

Weavers in the Shed
Total Number of Weavers in the Mill = ___________________________
Total Number of Machines in the Mill = __________________________
Looms/Engineer = No. of Machines in Unit
Engineers in the Unit
Total Number of Engineers in the Mill = __________________________
People Hierarchy:

Make a tree diagram of total Hierarchy of the complete Weaving Unit, Starting from top
management like Technical director, General Manager, Administrator, Mills Manager; to All
possible departments like HR, Quality Assurance, Production, Maintenance, Back-process,
Air-conditioning, Inspection and Packing; to the lowest most staff like inspectors, weavers,
sweepers and floor cleaners etc.

Fabric Inspection, Folding and Packing:

1. What is flow process of folding department?
2. What is checked at first inspection or folding booking table?
3. No of inspection frames?
4. Maximum Width of inspection frames
5. Maximum speed of inspection frame
6. Production per inspection frame?
7. Number of fold machines?
8. Maximum bale weight possible on bailing press
9. Number of rolling machines?
10. Maximum length of roll possible
11. Production capacity of folding?
12. Nature of major faults in folding
13. Detail of System in use in folding for grading and inspection
14. Length wise classification of fabric? A,B,C,CP
15. Man power/Strength of folding
16. Mend able faults in folding
17. A-grade percentage
18. Long piece percentage
19. Any UV light frame in folding? reason

Commercial Fabric Collection:

Sample Commercial Sample
Construction Domestic Name
# Name Collection Status
1
2
Services Departments:
1. No of compressor. Model. Mac.
2. No of motors on compressor, their wattage, air production ability of each
compressor
3. No of dryers, cooling towers with compressor
4. Line diagram of compressor
5. Total capacity of compressor system
6. Pressure on main tank gauge and main gauge in shed
7. Maintenance schedule of compressors, details
8. Capacity of AC system, model, Mac
9. No of supply and return fans of AC
10. Dimension of trenches of AC
11. Cleaning system of AC
12. Service system of AC
13. Chemicals used in AC
14. Line diagram of different trenches of AC
15. Chiller system
16. Line diagram of chiller system
17. Cooling capacity of chiller
18. Model, Mac of chiller
19. Minimum and maximum temperature possible by the chiller system
20. Chemicals used in chiller
21. Maintenance schedule of chiller
22. No of boilers, model, Mac
23. Type of boilers
24. Working principle of boilers
25. Capacity of boilers
26. Chemicals used in boilers
27. Water and steam line of boilers