BAHIR DAR UNIVERSITY

INSTITUTE OF TECHNOLOGY FOR TEXTILE, GARMENT AND

FASHION DESIGN

iOTEX

FINAL INTERNSHIP REPORT IN KK TEXTILE P.L.C

FOCUSED ON REDUCING UNECONOMICAL RAW MATERIAL

CONSUMPTION FOR WATER BOILER IN DYEING SECTION

Conducted by:-

Luwam Bahta

ID.NO. 208/00

Advisor; Mr. Getnet Belay

February 13, 2012

Bahir Dar

Ethiopia
 DECLERATION

I LUWAM BAHTA fourth year textile engineering student have under taken my internship
experience in KK plc. from a period of October 2011 to January 2012 under the guidance of Mr.
GETNET BELAY (academic advisor) and W/ro ABEBA TAYE (company advisor).

I certify that my work is original and compiled according to the internship report writing guide
line given by the industry linkage office of the institute.

As the student`s academic advisor I certify that the internship report written by the student is her
original work and compiled according to the guide line provided by the institute (ILOI) as far as
my knowledge is concerned.

……………………………… ………………… ……………………..

Name of advisor signature date

…………………………… …………………… …………………….

Name of student signature date

 AKNOWLEDGMENT

I would like to express my deep gratitude to the institute for giving me such chance to
experience the overall practical skills and I am grateful to my Advisor Ato GETNET BELAY for
guiding me during my stay in the internship session and during working task two. I also would
like to thank everyone who has been willing to help me in the company.
 EXECUTIVE SUMMARY
In this practicum final report the overall activities took place in KK textile plc. are
described. The company has been characterized by several distinct trends in terms of its
organizational evaluation. The production process of the company follows the
conventional system practiced in every textile industries. The idea of this task is to
minimize supply expenditure occurs in the water boiling section of acrylic dyeing in KK
textile plc. Consecutively running such a scheme would destroy too much of raw
materials like furnace, labor and reprocessing time as well. Due to such reasons i have
suggested the company to find other alternatives.
 List of tables and figures

List of tables Pages

1) Table 1.1 (over all employee’s information ) 4

2) Table1.2 (number of employee (based or sex)) 4
3) Table1. 3 (education level of employee’s) 4
4) Table1. 4 (list of machinery in the blanket factories) 10
5) Table1. 5 (list of machinery in acyclic list dyed factory) 13
6) Table2. 1 (annual labor cost in the machinery ) 22
7) Table 2.2 (total annual cost of the company) 27
8) Table 2.3 (reduced annual labor cost of the company) 29
9) Table 2.4 (reduced total annual cost of the company) 30
List of the figures
1) Fig 1.1 (organization structure) 3
2) Fig1. 2 (previous blanket factory production process work flow) 7
3) Fig1. 3 (acyclic factory production process work flow ) 8
4) Fig1. 4 (new blanket production process work flow) 9
5) Fig1. 5 (panter weaving room) 11
6) Frig1. 6 (sectional warping) 11
7) Fig1. 7 (raising machine) 12
8) Fig1. 8 (water softening unit ) 12
9) Fig1.9 (dyeing machine) 14
10) Fig1. 10 (hydro extraction machine) 14
11) Fig1. 11( produced blanket at KK PLC) 15
12) Fig 1.12 (dyed acyclic yarns) 16
13) Fig1. 13 (end products store) 18
14) Fig1. 14 (dyed acyclic yarn dyes) 18
15) Fig2. 15 (bono water boiler) 20
16) Fig 2.16 (over all consumption cost during furnace oil) 30
17) Fig 2.17 (over all consumption cost during diesel oil) 31
 18) Fig2. 18 (laboratory dyeing a tool) 34

Table of contents

Chapter one……………………………………………..………………………..….1

1. Introduction…………………………………………………………………...1

1.1 Historical back ground of the company………………………………1

1.2 Management and organizational structure…………………….………2

1.3 Human resource information………………………………….……..4

1.4 Raw materials………………………………………………………….5

1.4.1 Raw materials in blanket factory…………………………..…5

1.4.2 Raw materials in acrylic dyeing factory……………………....5

1.4.3 Raw materials quality parameters……………………………..6

1.5 Overall work flows in the company…………………………………..….7

1.5.1 Previous blanket factory production flow chart………………..7

1.5.2 Acrylic factory production flow chart………………………….8

1.5.3 New blanket factory production flow chart…………………….9

1.6 List of machinery and equipment in the company……………………….10

1.7 Main products………………………………………………...................15

1.7.1 Blanket………………………………………………………..15

1.7.2 Dyed acrylic yarn…………………………………………….15

1.8 Main customers of the company…………………………………….....16

1.9 Production program…………………………………………………….17

1.10 End product acceptance………………………………………………..17

Chapter two……………………………………………………………………………..19
 2. Overall internship experience …………………………......................................................19

2.1 Reducing uneconomical consumption of raw materials

in dyeing section……………………………………..19

2.2 Objective……………………………………………...20

2.3 Problem statement……………………………………..20

2.4 Methodology…………………………………………….21

2.5 Data analysis……………………………………………..21

2.6 Proposed solution……………………………………….28

2.7 Challenges ……………………………………………..32

Chapter three…………………………………………………………..33

3. Benefits gained from the internship………………………..33

Chapter four…………………………………………………………..36

4. Conclusion and recommendation………………………….36

Reference…………………………………………………...39