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HAMS
Chapter-1
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Introduction
As a part of course curriculum of Bangladesh University of Textiles, we were send for industrial attachment for two months starting from 1st July 2012 to 31st August, 2012 to
HAMS Washing & Dyeing Ltd. During the attachment we worked as a trainee textile engineer and had to attend the official working days in general working times i.e. 9 am to 5 pm.
To enhance our University learning experience through involvement in industrial and commercial field, thus enabling us to relate theoretical concepts with practical situations;
To develop our ability to evaluate issues and situations critically and propose well considered options and solutions; To develop and enhance our professional awareness and communication skills; To provide experiences that will enable us to achieve a breadth of understanding that will form a framework or agenda for our final year of study.
The experience offered by industrial training varies. However, by the end of the placement we were expected to have substantially met most or all of the following objectives:
Undertaken problem solving activities in the workplace; Further developed my communication skills; Shown the ability to accept responsibility, work independently, manage my own time and schedule my work; Understood the constraints of a formal working environment and the benefits of team work; Appreciated the relevance of my academic work and have applied this to new situations; Used new tools and techniques to supplement those covered on my scheme of study;
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Acquired the experience to understand, discuss and evaluate the professional issues relating to textile engineering. Gained an understanding of which final year courses will provide the best foundation for my int ended career.
During our industrial attachment we were overseen by our industrial tutor. We kept a log of our activities during my industrial attachment in a diary supplied from our institute, which was re-checked and signed by our industrial tutor.
We were also visited by our academic professionals of different departments whom discussed about our progress with our industrial tutor. Thus we had the opportunity to learn from our academic tutors in a practical field.
A routine was maintained to meet with our head of department. Once in every 15 days we met with our head of department and discussed about solutions of some problems that we had in the industry.
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Chapter-2
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Project Description
This chapter contains general overview of the industry where we have carried out the industrial attachment.
OVERVIEW
Company Name: Company Nature: Established Date: Location: Project Cost: Total area: Man-power: Business field: Main product: sweater . Manufacturing capacity:
M/S HAMS WASHING & DYEING LTD. Privet Limited Company September, 1998 Tejgaon Industrial Area, Dhaka 57.04 Cror Tk. 20,000 Square Feet (approx.) 350 Readymade Garments Washing & Dyeing Denim long pant, short pant, overall skirt, cotton
2000 Dozens/Day
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Types of wash: o Garments Wash o Heavy Garments Wash o Pigment Wash o Sand Blasting / Spray Blasting o Tinting Wash o Stone Enzyme Wash o Sand Wash o Enzyme-Silicon Wash o Acid Wash o Bio Wash o Bleach Wash o Stone Wash o Deep Dye o Tie Dye o Silicon Wash o Whickering
Local Buying House: o Li & Fung (BD Ltd.) o Nor Wester o Pelican Resources inc. o Lindex o JC Penny o DAC Pacific o Epic Designers o Linmark o ABA Group o Auchan o Texel Ltd. o NASSA o Tex-EBO
Washing Capacity: o Dye & Tint o Enzyme Wash o Bleach Wash o Enzyme Stone Wash o Pigment Wash o Garments Wash o Enzyme Silicon Wash o Avg. All type of Wash 12000 PCs/day 15000 PCs/day 20000 PCs/day 16000 PCs/day 25000 PCs/day 40000 PCs/day 25000 PCs/day 22000-23000 PCs/day
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Major customers: o JC-Penny o Primark o Vermukt o Walmart o K-Mart o Route-66 o Fashion Traders o Auchan
Product or , Item: 1. Washing of Denim gmts 2. Washing of Knit gmts 3. Washing of sample gmts 4. Different types of Dry wash.
Sales & Marketing policy: Improvement through Research and development for better marketing. Banks: 1. Premier Bank Ltd. Gulshan Branch
2. National bank. Address: Telephone: Fax: e-mail: Web: Different departments: 190, Tejgaon I/A, Dhaka-1208, Bangladesh 9885674, 9886406(off.) 8814365, 8814923(fac.) 880-2-9881067 hfl@bdcom.com www.hamsgroup.com Sample section, Washing & Dyeing section, Drying
section, Sand Blasting section, Quality assurance section, Laboratory, Storage section. Sister Concern: HAMS Fashion HAMS Fashions Ltd. Bijoy (Pvt.) Ltd. Fashion-2000 Ltd.
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HISTORY
Md. Shafiqur Rahman, founder & managing director of this company, is a textile engineer himself who provided service for five year in garments washing and dyeing sector. In September 1998 with five local made garments washing and dyeing machine he launched M/S HAMS WASHING & DYEING LTD. The commitment was TO MAINTAIN QUALITY AND TO DELIVER TIMELY and still strongly believes it.
REMARKS: Within five years the industry earned good reputation in garments washing & dyeing sector. Now HAMS WASHING & DYEING LTD. is one of the leading garments washing & dyeing industry in Bangladesh.
The industry is now equipped with modern washing & dyeing machines. The total numbers of machine are three times than the initial set up.
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Chapter-3
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ORGANOGRAM
MAN POWER-ADMINISTRATION:
SL. No. 1 2 3 4
Designation
No . of Po st 1 1 1 1
Gender
Local
Foreign expert
ORGANOGRAM-ADMINISTRATION:
Managing Director Director (Admin.) Manager (Account) Manager (Admin.) Manager (Compliance)
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ORGANOGRAM-PRODUCTION: Managing Director Director (Production) Production Manager Asst. production manager
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ORGANOGRAM-QUALITY CONTROL:
ORGANOGRAM LABORATORY: Production Manager Machine Operator (Sample washing machine) Assistant Operator Assistant (Laboratory) Machine Operator (Sample drying machine) Assistant Operator
ORGANOGRAM MAINTENANCE:
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ORGANOGRAM FINANCE:
Responsibilities of Production Manager: To give washing & dyeing slip. To match production sample with target sample. To collect production sample for sample matching for next production. To identify disputed garments & report to director. Also execute overall floor works. To maintain loading & unloading record. Any other assignment given by higher authority.
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Chapter-4
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Machine Description
There are three (3) sample washing machines and fifteen (15) industrial machines in washing section, seven (7) guns in sand blasting section, one (1) sample drying and twelve (12) industrial drying machines in drying section, four (4) hydro extractors in hydro extraction section. There is a modern sample washing machine, a modern industrial washing machine in washing section and a modern hydro extractor in hydro extraction section. The industry is in the process of upgrading its existing machines. Specifications of some incoming machines are also given in this chapter.
SAMPLE WASHING MACHINES No. of machines: 03 Specifications: Capacity: 30 kg Inner Cylinder: 28X34 Thickness of inner drum: 3mm Outer Cylinder: 34X40 Motor (HP): 1HP, 0.75KW Power Consumption: 2.3 Amp Steam Consumption: 2 HP, 31 Kg Water Inlet: 2, 1 way in. Steam Inlet: 1, 1 way in. Water Discharge: 3, 1 way out. Manufacturing company: Bengal Heavy Electric Engineering. Manufacturing country: Bangladesh. Features: Single door design for general washing, sample washing. Machine body and essential parts are made of stainless steel. Preset front and backward rotation.
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Conventional machine. INDUSTRIAL WASHING MACHINES No. of machines: 10 Specifications: Capacity: 200 kg Inner Cylinder: 42X88 Thickness of inner drum: 3mm Outer Cylinder: 54X960 Motor (HP): 10HP, 7.5KW Power Consumption: 17 Amp Steam Consumption: 15 HP, 230 Kg Water Inlet: 2, 2 ways in. Steam Inlet: 1, 2 ways in. Water Discharge: 3, 2 ways out Manufacturing company: Bengal Heavy Electric Engineering. Manufacturing country: Bangladesh. Features: Single door design for general washing, sample washing. Machine body and essential parts are made of stainless steel. Preset front and backward rotation.
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MORDERN SAMPLE WASHING MACHINES No. of machines: 01 Specifications: Capacity: 35 kg (Dry: Wet =1:10) Inner cylinder: 950 mm dial X 500mm Wash motor: 0.75 KW Extract speed: 200 RPM Main door opening: 500 mm dial Water connection consumption: 25 mm dial, 120 litres. Drain: 75 mm dial, 1 way out Steam connection consumption: 15 mm dial, 25 Kg/hr. Electric heating: 12 KW Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H) Manufacturing company: STEFAB INDIA LIMITED Model no: LXS 35. Manufacturing country: India. Features: Single door, front-loading, open pocket. Machine body and essential parts are made of stainless steel. Automatic timed. Auto reverse. Automatic 5 water level & auto digital temperature control. Electric solenoid water & steam valves. Non-clog motorised drain valve. Full electric protection.
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MORDERN INDUSTRIAL WASHING MACHINES No. of machines: 01 Specifications: Capacity: 280 kg (1:10) Inner cylinder: 1750 mm dial X 1180mm Wash motor: 7.5 KW Extract speed: 130 RPM Main door opening: 1000 mm dial Inspection door opening: 300 mm dial Water connection consumption: 50 mm dial, 960 litres. Drain: 115 mm dial, 2 ways out Steam connection consumption: 25 mm dial, 200 Kg/hr. Thermal fluid connection consumption: 1.5 X 1.5 BSP, 80000 KCAL/Hr. Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H)
Manufacturing company: STEFAB INDIA LIMITED, Model no: LXS 280. Manufacturing country: India. Features: Single door, front-loading, open pocket. Machine body and essential parts are made of stainless steel. Automatic timed. Auto reverse. Automatic 5 water level & auto digital temperature control. Electric solenoid water & steam valves. Non-clog motorised drain valve. Full electric protection.
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HYDRO EXTRACTORS No. of machines: 03 Manufacturing company: Tongxin Ltd. Manufacturing country: China. Features: Due to its solid constructions it can be positioned onto firm floorings to operate. It has excellent electrical layout in prevention of electricity leakage, shock, which is important in wet conditions in the operations. Machine operations are made easy, with convenient start-stop operations for maximum efficiency. The inner stainless steel is well balanced, thus achieving longer life span and assuming energy efficiency of machine. Shock absorbers are well paced in the three suspension points to reduce vibrations. Stainless steel constructions in major parts ensure durability. Specifications: Model no: SHE-42 Capacity: 280 LBS Inner cylinder: 1067dial X 419mm Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H). Wash motor: 7.5 KW Extract speed: 860 RPM
MODERN HYDRO EXTRACTORS No. of machines: 01 Manufacturing company: STEFAB INDIA LIMITED, Manufacturing country: India. Features: Full stainless steel outer drum and inner basket. Strong welded construction. Basket can be dismantled without dismantling outer casing. Electrically interlocked top lid stops the machine when opened. Three position drain connection. Outer casing mounted on heavy galvanised plate base frame. Long rust free life and strength.
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Direct drive. Basket is directly mounted on to a specially designed high torque heavy-duty motor resting on spigot of the base frame with built-in rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick selfbalancing. Noiseless & vibration less operation. Automatic timed. Automatic DC injection for braking. Safety devices against single phasing reverse phasing & motor overload. Great convenience & safety. No foot pedals, no levers, no brake liners, no maintenance.
Specifications: Model no: HX 50 Capacity: 80 Kg Inner cylinder: 1000dial X 300mm Volume: 235 Litres Basket speed: 750 R.P.M. Wash motor: 7.5 KW Drain: 75 mm dial Overall dimension: 1250mm(W) X 1550mm(D) X 1150mm(H)
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SAMPLE DRYING MACHINES No. of machines: 01 Specifications: Capacity: 18 Kg Basket size: 700 mm (dial) X 470 mm Volume: 180 Litres Dry clean motor: 0.37 KW Extract motor: 1.5 KW Extract speed: 220 rpm Loading door opening: 400 mm (dial) Base tank capacity: 250 Litres Filter tank capacity: 250 Litres Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H) Manufacturing company: STEFAB INDIA LIMITED, Manufacturing country: India. Features: Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body not painted. Long rust free life and sheen. Built in solvent filter housed in the top tank receives soiled from the base tank through a powerful centrifugal pump which pushes the soiled solvent through several fine mesh cylindrical filters for reuse. Maximum recovery of clean solvent. Low spin extract. Separate motors for dryclean & extract. Vibrationless during extraction. Low spin extract makes articles lighter to unload. No solvent dripping. No wastage of solvent. Automatic timed. Auto reverse. Full electrical protection against single phasing & motor overload. Operators convenience & machine safety. Efficient cleaning.
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No. of machines: 11 Specifications: Capacity: 35 Kg Basket size: 950 mm (dial) X 500mm Volume: 350 Litres Dry clean motor: 0.75 KW Extract speed: 200 rpm Loading door opening: 500mm (dial) Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H)
Features: Stainless steel inner cylinder and large S.S. loading-unloading door. Outer body painted. Low spin extract. Vibration less during extraction. Low spin extract makes articles lighter to unload. Automatic timed. Full electrical protection against single phasing & motor overload. Operators convenience & machine safety. Efficient cleaning.
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INDUSTRIAL WASHING PROCESSING & DYEING MACHINES No. of machines: 06 Specifications: Capacity: 280 kg (1:10) Inner cylinder: 1750 mm dial X 1180mm Wash motor: 7.5 KW Extract speed: 130 RPM Main door opening: 1000 mm dial Inspection door opening: 300 mm dial Water connection consumption: 50 mm dial, 960 litres. Drain: 115 mm dial, 2 ways out Steam connection consumption: 25 mm dial, 200 Kg/hr. Thermal fluid connection consumption: 1.5 X 1.5 BSP, 80000 KCAL/Hr. Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H) Manufacturing company: STEFAB INDIAL LIMITED, Manufacturing country: India.
Features: Single door, front-loading, open pocket. Machine body and essential parts are made of stainless steel. Automatic timed. Auto reverse. Automatic 5 water level & auto digital temperature control. Electric solenoid water & steam valves. Non-clog motorised drain valve. Full electric protection.
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HYDRO EXTRACTOR MACHINE: No. of machines: 01 Specifications: Model no: HX 50 Capacity: 80 Kg Inner cylinder: 1000dial X 300mm Volume: 235 Litres Basket speed: 750 R.P.M. Wash motor: 7.5 KW Drain: 75 mm dial Overall dimension: 1250mm(W) X 1550mm(D) X 1150mm(H) Manufacturing company: STEFAB INDIA LIMITED, Manufacturing country: India. Features: Full stainless steel outer drum and inner basket. Strong welded construction. Basket can be dismantled without dismantling outer casing. Electrically interlocked top lid stops the machine when opened. Three position drain connection. Outer casing mounted on heavy galvanised plate base frame. Long rust free life and strength. Direct drive. Basket is directly mounted on to a specially designed high torque heavy-duty motor resting on spigot of the base frame with built-in rubber buffer cushion for self-balancing. No v-belts, no speed loss, quick selfbalancing. Noiseless & vibration less operation. Automatic timed. Automatic DC injection for braking. Safety devices against single phasing reverse phasing & motor overload. Great convenience & safety. No foot pedals, no levers, no brake liners, no maintenance.
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INDUSTRIAL SAND-BLASTIG GUNS No. of machines: 07 Specifications: Model: SBT-650 Capacity: 200 Litres Dimension: 800mm X 1000mm X 1250mm Sand contains: 200 Kg Manufacturing company: Made in China Features: Single door design for general washing, sample washing. Machine body and essential parts are made of stainless steel. Preset front and backward rotation.
OTHER COMPONENTS/ACCESSORIES
No. of cabinets: 07 Hopper (for controlling dust in cabinets): 02 Helmet: 07 Pcs Musk: 07 Pcs Gloves: 07 pairs. Air preserver-1, capacity of 2000 c.c. Air preserver-2, capacity of 900 c.c.
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OTHER MACHINES Spray machines: 03 Nos. Manufacturing country: Hong Kong Compressor: 03 Nos. Two compressors with same following specifications. o Brand: ELGI o Capacity: 10 Jule/Bar o Made in INDIA One compressor with following specifications: o Brand: OSD o Made in ITALY o Includes Change Over o MCCB o Capacity: 10 Jule/Bar Boiler: Brand name: Sacca
Manufacturer: Made in ITALY Production capacity: 1.5 Tons/Hr. Pressure: 7.5 Jule Bar (5.0 Bar used) Supply system: Automatic Pressure control. Chimney: 50 Feet with 12-inch diameter.
Generator Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta" production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI) alternators. All alternators are three phase, four pole, single bearing, synchronous type, cosj=0.8, 50Hz.
Water supply pump: 03 Nos. 02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse Power. 01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power.
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REMARKS No live industry can keep place with the advance of technology without continuous renewal & transformation of its production facilities. Existing equipments must be kept on the defensive, compelled always to justify its tenure against the challenge of new & more modern machines. If any piece of existing equipment fails to meet this challenge, it must be displaced, regardless of its age or condition & regardless of whether it is physically worn out. Keeping the above in view, this industry is always replacing its existing machines in order to increase productivity & improve quality.
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Chapter-5
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Raw materials
Different sections of the industry require raw materials i.e. chemicals of various types in different quantity. Most of the chemicals are purchased locally. A few are imported directly.
Caustic Soda (NaOH) Type Unit price Source Uses : Alkali : Taka 24 per Kg : Clariant ( Switzerland ) / Dystar ( Germany ) : (Neutralize acidic materials, saponify glycerides (waxes and oils), solubilize silicate Monthly requirements : 4050 kg (approximately)
Soda Ash (Na2CO3) Type Unit price Source Uses : Alkali : Taka 14 per kg : Dystar ( Singapore ) / Clariant ( Germany ) : Used to alkaline the solution/medium. Control PH
Monthly requirements : 2000 kg (approximately) Wetting agent: Type Unit price Source Uses : Combination of Detergent & Surfactant : Taka 150 per kg : Clariant ( Switzerland ) / Dystar ( Germany ) : Emulsify oils, fats and waxes; remove oil-stains; Suspend materials after they have been removed. Reduce surface tension & minimize inter facial tensions. Monthly requirements : 2000 kg (approximately) Anti-back Type Unit price : Anti back staining agent : Taka 175 per kg
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Source Uses
Monthly requirements : 2000 kg (approximately) Acetic Acid Type Unit price Source Uses : Organic acid : Taka 70 per kg : Clariant ( Switzerland ) / Dystar ( Germany ) : Used to make solution/medium acidic. Control PH
Monthly requirements : 1000 kg (approximately) Sodium Hypo Chloride (NaOCl) Type Unit price Source Uses : Oxidizing agent : Taka 18 per kg : India, China : Used to uniform lightening of the colour of the indigo or sulphur dyed garments in bleach wash. Monthly requirements : 1500 kg (approximately) Bleaching Powder [Ca (OCl)Cl] Type Unit price Source Uses : Oxidizing agent : Taka 21 per kg (KCI, 33% Chlorine), Taka 105 per kg (Japan, 65% Chlorine) : Clariant ( Switzerland ) / Dystar ( Germany ) : Used to decolouration of fabric
Monthly requirements : 3590 kg (KCI), 142 (Japan) (approximately) Enzyme Type Unit price Source Uses : Enzyme : Taka 300 per kg (liquid), Taka 400 per kg (powder) : Clariant ( Switzerland ) / Dystar ( Germany ) : Used to breaks down the long starch molecular chain into smaller sections, that can be easily washed from garments. Monthly requirements: 1500 kg (liquid), 1000 kg (powder) (approximately)
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Silicon Type Unit price Source Uses : Softener : Taka 130 per kg : Clariant ( Switzerland ) / Dystar ( Germany ) : Creates the fabric surface oily/ used for lubrication
Monthly requirements : 500 kg (approximately) Softener Flax Type Unit price Source Uses : Softener : Taka 105 per kg : Clariant ( Switzerland ) / Dystar ( Germany ) : Soften fabric handling
Monthly requirements : 500 kg (approximately) Potassium Permanganate Type Unit price Source Uses : Decolouration agent : Taka 80 to 370 per kg : India, Bangladesh : Used to decolouration of fabric
Monthly requirements : Locally purchased when required. Sodium Meta bi Sulphate Type Unit price Source Uses : De-chlorination agent : Taka 28 per kg : Clariant ( Switzerland ) / Dystar ( Germany ) : Used to neutralize activity of chlorine on fabric/solution Monthly requirements : 475 kg (approximately)
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Peroxide (H2O2) Type Unit price Source Uses : Oxidising agent : Taka 35 per kg : Clariant ( Switzerland ) / Dystar ( Germany ) : OH- ions destroy the colouring material and improve whiteness Monthly requirements: 1000 kg (approximately)
Common Salt Type Unit price Source Uses : Salt : Taka12 per kg : Clariant ( Switzerland ) / Dystar ( Germany ) : Used as electrolyte for solution, improves shining of fabric. Monthly requirements : 2200 kg (approximately)
The following raw materials are used in garments dyeing in addition to some of the raw materials already listed above.
Dyestuff o Type : Direct dye o Unit price: Taka 300-1200 per Kg o Source: Clariant ( Switzerland ) / Dystar ( Germany ) o Use: Cotton & Viscose garments dyeing. o Monthly requirements: Depends on ordered quantity. o Type: Reactive dye o Unit price: Taka 275-850 per Kg. o Source: Clariant ( Switzerland ) / Dystar ( Germany ) o Use : Cotton & Viscose garments dyeing. o Monthly requirements: Depends on ordered quantity. o Type : Pigment dye
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o Unit price: Taka 300-500 per Kg o Source: Clariant ( Switzerland ) / Dystar ( Germany ) o Use: Cotton & Viscose garments dyeing. o Monthly requirements: Depends on ordered quantity.
Glauber salt o Type : Salt o Unit price: Taka 14 per Kg o Source: Bangladesh o Use: Levelling agent. o Monthly requirements: Depends on ordered quantity.
Fixing Agent o Unit price: Taka 500 per Kg o Source: Clariant ( Switzerland ) / Dystar ( Germany ) o Use: Colour fixation. o Monthly requirements: Depends on ordered quantity.
Dispersing agent o Unit price: Taka 500 per Kg o Source: Clariant ( Switzerland ) / Dystar ( Germany ) o Use: Assists in the process of particle size reduction of dye. o Monthly requirements: Depends on ordered quantity.
REMARKS
The monthly requirements of raw materials vary depending on the type of washing & ordered quantity. Sometimes the price of the materials also varies due to the availability of the materials in the market.
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Chapter-6
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Batching Pre-treatment Dyeing Sample Check Hydro Extraction Drying Quality Control Storage
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PROCESS TECHNIQUE OF SOME WASHING & GARMENTS DYEING METHODS NORMAL WASH: Batch 60 PCs. Liquor 400 Litre
Step 01 Desizing
Water is added (400 Lt) Garments are added Machine started running 200 gm Detergent added Temperature raise to 60C Time 5-10 minutes Drop the liquor Add water and cold wash
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Step 02 Softening
Water is added (400 Lt) Garments are added Machine started running 240 gm Softener added Temperature Cold Time 5-10 minutes Drop the liquor Unlaod garments on trolley
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Load the garments on m/c R.P.M 700-900 Time 3-5 minutes Unload the garments on trolley Unload the garments Trolley
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Step 04 Drying
Load the garments on dryer m/c Temp 60- 70C Time 40-50 minutes Time 10-15 minutes for cold dry Unload the garments Quality checking
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Step 01 Desizing
Water is added (400 Lt) Garments are added Machine started running 500 gm Soda Ash added 500 gm Caustic Soda added 200 gm Bio. D added Steam to raise temp 60C Process time 25 minutes Drop liquor Wash down twice
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Water is added (400 Lt) Machine started running 200 ml liquid, 400 gm powder type Enzyme added 150 ml Acetic Acid Added 200 gm Anti back added 10 Kg Peumic Stone added Steam to raise temp 50C Process time 60 minutes Drop liquor
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Step 03 Bleaching
Water is added (400 Lt) Machine started running 4 Kg KCI (35% Cl2) added 500 gm Soda Ash added Steam to raise temp 60C Process time 10 minutes Drop liquor
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Water is added (400 Lt) Machine started running 500 gm Hypo sulphide added Steam to raise temp 45C Process time 10 minutes Drop liquor
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Step 05 Tinting
Water is added (400 Lt) Machine started running 0.02% Direct Brown GTL & 0.01% Direct Black V-200 added 4 Kg Salt added Steam to raise temp 70C Process time 20 minutes Check Shade Drop the liquor
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Step 06 Drying
Garments are then taken out Hydro extracted Send to dryer for drying of garments.
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Step 01 Desizing
Water is added (400 Lt) Garments are added Machine started running 320 gm Detergent added 320gm Caustic soda added Temperature raise to 60C Time 20-60 minutes Drop the liquor Add water and cold wash
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Add water 300 lit Temperature cold Acetic acid 150gm added Time 5 minutes
Step 02 Softening
Water is added (400 Lt) Garments are added Machine started running 240 gm Softener added 200gm Acetic acid added 160gm silicon softener added Temperature Cold Time 15 minutes Drop the liquor Unlaod garments on trolley
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Load the garments on m/c R.P.M 700-900 Time 3-5 minutes Unload the garments on trolley
Step 04 Drying
Load the garments on dryer m/c Temp 60- 70C Time 40-50 minutes Time 10-15 minutes for cold dry Unload the garments Quality checking
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Step 01 Desizing
Water is added (400 Lt) Garments are added Machine started running 320 gm Detergent added 320gm Caustic soda added 600gm Soda ash added Temperature raise to 60C Time 20-60 minutes Drop the liquor Add water and cold wash
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Step 02 Softening
Water is added (400 Lt) Garments are added Machine started running 240 gm Softener added 200gm Acetic acid added 160gm silicon softener added Temperature Cold Time 15 minutes Drop the liquor Unlaod garments on trolley
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Load the garments on m/c R.P.M 700-900 Time 3-5 minutes Unload the garments on trolley
Step 04 Drying
Load the garments on dryer m/c Temp 60- 70C Time 40-50 minutes Time 10-15 minutes for cold dry Unload the garments Quality checking
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Step 01 Desizing
Water is added (500 Lt) Garments are added Machine started running 400 gm Soda Ash added 400 gm Caustic Soda added 200 gm Bio. D added Steam to raise temp 60C Process time 20 minutes Drop liquor Wash down twice
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Water is added (500 Lt) Machine started running Steam to raise temperature 40C Process time 5 minutes Drop liquor Take out the garments Hydro extract the garments Dry the garments
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Load the pre-treated & dried garments in another washing machine Machine started running Add stones soaked with potassium per magnate double the volume of garments Continue machine running for 7 minutes Unload the garments from the machine
Load the garments into another washing machine Water is added (500 Lt) Machine started running 1.5 Kg detergent is added Steam to raise temp 50C Process time 15 minutes Drop liquor
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Water is added (500 Lt) Machine started running 500 ml Auxalic Acid added Process time 5 minutes Check Shade Drop the liquor Garments are then taken out Hydro extracted Send to dryer for drying of garments.
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COTTON GARMENTS DYEING PROCESS (Sample Dyeing) Batch 1.4 Kg Liquor 14 Litre
Step 01 Desizing
Water is added (14 Lt) Garments are added Machine started running 500 gm Soda Ash added 500 gm Caustic Soda added 100 gm Bio. D added Steam to raise temp 80C Process time 45~60 minutes Drop liquor
Water is added (14 Lt) Machine started running Steam to raise temperature 50C Process time 5 minutes
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Drop liquor
Step 03 Scouring & Bleaching Start machine running Added 1 litre H2O2 50 gm Stabiliser added 150 gm Soda Ash added 250 gm Caustic Soda added 100 gm Bio-D added Process temp 80 C Process time 90 minutes Drop the liquor Water is added 14 litre
Water is added (14 Lt) Machine started running Steam to raise temperature 50C Process time 5 minutes
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Drop liquor
Water is added (14 Lt) Machine started running 200 ml Acetic Acid added Process time 5 minutes Drop the liquor
Step 06 Dyeing
Water is added (14 Lt) Start machine running 560 gm Salt is added Reactive dye (T. Blue. G) - 0.2% & Drimerine Blue K2RL-0.03% is added 20% Soda Ash is added Processing temp 80 C Processing time 60 minutes Drop the liquor
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Step 07 Washing
Water is added (14 Lt) Machine started running 1 % Detergent is added Steam to raise temperature 50C Process time 10 minutes Drop liquor Again Add water of 14 litre Process time 5 minutes Drop liquor Unload the Garments Hydro extractor Drying
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Dry process Hand scraping Sand blasting Whiskering Grinding Destroy P.P spray Resin application Wrinkle (permanent) Overall wrinkle Laser draw
Hand Scraping: Hand scraping is generally being done in rigid form of garments to get distress look. Locations can be front thigh & back seat or it can be over all as per standard. Emery paper is being used to scrape the garments in particular placement & design.Emery paper comes in different number generally starts from 40 till 600 and above, higher the number finer the emery paper, lower the coarseness of the paper. In garments industry from 220, 320& 400 numbers papers are most popular & widely used. The most important factor is to select right number of paper according to the fabric strength & intensity need. Scraping can be done on inflated rubber ballons for better effect (horizonta or vertical its up to operators convinence),even it can done plain wooden board of garments size & hand pressure should be uniform in order to get better results. Sand Blasting Sand blasting is recently popular dry process. It is a mechanical process by which we can fadding effect/old looking effect on heavy garments like denim, twill etc by the action of aluminium oxide which looks like sand. Sand blasting is applied on specific area of a garments.Sand blasting is performed with combine the wash like bleach wash, enzyme wash,normal wash, stone wash & tinting/over dyeing.
Process of sand blasting: The garments to be sand blasted are placed on the bed in a closed chamber Aluminium oxide is very hard, fine, sharp. Aluminium oxide through by gun with dry air to perform sand blasted action. The gun has a switch to start and stop the flow of aluminium oxide. The flow of aluminium oxide on fabric is done at an angle 10-20 degree. Higher the blowing angle higher the fadding effect. Sand blasting is a hazardous process and its area is isolated from other producion areas. Producion per gun per hour varies from 25-50 garments, depending on the area. After prodution chemical treatment are required as per buyer requirements.
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Operator should wear protective wear includes glass,helmet,gloves,uniform,masks etc. Whiskering: We need a rubber board. Design should be placed on rubber board. Then the board is placed inside the garments Hand rubbing is done on the upper side of the garments. After wash design produced. It may be rectangular or circular. Wet wash is must. Grinding: Grinding is done on pocket edges & bottom hems edges by running against abrasion surface or stone to achieve worn out effect. Many different make of machines & pen grinding tools are avilable in the market which runs with pneumatic system.
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Destroy: One o the most popular distressing effect currently. Destruction is an art which makes denim look unique and used. To make destruction pen type stone tools being used in mid of wash process to apply on desired area. It can also be achieved by cutting it through knife the warp yarns & keep the weft yarn as is to show white thread. Holes can also be made by cutting weft & warp yarns. These are manual processes & every garments will look unique & different than others.
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P.P Spray: PP spray is done on denim garments to achieve local abraded area to appear whiter than back ground indigo color shade. This can be applied by spray gun or by towel dipped into pp solution & rubbed on desired area followed by neutralization in wet wash process. This process sone in rigid after doing hand scrape or in the middle of the wash. Doing after bleach or enzyme cycle will give more natural & whiteb effect than doing in rigid form. There are many additives that can be added in order achieve desired intensity and out look. The same way bleach solution can also be spray or rubbed on the garments on desired area. But this process is more complicated & neeed high skilled operator to execute it followed by immediate neutralization. There are many parameter to control during pp spray or bleach spray spray gun pressure, width of spray,flow and way of spraying.
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Resin Application: Resin being used for achieving 3D effect,rigid look,etc. this process can be done by spraying or dipping the garments into resin ,catalyst,silicone,PU solutionin right combination according to the fabric strength & desired effect needeed. After aplication of resin solution in right proportion,make manual desinig as needed on the thigh hip & back knee area to get 3D effect. After making it , it should be dried with hot press or by hairb dryer & then must be cured in woven at right temperature , time as mentined in resin product manual.
Permanent wrinkle: This is one of the most popular dry process recently and being done on front thigh, front knee, back knee. Resin is applied on the required area where wrinkle is to be done. Then garments is squeezed by machine or by hand and clip is placed on the dsign to keep in riginal design. Then garments with the resin is kept in woven for half an hour for permanency of wrinkle. Next wet is done as per buyer demand.
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Laser Draw: Wrinkle effect or burn out effect is produced by laser ray. If the production area of wrinkle is more than laser draw is done on the required area of the garmnets. The effect is produced by burning out the fibre of garments surface. The system is controlled by computer. The required design is kept inside computer. There is a chamber where garments are placed to get the required effect. There is also a switch controlled by oprator to controll laser draw and to get desired design on desired area.
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PRODUCTION REPORTS
Date:05.08.2012 Sl. No. Name of Buyer Name of Garments Order/ Style no. Types of Process Total received (pcs) 17745 4129 5100 18935 19576 8696 7990 7628 1200 5793 2934 7404 5903 5155 4527 3767 798 2932 1500 4506 3769 Delivery Amount (pcs) 14899 778 3576 15127 15679 8124 7191 5500 Balance (pcs)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Snoopy Snoopy Caree Four Etam Caree Four Etam Texel Texel Primark RN RN Nor Wester Nor Wester Nor Wester
Utah Washing Yoke Design Tusuka Fashion Aba Fashion Aba Fashion Export Knit Sportx Gmts. Sportx Gmts. Universal Sha Sha Gmts. Sha Sha Gmts. Leader Gmts. Leader Gmts. Fasnoor Gmts.
Sand Blast G-21 100341/2 Sand Blast + Bleach Rewash Enzyme Silicon Enzyme Silicon 6094619 100093 100093 52510 1161R 8488 25021X Z 25027X Z 25069X Z Enzyme Silicon Enzyme + Dyed Enzyme Wash Sand Blast + Dyed Sand Blast + Dyed Sand Blast + Enzyme Sand Blast + Enzyme Sand Blast + Enzyme Enzyme Silicon Silicon Wash
2846 3351 1524 3808 3897 572 99 2128 1200 2029 2136 3122 4633 649 758 3275
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Chapter-7
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Maintenance
Maintenance is considered as important as other engineering functions. It makes responsible for provision of a condition of machines, buildings and services that will permit uninterrupted implementation of plans requiring their use.
OBJECTIVES OF MAINTENANCE: To keep the factory-plants, equipments, machine tools etc. in an optimum working conditions. To ensure specified accuracy to products and time schedule of delivery to customers. To keep the down time of machines to the minimum thus to have control over the production program. To keep the production cycle with in the stipulated range. To modify the machine tools to meet the augmented need for production. To improve productivity of existing machine tools and to avoid sinking of additional capital. To reduce the maintenance costs as for as possible thereby leading to a reduction in factory overheads. To prolong the useful life of the factory, plant and machinery, while retaining their acceptable level of accuracy of performance thus avoiding or prosponding incurring of heavy capital expenditure involved in their replacement.
ECONOMIC CONSIDERATION OF MAINTENANCE It is very profitable activity & ensures maximum productivity at minimum costing. It improves product quality. It ensures less time to produce a specific product. It improves machine accuracy. It maintains a long life of the machine. No chance of back order.
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Inspection or Check-Ups: External inspections: Watching and detecting defects form abnormal sound, vibration, heat, smoke etc when machine is in operation. Internal inspections: Inspection of parts such as gears, bushes, bearings, tolerances in the parts etc. when machine is under pre-planned shutdowns. Inspections of important machines: Machines, which can disrupt whole of the production, are delicate and require much time for the repair. Attentions are given for inspection of these machines and schedule for inspection, cleaning lubrication are done rigidly. Inspections of ordinary machines: Frequency of inspection of ordinary machines is kept as low as they do not affect the production.
Lubrication: Mechanical components like gears, bearings, bushes and other friction surfaces etc. give good performance for long periods when they are systematically lubricated. Systematic lubrication means the application of right type of lubricants at the right time, at right place and in right quantity. For lubrication, a lubrication schedule should be prepared and that should be followed strictly. Here lubrication is done whenever is needed.
Planning and scheduling: Every preventive maintenance work should be pre-planned in detail on the basis of the analysis done on the past records. A scheduled programme thus prepared should be followed strictly. Thus programme should be in detail specifying the point-requiring daily, weekly, monthly, half yearly or yearly attention.
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Records and analysis: Good record keeping is essential for good maintenance, as it helps in for casting maintenance. For this purpose following records are generally maintained: Operation manual Maintenance and instruction manual History Cards and History Registers Spares Procurement Registers Spare Procurement Register Inspection Register Log books Defect Register etc.
Training of Maintenance personnel: For the success of maintenance a sound training is essential for the maintenance personnel. Hence the technicians and supervisors are trained to carry out maintenance, inspection and repaired in a systematic way.
Storage of Spare Parts: Sometimes machine remains idle for want of spare parts for considerable time and thus it affects considerable loss of production. Hence it is essential to keep the spare parts so as to avoid loss of production.
Maintenance practices are made from the following ways: Capital replacement: capital replacement is undertaken if analysis reveals that the retention of equipment no more remains an economical proposition. Provision of stand-by-capacity: Stand by capacity is often provided for items of equipment that we are critical to production. It is sometimes an economical maintenance practice to install such spare capacity to be put into operation while the original unit is under repair or is over-hauled. Break-down maintenance: Break-down maintenance practice allows a machine or any other facility to run without much of routine attention, till it actually breaks down to be then put back into commission. Scheduled maintenance: Scheduled maintenance system provides for inspection, overhaul lubrication, and servicing of certain machines at predetermined dates. Over-
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hauling of machines, cleaning of tanks and white washing of buildings is normally done in this manner. Planned maintenance: Planned maintenance visualise the work contained in a future job determines the best method to be adopted and skills required for its execution; estimates the time, material and costs involved assigning jobs to individuals; programmes the work to specific time periods on the basis of priority and after ascertaining production requirements; arranges for availability of material tools and man-power and for release of machines in time. Preventive maintenance: It consists of routine actions taken in a planned manner to prevent breakdowns and to ensure operational accuracy to the extent it is economically and practically possible to do so.
Tools Measuring Tape Hammer Screw Driver (flat type) Screw Driver (Phillips head) Pliers Nose Pliers Wrench (Locking adjustable) Wrench (Pipe) Wrench (Double head open end) Wrench Hacksaw Chisels (cold, flat point) Table vice File Mobil Gun Wielding Machine Hand Grinding Machine Fixed Grinder
Nos. Specifications 02 Both British and Metric system measurement. 01 It is just a weighted head and a handle that directs its course. 02 10 steel shank, with flat blade and plastic handle. 01 8 steel shank, with star blade and plastic handle. 01 01 02 03 06
Uses Mostly used for linear measurement The Hammer is very simple striking tool. To loosen or tighten screws. To loosen or tighten screws
01 01 01 01 01 01
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Hand drill
01
Chapter-8
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Utility Services
Man, Machine and Material, the three main things that can accelerate the production, if it is used in proper and organized way. In the Industry, UTILITY plays an important role in case of production. Production and profit are closely related. In order to get a qualityfinished product, it needs fresh raw materials as well as effective manpower and machinery in good working condition. Utility is closely related to the three M's plays a vital role to maximize the production as well as profit.
FUNCTIONS OF UTILITY
Utility ensures power supply by generator. Utility ensures water supply by pump. It ensures steam by boiler. It ensures compressed air handling by vacuum planning system. It provides fuel and gas supply. It provides workshop facilities.
AVAILABLE UTILITIES
The following utility facilities are available at HAMS WASHING & DYEING LTD. Water. Steam. Electricity. Gas. Compressed air. Covered Van for Transportation.
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SOURCES OF UTILITIES
Water: Own Supply (Pump) Steam: Own supply (Boiler) Electricity: Generator & PDB Gas: Titas Gas Transmission & Distribution Co. Ltd. Compressed Air: Own supply (Air compressor)
WATER: Water is supplied by pump. Pump supplies water on the basis of pressure. Pump pressure ranges 0-10 bar. The pump is operated at 2-4-bar pressure. 3 motors are used for uniform water supply. These are automatic on-off system motor. When the pressure is reduced to the desired level (2 bars) then the motor is turned on. Similarly when the pressure is above the desired level (4 bars) then the motor is turned off. So, it has variable water supply capacity & supplies water as required. The water, which is used for cooling, is brought to a tank & again supply by a pump.
There are 3 deep tube wells used in this project. Water is directly used in washing & dyeing & other subsequent process.
02 PCs. Deep Tube wells are submersible, Made in ITALY, BG brand with 30 Horse Power. 01 PC. Deep Tube well is submersible, Sigma branded, Made in ITALY with 42 Horse Power.
STEAM: Heat generation is a very important factor for washing and dyeing process. Steam is a very efficient & easy way to transfer heat. There is a boiler to generate steam. By pipe line the generated steam is supplied to the washing and dyeing
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machines & where it is necessary. The boiler has the capacity to generate steam 1.5 Tons/Hr. Technical details about the boiler: Boilers function is to transfer the heat produced by the combustion of fuel (gas) to water and ultimately to generate steam. Brand name: Sacca Manufacturer: Made in ITALY Production capacity: 1.5 Tons/Hr. Pressure: 7.5 Jules Bar (5.0 Bar used) Supply system: Automatic Pressure control. Chimney: 50 Feet with 12-inch diameter.
ELECTRICITY: It is totally impossible to continue the production without electricity. A frequent supply of electricity is very essential for soundless production. Here all the machines in washing and dyeing section are provided electricity by the govt. electricity with own standby generator of the industry.
Technical Details about the Generator:Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta" production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI) alternators. All alternators are three phase, four pole, single bearing, synchronous type, cosj=0.8, 50Hz.
Rated power Voltage AlterDiesel engine Dimensions Weight nator specification KVA KW V LxWxH cm Kg E275VM 275 220 400/230 MA "VOLVO" TWD1210G, 2400 300x110x192 6 cyl., turbocharg
Model
Electric Substation: o 500 KVA Transformer (11 KV to 440 KV) Brand: Power man Three phase Rated power: 500 KVA
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Standard: Bs-171 Class: A Rated Frequency: 50 Hz Type of cooling: ONAN AMBIENT Temperature: 50C Duty: Continuous. Voltage: 11000 Volt (HT) 415 (LT) Rated Current: [HT - 26] [LT - 695] AMP Vector group Dyn 11 Impedance Voltage: 0.5% Total Weight: 179 Kg Lift able Weight: 990 Kg Oil Weight: 610 Kg Winding Temperature: 55C Manufacturing Year: 2003 Made in Bangladesh.
o High Tension Switch. o Switch Gear Brand: Power Man Voltage: 415 Volt, 50 Hz Phase: 3 Phase, 1 Neutral Incoming: 800 AMP MCCB/ACB Made in Bangladesh
o MCCB (Magnetic Contact Current Circuit Breaker) o PFI (Power Factor Improvement Plant, 6 step auto control) Brand: Power man Rating: 200 KV Voltage: 415V, 50 Hz
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Compressor: Two compressors with same following specifications. o Brand: ELGI o Capacity: 10 Jule/Bar o Made in INDIA One compressor with following specifications: o Brand: OSD o Made in ITALY o Includes Change Over o MCCB o Capacity: 10 Jule/Bar
Fire Fighting Tools: o Washing section: 10 Nos. Fire Extinguisher Air Dryer: o For Compressor: 3 Nos. Cover Van: o 3 Cover Van used to carry garments. Gas: The company gets natural gas from Titas Gas Transmission & Distribution Co. Ltd. Capacity of gas line is variable ie. line able to supply gas according to the requirements.
COST OF UTILITIES
Water: Own supply (Pump) Electricity Required- 46 KW/Hr. Cost 5 TK/KW. Steam: Own Supply (Boiler) Gas required: 670 Meter3/Hr. Cost 5.60 TK/ Meter3 (Aprox.) Compressed Air: Own Supply (Air compressor)
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REMARKS
There is problem with water supply in the company. The supply of water is not sufficient, which create problem in washing and dyeing. The quality of water is not up to the level. The hardness & presence of iron in water is high. A water treatment plant is very essential to continue the production without disturb & to increase the production. The generator of the industry is too old to supply the electricity fluently. Sometimes it trip without any warning. So, its necessary to have a new generator for the industry. The boiler also very old to maintain it high bar pressure. It should be replaced with modern boiler for better service.
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Chapter-9
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Store & Inventory Control In HAMS WASHING & DYEING LTD. there are different inventory systems for different raw materials and finished materials. DYE & CHEMICAL STORE
There is a different store for dyes & chemicals. Various types of dyes & chemicals are stored here according to the dyes & chemical company.
Different types of dyes & chemicals are listed in a sheet. In the sheet the stored quantity of dyes & chemicals are also included. Everyday the sheet is updated & a copy of this sheet is supplied to the GM (production), Dye house & lab section.
SPARE STORE
In HAMS WASHING AND DYEING LTD. required amount of spears of different machines are stored in the mechanical storeroom. All the spears are listed in a sheet, which is controlled by the mechanical & maintenance personnel. Spares are arranged in the storeroom according to their size, quantity & requirements. There are shelves in the storeroom to keep the small spare parts. FINISHED PRODUCT STORE
HAMS WASHING AND DYEING LTD. supplies its finished dyed fabrics to its garments section. So, dyed finished fabrics are stored for short time in the finishing section. All the delivered fabrics are noted on the tally khata according to the lot no, quantity, fabrics diameter, buyers name, colour& considering other technical parameters.
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OTHERS STORE
There is a central store at HAMS WASHING AND DYEING LTD. In that store the various types of forms, papers, stationary & other necessary goods are kept.
Chapter -10
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Cost analysis
Cost analysis is a crucial step for any business organization, specially if it is a manufacturing company. Here cost analysis is done in conventional method. SAMPLE COST ANALYSIS
Process
Issue Date: Buyer: Po-Style-Ref. : Type of Garments: Type of Wash: Quantity/ Machine: Weight of Total Garments: Chemicals Caustic Soda Soda Ash Bio. D Enzyme Powder Enzyme Liquid Anti Back Staining Acetic Acid Stone Bleaching (Japan) Hypo Sulphide H2O2 Bio. D Dir Brown GTL Dir Yellow Salt
10-07-2004 Nassa Pinacle 21051 Denim Long Pant Enzyme/ Bleach/ Tint 60 PCs. 62 Kg. Quantity 500 gm 500 gm 400 gm 400 gm 200 gm 200 gm 100 gm bag 500 gm 500 gm Temp Time Total 12 /= 7 /= 25 /= 152 /= 48 /= 25 /= 7 /= 212 /= 46 /= 9 /= 18 /= 12 /= 14 /= 2 /= 28 /= 617/= 678/= 135.6/=
Desizing
60C
15 min
Enzyme Wash
40C
55-60 min
50C Cold
500 gm 50C 10 min 100 gm 20gm 2 gm 50C 20 min 4 Kg Total Chemical Cost= Add 10% Wastage = Per Dozen =
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Chemical Cost in USD/Doz = Overhead Cost USD/Doz = Total Cost USD/Doz = 3.97/= ~ Profit USD/ Doz = Final Cost USD/Doz =
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Chapter -11
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Marketing Activities
MARKETING: Marketing plays a vital role in the field of displaying/showing the good criteria of the products to the buyer & to communicate with the buyer .there about 30 people in the marketing section of the industry .
Marketing Strategy :Marketing strategy is a very important factors to sale the products to the buyers If the marketing strategy Is not so developed it will be very hard to reach the goal In case of garments marketing the dealings with the buyer is a very important factor.In one Washing & Dyeing Mainly senior marketing officers ,merchandisers & higher officials deal with the buyer There are some fixed buyers of the industry. The buyers give their orders continuously all over the year. The marketing officers & by both side understanding The rate & the order quantity are fixed.
DUTIES & RESPONSIBILITIES OF MARKETING OFFICERS Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A marketing officer has some also other duties The main duties & responsibilities of a marketing officer are given below : To prepare cost sheet by dealing with buyer . To take different steps by discussing with the high officials & merchandisers . To maintain a regular & good relationship between commercial officers &
merchandisers To maintain a regular communication with the buyers & buying houses . Communicate with the new buyers . Display the better criteria of the products .
Actually the responsibilities & duties of marketing officer begins from getting order of buyer & ends after & sincere. receiving goods by the buyer So he should be always smart energetic
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CONSUMER OF THE PRODUCT HAMS Washing & Dyeing Ltd. is a 100% export oriented industry. All the goods produce in this industry are exported to various country .
Product Label: Product label differs from fabric to fabric. The product labels are prepared according to the quality & the buyer requirements .
LOCAL MARKET HAMS Washing & Dyeing Ltd is a 100% export oriented industry. All the goods produced in this industry are exported into various foreign countries . So, goods are not supplied into local market.
MARKETING STRATEGY Marketing strategy is a very important factors to sale the products to the buyer . If the marketing strategy is not so developed , it will be very hard to reach the goal . In case of garments marketing the dealings with the buyer is a very important factor . In HAMS Washing & Dyeing Ltd. mainly senior marketing officers ,
merchandiser & higher officials deal with the buyer . There are some fixed buyers of the industry. The buyers give their orders continuously all over the year . The marketing officers & the merchandisers communicate with the buying houses to collect the orders . By both side understanding the rate & the order quantity are fixed .
REMARKS HAMS Washing & Dyeing Ltd has a well learned marketing & merchandising team. They always communicate with the buyers HAMS Washing & Dyeing Ltd has some fixed buyers The marketing section also looks for the quality & quantity of buyers .
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Chapter-12
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Compliance
Compliance: Compliance is undertaking activities or establishing practices or policies in accordance with the requirements or expectations of an external body such as ILO,ISO,WARP,ETI etc and international buyer. Benefits for business: Putting company values into action. Enhancing company reputation. mprove company requirement. Better supply chain management and performance. Benefits for workers Educating the worker to avail a better life style. More awareness about quality Better job satisfaction will be developing. Benefits for investor and customer: Identification of product made ethically Clear and credible assurance for ethical purchasing. The return will be greater on less investment Compliance with the law. 1. Fire Training: At least 20 percent of factory personnel are trained in fire safety and emergency evacuation. Certificates and pictures of fire safety and emergency evacuation training are maintained. Factory holds fire emergency drills regularly. For factories with high turnover, fire drills are held more frequently. Factory trains new employees in fire drill procedures. 2. Fire alarm: Factory has fire alarm system that is audible throughout entire facility. Fire alarm has a distinct sound from other notice systems. Alarm is tested regularly in coordination with fire drills. Factory trains all new employees about alarm system sound and procedures. 3. Emergency Exits: Factory has at least two emergency exits per floor in buildings with less than 1000 workers. At least three exits exist per floor in buildings with more than 1,000 workers. Factory ensures that the maximum travel distance to an emergency exit is 200 feet or 60 meters for unsprinklered industrial buildings.
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Exit doors are at least 28 inches, 71 cm or 2.3 feet and have a width adequate for the number of persons it must accommodate. Exit doors are not unlocked and do not have locks that require special operation. Door should open outwards. Emergency signs are visible for 30m and use letters at least 18cm high. Also, signs have bright colors are illuminated or have a photo luminescent front panel. Battery operated exit signs are checked regularly and batteries are replaced. 4. Emergency exit routes: As referenced above, factory posts diagrams/maps of emergency exit routes at various locations throughout the factory. All exit routes are at leastl 12cm wide. Exit routes are not obstructed by equipment, materials, product, etc. and are regularly checked. Two exit routes exist on opposite sides of the factory. 5. Emergency lighting: Factory has emergency lighting for all stair ways and where needed on exit routes. Lighting will last for at least 90 minutes. Factory regularity checks test-button and replace batteries immediately if needed on emergency lighting systems. 6. Electrical Wiring: Electrical cords in the factory and dormitories are in good condition and properly encased to prevent shorting or fire. Electrical equipment is grounded to prevent injury and or fire. Electrical cords are not found in damp areas of in standing water. Electrical wiring does not obstruct aisles unless they are securely taped to the floor in a manner that does not create additional hazard 7. Lighting: Factory uses a light meter to take periodic measurements of light levels in the factory and keeps a record of light levels in various work areas. Factory has minimum illumination of 30 foot-candles (300 Lux) in work areas. Factory has minimum illumination of 5 foot-candles (50 Lux) in corridors utilized as emergency routes.
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8. Ventilation: Factory has adequate ventilation system in work areas where chemicals are handled and where there are significant dusts or metal particles. Factory has ventilation system present in enclosed spaces where heat-generating equipment is operated. 9. Hazardous Chemicals or Materials: Factory stores chemicals in separate area, which is equipped with appropriate fire extinguishers, safety signs, and ventilation, instructions on handling or disposal, and personal protective equipment for personnel. Factory is familiar with all chemicals on site and the potential health effects. Explore opportunities for hazardous chemical/material minimization and document changes made
10. Medical Care: Factory has a medical clinic available on-site or in close proximity to address basic health and injury needs. Factory has a system in place to address severe injuries. Factory maintains copies of licenses for all applicable medical personnel. A record of injuries is maintained at the factory to focus on how injuries can be reduced.
11. First Aid: Factory has one properly stocked first aid kit available for every 100 employees. Factory maintain standard first aid kits that includes basic supplies, a kit for blood borne pathogens protections, an emergency log, and a first aid guide in the local language. First aid stations are posted with a first aid sign. The first aid kit is inspected regularly and restocked when needed. Factory trains at least 10 percent of personnel in basic first aid. Records are maintained for employees seeking first aid to track injury/illness as well as remedy.
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Responsibilities & Duties Of Compliance Team of HAMS Washing and Dyeing Ltd 1. To floor visit at least thrice a day. 2. To ensure workers fire safety, fire prevention, fire equipment, health & safety & comfortable environment at work place. 3. To aware the workers about personal protective equipment. 4. To receive grievance, complain, demand & suggestion from the workers & after receiving the issue discuss with related persons & local management immediately. 5. Try to find out emotional problem of an employee. The problem may be work related or personal or family which affects his/her work performance. 6. To provided supportive counseling the sick worker for medicinal support on the workers requests, complain or situational demand. 7. Try to make aware the existing workers about by company provided all facilities 8. Necessity of compliance. 9. To perform when social compliance audit. 10. To follow up aisle mark free, fire extinguisher no blocked, emergency exit free, fire equipment free, stair free from carton in the floor 11. To check all production related register if any date mentioned of holiday or not. 12. To conduct orientation program for newly appointed worker. 13. Try to motivate & make them conversant with the company objective, rules & regulations, buyer code of conduct & local laws. 14. To briefing the employees about all facilities of company, mandatory safety instruction including all dos & Donts. 15. To make aware the employees about leave procedure, maternity benefits, working hour & over time system according to local laws. 16. To make aware the employees about personal health & hygiene, HIV/ AIDS/STD. 17. To conduct awareness programs the pregnant workers about safe motherhood 18. To ensure that no employee each maltreated mentally or physically abused & they should be treated with respect & dignity. 19. And any other work assigned by the Management.
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Chapter-13
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ETP (EFFLUENT TREATMENT PLANT) ETP- Effluent Treatment plant Capacity of ETP : 30,000 Litres Working Procedure: We use different type of chemical, detergent, which is mixed with water & also mixed different types of fiber, that pollute our environment. Wastewater contains both organic & inorganic chemical. The inorganic constituents are present in the carriage water & increase because of water use. In the case of industrial wastewater, inorganic are highly present & physio-chemical treatment has to be employed to maintain desirable water quantity. We treatment the wastewater by using modern technology & decontaminate water & the drag out which is not harmful for our environment. The process by which wastewater treatment is occurred to obtain pure water to kept our environment free from pollution that process is known as ETP (Effluent Treatment Plant). By using ETP we are getting the result of distillation water is 6-8. Waste water chamber: Firstly the waste water which is mixed with different types of chemical & detergent used for washing in the factory is stored in the waste water chamber. Effluent Transfer Pump: There is a Effluent transfer pump connected with this chamber for the treatment of waste water which is connected with three other chambers. Two of them are chemicals & another one is lime. Chemical pumps are called Alum pump & Poly Electrolyte pump & the Lime is called the waste water pump. Ploy-Electrolyte Chemical pump: The chemical pump which is poly electrolyte, in this chamber 250gm poly electrolyte is mixed with 1000 litter of pure water. Alum Chemical pump: In the Alum chemical pump 5kg Alum is mixed with 1000 litter of pure water. Lime waste water pump: And in the Lime waste water pump 1kg lime is mixed with 100 litter of pure water. After mixing with Alum & poly electrolyte & also mixing with lime the waste water is purified. By flowing through these three pumps like Alum, Poly electrolyte & lime waste water becomes purified, then this purified water is preserved in the preserver. Preserver: the treated water which is preserved in the preserver pass through the treated water drain outline & the sediment is stored in the lower portion of the preserver.
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Blow down chamber: There is a blow down line connected with the lower portion of the preserver 7 sediment pass through this blow down line to the blow down chamber. This blow down chamber is connected with the suction chamber with three valves.
Suction chamber: Sediment water from the blow down chamber comes to the suction chamber. After purifying in this chamber the purifying water flows to the drain out chamber & then discharge to the sewer
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Chapter-14
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Conclusion
As a ready made garments washing and dyeing sector, HAMS WASHING & DYEING LTD. is excellent among the industries of Bangladesh. Garments washing and dyeing sector comprise varieties of machineries. It is still completely running position.
The Management system of the factory is quite well too. All the personnel of the factory are co-operative and friendly with us. The security system is very good too.
In the training period, we were introduced as a member of the factory. For that, they gave us all kind of facilities and scope for learning about washing and dyeing production and machineries.
Above all the industrial attachment has given us new ideas for practical life.
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