Viyellatex Group

ACKNOWLEDGEMENT:
We are extremely delighted to express our indebtedness and deepest sense of

gratitude to our supervisor Md. Dewan Mahbub Kamran(Sr.Executive,
Dyeing).for his able guidance, untiring efforts, stimulating influence and
valuable comments during the training period .
We would like to offer sincere thank to the DGM (Dyeing) Engr. Md. Shamim
Rahman for his invaluable suggestions regarding this training period.
The authority of the VIYELLATEX GROUP who gave us the opportunity to
complete our industrial attachment with great success is remembered with
honor. Thanks are due to all Engineers, officers, technicians, employees, stuffs,
all section in-charges for their cordial behavior. We are really lucky that we have
gotten such helping hand without whom, this attachment could not be completed.
We also like to thank Dr. Shah Mohammad Fatah-ur-Rahman, department of
Wet Processing Technology for his encouragement, valuable suggestion, and for
the completion of this Industrial attachment successfully.
Last but not least, thanks goes to my precious family for their never-ending
support and loves in every stages of my life which has motivated me to do such
type work.
I N D U S T R I A L A T T A C H ME N T O N V I Y E L L A T E X Page 4
EXECUTIVE SUMMARY
The internationally recognized Buyers or clients are looking for those countries
for producing their apparel products where different types of mills have
established as a one stop source for the global apparel market, satisfy and
meet customer's expectation by developing and providing products and
services on time, which offer value in terms of Quality, Price, Safety &
Environmental impact. And also assure complete compliance with the
international quality standards and also to provide the employees
internationally acceptable working condition/standards. In Bangladesh, there are
different types of Textile Industry those are producing high quality textile and
apparel product. VIYELLATEX GROUP is one of them.
VIYELLATEX GROUP is a Knit Composite Garments, having all state of the
art facilities with the annual turnover US$ 106.6 Million (2006-2007). They have
different types of Knitting, Dyeing, Cutting, Sewing, and Finishing machines
supplied by mostly Germany, Japan, Taiwan, China, U.K, U.S.A, Singapore, etc.
which are very latest. It has high production where 30 Metric tons of dyed and
finished fabrics are produced per day. The production is controlled by technical
persons. All of the decision makers of production sector in VIYELLATEX
GROUP are textiles graduates. All the chemicals and dyes use for dyeing and
finishing are well branded.
They produce their product for their buyer and client those are coming from
international market like U.K, Sweden, Netherland, France, U.S.A, Germany
and Spain. Their customer profile is big and top end such as Esprit, M&S, S-
Oliver, Puma, G-star, Gap, Tesco and Grew waver etc. They follow all the system
for their machines maintenance so production can not hamper.
In this report, we have tried to give some information about VIYELLATEX
GROUP and we have observed that VIYELLATEX GROUP produce high
quality fabric and fulfill the special requirements from the different types of
buyers by following different internationally recommended standard method.
INTRODUCTION
The industrial attachment is the process, which builds understanding,
skills and attitude of the performer, which improves his knowledge in boosting
productivity and services. University education provides us vast theoretical
knowledge as well as more practical attachment, in despite of all these industrial
attachment helps us to be familiar with technical support of modern machinery,
skillness about various processing stages.
By means of practical knowledge its not possible to apply the theoretical
knowledge in the practical field. For any technical education, practical experience
is almost equal important in association with the theoretical knowledge.
It also provides us sufficient practical knowledge about production
management, work study, efficiency, industrial management, purchasing, utility
and maintenance of machinery and their operation techniques etc. the above
mentioned can not be achieved successfully by means of theoretical knowledge
only. This is why it should be accomplished with practical knowledge in which it
is based on. Industrial attachment makes us reliable to be accustomed with the
industrial atmosphere and improve courage and inspiration to take self
responsibility.
Textile education cant be completed without industrial training. Because
this industrial training minimizes the gap between theoretical and practical
knowledge and make us accustomed to industrial environment. I got an
opportunity to complete two-months long industrial training at VIYELLATEX
GROUP, which is a 100% export-oriented composite Knit Dyeing Industry. It has
well planned & equipped fabric dyeing-finishing and garments units in addition
to facilitate knitting and knitwear manufacturing. .
TABLE OF CONTENT
GENERAL INFORMATION ABOUT THE FACTORY
Name of Company : VIYELLATEX GROUP.
Factory: VIYELLATEX GROUP.
297 Khortoil, Tongi,
Gazipur-1712.,Dhaka
Bangladesh.
Tel : 880-2-9813001, Ext: 110
Fax : 880-2-9811400
http//www.viyellatexgroup.com
VIYELLATEX LTD. is a well establishe !"it #$%&$site i"'st(). The i"'st()
sta"s $" i"'st(ial a(ea $* +a,i&'(. VIYELLATEX GROUP. is a +($'& $* C$%&a"ies-
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that thei( (e&'tati$" e&e"s $" its 1'alit). VIYELLATEX LTD. is a &($*itable &($2e#t a"
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PROJECT DESCRIPTION
Name of the Company : VIYELLATEX GROUP
Status : Private Ltd. Company
Type : 100% Export oriented composite knit Dyeing
Year of establishment : 2001
year of starting production : 2002
Location : Gazipura, Tongi
Address:
Factory: 297, Khortoli, Tongi, Gazipur-1712
Head Office : 297, Khortoli, Tongi, Gazipur-1712
Tel : No: 88192812
Fax No: 880-2-8810445
E-mail: www.viyellatexgroup.com
Sponsors :Mr. Rezaul Hasnat
Product Mix
100% cotton
100% polyester
Spun
Filament
Nylon
Chief Value Cotton (CVC)
Polyester Cotton (PC)
Grey melange (15% Voscose 85% cotton)
10% Voscose 90% cotton
Ash melange (1% Viscose 99% cotton)
Different Departments of VIYELLATEX knit dyeing composite
unit
a) knitting Section:
Knitting
Inspection
b) Dyeing section:
Batch section
Dye house
Dyeing lab.
Quality control
Finishing
c) Garments section:
Merchandising
Sample
Cutting Section
Sewing Section
Finishing Section
d) Maintenance section:
Electrical
Mechanical
e) Store Section
f) Administration Section
g) Security Section
h) Marketing Section
i) Production Planning & Control
j) Human Resource & Development Section
Departments Structure of Knitting Section
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KNITTING:
KNITTING IS THE PROCESS OF PRODUCING A FABRIC BY FORMING
A SERIES OF CONNECTED LOOPS FROM A SERIES OF YARN. IN THIS
METHOD FABRIC IS PRODUCED BY INTERMESHING OF LOOPS.
KNITTING TYPES:
warp knitting: each loop in the horizontal direction is made from a
different thread and the number of threads used to produce such a fabric is at
least equal to the number of loops in a horizontal row.
Weft knitting: a horizontal row of loops can be made using one thread and
the thread runs in horizontal direction.
Raw Material for Knitting
The raw material for knitting is the yarn. Different types of yarn of wide range of
count are used. In yarn store section we had the chance to know about different
yarns of different count used in \/IYELLA TEX knitting. We also have known
different yarn manufacturer/suppliers name for this knitting section i.e. sources
of yarn. Both carded and combed yarn is used for knitting.
Cotton 24
S
, 26
s
,30
S
, 32
S
,34
S
,40
S
Polyester 75D, lO0D
=
Spandex yarn 20D,40D, 70D
Grey Mlange (C 24
S
,26
S
Ecru Mlange (C-85% V-15%) 24
S
,26
S
,28
S
Anthra Mlange (C-65% V-35%) 24
S
,26
S
,28
S
PC (65%Polyester & 35% cotton)24
S
,26
S
,28
S
,30
S
CVC 24
S
,26
S
,28
S
,30
S
Knitting section is divided in four sections,
1. Inspection section
2. Flat knitting section
3. Circular Knitting section
4. Store section
I. Cloth Inspection Section:
In cloth inspection section two machines are available. Specification of those
machines is given below
Type Cloth Inspection Machine
Manufacturer name Uzu fabric Inspection
County Thailand
Model No. UZ 900.31
2. Flat Knitting Section:
Generally collar, cuff of knitted garments is produced in this section. In this
section there are 25 flat knitting machines. all of them are same type and also
have same specification. The specification of all machines is given below:
Type Automatic Flat knitting machine
Manufacturer namePrecision Fukuhara Works Ltd.
Country Japan
Model No. \l-100
Gauge G14
3. Circular Knitting Section:
This section contains 72 circular knitting machines. Circular knitting machines
are of different types, made by different manufacturer and also have different
specifications. In this section body fabric for knitted garments is produced. The
different specifications of different machines are given one after another

4. Store section:
In this section knitted fabric and yarns are stored.
Automatic Flat Bed M/C
Automatic Flat Bed M/C
Machine List of Knitting Section in Viyellatex :
Machine name Machine Quantity
Circular Knitting(Single jersey) m/c 32
Circular Knitting(Rib) m/c 18
Engineering Stripe m/c 08
V-bed Knitting m/c 26
Grey Fabric Inspection m/c 03
Specification of Circular Knitting Machine:
PROCESS FLOW CHART FOR KNITTING
YARN IN PACKAGE FORM
PLACE THE YARN PACKAGE IN THE CREEL
FEEDING THE YARN
SET THE M/C AS PER DESIGN &GSM
KNITTING
WITHDRAW THE ROLLED FABRIC AND WEIGHTING
INSPECTION
NUMBERING
FAULTS, CAUSES & THEIR REMEDIES IN KNITTING:
1. Hole Mark
Causes:
Holes are the results of yarn breakage or yarn cracks.
During loop formation the yarn breaks in the rejoin of the needle hook.
If the yarn count is not correct on regarding structure, gauge, course and
density.
Badly knot or splicing.
Yarn feeder badly set.
Remedies:
Yarn strength must be sufficient to withstand the stretch as well as
uniform.
Use proper count of yarn.
Correctly set of yarn feeder.
Knot should be given properly.
2. Needle Mark
Causes:
When a needle breaks down then needle mark comes along the fabrics.
If a needle or needle hook is slightly bends then needle mark comes on the
fabrics.
Remedies:
Needle should be straight as well as from broken latch.
3. Sinker Mark
Causes:
When sinker corrode due to abrasion then some times can not hold a new
loop as a result sinker mark comes.
If sinker head bend then sinker mark comes.
Remedies:
Sinker should be changed.
4. Star
Causes:
Yarn tension variation during production.
Buckling of the needle latch.
Low G.S.M fabric production.
Remedies:
Maintain same Yarn tension during production.
Use good conditioned needles.
5. Drop Stitches
Causes:
Defective needle.
If yarn is not properly fed during loop formation i.e. not properly laid on to
the needle hook.
Take-down mechanism too loose.
Insufficient yarn tension.
Badly set yarn feeder.
Remedies:
Needle should be straight & well.
Proper feeding of yarn during loop formation.
Correct take up of the fabric & correct fabric tension.
Yarn tension should be properly.
6. Oil stain
Causes:
When oil lick through the needle trick then it pass on the fabrics and make
a line.
Remedies:
Ensure that oil does not pass on the fabrics.
Well maintenance as well as proper oiling.
7. Rust stain
Causes:
If any rust on the machine parts.
Remedies:
If any rust on the machine parts then clean it.
Proper maintenance as well as proper oiling.
8. Pin hole
Causes:
Due to break down or bend of the latch, pin hole may come in the fabric.
Remedies:
Change the needle
9. Grease stain
Causes:
Improper greasing
Excess greasing
Remedies:
Proper greasing as well as proper maintenance
10. Cloth fall- out
Causes:
Cloth fall- out can occur after a drop stitch especially when an empty
needle with an empty needle with closed latch runs into the yarn feeder
and remove the yarn out of the hook of the following needles.
Remedies:
Make sure all the latches of needle are closed with feeding yarn after a
drop stitch.
11. Barre:
A fault in weft knitted fabric appearing as light or dark course wise
(width wise) Stripe.
Causes:
This fault comes from yarn fault.
If different micro near value of fiber content in yarn.
Different lusture, dye affinity of fiber content in yarn.
During spinning different similar classes of fiber is mixed specially in
carded yarn & these fibers have similar characteristics.
In draw fame different similar classes sliver is mixed and make one sliver.
Remedies:
We can use this fabric in white color.
12. Fly dust:
Causes:
In knitting section too much lint is flying to and fro that are created from
yarn due to low twist as well as yarn friction. This lint may adhere or
attaches to the fabric surface tightly during knit fabric production.

Remedies:
Blowing air for cleaning and different parts after a certain period of time.
By cleaning the floor continuously.
By using ducting system for cleaning too much lint in the floor.
Over all ensure that lint does not attach to the fabric.
13. Yarn contamination
Causes:
If yarn contains foreign fiber then it remains in the fabric even after
finishing,
If lot, count mixing occurs.
Remedies:
By avoiding lot, count mixing.
Fault less spinning.
14. Yarn Faults:
Neps.
Slubs.
Yarn count variations.
Thick/Thin place in yarn.
Hairiness.
Batching is the process to get ready the fabrics which should be dyed and
processed for a particular lot of a particular order.
Function or Purpose of Batch Section
B To receive the grey fabric roll from knitting section or other source.
B Turn the grey fabric if require.
B To prepare the batch of fabric for dyeing according to the following
criteria
Order sheet (Received from buyer)
Dyeing shade (color or white, light or dark)
M/C capacity
M/C available
Type of fabrics(100% cotton, PE, PC, CVC)
Emergency
B To send the grey fabric to the dyeing floor with batch card.
B To keep records for every previous dyeing.
Proper batching criteria
B To use maximum capacity of existing dyeing m/c.
B To minimize the washing time or preparation time & m/c stoppage
time.
B To keep the no. of batch as less as possible for same shade.
B To use a particular m/c for dyeing same shade.
Batch management
Primarily batching is done by dyeing manager taking the above
criteria under consideration. Batch section in charge receives this primary batch
plan from dyeing manager. Some time planning is adjusted according to m/c
condition or emergency.
Machines in batch section
M/c quantity: 02
M/c Specification:
Machine Name : Air turning m/c
M/c No : 01
Brand Name : Taida
Origin : China
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company :Shandong Taida Dyeing & Finishing
Machinery Co.Ltd
Machine Name : Air turning m/c
M/c No : 02
Brand Name : Taida
Origin : China
M/c Speed : 300-500m/min
Model : DF 200
Max up clothing : 150 kg
Company :Shandong Taida Dyeing & Finishing
Machinery Co.Ltd.
I N D U S T R I A L A T T A C H ME N T O N V I Y E L L A T E X Page @>
LABORATORY
LABORATORY MACHINERIES WITH ITS SPECIFICATION
1. Tearing Strength Tester:
Brand Name :Elmatear
Origin : U.K
2. Button Strength Tester:
Brand Name : Titan
Origin : U.K
Max.Pressure: 10 bar
Capacity : 3000N
3. Bursting Strength Tester:
Brand Name : TruBurst
Origin : U.K
4. Pilling Resistant Tester:
Brand Name : Impulse
Origin : U.K
5. Sprectra Flash:
Brand Name : Data Color
Origin : U.S.A
Test Name: Colorfastness to Washing, Dry cleaning.
Name of the m/c : Rota a!h
Origin : U.K
Test Method :ISO105-C06, ISO105-D02
Test Name: Dimensional Stability, Spirality, Appearance after washing.
Name of the m/c : Eltrolux wascator.
Origin : U.K
Test Method : ISO 6330, ISO 26330
Test Name : Shrinkage Test.
Name of the m/c : Eltrolux
Origin : U.K
Test Name : Color Fastness to Wash Test.
Name of the m/c : Gyro wash
Origin : U.K
Test Method : ISO 105-C06
Lab Dip m/c:
No.of m/c: 02
M/C NO- 01
Brand name : Ahiba Nuance Lab Dip Dyeing m/c
Origin : U.S.A
M/C NO- 02
Brad name : Ahiba Nuance Lab Dip Dyeing m/c
Origin : U.S.A
Color Matching Cabinet (Light box):
No. of Light Box: 02
Light Box no: 01
Brand : Spectralight-111
Origin : U.S.A
Light Source:
Day Light (D-65)
Cool White
Horizon
UV
TL-84
A (F11-10 degree)
Light Box no: 02
Brand : Verivide
Origin : U.K
Light Source:
Day Light (D-65)
UV
TL-84
A (F11-10 degree)
Laboratory is the heart of dyeing Industry. An efficient laboratory can increase
the efficiency of dyeing. So, laboratory in-charge is sometimes called pilot. Before
bulk production a sample is sent to buyer for approval. Laboratory supplies the
recipe to the floor.
Purpose of Laboratory:
Get color approval from buyer.
Recipe supply to the floor.
Shade correction.
Minimize the deviation between bulk and laboratory.
Laboratory line:
Standard sample:
At first recipe % of standard sample is measured by CCM (computer color
matching) system.
Laboratory Trial:
Then by taking those recipe laboratory officers produce laboratory trial and
match with standard according to buyer requirement.
Approved Sample:
Then sample swatch, which is matched with the standard, is send to buyer for
approval.
Off-Line Tests:
Off-Line tests for finished fabrics are divided into two groups. These are as
follows:
Physical tests
Chemical tests
Scope for Quality control, quality assurance and testing
1 Testing lab
2. Machine auditing system
3. A good training system
4. Excellent analytical back up
5. Technical expertise
QUALITY ASSURANCE SYSTEM
The Quality assurance Department is assigned to maintain consistently
uniform quality of the material in process and various stages of its
manufacturing. VIYELLATEX LTD is more about concern about quality. In this
factory quality assurance is more preferred than quality control, but both are in
advancement.
Objects of Quality Control:
1. Research.
2. Selection of raw materials.
3. Process control.
4. Process development.
5. Product testing.
6. Specification test
Quality management system in viyellatex:
Online Quality control:
There are two types of online quality control. These are as follows: B
Raw material control:
Raw material control means control the quality of raw materials (e.g.- Quality of
Grey fabric, Dyes, Chemicals and Auxiliary)
Process control:
Process control means the selection of right process and controlling of some
parameters. Such as P
H
, Water hardness, water volume, Temperature, Reel
Speed, Pump pressure, etc.
Online Tests:
Dyed fabric.
Shade check.
Wash fastness.
Water fastness.
Crocking fastness.
Off-Line Tests:
Off-Line tests for finished fabrics are divided into two groups. These are as
follows:
Physical tests
Chemical tests
Physical Tests:
GSM of Fabric.
QA
On-Line Off-Line
Abrasion resistance / Pilling.
Dimensional stability test.
Spirality test.
Color fastness to rubbing test (Dry / Wet).
Bursting strength test (For Knitted fabric).
Tensile Strength test (For Woven fabric).
Chemical Tests:
Color Fastness to washing.
Color Fastness to light.
Color Fastness to heat.
Color Fastness to actual laundering
Color Fastness to Chlorinated water.
Color Fastness to water spotting.
Color Fastness to perspiration.
Color Fastness to Seawater.
Flammability test.
Fibre analysis.
P
H
test.
Spray test (water repellency).
Phenolic yellowing.
RESPOSIBILITY OF OFF-LINE QUALITY CONTROL:
To check the following things:
Inspection of fabric in the inspection M/C under 4-point system.
Yarn count and lot no.
Buyer.
Design.
Stitch length of grey fabric.
Shade of grey fabric with in one order.
RESPOSIBILITY OF ON LINE QUALITY CONTROL
To check the following things:
M/C Dia/Gauge
Buyer
Design
Grey fabric GSN & Stitch Length
Yarn count & Lot no
Yarn whether approved or not by Q.C. Department
Finished dia & grey dia.
Fabric quality checking under 4-point system.
RESPONSIBILITY OF IN CHARGE OF QUALITY CONTROL
Making report.
Supervise the grey Q.C.
Check machine is running according to program or not
Check program can meet the requirement. Which is mentioned in the
order sheet or not.
Check yarn is approved by Q.C. or not.
RESPONSIBILITY OF THE FINISHING Q.C.
Finishing Q.C. (shade):
After unloading from dyeing cut small piece, check shade with
std/approved lab dip/production sample & previous production batch (if
any).
Then instruction to finishing for finish by mentioning specific temperature
in dryer.
After finish again cut sample & check same way like before at dry state.
Keep the record of every lot after dry & after finished state.
If any batch is not OK at any stage then make the re-process card for
dyeing.
If any batch is closer to standard but not exactly pass with standard, then
make trial for that batch in finishing to make it OK.
Maintain the resister of all batches.
Check the shade of Body to Rib, Body to Collar & Cuff.
In charge:
Supervise the trainee Q.C. & Q.C.
Make report every day.
Cross check whatever shade already checked by Q.C.
Q.C. (Finishing):
Make the R
2
R continuity of each dye lot by cutting small piece from each
roll of dye lot.
Inspect 30-40 % of each dye lot under 4-point inspection system & report
accordingly.
If found any problem then re-inspect 100% of that dye lot and make report
& re-process card (if re-process able) for dyeing. If it is knitting faults then
immediately inform to officer asking decision.
Check the evenness of a dye lot by checking R
2
R continuity.
Check the shade of body to rib, body to collar & cuff.
In charge:
Monitor the all Q.C.S (finishing) work including shade Q.C.
Take decision when asking advise from his subordinate.
Make daily problematic batch report.
Make daily production report.
Maintain resister khata.
Make daily batch re-process job card.
RESPOSIBILITY OF QUALITY ASSURANCE MANAGER:
Responsible for all quality matter of fabric.
Yarn selection.
Monitoring product development.
Organize Laboratory.
Control grey and finished fabric inspection under 4- point system.
!cumentati!n a"ter s#ade c#ec$ !" e%ery &!t.
Quality Assurance Procedure
1) Body & Rib Inspection:
All rolls are kept in front of the inspection m/c time to time and are inspected
over the inspection m/c visually in a pre-set speed against light. For any major or
minor faults like thick-thin, barre mark, fall out, contamination, fly, holes, oil
lines, needle line, stubs etc are recorded in inspection report to classify the fabric
based on the four point system.
2) Collar cuff Inspection:
Collar& cuff are inspected visually under the tight box, any major or minor faulty
collar/cuff like having wrong ply, hole, needle line, stubs, wrong design, first
round problem etc properly counted and recorded.
Quality Standard:
VIYELLA TEX Ltd. maintains the ISO: 9002 standard in case of quality.
Therefore the four point system is followed to inspect the body & rib fabric. The
defects found and points given against are recorded in the inspection sheet.
Following table shows the four point grading system followed by inspection at
VIYELLA TEX Ltd.
Four point grading system
Size of defects Penalty
3 inches or less
1 point
Over 3 inch but not over 6 inch

2 point
Over 6 inch but not over 9 inch 3 point
Over 9 inch
4 point
Following table shows common body and rib faults and response by inspection
section at VIYELLA TEX Ltd.
Acceptance Calculation
Factory: Roll yardage (A) Total points founds(B)
Formula : X100 =points per 100 yard
Classification:
40 points =A type
41-60 =B type
61-80 =C type
Above 8Opoin = Reject
Tests
There are two types of tests are done in Quality Assurance Department. They are
1. Physical Tests
2. Chemical Tests
Physical Tests:
Yarn Grade
GSM test
Shrinkage test
Spirality test
Tensile strength
Abrasion resistance
Button Strength Testing
Lycra% determination
Crease resistance
Chemical Tests:
Fastness to washing.
Fastness to light
Fastness to actual laundering
Fastness to sea water
Fastness to water
Fastness to perspiration
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Responsibility of production officer
o Overall supervision of dyeing & finishing.
o Dyes & chemicals requisition issue & check.
o Program making, sample checking color measurement.
o Control the supervisors operators & helpers of machines.
o To give dye-line or the program slip according to daily production
plan, batch preparation & P
H
check.
o To rectify the finished fabric which rejected from quality control
department
o To check daily production report.
o To study dye & chemicals nature delivery by the manufacture &
applied them correctly to the production to get best product
Job Description:
Title: Production officer.
Dept: Dyeing
Report to: Senior production officer.
Job summary: To plan execute & follow up the production activities
& control the quality production with related activities.
Title: Senior production officer.
Dept: Dyeing.
Report to: Dyeing manager.
Job summary: To plan execute & follow up the production
activities & control the quality production with related activities.
Duties & Responsibilities :
Overall supervision of dyeing, finishing production.
Checks the different log books of different areas & report to management.
Checks the sensitive parameters of different machine for smooth dyeing.
Checks out the plan to control the best output from supervisor & workers.
To trained up & motive the subordinates how to improve the quality
production.
Maintenance of machine & equipment. Any other works & when required
by the management.
Control the supervisors, operator, asst. operator & helpers of dyeing m/c.
REMARKS:
The manpower management system VIYELLATEX GROUP is well arranged.
Every officers & stuffs are responsible for their duty. But there are only six
textile engineers in the industry 11 for dyeing & 1 for Finishing. It is sufficient
for Finishing). It is sufficient for fluent production. The efficiency of the \\orker
should be increased for more quality production.
Raw materials for dyeing
Raw materials used in the dyeing section are:
1. Grey fabrics
2. Dyes
3. Chemicals.
Grey fabrics
Following types of gray fabrics are dyed in ViyellaTex:
Single jersey
Single jersey with lycra
Polo pique
Back Pique
Single lacoste
Double Lacoste
Fleece
Rib
Rib with lycra
1C1 rib
FLOW CHART FOR DYEING
BATCHING
SELECT M/C NO.
FABRIC LOADING
SELECT PRODUCTION PROGRAMME
PRETREATMENT
SELECT RECIPE FOR DYEING
RECIPE CONFIRMED BY DM/PO
DYEING
POST TREATMENT
UNLOAD
Finishing:
Textile finishing, in a restricted sense, is the term used for a series of processes
to which all bleached, dyed, printed and certain grey fabrics are subjected before
they are put on the market. In fact, finishing includes the final treatment of
every kind of fabric made from every kind of fiber
Objective of finishing:
Improving the appearance Luster, whiteness, etc
Improving the feel, which depends on the handle of the material and its
softness , suppleness , fullness, etc.
Wearing qualities, none soiling, anticrease, antishrink, comfort, etc.
Special properties required for particular uses water proofing, flame
proofing, etc.
Covering of the faults in the original cloth.
Increasing the weight of the cloth.
Types of finishing:
1) Chemical finishing:
a) Chemical reaction of auxiliaries with fibers.
b) Application of the handle modifying products / additives.
2) Mechanical finishing:
Mechanical treatment with machines
Finishing effects:
Easy - care
Crease recovery.
Dimensional stability.
Good abrasion resistance.
Improved tear strength.
Good sew ability
Soft or stiff handle.
Shine or luster
Departments Structure of Finishing Section:
E:e#'ti0e Di(e#t$( 4E.D6
Ma"age( 3 Asst.Ma"age(
S(. P(i"#i&le $**i#e( 4P.O6
;i"ishe ;ab(i# ;i"ishe C$lla( 3 C'**
S(. S'&e(0is$( 3 S'&e(0is$( 3
O" li"e S)ste% O** li"e s)ste% =(. S'&e(0is$(
S(. S'&e(0is$( 3 S'&e(0is$( S(. S'&e(0is$( 3 S'&e(0is$( D'alit) C$"t($lle(
3 =(. S'&e(0is$( 3 =(. S'&e(0is$(

Asst. D'alit) C$"t($lle(
D'alit) C$"t($lle( D'alit) C$"t($lle(
Asst. D'alit) C$"t($lle( Asst. D'alit) C$"t($lle(
Flow chart of finishing section :
Finishing Section
O&e" *ab(i# T'be *ab(i#
Slitti"g %a#hi"e Dewate(i"g %a#hi"e
Ste"te(i"g D()i"g Ma#hi"e
C$%&a#ti"g
%a#hi"e
T'be #$%&a#ti"g
%a#hi"e
;i"al
I"s&e#ti$"
;i"al
i"s&e#ti$"
Process Flow Chart of Final Inspection :(Q.A.D)
After completing finishing process here firstly check the shade as per buyer
standard with dimensional stability from lab.
Secondly check dia / width fabric weight or G.S.M
Thirdly check fabric surface or appearance as per buyer standard.
The every roll with every meter check as per four (04) point system.
Make a report.
If OK then ready for delivery.
If not OK then identify the fault.
If it is knitting fault then inform the knitting department by job card and mail, &
requested the fabric for replacement.
If it is dyeing fault & If make sure that it is reprocess able then give job card to
dyeing department correction. And if is not reprocess able then reject the fabric &
inform the dyeing department to replace the rejected quantity.
Sample Development :
Sample is the prototype or model o the garment, upon what the buyer can decide
on how and whiter to confirm the order or not.
Organ gram of sample department :

There are about 175 total employees working in the Viyellatex Group sample
department including executives and workers. There are also some supervisors
and coordinators to stimulate and take care the sample job. Let us see the
Departments Structure below to know more about the sample department
Manager
Patten Master Officer/Coordinator Officer. QC
Pattern asst. Fabric Coordinator QC/AQC
Sample man Folding Man
Accessories Issue Man
Cutter man
Iron Man
Purchase/Marketing man
Sample Asst.
Sample Input man
Sample Operator
Sampling Process Flowchart :
Receiving Tec Pak from buyer (Via Merchandiser)
CAD & Pattern Making (Styling & Measurement)
Sample Making
Approval Failed
Size Setting (One Development Stage) Re Sample Making
Evaluation the Sample
Pre Production Meeting (Decides on when to produce) Sending Sample
to the Cutting Section
Grading of sample Market Making Production stats
Sending sample to the buyer Approval Grading of Sample
Brief Description of the Sampling Processes:
1. Tec Pack Receiving: This is the firs stage of the sampling processes. In
this stage Tec Pack or the technical pack is received from the buyer, via
merchandiser. Tec pack contains all the specifications to produce a garment.
2. CAD & Pattern Making: In this stage pattern is made through CAD.
Sometimes pattern is made manually, but CAD is more popular and easy.
Computer-aided design (CAD) is the use of computer technology for the
design of objects, real or virtual. The design of geometric models for object
shapes, in particular, is often called computer-aided geometric design
(CAGD).However CAD often involves more than lust shapes. As in the manual
drafting of technical and engineering drawings, the output of CAD often must
convey also symbolic information such as materials, processes. dimensions,
and tolerances, according to application-specific conventions. CAD may be
used to design curves and figures in two-dimensional (2D) space; or curves,
surfaces, or solids in three-dimensional (3D) objects. Viyellatex pattern
section uses OptiTex CAD software for pattern making.
3. Sample Making: Sample making is the ultimate goal of this department.
After making the pattern, the sample is made by using the pattern set.
4. Size Setting: After making the sample, size is set according to the Tec
Pack. If there is any fault, the sample is redone
5. Pre Production (PP) Meeting: after the buyer has inspected the sample,
a preproduction meeting is called. In this meeting buyer or his agent,
merchandiser, sample manager. all remain present. They decide on how to
and when to start the production. If the decision Okayed. the sample is ready
to go for final production.
6. Grading of Sample: After finalizing the sample. grading is done to separate
the samples and patterns from each others.
7. Marker After grading the samples. the design is inputted into the marker
software. This software specifies how to set the pattern in the actual fabric.
By using the marking software efficiently, fabric can be saved. Viyellatex uses
Gerbar Garment Technology (GGT) for marker making.
8. Cutting: After making the pattern is delivered to the cutting unit and the
fabric is cut for final production.
DEPARTMENTS STRUCTURE
CEO
E
COO
E
DGM
E
EXECUTIVE
E
PRODUCTION OFFICER
E
SUPERVISOR
E
E E E
SHIFTSUPERVISOR QUALITY SUPERVISOR STORE
SUPERVISOR
E E E
OPERATOR Q.I STORE
STUFF
E E
HELPER
LOADER

EMBROIDERY
DEPARTMENTS STRUCTURE OF EMBROIDERY

CO (Embroidery)
Embroidery manager
Assistant manager (designer)
Supervisor ( A.Q.C) Sample man

Q.I senior operator
Helper Helper
Senior operator

Assistant operator

Frame men

M/c men
Helper
Iron men

Embroidery Machine Specification
Electronic multi-head automatic Embroidery M/C

Brand: Tajima
Country: Japan
Model: TFGn-920
No. of head: 20
No. of Needle per head: 9

No. of Embroidery M/C: 7 M/Cs for Bulk production
: 1 M/C for Sample
Machine RPM= maximum 950
Maintenance
Maintenance is a procedure by which we can maintain active functioning in
operation according to the behavior and utility of a particular element. Machine,
buildings and other facilities are subjected to deterioration due to their use and
exposure to environmental condition. Process of deterioration, if unchecked.
culminates in rendering these service facilities unserviceable and brings them to
a standstill. In Industry, therefore has no choice but to attend them from time to
time to repair and recondition them so as to elongate their life to the extent it is
economically and physically possible to do so. In engineering, we use this
terminology for maintaining smooth and uninterrupted performance of machines,
tools and metallurgical characteristics in practical uses
Objective of maintenance:
To keep the factory plants, equipments, machine tools in an optimum
working condition.
To ensure specified accuracy to product and time schedule of delivery to
customer.
To keep the downtime of machines to the minimum thuds to have control
over the production program.
To keep the production cycle within the stipulated range.
To modify the machine tools to meet the need for production.
Three types of maintenance are performed in Viyellatex
Group.
1. Preventive Maintenance.
2. Routine/ Schedule Maintenance.
3. Breakdown Maintenance.
Preventive Maintenance: Preventive maintenance is a predetermined
routine actively to ensure on time inspection checking of facilities to uncover
conditions that may lead to production break downs or harmful description.These
actions are performed to prevent or reduce consequences of failures.
Schedule maintenance: Maintenance of different machines are prepared
by expert engineer of maintenance department. It is time-based maintenance and
pre-planned to perform on machine and equipments Normally in case of dyeing
machine maintenance after 30 days complete checking of different important
parts are done.
Breakdown maintenance: In this type of maintenance when the machine
remains stop that time the maintenance is done.
CONCLUSION :
Fe ha0e #$%&lete $'( i"'st(ial atta#h%e"t s'##ess*'ll) b) the g(a#e $* Allah.
Industrial attachment sends us to the expected destiny of practical
life. The completion of the two months Industrial attachment at VIYELLATEX
GROUP, we have got the impression that factory is one of the most modern
export oriented knit composite complex in Bangladesh. Though it was established
only a few years ago, it has earned very good reputations for its best
performance over many other export oriented textile mills.
During our training period, talking with the clients of this mill we
knew that the mill is fulfilling the countrys best export oriented white finished
fabric as well as very good colored fabric due to its modern machinery & good
management system.
Mill is settled with utility to give all convenient supports to the
productions for twenty-four hours. It had self-power generator system to satisfy
total power consumptions of the mill.
We are enough fortunate that we have got an opportunity of having a
training in this mill. During the training period we are received co-operation and
association from the authority full & found all man, machines & materials on
appreciable working condition. .\ll stuffs & officers were very sincere & devoted
their duties to achieve their goal.
There are some suggestions from us within our limited knowledge
Some Suggestions:
The dyeing floor is watery most of the time: it should be cleaned all the
time.
To increase overall efficiency, more skilled labor should be used in a
project.
The m/c stoppage time should be analyzed and minimized.
The maintenance should be carried out when the m/c is out of action
(wherever possible) and routine maintenance should be carried out
regularly.
There should be a yarn dyeing project.
Sitting arrangement of production officers should be improved.
Lastly:
We tried our best to gather all necessary information but it is true that within
this short period it is quite impossible to achieve 100% success but as a whole
this industrial training was a satisfactory one and once again wed would like to
thank the authority of VIYELLATEX GROUP. as well as our honorable
teachers far their altruistic help and advice. We are fortunate enough that we
have got an opportunity to have training in this mill. During the training period
we have received enough co-operation and association from the authority and
found all personnel. All stuffs and officers were very sincere and devoted their
duties to achieve their goal.

Viyellatex Group

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ACKNOWLEDGEMENT:

We are extremely delighted to express our indebtedness and deepest sense of

Over 3 inch but not over 6 inch

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