Merchandiser takes order from buyer
Merchandiser estimates total amount of yarn of
production
Knitting manager gets production order sheet
Production
officer ordered by K.M. and he orders technical in-charge.
Mechanical fitters fix up stitch length
Definite
operator operates machine in his full conscious and attention
Mechanical fitters fix machine if there is any machine
fault
Supervisors
keep daily production report and assure m/c
is OK.
Fabric
roll is checked by a group of inspectors in inspection unit and weighted.
Final product to the required amount is delivered to
dyeing unit.
Grey
fabric inspection
Batching
Fabric
turning
Loading to the m/c
Pre-treatment(Scouring
& bleaching)
Dyeing
Dewatering
Drying
Compacting & calendaring
Final inspection & packing
=
=
3527.80* Yarn count
=
=
=
=
=
=
=
=
=
DESCRIPTION OF PRODUCTION PROCESS:
In every mill , there maintains
a sequence in production processing.
It
is also followed in this mill where I was in industrial attachment.The process
sequences are in list below:
1)Firstly, knitting manager gets
a production sheet from merchandisers as accordance as consumer requirements.Then
he informs or orders production officer
about it.
2)Prodution officer informs
technical in charge and knows about m/c in which the production will be
running.
3)Technical in charge calls for
leader of mechanical fitter troops ;they two take decision about m/c for
production considering m/c condition , production capacity, maintenance
complexity etc.
4)Production officer with experienced
mechanical fitter adjusts required stitch length for required GSM.
5)Supervisor check daily production
regularity and make operators conscious about finishing in due time.
6)Operators operate m/c in
highly attention as if there were no faults in the fabrics.
7)After required production and
final inspection in 4-point system, they are sent in dyeing section.
PRODUCTION PARAMETERS:
Machine
diameter;
Machine
rpm(revolution per minute);
No.
of feeders in use;
Machine
gauge;
Count
of yarn;
Required
time(M/C running time);
Machine
running efficiency.
PRODUCTION CALCULATION:
1.Production/shift
in kg at 100% efficiency:
RPM*No. of
Needle*SL(mm)*60*12
=
10*2.54*36*840*202046*Yarn count
RPM*No. of Needle*SL(mm)*60*12
= 3527.80* Yarn count
2.Production/shift
in meter:
Course/min
=
Course/cm
RPM*No. of Feeder*60*12*Effeciancy
=
Course/cm*100
Fabric
width in meter:
Total no. of wales
=
Wales/cm*100
Total no. of needles knitting
=
Wales/cm*100
Fleece machines working operations:
Production
calculation:
As
fleece fabric is constructed with 3 threads in 3 threads fleece we have to
calculate production for each loop yarn. Calculations are as below mentioned.
For Base or knit yarn
Production/hr
No. of needles x Feeder no. x rpm x Stitch
length(mm) x 60
=
10 x 2.54 x 36 x 840 x count(Ne) x
2.2045
2162x108x17.3x3.8x60
=
10x2.54x36x840x30x2.2045
=18.130Kg
For
Binding or Tuck Loop yarn
Production/hr
No. of needles x Feeder no. x rpm x
Stitch length(mm) x 60
=
10 x 2.54 x 36 x 840 x count(Ne) x 2.2045
2162x108x17.3x3x60
=
10x2.54x36x840x30x2.2045
=14.313Kg
For
Fleece or Loop yarn
Production/hr
No. of needles x Feeder no. x
rpm x Stitch length(mm) x 60
=
10 x 2.54 x 36 x 840 x
count(Ne) x 2.2045
2162x108x17.3x1.7x60
=
10x2.54x36x840x16x2.2046
Total
production/hr=(18.130+14.313+15.208)Kg
=47.651Kg
V-Bed machines working operations:
In
this industry flat bed m/c is used. As collar & cuff is the essential part
of a garment so the m/c used to manufacture this is also essential. In our
MONDOL FABRICS LTD. Shima Seiki types of flat bed m/c is used.
Production
Parameters:
At
flat bed or V- bed knitting machine tubular & open width both type of
knitting can be done. The count selection of tubular & openwidth are
different. For tubular knitting 7-10 count is used. The counts used for open
width fabric are given below-
18
28
20
30
22
32
24
34
26
40
Average
length of collar is 39-45cm. At the top edge of collar i.e. at the topping edge
mending is done. Mending is the process by which extra thread enters into the
tube.
For
making yarn consumption at flat knitting, allowance is taken into account.
Total yarn required in kg = (calculated yarn wt.)*4%+1kg.
But
in general no. of ply used for specific count are given below:
|
Count
|
No.
of ply
|
|
18S
|
4
|
|
20S
|
3
|
|
22S
|
3
|
|
24S
|
4
|
|
26S
|
4
|
|
28S
|
4
or 5
|
|
30S
|
4
or 5
|
|
32S
|
5
|
|
34S
|
5
|
|
40S
|
6
|
If ply increases, then production
increases. Because in this time loop length will decrease & GSM will increase.
At flat knitting cam setting and
needle setting are very important. Here in both bed cam and needle are
positioned, cam is positioned on the carriage. Here four types of cam are used.
These are miss cam, guide cam,raising
cam and knit cam. Carriage moves left to right or right to left direction ie.
Horizontal direction. Here cam is fixed and no setting are required of cams for
producing various design. Cams movement,
height,active and inactive positions are controlled by the programming at
control panel. Needles are positioned on the track of front and back bed. Here
low butt and high butt needles are used for making various design.
For knitting tube , we have to
determine no. of course required for that tube width. Mostly filament yarn is
used here:
|
Tube
width(cm)
|
No.
of course
|
|
0.5
|
11
|
|
0.4
|
9
|
|
0.3
|
7
|
|
0.2
|
5
|
The step portion contains rib design.
Basically, after tube part, rib design is done. For step part of rib design of
filament yarn, we have to determine number of course required for that step
width.
|
Step
width(cm)
|
No.
of course
|
|
0.2
|
2
|
|
0.3
|
4
|
|
0.4
|
4
|
|
0.5
|
6
|
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