Industrial attachment of viyellatex group

Industrial attachment Page no. 1
VIYELLATEX GROUP
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
VIYELLATEX GROUP

VIYELLATEX GROUP
CHAPTER:01
PROJECT DESCRIPTION
1. Name of the Company: VIYELLATEX GROUP
2. Status: Private Ltd. Company
3. Type: 100% Export oriented composite knit Dyeing Industry
4. Year of establishment: 2001
5.Year of starting production: 2002
6. Location: Gazipura, Tongi
7. Address:
Factory : 297, Khortoil, Tongi, Gazipur- 1712
Head office: 297, Khortoil, Tongi, Gazipur- 1712
Tel. No. 8819281-2 Fax No. 880-2-8810445
E-mail : viyellatex@youngonesgroup.com
8. Sponsors: Mr. Rezaul Hasnat
9. Product Mix: 100% cotton,
100% polyester
a) Spun
b) Filament
Nylon
Chief Value Cotton (CVC)
Polyester Cotton blend
Grey mélange (15% Viscose 85% cotton
10% Viscose 90% cotton
30% Viscose 70% cotton)
Ash mélange (1% Viscose 99% cotton)

VIYELLATEX GROUP
10. Production Capacity:
a) Knitting section 19Tons per day (Body fabric)
20,000 pcs (Collar & cuff)
b) Dyeing Section 28 Tons per day
c) Garments Section 18 million pieces per year
11. Project cost: 20 million $
12. Different Departments: a) KNITTING SECTION:
 Knitting
 Inspection
b) DYEING SECTION:
 Batch section
 Dye house
 Dyeing lab.
 Quality control
 Finishing
c) GARMENTS SECTION:
 Merchandising
 Sample
d) MAINTENANCE SECTION:
 Electrical
 Mechanical
e) STORE SECTION
13.Supporting department:
a) Personnel administration
b) HRD
c) Marketing
d) Procurement
e) Finance and accounting

VIYELLATEX GROUP
f) Security department
13. Total Manpower:
a) Knitting section 250
b) Dyeing Section Dyeing- 300
Finishing- 250
c) Garments Section 3200
14. Major customers: a) Marks & Spencer
b) S. Oliver
c) ESPRIT
d) Tesco
e) Puma
g) GAP
h) G.Star
i) Wool worths
j) TU

VIYELLATEX GROUP
W
Maintenance
room
Maintenance
room
Maintenance
room
Washing
Ground
floor
L
I
F
T
L
I
F
T
L
I
F
T
L
I
F
T
2
1
3
4
7
6
5
EmergencyExitStairs
EmergencyExitStairs
Reception
room
IT, guest &
conference room
Office
Office
Product
Development
Office
Rest
room
Dinning and Prayer room
Work
shop
Sewing floor
Cutting
room
CAD
Room
Central store (Fabric
& accessories)
Sewing floor
Sewing floor
Medical
centre
Inspection
room
Finishing
section
Chemical
store
Raw
material
store
Garments
store
Child care
centre
Store Room
ViyellaTex LTD
(Dyeing and
finishing)
Maintenance
manager
Lab
manager
TextileTesting
Corporation
1st
floor
Ground
Centralstore
Fashion
plastic &
package
LTD
ETPcontrol
centre
ETP
Boiler
room
Boiler
room
Substation &
maintenance
room
Cargo
lift
WTP Oxidation
plant
Generator
room
Chemical
room
Fashion plastic &
packaging sub station
room
RMS room
Security
room
Store
Bonded
ware
house
Generator room
Generator room
Garden & rainfall
Maingate
Pocket gate
Washing
Embroi
dery
Printing
YarnStore
1st
floor

VIYELLATEX GROUP
Mohakhali
Airport
Uttara model
town
Tongi bus
station
Station road,
tongi
College
gate
Gazipura,
tongi
Baro
bari
Board
barzar
National
university
Ashulia
Bishwa
Estema
Shatrashta
College of
Textile
Technolog
y NS
Location Of The
VIYELLATEX Group
VIYELLATEX
NS

VIYELLATEX GROUP
15. Physical Infrastructure:
The mill is built in such a way that there is possibility for further expansion of the mill. The
structure such as mill, office buildings, record rooms, guardrooms & dining room etc. are made
of solid hard concrete & brick mtls. . The whole area is surrounded by safety brick wall .The
main set up for m/c’s are built of corrugated iron & iron sheet, transparent hard plastics with
enough ventilation & scope for passing light & air.
Remarks:
VIYELLATEX LTD. is a well established knit composite industry. The industry stands
on industrial area of Gazipur. VIYELLATEX GROUP. is a Group of Companies, Viyella spinning,
Youngone’s fashion LTD, Viyella knitting and dyeing,. VIYELLATEX LTD. is going to prove its
own standard about product quality in world market as they know that their reputation depends on its
quality. VIYELLATEX LTD. is a profitable project and contributes the economy of our country.

VIYELLATEX GROUP
CHAPTER -02
MAN POWER MANAGEMENT
Organogram of manpower:
Company Organogram
Finance
CHIEF EXECUTIVE OFFICER (CEO)
CHIEF OPERATING OFFICER (COO)
HEAD OF
PRODUCTI
ON
HEAD OF
MERCHAN
DISING
HEAD OF
COMMERCI
AL &
ACCOUNTS
HEAD OF
BU HRD
HEAD OF
QUALITY
ASSURAN
CE
HEAD OF
DESIGN &
PRODUCT
DEVELOP
MENT
HEAD OF
PLANNING
/ IE
HEAD OF ACCOUNTS & COMMERCIAL
ACCOUNTS DEPARTMENT COMMERCIAL DEPARTMENT
FAVP
(Preparation of Financial
Statement & Group Cheque Issue)
PRINCIPAL OFFICER
(Salary & Wages)
OFFICER
(Petty Cash &
Staff Salary)
IMPORT DIVISION
(In-Charge & FAVP)
EXPORT DIVISION
(In-Charge & FAVP)
PRINCIPAL OFFICER
Sr OFFICER SPO OFFICER
Jr OFFICER

VIYELLATEX GROUP
Organogram from knitting
Organogram of Dyeing
DGM/AGM
Manager / Asst. Manager
(Store)
Sr. Executive
/ Executive
Jr. Executive
(Yarn)
Jr. Executive
(Grey Fabric)
Store Asst.
(Yarn)
Store Asst.
(Grey Fabric)
Loader
(Yarn)
Batch
Helper/Loade
r
Manager/Asst. manager
(Technical)
Sr. Fitter / Fitter
Asst. Fitter
Servicing
man
Needle man
Servicing
helper
Manager / Asst. Manager
(Prodn
& Plan)
Knitting Master/
Executive (Flat)
Operator /
Asst. Operator
Sr. Fitter /
Fitter
Helper
Sr. Executive
(Prodn
,Plan & Sample)
Executive /Jr. Executive
(Prodn
, Plan & Sample)
Sr. Supervisor
/ Supervisor
Asst. Operator
Sr. Operator
/ Operator
Production Helper
Sample
supervisor
Sample asst
DGM/AGM
Manager
Planning
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor
Production
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor
Store
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor
Washing
Asst.Manager
Sr.Executive
/Executive
Jr.Executiv
e
Sr.Supervisor
/Supervisor

VIYELLATEX GROUP
JOB DESCRIPTION ( IN GARMENTS SECTION)
TITLE: DEPUTY GENERAL MANGER
Job summary: Overall supervision of Garment Section.
Responsibilities:
 Has the responsibilities for running the garment department including
production planning, operation control, measuring and monitoring of
product and the process.
 Establishing and maintaining identification and traceability requirement.
 Inspection test status, taking corrective and preventive action.
 Controlling nonconforming products at intermediate and final stages in
Garment Department.
 Analyzing product and process performance form measurement process
to identify area for improvement.
 Provide supports for approval and maintenance of equipment related to
Garment Department and training of stuff in the department.
TITLE: PRODUCTION MANAGER
Job summary: Overall supervision of sewing section.
Responsibilities:
 Receives cutting fabrics according style, color and size form cutting
section.
 Prepare sewing lines of floor & report to A.G.M. in three time everyday
 Distribute the cutting fabrics according to style, size & color to the
respective line supervisors.
 Control the Sewing In charge, Q.C, Assist Q.C., supervisor, Asst. Supervisor,
quality Inspector, Operator & helper
 Maintain floor discipline & cleanness.
 Any other works as & when required by the management.
TTILE: Q.C. (SEWING)
Job summary: Directly control the quality of complete garment in the sewing
line.
Responsibilities:
 Check every complete garment, oil mark, dirty spot, yarn marks, fabric
fault.
 Check the ironing of complete garment.
 Control the measurement and tolerance.
 Prepare the pre-final quality control report.
 Checks getup property.
 Shade matching base to base & country wise.
 Any other works as and when required by the management.

VIYELLATEX GROUP
TITEL: Q.C. (CUTTING)
Job summary: Overall supervision of cutting section.
Responsibilities:
 Prepare batch wise cutting report and send to the authorized person.
 After complete the fabrics cutting report to A. G. M. of garment.
 Prepare weekly cutting report.
 Control the pattern master, Cutting master, Cutting supervisor, Cutting
man, Neck man, Cutting helper & Labor
 Control the cutting quality for bulk production, shrinkage & consumption.
 Look after the cutting & band knife machine.
TITEL: SEWING IN CHARGE
Job summary: Overall supervision of sewing section
Responsibilities:
 Receives cutting fabrics according to style, color & size from cutting
section.
 Prepare sewing lines of floor & report to A. G. M. in three time everyday.
 Distribute the cutting fabrics according to style, size & color to the
respective line supervisors.
 Control the sewing in charge Q.C., Asst. Supervisor, quality inspector,
operator & helper.
 Maintain floor discipline & cleanness.
 Any other works as & when required by the management
TITEL: FINISHING IN CHARGE
Job summary: Overall supervision of finishing section.
Responsibilities:
 Looks after the overall finishing section
 Supervising the poly packing & cartooning.
 Maintains shipment schedule
 Procurement of required accessories & cartoons
 Maintain the daily finished garments record
 Any other works as & when required by the management
REMARKS :Production runs with the help of mechanical fitters.for any kind of mechanical
faults of any machine they fix and work under technical in-charge.

VIYELLATEX GROUP
CHAPTER -03
MACHINE DESCRIPTION
SL ITEM DESCRIPTION (MESUREMENT) PCS.
1 Gerber Cutter L=174inch, W=109.5inch 1
2 Band Knife L=59.5inch, W=83inch 1
3 Straight Knife 18
4 Spreader Machine L=108inch, W=100inch 4
5 Spreader Table L=32.53m, W=2.23m 2
8 Manual Table L=12.59m, W=2.236m 1
9 Manual Table L=10.76m, W=1.5238m 1
10 Scissor 70
11 Small Table L=38.5inch, W=30inch 98
12 GSM Cutter 1
13 GSM Weight Machine 1
14 Fabric Weight Machine 1
15 Input Rack L=470inch, W=40inch, Height=84inch 12Self,
Capacity=KD-5000, TESCO-1500 Per Self
7
16 Input Fabric Rack L=90inch, W=72inch, Height=72inch Per Self,
Capacity=1500-1600kg
6

VIYELLATEX GROUP
Some industrial sewing machine
Name No. of
needle
Thread Stitch
length (mm)
SPM
Lock
stitch m/c
1/2 5mm 1500-
5500
Chain
stitch m/c
1/more 1/more 1.4-
4.5mm
1800-
6000
Over
lock/ over
edge m/c
½ 2-5 4mm 6500-
8000
Zig-
zag m/c
1 2 2-
2.5mm
5500
Flat
lock m/c
Up to
4
4-9 SPI 8-
16
6000
Blind
stitch m/c
1 1/2 3-8mm 2500
Button
8holing m/c
Bar
tack m/c
Smock
ing m/c
33 66
Work Aids
The extra m/c parts which may be attached to speed up to the production and improve
quality in sewing m/c are called work aids .Some work aids are:
1.Guide
2.Compensating foot
3.Specialized pressure foot
4.stitching zig
5.Rack guide
6.Light
7.Folder
8.Slack feeder
9.Elastication
10.thread cutting
11.Latch back device

VIYELLATEX GROUP
Specification of Cutting Machines
Spreader Table (Tube):
Model: SY: 100
Fabric Ply: 7cm
Length: 35 yds
Width: 52 inch
Brand:Gerber (USA)
Spreader Table (Open):
Model: SY: 100
Length:35 yds
Width: 80 inch
Auto Spreader Machines:(3)
Model: SY101
Brand: Gerber (USA)
Speed:75 mmin
Auto Spreader Machine:(1)
Brand: Autex
Country: Spain
Computerised Cutting m/c: (1)
Model: Gerber Cutter GT 7250
Brand:Gerber (USA)
Serial number: 7552
Year built: December 2002
Cutting Time: 1-15minutes
Capacity: 50000 gtsday
Band Knife:
Model: EC-900N
Brand: Eastman
Country: USA

VIYELLATEX GROUP
Straight Knife
Number of mc: 18
Active=14, Inactive=4
Brand: KM-14
Eastman-4
Knife Length=12inch
Knife Length used in cutting=7-8cm
Mc no. Brand name Serial Speed Volts AMPS Cycle Phase
1 Eastman 2F61378-5 2850 220 4.2 50 1
2 Eastman 2F61159-5 2850 220 4.2 50 1
4 Eastman 2F61163-5 2850 220 4.2 50 1
5 KM 242430 3000-3600 220 3.32.6 5060 1
6 KM 264021 3000-3600 220 3.32.6 5060 1
10 KM 276350 3000-3600 220 3.32.6 5060 1
11 KM 270124 3000-3600 220 3.32.6 5060 1
12 KM 270152 3000-3600 220 3.32.6 5060 1
13 KM 276369 3000-3600 220 3.32.6 5060 1
14 KM 270149 3000-3600 220 3.32.6 5060 1
15 KM 247606 3000-3600 230 3.32.6 5060 1
16 KM 264059 3000-3600 220 3.32.6 5060 1
17 KM 276337 3000-3600 220 3.32.6 5060 1
18 KM 261615 3000-3600 220 3.32.6 5060 1

VIYELLATEX GROUP
SEWING SECTION
List of Machineries
SL Sewing Machine Quantity Brand
1 1-Needle Lockstitch (auto thread trimmer) 471 Juki, Brother, Sunstar,
Puff
2 1-Needle Chain Stitch, Flatbed 10 Joje, Feiyue
3 Vertical Trimmer 25 Juki, Sunstar
4 2-Needle Lockstitch 6 Sunstar
5 2-Needle Chain Stitch, Flatbed 16 Kansai, Joje, Feiyue
6 Multi Needle Chain Stitch 10 Kansai
7 4-Thread Over Lock (With electrical chain
cutter)
201 Juki, Pegasus, Kansai
8 2- Needle Piping (Backtape) 11 Pegasus, Kansai
9 2/3-Needle Covering Stitch (Flatlock) 167 Juki, Pegasus, Kansai
10 Zig-Zag Machine (Computerized) 2 Juki, Sunstar
11 Bartack Machine (Computerized) 30 Juki, Brother, Sunstar
12 Button Hole Machine (Computerized) 23 Juki, Brother
13 Button Sewing Machine (Computerized) 23 Juki, Brother
14 Smocking Machine (12 & 33 needle) 2 Kansai
15 Shirring Machine 1 needle elastic threads (12
ndl)
1 Kansai
16 Picoting Machine 2 Kansai
17 Rib Cutting Machine 12 Idea, Iu-922
18 Blind Stitch (Overlock) 4 Pegasus
19 Heat Transfer Machine 13 Lee way, Local
20 Hot Fixing Machine 4 Salli
21 Snap Button 13 Nyto, Uzu, Max
22 Fusing Machine 8 Hashima
23 Shaddle Stitch 4 Joje
Grand Total=2248

VIYELLATEX GROUP
NEEDLE GROUPS & SIZE
Machine Name Needle Group Size
PM DB*1 9
PM DB*1 11
PM DC*1 14
OL DC*1 9
OL DC*1 11
FL UY*128 9
Picoting FL UY*128 11
BH Tone DB*5 11
BS DP*17 11
Kansai Special UO*113 11
Nobilon Tape: Used in shoulder
Accessories used in Garments Sewing:
1. Button
2. Thread
3. Zipper
4. Main Label
5. Logo
6. Sticker
Allowance: (ILO)
1. Relaxation Allowance: 3%
2. Fatique Allowance: 3%
3. Personal Needs: 4%
4. Contingency Allowance:1%
5. Delay: Depends on Breakdown)

VIYELLATEX GROUP
Machine Band Country
SUNSTAR KOREA
KANSAI SPECIAL JAPAN
JUKI JAPAN
PEGASUS JAPAN
BROTHER JAPAN
PUFF JAPAN
FIG:BAND KNIFE FIG:STRAIGHT KNIFE

VIYELLATEX GROUP
FIG:AUTO4 SPREADER FIG: GERBER CUTTER

VIYELLATEX GROUP
Fig:SMOCKING M/C
No of needle: 33
No of needle thread:33
No of looper thread:33
Country origin:Srilanka
REMARKS:Viyella tex group well planned factory.Every thing which required for good working
condition is present here.All section in garments are well furnished.
2

VIYELLATEX GROUP
CHAPTER -04
RAW MATERIALS
In garments section different types of raw materials are used .They are describe
below
1.Fabrics:(Feed back from viyella tex knitting section)
1. Single jersey
2. 1*1 Rib
3. 2*2 Rib
4. Interlock
5. 3- thread fleece
6. 2- thread fleece
7. Single lacost
8. Auto striper Rib
9. Double lacost
10.Auto striper Single jersey
11.Auto striper lycra Single jersey
12.2.Thread:(Feed back from WELL,Coats Sylko,Purl,Merathon,Air Plane,Basic)
13.Spun polyster-4000m/cone
14.Filament thread -4500m-5000m/cone
15.Metal thread(gold,silver,bronge) -2500m-3000m/cone
16.Nylone thread
17.Aramid thread
18.Soft cotton thread
19.Glaced cotton thread
20.silk thread

VIYELLATEX GROUP
Thread required for
Basic T-shirt -120m-130m
Basic Polo-shirt -140m-180m
Basic Trouser for
Fleece fabric -250m
Rib fabric -175m-180m
Single jersey -150m-160m
Package:
Spool -100m-500m
Cop -1000m-2500m
Cone- 5000m
Vicone-filament thread & soft thread
Container
Large pakage-20000m

VIYELLATEX GROUP
SHORT NOTE
Thread Consumption: (Depends on G.S.M)
Plain machine:
Single Jersey: 2.5-2.75/inch
Rib/Fleece:3/inch
Overlock:
Single Jersey/Rib: 19-20/inch
Fleece:25-27/inch
Chain:
Single Jersey/Rib:5-6/inch (Single needle)
11-12/inch (Double needle)
Fleece: 8/inch (Single needle)
16/inch (Double needle)
Flatlock:
Single Jersey/Rib:
2 needle + 1 looper: 14/inch
Fleece: (Same as Single Jersey/Rib)
Smocking machine: 8/inch
Button holing m/c:
2 round: 25-30/inch
1 round: 22-23/inch
Button attaching m/c:
2hole:14/inch
4hole:16/inch
6hole:20/inch
6hole (Puma): 36/inch
Bartack: 28/(1/2)inch
Thread need for Garments making:
Basic T-Shirt:120-130m
Basic Polo-Shirt: 140-150m
Basic Trouser:
Fleece: 250m
Single Jersey/Rib: 175-180m

VIYELLATEX GROUP
3.Trimmings:
Chain
Zipper
Label & motif
Button :plastic,metal,wooden,horn.chalk,printed button
2-hole button
3-hole button
6-hole button(desin for PUMA)
Interlining :tearable,soft,hard,fusion.
Linning
Hook & loop fastening
Lace braid &elastic
Care label code for
Washing
Chlorine bleach
Ironing
Dry cleaning
Dry condition
Remarks:Viyella tex compomsite mill is self sufficient for collecting it fabrics .But it collects
thread & others trimmings & accessories from differents sources.

VIYELLATEX GROUP
CHAPTER -05
PRODUCTION PLANNING SEQUENCE & operation
PROCESS FLOW CHART
( CAD DEPARTMENT)
MERCHANDISING CUTTING
Art work + Spread Sheet RCVD buyar approval
From Merchandiser Master Pattarn
Making Pattern Completion of Grading
as per Spread Sheet+ Art Work As per spec sheet / sample
Computer processing Grading pattern with marker send
to
Order Model cutting section for Trial cut / Size
set
Marker Making Pattern update after getting size
set
As per Color Art Work Report as per color wise
Manual Work for neck rib+ The separate color pattern
Computer
Binding or Back Tape marker making as per ratio
Marker Delivery to Concern Delivery to cutting
Merchandiser for approval production

VIYELLATEX GROUP
LAYOUT PLAN OF CUTTING SECTION
LAYOUT PLAN OF CUTTING SECTION
LAY OUT PLAN OF SEWING FLOOR ( 2nd
floor right)

VIYELLATEX GROUP
Cutting Section (Sequence)
File collect from merchandiser
Fabric collect from store
Marker come from CAD
Fabric spreading (Lay)
Marker setting on the lay
Cutting(By using Straight knife, Band knife, Gerber cutter)
Sticker attach & hand check
Reject part change
Bundling
If required Print / Embroidery
Store on input rack

VIYELLATEX GROUP
LINE BALANCING OF A LONG PANT
SL PROCESS MACHINE QTY FOLDER GUIDE SO ASO
1 Care label joint PM 1 N/A PG 1 1
2 Back rise joint OL 1 N/A N/A 1 1
3 Front rise joint OL 1 N/A N/A 1
4 Fly inside overlock OL 1 N/A N/A 1
5 Back rise top FL 1 N/A NG 1
6 Fly false tack PM 1 N/A PG 1
7 Front rise top FL 1 N/A NG 1
8 Fly top FL 1 N/A NG 1 1
9 Pocket side tack PM 1 N/A PG 1
10 Pocket opening 2 part tack PM 1 N/A PG 1
11 Pocket opening top FL 1 N/A TG 1 1
12 Pocket tack with side PM 1 N/A PG 1
13 Pocket bag overlock OL 1 N/A N/A 1
14 Side seam OL 1 N/A N/A 2 1
15 Side seam top FL 1 N/A NG 1 1
16 Waist band make PM 2 N/A PG 1
17 Waist band contrast rib tack PM 1 N/A PG 1
18 Hole stitch HS 1 N/A N/A 1 1
19 Elastic make PM 1 N/A PG 1
20 Waist band round tack PM 1 N/A PG 1
21 Waist band joint OL 1 N/A N/A 1
22 Waist band top FL 1 N/A NG 1 1
23 Drawcord make PM 1 N/A PG 1 1
24 Drawcord tack PM 1 N/A PG 2
25 Pocket flap make PM 1 N/A PG 1 2
26 Flap top PM 2 N/A PG 1
27 Pocket folded tack PM 1 N/A PG 1 1
28 Pocket box top PM 1 N/A 1/16 CL 1
29 Pocket rolling FL 1 N/A TG 1
30 Pocket joint with lower panel PM 2 N/A PG 1 1
31 Pocket panel 1/16 top PM 2 N/A 1/16 CL 1
32 Pocket panel 1/4 top PM 2 N/A 1/4 CR 1
33 Pocket joint with body PM 1 N/A PG 1 1
34 Pocket 1/16 top PM 1 N/A 1/16 CR 1
35 Pocket flap joint + 1/16 top PM 2 N/A PG 2
36 Pocket flap 1/4 top PM 1 N/A 1/4 CR 1
37 Inseam OL 1 N/A N/A 1
38 Leg hemp tack PM 1 N/A PG 1 1
39 Leg hemp FL 1 N/A TG 1 1
40 Leg top FL 1 N/A TG 1
41 Bartack BTK 1 N/A N/A 1 3

VIYELLATEX GROUP
LINE BALANCING OF A SHORT SLEEVE polo-SHIRT
SL PROCESS MACHINE QTY FOLDER GUIDE OP HP
1 Placket Rolling PM 1 N/A PG 1 2
2 Placket Join PM 1 N/A PG 1 1
3 Placket Kacha PM 1 N/A PG 1
4 Placket Inside Fals Tack PM 1 N/A PG 1 1
5 Nose Tack PM 1 N/A PG 1 1
6 Placket 1/16 Top PM 1 N/A 1/16 CL 1
7 Placket Box PM 2 N/A PG 2
8 Shoulder Joint OL 1 N/A N/A 1 1
9 Care Label Joint PM 1 N/A PG 1
10 Collar Joint VT 1 1 cm N/A 1 2
11 Back Neck Tape Joint PM 1 1 cm N/A 1 1
12 Back Neck Tape Top PM 1 N/A 1/16 CL 1
13 Sleeve Hemp FL 1 N/A TG 1 1
14 Sleeve Joint OL 2 N/A N/A 2 1
15 Sleeve Opening Tack PM 1 N/A PG 1 1
16 Side Seam OL 2 N/A N/A 2 1
17 Sleeve 1/4 Tack PM 1 N/A 1/4 CL 1
18 Body Hemp FL 1 N/A TG 1 1
19 Side Seam Tack PM 1 N/A PG 1
20 Side Vent Top PM 2 N/A 1/4 CR 2
21 Hole Stitch HS 1 N/A N/A 1 1
22 Button Stitch BS 1 N/A N/A 1 1
23 Main Label Attach HEAT SE 1 N/A N/A 1 1
24 Bartack BTK 1 N/A N/A 1 3

VIYELLATEX GROUP
LINE BALANCING OF A SHORT SLEEVE T-SHIRT
SL PROCESS MACHINE QTY FOLDER GUIDE SO ASO
1 Front part shearing SM 1 N/A N/A 1 2
2 Arm hole + Neck shape tack PM 2 N/A PG 2 1
3 Shoulder joint (1) OL 1 N/A N/A 1 3
4 Back neck piping joint PM 2 1CM TG 2 2
5 Neck binding FL 1 8MM TG 1 1
6 Neck binding tack PM 1 N/A PG 1
7 Shoulder joint (2) OL 1 N/A N/A 1 1
8 Neck binding 1/4 tack PM 1 N/A 1/4CR 1
9 Care label joint PM 1 N/A PG 1
10 Sleeve overlock OL 1 N/A N/A 1
11 Sleeve rolling FL 1 N/A TG 1 1
12 Sleeve joint OL 2 N/A N/A 2 2
13 Sleeve opening tack +
Underarm tack
PM 2 N/A PG 2
14 Side seam OL 2 N/A N/A 2 1
15 Sleeve 1/4 tack PM 1 N/A 1/4CR 1
16 Bottom overlock OL 2 N/A N/A 2 1
17 Main label joint PM 1 N/A N/A 1 4
18 Label joint PM 1 N/A N/A 1

VIYELLATEX GROUP
Merchandising
Garment merchandising is an intricate and detail oriented job. If it can be done properly
can be very rewarding. On the country, if it is done with lack of knowledge, insufficient skill
and thoroughness, it can be destructive.
In the VIYELLATEX GROUP, very skilled and experienced personnel run the
merchandising section. After receiving an order, the merchandiser with the help of pattern
master calculates the total consumption of fabric. Then according to the cost detail sheet and
the price mentioned by the buyer costing is done. After the price is negotiated with the buyer
order is placed to the suppliers of raw material and accessories.
The manufacturing factory as per the requirement suppliers the fabric and a ledger is
maintained regularly to assess the production status. The accessories such as label, button,
zipper, sewing thread, packing materials are collected from outside [sometime mentioned by
the buyer] through back-to-back L/Cs. The merchandising department also looks for the
sources for procuring yarns to produce fabric.
Merchandising section monitors the production status regularly and ensures timely
delivery of the shipment.
Job responsibilities of Merchandising Team:
Job responsibilities of Merchandising Team
DEVELOPMENT AND COSTING
01
 Reviewing the development packs RCVD from buyer.
 Put the developments into work with product development team.
 Clarify all necessary info with buyer as much as possible.
 Follow up on the delivered sample deadline.
 Work out the initial costing (all costing must be checked by
merchandising manager)
 Price negotiation with buyer.
 Follow up with buyer reg. the feed back of the sample and costing
ORDER CONFIRMATION
02  Quoting the delivery dates to buyer after checking factory’s capacity
situation.
 Checking all the details in the order sheet once received form buyer.
 Communicate with buyer reg. any discrepancy in the order sheet.
 Passing the correct order sheet to all concerned dept i.e. planning,
production, commercial etc.

VIYELLATEX GROUP
Job responsibilities of Merchandising Team
SAMPLING
03  Updating production development tem reg. different sample
requirement of buyer at various stage (sales man, fit , sz set, pp
sample etc)
 Coordinating all fabric + trims which are required for sampling
purpose.
 Coordinating print, embroidery, wash for sampling.
 Checking all the technical aspects of samples before releasing to
customer.
 Checking all the aesthetic aspects of samples before releasing to
customer
 Checking the quantity requirement of each sample.
 Checking the necessary paper work of reach sample.
 Follow up the buyer reg. each sample comments.
BULK FARBIC
04  Work out the consumption for each new styles from CAD.
 Provide fabric booking to fabric department with correct quantity
and all necessary information.
 Follow up on the labdips/ strike off submission and chase approval
comments.
 Follow up on the fabric delivery against critical path
 Follow up on all fabric approval related issues.
 Prioritizing the fabric delivery schedule based on the garment
delivery dates.
BULK TRIM
05  Preparing the cost sheet/ check list for individual trims required for a
style.
 Chasing the trim details from the buyer.
 Submitting required trims to buyer for approval.
 Provide booking for individual trims to the approved source.
 Chasing the P/I from the most ensure ontime delivery.
 Monitoring the B/B L/C or TT payment status.
 Sourcing all trims form the most commercially viable source.
 Follow up with suppliers to ensure ontime delivery.
 Lialise with store in order to ensure all trims RCVD in correct
quantity and quality.
ESTABLISHMENT
06  Chasing the correct artwork for all print/embroidery from buyer.
 Develpping the design in the best possible method
 Provide capacity booking to print /embroidery plant in advance.
 Submitting print/embroidery strike off for buyer’s approval

VIYELLATEX GROUP
 Passing approved copy of the strike off to the print/embroidery plant.
 Negotiating the price with the subcontractors.
 Monitoring the panels sent and receive dates to ensure smooth
production flow
 Communicate with supplier for general issues.
FILING & CORRESPONDENSE
07  Maintaining style file for all running orders
 Maintaing the development file.
 General correspondence with buyer and suppliers.
 Critical correspondence with buyer and suppliers
 Weekly updates for buyer, such as audit schedule, production status
etc.
MEETING
08  Meeting with foreign buyers and suppliers.
 Meeting with local buyers and suppliers.
 Internal meeting with production, planning, quality, commercial and
HRD.
Remarks:
VIYELLATEX GROUP. has a well learned marketing & merchandising team. They always
communicate with the buyers. VIYELLATEX GROUP. has some fixed buyers. The
marketing section also looks the quality & quantity buyers.
Chapter-06

VIYELLATEX GROUP
QUALITY ASSURANCE SYSTEM
QUALITY CONTROL OF PRIECE GOODS:
To get quality products it requires good quality control of piece goods.
Even the most modern manufacturing methods cannot ensure quality of
the product if the material is defective. Fabric and the end product must
meet the expected requirement of the valued customer. It is the
responsibility of the manufactures and the fabric suppliers to ensure the
quality. Standar
 All holes regardless of 8size will be penalized 4 points
 No linear yard is to be penalized more than 4 points
 The average point value per shipment should not exceed 28 points
per 100 square yards
 Individual rolls exceeding 40 8points will be rejected and put out of
2production process
 The maximum number of 1-point defect per 10 square yards is 20.
But the average number of 1-point defects must be 14 or less per
fabric delivery.
MAJOR & MINOR DEFECTS:
MAJOR DEFECTS:
A defect that if so conspicuous that it would cause the item to be a
‘Second ’ is called a major defect. [A ‘Second’ is a garment with a
conspicuous defect that affects the saleability or serviceability of the
item.]
MINOR DEFECTS:
A defect that would not cause the product to be termed a second either
because of severity or location. When inspecting piece goods prior to
cutting, it is necessary to rate questionable defects as major.
GENERAL PROCEDURE:
i. Fabric / Garments are placed for visual Inspection
ii. An inspection table which is used to check the roll of fabric visually

VIYELLATEX GROUP
Types of fabrics fault
Slub (Major)
Knot (Major)
Missing yarn (Major)
Spot (Major)
Contamination (Major)
Weaving Fault
Thick yarn (4 point)
Stop mark
Dyeing stain
Hole (4 point)
Crease & stick mark
Jerk in
Oil Spot (4 point)
Quality control in sewing section
Front joint
↓
Make Section
↓
Collar closing
↓
One robbing QC check
↓
Output table checking
Working procedure
Front Joint  1 QC check 100%
Make Section  1 QC check 100%
Collar closing  1 QC check 100%
One robbing QC check full time
Output table  4 QC check 100%
Input section (Quality Checking)
Label measurement
Label placement
Shoulder point
Back yoke attachment
Back part
Box plate
Pocket
d Group in all steps of production maintain and ensure the quality of
piece goods and as well as the end product. The process of piece
goods inspection of Standard Group is described below-
Piece Goods Inspection:

VIYELLATEX GROUP
It is ensured by the Standard Group that suppliers carries out 100%
inspection prior to shipment. In addition 15% random inspection based
on 4-point system has to be carried out and a report must be
submitted to the group. Upon receipt of that report the inspection
team of the group again inspect the goods and accept / reject those.
Quality to inspect:
At least 10% goods covering all the lots of every colour and dye of
each shipment is inspected prior to spreading.
Selection of Rolls:
At least one roll of each colour is inspected.
Defect Classification:
The 4-point system followed by the group is described below:
Size of Defects Penalty point
Defects up to 3” in length 1 point
Defects up to 6” length 2 point
Defects up to 9” length 3 point
Defects over 9” length 4 point
Qualitypts/100 sq meter=(Total point*G.S.M)/( roll weight*10)

VIYELLATEX GROUP
Make Section
V-V measurement
Band overall
Band width
Collar point
Top stitch
Band rolling
Cuff overall measurement
Cuff rolling
Top stitch
Collar Closing
Size label
V-V measurement
Collar to collar band joint
Band down stitch
Shoulder joint accuracy
Sleeve length
Quality Control Finishing Section
Get up checking
Collar closing
Side seam
Sleeve placket attach
Cuff attach
Bottom hem
Back yoke
Every parts of a body
Records
Records of check list for inspection of accessories and packing
material
Records of swatch cards of approved accessories
Records of production swatch
Records of daily QC report
Records of cutting problem report
Records of inspection report during embroidery
REMARKS: Quality of viyella tex group is very good. 4-point system is used to
assure quality. From knitting to finishing in garment section quality is checked
step by step.

VIYELLATEX GROUP
Chapter-07
MAINTENANCE
Name of different maintenance equipment’s or tools:
1. Screw driver (Flat & Star)
2. LN key
3. Hand Socket Wrench Set
4. Manual & Digital Slide Calipers
5. Slide Wrench
6. T – Wrench
7. Pipe wrench
8. Dull Wrench
9. Phile (Half round, round, triangular, flat, square)
10. Pliers (Normal & Nose)
11. Stop ring pliers (Inside & Outside)
12. Timing gauge
13. Table vice
14. Hand vice
15. Hack saw
16. Hack saw frame
17. Hand drill machine
18. Stand drill machine
19. Hammer
20. Ball pin Hammer
21. Mobil gun
22. Grinder
23. Welding machine
24. Drill bit
25. Top bit
26. Top bit drill
27. Varnier outside calipers
28. Tester
29. Multi meter
30. Sucker
31. Shouldering wire
32. Electronic balance
33. Digital lux

VIYELLATEX GROUP
SEWING MACHINE LUBRICANT
PHYSICAL AND CHEMICAL PROPERTIES
SPECIFICATION EJ58/052
1 Supplier MOBILE OIL CORP
2 Viscosity ISO VG22
3 Color CLEAR + 30 (SAYBOLT)
4 Relative density 0.849 G/CM3
5 Flash point 2040C
6 Pure point -12.50C
7 Viscosity at 40C 21.0 CST
8 Viscosity at 1000C 4.3 CST
9 Usage for FOR E, L, M, W ETC
TO MAINTAIN MACHINE TROUBLE FREE:
The following instruction must be carried out to secure the utmost in
production and to the prolong the life of your machine-
Before morning start
 To oil every moving parts with one or two drops of oil
 To check whether needle is correctly set or not damage
 To check whether threading is correct
 To check whether chaining thread of approximately 10 mm long
remain behind pressure foot.
PLAIN MACINE
Changing Over The Specified Voltage And Changing The Fuse
Be sure to turn off the power to the machine before starting the
procedure
Insert a slotted screwdriver into the slot of change over the voltage
and set the voltage to a desired voltage. Set the operating voltage to the
position with ‘’ mark
Replacing the fuse
Be sure to turn off the power to the machine before starting the procedure
Starting the procedure and remove the cap from the fuse holder. Then, take
out the fuse and replace it with a new one.

VIYELLATEX GROUP
Error Message
The error will be shown by the number of times of flashing on an off of the
LED lamp in the control box when any error is detected during operation.
No of times
of LED
Flashing
Error
Description
Item of confirm
1 Defective
ED-2
 Check whether connector of the ED-2
is securely inserted
 Check whether adjustment of material
detection is properly performed
2 Abnormal
memory
 Turn OFF and return ON the power
switch
3 Abnormal
synchronizer
 Check whether connector of the
synchronizer is securely inserted.
4 Abnormal
panel
communication
 Check whether the panel cord
connector is disconnected or loose
5 Motor lock  Check whether thread is caught in the
motor pulley shaft
 Check whether anything is entered in
the motor pulley cover
 Check whether the v-belt is not on the
motor pulley
Safely Circuitry
The machine incorporates the following safety circuitry
If the V-belt is not on the motor pulley
If the sewing machine is driven with its V-belt off, the safety
circuitry is actuated in about 2 seconds to stop the whole operation. If this
happens, turn the power OFF, properly mount the V-belt before turning the
power ON again. This safely circuitry is also actuated when the sewing
machine has been subjected to any abnormal load.
If a needle position detector has failed
Failure of the upper or lower needle stop position detecting function is
automatically directed by the safety circuitry. Then, the machine actuates
as one with a clutch motor, and it is possible for the motor to be used in this
state until it is repaired

VIYELLATEX GROUP
OVER LOCK MACHINE
To protect against possible personal injury due to abrupt start of the m/c, be
sure to start the work after turning the power off and ascertaining that the
motor is at rest.
 Position of the needle thread take up and the needle thread eyelet
 The needle thread take up shall be positioned at the lower dead pt.
 Position of the looper thread take up and the looper thread guide
 Checking the cartridge filter and replacing it after a long period of
usage, cartridge filter may become clogged with dust
 Insert a cartridge
Remove first oil discharging screw
Remove screw and lift top cover just above until it comes off
 Dimensions use to adjust the looper and the needle guard
 Lubrication
Remove the oil cap
Poor juki m/c oil 18 into the oil reservoir
Supply oil until the pointer bar almost reaches the upper red marker
line when oil guage is observed from the side.
BUTTON ATTACHING MACHINE:
Checking the needle
Always check that the tip of the needle is not broken and also the
needle is not bent before starting sewing
Cleaning the Rotary Hook
Pull the shuttle race cover toward you to open it and then remove the
bobbin case
Open the setting claw in the direction indicated by the arrow and
then remove the shuttle race body and the shuttle hook
Clean all the dust and thread ends from around the driver, the top of
the rotary hook thread guide and the shuttle race
Lubrication
 Fill the arm-side oil tank with oil
 Fill the bed side oil tank with oil
 Add oil to the felt of the shuttle race base
When setting up the sewing machine and when it hasn’t been used for
an extended period of time, be sure to add 2-3 drop oil to the felt
If using the liquid cooling tank, fill it with silicon oil.

VIYELLATEX GROUP
BUTTON HOLING MACHINE
 Turn off the power switch before carrying out cleaning, otherwise the
machine may operate if the treadle is depressed by mistake, which
could result in injury.
 Be sure to wear protective goggles and gloves when handling the
lubricating oil and grease so that they do not get into your eyes or
onto your skin otherwise inflammation can result.
 Furthermore do not drink the oil or eat the grease under any
circumstances as they can cause vomiting and diarrhea, keep the oil
our of the reach of children.
Cleaning
 Remove lint and dust from the thread passages
 Remove lint and dust form around the work clamp
 Remove the bobbin case and remove lint and dust from around the
shuttle
 Clean away any thread scraps and cotton dust from around the lower
thread trimmer mechanism.
BAR-TAKE MACHINE:
Maintenance of Bar-take machine
 Adjust the height of the needle bar
 Adjusting the needle to shuttle relation
 Adjusting the lift of the work clamp foot
 Adjusting the rising amount of the thread tension dist
 The moving knife and counter knife
 Cleaning the filter
 Draining waist oil
 Replacing the fuse
REMARKS: This mill has strong maintenance fitter`s troop to fix up the
problem. They are very active to perform their duty.S

VIYELLATEX GROUP
KNITTING SECTION
INTRODUCTION
Knitting is one kind of fabric manufacturing process in which fabric is produced by
interlooping among loops formed by single or several yarn feeding simultanesously.Knitted
fabrics produced with stitch formation.
Stitch is most important structural element of knitted fabrics .The stitch consists of a head
,two legs ,two feet and upper&lower connection point.
Knitting Process Flow Chart
Yarn collect by cone package from spinning
Setup yarn on creel
Yarn passage through different tentioner and possitive feeder
Adjust stitch length and GSM by VDQ pulley
Produce ½ inch fabric and inspection
Knitting the fabrics and without any fault / If fault correct it
Cut the roll of fabric
Marking theroll
Inspection and grading according to Quality Control
Transferred the fabric to grey store.

VIYELLATEX GROUP
MACHINE DESCRIPTION
SL
NO.
M/C
NO.
Model Type of m/c Dia &
Gauge
No. of
feeder
No.
of
needl
e
Saf
ety
rp
m
Brand
name
1. 06161
2
PL-XRA/CE Rib 38”*18 76 2124 23 PAI LUNG
2 06161
0
pL-XS4B/A/CE Single jersey 36”*24 144 2712 25 PAI LUNG
3
4
5
6
7 05119
4
PL-
XS3B5MW/A/B
/CE
Single jersey
30”*24
90 2256 25 PAI
LUNG
8
9
10
11
12 Single jersey 26”24 78 1856 22 FUKUHA
RA
13
14 07082
8
PL-XS3B/A/CE Single jersey 26”24 78 1856 22 PAI
LUNG
15 05119
4
PL-
XS3B5MW/A/B
/CE
Single jersey 30”*24 90 2256 25 PAI LUNG
16 05119
4
PL-
XS3B5MW/A/B
/CE
17 05119
4
PL-
XS3B5MW/A/B
/CE
18 05119
4
PL-
XS3B5MW/A/B
/CE
19 05119
4
PL-
XS3B5MW/A/B
/CE
20 36”*22 CAOTRR
21 36”*18 24 CARROT
22 06061
3
PL-XS3B/A/CE Single jersey 24”*24 72 1800 40 PAILUN
G
23 06061
3
G
24 05119
2
G

VIYELLATEX GROUP
25 05119
2
PL-XS3B/A/CE Single jersey 25”*24 74 1872 42 PAINGL
U
26 06124
2
PL-XF3B-LD/C Single jersey 30”*20 90 1872 25 PL
27 06124
2
PL-XF3B-LD/C Single jersey 30”*20 90 1872 25 PL
28 Single jersey 36”*22 72 2484 25 PL
29 PL-XD2B/CE Interlock 36”*22 72 2484 25 PL
30 06061
7
PL-XRA/CE Rib 38”*18 72 2160 23 PL
31 06061
8
PL-XR2B/CE Rib 38”*18 76 2124 23 PL
32 06061
8
PL-XR2B/CE Rib 38”*18 76 2124 23 PL
33 06061
8
PL-XR2B/CE Rib 38”*18 76 2124 23 PL
34 Single jersey 30”*24 32 MAYER
& CIE
35 Single jersey 30”*24 32 MAYER
& CIE
36 O7083
2
PL-XRA/CE Rib 40”*18 80 2256 22 PL
37 O7083
2
PL-XRA/CE Rib 40”*18 80 2256 22 PL
38 07082
1
PL-XR2B/CE Single jersey 42”*14 84 2370 21 PL
39 07082
1
PL-XR2B/CE Single jersey 42”*14 84 2370 21 PL
40 07083
1
PL-XRA/CE Rib 36”*16 72 1800 25 PL
41 05119
2
U
42 05119
2
U
43 07082
8
LUNG
44 07082
8
LUNG
45 NOT FOUND FUKUHA
RA
46 06161
0
pL-XS4B/A/CE Single jersey 36”*24 144 2712 25 PAI LUNG
47 Rib PAI
LUNG
48 Single jersey 30”*24 PAI
LUNG
49 05119
5
PL-XSCS/6 Single jersey 30”*24 42F*6
C
2256 20 PAI
LUNG
50 05119
6
C
2256 20 PAI
LUNG
51 06123 PL-XDCS/E-U Rib 36”*18 54 2040 16 PAILUN

VIYELLATEX GROUP
V-Bed Knitting machine specification:
M/C
NO.
MODEL NO. GAUGE DATE
1 M-100 14 10.2000
2 M-100 14 10.2000
3 M-100 14 10.2000
4 M-100 14 10.2000
5 M-100 14 10.2000
6 M-100 14 10.2000
7 M-100 14 04.2001
8 M-100 14 04.2001
9 M-100 14 04.2001
9 G
52 06124
0
PL-XDCS/E-U Rib 36”*18 54 2040 16 PAILUN
G
53 07082
3
C
2256 20 PAI
LUNG
54 07082
2
C
2256 20 PAI
LUNG
55 06082
4
PL-XSCS/6 Single jersey 36”*24 50*6(
Sinker
)
2256 22 PAI
LUNG
56 07082
5
PL-XSCS/6 Single jersey 36”*24 50 2712 19 PAI
LUNG
RA
RA
RA
RA
61 VXC-3.2S Single jersey 30”*28 FUKUHA
RA
RA
RA
RA
65 VXC-3S Single jersey 28”*24 FUKUHA
RA
RA
RA
RA

VIYELLATEX GROUP
10 M-100 14 04.2001
11 M-100 14 04.2001
12 M-100 14 04.2001
13 M-100 14 04.2003
14 M-100 14 04.2003
15 M-100 14 04.2003
16 M-100 14 04.2003
17 M-100 14 04.2003
18 M-100 14 04.2004
19 M-100 14 04.2004
20 M-100 14 04.2004
21 M-100 14 04.2004
22 M-100 14 04.2004
23 M-100 14 04.2004
24 M-100 14 04.2004
25 M-100 14 04.2004
FLAT BED M/C CAPACITY
Productin/1 hr= 21 pcs (m/c manufacture date 2003,2004 =13)
Total production=13*21*8=2184 pcs/shift
Productin/1 hr= 14 pcs (m/c manufacture date 2000,2001 =12)
Total production=12*14*8=1344 pcs/shift
Total production=3528 Pcs
Note: All m/cs are conventional . There is no modern m/s. It is not suitable for industry.
FABRIC WIDTH: Two types of fabric width
1) Open width
2) Tubular width
Difference between Open width & Tubular width
Open width Tubular width
Mark line contains for fabric cutting No mark line
Fabric dyes in open form Fabric dyes in tubular form
Open width is double than tubular
width
Tubular width=12*open width
For single jersey For Rib, Interlock

VIYELLATEX GROUP
Production Calculation:
asM/C
NO.
M/C Dia
&
Gauge
Fabric
type
Production
kg/shift
Yarn type S.L/GG
1 38”*18 Rib 126 30’s CB 2.52
2 36”*24 Single
jersey
115 26/1 CD 2.70
3 36”*18 Rib 78 26/1 D/L SCHOCO 2.65
4 36”*18 Rib 72 34/Spun poly 2.40
5 36”*18 Rib 72 28/1 CD 2.40
6 30”*24 Single
lacoste
65 26/1 CD 2.62
7 30”*24 Single
jersey
107 28/1 CD 2.75
8 28”*24 Single
jersey
100 26/1 CD 2.70
9 30”*24 Single
jersey
112 28/1 CD 2.75
10 30”*24 Double
lacoste
72 28/1 CD 2.62
11 26”*24 Single
jersey
110 26/1 CD 2.84
12 26”*24 Single
jersey
85 2.75
13 26”*24 Single
jersey
86 26/1 CD 2.84
14 26”*24 Single
jersey
110 26/1 CD 2.70
15 30”*28 Single
jersey
64 34/1 CD+20Dlycra 3.02
16 30”*20 Fleece 55 34/1 CB+75D Poly 280
17 30”*20 Fleece 55 34/1 CB+75D Poly 230
18 36”*24
19 30”*24
20 36”*22 Fleece 45 150/2 Poly+20D Lycra 215
21 36”*18 Rib 80 28/1 CD+40D Lycra 280
22 24”*24 Single
jersey
90 26/1 CD 2.70
23 24”*24 Single
jersey
80 26/1 CD 2.70
24 25”*24 Single
jersey
90 24/1 CD 2.70
25 24”*24 Single
jersey
90 24/1 CD 2.70
26 30”*20 Single
jersey
80 34/1 CD+12/1 CD 235
27 30”*20 Single
jersey
88 34/1 CD+12/1 CD 235
28 36”*22 Single 34/1 CD+20D Lycra 3.02

VIYELLATEX GROUP
jersey
29 36”*22 Interlock 70 150D Poly+20D Lycra 215
30 38”*18 Rib 125 30/1 2.52
31 38”*18 Rib 115 30/1 CD+40D Lycra 200
32 38”*18 Rib 112 30/1 CB 2.75
33 38”*18 Rib 110 30/1 CB 2.75
34 30”*28 Single
jersey
70 34/1 CB 2.52
35 30”*28 Single
jersey
34/1 CB 2.52
36 40”*18 Rib 140 34/1 CB 2.68
37 40”*18 Rib 140 34/1 CB 2.68
38 42”*18 Rib 130 34/1 CB 2.52
39 42”*18 Rib 135 34/1 CB 2.52
40 36”*18 Rib 90 28/1 CD+40 Lycra 280
41 25”*24 Single
jersey
100 24/1CD 2.84
42 25”*24 Single
jersey
100 24/1CD 2.84
43 26”*24 Single
jersey
110 28/1 CB 2.70
44 26”*24 Single
jersey
100 28/1 CB 2.70
45 30”*20 Single
jersey
123 28/1CD 2.98
46 36”*24 Single
jersey
30/1 CB 2.68
47
48 30”*24 Single
jersey
98 26/1 CD 2.75
49 30”*16 Double
jersey
36 24/2
GM+22/2L+ZADE+M.Navy
4.23
50 30”*24 Single
jersey
22 28/1
metal+white+black+30/1
GHTR
2.75
51 36”*18 Rib 26/1 TAVPE
MARL/SCHOCO/OFF
WHITE/ROSE
2.65
52 2.80
53 30”*24 Single
jersey
19 20/1 D/Y DK-
CALICO+RED
3.20
54 30”*24 Single
jersey
22 28/1
D/Y+WHITE+BLACK+30/1
GHTR
2.75
55 36”*24 Single
jersey
28 28/1 WHITE+ DK+DK
NAVY+30/1 GHTR
2.75
56 36”*24 Single
jersey
30 28/1 WHITE.30 g.mtl+28/1
CB
2.70
57 26”*24 Single
jersey
110 28/1 WHITE.30 g.mtl+28/1
CB
2.70
58 26”*24 Single 112 28/1 WHITE.30 g.mtl+28/1 2.68

VIYELLATEX GROUP
jersey CB
59 26”*24 Single
jersey
108 26/1 CD 2.75
60 26”*24 Single
jersey
90 26/1 C D 2.70
61 30”*28 Single
jersey
60 40/1 CB-PT44O8 2.52
62 30”*28 Single
jersey
53 40/1 CB-PT44O8 235
63 30”*20 Fleece 75 34/1 CV+75D Poly+10/1 cvc 235
64 30”*24 Fleece 76 34/1 CB+75D Poly+1`2/12
CB
2.70
65 28”*24 Single
jersey
92 28/1 CB 2.75
66 32”*24 Single
jersey
146 28/1 CB 2.75
67 32”*24 Single
jersey
168 28/1 CB 2.75
68
Total production/shift =5242 kg
Total inactive m/cs =8
KNITTING
MACHINS

VIYELLATEX GROUP
Types of Yarn
Yarn:
1. Combed (601,501)
2. Carded(341)
CVC=Chief Value of Cotton (60%Cotton+40%Polyester,
65%Cotton+35%Polyester,70%Cotton+30%Polyester)
PC=Polyester-Cotton (60%Polyester+40%Cotton)
Mellange:
1. Anthra (5%Viscose+95%Cotton)
2. Ecru (2%Viscose+98%Cotton)
3. Normal (10%Dyed+90%Undyed)
*100% Cotton Mellange : 10%Dyed+90%Undyed , 10%Dyed+90%Undyed
COSTING OF YARN
Combed yarn:
Count Price ($/KG)
40/1 3.70/72
34/1 3.40/42
32/1 3.35
30/1 3.30
28/1 3.25
26/1 3.20/22
24/1 3.15
22/1 3.15/10

VIYELLATEX GROUP
20/1 3.05
Carded yarn:
Count Price ($/KG)
34/1 3.05
30/1 2.95/90
28/1 2.82
26/1 2.80
24/1 2.60
22/1 2.45
20/1 2.25
16/1 1.90
12/1 1.80/85
10/1 1.75
7/1 1.70
Spandex:
Count Price ($/KG)
20D 13.70
40D 8.80
70D 8.60
Machine Maintenance Flow Chart
Belt open
Thread cutting
Running machine with oil
Fabric cutting
Cam box open
Needle open
Clean cylinder & dial
Separate reject needle

VIYELLATEX GROUP
Creel capacity:
Single jersey (PAI LUNG)=31*9=279
Single jersey (FUKUHARA)=26*8=208
CARROT=16*8=128
MAYER & CIE=24*8=192
CONCLUSION
Bangladesh export 37%(2007) knitted fabrics to differnt countries such as USA,UK
,Germany but cotton produce 0% in Bangladesh.
It is a great problem for us. On the other hand cotton produce in USA 23% ,China
37%,Pakistan 10%,India 23%,Uzbek 6%(2007).
From knitting section we can learn about different types of m/cs, m/cs design change,
production capacity, helping us.it will be very helpful for our practical life.layout plan,
knitting elements,fabrics faults & solution etc. Thanks to knitting AUTO
STRIPER=126*4=504
DYEING SECTION
Flow chart of dyeing Section
Grey fabric from knitting section

Batching

Dyeing

Transfer to finishing

VIYELLATEX GROUP
Flow chart of finishing Section
Flow chart for Peach finish/Brush:
Slitting
Stenter
Sueding/Raising
Stenter
Compacting
For Lycra:
Slitting
Heat Setting
Sewing
Drying
Slitting
Stenter
Compactin
Finishing section
Open fabric Tube fabric
Slitting machine
Stentering
Compacting
machine
Final
inspection
Dewatering machine
Drying machine
Tube Compacting
machine
Final
inspection
Line Diagram of Jet
Dyeing M/c

VIYELLATEX GROUP
No of Machine for Dyeing and Finishing Section:
Specification of Different Machines:
DYEING SECTION:
Dyeing Machine. 01(Fongs)_
Type Jet Dyeing Machine
Manufacturer name FONG’S
Country China
Model No. ECO-38-2T
Year of manufacturing 2003
Temp. Range 00
-980
C
Used Utilities Water, Steam, Electricity, Compressed Air
No. of Motor 7
Production Capacity 500 KG
Dyeing Machine.02(Thies)
Manufacturer name THIES
Country Germany
Model No. D-48653 COESFELD
Temp. Range 00
-1400
C
No. of Motor 7
No Of Nozzle 04
Dyeing Section
1. Dyeing Machine 15
2. Sample Dyeing Machine 07
Finishing Section
1. Super Slitter 03
2. Dewatering Machine 02
3. Stenter 02
4. Dryer 02
5. Tube compactor 02
6. Open width compactor 02
7. Raising Machine 02
8. Sueding Machine 02
9. Turning Machine 01
10. Slitting & Dewatering
Machine
01

VIYELLATEX GROUP
Dyeing Machine. Thies-03
Country GERMANY
Model No. D-48653 COESFELD
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 4
Dyeing Machine. THIES-04
Country GERMANY
Model No. ECOSOFT PLUS
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 1
Country GERMANY
Model No. 41350
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 2
Type HTHP Dyeing Machine
Country GERMANY
Model No. 41354
Temp. Range 00
-1400
C

VIYELLATEX GROUP
No. of Motor 7
No. of Nozzle 4
Dyeing Machine. FONGS-07
Type BULK Dyeing Machine
Manufacturer name FONGS
Country CHINA
Model No. ECO-6-1T
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 1
PermissibleWorkingPressure 380 Kpa
Test Pressure 585 Kpa
Country CHINA
Model No. ECO-6-1T
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 1
PermissibleWorkingPressure 380 KPA
Type BULK Dyeing Machine
Country CHINA
Model No. ECO-6-3T
Temp. Range 00
-1400
C
No. of Motor 7
No. of Nozzle 3

VIYELLATEX GROUP
Type High Speed jumbo Dyeing Machine
Country CHINA
Model No. HSJ-4T
Temp. Range 00
-1400
C
No. of Motor 8
No. of Nozzle 4
Test Pressure 520 KPa
Type HSJ Dyeing Machine
Country CHINA
Model No. HSJ-3T
Temp. Range 00
-1400
C
No. of Motor 8
No. of Nozzle 3
Dyeing Machine.FONGS-12
Country China
Model No. HSJ-SR-3T
Temp. Range 00
-1400
C
No. of Motor 3
No. of Nozzle 3
Test Pressure 520 KPa

VIYELLATEX GROUP
Country CHINA
Model No. HSJ SR 6T
Temp. Range 00
-1400
C
No. of Motor 9
Production Capacity 1680KG
No. of Nozzle 6
Country CHINA
Model No. HSJ SR 3T
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 3
Country CHINA
Model No. HSJ SR 4T
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 4
Sample Dyeing Machine.FONGS-01
Type ALL FIT-30 Dyeing Machine
Country CHINA

VIYELLATEX GROUP
Model No. P-D 5500-2000-CAT -2
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 1
Sample Dyeing Machine.THIES-02
Type Sample Dyeing Machine
Country GERMANY
Model No. D-48653-COESFELD
Temp. Range 00
-1400
C
No. of Motor 9
Inhalt Capacity 523 Litre
No. of Nozzle 1
Country CHINA
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 1
Country CHINA
Temp. Range 00
-1400
C

VIYELLATEX GROUP
No. of Motor 9
No. of Nozzle 1
Country CHINA
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 1
Country CHINA
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 1
Country CHINA
Temp. Range 00
-1400
C
No. of Motor 9
No. of Nozzle 1

VIYELLATEX GROUP
FINISHING SECTION:
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 – Lustre , whiteness , etc .
- Improving the feel , which depends on the handle of the material and its
softness , suppleness , fullness , etc .
- Wearing qualities , non – 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:
1) Chemical reaction of auxiliaries with fibers.
2) 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 sewability
 Soft or stiff handle.
 Shine or luster

VIYELLATEX GROUP
FINIS
HING
MAC
HINS
(OPE
N
LINE)
Slitting,De-
watering &
Detwisting
m/c
St
en
te
r
Raising
m/c
Seudi
ng
m/c
Open
Compa
ctor

VIYELLATEX GROUP
Open fabric line for finishing
Slitting and dewatering machine
Machine specification:
Brand name: CORINO MACCHINE
Type/model no:
Company: Italy
Year: 2005
No of motor: 08
Function of the Machine:
 Used to remove excess water after pretreatment and dyeing
 To slit the tube fabric by the knife for opening of the fabric and ready for
stentering
 Delivered fabric is crease free state
 Before squeezing balloon is formed with the help of compressed air
passing by a nozzle or air sprayer
 It can control the diameter of fabric and GSM and shrinkage by over
feeding mechanism
 To impart soft finish to the fabric by using required softener.
Main parts of the machine:
- Squeeze roller (to remove water)
- Stretcher (to control width)
- Over feeding wheels (to control GSM)
- De-twisting device (To delivery the fabric roll in untwisted form)
- Folding device (to delivery the fabric in folded form)
- Squeezing roller
- Padder for softener
Controlling points or Control system:
1. Overfeed control
2. Pressure
3. Speed control
4. Width control
Power consumption:
Voltage: 400V
Frequency: 50Hz
Maximum power: 24kwatt
Manpower Required:
Worker: 02

VIYELLATEX GROUP
Production:
Capacity: 10 tones/shift
Actual production: 7 tones/shift.
Utility:
i) Water
ii) Electricity
iii) Compressed air or Processed air (to form the tube fabric into ballon with a
view to remove crease)
Feed roller pressure:
Bar PSI Kg Lbs
1 14.5 90 200
2 29 205 450
3 43.5 315 700
4 58 425 940
5 72.5 540 1200
6 87 650 1440
Work instruction:
Fabric Type Pad pressure Speed Over Feed
S/J 2.5 – 3 40 -50 40
PK 3 40 -50 40
1x1 Rib 3 -3.5 50 -60 25
Mini
padder
De-twister
Rubber coated
padder
Wooden padder
Plaiter
Camera
Dancing roller
Dancing
roller
Fabric path of Slitting, De-watering &
De-twisting m/c
Feed
Delivery

VIYELLATEX GROUP
2x2 Rib 3 – 3.5 60 40
P/I 3 – 3.5
Mer S/J 2 40 40
Mer PK 2.5 40 40
Mer 1x1 Rib 2.5 – 3 50 25
Mer 2x2 Rib 2.5 – 3 60 40
Mer P/I 2.5
Find out the limitations and faults of the machine and advise for removing these.
i) Workers does not record the pressure, in dia and out dia of different fabric in
record book
ii) Workers set the pressure of squeeze roller for different fabrics same. But
higher GSM fabric needs more pressure than lower GSM fabric. So removal
of excess water is not sufficient.
iii)
Stenter machine
Machine no. 01
Brand name: BRUCKNER +MAHLO
Type/model no: 72276-0463
Company:
Country: Germany
Year: 2004
Other specification:
Speed range:
15-30 m/min (for knit)
15-80m/min (woven)
Temperature range: 20-2500
C
No of motor in drying unit: 29
Total no of motor: 49
Maximum width = 102
Minimum width = 30
Steam pressure: 2 bar
Air pressure: 10 bar
Applied for: Open width fabric

VIYELLATEX GROUP
Machine no. 02
Mc specification:
Brand name: SUN SUPER.
Country: KOREA.
Speed range:
Max: 110m/min.
Use: 45 m/min.
Temperature range:
Max: 500 C
Use: 180 C (For heat set).
No of motor in drying unit:
Total no of motor:
Max dia: 295cm.
Min dia: 95cm.
Steam pressure: 2 bar
Air pressure: 10 bar
Applied for: Open width fabric
Fabric path of stenter
Overfeed & pinning
Fabric in the chain

VIYELLATEX GROUP
Extra attachment:
iv) Mahlo attachment for bowing control.
v) Selvedge gumming device
vi) Selvedge cutting device
i) Drying
ii) GSM control:If overfeed increases,then GSM increases and vice versa.
iii) Width control :The width is controlled by means of Spreader,Expander.
iv) Shrinkage control
v) Decrease sprirality
vi) Decrease Bowing effect
vii) Softener application
viii) Surface coating for Teflon finish
ix) Soil release chemical finish
x) Heat set for cotton lycra fabric
i) Feed zone
-Centering device
ii) Chemical padding zone
-Squeezing roller
-Chemical tray
iii) Bowing control zone
-Bowing roller (rubber roller, no of roller -2)
-Sensor (no of sensor -6)
-Uncurling roller
iv) Chain entry zone
-Uncurling device (both side of the chain entry)
-Sensor (both side of the chain entry)
-Brush roller (for attaching the fabric with the pin of the chain, no of
brush roller -4)
-Selvedge gumming device with gum box under the chain entry
v) Drying zone
-Gas rotamatic burner (10)
vi) Cooling zone
vii) Delivery zone
viii) Relax R/r
ix) Padder
x) Pin roller
xi) PLC profivassleeve converter.
xii) Plaiter roller
xiii) Take up roller
xiv) Wheel
Burner used in Bruckner:Radiomatic burners are used.The parameter of radiomatic
burner is as follows
Capacity:150kw
Voltage:230-240V
Freequency:50-60Hz
Fuel:Natural gas

VIYELLATEX GROUP
Pressure:50 mbar
Function of angular roller:
Stripe control
Bowing control
Straightness of fabric
Chemical used:
Silicon softener (It is used to soft and slippery of the fabric)
Manpower Required:
Worker: 6
Production:
Actual production: 3.5-4.5 tones/shift.
Heating arrangement:
No of Rotamatic burner: 10
There are 5 heating chamber in this machine. Each chamber has two burners which is
placed two sides of the machine.
Chamber Burner Burner
01 1A 1B
02 2A 2B
03 3A 3B
04 4A 4B
05 5A 5B
Temperature:
Maximum = 2500
C
Sample = 1100
C
Average = 130-1700
C
Utility:
i) Gas
ii) Electricity
iii) Compressed air.
Parameters used for different types of fabric:
BRUCKNER
Fabric Req.
GSM
Finish
GSM
R F B Temperature Speed
m/min
Over
feed
S/J 140 - 68” 71” 67” 140 14 60%
” 160 150/52 56” 64” 60” 150 20 10%
” 180 170/72 54” 56” 54.5” 110 12 60%
“ 190 188/90 58” 61” 57” 110 15 60%
H/J 280 270/75 64” 67” 62” 110 7 50%
Loop
back
280 255/60 74” 78” 75” 110 9 60%
Fleece 260 260/65 74” 80” 75” 110 9 60%
1×1 rib 240 224/26 72” 75” 74” 110 10 60%

VIYELLATEX GROUP
SUNSUPER
Fabric Req.
GSM
Finish
GSM
R B F Temperature Speed
m/min
Over
feed
S/J 190 178 58” 56” 60” 110 24 50%
S/J(c.v.c) 180 180 56” - 59” 110 35 50%
H/J 280 276 70” 72” 73” 120 18 50%
1*1 Rib 240 244 72” 73” 75” 120 18 40%
Bolton
stripe
330 335 62” 66” 70” 130 16 60%
Fleece 280 270 76” - 78” 110 16 50%
Open compactor
Machine no. 01
Brand name: HELIOT International
Type/model no: HC2000GL
Company: France
No of motor: 08
Over feed = m/min
Machine speed = m/min
Speed range: 13-22m/min
Termperature range: 100-1400
C
Maximum width 86
Minimum width 36
Applied for: Open fabric
Left over feed: -20%+20%
Right over feed: -20%+60%
High production: -20%+60%
Front over feeding cylinder: -20%+60%
Middle belt: -20%+60%
Check point:
1. Check steam & air line pressure
2. adjust felt temperature
3. Blanket pressure:3.5-4.0-4.5
Some instructions for optimum performance:
1. Center the felt blankets on the cylinder. Ensure that all cylinders are running parallel
relative to each other. Adjust the limit switch against the edge of the felt.
2. Place the felt under tension. Upper felts tension-2 bar, Lower felt tension-1 bar.
3. raise the heated drum working temperature to 200 f| & set the speed to 11-22
yd/min(10-20 m/min)
4. Open the humidification ramp in order that felts are in a steam atmosphere.
5. As soon as these conditions are reached, let the felt run for 2.5 m

VIYELLATEX GROUP
Machine no. 02
Brand name: FERRARO
Type/model no: COMPTEX-RE 2800.
Company: ITALY.
No of motor: 17
Over feed = Max + 35%, Min -35%.
Machine speed = Max 32m/min, Min 4m/min.
C
Maximum width =240cm
Minimum width =100cm
Applied for: Open fabric
Left over feed: -20%+20%
Right over feed: -20%+60%
High production: -20%+60%
Front over feeding cylinder: -20%+60%
Middle belt: -20%+60%
1. To compact the fabric
2. To control the shrinkage
3. To maintain proper width and G.S.M
Heating system:
Steam
1. Heating chamber
2. Blower (2, one at the entry chain zone for uncurling and another at the
entry of compacting zone)
3. Synthetic blanket as a conveyor,
4. Folder
5. Exhaust fan
6. Unpinning cylinder (-40%+40%)
7. Belt cylinder (-40%+40%)
8. Uncurling device at entry of compacting zone.
9. sensor
10.brush roller
Additional attachment:
i) Selvedge cutting
ii) Selvedge safety
iii) Pinning safety
iv) Selvedge unrolling
v) Selvedge drying
vi) Steam zone heating

VIYELLATEX GROUP
Controlling points:
- Water pressure 2.5 lb
- Air pressure 4 lb
- Steam pressure 6 lb
Manpower Required: Worker: 06
Production: Capacity: 5 tones/shif
Actual production: 4 tones/shif
Utility: Steam Electricity, Compressed air.
Special finishing machine
Sueding
A sueder is sometimes referred to a s a sander since the machine consists of one or more
rolls covered with sand paper as the abrasive. Fabrics traveling over these rolls develop a
very low pile and the material's surface can be made to feel like suede leather. The hand will
depend on the fiber composition, the filament count in the yarn and the intensity with which
the fabric is worked.
Filament fabrics can be made to feel like a spun fabric and all fabrics will have a softer hand.
Brush: The brushes of Sueding mcs are made up of Silicon carbide.
Sueding machine
Machine parts:
Suction hood

VIYELLATEX GROUP
Fabric slowing roller
Drag cylinder
Sueding brush
Feeding roller
Folding unit
Inlet tighter
Brand name: Lafer SPA
Type/model no: GSI106
Company: Italy
Year: 2002
No of motor: 08
Winch speed: 10-30m/min
Machine speed: 50m/min (max)
Drum speed: 30-35-50 rpm (Max 70)
Pile roller no: 06
Pile made of Plastic
Plaiter tension: 6kg
Taker in tension: 20kg
Fabric return driver Tension: 25kg
Drum Tension: 50kg
Speed range: 10-40 m/min
No of cylinder/drum:
2 for double cylinder
1 for single cylinder
No of pin roller: 24 2 = 48
24 1= 24
Cylinder r.p.m (General): 100
Tension: 3 kg
Manpower Required:
Worker: 03
Production:
Capacity: 40 tones.
Raising m/c:
In which process a layer of fibers lifting from the body of the fabric to achieve
soft and lofty effect on the surface is called raising.
Raising machine -1 (Single drum)
Type/model no: GRI 124C
Country: Italy
Year: 2002
No of motor: 04
No of pile roller: 24
Machine speed: 50
Drum speed: Max 120

VIYELLATEX GROUP
Manpower Required: Worker: 05
Production : Capacity: 2 tones/shift
Utility : Electricity, Compressed air.
Raising machine-2 (Double cylinder)
Type/model no: GRI 224A
Country: Italy
Year: 2003
No of cylinder: 2
No of pile roller: 24+24
Machine speed: 50
Drum speed: Max 120
No of motor: 05
Speed range: 20-30 m/min
No of cylinder/drum: 1
No of pin roller: 6
Cylinder r.p.m (General): 100
Tension: 3 kg
Production: Capacity: 5 tones/shift
Utility : Electricity, Compressed air.

VIYELLATEX GROUP
Tube fabric line for finishing
Dewatering machine -1
Dewatering Machine
No. of the machine 02
Manufacturer name Heliot International
Country France
Model No. EXP-24C
Speed 90 m/min
Used Utilities Water Electricity, Compressed Air
No. of Motor 06
Slitting machine
Sutter Slitter
Manufacturer name AKAB
Country Sweden
Model No. CR-2400
Used Utilities Electricity, Compressed Air
No. of Motor 03
De-twister
Rubber coated
padder
Conveyor belt
Width controller

VIYELLATEX GROUP
Tensionless Dryer Machine
Functions:
1. To dry the fabric with help of steam
2. To control the shrinkage
3. To prepare for next subsequent process
4. To dry tubular and open width fabric without tension
Brand name:HELIOT international
Serial no: D700HWT
Company: France
Temperature range: 110-1600
C
Each motor required 300 watt.
No of motor: 08
Worker: 04
1. Heating chamber (2)
2. Blower (8)
3. Synthetic blanket as a conveyor
4. Folder
5. Exhaust fan
Production:
Actual production: 8 -9 ton/shift.
Heating chamber: 3
No of rotamatic burner: 3
Heating system:
1. Gas fired
Temperature of the machine:
PV PV PV
129.50
C 1300
C 1350
C
SV SV SV
1300
C 1300
C 1350
C
Utility:
1. Gas (to make fire)
2. Electricity (to rum the machine)
3. Compressed air (to spread the fire)

VIYELLATEX GROUP
Parameters used for different types of fabric:
Types of
fabric
Buyer Batch Color In
dia
Out
dia
Overfeed Machin
e speed
Temperat
ure
Vibra
tion
Collar TESCO White 6 (m).
10(monito
r)
6 1300
C 120
5885 Blue 6 .10 7.0 1400
C Off
S.
Oliver
5843 0147 6 .10 4.0 1600
C Off
11 Rib 6.10 7.0 1300
C 120
TESCO 5870 White 36 34 6.10 7.5 1300
C 120
5874 Hela
pink
6.10 8.5 1400
C 120
5888 Black 38 36 6.10 7.0 1500
C 120
ESPRI
T
5836 Black 38 35 6.10 5.0 1600
C
22 Rib W.W 1480/06 Blue 6.10 5.0 1500
C 120
52 Rib M&S Sample Pink 6.10 5.0 1400
C 120
Interlock 1300
C 120
Single
lacost
TESCO 5882 RED 6.10 8.0 1400
C 120
Double
locost
EMA 5828 White 46 44 9.10 5 1400
C 120
Conveyor belt
Feed
Delivery
Conveyor belt
Feed roller
Vibrating roller
Burner

VIYELLATEX GROUP
Find out the limitations and faults of the machine and advise for removing these.
i) Selvedge drying system is not properly functioning.
ii) Maximum over feed of the machine is +60%.
iii) When the steam temperature is 1000
C-1200
C, then delivered fabric temperature is
45-500
C. But there is no cooling zone in this machine to reduce the excess
temperature. So a cooling zone in delivery zone can be attached.
Tube compactor machine -1,2
Brand name: HELIOT International
Type/model no: HCPPI
Company: France
No of motor: 07
Over feed = 40m/min
Machine speed = 25m/min
C
Maximum width 52
Minimum width 16
Applied for: Tube fabric
Manpower Required:
Worker: 06
Production:
Capacity: 5 tones/shift or 10 tones/day
Temperature: 1100
C
Utility:
Steam, Electricity, Compressed air.

VIYELLATEX GROUP
REMARKS:
VIYELLATEX GROUP. is a well equipped industry. As the quality of the
machineries of dyeing, finishing & testing section are good, so the quality level of the
product is also good.
Sequence of Operation for Knit Dyeing:
Grey fabric received from knitting section

Batching

Fabric turning

Loading to the m/c

Select production programme

Pre-treatment (Scouring & Bleaching)

Select recipe for Dyeing

Recipe confirmed by DM/SPO

Dyeing

Post Treatment

Unload
Steam
arrangement
Upper shoe
Lower
shoe
Big
cylinder
Fabric Path of Tube Compactor
Feed
Delivery
Feed roller

VIYELLATEX GROUP
Production Parameters:
1) PH
- During H2O2 bleaching PH
9.2-12(Alkaline)
- During reactive dyeing PH
10.5-12.5(Alkaline)
- During disperse dyeing PH
4.5-6.0 (Acidic)
2) Temperature:
- For cotton scouring: 900
-950
C
- For cotton cold wash: 300
-400
C
- For cotton hot wash: 700
-800
C
- For cotton acid wash: 600
-700
C
- For cotton dyeing: 80-900
C (For hot brand)
600
C (For cold brand)
- Polyester dying: 1000
-1300
C
3) Time:
- For Scouring: 60-90 minutes
- For Disperses dyeing 60-90 minutes.
4) M: L ratio:
- For reactive dyeing M: 1 ratio maintained between 1:6 to 1:10.
Description of Production Process:
Washing for colored fabrics:
 The colored fabrics, to be washed is loaded in the machine
 Required amount of water is taken.
 Felosan NOF (detergents) added & washing continued at 800
C for 20 minutes.
 Cold washing
Scouring-bleaching:
 Fabric, to be scoured is loaded in the machine
 Required amount of water is loaded
 Washing agent| detergent is added
 Steam pipes are on & scouring agents (i.e., caustic soda/ soda ash) added when the
temperature reaches at 700
C
 Then H202 is added.
 Temperature is then raised to 1050
C & the process is then carried out for 60-90
minutes depending on the requirements.
 The liquors are then drained.
 Then wash with Felosan NOF (detergent) at 980
C for 5 min.

VIYELLATEX GROUP
 Then cold wash, at 350
-450
C & acid wash, at 600
-700
C is done.
Dyeing:
 After acid wash all liquors are drained out.
 Required amounts of water is taken
 Then leveling agents, anti-creasing agents, de-foaming agents are added according to
the requirements.
 Steam pipes are on & after 10-15 minutes dyes are added.
 Salts are added and runtime is 15-20 minutes.
 Then soda ash, after another 35minutes.
 Then the temperature is raised slowly up to the mark.
 The process is carried on & samples are taken after every 30-40 minutes to match
with the target shade. It continues until shade matching.
 If the sample is matched, then the liquor is drained out.
 Then cold wash at 350
-450
C.
 Wash with Cibapon R (Washing agent) for 5 minutes.
 Acid wash at 550
C is done.
 Fixing agent is added at 450
C for 15 minutes.
 Then softener is added at 450
C for 15 minutes.
Dyeing Curve:
600
C
900
C
&
10’
CBB
+
NOF
Caust
ic H2O2
1050
C
& 30’
700
C
600
C
980
C
&
10’
Drain
Drain
Acid PC
Acid Bioace
900
C
&
10’
CS
Drain
Drain
Drain
NOF
Scouring & Bleaching Curve
600
C
&
10’
550
C
&
30’
A. Acid
+C+DBC
Color Dosing
(20’)
Salt
Soda Dosing
(35’)
Check
Shade
Dyeing Curve
10
R
Acid Bioace
Drain
550
C
& 30’
Hot
Wash
450
C
& 30’
EC
450
C
& 30’
Acid Softener
Cold
Wash
Fabric
Unload
15’ 20’ 20’

VIYELLATEX GROUP
Production Flow Chart:
Production flow chart for 100% cotton fabric:
Dyeing procedure for dark shade
Felosan NOF/Wetting agent = 0.5g/l
Kappazon H53NEU/Stabilizer (H2O2) = 0.5 g/l
Anticreasing agent = 1.0 g/l [Only for S/J]
60o
C x 5'
Caustic → 2 g/l
60o
C x 15'
Hydrogen peroxide → 2.5 g/l [Dosing 10']
(60o
C - 80o
c)
Temperature rise up to 105o
C
30'
Acetic acid → 1.0 g/l
H2O2 killer → 0.5 g/l
60o
C x 10'
Acetic acid → 0.8 g/l (To control pH
= 4.5-5.5)
Enzyme → 1.5 g/l
55o
C x 45' - 60'
Kappaquest FE / Sequestering Agent → 0.35 g/l
90o
C x 5'
Sarabid LDR → 0.5 g/l (leveling agent)
60o
C x 5'
Gluber Salt (Runtime → 10')
60o
C x 10'
Dye stuff
60o
C x 35' Runtime 20'
Soda ash
60o
C x 40' Runtime 60'
Bath drop after shade matching
Hot rinse
60o
C x 10'

VIYELLATEX GROUP
Soaping
80o
- 95o
C x 10'
Cold rinse
45o
C x 10'
Neutralize (Acetic acid = 0.5 g/l)
45o
C x 10'
Fixing
40o
C x 15'
Softening
Unload
Dyeing procedure for Light / Medium Shade
Felosan NOF/ Wetting agent = 0.5 g/l
Kappazon H53NEU /H2O2 Stabilizer = 0.5 g/l
Anticreasing agent = 1.0 g/l
60o
x 5'
Caustic = 2 g/l
60o
C x 15' [Dossing]
Hydrogen peroxide (H2O2) = 2.5 g/l
(60o
- 80o
C)
Temp rise up to 105o
C & Run - 30'
Acetic acid = 1.0 g/l
H2O2 killer / Kappaquest FE = 0.5 g/l
60o
C x 10'
Acetic acid = 0.8 g/l [To control PH
- 4.5 - 5.5')
Enzyme = 1.5 g/l
55o
C x 45' - 60'
Sequestering agent = 0.35 g/l
90o
C x 5'
Sarabid LDR /Levelling agent = 0.5 g/l
Anticreasing - 0.5 g/l
60o
x 5'
Dye stuff
60o
x 35' - Run time - 20'
Glauber Salt
Dosing - 60o
x 10' - run time - 20'
Soda ash
60 x 40'
Bath drop after shade matching

VIYELLATEX GROUP
Hot rinse - 10' x 60o
C
Soaping
80o
- 90o
C x 10'
Neutralization / Acetic acid
45o
C x 10
Cold rinse - 45o
x 10'
Softening
Unload
Dyeing Procedure for White Colour
Felosan NOF/wetting agent → 0.5 g/l
Kappazon H53NEU /Stabilizer → 0.5 g/l
Anticreasing agent → 1.0 g/l [Only for S/J]
Caustic → 3 g/l
60o
C x 15'
Hydrogen peroxide → 10.0 g/l
60o
C x 10'
Syno white 4BK/Optical brightener (60o
→ 80o
C)
105o
x 60'
NT x 10'
Acetic acid → 0.8 g/l [To Control PH
- 4.5 - 5.5]
Enzyme → 1.5 g/l
55o
C x 45' - 60'
Sequestering agent → 0.5 g/l
90o
C x 5'
Softener → 1.5 g/l
40o
C x 10'
N. Hot
Unload
Remarks:
VIYELLATEX GROUP., strictly follow up the production parameters like time,
temperature, M:L ratio, PH
etc. As they do some difficult shade, it takes more time for the
production of the batch and the dyeing process may vary from the dyeing flow chart for
different types of fabric & different types of shade.

VIYELLATEX GROUP
WORKING PROCEDURE FOR LAB
SAMPLE IN (FABRICS)
Physical Test Wet Lab.
 Color fastness to light
 Bursting strength Color Fastness To Washing Dimensional Stability
 Pilling
 Crocking Prepare the sample
Pre-Production Sample Final Sample
Evaluate the Sample Wash the sample according to buyer measure
Test Testst
Report Making Tumble dry
Prepared the Report
Keep the sample Flat in conditioned temp
Pass Fail at least two hours before measure
Pass Fail
Delivery Refinish Measure the sample
Go for the final Refinish
Need to test again Prepared the Report
Need to test again
Pass Fail
Ready to deliver Refinish
Need to test again

VIYELLATEX GROUP
1.
Procedure of the Different Tests:
Different types of fastness tests of the dyed fabric are done in quality control
department of the VIYELLATEX GROUP LTD. Different types of method (Standard or
buyer’s recommended) are followed for different types of tests. The process of the different
tests of fabrics & lab. dip dyeing is described in the following section:
Color Fastness Test Procedure
Color Fastness:
The “color fastness” of a colored textile is defined as its resistance to these changes
when subjected to particulates of conditions. It follows that color fastness must be specified
in terms of these changes and expressed in terms of the magnitude.
1. Color Fastness to Wash Test
Required materials:
1. Sample size 40  100 mm
2. Multifiber at 40  100 mm
3. ECE detergent (WOB) – 4g/L
4. Sodium Perborate (Na2BO3.H2O2.3H2O2-1g/L) - 1g/L
5. Distilled water
6. Normal cold water
7. Steel balls
Required instrument:
1. Rota Wash
2. Scissor
3. Stitch machine
Procedure :
1. Cut sample & multifibre at 100  400 mm and then stitch.
2. 50 ml ECE detergent (WOB) & 50 ml Sodium per borate is taken with the
sample.
For Marks & Spencer, the solution is taken by the following formula:
(Sample fabric + Multifibre weight)  50 ml
3. The sample is kept in 600
C for 30 minutes in Rota Wash Machine
4. Rinse the sample twice with cold water.
5. Dry at 60°C by hanging or by Flat iron pressing but temperature should not
be more than 150°C.
Report:
Dry the specimen and the change of shade & degree of staining is measured by Grey
Scale & Staining Scale.

VIYELLATEX GROUP
2. Color Fastness to Perspiration Test
Test specimen:
 Sample fabric – 50 mm  50 mm
 Multifibre fabric – 50 mm  100 mm
 Cut the multifibre into two piece
 Sandwich the test specimen between two piece of multifibre
Testing Solution:
1. Alkaline Solution:
Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/L
NaCl – 5.00 g/L
Disodium hydrogen orthophosphate (Na2HPO4.2H2O) – 2.5 g/L
PH
– 8 (Adjust by 0.1 N NaOH)
2. Acidic Solution:
Histidine monohydro chloride monohydrate (C6H10ClN3O2.H2O)– 5.00 g/L
NaCl – 5.00 g/L
Sodium di-hydrogen orthophosphate (NaH2PO4.2H2O) – 2.2 g/L
PH
– 5.5 (Adjust by 0.1 N NaOH)
Method:
- The composite specimen is put in a peri dish (2 specimen of a sample).
- Solution (Alkaline & Acidic) is taken in the two peri dish. Here, M:L is taken
1:20.
- Bubble is made out from the specimen by tapping.
- The specimen is put for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.
- Excess solution is poured off.
- Peri dish with composite specimen & glass plate is placed into the incubator at
(372) 0
C for 4 hours.
- The specimen is dried (Temp  600
C)
Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.
3. Color Fastness to Water Test
Test specimen:
 Sample fabric – 50 mm  50 mm
 Multifibre fabric – 50 mm  100 mm
 Cut the multifibre into two piece
 Sandwich the test specimen between two piece of multifibre

VIYELLATEX GROUP
Testing Solution:
 Water is taken as required
Method:
- The composite specimen is put in a peri dish (2 specimen of a sample).
- Water is taken in the peri dish as required.
- Bubble is made out from the specimen by tapping.
- The specimen is put for 30 minutes.
- A glass plate is placed on the composite specimen for 15 minutes at room
temperature.
- Excess solution is poured off.
- Peri dish with composite specimen & glass plate is placed into the incubator at
(372) 0
C for 4 hours.
- The specimen is dried (Temp  600
C)
Report:
- Change of shade & degree of staining is measured by the Grey Scale & Staining
Scale.
5. Color the Fastness to Rubbing (Dry & Wet) Test
Sample:
- Dyed fabric – 15 cm  5 cm
- White Test Cloth - 5 cm  5 cm
Procedure:
- White test cloth is put on to the grating and stag by steel wire.
- The sample is run twenty times manually for ten seconds. and the rubbing
fastness of the sample cloth and degree of staining is accessed.
- For rubbing fastness (Wet), the rubbing cloth is placed in the water and socked
and squeeze. The wet rubbing cloth is placed on to the grating and stag with
stainless steel wire and run ten times manually then assess the staining on to the
rubbing cloth and the rubbing fastness of the sample cloth is accessed.
Report:
- Change of shade of the sample is measured with grey scale and degree of staining
of the white test cloth is measured by Staining Scale.
There are also some tests are done in the lab. And the process is described below-
A. Measuring the Dimensional Stability (Shrinkage & Spirality):
Sample:
 Two piece of 50 cm  50 cm fabric is taken for test.
Procedure:
a. Conditioning: Put the sample in table for 4 hrs for conditioning before starting
test.

VIYELLATEX GROUP
b. Cut the sample 50x50 cm & benchmark should be 35x35 cm. Stitch the sample
(3 sides) by over lock sewing machine.
c. Put sample in washing machine and run according to buyer’s choice.
d. Drying: All Buyers’ requirement is tumble Dry except ECHO SCOURING is
flat dry.
SHRINKAGE TEST CALCULATION:
Before wash – After wash
Shrinkage % = X 100
Before wash
Spirality test calculation:
S = (S1+S2) / 2
Spirality = (S+S  L)/100.
Suppose,
S1 = The right side distance of the specimen from the stitch line after
wash.
S2 = The left side distance of the specimen from the stitch line after
wash.
L = Length before wash
B. pH of a Dyed Fabric Test
Test specimen:
 2 gm of dyed fabric is taken.
 The fabric is cut into pieces of (0.5 cm  0.5 cm)
Procedure:
1. The sample is taken into conical flax.
2. 100 ml distilled water (slightly warm) is taken into the conical flax.
3. The conical flax is put on the Magnetic Stirrer for 30 minutes.
Report:
The PH
of the conical flax is measured by Digital PH
meter.
Remarks:
VIYELLATEX GROUP. always aware about the quality of the product. The quality
of the product is always approved by the buyer. They follow the quality standard: ISO -
9002:2000. VIYELLATEX GROUP. is well equipped for checking the quality of the
product. They sent the quality report to the buyer time to time/batch to batch.

VIYELLATEX GROUP
Print
Sample Preparation
After getting work order from product development dept.

Prepare design according to outwork

Screen preparation

Sample preparation

Approved Sample

Bulk production
Bulk Production:
Screen Preparation

Print Paste preparation

Printing is done on the mc or manually

Drying

Curing

Final Inspection
Printing m/cs:
1. Flat bed Screen Printing (04 m/cs)
Red Chili( USA )
No of Head-10
Stroke-02

Conveyor Dryer(04 M/cs )
Radicure(USA)
Three chambers:Chamber 1-Temp.-200 C
Chamber 2-Temp-200 c
Chamber 3-Temp.-200c
Expose Room:
1. Sensitizing emulsion-Polymer type,Photocure TXR -97%
2. Hardener-3%
3. Mesh-90-130
4. Heat

VIYELLATEX GROUP
Heat Press machine-02 m/cs
Temperature-160 c
Pressure-5-6 Kg
Time-3-5-10-15 seconds.
Types of Printing in VIYELLATEX GROUP:
1. Pigment printing
2. Plastic printing
3. Rubber printing
Capacity:
Average 30000 pcs/day.
EMBROIDERY SECTION:
No of machines:08
Brand Name:Tajima
Country:Japan
No of Head:20
Electronic multiheaded automatic embroidery machines
20 Head machine-07
12 Head machine-01
Highest RPM-1200 (It depends on design of fabric)
The following types of stitches are used here:
Run stitch
Tatami stitch
Sateen stitch
Motif stitch
Jig-jag stitch
Threads Used in Embroidery Section:
Polyester, Cotton, Rayon, Metalic threads
Capacity: 3000pcs/shift(1 shift = 12 hr

VIYELLATEX GROUP
CHAPTER 08
UTILITY SERVICE
Introduction:
VIYELLATEX GROUP LTD. is a big project and so of course having a vast
project of utility service. Here the total account of utility facilities are available. The utilities
are
a) Water
b) Gas
c) Electricity
d) Compressed Air
e) Steam.
WATER
Water treatment plant:
(Water Softening Method – Base Exchange Process)
Source of water is deep tube well.
Production capacity – 80 m3
/hr = 1920000 liter/day
Actual Production – 1500000 liter/day
Required water - 1300000 liter/day
Technical
Details
Raw Water
tank
Filter Tank (1) Filter Tank (2) Hardness
Removing Tank
Size Length – 30´
Width - 15´
Height – 6’
Diameter – 6´
Height - 15´
Diameter – 6´
Height - 15´
Salt reqd:
190 kg/day/tank
Regeneration
time 1.30 hrCapacity 360 Ton
Source Natural source
Deep tube well
Raw Water
Tank
Filter Tank (1) Filter Tank (2)
ELECTRICITY
Gas Generator is used for supplying electricity for the dyeing, knitting & office of the
VIYELLATEX GROUP LTD.
Total power produced by Gas Generator – 945 KW = 1134 KVA
Factory (Dyeing & Knitting) Power Needed for Installation – About 1200 KW
Factory (Dyeing & Knitting) Power Needed at Running stage – About 720 KW
Power Needed for Office – About 250 KW
Specification of Gas Generator is given below:
Technical Details Generator Data
Type Gas Generator

VIYELLATEX GROUP
Manufacturer Cummins Power Generation
No. of Gas Generator 03
Model No. 315 GFBA
Manufactured Country England
Year of Construction 2002
Rated Power Prime
Rated 315 KW
Power Factor 0.8
Voltage 400
Rated Current (amp) 568
Frequency (Hz) 50
Rotating Speed (RPM) 1500
Battery Volts 24
Control System PCCP
Site altitude before derate 800 MASL
Site ambient temp. before derate 400
C
Source of Power used for Garments – DESA
Power Capacity – 750 KVA = 900 KW
There is a diesel Generator in the industry.
Capacity of Diesel Generator – 800 KW
Specification of Diesel Generator is given below:
Technical Details Generator Data
Type Diesel Generator
Manufacturer CATERPILLAR
No. of Diesel Generator 02
Model No. SR4B | SR4
Manufactured Country U.S.A.
Rated 649 H.P. or 484.0 KW
Rotating Speed (RPM) 1500
Voltage 400
Rated Current (amp) 723
Maximum Temp. 1050
C by Resistance

VIYELLATEX GROUP
COMPRESSED AIR
Compressed air is produced by air compressor.
There are two air compressors for producing compressed air.
Specification of the air compressor is given below:
Technical Details Air Compressor 1 Air Compressor 2
Type Atlas Copco Atlas Copco
Manufacturer Atlas Copco Airpower Atlas Copco Airpower
Model No. GA 30 GA 55
Manufacturer Country Belgium Belgium
Year of Construction 2002 2004
Maximum Working Pressure 10 bar 10 bar
Free air delivery 78 liter/sec 145 liter/sec
Nominal Shaft Power 30 KW 55 KW
Rotational Shaft Speed 3000 r/min 3000 r/min
Gross Weight 995 Kg 1550 Kg
STEAM
Steam is produce by Boiler.
From the Water Treatment Plant, water is stored in a reserve tank and from there water goes
to boiler & steam is produced.
Specification of the Boiler is given below:
Technical Details Boiler Data
Type Fire Tube Boiler
Manufacturer OMNICAL BORSIG ENERGY
Model No. DDHI 60 – 10
Manufacturer Country Germany
Thermal Capacity 3.9 MW
Maximum Steam Out 6 ton/hour
Maximum Working
Pressure
10 bar-g
Content up to NW 10940

VIYELLATEX GROUP
GAS
The source of Gas is TITAS GAS LTD.
The gas is supplied to gas generator or different section (Boiler- for heating water) from the
main line of the TITAS GAS LTD.
Sources of Utility:
Electricity : PDB & Generator
Steam : Boiler
Water : Pump
Compressed air : Compressor
Gas : TITAS GAS LTD.
Remarks:
As the biggest project the VIYELLATEX GROUP., so the vast utility systems.
There is a skill manpower group of engineers and other technical staffs to look after these
utility services. They have to remain aware of solution on a great sense of responsibility for
any type of problem due to utility supply

VIYELLATEX GROUP
CHAPTER: 09
STORE AND INVENTORY CONTROL
CHAPTER 1
Inventory Control:
Store is the place where every type of raw materials, spares, finished goods are kept
in proper system. Inventory control means the accurate calculation and data of every type of
raw materials spares and finished goods in time to time store 4 inventory control are
necessary, because –
1. To know about the required amount of raw material
2. To know about the job no – which would be processed
3. To be continued the production process
4. To find out the profit or loss of a company
5. Stock and stock value for consumption measuring
Frequency of Inventory Update:
- Monthly inventory control.
- Annual inventory control.
Scope of Inventory Control:
- Raw materials
 Dyes store.
 Other chemicals.
 Grey fabrics.
- Finished fabric.
- Spare parts.
- General store:
 Capital equipments.
 Accessories.
 Stationary.
 Maintenance parts.
Inventory System for Raw Material:-
 Raw materials partially received from production planning & directly from head office.
 Material receiving & inspection report (MRIR) is prepared. Received quantity is
mentioned and noted down.
 Submitted to Q.C. department. Some are OK & few rejected.
 Entry of data of goods in DATATEX.
 Goods are arranged according to OK or rejected group.
 Department gives store requisition to warehouse.
 As per requisition materials supplied & this record are noted down.

VIYELLATEX GROUP
In VIYELLATEX GROUP LTD. there are different inventory systems for different raw
materials.
Grey Fabric Store:-
All the grey fabrics are stored in the fabric store near the batch section. Different types
of fabric are listed in the sheet according to fabric types, quantity and consumer’s
requirement. Fabrics GSM, shrinkage, diameter & other properties are also taken into
consideration. The batches are prepared by taking the required fabrics from the grey store.
Stages of Grey Fabric Inventory Control:
 After knitting production.
 Grey inspection.
 Warehouse.
 Batch preparation.
 Dye house.
Dyes And Chemicals:-
There is a different store for dyes and chemicals. Varies types of dyes and chemicals are
stored here according to dyes and chemicals companies. Different types of dyes and
chemicals are listed in a sheet. In the sheet the stored quantity of dyes and chemicals are also
included. Every day the sheet is updated and a copy of this sheet is supplied to the dyeing
manager, dye house and lab section.
Spares:-
In VIYELLATEX GROUP LTD. required amount of spears of different machines are
stored in the mechanical store room. All the spears are listed in a sheet which is controlled
by the mechanical & maintenance personnel. Spares are arranged in the store room
according to there size, quantity & requirements. There are shelf's in the store room to keep
the small spare parts.
Finished Goods:-
VIYELLATEX GROUP 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, buyer's name, Color & considering other technical parameters.
Stages of Finished Fabric Inventory Control:
 Finishing section.
 After final inspection.
 Warehouse.

VIYELLATEX GROUP
Others:
There is a central store at VIYELLATEX. In that store the various types of
forms, papers; stationary & other necessary goods are kept.
Inventory Procedure
 Bin Card
 Store Requisition
 Store Ledger Account
 Daily Inspection & Package Report
 Monthly Stock & Consumption Report
 Monthly L/C wise Delivery Report
 Received Delivery & Balance Stock
Remarks:-
VIYELLATEX GROUP. has individual stores for raw materials, finished goods etc.
There is not enough space to store the finished goods. It requires increasing the store area.
In VIYELLATEX GROUP. the store for inventory control is satisfactory. Sometime, they
fluctuate from ideal process otherwise they are ok.

VIYELLATEX GROUP
CHAPTER :10
COSTING
Introduction:
Costing is a process by which the setting price of a product is calculated. It is a very
important task for a factory which runs for business purposes.
And it is also strictly followed in the VIYELLATEX GROUP. Costing of the products
considering the raw materials expenditure, salary and wages of officers and workers,
distributions and advertisement expenses etc. all direct and indirect expenses is done in this
factory. It is determined by a troop of accountants with advice and consultancy of executive
director.
Costing Of the Product
The following points are considered for costing any dyed product in VIYELLATEX.
1. Total dyes & chemical cost
2. Total utility cost
3. Salary
4. Payment
5. Transport cost
6. Lunch
7. Entertainment cost
8. Miscellaneous cost
9. Government cash incentive
Price of the Product:
Generally price of product is determined by the required profit adding to the total
expenses. So,
Price of products= (Direct expenses + Indirect expenses + Factory
Overhead) + Required profit
Price Range of Different Products:
T-Shirt = $0.75 - $4.50 /Pcs
Polo Shirt =$2.00 - $6.50 /Pcs
Kids Wear ==$0.75- $2.15 /Pcs
Knitting Charge of Different Fabrics:
Fabric name Charge per
kg(Tk)
1. Single Jersey 09
2. Single Jersey with Lycra 30

VIYELLATEX GROUP
3. Single locust PK 16
4. Double lacost PK 16
5. Single PK 16
6. Double PK 16
7. Rib 17
8. Rib with Lycra 30
9. Interlock 25
10. Auto striper 80
11. Auto striper with Lycra 100
12. Fleece 22-25
Dyeing Charge of Different Fabrics:
Name of fabric process Charge per
kg(Tk)
1. White with Enzyme 35
2. White without Enzyme 30
3. Avg. color with Enzyme 85
4. Avg.color without Enzyme (Light&
med.)
75
5. Deep shed with Enzyme (Black) 110
6. Deep shed without Enzyme (Black) 95
7. Only wash (Tubular) 25
8. Only wash (Open) 45
9. Double dyeing (Face & Back) 115
Finishing Charge of Different Fabrics:
Name of fabric process Charge per
kg(Tk)
1. Slitting only 5
2. Stenter only 25
3. Compacting only 15
4. Stenter + Compacting 35
5. Stenter + Compacting+ wash 50
6. Tube Compacting 10

Industrial attachment of viyellatex group

Industrial attachment of viyellatex group

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