An overview of Fakir Knitwears Ltd..pptx
- 1. Presentation on Industrial Attachment of Fakir Knitwears Limited Supervisor Dr. Md. Ahashan Habib Associate Professor & Head Department of Textile Engineering Management Submitted By Name Student id Samia Siddika Mou 2017-1-5-001 Assadudjaman Redoy 2017-1-5-046 Nanjiba Fairuz Rifa 2017-1-5-047 Shaishab Dey 2017-1-5-070
- 2. PROJECT DESCRIPTION Profile • Comprehensive knitwear manufacturing • Ultra modern plant with backward linkage Guideline • High quality Innovation & Development • Gaining through honesty Plan • Empowering women • Education for next generation
- 4. FACTORY LAYOUT A= Knitting (Unit 1), WTP, Dyeing, Finishing, Washing Plant B= Screen Printing Unit C= Manual Printing, Embroidery unit D= Administrative Building, Garments Unit ( Cutting , Sewing & Finishing) E= “ Green Building “ Under Construction F= Yarn Storage, Knitting ( Unit-2) Plant G= Effluent Treatment Plant
- 5. Mission & Vision Mission Best value for money One stop knit products manufacturing Ensuring Excellent management practices Be a model for other Vision Set a benchmark Leading Garment manufacturer
- 6. Product Focus T- Shirt(35% ) Leggings (20%) Polo Shirt(5%) Accessori es(10%) Dress(15 %) Vest(15% )
- 7. FKL’S BUYERS
- 9. Production • Knitting capacity: 55 tons per day • Dyeing capacity: 50 tons per day • Finishing Capacity: 60 tons per day Garments • Cutting Capacity : 35000 pcs per day • Garments Capacity: 300000 pcs per day • Washing Capacity: 8000 pcs per day Printing & Embroidery • Printing Capacity: 200000 pcs per day • Embroidery Capacity: 80 million stitch per day
- 10. Man Power Management: Manpower management is the way of controlling manpower to ensure the most efficientand economical use of available workforce. In a composite texture industry a huge amount of manpower is needed to draw proper and quality production.
- 11. Shifting System 1ST Shift: From 8 am to 8 pm. 2nd Shift: From 8 pm to 8 am. Number of employees :10,500
- 12. Prohibition of FORCED LABOUR Prohibition of CHILD LABOUR Working HOUR Environmental PROTECTION Social Compliance Occupational HEALTH & SAFETY Compensation & BENEFITS Custom COMPLIANCE Security COMPLIANCE No DISCRIMINATION DisciplinaryPRACTICES Welfare FACILITIES
- 15. Quality Control
- 16. Four Point system Size of Defect Point Acceptance Calculation 3 inch or less 1 Ponts/100sq yard = 𝑇𝑜𝑡𝑎𝑙 𝑃𝑜𝑖𝑛𝑡𝑠×100×36 𝑅𝑜𝑙𝑙 𝑙𝑒𝑛𝑔𝑡ℎ 𝑦𝑑 ×𝐹𝑎𝑏𝑟𝑖𝑐𝑊𝑖𝑑𝑡ℎ(𝑖𝑛𝑐ℎ) Classification: ≤ 20 points = A Grade 21-30 points = B Grade 32-40 points = C Grade ˃40 points = Rejected 3 inch to 6 inch 2 6 inch to 9 inch 3 Over 9 inch 4 Hole ≤ 1 inch 2 Hole ˃ 1 inch 4
- 17. Knitting Section Two Knitting Section: 1st Floor: 98 M/C 2nd Floor: 58 M/C Open Width 54 m/c Single Jersey Tube 51 m/c Single Jersey Engineering-Stripe (Tube) 6 m/c Rib Machine 39 m/c Rib Engineering Stripe 1 m/c Fixed Interlock 5 m/c 3th Fleece (Tube) 2 m/c Total 158 m/c
- 19. Dyeing Section Total No of machineries in dyeing : 55 Bulk Dyeing machine : 34 Sample dyeing machine: 21 Types of Machineries : 1. Winch Dyeing machine (Sclavos) 2. Soft Fabric Dyeing machine (Canlar) 3. EcoCompact HT Fabric Dyeing m/c (Beneks) 4. Airflow Dyeing Machine ( Fong’s)
- 20. Batching Demineralization Scouring Bleaching Bio Polishing(optional) Dyeing Soaping Softening Flow Chart of Bulk Fabric Dyeing
- 21. LAB DYEING •Standard Swatch •Color Code 01 •Recipe Formulation •Color Combination 02 •Lab Dyeing •Selected Shades 03 • Shade Matching • Lab dip Approval 04 • Final Recipe • Deliver to Bulk 05 Figure 47: Reflectance Spectrophotometer for color matching
- 26. Production planning & Control PPC Fabric type wise PPC GLM calculation for batch loading Daily & Monthly loading by Shedomat Line wise allocation plan ERP Software for PPc Program Card
- 27. Knitting program card Batch Card ERP Software
- 28. R&D Department Of FKL Sample order received from merchandiser Analysis of the sample Selection of yarn Knitting parameter setting Finishing parameter setting Check and testing of the sample Approval of the sample and prepare for bulk production
- 29. Different Sample of R&D Department Plain S/J 1×1 Rib Plain S/J Jersey Waffle
- 30. Different Sample of Knitting R&D Department Pointal Rib Fleech Double Pique Auto Stripe
- 31. Industrial Engineering (IE) Department Works for Profit Optimization Increase Productivity Cultural Development Method Improvement Lean, Six Sigma Aplication
- 35. Merchandising Relationship With Other Department Merchandisnig Samplin g Store Cutting Sewing Finishin g Quality Complia nce Shippin g Design Work Study PPC
- 36. ETP • One of the biggest & Green ETP in Bangladesh • Capacity: 8000 m3 Sludge ETP Plant
- 37. KPI 0.00% 20.00% 40.00% 60.00% 80.00% 100.00% February March April Chart Title Dyeing Section Finishing Sewing Key Performance Indicators (KPIs) is an important terminology which is used to measured and assess where the factory currently stands and to find key focus areas where management needs to look into and work upon Factory Efficiency Man to machine ratio 1: 4.1 Cut to ship ratio 1: 1.005 On time delivery rate: 1
- 38. KPI 0.00% 1000000.00% 2000000.00% 3000000.00% 4000000.00% 5000000.00% 6000000.00% Monitoring Problem Alteration Problem Machine Breakdown Fabric Delay Cutting Problem Input Gap (Order NA) Color Shading Lost time % Percentage Pieces Column1
- 39. •Strength Weakness Swot Analysis • Mass Production Capacity • Foreign Buyers • On time delivery • Advance Technology • No AOP Unit • Limited R&D Facility • One Stop Knit Products Facility • Worldwide demand for knit garment increasing Opportunity Threats • Lack of Safety Issue • Modified Product Entrance
- 40. Conclusion • Tremendous Experience • Co-operative management