by Engr. Kh. Mashiur Rahman | Apr 15, 2019 | Dyeing & Dryer
IR Dyeing Machine?
IR Dyeing Machine -Temperature range: 40.135 C or higher, accuracy +/-1t, gradient at 3t/min up to 135C ring or cooling speed: 0.5 — 3.5 *C / min . Control accuracy: 0.5 *C-1*C
peed: 10— 50 rpm (adjustable) Dyeing eaker : 180-200m1, 450-500 ml, 1000-1200m1
Can test the length, strength, fineness, color and moisture, color characteristics and trash particle content in cotton ,able to determine fineness and maturity properties of fiber Determine fiber length and tensile properties
Automatic Color Tray or increased sampling for higher throughput
Dual Sampler for increased sampling for higher throughput
Data acquistion system ust include Standard Calibration Materials
Micronaire Measured by relating airflow resistance Maturity, Calculated using algorithm itl’I Length, Upper Halt Mean Length, Uniformity Index, Short Fiber Index Measured optically in a tapered fiber beard which is automatically prepared, Strength and elongation, measured physically by clamping a fiber bundle between 2 pairs of clamps at known distance Moisture content, using conductive moisture probe (Color, Rd (Whiteness), +b (Yellowness), color grade, measured optically by different color
Trash, Particle count. % surface area covered by trash, measured optically by utilizing a digital camera ;Calculation of spinnability of cotton. Read about Pilot-scale Garment Dyeing Machine
Fabric Odor-
Definition and Causes – IR Dyeing Machine
This is a common problem and it is mainly due to one or a
combination of the following:
The use of certain chemicals in the dyeing process such as Carriers in the dyeing of Polyester fabrics at low temperatures The over-use of neutralizing chemicals such as Acetic Acid or Sodium Thiosulfate The use of incorrect softeners .The use of incorrect Anti-Odor and Wicking chemicals
Preventive Suggestions
The use of correct dyeing and finishing procedures and considering all technical aspects of the used chemicals are essential .The use of Carrier based chemicals needs to be avoided. This chemical not only creates offensive odors on the fabric but it is also known to adversely affect the environment. The neutralizing chemicals used during the dyeing process need to be thoroughly rinsed.
Corrective Measures
- In most cases a prolonged exposure to air will remove the odor.
- In more severe cases a high temperature scour will be necessary.
Yarn Related Defects /Problems:
Pilling-
Definition and Causes
This is the formation of tiny balls of fiber on the surface
of the fabric caused by frictional forces.It is normally attributed to the low twist factors in the
yarn. Low twist levels create protruding fibers from the yarn, particularly
when short staple fibers are used.Spinning methods also play a roll. Air jet spinning produces
less protruding fibers than open-end spinning.
Other factors can also be considered. Such as the use of
different fiber staple lengths in blended polyester cotton and nylon cotton
yarns(having different tensile strengths) where pilled cotton components that
are formed are held on to the surface by the stronger synthetic fiber and can
not easily and naturally be removed.
Preventive Suggestions
Based on the end-use, yarns with correct twist factor and
fiber lengths must be used.Attentions must also be paid to methods of dyeing and
finishing to ensure correct procedures are employed (fabric rotation speed,
water levels, dye load size, etc.).The use of fiber to fiber and fiber to metal lubricants is
strongly recommended.
Corrective Measures -IR Dyeing Machine
Most of the pills can be removed by washing the fabric with
a mild solution of Enzyme at high temperatures. Using excessive amounts of
enzyme, however, may result in changing the color or weakening of the spandex
yarns. In severe cases a light brushing
and/or sueding may be an alternative.
by Engr. Kh. Mashiur Rahman | Apr 15, 2019 | LAB
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Characteristic
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Tender Specifications
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Instrument
Type
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d/8°
spectrophotometer
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Spectral
Analyser
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Dual Beam analyser
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Able to work between 360-700 nm
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Reflectance
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Yes
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Tranmittance
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Yes
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Measuring resolution
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2 rm
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Spectral Interval
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10 nm
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Illumination Source
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Pu se Xenon filtered to D65
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Sphere Diameter
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Minimum 150 nm
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Photometric Range
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0-200
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Inter-instrument agreement CIE AE
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0.08
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UV cutoff Filters
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400 nm, 420 nm, 460 nm
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Reflactance
Apertures
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26mm, 16 mm, 5 mm, 2.5 mm
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Transmission Apertures
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22 mm
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Sample Positioning
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Adjustable with camera
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Display
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Builtin Color LCD Display
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Lens
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Auto Zoomable
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Softwares
Data Acquisition System
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Co or Measurement
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Prediction/Matching Database
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Co–npatible with
equipment • All softwares pre- nstalled & upgradable
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Accessories
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All accessories to make and keep the unit
operational
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Most defects arising in the production process of textiles and apparels are detected by inspectors. In order to promote consistent inspection decision from factory inspector, we recommend our factory to provide adequate inspector training in recognizing fabric and apparel defects and cause.
Under the new concept of Auto Sportswear Quality Assurance program and partnership with our factories, Definition and Classification of Defects are developed and established as follows: Read more about Non-Contact Portable Spectrometer
Defect Definition:
Critical Defects: A
defect that fails to meet mandatory regulations and/ or affects the safety of
the consumer. Results in automatic
rejection of inspection.
Major Defects: Any defect severe enough that it would result in customer dissatisfaction, or generally classify the garment as a second, or of less quality.
Minor Defects: An imperfection that may or may not cause a second, depending upon it’s location in the finished garment.
Apparel Defect Classification
A simplified list of defects, explanation and the judgments
are used in classifying apparel defects found in final inspection.
Fabric defects Classification
A fundamental list of defects, explanation and the judgments
are used in classifying both woven and knit fabric defects.
Factory Quality Control Manager should offer continuous
inspection training with showing written standards, using sample fabric
standards / defective garment samples and photograph.
*Note “Sewing Defect Manual” and “Seam Puckering Technical
Bulletin” are property of American & Efird Inc.
by Engr. Kh. Mashiur Rahman | Apr 14, 2019 | Blog
Child Labor Policy
Child Labor Policy -All Vendors shall comply with all applicable laws of the countries in which the Vendors are doing business, including (but not limited to) laws and regulations relating to prison or other forced labor, child labor, freedom of association, pay and compensation, employment discrimination, the environment, health and safety, the apparel industry and any related fields. Read more about Attendance & Overtime Management ….
- The Vendor should encourage and allow eligible workers to participate in work-study or apprenticeship programs, and other government-sponsored educational programs. Auto Fashion Ltd. does not recruit any worker under age of 18 years.
- In case if required to recruit adolescent workers, i.e. under 18 years and above 14 years of age, will follow following procedure:
- The Vendor shall follow all applicable laws concerning employment of persons between the ages of 16 and 18 . Work hour not more than 5 hours a day.
- Will not work between the hours of 7 p.m & 7 a.m
- The Vendor shall not use forced or involuntary labor of any kind, including prison labor, debt bondage, forced labor, or labor that is required as a means of political coercion or as punishment for holding, or for peacefully expressing, political views.
- Will require certificate of fitness from civil surgeon.
- Will require written consent from parents.
- Employees are free to choose whether or not to lawfully organize and join associations. Auto will seek business partners that share its commitment to the right of employees to establish and join organizations of their own choosing.. Will keep separate register.
- Auto requires that its foreign Vendors and its U.S. Vendors of imported merchandise supply a manufacturer’s certificate for each shipment of foreign-produced merchandise . Some laws may restrict such employees from working overtime, in a hazardous environment or during school hours. Will carry a token
- The manufacturer’s certificate will verify that the merchandise was manufactured at a specific factory, identified by name, location and country, and that neither prison labor, forced labor, indentured labor, nor child labor was employed in the manufacture of the merchandise.Will not work in any machines that are in motion.
- Will get annual leave based on one day for every fifteen days of work.
- factory does not have written child labour policy
- age verification system not in place
- factory has no written child remediation policy – young workers have no health examination & registration approval from local labour bureau not obtained
- Auto will not knowingly utilize or purchase materials and/or products manufactured by prison, forced or involuntary labor.
Conclusion
Child Labor Policy -In case if mistakenly a child labor (Under 14 years of age is recruited), immediately Company will discontinue the service of that worker and will arrange and bear the cost of education, and will also give guarantee that on completion of education and achieving the age of 18 years will give priority and will offer him / her job in this company.
by Engr. Kh. Mashiur Rahman | Apr 14, 2019 | Blog
Security Audit Check List
Security Audit – Insufficient Security Audit seating arrangement due to yarn storage in the dining room of the workers was discussed with due importance and Mr. ggg express his utter dissatisfaction for the mismanagement. It was recommended that the dining space for the workers should be free for taking food conveniently. We sale electronic document management system …
Sufficient seating arrangement is to be provided in the owrkers dining room. Decision has taken that nothing to be kept in the workers dining room. It should be always free from any obstacle. All concerned persons are informed to take necessary measures.\
Factory management has not yet implemented the new Labour Law
Management Representative said at this moment all types of law and regulations have been implemented in the factory. Ms. Vice gggemphasis on this issue and she proposed to appointment a Law Consultant for the company. Manager, GS & Compliance, Corporate Head Office will be monitoring the legal requirement of the factory and a Law consultant to be appointed as soon as possible.
- Hiring procedure.
- Termination policy.
- Employee training manual (related to security).
- Incident reports.
- Copy of background check.
- Copy of employment verification.
- Security meeting minutes (attendees list).
- Security training program/schedule (type of training).
- Invoice from alarm Company and surveillance camera(s) (or maintenance bill).
- Documentation of internal Security Audit.
- Employee identification badges.
- Crisis management plan.
- Certificate of Incorporation
- Company Income Tax Clearance Certificate
- VAT Clearance Certificate
- Building Approval
- Environment Certificate
- Trade License
- Export License
- Import License
- Visitor’s log book.
- Incoming vehicle registration log.
- Vehicle release slip.
- Visitor passes/identification badges.
- Security guard patrol log.
- Factory License
- Export Promotion Bureau Certificate (EPB)
- Bond License
- Fire License
- Permission for Generator From the Legal Authority
- Certificate from the Ministry of Power, Electricity & Mineral Resources for the
- Bill of lading, if any (copy)
- Commercial invoice, if any (copy)
- Packing List (copy)
- Other related shipping manifest, if any (copy)
- Any other documentation related to shipments
- Electric Sub. Station.
- Boiler License & Competency Certificate for Boiler Operator Certificate for Electrician
- Latest Drinking Water Test Report
- Group Insurance Records
- BGMEA/ BKMEA Membership Certificate.
- M/C List
- Manpower Status (Total: Male, Female: Present (Male & Female)
- No of Security Guards
- Name, address and phone no of subcontractors.
- Fire Drill Register
- Broken Needle Register
- List of Trained Fire Fighters
- List of Trained First Aides
- Fire Equipment List (Floor wise)
- Accident & Injury Register
- Waste Water Test Record
- Training Record on fire, PPE, M/C operation, First Aid
- Worker’s Service Book
- Personnel files
- ID Cards/ Appointment Letter
- Attendance Records
- Time Cards
- Payroll Sheets & Overtime Payment Records Last 03 Months
- Maternity Benefit Payment Documents & Register
- Leave Documents & Register
- Leave encashment Docs for the Resigned Worker’s/ Final Settlement Records
- Festival Holiday List
- Copy of Pay Slips / Copy of Overtime Slips
- Labor Union Agreements/ Workers Participation Committee minutes/ Worker’s Welfare Committee.
Conclusion
The Management reiterated the importance of Health and Safety Management System. Manager GS & Compliance, Corporate Head Office pointed out that it is deeply associated with the matter of health and safety. All types of chemical containers those are using in the production process and ETP the Labels and MSDS have to be prepared and attached in the container if there is missing any Manufacturer Security Audit & Document Check List
by Engr. Kh. Mashiur Rahman | Apr 14, 2019 | ETP WTP
Audit Report
Audit Report – Environmental Management System Implementation for verification the effectiveness of the system in compliance with the ISO 1401 requirements. aaaa
Maintenance
coordinated the review meeting as the Environmental Management representative
while the meeting was presided. All the Department Heads attended the meeting
as per the schedule. The Managing Director welcomed and thanked all the persons
for attending the meeting on time. At the beginning of the meeting the
Environmental Management representative reminded all regarding the agendas of
the meeting, which was discussed individually with the recommendations and the
actions rising from the concerned department head. The following agenda were
discussed:
- Internal Audit.
- ETP present condition and future development program.
- Environmental program (Targets and Objectives)
- Complain from Neighbors
- Suitability and Effectiveness of EMS
- From the above features of the non-compliance report
of the last audit, it is seen that a total of
03 NCRs were identified in the different Departments.
- Almost all the NCRs were identified due to the lacking
public focussing, Preservation of emergency telephone numbers, etc.
- A systematic follow up audit was conducted to against
corrective and the preventive actions that were taken by respective
departments.
- Out of the total NCRs 03 were closed within the
estimated time frame and 03 closed after exceeding the time frame.
Actions:
- According to the suggestion of the Managing Director, the CFT member will be more sincere and regular on their activity.
Internal Audit Result :
- Third Internal audit was held on September 27th, 2004 and conducted by the consultant and qualified auditors from the Auto internal auditors panel according to the schedule.
- All elements of the ISO 14001 standard for the EMS have been covered during the audit.
- The total features of the audit are given below to show the current status of the audit results:
Status of ETP
- Total water preserving capacity was three Lac litters
- At previous plants wastewater equalized by underground mixer motor
- At previous plants submersible pump capacity and quantity was not sufficient.
- The place where the operator stand for operating the lime dosing system was not sufficient.
- At previous plants acetic acid was mixed with waste water at step # 01
- Its capacity raise on twelve lack liters
- Now its developing by compressed air-mixing system.
- Now we purchase more capable of exerting great physical force submersible pump and other relative materials.
- Now we make a completely different modification in lime dosing system where have an automatic lime mixing system, In addition it will uplift limewater in the lime mixer tank.
- According to new diagram it will be mixed at step # 02
Environmental Program (Objectives & Targets)
In the meting, progress about environmental
program including objectives and targets has been discussed.
Requirements have been submitted as per
E.T.P step-1, and step-2. Because of some communication problems and settle of
rainwater, we could not continue our activities smoothly.
Several training programs have been arranged for proper disposal of solid waste. First, EMR trained the CFT members and department heads. Then the Departmental heads trained their employees respectively. After providing training on the basis of Training Needs Matrix and Training plan, we recorded all the training provided. Then we conducted an evaluation report for the provided training. We are now on the way of arranging refresher training. It was excepted that we shall be able to achieve the target within the scheduled time.
Action: At that situation, EMR has called
an immediate CFT meeting. As per the dissection of CFT members, Maintenance
department has taken the rapid action.
The pump was damage and immediate one new
pump replace their. In that time with help of construction department close
that way where from waste water go throw to the neighbours land and fishery
project. In this way, wastewater leakage has been solved and it was reported to
the neighbour.
Then they ware satisfied and given no
objection letter.
Conclusion
Audit Report -In the meeting the company environmental policy was reviewed for suitability. All the person agreed that we progressing towards our policy and its continuous process to improve continually. Concerns and consensus about stakeholders were discussed.
