Industrial Report on MASCO Group of

Industries Limited (Knitting)

A concern of MASCO GROUP

Kendua, Kanchan, Rupganj, Narayanganj

by
Muhammad SI Shourav
191-270-801
 Established: 2001
Founder: M.A. Sabur

Knitting capacity: 4.5 tons ( Kanchan Unit )

Major Compliance Certifications: BSCI, C-TPAT, SEDEX

Membership, OEKO-TEX 100, the Walt Disney

Certification, Organic Certificate, ECO Certificate & GOTS
Certificate.
Certifications of Masco Group
OVERVIEW OF THE ORGANIZATION
• There are 14 business units in Masco namely Masco Knitting Ltd,
Shanta Expressions Ltd, Concept Knitting Ltd, Tasniah Fabrics Ltd,
Masco Cottons Ltd , Mascotex Ltd, Masco Industries

• Ltd (G1), Masco Industries Ltd (G2 , MPL Wear Ltd , Masco Picasso
Ltd , Masco Embroidery Ltd, Masco Dyeing Ltd, Masco Sample
and CAD Section, Masminu motors.

• All the business activities are guided and controlled by Board of

Director led by Chairman of the group. The Board consists of five
members including Managing Director, two directors and
Executive Director of the Group
Vison of MASCO
Masco Group is an export-oriented manufacturer company established in 2001 . The
product type is Circular Knit Garments. At this time span, the group has employed around
18,000 people.

The goal of Masco is to remain at the cutting edge of every industry and create a
prominent value for all the stakeholders, surrounding communities and not to forget the
wider economy.

The group is planning to expand the textile business in near future and working on it. Masco
Picasso Ltd, Masco Exports Ltd and Concept knitting Ltd units are under expansion. This
iconic group Exports high standard quality of garments throughout the world.

Until now, the Masco Group has been doing business with almost 50 customers of
Europe/America. The German-based C&A is the largest buyer of Masco Group which
purchase approximately 23 percent of the Group’s total export volume. H&M is the second
largest buyer. The Groups sells around 22 percent of its export volume to the H&M. Top 36
buyers’ lists and export volume of 2018 are presented in Annex I. Figure 2.1 and Figure 2.2
present key clients and certification of Masco Group and .
Clients of MASCO Group
Over View of the Industrial Setup
• The 18000 square feet floor run with 148
Circular knitting machine .

• It have a own power station with 2 different power

• generation system

• And a compressor unit to maintain the pressure in the floor

with 5 bar air pressure

• It has also a pneumatic vacuum system to remove the yarn

fly & dust from the production floor.

• In 70% average efficiency now this industry can produce 4.5

ton Knit fabric per shift.
Production Sequence Of Masco Knit LTD.

MASCO KNIT INDUSTRIES LTD

Rupjangh,Narayanjangh

Yarn Test lab

Central R&D unit

Rupjangh R&D Unit

Production Unit

Circular Knittint Unit Flat Bed Knitting Unit

Quality Control Unit

Store

Transfer to Dyeing Unit

The term circular covers all those weft knitting machines whose
needle beds are
arranged in circular cylinders and I or dials, including latch, spring
bearded and very
occasionally compound needle machinery, producing a wide
range of fabric structures,
garments, hosiery and other articles in a variety of diameters and
machine gauges.
The common features of a circular knitting machine
• Circular knitting machine normally has rotating (clockwise) cylindrical needle bed (s).
• On circular knitting machines latch and compound needles are used. One seldom
finds bearded needles or other needle types. Normally one or two sets of Latch needles are used.
• For single-jersey machine holding down sinkers are used, one between every needle space.
• Normally stationary angular cam systems are used for needle and sinker.
• Latch needle cylinder and sinker ring (for single-jersey machine) I dial (for double jersey
rib and interlock machine) revolve through the stationary knitting cam system.
• For single-jersey machine, sinker trick ring which is simply and directly attached to
the outside top of the needle cylinder thus causing the sinkers to revolve in unison with the
needles.
• Needle retaining spring is also used
• Stationary yarn feeders are situated at regular intervals around the circumference of the rotating
cylinder.
• Yarn is supplied from cones, placed either on an integral overhead bobbin stand or
on a freestanding creel through tensioners, stop motions and yarn guide eyes down to the yarn
feeder guides.
Description Of a Single Jersey Circular Knitting Machine
Plain fabric is a single jersey fabric and is produced by one set of needle. Most of single- jersey
fabric is produced on circular machines whose latch needle cylinder and sinker ring revolve
through the stationary knitting cam systems, which together with their yarn feeders are
situated at regular intervals around the circumference of the cylinder.

The yarn is supplied from cones, placed either on an integral overhead bobbin stand or on a
free- standing creel, through tensioners, stop motions and guide eyes down to the yarn feeder
guides. The fabric, in tube form, is drawn downwards from inside the needle cylinder by tension
rollers and is wound onto the fabric batching roller of the winding down frame. The winding
down mechanism revolves in unison with the cylinder and fabric tube and is rack - lever
operated via cam- followers running on the underside of a profiled cam ring.

As the sinker cam- plate is mounted out side on the needle circle, the center of the cylinder is
open and the machine is referred to as an open top or sinker top machine. Compared with a rib
machine, a plain machine is simpler and more economical with a potential of more feeders,
higher running speeds and the possibility of knitting a wider range of yarn counts. The most
popular diameter is 26" giving an approximate finished fabric width of 60" to 70".
 Various Parts Of a Circular Knitting Machine

1. Yarn feeder guide which is associated with its own set of knitting cams.
2. Latch needle
3. Holding- down sinker, one between every needle space
4. Needle cylinder (in this case, revolving clockwise)
5. Cylinder driving wheel
6. Cylinder driving gear
7. Sinker operating cams which form a raised track operating in the recess of the sinker
8. Sinker cam- cap
9. Sinker trick ring which is simply and directly attached to the outside top of the
needle cylinder thus causing the sinkers to revolve in unison with the needles
10. Needle retaining spring
11. Needle- operating cams which, like the sinker cams are stationary
12. Cam- box
13. Cam - plate
14. Head plate
15. Cylinder driving pinion attached to the main driving shaft.
Quality Section

The quality section run with 8 Automatic inspection system

The system run with 4.0 quality management system

The quality section is connected with the central R&D unit

and The quality control unit of Gazipur the whole process is
observe by the MASCO IT unit .
The Supply Chain of Buyer Sample Developing
MASCO knit

Merchandizer Baulk Production

Booking to Factory Quality Check

Central R&D Heat Setting

Factory R&D Dyeing & Finishing

Yarn Testing

Sample testing
Some production Program Card of
[On going Baulk Production]
Production management process of MASCO Knit
Planning:
We set monthly, weekly, daily basis planning on the basis of raw materials availability. Everyday
makes a WIP (Work in Process) report and make forecasting report at previous day. Our planning
department get the shipment plan of each style of each buyer from our central planning
department. Usually we get information about all upcoming order booking from online MIS365
and take necessary preparation like raw material and machine availability, production planning.
If there is any raw material are to buy from international market development department share
the data to the planning department and planning department place the order of that yarn to
the procurement department. Finally, they provide An ETA (estimate time of arrival) then we make
knitting, dyeing & garments plan.

Organizing:
After getting production plan from the planning department production concern collect the
production file form the production coordinator along with approval strike off, FPS and organize all
the equipment & allocate line & machine as per capacity.
Leading:
Production officer of each floor and each shift lead the daily production. They give instruction to
their subordinate floor in-charge and supervisor to start the production and before starting the
production they also give a short brief about the style, what type of risk factor should be
considered in that particular style and what type of difficulties may face to complete that style
and what type of steps should be taken to avoid any unwanted damage of the goods

Controlling:
To solve any problem at production management stage our JAL team use the 5W1H questioning
technique (What, Who, Why, Where, When, How). During production running if there is any
problem occur they use 5W1H tools to solve that problem by the following way-At first they
identify the problem then by root cause analysis who is responsible for that problem, why the
problem is happening, where the problem is, when the problem is to be solved and how the
problem will be solved and finally make a SOP for future
Masco Group is crafting happiness to all of her employee since 2001. There are no
confusion that its countries one of the most reputed Group of Companies from my own
experience I can say that it is one of the best organizations in Bangladesh. Although there
need to make some improvement but still it provide enough facilities and work friendly
environment to its entire employee.
Boshra Textile is a concern of Jaz bhuiyan group which stablished in 2011. It’s a weaving industry
Which can produce 1 ton of woven fabric per day.

The whole industry was built in 120000 square feet area & it has own warping facilities.

The company produce various type of fabric at all but they produce a mass number of lycra denim
fabric
Different Departments:

Administration Warping Unit

Planning
Flow Chart of Sectional Warping:
Research & Development (R&D)
Creel
Store ↓
Drum
Weaving preparatory ↓
Beam (Weaver’s Beam)
Weaving

Mending & Inspection Cone to Cone Winding Machine

Quality control & Inspection Model No : GAD14MD-JBB

No of Spindle : 120
Utility Manufacturer: Shanghai Nanshi Foreign Economic
Corporation & Trading Company Limited. (China)
Mechanical
Motor R.P.M: 1440
Electrical
Working procedure of Sectional Warping

Sectional warping is used for short runs especially for fancy pattern fabrics.
In this case sections of the warp which may contain up to 1000 ends are first wound onto a drum
tapered with a given cone angle.
So cross wound sections are combined on the drum & thus each layer of warp contains the same
number of ends on the drum.
Then the warp threads altogether are transferred onto a weavers beam by unwinding the drum.
In this method the warp threads are not necessarily processed in sizing.

Sizing

Sizing is the process of applying protective adhesive coating on the yarn surface. This is the most
important segment of weaving preparatory process. Because sizing has direct influence on the
weaving efficiency. Better the quality of sizing higher the weaving efficiency & vice versa. In fact
without sizing, in most of the cases it is almost impossible to run the weaving process. Moreover in
case of towel manufacturing rotor (open end) & low twisted yarns are mostly used.
The common designs which developed in BOSHRA textile

Plain.
Twill.
Sateen.
Oxford. (Warp rib and weft rib).
Queen’s Oxford.
Matt.
Diamond.
Diaper.
Herring bone.
Honey comb.
Various type of loom of BOSHRA textile

Type of Loom: Air Jet Loom Types of loom: Rapier

Total Loom: 45 Name of loom: Picanol Rapier

Company Name: Toyota Tsushu No of loom: 40

Name of Loom: Toyota Air Jet-710 Picanol optimax: 17 ( 6 heald shaft ).

Model: JA2S-340TP-ET-T710 ( Manufacturing date: 2010

JAT-710 ).
Weft insertion capacity: 8 color.
Weft Insertion Capacity: 2 color.
Manufacturing Country: Belgium
Loom Width: 340cm.
Machine Speed: 1000 r.p.m (max)
Manufacturing Country: Japan
Loom width: 190 cm.
Rapier Picking Mechanism
A rapier loom has a picking mechanism in which one rapier (a giver rapier) transfers a
weft yarn to another rapier (a taker rapier) in mid-shed. Each rapier is oscillated toward
and away from one another by a drive and includes a yarn clamp which is actuated
by a clamp opener to provide reliable yarn transfer from one rapier to the other. The
rapier drives and/or clamp openers are driven by programmed servomotors. In this
way, the velocities of the rapiers and/or the interval in which the clamp openers are
opened can be adjusted according to the properties of the particular weft yarns used
to ensure reliable transfer without damaging the yarn
Air jet picking Mechanism
Air jet weaving machines were invented in Czechoslovakia and later refined by the Swiss,
Dutch, and Japanese were designed to retain the tension less aspect of the picking action
of the water jet while eliminating the problems caused by the use of water.

The yarn is pulled from the supply package at a constant speed, which is regulated by the
rollers, located with the measuring disk just in front of the yarn package. The measuring disk
removes a length of yarn appropriate to the width of the fabric being woven. A clamp
holds the yarn in an insertion storage area, where an auxiliary air nozzle forms it into the
shape of a hairpin.
University Supervisor Industry Supervisor
Engr. Taslima Ahamed Tamanna Md Maydul Hasan
Lecturer [Fabric Manufacturing Engineering ]
Department Of Textile Engineering Asst. Manager, knitting
BGMEA University Of Fashion & Technology. Masco Industries Limited
 Submitted By

Alif Ahmed Zahin Solvi Khan

191-159-801 191-144-801

Thank You
Monjurul Abedin Sharmin Ara Radiya
191-215-801 191-253-801

Kazi Fahim Habib Saki Rizoan Shipu

191-216-801 191-257-801

Ashik Umar Limon Shoriful Islam Shourav

191-129-801 191-270-801

Suzzat Hossain Shoaib Aktar

191-143-201 191-280-801