BAHIR DAR TEXTILE S.

C
CHEMICAL PROCESSING SECTION
PROGRESS AUDIT

(ETIDI TEAM)

BY MARKOS
 OUTLINES

• Introduction

• progresses of activities performed

• Recommendation

• Future plan

• Conclusion
 INTRODUCTION

• The audit was conducted in two stages:

• 1. the machine was visualized in running condition for a period of time and its

output was noted. For the duration of the second stage, the three month (July to

Sept 2018) production and quality report was investigated . During the technical

audit we have gathered much information about the machines;

we performed an intensive section-by-section visual inspection of the systems in

place .

• 1. Review the current effectiveness of processes done on the section .

• 2. Suggest improvements to ensure that the section is maintained well..

 FINISHING SECTION

• General background of the section

 The section designed in specialization on dyed or printed bed sheet

home textile ( sheet , quilt cover, kuta, Shema and related articles.)

 The processing section contains

Single line processing line i.e. Roll to Batch with brushing – desizing
and cold bleaching – pad roll bleaching – dryer integrated washing –
jiggers (2+2+1)- stenter – rotary printing (8 head)- calendaring and CPB
dyeing machine for processing and final inspection (9), folding (3)
stitching and packing machine( 2).

 Chemical and environmental lab equipped with basic equipment's

 CONT.….
 Effluent treatment plant 10% advanced capacity working and equipped with modern

electrolyte precipitate system with 1000m3/hr.

 two electrical boilers ( 3.5ton each ( 6 bar) and loose boiler with capacity of 13.5bar.70%

load

 industrial water softening system sedimentation by aluminum sulphate and calcium

carbonate)

 Screen designing room equipped latest laser engraving machine (Spy stroke, Austria).

 Daily production capacity of 66,000m/day (23000m stenter /shift) in three shift with even

85 efficiency and 2,350 pair of bed sheet / shift

 Capacity utilization was 64% ( official three month report 2011 E.C)

 weaving section deliver around 18500- 23000 linear meter fabric per day in last three
 Activities performed in last visit to Bahir dar textile s.c
s.no. Activities performed in last visit to Progress Remarks
Bahir dar textile s.c
Activities performed in last visit to Bahir dar textile s.c
1. Activities performed in last visit to Bahir In working condition Dust collector not maintained
dar textile s.c

2 Activities performed in last visit to Bahir Not in working condition Not operational
dar textile s.c since then

3 Activities performed in last visit to Bahir Not in continued Due to axial piston of hydraulic
dar textile s.c pump shortage stopped as it is.

4 Activities performed in last visit to Bahir Operation but Circulation pump is not replaced
dar textile s.c Steam leakage maintained yet

5 Activities performed in last visit to Bahir Not maintained Complete machine overhauling
dar textile s.c needed.

6 Activities performed in last visit to Bahir Operational but Complete machine overhauling
dar textile s.c overhauling is not done needed.
yet
s.no.
Conti..
Activities performed and Progress Remarks
recommended

Machine technology

7 ROTARY PRINTING Operational / heating LTC binder and loop steamer

system changed machine needed.

8 CALENDER 5- BOWL Operation become 3 Maintained properly

bowl

9 ORMIC HYDRAULIC PRES Operational Both are working

10 YASHMAAG INSPECTION Operational Max. 4 m/cs per shift has

MACHINE GARMENT SECTIO been working

11 APFC BANK

12 Spinning section machines Most are operational Combers still idle

13 PROCESS FEED WATER PUMP Maintained Operational

14 Weighing bridge Operational

Activities performed in production and material handling systems
s.no. Activities performed and Progress Remarks
recommended
Production area
1. WI and SOP for each machine Maintained Some m/cs are not
operational due to orders

2 Organization of the section Well maintained and

progressive Quality production and
maintenance
responsibilities reconciled
3 Production planning and execution Progressive but still needs Most of time batching
attention machine idle due to frame
shortage
4 Machine set ups and technology Only jiggers are operation The needs one drier and
and other line is idle loop steamer at least for
smooth processing

5 Chemical and auxiliaries utilization Maintained minimum minimum quality

recipe requirement shall be
maintained
6 Steam and boiler Maintained in better way Steam shortage is
eradicated
Activities performed in production and material handling systems
s.no. Activities performed and recommended Progress Remarks

Quality control and laboratory system

1 Online quality checking system Formats for all

processing machines Quality teams needs
with mandatory empowered
parameters on process
2 Continuality of laboratory Not in progress All trainee were
practice dispersed due new
structure
3 Pigment printing shade matches Not in progress
practice
4 Standardization of basic Not in progress Trainee dispersed
chemicals
5 Reactive dyeing data base Not in progress
preparation
6 Laboratory maintenance Good Utility and wwt system
condition still in good condition
Suggestion,

keep your eyes on quality, it will be paid off

 Conclusion
 Overall future of the factory is bright due to its young staffs
and workable organization structure

 The processing section is better position in product quality

follow up system but needs strict follow up and documentation
online and final product quality parameters.

 The demands loop streamer and semi continuous dyeing

technology ( CPB)

 Quality of final product must be maintained

 Ppc in the section shall be in place

Conti..
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