An Internship Report On

This internship report is production based insight of YKK Pakistan private limited prepared on HEC recommendation for the degree of Bachelors of Engineering in Chemical.

Prepared by Saad Arif CH-037 Internship duration: 1 month Date of submission: 28 June, 2013 Submitted to Sir Khurram Jamal

Supervisors signature

Worlds Largest Zipper Manufacturer

NED University of Engineering and Technology Department of chemical engineering

TABLE OF CONTENTS S.NO

1.
1.1 1.2 1.3 1.4 1.5 1.6

CONTENTS
INTRODUCTION
ABOUT YKK GROUP OF COMPANIES COMPANYS PHILOSOPHY YKK PAKISTAN ISO CERTIFICATION HOW ORDERS ARE COMPLETED? RAW MATERIALS

PAGE NO
3
4 4 5 5 6-7 8

2.
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

DYEING DEPARTMENT
DYEING DEPARTMENT LAYOUT FLOW CHART: HOW THINGS WORK? DYEING AT YKK: DETAILS AND SOP DISDPERSE DYES DYEING METHODOLGY POLYESTER DYEING CYCLE OPTIMUM CONDITIONS CHECK POINTS SOP FOR DYEING MACHINES INSPECTION: COMPUTER COLOR INSPECTION, LIGHT SOURCE TESTING AND BLEED TEST

9 10 11 12 13 13 13 14 15 15 16 17-18 19 19 20 21 22 23 24 25 26 27 28 28 28 29 30 31 32

3.
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11

CHAIN DEPARTMENT
FLOW CHART PRODUCTION DETAILS STANDARD DIMENSIONS ELEMENT NOMENCLATURE SURFACE TREATMENT GTH/GTX SURFACE TREATMENT GTH/GTX SURFACE TREATMENT FLOW CHART GTH/GTX SURFACE TREATMENT PROCESS DESCRIPTION GKB SURFACE TREATMENT GKB SURFACE TREATMENT FLOW CHART GKB SURFACE TREATMENT PROCESS DESCRIPTION

4.
4.1 4.2 4.3 4.4

ASSEMBLY
INTRODUCTION METAL CHAIN ASSEMBLING VISLON CHAIN ASSEMBLING COIL CHAIN ASSEMBLING

5.
5.1 5.2

QUALITY CONTROL
YKK QUALITY CONTROL POLICY AND MEASURES QUALITY APPROVAL PROCEDURE

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6.
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10

UTILITIES
REVERSE OSMOSIS PLANT RO PLANT PROCESS DESCRIPTION AND TERMINOLOGY REVERSE OSMOSIS PERFORMANCE & DESIGN CALCULATIONS DOSAGES AND THEIR FUNCTIONS RO PLANT BLOCK DIAGRAM WASTE WATER TREATMENT PLANT DYEING WASTE WATER TREATMENT FLOW DIAGRAM SURFACE TREATMENT WASTE WATER TREATMENT FLOW DIAGRAM REVERSE OSMOSIS PERFORMANCE & DESIGN CALCULATIONS WASTE WATER TREATMENT DESCRIPTION

33 34-35 36-37 37 37 38 39 40 41 42

7.
7.1 7.2

CONCLUSION
FLAWS RECOMMENDATIONS

43 44

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INTRODUCTION
ABOUT YKK GROUP OF COMPANIES
The YKK Group is a Japanese group of manufacturing companies. As the world's largest zipper manufacturer, YKK Group is most famous for making zippers; however, it also manufactures other fastening products, architectural products and industrial machinery. The initials YKK stand for Yoshida Kgy Kabushiki Kaisha, Yoshida Manufacturing Corporation. YKK produces fasteners and architectural products at 109 YKK companies in 71 countries around the world. YKK claims to be the first zipper company to promote environmental protection measures. YKK developed a line of environmentally friendly zippers.

YKK Group
Founded Headquarters Profit Total assets Website Nihonbashi, Tokyo, Japan, 1934 Japan JPY 16,334 million (2012) JPY 715,364 million (2012) www.ykk.com

COMPANYS PHILOSOPHY
Companys philosophy is The Cycle of Goodness, which means that one prospers when one renders benefit to others. YKK is the sole believer and follower of this philosophy. YKK design such policies that are always environmental friendly and they are in no way harmful for all forms of lives on this earth.

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YKK PAKISTAN
YKK is one of the leading companies in Pakistan and it is working as a Zipper Manufacturing company. YKK Pakistan is rendering its service to the garment industry since 2007. YKK believes in creating loyal partnerships with their diverse customers. YKK Pakistan has its sales office in the heart of garment supply, Karachi and Lahore. YKK is a leading company having diversified products and industrial machinery having its plant in Landhi industrial area Karachi. YKK is offering world class quality to their customer which is the secret behind YKKs progress and demand among world class brands which demand quality zippers for their quality products.

ISO CERTIFICATION
YKK Pakistan is ISO certified. The company has following certifications: 1. ISO 9001: 2008 specifies quality management system to meet customer requirements and to fulfill contractual obligations. 2. ISO 14001: 2004 specifies environmental management system and enable an organization to evaluate and control its environmental risks and impacts and improve its environmental performance. 3. ISO 27001: ISMS (Information Security Management System) ensures adequate security controls. 4. OHSAS 18001: specifies requirements for an occupational health and safety management system to enable an organization to control its OH&S risks and improve its OH&S performance.

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FLOW-CHART: HOW ORDERS ARE COMPLETED?

Orders are received at sales office in Karachi and Lahore WAVES entry Raw material if required is ordered PPC arranges and issues tickets to dyeing Schedule Dyeing WAVES entry PPC issues tickets to Chain department Schedule Chain making WAVES entry PPC issues tickets to Assembly Assembling takes place WAVES entry Segregation Dispatch

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HOW ORDERS ARE COMPLETED?

Different companies place their orders at sales office in Karachi and Lahore. They are shown YKK color card to choose color for tape. They can choose from color card or can give their sample and request for DTM. YKK offers two varieties: Coil and tape. On tape customers can choose metal or vislon chain. YKK receives orders of following quantities: 0.5 kg, 1 kg, 2.5 kg, 5 kg, 7.5 kg, 15 kg, 40 kg and 75 kg. Upon receiving orders they are entered in WAVES, which is a special-purpose software designed for YKK production and planning control. PPC (Production Planning and Control) department arranges the orders giving preference to delayed and remake orders. They issue tickets with delivery dates to dyeing department. Dyeing department achieves their task and enters it in WAVES which is further organized by PPC and tickets are issued to chain department. Chain department is the production department; chain is made from metal or vislon. The order upon completion is entered in WAVES and PPC then issues tickets to assembly department. In assembly department, top stop, bottom stop and slider is attached to chained tape to make a complete zipper. Quality is assured at each step via various quality control testing.

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RAW MATERIALS
YKK Pakistan imports and purchases following raw materials: 1. 2. 3. 4. 5. 6. 7. Tape (3M,5M,7M,10M,3Y,5Y,3VS,5VS,8VS) Coil (3CF,3FRF,5CI) Disperse dyes from Clariant Pakistan Chemicals for dyeing i.e. Opticid PB, Eganal PS, YK 40, Caustic and hydrosulfite Metal wire (golden brass, aluminum and silver) Master chips Chemicals for surface treatment i.e. P3 Saxin, Melt Cleaner, Neoluster, BBN, Rusmin-R, 5u 100k, Samsilicon, acretane matt clear, thinner 800 R, MS Hardener 8. Top stops, bottom stops, retainer box, sliders and inner pins 9. Rexol T-32 oil

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DYEING DEPARTMENT
CONTENTS:

DYEING DEPARTMENT LAYOUT FLOW CHART: HOW THINGS WORK? DYEING AT YKK: DETAILS AND SOP DISDPERSE DYES DYEING METHODOLGY POLYESTER DYEING CYCLE OPTIMUM CONDITIONS CHECK POINTS SOP FOR DYEING MACHINES INSPECTION: COMPUTER COLOR INSPECTION, LIGHT SOURCE TESTING AND BLEED TEST

DYEING EXECUTIVE

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DYEING DEPARTMENT LAYOUT

OFFICE AREA
COLOR WEIGHING ROOM COLOR INSPECTION ROOM PRODUCTION OFFICE

LARGE DYEING AREA

40 KG DYEING MACHINE

DRYING AREA
D-1

40 KG DYEING MACHINE

D-2

75 KG DYEING MACHINE

D-3

75 KG DYEING MACHINE

D-4

75 KG DYEING MACHINE

D-5

SMALL DYEING AREA

15KG DYEING MACHINE 15KG DYEING MACHINE 15KG DYEING MACHINE 15KG DYEING MACHINE 15KG DYEING MACHINE 5KG DYEING MACHINE 5KG DYEING MACHINE
2.5KG DYEING MACHINE

WINDING AREA
0.5, 1, 2.5 AND 5 KG WINDING 0.5, 1, 2.5 AND 5 KG WINDING 0.5, 1, 2.5 AND 5 KG WINDING TAPE WINDING MACHINE CHAIN WINDING MACHINE

1KG DYEING MACHINE 1KG DYEING MACHINE

0.5 KG DYEING MACHINE

0.5 KG DYEING MACHINE

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FLOW CHART
PPC issues tickets

Schedule

Winding and weighing

Dyeing

Sampling
OK

Not OK

Dryer

Re-sampling

WAVES entry

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DYEING AT YKK: DETAILS AND SAFE OPERATING PROCEDURE

Sales department upon receiving orders informs PPC regarding new orders through entering in WAVES. PPC arranges all the orders, giving special preference to orders that are requested for DTM, urgent, delayed and remake orders. PPC updates dyeing schedule and issues tickets to dyeing department. At dyeing department, weighing and winding goes on simultaneously. Color weighing is done via DMS software if color requested by the customer is from YKK color card or previous DTMs. The software facilitates up to 3000 different color recipes. Color weighing is carried out at color weighing room. At color weighing room, temperature and humidity must not exceed certain specified level. Temperature and humidity are controlled via air-conditioning. During color weighing safety measures should be followed. PPEs for color weighing are: wear goggles, gloves and face mask while handling dye stuffs. Winding is carried on winding machines. Five winders are available, three for small winding and two for large winding. Orders obtained in Kg are converted to respective length. Line speed is set by winder, 120 m/min for small winders and 170 m/min for large winders, and winding machine is set on operation. After winding beams are dyed in dyeing machines. Dyeing is the process of adding color to textile products like fibers, yarns, and fabrics. Dyeing is normally done in a special solution containing dyes and particular chemical material. The temperature and time controlling are two key factors in dyeing. There are mainly two classes of dye, natural and man-made. At YKK Pakistan, polyester, a synthetic fiber, is dyed. Polyester differs from natural fibers and rayon in moisture regain and difficulty of dyeing. Nylon can be conveniently dyed with water-soluble acid dyes. Polyester exhibits a lower regain (0.4% vs. 4% for nylon) and does not possess a terminal functional group to which an ionic dye is attracted.
For dyeing polyesters, disperse dyes are used.

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DISPERSE DYES
Disperse dyes are non-ionic dyes with finite, but very limited water solubility. This class of dyes obtained its name from their application conditions, as they are applied as a very fine dispersion or suspension in water. In hydrophobic fiber OH group has been blocked by COOCH3 group therefore acetate dyes or disperse dyes are used for dyeing such fibers. The term disperse dyes means free from ionizing groups, low water solubility and are suitable for dyeing hydrophobic fibers from colloidal dispersion. A dye that is almost totally insoluble in water. Disperse dye exist as a suspension or dispersion of microscopic particles in water bath with only a tiny amount in true solution at any time. They are the only dyes that are effective for normal polyester. Polyester is dyed with disperse dyes by boiling with carrier chemicals or by heating the liquor to about 130C which requires elevated pressure.

DYEING METHODOLGY
Four methods have been used for dyeing polyester fabrics: I. Conventional aqueous dyeing (batch dyeing) II. Aqueous dyeing with a carrier (batch dyeing) III. High-temperature (above 100C usually 130C) aqueous dyeing (batch dyeing) IV. Thermo sol dyeing (continuous dyeing) When dyeing polyester with disperse dyes at 100C without special auxiliaries known as carriers only light shades can be obtained, this is because of the low dye absorption rate by this method, and other techniques are required to obtain medium or heavy shades. At YKK Pakistan, High Temperature High Pressure Dyeing method is used to dye polyester. High temperature usually refers to temperatures greater than 100C. In commercial dyeing, it refers specifically to 130C. Dyeing at high temperature eliminates the need for a carrier to carry the dye into the fibers. Dyeing at 130C without carrier causes an even greater increase in dye absorption and promotes leveling. Another advantage of dyeing at elevated temperatures or with a carrier is increased penetration into the fiber. This is important because with disperse dyes on polyester, complete penetration results in better fastness to washing, rubbing, and sublimation than with similar but unpenetrated dyeing.

POLYESTER DYEING CYCLE

There are three main stages in a polyester dyeing cycle: I. Dissolution of dye in water in the form fine dispersion.

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II. Adsorption of the dissolved dye onto the fiber surface. III. Diffusion or penetration of the dye molecules deep inside the inner cores of the fiber.

OPTIMUM CONDITIONS
I. Temperature: 140 0C for dyeing and 90 0C for hot rinse II. Pressure: 0.2 MPa

III. Water level: 900 m CHECK POINTS

Following parameters must be checked as dyeing machine is set on operation: I. Pump sound II. Belts (motor, pump) III. Leakage (pump, mechanical seal) IV. Actuators V. Air pressure VI. Air connectors VII. Buzzer VIII. Condensate trap IX. Valves X. Soft water inlet XI. Safety and exhaust valves XII. Cussion tank pressure (0.2 MPa) XIII. Dyeing cycle temperature (130 0C) XIV. Potentiometer valve at 130 0C SOP (SAFE OPERATING PROCEDURE) FOR DYEING MACHINES: As beam is loaded in dyeing machine, operator must ensure that the door is closed properly. Machine will ask for pattern: I. For light color: 01 II. For dark color (Tape): 02 III. For dark color (Chain): 03 IV. Manual washing: 18 V. Machine cleaning: 50 Machine will take water upto specified level. Firstly there is a hot rinse at 90 0C. Hot rinsing completes within 5 to 6 minutes.

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Machine then asks for dyeing chemicals. There are five separate tanks for different chemicals. I. Tank A: Dye stuff II. Tank B: Eganal PS III. Tank C: Opticid PB IV. Tank D: Hydro-sulfite V. Tank E: Caustic Dye-stuff, Eganal PS and Opticid PB are added in their respective tanks. Dyeing proceeds for 2 hours 30 minutes. For light shades, process comes to an end.

REDUCTION CLEANING: For darker shades, there will be another process called Reduction Cleaning. This process is carried out to remove excess dye stuffs or chemicals from the tape and bobbin. Caustic and hydro-sulfite are commonly called PROCESS RC. They are added for Reduction cleaning process for darker shades only.

FINISH TREATMENT: For light colors there is no finish treatment. For dark colors, after the process of reduction cleaning, finish treatment is carried out. Opticid PB is used for finish treatment.

pH MAINTAINER AND LEVELING AGENT: Opticid PB is used as pH maintainer and Eganal PS is used as leveling agent. Eganal PS promotes leveling and hence dyeing is uniform.

SAMPLING: Sample is taken from the end. Sample is dried and tested for bleeding, color fastness and checked whether required color is obtained or not.

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INSPECTION:
I.COMPUTER COLOR INSPECTION: Sample is checked via spectrophotometer which gives CMC factor for that particular sample against the standard. CMC factor is a measure of perfectness obtained in dyeing. Its tolerance limit is + 0.82. If CMC factor exceeds tolerance limit, then the adding is suggested by the software. II.LIGHT SOURCE INSPECTION: Sample is tested in the required light source. III.BLEED TEST: Sample is taken on a filter paper and is dipped in a beaker containing 5 ml chloroethylene. If there are any spots on filter paper, shows bleeding of color.

If the sample passes CCI and bleed test, then the beam is forwarded to dryer otherwise the suggested adding is added and the order is re-dyed. After drying, two samples are taken from the two ends and they are inspected via spectrophotometer. CMC report is prepared and the dyeing department enters its completed and inspected orders in WAVES.

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CHAIN DEPARTMENT

CONTENTS: FLOW CHART PRODUCTION DETAILS STANDARD DIMENSIONS ELEMENT NOMENCLATURE SURFACE TREATMENT GTH/GTX SURFACE TREATMENT GTH/GTX SURFACE TREATMENT FLOW CHART GTH/GTX SURFACE TREATMENT PROCESS DESCRIPTION GKB SURFACE TREATMENT GKB SURFACE TREATMENT FLOW CHART GKB SURFACE TREATMENT PROCESS DESCRIPTION

CHAIN EXECUTIVE

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FLOW CHART
PPC issues tickets to chain department

Schedule is prepared

Metal and vislon chain are produced

Dimensional checking

Surface treatment or washing

WAVES entry

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PRODUCTION DETAILS
Chain department is responsible for producing metal and vislon chain. For metal chain, three wires are imported: I. Golden brass II. Aluminum III. Silver METAL CHAIN: Metal chain is produced at F-13 machine F-13 has following units: I. Wire spool unit - This unit feeds wire to chain making unit. II. Chain making unit - Wire is cut, element is formed and pressed on the cord of the tape. III. Joining unit - Two elements are combined. IV. Suction unit - This unit provides REXOL T-32 oil for lubrication and cutting. POINTS TO BE NOTED BEFORE STARTING MF MACHINE: I. Ensure all rollers and die parts are cleaned properly. II. Check suction pressure and ensure pipes are attached. III. Ensure belt is attached. IV. Clean all outside rollers. DIMENSION CHECKING: After starting the machine, first ten pieces must be checked. Following dimensions must be measured and compared with the standard: I. Head height II. Hammer thickness III. Chain thickness Two types of micrometer are used for dimensional analysis of elements: I. Disc micrometer for head height and element length. II. Flat micrometer for hammer thickness and chain thickness. CHECK POINTS FOR SUCTION PUMP: Following points must be checked: I. Attach suction pipe if found removed. II. Check belt condition. III. Check packing and center seal. IV. Whenever remove, clean and then assemble. V. At suction pump, pressure should be 50-60 KPa. VI. At machine input, pressure should be 15-30 KPa. DEFECTS IN ELEMENTS AND THEIR REASON: I. Head lean forward die life over, die lapping is too much II. Head and Neck problem die broken III. No back pocket and head forming punch broken

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IV.

Cut off thickness is less metal feed head is broken

STANDARD DIMENSIONS
ITEM ELEMENT LENGTH (mm) 3.62 3.62 3.13 2.79 2.65 4.04 2.63 4.04 5.38 HAMMER THICKNESS (mm) 2.62 2.62 2.40 2.18 1.95 2.85 1.95 2.85 3.45 HEAD HEIGHT CHAIN (mm) THICKNESS (mm) 1.57 2.55 1.53 2.55 1.54 2.25 1.43 2.06 1.25 1.86 1.71 2.70 1.25 1.86 1.71 2.70 2.15 3.30

5RA 5RGM 4YGR 3YG 3MG 7MG 3MA 7MA 10M

ELEMENT NOMENCLATURE:

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SURFACE TREATMENT
Surface treatment is a finishing process that alters the surface of industrial product to achieve certain specific property. At YKK Pakistan, electroplating is carried out to change golden brass metal elements to antique silver, antique copper and antique brass. Three different treatments are available for three color changes. GKB: this surface treatment changes golden brass to antique brass. GTH: This surface treatment changes golden brass to antique silver. GTX: This surface treatment changes golden brass to antique copper. Manganese and aluminum zippers are only washed on washing unit.

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GTH/GTX SURFACE TREATMENT:

WORKING PARAMETERS: Degreasing tank temperature: 60 0C + 5 0C Coloring tank temperature: 50 0C + 1 0C Washing (RO-Water ) tank temperature: Room temperature Washing (S-Water) tank temperature: Room temperature Dryer temperature: 130 0C + 10 0C Hot win section: 55 0C 65 0C Line speed: 25 md/min Air: 0.4 MPa Steam: 3.5 MPa 4.5 MPa RO-Water: 25 L/min S-Water: 25 L/min

CHEMICAL RATIO: P3 saxin: 3% Melt cleaner: 0.30% Rusmin-R: 0.40% 5U 100K: 120 ml/L

CHEMICAL CONSTANT CONCENTRATION VALUE: Al 120 ml/L OX 120 ml/L Cu 130 ml/L

CHEMICAL PREPARATION METHOD: I. II. III. IV. FOR DEGREASING TANK: Fill sub degreasing tank up to 79 cm water, pour 20 Kg P3 Saxin (3%) and 2 liter Melt Cleaner (0.3%). FOR COLORING TANK: FOR GTH: Fill sub coloring tank up to 470 liter water, add 5U 100K 120 ml/L. FOR GTX: add NaOH 40gm/L to coloring tank FOR RUSMIN-R TANK: Fill tank up to 40 cm water, pour 332 gm. of Rusmin-R (0.4%) LACQUER COATING: Take 47% of ACRETHANE MATT CLEAR, 47% of ACRETHANE THINNER 800R AND 6% of ACRETHANE MS HARDENER.

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GTH/GTX SURFACE TREATMENT FLOW CHART

FEEDING UNIT

SUB-DEGREASING TANK

DEGREASING TANK

RO-WATER

RO-WATER TANK

SUB-COLORING TANK

COLORING TANK

AIR

SOFT WATER TANK

RUSMIN-R TREATMENT

DRYER

LACQUER COATING

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GTH/GTX SURFACE TREATMENT PROCESS DESCRIPTION

Metal chain is fed to degreasing unit from feeding unit. Degreasing unit takes its dosage from sub-degreasing tank that contains P3 Saxin and melt cleaner solution. Steam is continuously charged to degreasing unit to raise the temperature of the contents. The charge is transferred to RO-Water tank. The charge then enters coloring tank where the temperature is maintained at 50 0C. Coloring tank takes its dosage from sub-coloring tank. The charge then enters soft water tank. Chain is then treated with Rusmin-R. Rusmin-R protects metal elements from corrosion. It is an anti-corrosive agent. Chain is dried at 130 0C. Chain then enters lacquer machine. Lacquer treatment is essential for shining, color fastening and smoothness of zipper.

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GKB SURFACE TREATMENT:

WORKING PARAMETERS: Degreasing tank temperature: 60 0C + 5 0C Coloring tank temperature: 40 0C + 1 0C Washing (RO-Water ) tank temperature: Room temperature Washing (S-Water) tank temperature: Room temperature Dryer temperature: 130 0C + 10 0C Hot win section: 55 0C 65 0C Line speed: 25 md/min Air: 0.4 MPa Steam: 3.5 MPa 4.5 MPa RO-Water: 25 L/min S-Water: 25 L/min

CHEMICAL RATIO: P3 saxin: 3% Melt cleaner: 0.30% BBN-1: 110 + 5 ml/L Rusmin-R: 0.40% N-U-7P: 15%

CHEMICAL PREPARATION METHOD: I. II. III. IV. FOR DEGREASING TANK: Fill sub degreasing tank up to 79 cm water, pour 20 Kg P3 Saxin (3%) and 2 liter Melt Cleaner (0.3%). FOR COLORING TANK: Fill sub coloring tank up to 470 liter water, add 51.7 litre Brass Brown N-1 (140 ml/L) FOR RUSMIN-R TANK: Fill tank up to 40 cm water, pour 332 gm. of Rusmin-R (0.4%). FOR U-7P ZONE: In 15 litre of water, pour 2.25 litre of Neoluster U-7P (15%)

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GKB SURFACE TREATMENT FLOW CHART

FEEDING UNIT

SUB-DEGREASING TANK

DEGREASING TANK

RO-WATER

RO-WATER TANK

SUB-COLORING TANK

COLORING TANK

AIR

SOFT WATER TANK

RUSMIN-R TREATMENT

DRYER

U-7P ZONE

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GKB SURFACE TREATMENT PROCESS: DESCRIPTION

Metal chain is fed to degreasing unit from feeding unit. Degreasing unit takes its dosage from sub-degreasing tank that contains P3 Saxin and melt cleaner solution. Steam is continuously charged to degreasing unit to raise the temperature of the contents. The charge is transferred to RO-Water tank. The charge then enters coloring tank where the temperature is maintained at 40 0C. Coloring tank takes its dosage from sub-coloring tank. The charge then enters soft water tank. Chain is then treated with Rusmin-R. Rusmin-R protects metal elements from corrosion. It is an anti-corrosive agent. Chain is dried at 130 0C. Chain then enters U-7P zone. U-7P treatment is essential for shining, color fastening and smoothness of zipper.

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ASSEMBLY DEPARTMENT
CONTENTS: INTRODUCTION METAL CHAIN ASSEMBLING VISLON CHAIN ASSEMBLING COIL CHAIN ASSEMBLING

ASSEMBLY EXECUTIVE

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INTRODUCTION:
Three items are assembled in this department i.e. vislon, metal and coil. METAL CHAIN ASSEMBLING: Open end: Following open end items are assembled 1. 5MFO
F-52 F-60 F-54

F-52 is cord press machine F-60 is film and punch unit F-54 is pin and retainer box unit

2. 7MFO AND 10MFO

F-60 F-54

F-60 is film and punch unit F-54 is pin and retainer box unit

Close end: Following close end items are assembled 5MFC, 7MFC AND 10MFC
F-48

F-48 is assembling machine, it has a cutting unit as well. Top stop, bottom stop and slider are attached in this machine.

VISLON CHAIN ASSEMBLING: Open end: Following open end items are assembled in this section. 3VS, 5VS AND 8VS
F-30 F-60 F-63 F-61

F-30 is a spacing machine; it removes vislon elements from continuous chain.

F-60 generates reinforcing film and is a piercing machine; it creates pierces on reinforcing film.

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F-63 attaches top stop, retainer pin and separable pin. F-61 attaches retainer box and slider.

Close end: Following items are assembled in this section: 3VS AND 5VS
F-30 F-48

F-30 is a spacing machine; it removes vislon elements from continuous chain. F-48 is assembling machine, it has a cutting unit as well. Top stop, bottom stop and slider are attached in this machine.

COIL CHAIN ASSEMBLING: Open end: Following open end items are assembled in this section. 5CFO
F-64 F-60 F-54

F-64 is a spacing machine; it removes coil elements from continuous chain.

F-60 generates reinforcing film and is a piercing machine; it creates pierces on reinforcing film. F-54 attaches top stop, retainer pin and separable pin.

Close end: Following items are assembled in this section: 2CFC, 3CFC AND 5CFC
F-64 F-32 F-40

F-64 is a spacing machine; it removes coil elements from continuous chain. F-32 is assembling machine, it has a cutting unit as well. Top stop, bottom stop and slider are attached in this machine.
F-40 attaches retainer box and slider.

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QUALITY CONTROL
CONTENTS: YKK QUALITY CONTROL POLICY AND MEASURES QUALITY APPROVAL PROCEDURE

QUALITY CONTROL EXECUTIVE

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YKK QUALITY CONTROL POLICY AND MEASURES

YKK Pakistan has a quality control team who check the quality in production line 24 hours. They find the problems and solve the problems right away while producing. Each quality control procedure involves strict methods with thorough checking processes by professional testing machine for resistance of chain to lateral load and reciprocating movement of slider. They also can produce quality according to customer's exact specifications for garment and bag application. Initially, all materials/components undergo quality testing with quality assurance from their suppliers. Next, finished products are inspected before and after packaging. Finally, each product is checked before delivery. YKK Pakistan ensures quality at each stage of its processing and production. To maintain its quality and render world-class zipper to its customers YKK carry out quality control testing. Quality control testing is divided into three categories: 1. Raw material testing 2. In process testing 3. Final inspection As raw materials are received, QC team member takes random samples of the raw materials and different tests are carried out. Sliders are tested for lead and cadmium contents via EDX (Energy Dispersive Spectrophotometer). Lead and cadmium contents should not exceed 90 and 40 ppm respectively. Sliders strength is also determined through pull tap strength test. Tape strength is also determined by testing it lengthwise and folded crosswise. QC members also carry out random or scheduled in process testing. Machines that are newly purchased are regularly tested. Different samples are daily obtained from dyeing, chain and assembly department. YKK QC team carries out rigid testing procedures to ensure guaranteed quality. All materials/components are inspected. All products undergo strict QC before and after packaging.

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QUALITY APPROVAL PROCEDURE

STRENGTH TEST FOR ZIPPER AND SLIDER: Chain crosswire strength Top and bottom stop holding Separable pin, pull-off resistance to pull-off of slider pull resistance to twist of pull & slider element slippage Color fastness to dry cleaning Color fastness to light Color fastness to crocking zipper tapes

MEASURING ZIPPER DIMENSIONS Chain width Chain thickness Pitch Element length Element cut off Head height Top stop thickness Bottom stop thickness Total chain width

PERFORMANCE: Opening force Closing force Crosswise Folded crosswise Top stop strength Bottom stop strength Slider lock strength Element slippage Element pull off Puncture Durability

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UTILITIES
CONTENTS: REVERSE OSMOSIS PLANT RO PLANT PROCESS DESCRIPTION AND TERMINOLOGY REVERSE OSMOSIS PERFORMANCE & DESIGN CALCULATIONS DOSAGES AND THEIR FUNCTIONS RO PLANT VLOCK DIAGRAM WASTE WATER TREATMENT PLANT DYEING WASTE WATER TREATMENT FLOW DIAGRAM SURFACE TREATMENT WASTE WATER TREATMENT FLOW DIAGRAM REVERSE OSMOSIS PERFORMANCE & DESIGN CALCULATIONS WASTE WATER TREATMENT DESCRIPTION

UTILITY EXECUTIVE

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REVERSE OSMOSIS PLANT

WHAT IS REVERSE OSMOSIS? Reverse Osmosis is a technology that is used to remove a large majority of contaminants from water by pushing the water under pressure through a semi-permeable membrane. DEFINITION OF REVERSE OSMOSIS Osmosis is a natural phenomenon in which a solvent (usually water) passes through a semipermeable barrier from the side with lower solute concentration to the higher solute concentration side. Water flow continues until chemical potential equilibrium of the solvent is established. At equilibrium, the pressure difference between the two sides of the membrane is equal to the osmotic pressure of the solution. To reverse the flow of water (solvent), a pressure difference greater than the osmotic pressure difference is applied; as a result, separation of water from the solution occurs as pure water flows from the high concentration side to the low concentration side. This phenomenon is termed reverse osmosis (it has also been referred to as hyper-filtration). REVERSE OSMOSIS MEMBRANE A reverse osmosis membrane acts as the semipermeable barrier to flow in the RO process, allowing selective passage of a particular species (solvent, usually water) while partially or completely retaining other species (solutes). REVERSE OSMOSIS PLANT AT YKK PAKISTAN: YKK Pakistan has three RO Plants of different capacities: I. 3 m3/h RO Plant II. 5 m3/h RO Plant III. 30 m3/h RO Plant I. II. III. These RO-Plants are providing RO-Water for: Water tube boilers Dyeing machines Surface treatment machines

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RO PROCESS DESCRIPTION AND TERMINOLOGY

Reverse osmosis, commonly referred to as RO, is a process where you demineralize or deionize water by pushing it under pressure through a semi permeable reverse osmosis membrane. The RO process is relatively simple in design. It consists of a feed water source, feed pretreatment, high pressure pump, RO membrane modules, and, in some cases post treatment steps. The three streams of the RO membrane process are feed; the product stream called permeates; and the concentrated feed stream, called the concentrate or retentate. Reverse osmosis works by using a high pressure pump to increase the pressure on the salt side of the RO and force the water across the semi-permeable RO membrane, leaving almost all (around 95% to 99%) of dissolved salts behind in the reject stream. The amount of pressure required depends on the salt concentration of the feed water. The more concentrated the feed water, the more pressure is required to overcome the osmotic pressure. As the feed water enters the RO membrane under pressure (enough pressure to overcome osmotic pressure) the water molecules pass through the semi-permeable membrane and the salts and other contaminants are not allowed to pass and are discharged through the concentrate stream, which goes to drain or can be fed back into the feed water supply in some circumstances to be recycled through the RO system to save water. The water that makes it through the RO membrane is called permeate or product water and usually has around 95% to 99% of the dissolved salts removed from it.

WHAT WILL REVERSE OSMOSIS REMOVE FROM WATER? Reverse Osmosis is capable of removing up to 99%+ of the dissolved salts (ions), particles, colloids, organics, bacteria and pyrogens from the feed water. An RO membrane rejects contaminants based on their size and charge. Any contaminant that has a molecular weight greater than 200 is likely rejected by a properly running RO system. Likewise, the greater the ionic charge of the contaminant, the more likely it will be unable to pass through the RO membrane. An RO system does not remove gases such as CO2 very well because they are not highly ionized (charged) while in solution and have a very low molecular weight. Because an RO system does not remove gases, the permeate water can have a slightly lower than normal pH level depending on CO2 levels in the feed water as the CO2 is converted to carbonic acid.

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Reverse Osmosis is very effective in treating brackish, surface and ground water for both large and small flows applications.

REVERSE OSMOSIS PERFORMANCE & DESIGN CALCULATIONS

There are a handful of calculations that are used to judge the performance of an RO system and also for design considerations. An RO system has instrumentation that displays quality, flow, pressure and sometimes other data like temperature or hours of operation. In order to accurately measure the performance of an RO system you need the following operation parameters at a minimum: Feed pressure Permeate pressure Concentrate pressure Feed conductivity Permeate conductivity Feed flow Permeate flow Temperature

1. 2. 3. 4. 5. 6. 7. 8.

RO PRETREATMENT Proper pretreatment using both mechanical and chemical treatments is critical for an RO system to prevent fouling, scaling and costly premature RO membrane failure and frequent cleaning requirements. Below is a summary of common problems an RO system experiences due to lack of proper pre-treatment. Fouling: Fouling occurs when contaminants accumulate on the membrane surface effectively plugging the membrane. Fouling typically occurs in the front end of an RO system and results in a higher pressure drop across the RO system and a lower permeate flow. This translates into higher operating costs and eventually the need to clean or replace the RO membranes. Fouling can be caused by the following: Particulate or colloidal mater (dirt, silt, clay, etc.) Organics (humic/fulvic acids, etc) Microorganisms (bacteria, etc). To prevent fouling of an RO system, mechanical filtration methods are used. The most popular methods to prevent fouling are the use of multi-media filters (MMF) or microfiltration (MF).

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SCALING: As certain dissolved (inorganic) compounds become more concentrated then scaling can occur if these compounds exceed their solubility limits and precipitate on the membrane surface as scale. The results of scaling are a higher pressure drop across the system, higher salt passage (less salt rejection), low permeate flow and lower permeate water quality. CHEMICAL ATTACK: Modern thin film composite membranes are not tolerant to chlorine or chloramines. Oxidizers such as chlorine will burn holes in the membrane pores and can cause irreparable damage. The result of chemical attack on an RO membrane is a higher permeate flow and a higher salt passage. PRETREATMENT SOLUTIONS Below are some pretreatment solutions for RO systems that can help minimize fouling, scaling and chemical attack. I. Multi Media Filter (MMF) A Multi-Media Filter is used to help prevent fouling of an RO system. A MMF typically contains three layers of media consisting of anthracite coal, sand and garnet, with a supporting layer of gravel at the bottom. A well-operated Multi-Media Filter can remove particulates down to 15-20 microns. A MultiMedia Filter that uses a coagulant addition can remove particulates down to 5- 10 microns. Multi-media filter is suggested when the Silt Density Index (SDI) value is greater than 3 or when the turbidity is greater than 0.2 NTU. II. 5 MICRON CARTRIDGE FILTER It is important to have a 5 micron cartridge filter placed directly after the MMF unit in the event that the under drains of the MMF fail. This will prevent the MMF media from damaging downstream pumps and fouling the RO system. III. ANTISCALANTS/SCALE INHIBITORS Anti-scalants and scale inhibitors are chemicals that can be added to feed water before an RO unit to help reduce the scaling potential of the feed water. Anti-scalants and scale-inhibitors increase the solubility limits of troublesome inorganic compounds by increasing the solubility limits. Anti-scalants and scale inhibitors work by interfering with scale formation and crystal growth. IV. SODIUM BISULFITE By adding sodium bisulfite (SBS or SMBS), which is a reducer, to the water stream before an RO at the proper dose we can remove residual chlorine and chloramines. V. GRANULAR ACTIVATED CARBON (GAC) GAC is used for both removing organic constituents and residual disinfectants (such as chlorine and chloramines) from water. GAC media is made from coal, nutshells or wood. Activated carbon removes residual chlorine and chloramines by a chemical reaction that involves a transfer of electrons from the surface of the GAC to the residual chlorine or

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chloramines. The chlorine or chloramines ends up as a chloride ion that is no longer an oxidizer

DOSAGES AND THEIR FUNCTIONS

1. Pre-chlorination Dosage-Sodium hypo chlorite (NaOCl) is normally used as the disinfectant to protect dual media filter from bacterial contamination. 2. Sulfuric Acid Dosage-Before treating water by the R.O. units, acid is fed to lower the pH in the feed water to protect the R.O. membranes. Sulfuric acid also prevents calcium carbonate and calcium phosphate scaling. 3. Anti-scaling Dosage-A polymer based M50 anti-scalant is used to prevent precipitation of all other kinds of scaling. M50 anti-scalant inhibits sulfate and fluoride scales, disperse colloids and metal oxides. 4. De-chlorination Dosage-Sodium Meta bisulfite (SMBS) is normally used as the dechlorinating agent. Whenever water is to be treated by the RO units, SMBS must be fed to de-chlorinate the flow to protect the R.O. membranes. Approximately 1.5 parts of bisulfite are required per part chlorine. Additional two parts of bisulfite are provided for safety. 5. Post-chlorination Dosage- Sodium hypo chlorite (NaOCl) is added to permeate to prevent RO-water from disinfectants as it is stored in tank

RO-PLANT BLOCK DIAGRAM

Intake System

PreTreatment System

High Pressure Pumps

Reverse Osmosis Section

Post Treatment Section

Product Delivery System

Electrical & Control System

Chemical Dosing Systems

Energy Recovery System

Cleaning in Place & Flushing System

Chemical Dosing Systems

Brine Discharge System

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WASTE WATER TREATMENT SYSTEM 475 m3/DAY

Waste water is usually of two types: 1. Industrial waste water 2. Sewage waste water YKK Pakistan is currently treating two types of industrial waste water 1. Waste water from dyeing machines 2. Waste water from surface treatment machines

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DYEING WASTE-WATER TREATMENT FLOW DIAGRAM

HELDY FeCl3 TANK 0.05% POLYMER TANK ANTI-FOAMING TANK

10% CaCl2 TANK

10% NaOH TANK

5%H3PO4 TANK

DYEING WASTE STORAGE TANK T101 DYEING REACTION TANK T-102 DYEING pH ADJUST TANK T-103 DYEING FLOCULATION TANK T-104

OVERFLOW

DYEING HOLDING TANK T-106

FLOW CONTROL TANK FC-01

AERATION TANK T-107

AIR FROM BLOWERS

UNDERFLOW

DYEING SEDIMENTATION TANK T-105

SLUDGE CONTROL TANK FC-02

CLARIFIED LIQUID HOLDING TANK T-109

SLUDGE FOR DYEING WASTE TANK T-115-1

UNDERFLOW

SEDIMENTATION TANK T-108

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SURFACE TREATMENT WASTE-WATER TREATMENT FLOW DIAGRAM

HELDY FeCl3 TANK

10% CaCl2 TANK

10% NaOH TANK

0.05% POLYMER TANK

Se WASTE STORAGE TANK T-121 Se REACTION TANK T-122 Se pH ADJUST TANK T-123 Se FLOCULATION TANK T-124

OVERFLOW

Se HOLDING TANK T-126

CLARIFIED LIQUID HOLDING TANK T-109

UNDERFLOW

Se SEDIMENTATION TANK T-125

SLUDGE CONTROL TANK SC-02

SLUDGE FOR Se WASTE TANK T-115-2

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CLARIFIED LIQUID TREATMENT FLOW DIAGRAM

DYEING WASTE WATER

Se WASTE WATER

CLARIFIED LIQUID HOLDING TANK T-109

BACKWASH TANK T-113

D/L FILTER TANK V-110

A/C FILTER TANK V-111

10% H2SO4 TANK V-203

NEUTRALIZATION TANK T-112

MONITORING WATER TANK T-114

POND

DISCHARGED TO MUNICIPAL SEWERAGE SYSTEM

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FLAWS
Safety precautions and PPEs are not followed by all the employees. Measuring cylinders are not always used for measuring the exact amount of chemicals for dyeing. Surface temperature of dyeing machines is approximately 70 0C which implies machines are not properly insulated. Steam escapes from the drainage line of one of the large dyeing machines hence resulting in less energy recovery and rise in the floor temperature. No proper exhaust system designed for dyeing and chain department thus resulting in accumulation of heat and rise in temperature. Improper functioning air-conditioning system that supplies air at 350C and incorrect position of chillers waste energy and contributes nothing in cooling the floor or removing heat. Engineers are not given chance to overcome the problems for which they are. Leveling is not achieved of the desired degree which results in adding and re-dyeing which is not economical for the company. No experiments or research is carried out to overcome day to day challenges and problems. Many golden elements are found in surface treated chains. At RO-Plant, valve that has stopped functioning automatically is not replaced and is operated manually which may result in any hazard. No exhaust system in even enameling room for the removal of thinner fumes. These fumes can damage the lungs of the employees working in that room. FLAWS IN ITERNSHIP PROGRAM: Internship program was not a scheduled one. Machine operation was emphasized too much although engineering is not all about operating machines.

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RECOMMENDATIONS
There must be a strict check over employees to make sure whether they are following PPEs and SOP. Proper exhaust and vacuum system must be designed for dyeing and chain departments to remove heat released from machines. Dyeing machines must be insulated well. Steam and heat losses must be minimized. Air-conditioning system must be serviced and re-designed for proper functioning. Engineers must be given projects for the betterment of the company. Experiments must be carried out using different leveling agents to solve leveling issue. Engineers must research and devise better coloring agents to solve golden element problem.

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