Process & Procedural Process & Procedural Responsibilities Of Dyeing Responsibilities Of Dyeing

DepartmentDepartment

Be Attentive B4 Start DyeingBe Attentive B4 Start Dyeing

Whatever goods are received from pretreatment, they Whatever goods are received from pretreatment, they should be fully checked according to the dyeing should be fully checked according to the dyeing requirement with regards to all parameters such as;requirement with regards to all parameters such as;

Consistent Consistent AbsorbencyAbsorbency Consistent WhitenessConsistent Whiteness WidthWidth Stitching Of The PiecesStitching Of The Pieces Proper heat setting in case of CVC & PC.Proper heat setting in case of CVC & PC. Seinging QualitySeinging Quality Consistent Consistent TegawaTegawa Consistent Consistent pHpH of the fabric of the fabric Master cardsMaster cards

Are you Satisfied With Received Are you Satisfied With Received Fabric & Documents Fabric & Documents

THENTHEN After satisfying with the all above in the production, After satisfying with the all above in the production,

following cares have to be taken;following cares have to be taken; The batchers are put before the machine in absolute The batchers are put before the machine in absolute

parallel form otherwise crease or bowing may appear parallel form otherwise crease or bowing may appear which may cause increase rejection percentage.which may cause increase rejection percentage.

Look after exact shade matching for which standard Look after exact shade matching for which standard should always be available to that quality assurance should always be available to that quality assurance online can also check in addition to the dyeing staff.online can also check in addition to the dyeing staff.

Dyeing consistency should be 100% and all concerned Dyeing consistency should be 100% and all concerned should react without losing any fabric and without should react without losing any fabric and without increasing rejection and wastages.increasing rejection and wastages.

Throughout the dyeing of the fabric, curing Throughout the dyeing of the fabric, curing or steaming temperature should be or steaming temperature should be accurate to maintain the shade accurate to maintain the shade consistency on each batcher’s tailing, consistency on each batcher’s tailing, there should be the following information:there should be the following information:

• Name Of Operator Name Of Operator • Name of In-chargeName of In-charge• Time & Date Time & Date • Frequency Of Tailing (in meter)Frequency Of Tailing (in meter)

…….Be Responsible……..Be Responsible……. Calculate color consumption according to the program. Calculate color consumption according to the program.

All color weighing should be in front of responsible All color weighing should be in front of responsible supervisor or shift in-charge.supervisor or shift in-charge.

Must follow the sequence of dyes/ chemicals according Must follow the sequence of dyes/ chemicals according to the preparation method.to the preparation method.

During washing, pH should be maintained, minimum flow During washing, pH should be maintained, minimum flow rate as per shade to safe the water.rate as per shade to safe the water.

All the listings and tailing cards record of each shade All the listings and tailing cards record of each shade should be maintained on the daily basis and the dyeing should be maintained on the daily basis and the dyeing as well as Q.C. must sign on those records regularly.as well as Q.C. must sign on those records regularly.

All batchers should be covered from the machine.All batchers should be covered from the machine.

Maintain Paper Work..Maintain Paper Work..

On the Job card, which is attached to On the Job card, which is attached to every batcher, in-charge or supervisor every batcher, in-charge or supervisor should endorse information as below:should endorse information as below: Time Time ShiftShift OperatorOperator SupervisorSupervisor

Quality Means Survival!!!Quality Means Survival!!! Before starting new shade, take one sample from the lab Before starting new shade, take one sample from the lab

recipe; make its record then correct the shade by given recipe; make its record then correct the shade by given addition whatever it requires. After proper matching, do addition whatever it requires. After proper matching, do the confirmation of almost the confirmation of almost 250250 meter fabric and meter fabric and throughout the confirmation, check the problems onto throughout the confirmation, check the problems onto the fabric which may come from pretreatment like the fabric which may come from pretreatment like creases, spots etc and also check the machine creases, spots etc and also check the machine problems. problems.

The dyeing staff should also follow the production until The dyeing staff should also follow the production until finishing is done.finishing is done.

The In-charge is required to know the required The In-charge is required to know the required parameters of the customers with regards to dry, wet parameters of the customers with regards to dry, wet rubbing and washing fatness as well as light source.rubbing and washing fatness as well as light source.

Be Machine’s FriendlyBe Machine’s Friendly

Whenever the machine is free, in-charge must Whenever the machine is free, in-charge must make their responsibility to activate all make their responsibility to activate all attachments of machine like e-control, pad batch attachments of machine like e-control, pad batch process etc.process etc.

In-charge, supervisor must make to receive the In-charge, supervisor must make to receive the maintenance job card whenever the electrical or maintenance job card whenever the electrical or mechanical problem occur on the machine, if mechanical problem occur on the machine, if they realize that no body in taking immediate they realize that no body in taking immediate action upon the complain then directly approach action upon the complain then directly approach to maintenance manager or G.M. to save the to maintenance manager or G.M. to save the down time.down time.

Efficiency & ProductivityEfficiency & Productivity For good productivity of the dyeing department do care of the For good productivity of the dyeing department do care of the

following responsibilities;following responsibilities; To see it that dyeing is done according to the program without to To see it that dyeing is done according to the program without to

much deviation of timing.much deviation of timing. The change over should be accelerated minimum time should be The change over should be accelerated minimum time should be

taken in change over.taken in change over. Area around dyeing machine should be kept clean and wiped out Area around dyeing machine should be kept clean and wiped out

from water around the machine.from water around the machine. For any shade maximum speed should be attained without For any shade maximum speed should be attained without

deteriorating quality parameters and consistency of the shade and deteriorating quality parameters and consistency of the shade and dyes results.dyes results.

The next program which is to be taken into production should be The next program which is to be taken into production should be always available behind the machine before the running should is always available behind the machine before the running should is going to end to minimize down time. going to end to minimize down time.

Color for the next program should always be ready before the Color for the next program should always be ready before the running shade is going to end.running shade is going to end.

The last color tank of every shade should be calculated The last color tank of every shade should be calculated accurately according to the running. Fabric to minimize accurately according to the running. Fabric to minimize the wastage of color.the wastage of color.

The batcher for the next program must be arranged in The batcher for the next program must be arranged in Mill # 2 from Mill # 4 before the ending of running Mill # 2 from Mill # 4 before the ending of running shade.shade.

The requirement of dyestuff for the 24 hours program The requirement of dyestuff for the 24 hours program should be arrange from the gulf to same production should be arrange from the gulf to same production loss.loss.

All the dyed batchers should be received to finish All the dyed batchers should be received to finish department on time to safe blockage of transportation.department on time to safe blockage of transportation.

Just in time theory should be applicable in dyestuff and Just in time theory should be applicable in dyestuff and chemical store, so that more space will be available chemical store, so that more space will be available and it also minimizes the holding cost.and it also minimizes the holding cost.

The in charges, supervisors should give accuracy to The in charges, supervisors should give accuracy to their operators and A.M.C’s about “the loss due to their operators and A.M.C’s about “the loss due to down time and the loss due to wastage of color time to down time and the loss due to wastage of color time to time and how can we save our company from these time and how can we save our company from these losses.losses.

House KeepingHouse Keeping Every person is responsible for house keeping. There Every person is responsible for house keeping. There

should be no torn pieces lying around, no color spread should be no torn pieces lying around, no color spread around the machine, pieces hidden on the side of the around the machine, pieces hidden on the side of the dyeing machine and no untidiness behind machine, on dyeing machine and no untidiness behind machine, on the side of the machine has to be taken care of.the side of the machine has to be taken care of.

General protection equipments have to be used General protection equipments have to be used wherever required.wherever required.

All the color men should wear P.P.E. during making All the color men should wear P.P.E. during making color and chemicals.color and chemicals.

No blockage on the way of transportation so that No blockage on the way of transportation so that batchers can easily move to safe the down time.batchers can easily move to safe the down time.

General MaintenanceGeneral Maintenance

In-charges, operators should be pro-active to In-charges, operators should be pro-active to save the machine from big loss.save the machine from big loss.

Machine should be hand-over for maintenance Machine should be hand-over for maintenance on its schedule date. During maintenance, on its schedule date. During maintenance, machine staff should clean the machine from machine staff should clean the machine from top to bottom.top to bottom.

Both electrical and mechanical engineer Both electrical and mechanical engineer should visit the machines their self three times should visit the machines their self three times a day to check and control all the pro-active a day to check and control all the pro-active measures. This habit can safe the machine measures. This habit can safe the machine from expensive losses.from expensive losses.

ConclusionConclusion

Keeping all above factors, productivity, Keeping all above factors, productivity, efficiency, consistency has to maintained efficiency, consistency has to maintained and will be part of evaluation of the and will be part of evaluation of the person/ persons, department in-charge / person/ persons, department in-charge / in-charges, are required to impart training in-charges, are required to impart training according to above procedure to all their according to above procedure to all their workers and frequent audits will be carried workers and frequent audits will be carried out for the evaluation of training imparted out for the evaluation of training imparted and performance.and performance.