Shift Incharge - Dyeing, Linen Fabric

Job Purpose

Job Context & Major Challenges

• Process changes for bleaching due to different type of fabric lead to slow down of processing. For this, we need to accumulate different processes together to achieve less process change.
• Many times, we get improper results in terms of whiteness variation, so we need to conduct trials for existing chemicals and new chemicals to eliminate variation
• Minimize reprocessing of material because it leads to production loss, time loss, material loss, cost increases, waste increase.
• To maintain RFT about 85% in Coldpad Batch
• To produce fabric defect free is a challenge due to piece-to-piece variation at short lengths of the fabric.
• Changing the color for shade matching is a challenge because there are no steadfast rules for this. We work purely on rule of thumb and experience gained over the year.
• Matching the shades of same color is difficult visually as always checking from machine is not possible. Improvising and making assumption on new shade.
  

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)

Supporting Actions (Max 1325 Characters)

• Achieve machine production as per agreement with operator
• Maintain crucial machine parameters as per SOP for different fabric processes.
• Maintain good machine health by informing the maintenance team for attending to it and getting feedback from them.
  

• Providing instruction for fabric lifting as per process and ensuring quality of grey goods of yarn dyed and piece dyed are as per norms.
• Before starting the chemical dosing, ensuring proper initial chemical fill up, steam pressure, air pressure (for closing and opening valves) as per SOP
• Planning the bleaching method (dosing chemical as per GSM of fabric, cleaning, etc.) parameters and entering it into the PLC machine for starting the process.
• Checking the sample in between the process to ensure there are no hassles and discrepancies, and doing extra treatment in case of any, as per experience.
• Checking for any chemical leakage in the entire operation and attending to it promptly.
  

• Deliver good quality material to next department (dyeing and finishing) in time.
• Identifying the packable and non-packable defects in fabric and taking action to remove the former
• Establish and monitor well-defined quality parameters like whiteness, absorbency, pH, etc. and ensuring that the requirement is met for the next process.
• Taking corrective and preventive action through regular m/c monitoring and consulting with dyeing and finishing.
  

• Shade matching with Standard and control CSV, stain, dagi, tailing, shade variation, creases by monitoring different process and machine parameters.
• Monitoring the quality of the final product to identify the mendable defects for prompt action.
• Establish and monitor well-defined quality parameters.
• Minimize reprocessing of material
  

• Train all workmen to increase multiskilling
• Timely feedback to workmen about their progress
• Motivation of workmen for good work life
  

• Creating a culture of continuous improvement among the workmen
• Leading all WCM and six sigma projects along with coordination with BE for their audits.
  

• Ensure all workers follow the required safety standards
• Undertake various activities/ projects to reduce wastage and make the process more efficient, like
• Reduce stitching cutting size
• Using the same leader cloth of lighter shade in dark/medium shade after repeated usage to prevent usage of separate cloths for light, medium, and dark shade.
• To Prepare Chemical and color as per requirement.
• Ensure lot to lot tracing by not cutting any lot.