DENIMS

                                                 Loom Machine Operation

Weaving specification

Document Control

                       

Document No..………………………………

Revision No.…………………………………

D.C. Signature.……………………………....

Date………………………………………….

                                                      

A  Denims Limited

         Document No: 52-302

AUTHOR        Md.Rafiqul Islam raTan

                                                                       

                                         DOCUMENT OWNER   

Approvals:

DOCUMENT OWNER   ……………..

Head Of DOCUMENT Control ……….

JEON NASIR

                       A Denims Limited

AUTHOR: THE PERSON WHO WRITERS, PRODUCTS CREATES, ORGANIZE OR REDESIGNS the document:

DOCUMENT OWNER: HEAD OF THE DEPARTMENT OF THE PRIMARY DOCUMENT USER GROUP IS THE DOCUMENT OWNER. HE OS RESPONSOBLE FOR ENSURES THE APPROPRIATENESS OF DOCUMENT AND GIVES APPROVAL UPON. COMPLETION

Doument Editor	Date	Section Edited
		Corrections are made in the section 2&4

Table of content

1.    Process Definition……………………………………………..

2.    Process requirement……………………………………………

3.    Equipment……………………………………………………...

4.    Key accessories…………………………………………………

5.    Materials/ chemical used……………………………………….

6.    Safety measures…………………………………………………

7.    Production procedure…………………………………………..

8.    Operation staff………………………………………………….

9.    Machine setup………………………………………………….

10.           Check list before production…………………………………

11.           Operation procedure…………………………………………

12.           The technical responsibility…………………………………

13.           Beam piecers responsibility…………………………………

14.           Operation responsibility……………………………………

15.           The shift officers/ in charge responsibility…………………

16.           Product quality check………………………………………

17.           Qc sample list ……………………………………………

18.           Response to equipment faults ……………………………

19.           Machine / area cleaning……………………………………

20.           Applicable forms / documents………………………………

21.           Forms and documents used………………………………

22.           Document flow……………………………………………

23.           Attachments ………………………………………………

AUTHOR: THE PERSON WHO WRITERS, PRODUCTS CREATES, ORGANIZE OR REDESIGNS the document:

DOCUMENT OWNER: HEAD OF THE DEPARTMENT OF THE PRIMARY DOCUMENT USER GROUP IS THE DOCUMENT OWNER. HE OS RESPONSOBLE FOR ENSURES THE APPROPRIATENESS OF DOCUMENT AND GIVES APPROVAL UPON. COMPLETION

1.0           Process Definition

Interlacement of two or more yarns/ thread warp and weft yarns in A definite order to form A fabric which is suitable for dress material domestic and industrial purpose is called weaving. The machine use for this purpose is called weaving machine or loom.

2.0 Process Requirement 

2.1 Equipment

The machine used for the purpose of weaving can be categorized are as follows:

Model	Sheding Device	No. Of loom
Tsudakoma Air jet loom, Japan ZA 2051	Cam shedding	56
Sulzer ruti loom, switerland 153n VSD110KR D1	Cam shedding	12

2.2 Key Accessories

 The key accessories used for weaving are as follows:

v Weavers hook

v Weavers cutter

Pick counting glass

Measuring tape

2.3 Materials / chemicals used

Not Applicable

3.0 Safety Measures

          In order to ensure floor and personal safety, personal are instructed to follow the safety guidelines given below:

v Smoking is strictly prohibited in the factory premises.

v Operators are instructed not to touch any rotating or operating parts until the machine comes into A complete stop.

Weaving Process                             Rev:                                                           Page

v Do not operate the machine in cloths/ yarn that could get entangled in the rotating parts,

v During maintenance turn All the electrical switches into manual position all electric supply get cut off and the machine stops.

v Put sign on the machine (yellow-Weft, Green-warp,Red-mechanical)

As per requirement.

4.0 Production procedure

4.1 operation staff

Operation staffs for weaving operation and their responsibilities are given below:

Operating Staff	Responsibilities
Section Head	In-charge   of overall loom operations
Head of Technicians	Maintenance In charge
Production  Officer	Shift In charge
Loom Technicians	Shift wise running loom checking, setting,gauging.tuning etc
Beam piecer	Loading new beams on machine and unloading empty beam from machines and pass the knotting beams and machines that are ready for production.
Loom Operator	Operator run the machine
Weft supplier	Supply weft yarn and remove yarn and clean waste box
Cleaner	Cleaner the machine and department.

4.2 Machine setup

          The machine set up for weaving operating are given below:

Model	Weft insertion capacity	R.P.M
Tsudakoma Air jet Loom, Japan  ZA 2051	2	Up to 650
Sulzer Ruti projectile loom, Switzerland 153 VSD 110 KR d1	4	Up to 220

4.3 Checklist before production

 Operator must check the following points prior to operation:

Ø Check safety switch.

Ø Check drawing, denting, frabic width, weft density and any other fabric defect.

Ø Check yarn count and manufacturer.

Ø Check the quality card (F52-302-05).

4.4 Operation procedure

      After article is done, A new weavers beam is set on the machine and drawing or trying id done. It is the duty of the loom technician to check and set all necessary setting, gauging and operating and operating values through mechanical means. After setting is done, he hands over the machine to beam piecers /beam fitter. The beam piecer checks the fabric for:

v  Any wrong or broken design

v Any wrong drawing and denting

v Fabric width , warp, weft density

v Any other cloth defect

Any fault found in the fabric is correct over the loom and then handed over to operators for normal running

For all types of fabric, the first meter of fabric is sent to quality control Department for subsequent parameter test. Upon getting quality approval from quality control department the operator status the machine for bulk production. The quality approval sheet (F82-101-01) is filed in the weaving department as A reference.
4.4.1 The Technicians Responsibility

Following are the Responsibilities of A Loom Technician:

v  Depending upon yarn count, weave design and sizing condition of the beam RPM of the loom is decided and set (if required).

v Based on quality, pick gear is changed and Dobby card is set.

v Regular checking is also carried out during operating and different parameters are fine-tuned as required to achieve optimum loom running efficiency.

v Articles are changed as per quality requirements

v All running maintenance works are done in A shift.

4.4.2 Beam piecers Responsibility

At the completion of articles by maintenance people, looms are handed over to the beam piecer Beam piecer should perform the following tasks:

v Pass the knotting beam and machine that are ready for production.

v Unload empty beam and load weavers beam on the machine

v  Visually cheek the fabic quality:

v Any wrong or broken design

v Any wrong drawing and denting

v Fabric width , warp, weft density

v Any other cloth defect.

4.4.3 The operators Responsibility

 Following are the Responsibility of an Operator:

v  To run the machine in the systematic way as advised by the department head    and guided by the shift officers in –change and beams piecers

v  T o repair or knot the broken warp and weft yarn during operation in the quickest possible time so that the down time for short stops ate minimized.

v  To ensure and use the correct weft yarn, which did weft supplier, publish.

v  To cut long tails of knots of warp ends by cutter to improve the quality of denim fabric.

v To produce defect –free fabric that was occurred as A result of missing ends and pocks, wrong drawing denting, miss selection of weft yarn.

4.4.4.      The shift officers –in charge responsibility

Following are the Responsibility of shift officers –in charge:

v Ensure all the activities of the department are performed satisfactorily

v Take best effort to control wastage

v Ensure optimum house keeping

v Check the attendance

v Encourage workers not to indulge in any malpractice and motivate them for  higher efficiency

v Make operation wise daily production and shift efficiency

v Make A comprehensive activity report of his shift in the log book (Log book No. L52-302-01)

4.5 Product Quality cheek

The first meter of the fabric is made and checked visually for:

v Any wrong or broken design

v Any wrong drawing / denoting fabric width, warp and weft density

v  Any sorts of fabric defect

Any fault found in the fabric is corrected is corrected over the loom and it  is handed   over the operator for production. 

4.6 Sample Test

For all types of fabrics, the first meter of the fabric is send to Q.c department for subsequent tests and upon receiving the quantity approval from Q.c. Department weaving machine is started for bulk production. The quantity Approval sheet (F82-101-01) is filed in the weaving section as A future reference.

4.7 Response to equipment faults:

Following are the responsible to be taken in case of any equipment fault (s):

Equipment faults:	Response
Mechanical problem	Call loom Mechanical Maintenance
Electrical problem	Call loom Electrical Maintenance
Utilities problem	Call Utilities department

4.8 Machine /Area clearing

All machines are cleaned with compressed air in each shift.

The cleaners clean the floor with wiper in every shift.

The loom Maintenance department performs the precognitive maintenance task as per the PM schedule. Refer to loom Maintenance Specification (Document No.30-201) for details.

5.0 Applicable forms /Documents.

5.1Forms and documents used

 The necessary forms & documents used for weaving process are listed below:

1.    Daily production Report (Form No.F52-302-01)

2.    Weaving program report ((Form No.F52-302-02)

3.    Daily Weaving Report (Form No.F52-302-03)

4.    Sizing beam requisition (Form No.F52-302-02)

5.    Greige sample washing record (Form No.F52-302-04)

6.    Quality card (Form No.F52-302-05)

7.    Fabric Transfer statement (Form No.F52-302-06)

8.    Wastage return statement (Form No.F52-302-07)

9.    Quality Approval sheet (Form No.F52-302-07)

10.           Weaving log book (log book no.L52-302-01)

5.2 Document Flow:

The document flow of the above document is as follows:

The daily production report (Form No.F52-302-01) is maintained to record details of per day shift wise production. The concerned person fills it and the area in-charge verifies the data mentioned on it.

The Weaving program report ((Form No.F52-302-02) is used to give detailed written instruction to the operators.

     The Daily Weaving Report (Form No.F52-302-03) shows the details of per day shift wise production. It also includes the machine stoppage details.

Based on weaving plan, the required number of sized beam is written down on the sizing beam requisition form Sizing beam requisition (Form No.F52-302-02) by the planing weaving department. Beam requisition form is sending to dying and sizing department as per quality.

11.           For all types of fabric, after producing the first meter of the fabric of is sent to Q.C department for subsequent test. The Q.c fills out the greige sample washing record (Form No.F52-302-04) and sends A copy to the weaving section for further reference.

12.           The quality card (Form No.F52-302-05) is used to show loom wise quality order to guide the operators to achieve desired quality.

   

The Fabric Transfer statement (Form No.F52-302-06) is used to transferred the produced fabric the greige fabric stores. The concerned person of weaving department prepares it and sign on it .The concerned stores personal sign on it upon receiving the good as per this statement.

The Wastage return statement (Form No.F52-302-07) is used to transferred the wastage of the storage The concerned person of weaving department prepares it and sign on it .The stores personal sign on it upon receiving the good as per this statement

 Q.c department to specify the parameter test result and approval of the sample based on this report uses the Quality Approval sheet (Form No.F52-302-07), the operator goes for bulk production with necessary changes (if required).

Weaving log book (log book no. L52-302-01) to keep detailed record of production. The concerned operator fills it in each shifts the shift in –charge verifies the data and keep it for future reference.

5.3 Attachments

The forms used in this process are enclosed herewith.

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Weaving Process                             Rev:                                                           Page