Operators Skills development Training For knit dyeing Finishing

1. MAA Garment & Textiles
Finishing Department
(Dyeing)
Mohammad Mizanur Rahman.
Finishing Expert
(Kebire Enterprises PLC)

2. Mohammad Mizanur Rahman
Fabrics Finishing Expert (Manager)
Cell: +251 962 600 055
Email: mizan5379@yahoo.com
Presented By

3. Translations By
Subagadis Hagos Tesfay
Finishing Department Head

4. Operator's Training Programs

5. Job Responsibility

6. Job Responsible of
Coordinator
 Coordinate with Dyeing & Quality.
 Priority wise M/c plan
 Follow up Standard parameter
 Fulfil Production Target
 Manpower utilization
 Control Quality Rejection
 Control M/c downtime

7.  Follow the Coordinator Concept
 Timely M/c Clean
 Fulfil Production Target
 Floor Clean
 Fulfil all information in the Batch Card
 Every Batch must be conform with information
 Fulfil Quality Requirement
 Every Batch Time maintained
Job Responsible of
Operator

9. 1. GSM & Shade Check Near of the Stitch.
2. Follow Standard Parameter Sheet if face any problem inform to shift head, As like required
width 180 but you get 190, Also note by log book.
3. Every joint straight sewing.
4. Any hole sewing
5. Rib Separate finish, Frist or Last
6. Without sewing/ Knotted not pass the padder.
7. Started & End time attach reject fabrics avoid the Colour variation.
8.Every time minimum 3 person standby in stender m/c, (Back, Operation & Delivery side).
9. Pin out & crease mark need to be correction or Remove from Batch.
10. Ensure the Hand feel as buyer Requirement.
11. In Batch card need to be Knitting M/c Dia, Gauge, Loop length, Yarn count & Required GSM.
If any one missing, please not finish that batch without Batch card correction.
12. Our Expectation good Quality fabrics.

10. Corino Slitting M/c Side View

11. Slitting Machine
Batch Card
1 Collect Batch Card
2 Check Slitting Mark Available or not
Required
1 Need m/c clean or not
2 M/c Tension ok or not
3 Water & Air Pressure available.
Manpower
1 Operation Area one person/Operator
2 Delivery side one person
Check
1 Check Crease, Needle drop, Wrong Slitting, any visible problem.
2 Elongation % (Cotton S/J 7-8% Allowable)

13. Corino Slitting M/c
 What type of Problems
Face:
 Wrong Slitting
 Crease Mark
 Dirty Spot
 Pick up %
 Elongation

14. Proper Plating in Slitting

16. Not Covering in Slitting

17. Covering in Slitting

18. Purpose: Light Mark/Stain
Who Responsibile: Coordinator,
Procedure: Regular Cleaning-
1. Corino (Slitting M/c)
A. Color Change then Must be clean
B. Every rollers clean by water.
C. Maximum people use clening time.
D. Electrical Divise avoid clean by water, becareful clean by air
E. Same color to Same color no need clean.
F. Within 10-30 minte need to be clean.
G. Must be record Started to Finish time.
Cross Check by: Supervisor
Check List : Corino (Slitting M/c Cleaning Check List
Date Color to Color Start Finish Total time Shift Person Coordinator Check

19. Dryer M/c Side View

20. Dryer M/c
 What type of Problems
Face:
 Over dry
 Over Compaction
 Dirty Spot
 Unlevel
 Elongation

21. Dryer M/c Not Proper Use

22. Stenter M/c Side View

23. Standard Operating Procedure
Stenter Machine
Batch Card
1 Check Buyer, Dia, Gauge, Stitch Length, Required GSM
2 Match with Standard Parameter Sheet
Parameter
1 Set Temp, Width, Overfeed, Speed As a Standard Parameter Sheet.
2 If Not match with Standard Parameter sheet then Inform to Shift head.
3 Prepare Softener as Buyer standard.
Manpower
1 Set Manpower, Back 1 person, Operation area 1 person & Delivery side 1 person.
2 Re-check set parameter & standard parameter.
Check
1 Temperature, Air Pressure & Water if set up & actual same.
2 Now can started machine.
3 Check after delivery, GSM, Width, Hand feel & Shade , If ok as buyer standard then continue

24. Temperature Setting

25. Temperature Check

26. Width Setting

27. Width Check in Stenter M/c

28. Stenter M/c
 What type of Problems Face:
 Shrinkage
 Spirality
 Width Variation
 GSM
 Colour Variation
 Dye Unlevel
 Middle Fabrics Loose
 Crease Mark
 Hand feel
 Hairiness

29. Shade Check In Finishing
Shade & GSM check
1 Check dyeing unload result
2 Stenter m/c setup as Standard parameter.
3 First Roll within 20 meter check Shade & GSM
4 Second time next roll within 10 meter again check shade & GSM
5 If needed then last adjust parameter then again check.
6 Every thing ok then continue & after 5 rolls againe check .
7 If Not accepteable range then infrom to shift head.

30. Physical Operating

31. Wrong Operation

32. Physical Operating

33. Wrong Operation

34. Wrong Operation

35. Physical Operating

36. Physical Operating

37. Pin Out & Selvedge Guide Not
Auto

41. 1. Width Variation
2. Selvedges in pin Hole
3. More Rejection
4. Elephant Skin

42. Joint Not Proper Stitching

43. Width Variation

44. Width Variation in Cutting

46. Width Variation in Cutting

47. Width Variation

49. Proper Width in Cutting

50. Proper Width in Cutting

51. Hole Not Stitching

52. 1. Width Variation
2. Selvedges
3. Crease Mark
4. More rejections
5. In Selvedges pin hole

53. Knots Use

54. 1. Padder Damage
2. Crease Mark
3. Width Variations
4. More Rejection
5. Selvedge's in pin hole

55. Every joint not straight
sewing

56. 1. Elephant Skin
2. Crease Mark
3. More Rejection
4. Compactors Teflon Damage

57. Every joint straight sewing

58. Trolley Management

59. Trolley Management

60. Fabrics not Covered with
Places

61. Fabrics Covered with Places

62. Stenter M/c Cleaning
Procedure
1. Color Change then Must be clean
2. Every rollers clean by water (Padder Area).
3. Mahlo Area Clean by Air.
4. Chain Area Also Clean by Air, Not use water.
5. Maximum people use cleaning time.
6. Electrical Devise avoid clean by water, be carefully clean by air
7. Same color to Same color no need clean. But within 4 hours should be Filter clean .
8. Within 20-30 minte need to be clean.
9. After Clean then run reject fabrics avoid the micro dust
10. Must be record Cleaning Started to Finish time.

63. Stenter M/c Cleaning
Purpose: Light Mark/Stain/ Oil Stain
Who Responsibile: Coordinator,
Procedure: Regular Cleaning-
1. Stenter M/c
A. Color Change then Must be clean
B. Every rollers clean by water (Padder Area).
C. Mahlo Area Clean by Air.
D. Chain Area Also Clean by Air, Not use water.
E. Maximum people use clening time.
F. Electrical Divise avoid clean by water, becareful clean by air
G. Same color to Same color no need clean. But within 4 hours should be clean Felter.
H. Within 20-30 minte need to be clean.
I. After Clean then run reject fabrics avoid the micro dust
I. Must be record Cleaning Started to Finish time.
Cross Check by: Supervisor
Check List : Stenter M/c Cleaning Check List
Date Color to Color Start Finish Total time Shift Person Coordinator Check

64. Stenter M/c Filter Clean

65. Filter Cleaning Not Proper

66. Filter Cleaning proper way

68. Arrangement Not Good

69. ArrangementArrangement Good

70. Material Handle

71. Arrangements

72. Arrangements

73. Standard Finishing Parameter
MAA Garment & Texile Factory
P .O Box No-1976, Quiha, Mekelle, Ethiopia
Standard Finishing Parameter Update: 21/07/2016
From: 06/1/2016
SL Buyer Fabrication Colour
Knitting Parameter Required Stenter Parameter Required After Stenter
Count Dia Gauge Stitch Length Grey Width Grey GSM Req Width Req GSM Temperature Speed Overfeed Width Set Width GSM Next
1
H&M
Lycra S/J White 36 30 28 2.88 174 170 170 160 130 15 50% 170 170-175 150-155 Compactor
2 Lycra S/J White 36 30 28 2.7 174 180 170 180 130 15 60% 165 165-170 165-170 Compactor
3 Lycra S/J White 36 34 28 2.7 180 190 180 130 15 60% 185 185-190 165-170 Compactor
4 Lycra S/J Black 36 30 28 2.88 170 175 160 160 15 50% 175 175-180 150-155 Compactor
5 Single Jersey White 28 30 28 2.85 145 180 145 130 15 50% 180 180-185 140-145
6 Single Jersey White 30 30 28 2.70 216 138 170 160 130 15 50% 170 170-175 155
7 Single Jersey Black 30 30 28 3.00 125 190 145 180 20 50% 190 190-195 140-145 New
8 Single Jersey Junbug 28 30 28 2.95 135 190 145 170 16 50% 190 190-195 140 New
9
NJ
Single Jersey White 28 30 28 2.85 145 180 145 130 15 50% 180 180-185 140-145
10 Single Jersey White 28 30 28 2.70 155 170 160 140 15 50% 170 170-175 150-158
11 Single Jersey Black 28 30 28 2.90 135 185 160 170 18 50% 180 180-185 150-158
12 Single Jersey Turquist 28 30 28 2.75 150 175 160 160 16 50% 175 175-180 155-160
13 Single Jersey Green 28 30 28 2.75 150 175 160 160 16 50% 175 175-180 155-160
14 Single Jersey Orange 28 30 28 2.75 155 175 160 160 16 50% 175 175-180 155-160
15 Single Jersey Black 28 30 28 3.10 125 195 145 170 18 50% 195 195-200 140-145
16 Single Jersey Mellange 28 30 28 2.85 145 180 160 160 16 50% 175 175-180 150-158
17 Single Jersey Black (PC) 28 30 28 2.95 214 135 185 160 170 15 50% 180 180-185 155-160 New
18 Single Jersey White(PC) 28 30 28 2.85 145 190 160 160 18 50% 180 180-185 155-160 New
19 Single Jersey Navy 28 30 28 2.90 140 185 160 170 16 50% 185 185-190 155-160 New
20
NJ Primark
Single Jersey Mellange 28 30 28 3.1 125 190 140 160 16 50% 190 190-195 136-140
21 Single Jersey White 28 30 28 2.85 145 180 140 130 15 50% 180 180-185 136-140
22 Single Jersey Black 28 30 28 3.1 125 190 140 180 18 50% 195 190-195 136-140
23 Single Jersey Charcol 28 30 28 2.9 130 180 140 160 16 50% 185 180-185 136-140
Prepare Check Approved

74. MAA Garment & Texile Factory
P .O Box No-1976, Quiha, Mekelle, Ethiopia
Standard Finishing Parameter Update: 21/07/2016
From: 06/1/2016
SL Buyer Fabrication Colour
Knitting Parameter Required Stenter Parameter Required After Stenter
Count Dia Gauge Stitch Length Grey Width Grey GSM Req Width Req GSM Temperature Speed Overfeed Width Set Width GSM Next
24
KIK
Single Jersey White 26 34 24 2.78 180 160 140 15 50% 180 185-190 152-160
25 Single Jersey Black 26 34 24 2.90 190 160 170 18 50% 180 185-190 155-160
26
Tezenise
Single Jersey Black 28 30 28 3.1 125 195 145 170 18 50% 195 195-200 140-145
27 Single Jersey White 28 30 28 2.85 145 180 145 130 15 50% 180 180-185 140-145
28
Poly
Concept
Pique
Dark
Colour 24 30 24 2.85 234 175 215 200 170 10 60% 220 215-220 200-210 Compactor
29 Pique
White/Mel
lance 24 30 24 2.75 234 185 215 200 170 10 60% 220 215-220 190-200 Compactor
30
Beconect
Single Jersey White 28 30 28 2.85 145 180 140 130 15 50% 180 180-185 136-140
31 Single Jersey Black 28 30 28 3.1 125 190 140 180 18 50% 195 190-195 136-140
32 Takeza Single Jersey White 20 34 24 3.25 175 195 180 160 18 50% 195 195-200 175-180
33
VF Asia
Single Jersey White 30 30 28 2.65 145 165 160 160 15 50% 165 165-170 156-160 New
34 Single Jersey Navy 30 30 28 2.75 140 170 160 160 15 50% 170 170-175 154-158
35 Lycra S/J
Navy/W
hite
40 30 28 2.85 165 170 160 160 15 50% 170 165-170 150-155 Compactor
Prepare Check Approved
Standard Finishing Parameter

75. Keeping Record in Finishing

76. Heat Set Procedure
1 Knitting Machine wise Batch Prepare.
2 Dyeing Machine wiae Batch Prepare.
3 In Batch Card should be write M/c Dia, Gauge, Stitch Length, Yarn count & Required GSM.
4 Sewing time follow Needle line.
5 Slitting time need to be carefully follow slitting line.
6 Grey GSM & Width check also compare with standard.
7 Stenter M/c parameter set as a Standard parameter sheet.
8 Width, Temperature & Speed Fixed If needed then adjust only overfeed.
9 Follow Colour wise After heat set GSM
10 After Heat set keep record Roll to roll & Within roll GSM.
11 Colour wise identify & Some rolls need to be write then not mix-up with another Colour.

77. Heat Set Procedure
Lycra Grey Fabrics Relaxation Procedure
1 Knitting
1. After knitting should be Relax stage not Roll stage
2. Maximum 24 Hours.
2 Store
1. Not More the 24 hours
2. Within 24 hours hand over to Batch Section
3 Batch Section 1. Batch Knitting M/c wise & Dyeing M/c Capacity wise
2. Withing 2 hours Handover to Slitting.
4 Slitting
1. Within one trolley Maximum 500 KG Keep.
2. After slitting Need 4 hours keeping.
5 Stenter 1. Check Grey GSM & Width.
2. After stenter Relax minimum 2 Hours

78. Standard Heat Set Parameter
MAA Garment & Texile Factory
P .O Box No-1976, Quiha, Mekelle, Ethiopia
Heat Set Parameter
From: 06/1/2016
Update:
29/9/2016
SL Buyer
Fabricatio
n
Colour
Knitting Parameter Required Stenter Parameter Required After Stenter
Count Dia Gauge
Stitch
Length
Grey
Width
Grey
GSM
Req
Width
Req
GSM
Teparatur
e
Speed
Overfee
d
Width
Set
Width GSM
1
H&M
Lycra S/J White 36/1 30 28 2.88 174 170 165 160 200 18 35-40% 175 175 165-170
2 Lycra S/J White 36/1 30 28 2.70 174 180 165 180 200 23 60% 165 175 185-190
3 Lycra S/J White 36/1 34 28 2.70 180 180 195 180 200 23 60% 185 195 185-190
4 Lycra S/J Black 36/1 30 28 2.88 180 165 170 160 200 18 30-35% 175 175 150-155
5
KIK
Lycra S/J Black 36/1 30 28 2.88 174 165 170 180 200 20 50% 170 170 180-185
6 Lycra S/J Light Color 36/1 30 28 2.88 174 165 170 180 200 20 60% 170 170 185-190
7
VF Asia
Lycra S/J White 40/1 30 28 2.88 170 175 165 160 200 18 30-35% 170 170 165-170
8 Lycra S/J Navy 40/1 30 28 2.88 170 175 165 165 200 18 25-30% 170 170 155-160
Prepare Check By Approved

80. On Jobs Training

81. On Jobs Training

83. Compactor M/c Side View

84. Standard Operating Procedure
Compactor Machine
Batch Card
1 Collect Batch Card
2 Check Shrinkage & GSM
Parameter
1 Needed Clean or not
2 Set up Blanket Pressure,
3 Set Teflon (within 2inch)
4 Set the Overfeed as fabrics required,
Manpower
1 Operation Area 1 person/ Operator
2 Delivery side 1 person
Check
1 Check Crease, Elephant, Folder mark, GSM & Width
2 Compaction %
3 Hairness & Hand feel.

85. Compactor M/c
 What type of Problems
Face:
 Shrinkage
 Over Compaction
 GSM
 Elephant Skin
 White Mark/ Light Mark

86. Compactor M/c Cleaning
Procedure
1. Color Change then Must be clean
2. Compactor m/c Clean only by air..
3. Teflon open from Blanket then clean
4. Blanket clean by air pressure.
5. Same color to Same color no need clean.
6. Within 10-20 minute should be clean.
7. After Clean then run reject fabrics avoid the micro dust
8. Must be record.

87. Compactor Cleaning
Purpose: Light Mark/Stain
Who Responsibile: Coordinator,
Procedure: Regular Cleaning-
1. Compactor M/c
A. Color Change then Must be clean
B. Compactor m/c Clean only by air..
C. Teflon open from Blanke then clean
D. Blanket clen by air pressure.
G. Same color to Same color no need clean.
H. Within 10-20 minte need to be clean.
I. After Clean then run reject fabrics avoid the micro dust
I. Must be record Started to Finish time.
Cross Check by: Supervisor
Check List : Compactor M/c Cleaning Check List
Date Color to Color Start Finish Total time Shift Coordinator Check

88. Teflon Clean
Purpose: Light Mark/Elephant/ Crease Mark
Who Responsibile: Coordinator,
Procedure: Teflon Damaged (Compactor M/c)
1. Not Pass any knotted by teflon
2. Proper sewing, Not pass unproper sewing by teflon
3. Not use more pressure in blanket (Maximum 3 Bar).
4. Batch to Batch Clean the Teflon
Cross Check by: Supervisor
Check List : Compactor M/c Teflon Check List
Date Time OK Damage Shift Supervisor Remarks

89. Teflon Clean

90. Batch/Process Card

91. Batch/Process Card

92. Good Performer

94. Fire Hydrant

95. Fire Extinguisher

96. Fire Extinguisher

97. Fire Exit

98. Our Expectation Good Quality with
Quantity.