safety at textile industry

1. International Institute Of
Industrial Safety
Management
Peenya, Bangalore

2. TEXTILE INDUSTRY
Presented by-
- Singh Nikita
- Mukesh Kumar
- K. Raj
- Subbu kumar
-Dhruvan Raj

3. HISTORY
• The very first modern cotton textile mill was set up in
1818 at FORT GLASTER near KOLKATA.
• But this mill could not survive and had to be closed
down.
• REASON – LACK OF TECHNOLOGY AND MANPOWER.
• The first successful modern cotton textile mill was
established in MUMBAI in 1854 by a local Parsi
entrepreneur C.N.DEWAR.
• SHAHPUR MILL in 1861 and CALICO MILL in 1863 at AH
MEDABAD were other landmarks in the development of
INDIAN COTTON TEXTILE INDUSTRY.

4. REAL EXPANSION:-
Took place in 1870’s.
 By 1875-76 the number of mills rose to 47 of
which 60% were located in MUMBAI city
alone.
 The industry continued to progress till the out
break of the FIRST WORLD WAR in 1914.
 The total number of mills reached 271
providing employment to about 2.6 lakhs
person.

5. TRAGED
Y
 The industry suffered a serious setback in 1947 when most
of the long staple cotton growing areas
went to Pakistan as a result of partition.
 However the mills remained in INDIA.
 Scarcity of raw material.
 Therefore our country has to resort large-scale
imports of long staple cotton which was extremely
difficult.
SOLUTION:-
 The only solution was to increase hectare age and
production of long staple cotton whithin the country.
 The goal was achieved in the post partition era.

6. GROWTH DEVELOPMENT & CONTRIBUTION
 INDIA is the second largest producer and exporter of textile
in the world at $6.3 BILLION , marginally close to CHINA.
 INDIA has emerged as the largest producer of COTTON &
JUTE in the world.
 INDIA is the second largest producer of SILK in the world.
CONTRIBUTIONS:-
 Contributes to 7% of industrial output in terms of value.
 Contributes 2% of INDIA’S GDP.
 Contributes to 15% of country’s export earning.
 INDIA overall textile export during 2017-18 stood as US$39.
2 BILLION. And this is HUGE.
 The size of INDIA’S textile and apparel market recorded
USD 108.5 billion in 2015 and it is expected to reach USD
226 billion by 2023.

7. MAKE IN INDIA
Prime minister – NARENDRA MODI
Launched – 25 september 2014
Aim to boost the domestic manufacturing units.
Aim to increase the contibution of manufacturing GDP from
15% to 25%.
Aim to generate jobs and employment.
Aim for foreign direct investment and transform
 india into a MANUFACTURING HUB around the globe.

8. PLANT LAYOUT
• Definition
Plant Layout is the most effective
physical arrangement, either existing or in plans
of industrial facilities i.e arrangement of machines
,processing equipment and service departments t
o achieve greatest co-ordination and efficiency of
4M.

9. OBJECTIVES
• Increased output/turnover
• Great use of man/machinery
• Great utilization of cubic spaces
• Minimize material handling
• No congestion and confusion
• Safety and satisfaction of workers
• Quick and easy adaption in change of process
• Better supervision
• Improve maintenance and inspection
• Space for future expansion
• Lighting and ventilation
PLANT LAYOUT

10. REASONS FOR PLANT LAYOUT PROBL
EMS
• Design change
• An enlarged department
• A reduced department
• A new product
• A relocated department
• A new department
• A new plant

11. Factors affecting plant layout in text
ile
industry
• Policies of management
• Plant location
• Nature of product
• Volume of production
• Job production
• Mass production
• Batch production
• Availability of floor space
• Nature of manufacturing process
• Repair and maintenance of equipments an
d machines

12. PLANt layout
GROUND FLOOR:-
o Raw material storage department
o Cutting department
o Sampling department
o Warehouse
o Canteen
o Maintenance department
o Boiler room
o Training , utility & medical room
o Executive and labour parking
FIRST FLOOR:-
o Administrative and h.r. department
o Director cabin
o Production floor
o Conference room
o I.E. department & Q.A. department
o Complaince department
o Display room
o Finishing room
o Staff canteen

13. Factory Plant Layout

14. Process flow chart
+
production
in
Textile Industry

15. 1
• Ginning – pressing process
2
• Spinning preparatory process
3
• Spinning process
4
• Weaving preparatory process
5
• Weaving process
6
• Finishing process
7
• Quality check
8
• Folding department & cloth godown
9
• Truck out

16. Ginning – pressing process
 Cotton (with seed) from
agriculture
 Ginning machines (removal of
seeds)
 Press (gives bales)

17. Spinning preparatory process
 Cotton / man-made fiber bales.
 Opening, mixing & blowroom machinery (gives lap)
 Carding machine (gives sliver)
 Draw frames, combers, inter-frames
CARDING MACHINE

18. Spinning process
 Ring frames (gives fine
twisted yarn).
 Doubling frames (twisting of double yarn)
AIR-JET SPINNING

19. Weaving preparatory process
 Winding machine(give cheese or corn of yarn)
 Sizing machine
 Draw frames (gives drawn wrap)
WINDING MACHINE

20. SIZING MACHINE PROCESS

21. Weaving process
Looms (give grey cloth)

22. Finishing process
 Shearing singeing(gives singed cloth)
 Bleaching
 Dyeing
 Printing polymerizing
SHEARING MACHINE

23. BLEACHING & DYEING MACHINES

25. Folding department & clothgodown
Sanforizing .
Folding / plating.
Clothes bales (fabrics)
SANFORIZING ANT-SHRINKAGE FINISHING

26. WEARABLES ARE READY !!
Truck out

27. SAFETY
FEATURES
&
HAZARDS

28. The major hazards and safety issues i
n
textile industry
Exposure to
cotton dust
Exposure to
dangerous
chemicals
Exposure to
high noise
Ergonomic
issues

29. OCCUPATIONAL HAZARDS IN
TEXTILE INDUSTRY
 Physical hazards:-
Eg:- heat, lightning,noise, uv radiation,temperature, humidity.
 Chemical hazards:-
Eg:-vapours, fumes,gases,
 Biological hazards:-
Eg:-sharp needles, blood borne diseases
 Mechanical hazards:-
Eg:- moving equipments, housekeeping, tripping hazards
 Ergonomical hazards:-
Eg:- push/pull, vibration, repitition, environment
 Psycho – social hazards:-
Eg:- physical/mental treats, work load demands, no social support,
no control over work

30. HAZARDS IN VARIOUS PROCESSING UNI
TS
 YARN MANUFACTURING UNIT
 Health hazards
 Cotton dust inhalation
 High noise emission
 Heat stress
 WEAVING UNIT
 Health hazards
 Injury from machinery
 Fires and ignition
 High noise emission
 Fibre dust
 DYEING UNIT
 Fire & explosion
 Chemical hazards
 Accidents can occur due to hot liquid

31.  PRINTING UNIT
 Flammability
 Air emission ( due to used solvents)
 Sludge
 FINISHING UNIT
 Mechanical hazards (saforizing, brushing, sanding)
 Health hazards (presence of heat, noise,
moving machine parts)
 Chemical hazards (chemicals that change the texture
or appearance of a fabric)

32. PREVENTIVE MEASURES
FOLLOWING OSHA 1995
 Cleaning floors with vaccum cleaners or methods that cuts down
the dusts
 Spreading.
 Checking , cleaning and repair of dust collecting equipments.
 Employees must have annual medical check.
 Employees must be provided with proper training.
 Employees must use proper respirators.
 The seats of workers must be alligned in such a way that no
 musculoskeleton strain.
 Proper ligting facility.
 Proper ventilation facility.
 Machinery should be well maintained to reduce noise level.
 Proper dust controlling equipments must be installed.

33.  Exposure to potentially toxic solvents and chemicals sh
ould be maintained below LEV.
 Safe storage facilities must be provided for storing
chemicals and solvents.
 Sanitary facility for washing , bathing & changing
should be provided.
 Job rotation must be practiced.
Continue:-

34. SAFETYFEATURESFOR TEXTILEINDUSTRY
 Section 27 – the factories act 1948
“No employement of women & children near
cotton-opener.”
 The textiles sector contains many hazards and risks
to workers, ranging from exposure to noise and
dangerous substances, to manual handling and
working with dangerous machinery. Each processing
stage — from the production of materials to the
manufacturing, finishing, coloring and packaging —
poses risks for workers, and some of these are
particularly dangerous for women’s health.

35. Chemical safety:-
Hazardous chemicals and their
symbols
Material safety data sheet
Risk assessment of chemicals
Health affect of dyes and chemicals
Chemical storage and disposal of
waste
First aid

36. Safety protocols:-
LABORATORY SAFETY PROTOCOL:-
 Record keeping
 Protective gear
 Training
Factory floor safety protocol:-
 Protective gear
 Environment
 Training
 Lifting and carrying heavy objects
 Fire fighting equipments

37. Roles and responsibilities:-
 ROLE OF MANAGEMENT:- (F.A.1948- SECTION 7)
 Provide basic needs
 Record keeping
 Maintaining signs and symbols
 Audits
 ROLE OF WORKERS:- (F.A.1948 – SECTION-41G)
 MSDS follow instructions
 Follow all protocols
 Wash hands before meal and at the end of shifts
 Correct posture while lifting
 Accident and near miss reporting
 Defects and damages reporting

38. EVACUATION
PLAN FOR
TEXTILE
INDUSTRY

39. LEGAL REQUIREMENT
SECTION 38 - FACTORIES ACT 1948
 SECTION 38(1) – In every factory, all practicable measures shall be
taken to prevent the outbreak of fire & it’s spread internally &
externally . Provide & maintain
 Safe means of escape.
 Necesarry equipments for extinguishing of fire.
 SECTION 38(2) – Effective measures shall be taken to ensure that
in every factory, all the workers are familiar with means of escape
in case of fire and are adequately trained in the routine to be
followed in such cases.

40. Questions ??
1. Work place emergency ?
2. How to Protect yourself, employees and business ?
3. Emergency action plan & it’s contents ?
4. How to alert employees in emergency ?
5. Develop evacuation policy & procedure ?
6. Under what condition you should call for an evacuation ?
7. Accounting of employees after evacuation ?
8. Establish evacuation routes & exits ?
9. Type of training ?
10. Role of employees ?
11. What does the plan include about hazardous substances?
12. Special requirements ?

41. What is a workplace emergency?
A workplace emergengy is unforeseen situation that
Threatens your employees, customer & public or
causes physical and environmental damage.
 Example:-
 Floods
 Fires
 Toxic gas release
 Chemical spill
 Explosion
 Workplace violence resulting in bodily harm and
trauma

43. Emergency action plan

44. In case of fire

45. Special equipments for emerge
ncy
 safety goggles or face shield for eye
 protection. (IS 5983:1980)
 Hard hats (IS 2925:1984) and safety shoes
(IS: 10067:1983) for head and foot protection.
 Proper respirator. (IS 9623:2008)
 Chemical suits, gloves, hoods,boots, full
body suits (IS 15071:2002).
 Special body protection for abnormal
environmental conditions.
 Any special equipments or warning devices fo
r hazards unique to the worksite.

46. Role of employees for emergency
Keep a copy of emergency action
plan.
Communication.
Emergency training.
Assemble at assembly point.
Report emergency.

47. General training for emergency
 Define Individual role and responsibility.
 Threats hazards and protective actions.
 Notification , warning and
communication procedures.
 Emergency response procedures.
 Evacuation and shelter procedures.
 Location and use of common
emergency equipments.
 Emergency shutdown procedures.

48. INTERESTING FACTS ABOUT TEXTILE INDUS
TRY
 Cotton is the world’s most important and used natural fibre.
 Vegan and ethical are the newest trends in this industry.
 Bangladesh has the cheapest workforce for the textile industry.
 Clothes and textiles must follow national and international standards.
 The textile industry is now worth almost $3trillion around the globe.
 Textile is the second biggest polluting industry after oil.
 In the UK, the textile industries don’t pay even the minimum wages.
 INDIA’S textile market is expected to reach $226 billion market cap by
2023.
 US is the biggest importer of garments in the world.
 The most expensive fabric in the world is VICUNA WOOL.
 Textile piracy is causing significant loss in the industry.
 Technology in textile is the future of textile industry.
 China is the world’s largest textile producer.
 USA is responsible of 15 million tons of used textiles waste each year.

50. THANK YOU !!