Best Standard Operating Procedure of Dyeing / SOP for Dyeing / WI (Work Instruction) International Standard ( Part-3).

 
 

Process:    DYEING                                                                        Author:    A       
Document type:    WI-Work Instruction                                      Reviewer:    B       
Title:    AUTOMATIC CHEMICAL DISPENSING                       Approver:    C    

PURPOSE
 
1.0  PURPOSE    
 

This document describes the processes of utilizing the auto chemical delivery system and how the information is captured in the system to how it is delivered to the dyeing machines.

 
2.0 SCOPE    


This procedure covers the process from the development of the drug-line to the preparation of dyes and requires the Shift Supervisors, Executives, Operators and Dyestuff Store-men.
 
3.0  APPLICABLE REFERENCE/DOCUMENTS    
 
Reference / Document    Example       
3.2

3.1 Batch Recipe

A list of pre-determined dyes and chemicals used to precise weights to achieve a specific colour.    
 
       

3.2 Batch Processing Card

Batch processing Card is used to record all batch details, customer, EKL #, construction and operational actions.    
 
       
3.3 WI-EPY-PRD-001    

Operational Planning.
Process of preparing the dye house production plan for each machine. Usually prepared by colour, depth of shade and priority.       
3.4 WI-EPY-PRD-006    
Recipe Sheet Preparation.
The process of developing a recipe using colour, fabric weight, origin of fabric, machine name/number    


 
4.0 APPLICABLE SAFETY PRECAUTIONS& DOCUMENTATION    
 

Personal Protection Equipment
Worn at all times whilst working in the Chemical Store       


4.1 No Smoking
Smoking is not permitted on the production floor or offices.            


4.2 Footwear Protection

Used to eliminate corrosive burns and to eliminate slipping on wet floors.    
 
    
      
4.3 Eye Protection

Used to eliminate corrosive burns from chemicals.    
 
  

4.4 Hand Protection

Used to eliminate corrosive burns from chemicals and to improve grip of chemical containers.    
 
       
1.0
 
5.0 EMPLOYEE QUALIFICATIONS    


5.1 The dye store-men must be literate.
5.2 The dye store-men must undergo formalised training for a period not less then 4 weeks prior to being permitted to unsupervised operations.


 
6.0 EQUIPMENT USED / APPROVED MATERIALS    
 
Equipment    Reference       

6.1 Auto Dispensing Software.

The data is manually entered into the software for those chemicals required by the batch.
        


6.2 Control panel for Chemical Call off.

The control panel is used when the chemical is required at the machine. This requires manual acceptance to “push” the chemical before the machine begins the next treatment process from the chemical distribution store to the dye vessel.1    
 
       



6.3 Central Auto Dispensing Unit.

The area where the bulk chemicals are stored ready for pumping to the machine floor as requested from the “Controller Panel”.    
 
 

 
7.0 RESPONSIBILITIES    
 
Position    Responsibilities       


Shift Executive    

Is responsible for ensuring both the chemicals and the weights are accurate.       

Shift Supervisor    
Is responsible for the printing of the recipe rule from the system.       

Management Trainee    
Is responsible for supporting all areas of the process.       

Machine Operator    
To inform the management team when the chemical is required at the machine.    


 
8.0 PROCEDURE    

 

8.1 The Shift Executive (SE) or Management Trainee (MT) will prepare the recipe according to the batch plan (WI-EPY-PRD-001) and recipe preparation (WI-EPY-PRD-006).

 
8.2 Once the recipe has been created and printed the Management will then record the chemical rule (recipe) into the Company`s  Chemical Delivery system for all chemicals.


8.3 Once the data is entered into the Company`s Chemical Delivery system the batch recipe and the batch process cards are sent to the machine operator.


8.4 When the new batch is ready to start the Machine Operator will request the Senior Machine Operator to complete the previous batch and then begin the chemical delivery with the current batch.

8.4.1 The Sr. Operator will take the recipe sheet from the machine operator and then enter the batch number into the Auto Dispensing control panel and select “OK”.

 
     

8.4.2 The Sr. Operator will then select the first set of chemicals according to the process requirements for the 1st treatment.

   

 
8.4.3 Once the chemicals are entered and sent to the machine the Sr. operator ticks the chemicals to confirm the chemicals have been distributed to the machine.

8.5 Once the chemicals are transferred the Sr. operator will then send the recipe back to the machine operator and wait for the request for the next chemical treatment.

8.6 The process will repeat from 8.4 to 8.4.3 until the batch completes its dyeing profile.

7.0 RE

VISIONS
 
9.0 TERMS AND ACRONYMS    
 
Acronym    Term       
Auto Dispensing Unit    
A Dye house management system for digital recipe storage, automated chemical delivery and dye recording system.       


Distribution Centre    

The bulk chemical storage used by the Company`s system supplied from Italy.    

10.0 RE




VISIONS
 
10.0 OUT OF CONTROL ACTION PLAN (OOCAP)    


10.1 Where the Company`s Chemical Delivery system breaks down is in-operable, the chemicals are to be weighed manually.



 
11.0 REVISIONS    

 
Revision     Date                             Author of Change    What Alterations were Made       
1st    09/03/2020                                          A                         1st Generation of WI.       
                   
                   
         


 
        Signature       
Author:       A           
Reviewer    B           
Approver    C