Process: WI-DYEING Author: A
Document type: WI-Work Instruction Reviewer: B
Title: ADDITION Approver: C
PURPOSE
1.0 PURPOSE
This document describes the processes of reprocessing of batches failing colour quality or any physical defect of the fabric in the Dye-house.
2.0
SCOPE
The scope of this WI covers the dyeing process and any additional treatments;
Dyehouse Manager/Deputy Manager/Asst. Manager
Formulation Lab Manager/Asst. Manager
Shift Executive.
Shift Supervisor.
Senior Machine Operator.
Machine Operator.
3.0
APPLICABLE REFERENCE/DOCUMENTS
3.1 Batch Processing Card
Batch processing Card is used to record all batch details, customer, EKL #, construction and operational actions
3.2
Batch Recipe
A list of pre-determined dyes and chemicals used to precise weights to achieve a specific colour.
3.3 WI-EPY-PRD-006 Recipe Sheet Preparation.
The process of developing a recipe using colour, fabric weight, origin of fabric, machine name/number
3.4 WI-EPY-DYG-005 Dye & Chemical Distribution.
A process of preparation and distribution of chemicals prior to the demand from the machine.
3.5
WI-EPY-DYG-007 Dyeing Machine Operation
Operate the machine according to the company best practice process to ensure high colour quality and Right First Time.
3.7
WI-EPY-DYG-009 Colour Assessment.
A visual or digital assessment carried out against a physical standard to determine the colour variation.
3.8
WI-EPY-DYG-010 Unloading Machine.
The process to efficiently unload the machine to maximise machine operational hours.
4.0
APPLICABLE SAFETY PRECAUTIONS& DOCUMENTATION
Personal Protection Equipment
Worn at all times whilst working in the Chemical Store
4.1 Footwear Protection
Worn to eliminate continued wet feet, eliminate chemical burns and eliminate slippage on wet floors.
4.2
No Smoking
Smoking is not permitted on the production floor or offices.
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 Machine Operator must be literate and have achieved SS2 grade.
5.2
The Machine Operator is to receive 4 weeks formalised training before being released to operate the machine unsupervised.
6.0 EQUIPMENT USED / APPROVED MATERIALS
6.1 High PressureFabric Dyeing Machine.
6.2 Atmospheric Fabric Dyeing Machine
6.4
PH PAPER
Indicate the PH of any specific process.
6.3 Spectrophotometre.
6.4
Calculator
To calculate amount of dyestuff
6.5
SCISSOR
6.6
KNIFE
6.7
SAMPLE DRYER MACHINE
7.0 RESPONSIBILITIES
Position Responsibility
Shift Executive To estimate required dyes% to match a shade.
Shift Supervisor Measure the required Dyestuff.
Senior Machine Operator Check the dyestuff solution and required chemical dispensing
Machine Operator Follow providing Addition/Topping process in dyeing machine.
8.0 PROCEDURE
8.1 Addition
8.1.1
After 60 minutes from Dyes, Electrolyte, Alkali dosing in dyeing machine, Dyeing Machine Operator cuts a sample by using a scissor or industrial knife and washes it by using the same soaping chemical as the recipe.
8.1.2
The washed sample is sent to dryer for drying by Dyeing Machine Operator. As per sampling drying rule, sample is dried and taken out from Dryer by Dyeing Machine Operator.
8.1.3
Dyeing Machine Operator cuts the dried sample into square/rectangle shape by using a scissor and submit it to Dyehouse Shift Sr. Executive/Production Officer.
8.1.4
Dyehouse Shift Sr. Executive/Production Officer keep the sample for conditioning in temp controlled AC room. Heated sample/without conditioned sample is prohibited to check.
8.1.5
Dyehouse Sr. Executive/Production Officer will check the sample with the standard following WI-EPY-DYG-007 and assesses the colour of sample.
8.1.6
If responsible Sr. Executive/Production Officer finds difference of colour in thinner side and if the shade is not a critical shade, then he decides to go for Addition.
8.1.7
Sr. Executive/Production Officer writes down the required amount of dyes on the Recipe Sheet to achieve the right shade and provides it to Dyehouse Operator.
8.1.8
Dyehouse Operator writes the dyes name and amount on the MRS (Material Requisition Slip) and provides it Dyehouse Supervisor.
8.1.9
Dyehouse Supervisor measures the dyes following WI-EPY-DYG-002 and provides the dyes to Dyehouse Operator.
8.1.10
Dyehouse Operator mixed the dyes following WI-EPY-DYG-004 and distributed the mixed dyestuff to the Dyeing Machine Addition Tank following WI-EPY-DYG-005.
8.1.11
Dyehouse Operator doses the mixed dyestuff from Addition Tank to the dyeing vessel at 600 for 20 min.
8.1.12
After dosing of dyestuff in dyeing vessel, Dyehouse Operator cuts the sample once again after runtime of 20 min and follow exact previous process of sample wash, drying and submission of sample to Dyehouse Sr. Executive/Produciton Officer.
8.1.13
Dyehouse Sr. Executve/Production Officer assesses the colour again after conditioning the sample. If the colour is ok after visual assessment, then he decides to drop the Dyebath color water by rinse wash and pass the information to Dyehouse Operator.
8.1.14
Dyehouse Operator drops the Dye vessel water by rinse wash and follows the remainder of the dyeing program as per WI-EPY-DYG-007.
9.0
TERMS AND ACRONYMS
Acronym Term
Batch Card
Batch Recipe
ISIONS
10.0
OUT OF CONTROL ACTION PLAN (OOCAP)
If the program is incorrect the operator will seek out the Supervisor on appropriate action.
Equipment Fault Response
Pump Fault Call Mechanical Maintenance.
Dosing Fault Self / Call Mechanical / Electrical Maintenance.
Pump Leakage Call Mechanical Maintenance.
Filling Problem Call Mechanical / Electrical Maintenance.
Valve Leakage Call Mechanical Maintenance.
Program Deleting Call Electrical Maintenance.
Pressure Fluctuation Self / Call Mechanical / Electrical Maintenance.
Motor Fault Call Mechanical Maintenance.
11.0 REVISIONS
Revision Date Author of Change What Alterations were Made
1 13/03/2020 A 1st Generation of WI.
Signature
Author: A
Reviewer B
Approver C
