Best Standard Operating Procedure of Dyeing / SOP for Dyeing / WI (Work Instruction) International Standard ( Part-4).

 
Process:    DYEING                                                         Author:    A       
Document type:    WI-Work Instruction                           Reviewer:    B       
Title:    DYESTUFF MIXING PREPRATION                Approver:    C    

PURPOSE
 
1.0 PURPOSE    

This document describes the processes taking place in the Dye house of X-company including production and inspection, ensuring best possible quality of dyed thread obtained with highest possible efficiency. The Work Instruction applies to Dye house.


2.0 SCOPE    

This process covers the pre-mixing of all dyes into water prior to dosing into the machine add tank and is managed by the machine operator.


 
3.0 APPLICABLE REFERENCE/DOCUMENTS    
 
3.1 Batch Card

A record used to identify the unique batch properties from customer, construction, date required and operational actions.    
 

       
3.2 Recipe Chemical Rule

A list of pre-determined dyes and chemicals used to precise weights to achieve a specific colour.    
 
       
3.3 WI-FIRM-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-FIRM-DYG-002    Dyestuff Manual Dispensing.
The process of accurately weighing the dyes using digital balance for optimum Right First Time performance.       
3.4 WI-FIRM-DYG-007    
Dyeing Machine Operation.
The physical and sequential operation of a dyeing machine to achieve a Right First Time performance.
    
 
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 Staff are required to be literate.
5.2 Undergone 4 weeks of training before being released to unsupervised operations.
5.3 The staff are to undergo training in the correct techniques and disciplines and also complete the training course for dye pasting/mixing before authorised to work unsupervised.

 
6.0 EQUIPMENT USED / APPROVED MATERIALS    
 
6.1 Mixing Controller    6.2 Mixer    6.3 Mixer + Drum + Lid      
     
 
7.0 RESPONSIBILITIES    
 
Position    Responsibilities       
Shift Executive           
Shift Officer           
Shift Supervisor           
Dyestuff Store-man           
Machine Operator        

 
8.0 PROCEDURE    

8.1 After the recipe has been printed the Shift Executive (SE) or the Management Trainee (MT) will send the recipe and batch processing card to the Machine Operator.

8.2 The machine operator will fill the blue drum with 100 litres of water.

8.3 The machine operator will then carefully add the dyestuff to the water by sprinkling the dye slowly to the water. Do not simply drop the dye into the water.

8.4 Once the dye has been poured into the water (in the blue drum) the operator will use fresh water to rinse out the dye from the smaller drum and pour into the large blue drum.

8.5 Once all the dyes are transferred to the large blue drum the Machine Operator will place the blue drum under the spindle of the mixing device ensuring the drum is centred properly to the mixer propeller.

8.6 Once the propeller is properly aligned the machine operator will place the black lid on the drum.
 
8.6 Mixing Container

The lid is aligned to the mixing propeller. If the propeller is not aligned correctly the propeller will touch the lid causing the batch to potentially fall over.    
 
    

8.7 Once all is prepared the machine operator will then turn the start button on the controller to Zero (0) to activate the propeller.

 
8.7 Start Button

Turning the switch to zero (0) will cause the machine to turn on.
The machine operator is to run the mixing process according to the depth of shade (8.8).    
 
   
8.8 the mixing process of will last for either 5 minutes for pale colour or 15 minutes for heavier (darker) Extra Dark colours.

 
Depth Range    Mixing Time       
Pale Colours    5 minutes       
Medium Colours    10 minutes       
Dark Colours    10 minutes       
Extra Dark Colours    15 minutes    

8.9 Once the mixing process is complete the machine operator is to place the drum onto the trolley (seeking assistance to lift the drum) and carefully transfer the drum to the machine stock tank.

8.10 When the machine program calls for the dye to be added to the machine the Operator transfers 100% of the dye to the stock tank ensuring the drum is rinsed into the stock tank. The Operator is to rinse the lid of the drum into the stock tank as well.

NOTE: Failure to do this will cause the batch to be off shade.

8.11 Once the process of mixing has been completed at the mixing station, the machine operator is to carry out a cleaning process to ensure the dye mixer is clean and ready for the next dyestuff mixing process.
    
8.11.1 The process is to place water into a large container and turn the mixer on for 3 minutes to ensure the propeller, spindle and components is free from dyestuff and eliminate cross dye contamination.

 
8.11.1 Propeller Cleaning

Cleaning of the propeller and the shaft is critical to ensure there is no cross contamination from batch to batch.    
 
   
NOTE: Failure to clean this device effectively will cause batch to batch variation, delay to customers, T&A failure and increase operational costs.

 
9.0 TERMS AND ACRONYMS    
 
Acronym    Term       
Stock Tank    A secondary device used to effectively mix dyes and chemicals before the machine calls for the mixture.        
Propeller    A device which is used to stir the water/dyes in a circular motion to achieve 100% dissolved dye throughout the water.       
        
10.0 REVISIONS
 
10.0 OUT OF CONTROL ACTION PLAN (OOCAP)    

Where the dye weighing system should fail or is in-operable the team are to use the balances in a manual mode process.


 
11.0 REVISIONS    

 
Revision     Date                                 Author of Change    What Alterations were Made       
1st     09/03/2020                                             A                      First Generation of WI       
                   
                   
                 
        Signature       
Author:    A           
Reviewer    B           
Approver    C