Process: DYEING Author: A
Document type: WI-Work Instruction Reviewer: B
Title: DISTRIBUTION DYES & CHEMICALS Approver: C
PURPOSE
1.0 PURPOSE
The purpose of this document is to ensure that correct procedures are in place to efficiently and effectively distribute dispensed dyes and chemicals to dye vessel stock tanks/Addition tanks manually, limiting accidental spillages and procedural delays.
2.0 SCOPE
The scope of this WI covers the operations includes pre-treatment & Dyeing of the fabric into the dye vessel and is managed by;
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-FIRM-PRD-006 Recipe Sheet Preparation.
The process of developing a recipe using colour, fabric weight, origin of fabric, machine name/number
3.4 WI-FIRM-DYG-001 MANUAL CHEMICAL PREPARATION
The accurate process of developing the appropriate chemicals and weights for the development of dyed fabric.
3.5 WI-FIRM-DYG-002 MANUAL DYESTUFF DISPENSING.
The process of accurately preparing and weighing powdered dyestuff for reliable production of dyed fabric with a high Right First Time (RFT).
3.6 WI-FIRM-DYG-003 AUTOMATIC CHEMICAL DISPENSING
The process of utilising the auto chemical delivery system and how the information is captured in the system to how it is delivered to the dyeing machines.
3.7 WI-FIRM-DYG-004 DYESTUFF MIXING PREPARATION
Describes the processes taking place in the Dye-house including production and inspection, ensuring best possible quality of dyed fabric obtained with the highest possible efficiency.
3.7 WI-FIRM-DYG-007 Dyeing Machine Operation
Operate the machine according to the company best practice process to ensure high colour quality and Right First Time.
3.8 WI-FIRM-DYG-008 Addition or Topping.
The process required for improving colour or fabric quality by adjusting the treatment process to compensate for the drop in quality.
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 Suitable containing devices to transport dyes and chemicals to respective dye vessels (eg, baskets, trolleys, etc).
6.2 Rinsing facility at Addition tanks.
6.3 Transportation (Hand Lift)
7.0 RESPONSIBILITIES
Position Responsibility
Operators/ Sr. Operators
Execute the distribution process
Shift Supervisor
Supervise the whole process
Shift officer/ Executive
Supervise the whole process
8.0 PROCEDURE
8.1 Effective and efficient distribution of dispensed dyestuffs and chemicals to relative dye vessels and Addition tanks is vital. With the implementation of a simple distribution strategy, the following critical situations can be avoided:
Dye/chemical spillages during transit.
Dye spillages during transfer to Addition tanks.
Batch start delays due to lack of dyes/chemicals by respective machinery.
Failure to maintain an efficient and effective Distribution strategy will can seriously impact on Color Quality and Lots Per Machine Per Day (LpMpD).
The summarized distribution steps for all relevant dye vessel operators are as follows:
8.2 Identify next machine operation for Addition tank preparation
Dye vessel operators should be in a position to identify the next process that requires Addition tank preparation while a current process i.e. treatment is running, by visually recognizing empty machine preparation areas (i.e. there are no visible dyes and chemicals waiting in machine preparation areas).
8.3 Collect dispensed dyes and chemicals from Dispense area in suitable container
If a subsequent process and/or batch is scheduled, the operator must collect the dispensed dyes and chemicals from a location in the dispensing area which has been designated to that specific machine. The dyes, chemicals and recipe for the next process and/or batch should be available and grouped together in a suitable container.
WI-FIRM-DYG-008 relating recipe preparation to dyes & chemicals (Dispensing of Dyestuffs and Chemicals), all dyestuff and chemical receptacles should be clearly identified by some means e.g. labeled, to represent corresponding recipes. The operator should check that all products listed on the recipe have been inspected before distributing the container to the machine preparation area.
8.4 Distribute container and recipe to dye vessel preparation area
Carefully distribute the container to the dye vessel, ensure that no dyestuff or chemical contents are spillled or lost in transit. Place the container next to the machine with a designated preparation area. This area should be free of obstructions.
8.5 Check recipe with Standards color to be matched
To ensure that the dispensed dyes have been distributed to the correct amount, dip a corner of recipe paper into mixed dyestuff solution to compare with the standard color to be matched for clarification of desired shade.
8.6 Prepare next bath chemicals/dyes before current step/batch completes dye cycle
While the current batch or step is completing its dye cycle, as requested by the machine controller, prepare the next bath or process liquor for chemicals or dyes in advance to avoid delays associated with the preparation of the dyes and chemicals of next batch or steps.
8.7 Rinse residues of dye powder/solution into Addition tanks by activation of Rinse button Addition tank.
8.8 Clean the container used in dispensing area.
9.0 TERMS AND ACRONYMS
Acronym Term
Batch Card A physical card generated to record full batch details from customer name, Fabric and construction.
Recipe A piece of computer generated (excel/auto) printed copy of required dyes and chemicals as well as all information regarding the Batch being processed e.g. fabric specification, L:R, fabric weight etc.
Wetting Agent Reduces the surface tension and impart wet ability of fabric at semi-bleaching.
Anti-crease Act as lubricating to reduce friction
Hydrogen Peroxide (H2O2) Bleaching agent
Stabilizer Stabilizes H2O2 at semi-bleaching to obtain better bleaching performance
Peroxide Killer Act to destroy residual peroxide after semi-bleaching
Detergent Act as wetting agent or wash off agent.
Sequesterant To deactivate metal ion as well as reduce hardness of water.
Electrolyte (SALT) Act exhausting agent
Enzyme Process involved with Biocatalyst to remove protruding fibre from fabric
Levelling Control dye bath
Alkali Act as dyes fixation at dyeing operation
OBA Act as optical Brightening agent.
Dispersing Agent For well dispersion of disperse dyes
Reduction Clean Highly alkaline treatment to remove unfixed dyes from fabric.
ISIONS
10.0 OUT OF CONTROL ACTION PLAN (OOCAP)
10.1 SPILLAGES
Dye vessel operators must be trained in the handling of spillages. All spillages of dyes or chemicals whilst in transit to the dye vessel preparation areas, or during transfer into Addition tanks, must be reported to the shift supervisor or team leaders.
If the spillage occurred in transit to the dye vessel, procedures must be followed for a re-dispense of the required product(s). Consumption data must be updated accordingly.
10.2 Wrong Shade at mixing/Addition tank
Dye vessel operators must be trained to confirm the distributed dyestuffs in addition tank regarding the outcomes of shades of mixed dyes through the assessment supervisor/ Shift officer with desired color. If mismatch happen all the color must be drained and re-dispensed and information must be shared with manager.
11.0 REVISIONS
Revision Date Author of Change What Alterations were Made
1 28/03/2016 A 1st Generation of WI.
Signature
Author: A
Reviewer B
Approver C
