PROCESSING DIVISION OPERATING PROCEDURE

1.0 PURPOSE To describe the method of different types of Yarn production, Cotton
issue to machine as per requirement, approval of initial production.
To ensure that effective traceability and stock is maintained for all
produced goods

2.0 SCOPE This procedure is applicable to Yarn production areas. It covers

everything from raw material receipt to finished material dispatch
and covers maintenance instructions.

3.0 RESPONSIBILITY Deputy General Manager is responsible for Spinning activities,

Cotton clerk is responsible for day-to-day cotton stock. Spinning
master production is responsible for Production activities. Spinning
master maintenance is responsible for all preventive and
breakdown maintenance. The yarn store in-charge is responsible
for day-to-day yarn stock.
4.0 PROCEDURE
Documents/
Sl.
Activity / Description Responsibility Forms/
No
Records
4.1 COTTON BOOKING & PURCHASE ORDER
Cotton Requirement for the month is sent to SSM MD by our Purchase
a)
purchase team after approval from our MD. Executive
Confirmation
SSM Cotton mail shared to
b) Cotton Booking is done by SSM Cotton manager
Manager our Cotton
Clerk.
Mail to HO
Invoice from the supplier will be shared by the agent through
c) Cotton Agent purchase
mail to our Purchase team.
team
PO copy
Purchase shared to
d) Purchase order entry will be created in I-connect
Executive Cotton clerk
through mail
4.2 CREATE GRN
After invoicing by the supplier, cotton will be shipped in
a) container or by Lorry. If it is by container means it will reach Supplier
cochin port.
From cochin port container details will be shared with our Mail from
Cotton clerk. Cotton clerk should plan to receive the Logistics
container from the port to Cotton Godown by coordinate with regarding the
b) Cotton Clerk
respective Logistics such that container must be taken from details of
the port within in 5 days. (Note: If it exceeds 5 days penalty container in
is there as per the port norms.) cochin port.

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Once the container or lorry reaches the cotton godown

collect the invoice from the Driver and verify the invoice with
the PO. Check whether the container number or vehicle
c) number matches with the invoice. Then check the seal Cotton Clerk
condition of the container and take a photo of the seal. After
breaking the seal open the container and check for the bale
condition in the container.
Moisture test
Forklift will unload the bales from the container or lorry then
note ,HVI,
d) moisture test is done by random sampling of 10% received QA
AFIS and
bales.
Trash report.
If the samples do not meet the quality requirements debit
e) .
note will be raised.
Loadman weighs each bale and stacks four bales. During
weighing entry should be done in I-connect along with
g) Cotton Clerk GRN
location and print two barcodes for each cotton bale and
paste it in each bale.
Forklift picks the four bales and stack in the respective Forklift
g)
location. operator
After GRN, Spinning QC must confirm the quality in I-
h) Spinning QC
connect.
i) After QC confirmation, Cotton clerk should confirm the stock. Cotton Clerk
4.3 COTTON ISSUE
Get printed copy of Mixing chart from quality incharge.
a) Mixing chart contains no of bales to be picked from which Cotton Clerk Mixing chart
variety and laydown locations.
Forklift
b) Forklift picks the bales and place it below the respective lot.
operator
Loadman pastes the laydown location sticker as per mixing
Barcode
c) chart then removes the barcode sticker from each bale and Loadman
sticker
hand over to cotton clerk.
Forklift picks the bales and places it outside the cotton Forklift
d)
godown. operator
Loadman arranges the bales as per the laydown location
e) Loadman
sticker.
Verify the cotton stock physically and then do issue in I-
f) Cotton clerk
connect by scanning each barcodes.
4.5 COTTON LAYDOWN
Issued cotton bales are placed in blow room by forklift.
a) Loadman picks the bales and places the bales in laydown Loadman
area as per the Laydown chart.
Quality incharge verifies whether the laydown is done as per Quality
b)
quality chart. incharge
4.6 BLOW ROOM

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Bledomat plucks the cotton from the laydown and the

materials flow till carding as listed below
1.Pre cleaner
2.Multimixture
a) 3.Separomat
4.Step cleaner
5.Feed truck
6.Magic eye
7.Dustex
Ejections from Magic eye is collected and cleaned by
Contamination
b) contamination operator. Collected good cotton is weighed at Operator
note.
VXL during shift end and recorded in contamination note.
c) Periodically clean the metal waste ejections in blowroom. Operator
4.7 CARDING
Place the empty cans in carding after cleaning the castor
wheel and place the output cans near SBD 22. Attend the
a) breaks. Inform to supervisor in case of abnormal breaks and Operator T-Data Report
repeated errors. Production details will be saved in T-Data
software.
Collect the Sliver waste in bag at shift end and place it near
b) Operator
Omega 2.
4.8 BREAKER DRAWING
Place the carding output cans in breaker drawframe as per
channel feeding displayed in respective drawing machine
and do piecing. Attend the breaks. Inform the supervisor Spider web
a) Operator
incase of abnormal breaks and repeated errors. Place the Report
Drawing output cans near Omega. Production details will be
saved in spider web software.
Two hours once drafting zone should be cleaned and cots Colour Coding
should be changed as per colour coding chart displayed in chart
b) Operator
machine. Fan waste collection and creel cleaning should be displayed in
done hourly once. machine.
Collect the Sliver waste and Fan waste separately in bag at
c) Operator
shift end and place it near Omega 2.
4.9 LAP FORMER
Place the breaker drawframe output cans in Lapformer and
do piecing. Attend the breaks. Inform the supervisor in case
of abnormal breaks and repeated errors and place the lap
Spider web
a) former trolley in Comber based on the order of Lap gets Operator
Report
empty. Place the empty input cans in Output end of
respective Breaker draw frame. Production details will be
saved in spider web software.
Four hours once Drafting zone and stripper should be
b) cleaned. Fan waste collection and creel cleaning should be Operator
done two hours once.
Collect the Sliver waste and Fan waste separately in bag at
c) Operator
shift end and place it near Omega 2.
4.09 COMBER
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Place the empty from drawing to comber after cleaning the

castor wheel. Attend the breaks. Inform to the supervisor in Spider web
a) Operator
case of abnormal breaks and repeated errors. Production Report
details will be saved in spider web software.
b) Do semi cleaning once in a shift. Operator
Collect the Sliver waste in bag at shift end and place it near
c) Operator
Omega 2.
4.10 FINISHER DRAWFRAME
Place the comber output cans in finisher drawframe as per
channel feeding displayed in respective drawing machine
Spider web
a) and do piecing. Attend the breaks. Inform to the supervisor Operator
Report
in case of abnormal breaks and repeated errors. Production
details will be saved in spider web software.
Two hours once drafting zone should be cleaned and cots Colour coding
should be changed as per colour coding chart displayed in chart
b) Operator
machine. Fan waste collection and creel cleaning should be displayed in
done two hours once. machine.
Collect the Sliver waste and Fan waste separately in bag at
c) Operator
shift end and place it near Omega 2.
4.11 ROVING FRAME
Place the finisher drawframe output cans in rovingframe as
per batch feeding and do piecing. Attend the breaks. Inform
Spider web
a) to the supervisor in case of abnormal breaks and repeated Operator
Report
errors. Production details will be saved in spider web
software.
Once in a shift clean the drafting zone. Four hours once
b) Operator
clean the flyer waste and drafting zone backside.
c) At the time doffing check wheth
Check the ring color whether the respective count is running Identification
c) Operator
or not. Ring
Collect the sliver waste and roving waste separately in bag
d) Operator
at shift end and place it near Omega 2.
4.12 RING FRAME
Attend the breaks. Production details will be saved in spider Spider web
a) Operator
web software. Report
During exhaust time BTS operators were engaged for
b) Operator
bobbin change.
c) If linea red indication is visible clean the compact drum. Operator
Check whether the respective bobbin and cops are running
d) Operator
as per colour coding.
4.12 LINK CONER
Attend the alarm faults by taking off the yarn end from
Visual
running cone. Check the CBF periodically. Incase of any
a) Operator Manager
remaining cops inform to the Supervisor. Production details
report.
will be saved in Muratec Software.

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Paste the cone labels in cone tip before placing in linkconer.

Place 4 cone tips per drum and collect the output cones in
Cone
b) conetrolley and then weigh randomly whether the cone Operator
checking note
weight matches with the weight set in linkconer and entry
weight in cone checking note.
After weigh checking, pass the cone trolley in UV testing
c) Operator
room
Collect the hardwaste at shift end and place it near Omega
d) Operator
2.
4.13 YCP & PACKING
After UV testing move the cone trolley to YCP trolley area
and change the cones to YCP trolley, then place the YCP
a) trolley in YCP machine as per the count (One YCP trolley Operator YCP record.
must have only one count) and place the trolley in platform
and do YCP and record the no of cones based on count.
After doing YCP then move the YCP trolley from the
platform to respective count area and wait for 15 minutes
b) Operator
and then arrange in the pallets if it is sent to Jay Jay Knitting
else pack it in bags.
After arranging 300 cones of same count then do wrap with
stretch film then place the count slip and paste the count no Packing
c) Operator
at the last pallet and entry pallet weight, count, cone tip color record
with respect to date.
4.12 COUNT CHANGE
Planning team provide the count change details in whats
Planning Whats app
a) app group for which count how many frames need to be
Team group
changed.
Production team checks for the availability of manpower,
SM-
b) empties, cone tip and fitter and then inform to QAD
Production
regarding count change along with the frame no.
Quality team fill the change slip and gets approval from all
Quality
c) HOD’s and DGM and inform to the fitter about the count Change Slip
Incharge
change.
After the completion of Doff count change will be started by
d)
the fitter.
4.13 DISPATCH TO KNITTING
As per planning team requisition, an internal invoice will be
Yarn Dispatch I-connect
a) created in I-connect for the respective PO after approval
Incharge invoice
from accounts and transfer the yarn to knitting.
4.14 MANPOWER ALLOCATION AND CONTROL
Record attendance in each shift and allocate the operator for Attendance
a) Supervisor
all running machines. sheet
In case absenteeism, supervisor must send a mail to HR
b) Supervisor
department about the list of operators absent on their shift
4.15 EFFICEINCY & UTILIZATION MONITORING

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Daily
a) Efficiency is monitored machine wise. Supervisor Production
Report
SM-
b) Regular monitoring of machine Utilization on daily basis
Production

4.16 QUALITY MONITORING

First Piece
Verify the loop length as per confirmation with fabric Approval
a) QC
technologist while approval of first piece Report
R/KNT/03
Knitting
machine
Check the fabric quality in each machine and update in
b) QC online check
knitting machine online check list report
list report
R/KNT/10
In Fabric inspection machine 100% inspection should be Fabric
done for special fabric. inspection
c) QC
For normal and lycra type fabric inspection should be done machine
when a defect occurs while knitting. report
4.17 MACHINE CLEANING AND MAINTENANCE
Do preventive maintenance for each machine once in a Knitting m/c
a) Foremen
month / 10000 Kg Production service book.
Once for every 2 hrs machine & surroundings should clean
b) Operator
by air gun by the operator.
Spare should be maintained within the budget level, by
following minimum inventory level & Yearly maintenance
budget.
s

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