Process: DYEING
Author: Name of Concern Person
Document type: WI-Work Instruction
Reviewer: Name of Reviewer
Title: MANUAL CHEMICAL PREPARATION
Approved by : Head of Firm
PURPOSE
1.0 PURPOSE
This
document identifies the accurate process of developing the appropriate
chemicals and weights for the development of dyed fabric.
2.0 SCOPE
The
scope covers the process from receipt of the chemical drug-line to the
weighing and delivery of the chemicals to the machines.
3.0 APPLICABLE REFERENCE/DOCUMENTS
Reference / Document Example
3.1 Batch Recipe
The
recipe is a list of specific chemicals and dyes used to achieve an
exact colour. Any variation from using these amounts will cause the
colour to “shift” making the colour inaccurate to the customers’
requirement.
3.2 Chemical Requisition Slip (MRS).
The
MRS is a record used for the CDA to capture the quantities of dyes or
chemicals used to achieve the colour. This information is also used for
costing purposes.
3.3 Batch Processing Card
The
card is used to identify the process route in the production process.
The Card also records all relevant details pertaining to the production
of the batch.
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.
4.1 Footwear Protection
4.2 Eye Protection
4.3 Hand Protection
1.0
5.0 EMPLOYEE QUALIFICATIONS
The store staff require induction training in handling chemicals safely in the correct manner.
The store staff also require a minimum of 4 weeks supervised training.
The store staff require training in first aid practices.
6.0 EQUIPMENT USED / APPROVED MATERIALS
6.1 Balance
Used for weighing the exact amount to the demand of the chemical rule.
6.2 Dipper/Jug
Used for extracting the chemical from the chemical container.
6.3 Chemical Drum.
Used for holding the exact requirement of chemicals for the recipe.
7.0 RESPONSIBILITIES
Position Responsibility
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.
Shift
Officer := Is responsible for observing the process of weighing the
chemicals is accurate to the drug-line and machines are fully
utilized.
Chemical Store Staff Are responsible for weighing the chemicals exactly to the requirements of the drug-line.
8.0 PROCEDURE
8.1
Upon receiving chemical containers from the production floor the
Store-man are first required to clean the containers ensuring that the
inside and outside of the containers are free from chemicals.
Note:
Under no circumstances are the store-man to use containers for chemical
preparation that currently have chemical inside the container that
exists from the previous batch. The container is to be removed to the
cleaning station for cleaning.
8.2 The shift Officer is required
to prepare the drug-line in advance of the current batch in the machine
completes its process in order to maximise machine utilisation checking
the following;
Machine number.
Fabric construction.
Dye & chemical concentrations.
Program method
Illustration 1.0
Chemical Recipe (drug-line)
A
specific list of chemicals and dyestuff to achieve a specific colour.
Where personnel are not specific with the weights the colour will
shift.
8.3 The Shift Executive is required to review the chemical drug-line for errors prior to sending to the Machine Operator.
8.3.1 If errors are found the error is identified and corrected before sending to bulk for preparation.
Note:
Where chemicals are delivered to the machine through the auto-chemical
delivery system (see WI-EPY-DYG-003) the chemical is entered into the
computer when the machine requires it.
8.4 The Machine Operator then sends the drug-line to the chemical store for preparation.
8.5 Selecting a clean chemical container, the chemical Store-man then places the chemical container on the balance.
8.5 Clean Chemical Container
Make sure the chemical container is clean and free from other chemicals or contaminants.
Placed on the balance and tare before weighing.
Clean chemical container & Balance
8.6
Once the clean container is on the balance the store-man tare’s the
balance to ZERO, see illustration 2.0 so that the screen reads 0.000 by
pressing the tare button.
Illustration 2.0
Tare the balance to zero by pressing the tare button on the far right.
Illustration 2.0
8.7 The Store-man then identifies the 1st chemical from the list and locates the appropriate chemical in the store.
8.8
Using the dipper the store-man then scoops the dipper into the chemical
and then pours the chemical into the container that is on the balance.
8.9
The Store-man then begins adding the chemical to the container until
exact weights is identical to the chemic drug-line requirement decimal
value.
If the drug-line states 3.256 kilos, then the digital display will read 3.256 in weighed chemical.
8.10
Once completed the Store-man then pours any residual chemical back into
the original container the chemical was taken from and removes the
chemical from the balance in preparation of the next chemical.
8.11
Using a pen or marker the Store-man then ticks the chemical on the
drug-line to confirm the chemical was weighed and to ensure that there
is no mix up in selecting the next weight for preparation.
8.12
All the chemicals are weighed in the same manner excluding Caustic Soda
(NaOH) and Hydrogen Peroxide (H2O2). Peroxide and Caustic are only
prepared when the machine is about to call for these chemicals. This
acts as both a safety precaution as well as a technical precaution.
8.13
The machine Operator is required to relocate the chemicals from the
chemical store room to the machine in the exact sequence of the chemical
drug-line to ensure no mix up occurs when required to add to the
machine.
8.14 The machine Operator lays the chemical in a
sequence next to the machine (where no traffic occurs) in preparation of
adding to the machine chemical add tank.
9.0 TERMS AND ACRONYMS
Acronym Term
Drug-line A list of chemicals and quantities used as a medium to transfer dye from the water to the fabric.
Balance A digital device used to accurately weigh the chemicals for dyeing.
H2O2
Hydrogen Peroxide a clear liquid used in the process of bleaching
cotton. Avoid contact with skin or eyes. Eye wear is required when
handling this chemical.
NaOH Caustic Soda (Sodium Hydroxide) a corrosive chemical used in dyeing procedures. Eye wear is required when preparing this chemical
10.0 REVISIONS
10.0 OUT OF CONTROL ACTION PLAN (OOCAP)
Where a situation of incorrect chemical or recipe occurs the operator brings the drug-line to the Shift Executive for review.
Where chemical spillage occurs the Store-man are required to inform the Shift Executive for notification and if required actions.
Where chemical burns or contamination occur the store-man are to wash the effected areas according to health recommendations and seek the Shift Executive for aid.
11.0 REVISIONS
Revision Date Author of Change What Alterations were Made
1 08/03/2016 Name of concern 1st Generation
Signature
Author: Name of Concern Person
Reviewer Name of Reviewer
Approved by Head of Firm