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From Mixing to Packing
1. Keeping laps, full cans, bobbins, etc., in open air (fluffs get accumulated). 2. Poor stacking of empty cans.
3. Not using the waist bag for keeping the waste. Dropping the waste over floor.
Wasting time in dropping the waste in waste can for every occasion. 4. Following random can replenishment.
5. Giving more twists while joining the sliver/roving. Over twisted roving/sliver
leads to creel break in the subsequent process or else affects quality.
6. Making the stop motions, interlock and safety devices ineffective and running
the machines. 7. Utilizing part of machines due to back feed shortage, count changing and other reasons leading to an increase in count conversion cost. 8. Dragging sliver cans over floor and damaging the can bottom and floor. 9. Not piecing the broken sliver end with the delivery can sliver end while mending front break.
10. Not keeping the cans clean.g 11. Lack of co-operation among the tenders in stopping the frame at least when
simultaneous breaks occur in different machines.
12. Not stopping the frame properly while attending the breaks, this increases the
elemental timing. 13. Using Hessian cloth/pad/compressed air for cleaning the machines/machine parts while machines are running. 14. Dropping the waste inside the sliver cans. 15. Cleaning the roller clearers with hand at very low rating. 16. Handling the bobbins, cans, trolleys etc., roughly.
17. Achieving the settled production well before the shift end, stopping the
machines and standing idle, wandering here and there, disturbing other operatives and going out of the department etc.
18. Spoiling the good wastes by dropping over the floor, keeping over the
machine parts, using for cleaning the machine parts, hands etc., mixing with
saleable wastes, not collecting the wastes in time, cutting the wastes with knife, dropping the wastes inside the hot air exhaust grills. 19. Not opening or closing the door/windows/ventilators depending upon the requirements and affecting the departmental thermal, atmospheric conditions. 20. Not using the correct makings/not following the correct identification marks and making count mix-ups. 21. Not informing the concerned immediately even after hearing the erratic sounds of the machine and running the machine and leading to major breakdowns. 22. Making an attempt to rectify the machinery faults without informing the concerned and wasting time thus leading to major breakdowns or accidents. 23. Not keeping the hands, trolleys, floors, empties, machineries, rollers etc., neat and tidy which cause stains in the materials. 24. Not maintaining the trolleys and other equipments/devices provided properly and also handling them roughly. 25. Using compressed air for cleaning their dress, hands, legs etc. 26. Spilling water, oil, grease etc., over floor and not cleaning the same immediately. 27. Keeping the floor grills opened. 28. Starting the machines without noticing the machinery conditions and operatives attending on the machines. 29. Leaving the work spot during working hours without permission. 30. Keeping the idle machines in running condition, unnecessarily during shift changing, count changing, etc. 31. Changing the counts of the machines in rotation to make the operatives to have different counts in a cyclic manner and causing heavy down times. 32. Not using the right tools/equipments/devices for operating/handling and for assembling/dismantling the machineries/materials. 33. Keeping the machinery parts, oil cans, grease guns, materials, tools, etc., over window sills, machineries or else under the machines. 34. Wearing loose fitting dresses. 35. Not collecting the materials, tools, spares etc., scattered inside the department immediately.
tubes.36.. 53. 4 . Generating too much of waste while piecing. tools etc. for cleaning the waste. spares. Damaging the empty bobbins/cheeses/cones/rolls/drums/shafts by using sharp knifes. Making a heavy thick place or thin place while piecing. 41. in a corner or any place and keeping them as they are for a long time unnecessarily. 38. Not using the safety devices properly while working. Using sharp knives/saw toothed wires or blades for cleaning the roller lapping. Going to the next section for taking tea and wasting time. 50. 47. 43. smoking. Enjoying additional time for taking tea. Cleaning the parts while the machine is running which are to be cleaned after stopping the machine. drinking water. and not using the equipment/tools provided for cleaning. Cleaning the running machinery parts while the machine is running. 54. 39. 55. 52. saw toothed wires. 46. cops. 45. 51. spitting. Running the machines with less number of belts.. etc. Using a part of the machine for production. Running the machine without mounting the motor properly. 44. adjusting dress etc. top cover from a good can and using it for carrying the samples to quality control department. Taking more than the stipulated time for personal needs. empty bobbins. hooks. Interchanging the machinery parts without the permission of the concerned person. 37. Damaging the can spring covers by rough handling. 40. Using the machine for production without rectifying the defects. Not informing the concerned immediately after the breakdown and standing idle or else running only the remaining machines.. bobbins. 48. Running the machines with defective belts or ropes. 42. Removing the can spring. 49. Not following the educated/trained new methods and switching over to the original or old method gradually or immediately. Dumping the materials. etc.
Winding defective motors and using them. lightings. pillars etc. Not cleaning the fans. starters. 57. 61. Running the machine at very slow speed. Improper winding of motors. 68. Not maintaining the oil level of the spindle bolsters at optimum level. ventilators. etc. Keeping the ceiling too above than the recommended one. clean. Cleaning the parts with hands which are to be cleaned with compressed air on vacuum cleaner or hand brushes or small sticks or iron strings. 70. Keeping the doors. 71. Using higher horse power motor. 64. Not overhauling the motors as per the recommended schedule. 60. Running the empty machines unnecessarily. 67.56. 59. Depositing the wastes here and there and not using the equipments provided for them. Improper planning of lighting arrangements. Not keeping the roofs. windows and ventilators of the well humidified shed open while the plant is running. 72. 65. Running the machine beyond the optimum speed. 73. Not replenishing the spindle oil in right time. 63. 69. 5 . Unqualified workers trying to rectify the electrical repairs. windows. doors. Cleaning the machine parts by keeping it idle which can be cleaned while the machine is running. 58. motors. 66. 62.
Throwing the Hessian cloth without removing the adhered cotton. Few attendants just standing near the lorry and watching others. 18. dust cotton etc. 13. Not opening the wastes (lap bits and slivers) and fibers while preparing the mixing. taking tufts of cotton from bale with one hand and distributing over mixing and taking too much of time for distributing the cotton. while opening the bale and preparing the mixing. Not removing the foreign materials. 15. 6. Handling the materials handling equipments and other equipments roughly.GODOWN & MIXING ATTENDANT 1. Standing idle over stack mixing and waiting till the bale is opened and transferred to the mixing. 2. Two or three men moving a single bale placed in hand-truck on a plain road. Hessian bits. Dragging the cone bags and cartons over floor. 17. Keeping the mixing area and the path congested. 16. Wasting time in unloading. Two or four men working at a single bale for removing the hoop irons/Hessian cloth and wasting time. Working at very low rating particularly at the time of opening and preparing stack mixing. Not stacking the hoop irons while opening the bale. 9. 19. 14. 7. Taking too much of time in cleaning the Hessian (poor rating and method). 11. Moving bales over floor to a considerable distance and not using the trolley. After removing the hoop irons and Hessians. Not maintaining the materials handling equipments properly. 10. 3. disposing materials etc. Mixing the unopened roving waste with the stack mixing. keeping the bale over floor.. Cutting the hoop irons while opening the bale. 5. 12. 4. Not planning properly before starting the work and wasting time in bringing materials. 8. 6 .
Preparing the oil mixer after finishing the first layer of mixing (other mixing attendants standing idle). 26. Stacking the bales inside the go down after unloading and again bringing them out for weight checking and then taking them inside the godown. 22. 23. Not folding the hoop irons after removing. 24. 7 . just throwing them aside is causing entanglement. (Due to this practice an additional job of re-arranging the hoop irons is done) 25. Wastes are not distributed uniformly while preparing the mixing. Neatly arranging the bales near lorry after unloading and then taking them to the godown or for weighment. Spraying the oil mixer improperly.20. Waist bags are not used during mixing operation. 21.
18. Not keeping the surroundings clean. Not mixing the wastes properly. during roof cleaning with broom sticks or machine cleaning with compressed air. 15. spoiling the fallen cotton or fibers by walking over them. Not taking the specified quantities from each bale and feeding to the lattice/conveyor in case of bale mixing. Using defective trolley/damaged sheets for carrying cotton from mixing to MBO. Not cleaning the waste accumulated at lattice/beater bearings etc. 3. 13. 8 . Not maintaining the trolley properly. Feeding the cotton or synthetic blends tufts without opening. Not using the broom given for collecting the fallen/scattered cotton or fibers and wasting time by collecting them with hands. Not removing the foreign materials from the fibers. Not keeping the stack mixing tidy. Not opening the wastes properly. 6. Carrying too much of cotton or synthetic blends with hands from mixing to lattice or conveyor and dropping over floor and wasting time in collecting the fallen fibers or cotton. 19. Not disposing the lap rods immediately and keeping them here and there. Moreover. Keeping the mixing open. 7. 11. Not using the trolley/equipment/sheets provided for carrying the cotton or fibers from mixing to lattice or conveyor and carrying the cotton with hands. Taking cotton or synthetic blends from the top side and feeding layer by layer. 16.BLOW ROOM BACK ATTENDANT 1. 14. 9. Not feeding the cotton or synthetic blends uniformly. Not segregating the good waste fallen under the machine and disposing them along with the droppings. 17. 2. 4. Mixing the good waste with the sweeping waste. 10. 8. 5. 12.
23. 24. 25. Cleaning the lattice and beater bearings with hands for removing the wastes and wasting time.20. Not using the lap waste uniformly. Feeding the fibers without removing the dirty wastes and the sweeping wastes. Feeding the mixing without removing the roving bits coming along with the mixing. Not keeping the lattice or conveyor and the mixing trolleys properly filled-in while going for personal needs. 26. 21. accumulating them for a long time. Not removing the other mixing fibers or wastes coming along with the running mixing. 22. Not following the instructed methods for mixing the usable waste along with the bale fibers while following the bale mixing method. 9 .
Placing the lap in the stack without checking weight. 7. 4. 3. 17. oily/greasy cotton. 10 . 13. Using compressed air for cleaning the laps stack area and spoiling the top layers of laps. 15. 6. 5. Keeping the lap rods stand far away from the scutcher. 12. Mixing the droppings of different mixings. 18. Not informing the MBO tenter immediately whenever there is some problem at front side. Not carrying about the calendar roll pressure. Not recording the correct lap weight differences in the register/note book. 9. Stacking the laps over unclean floor / platforms. Not adjusting the lap weight regulator immediately and allowing too much of rejected laps. etc from the laps placing them as they are. Stacking the laps near the opened door/window. Not applying grease / oil to the respective parts in time. Not informing the concerned immediately when the white waste is falling. Not utilizing the provided lap rods stand for keeping the lap rods and keeping them in a corner or over the machine or over floor. 11. Not covering the laps with alkathene sheets or HDPE sheets when roof cleaning or machine cleaning is done. Not covering the laps with alkathene sheet or HDPE sheet when they are stored for long time. Not replenishing the roving bobbins in time which leads to lap licking at carding. 8.BLOW ROOM FRONT ATTENDANT 1. Not segregating the white waste while collecting the wastes. 14. 10. (Atmospheric air destroys the top layers of lap). 19. Not cleaning the droppings and other wastes in time 2. Not removing foreign matters. 16.
30. 29. Cleaning the oily/dirty/greasy hand over lap. 32. Using oily / greasy lap rods or lap spindles. 28. Not adjusting the lap starting end properly and leading to generate more lap bit wastes at carding. 27. Keeping the full bobbins or empty bobbins over dirty floor or machines or sills of the windows. Not putting the correct markings or labels when is essential. Not removing the air compressor’s condensed water in time. Mixing the rejected laps with the good laps. 25. Carrying the lap over head or shoulders. 36. 26. Carrying the lap in hands for a long distance and not utilizing the trolleys provided for this purpose. Stacking the laps far away from the scutcher even when it is not necessary.20. 24. Running the machine without cleaning the chocked/lapped wastes. Not keeping the weighing balances clean. 39. 37. 21. Not keeping the scutcher and grid bars clean. 22. Not carrying about the weighing balance accuracy and using it even when it needs some adjustments. 40. 33. 11 . Inserting the lap rod inside the lap spindle while the lap is running. Using rusty or dirty lap rods or lap spindles. Trying to clean the wastes without dismantling when it is essential and wasting lot of time. 38. Using different weight lap rods at a time and getting confused in maintaining the lap weight. 34. 31. 35. 23. Not keeping the cages clean which leads to (single or doubles) defective laps. Handling the lap rods and spindles roughly and damaging the parts or else causing accidents. Using dirty/oily/greasy alkathene sheets or HDPE sheets for covering the laps.
Over twisting the slivers while piecing.. Cleaning the roofs. Not attending the lap lickings in time and allowing single. 11. sliver wastes etc.. Bringing the laps from blow room to carding over shoulder or on head even if trolley is provided. Not doffing the can in time and running more than the specified length. Running the cards without the safety guards and machine covers. 19.CARDING TENTER 1. 12.) 12 . 9. floors. Feeding the lap bits/sliver bits along with the running lap. 17. Storing the wastes in bamboo baskets/cans/trolleys and transferring them to Hessian bag at shift end. Removing the old markings with knives/saw toothed wires or blades and damaging the cans. 13. 14. 2. etc. Not segregating the white wastes while collecting the wastes and mixing them with saleable waste. 3. 10. 8. machines. 6. Not removing the oily/greasy cotton and foreign matters from the lap while patrolling or lap changing. with compressed air while the cards are running. Not cleaning the flat strips properly. Keeping the waste cans/Hessian bag/trolley far away from the cards and wasting time in depositing the waste. Unwinding the lap and spreading it over floor. Not keeping the svival wheel/caster wheels clean. 15. Cleaning hands with good wastes (lap bits. 16. Not informing the concerned immediately when the white waste is generated. Spoiling the top layer of the lap due to poor handling. Not segregating the sweeping wastes and disposing them as they are. 20. Doffing well before time in order to makeup for the back feed shortage at drawing /sliver lap. 18. 7. 5. 4.
Keeping the reserve laps over dirty floors. 29. 41. 30. Collecting the under casing waste. Not keeping the central dust extraction units clean. 39. Not collecting the suction wastes. front wastes in time and cleaning them only after heavy accumulation. 27... trench waste etc. 33. Not stripping the cylinder/doffer in time when they are loaded. 35. etc. Not doffing the cans at shift end and also not keeping the reserve cans and laps to the sufficient level at shift end. Not keeping the lap rods properly in a particular place and throwing them here and there while changing the lap. 40. while the card is running. cylinder droppings. 34. 32. Generating more lap bit wastes. Making the safety/stop motion devices ineffective and running the cards. Causing count mix-up due to carelessness. Not changing the count boards immediately after count changing. 36. 37. 24. Running the cards at slow speed unnecessarily. are running.21. Not keeping the reserve laps and empty cans readily. laps. open while cleaning the department with compressed air or cleaning the roofs with broom sticks. 42. Stopping more than three cards at a time for stripping. Not piecing the sliver end with the can sliver end. 23. 28. 26. 38. 13 . 22. Not stripping the cards in time.. Not removing the thin/thick sliver which comes at the time of break mending or starting of card. Keeping the sliver full cans. Not cleaning the under casing wastes immediately when a defective web is produced. Not cleaning the wastes accumulated in at sides of cylinder. Not keeping the scrapper blades clean. 25. Going in between a very close machine side alley way where the belts etc. 31.
45. 49. Not removing the count label immediately after replenishment which goes along with the running lap. 51. Roughly handling the cans while loading and unloading. Not keeping the Humidification ducts clean. Throwing the alkathene papers/HDPE sheets etc. Not trimming the lap ends while changing the lap. etc. 48. clean. trumpets. 52. 50. 56.43. 47. 46. 57. 55. Not stacking the full cans and empty cans and reserve laps in the specified areas and keeping them here and there. here and there.. coiler tubes.. Not using the given face mask. Keeping the reserve lap’s top layer in hanging condition. Not mending the defective can springs and using as they are. 44. Using damaged cans. Keeping the front doors open. Dropping the wastes over floor. Depositing the flat strips inside the bin and transferring them to the Hessian bag. Not positioning the lap rod properly in the lap stand slot. 14 . 53. 54. Not keeping the calendar rolls.
15. Running more than the specified length of slivers in the can by re-setting the meter. 17. Not attending the lap lickings in time and allowing single. 22. Damaging the cans due to rough handling. Making heavy thick place while feeding the new lap. Dumping the noil waste bags near the machine. Feeding small bits along with the running lap. Interchanging the top detatching rolls by which quality is affected. 18.COMBER TENTER 1. Making too much of waste while attending lap licking. over the table. 14. Not exhausting the lap fully and generating remnants. 16. Wasting top few layers of lap unnecessarily. 20. 8. 21. 15 . 7. 4. 12. 9. brushes. Making the stop motion ineffective and running the machine. Running the machines without rectifying the earth faults. 19. 13. Collecting the noils in bamboo basket/trolley/can and transferring them to Hessian bag. 3. Not piecing the broken sliver end with the can sliver end. 11.. Keeping the equipment. etc. 5. Over twisting the slivers while piecing them. Not using the trolleys provided for transporting the cans. Damaging the spring tops by rough handling. Dropping the waste inside the can and not keeping the inside portion of can clean. 10. tools. Interchanging the detatching roller bearings. 6. Wasting the last few layers of lap unnecessarily. 2. Not cleaning the clearer waste in time and allowing the waste to go along with the material.
38. empty cans unnecessarily near the machine and not keeping them in their respective places. Using knives or saw toothed wire or hooks for cleaning roller lapping and damaging the rolls. etc. 43. Removing the waste from the moving parts particularly detatching rolls region while the machine is running. while it is running. Making too much of waste while attending table break or front break. 40. 28. Not keeping the empty spools over stand properly and keeping them here and there. Keeping too many sliver cans. 33. Running the machine either by lifting the top comb or without top comb. Applying too much of chalk powder/viboothi etc. Not cleaning the light roller lapping immediately. 26. 31. Damaging the half lap nails by carelessness. Not applying the varnish as specified and affecting the working performance. 29. Not cleaning the accumulated waste from aspirator tube in time. 34. 36. 16 .23. 35. Not collecting the noil waste in time leading to too much accumulation of waste at back side. Running the machine by keeping the table calender roller being lifted. 39. Not keeping the draw box region clean. Not straightening the bent needles nails with the tools provided. Not keeping the top comb clean. Cleaning the machine with compressed air/pad/Hessian cloth. 44.. Operating the machine with dirty/oily/greasy hand. Damaging the clearer cloth by cleaning with sharp fillet brush. 42. 27. Not placing the can properly while doffing by which the sliver falls down from the can and gets spoiled. Damaging the top comb needle by rough handling. 25. 24. 41. 32. Stopping the machine for a long time for roller varnishing. 37. 30.
62. Carrying the laps in hand or on shoulders or over head. 59. 51. 48. Not cleaning the embedded wastes from the cylinder assembly using the hook immediately while the defective web is produced. Not lubricating the top roll and feed roll bearings as specified. 47. 50. Not informing the concerned immediately when defective web is produced and running the machine as it is. feed roll bearings clean. for cleaning the trumpets. Cleaning the machines and the floors or roofs with compressed air or brooms by keeping the cans and laps in open air. Running the machine with defective top rolls. 46. Not keeping the reserve laps and cans readily and bringing them by keeping the machine idle. 49. Not depositing the wastes variety wise. Not keeping the trumpets clean 54.45. 57. 56. 17 . 55. 60. Using damaged springs and cans.. Not attending the noil chocking immediately. Not joining the required length of sliver for a table break. 58. 53. 52. Not cleaning the oily /greasy floors immediately. Not tieing the marking thread (identification thread) around the can properly. Inching the machine for a long time. Not keeping the top roll. Using knives/thin rods etc. 61. Not cleaning the spilling and excess oil greases from the machine immediately.
Making the stop motion ineffective whenever earth problem is there and not informing the concerned to rectify the fault. Transferring the slivers from can to floor and then creeling it. Taking the slivers from can and dividing them into parts and then creeling. Not placing the spools perfectly and damaging the spools. 11. etc. spool tray. 18. 6. Bringing the reserve spools by keeping the machine idle. Crossing the slivers over creel while creeling. 18 . 19.. 17. 9. Not stacking the lap properly. 12. 23. 20. 4. Not cleaning the creel roll clearers. Congested stacking of cans. Generating sliver waste unnecessarily while piecing the broken sliver ends. Not cleaning the empty spool properly and using it as it is. 3. Not lubricating the bearings properly. Poor starting of lap. 14. 7. 22. 16.SLIVER LAP / RIBBON LAP / SUPER LAP TENTER 1. Following random can replenishment method. Over twisting the sliver while piecing by which not only the quality is affected but also the rolls get damaged. Not keeping the cans. 8. 10. 2. 5. Not keeping the reserve cans readily for replenishment and wasting time in bringing the cans which leads to a loss in machine productivity. 13. etc. 21. Keeping the cans far away from creel by which the slivers get stretched. Guiding more than one sliver through a single creel calendar roll. Running the machine with low pressure and producing loose laps. Not cleaning the waste accumulated at lap guide. clean. lap rack. 15. Not collecting the laps from stand immediately. Not putting the specified markings. spools.
42. Doing external can replenishment. 26.24. 29. Running the machine without rectifying the earth faults. 38. Handling the cans. roughly. Not attending the lap licking in time and allowing singles. Not removing the thin/thick slivers and running them by keeping the creel roll being lifted. etc. 32. 46. Inching the machine for a long time. Not keeping the reserve laps / readily and bringing them by keeping the machine idle. etc. with good waste. 47. front zone covers. 36. Not exhausting the supply cans completely and leaving some coils of sliver inside the can. Making heavy thick places while feeding new lap. Making too much of waste while attending table break/front break. Dropping the wastes inside the empty cans. Damaging the can bottom while loading the can on trolley. trolleys. 45. Keeping too many sliver/empty cans unnecessarily near the machine and not keeping them in their respective places. Bringing/disposing a single can only at a time by dragging and not using the trolley provided for the purpose. 25. 31. 19 . 40. Cutting the laps and placing them aside and creeling the new laps unnecessarily. 35. 27.. 33. Piecing with dirty/oily/greasy hand. Carrying the laps in hand or on shoulder or over head. 30. Cleaning the machine. Cleaning the machine with compressed air while the machine is running. 37. 28. 39. Mixing the waste of different mixings and types. 44. hand. Not cleaning the light roller lappings immediately. Not keeping the cans clean. Making too much of waste while attending lap licking. 34. 41.. Stacking the different count sliver cans in the same place and making mix-up. 43.
20 . 55. 49. Not stacking the laps and empty spools at the racks and stacking those floors or machines. 57. Not cleaning the defective laps then and there and accumulating them. Running excess length of lap or short length of lap when the automatic doffing is not functioning or where the automatic doffing is not there. 51. Not keeping the drafting zone selvedge guide in position. 54. Running the laps without the presser plates. 56. Not keeping the machine and surroundings clean. 50.48. Not keeping the clearers clean. Not informing the concerned and rectifying the defects immediately when defective laps are produced. Not segregating the good wastes from the pneumafil wastes and disposing them as they are. etc. Not collecting the pneumafil wastes as specified then and there. 53. 52.
Not removing the thin / thick slivers and running them by keeping the creel roll being lifted.DRAW FRAME TENTER 1. 21 . Running the machine by keeping the creel calendar roll being lifted. 20. 16. Taking the slivers from can. 2.. 5. 8. Not keeping the rollers clearers clean and in correct position. Transferring the sliver from can to floor and their creeling. 9. 3. Over the rolls. Not piecing the broken sliver end with the delivery can sliver end. 17. Congested stacking of cans. 11. 18. 12. Running the machine by keeping the front zone cover being lifted.. Cleaning the machine with compressed air while the machine is running. Applying too much of chalk powder / viboothi etc. Running the machine with low pressure. 15. 6. Making the stop motion ineffective whenever earth problem is there and not information the concerned to rectify the fault. Generating sliver wastes unnecessarily while piecing the broken sliver ends. 4. Inter changing the top rollers which affects the quality seriously. 13. Mixing the wastes of different mixing and types. dividing them into parts and creeling them. 14. Over twisting the sliver while piecing by which not only the quality is affected but also the roller are damaged. Not keeping the reserve cans readily for replenishing and doffing and wasting time in bringing the cans which leads to heavy loss in machine productivity. 7. Guiding two slivers through a single creel calendar roll. 19.fluffs get accumulated inside the bearing which reduced the life of top roll and the bearings. Not keeping the drafting zone clean. Not keeping the top roll bearing zone clean . 10. Not changing the count board immediately after count changing and making confusion afterwards and also making mix-ups. 21.
Tieing the top roll strippers with twine etc. Bringing or disposing a single can only at a time by dragging and not using the trolley provided for the purpose. Using the sharp wire. Stopping the machine for applying varnish even when the working performance is good. 38. 37.. 34. 29. and running the frame. Dropping the wastes inside the empty cans. 32. 22 .. 31. Not maintaining the can wheels properly. front zone covers etc. Damaging the casters / svival wheels while loading the cans on trolley. 23. 25. 35. Cleaning the machine hand etc. 36. 30. Not keeping the cans clean. Pressing the delivery can slivers frequently while running. Not applying varnish when the working is poor.. trumpets. 42. Stacking different count sliver cans in the same place and making mix-up. 39. 24. fillet-brush or knives for cleaning the clearers and roll respectively and damaged them. trolley. Doing external can replenishment. Re-setting the full can length indicator and running the machine without doffing. pasting of tapes or twisted sliver etc. Not mending the defective springs. 28.22. Damaging the can bottom while loading on the trolley. Handing the cans. with good waste. roughly. 40. etc. Not putting the correct markings. Piecing with dirty / oily / greasy hand. 26. 33. Using damaged cans.) 43. condenser. Transporting one or two can only in a trolley and underutilizing its capacity. Not exhausting the supply cans completely and leaving some coils of slivers inside the cans. 27. 44. Clean.. Not keeping the funnel. 41. guides. (i.e.
Using defective rolls. 48. 23 . Not positioning the doff roll end bushes properly and using as they are. 49. 46.45. 47. Not collecting the wastes as per the schedule or in time. Not rectifying the defects immediately when a defective sliver is produced. Running single delivery.
13. Running the machine with low pressure. 16. Over twisting the sliver while piecing by which not only the quality is affected but also the rolls get damaged. hand. 4. Transferring the slivers from can to floor and creeling. 7.. Generating too much of sliver waste while mending the sliver break. 12. 20. 6. roughly. Not keeping the roller clearers clean and incorrect position. Taking the sliver from can. Not keeping the reserve cans readily and bringing the cans by keeping the Machine idle. Dropping the waste inside the empty cans. 10. 15. 9. 3. Checking all the flyers position immediately after doffing for every doff by Keeping the machine idle (doffers not positioning the flyers at the time of doffing.. Doing external can replenishment. trolleys. Not rectifying the single or thick sliver and running them as it is. 18. 2. Not exhausting the supply can completely and leaving some coils of sliver inside the can. 14. 8. 17. with good waste. Congested stacking of cans. Piecing with dirty / oily / greasy hand.SIMPLEX TENTER 1. Handling the can. Cleaning the machine. etc. 11. Mixing the waste of different mixing and types. Not keeping the drafting zone clean. 5. 24 . Not keeping the can clean. 19. dividing them into parts and then creeling it. front zone covers etc. Cleaning the machine with compressed air/ pad /Hessian cloth while the machine is running.
22. Not cleaning the presser & false twister perfectly while cleaning the flyer. 25. 29. Bringing or disposing a single can only at a time by dragging and not using the trolley provided for the purpose. 23. 42. Running the spindle without apron. 25 . Not making the correct marking on bobbin. 31. Not cleaning the air filter condensed water in compressor in time. 37. 38. Not cleaning the defective portion of the bobbin. Not piecing the rove as specified. 44. Not winding the specified number of coils over the presser while piecing. Not releasing the idle spindle top arms and running the machine. Stacking different count sliver cans in the same place and making mix-up. 26. Not cleaning the adjacent bobbin where double rove is there. 33. Not keeping the spindle rails and bobbin rails clean. Using sharp wire-fillet brush or knives for cleaning the clearers and rolls respectively and damaging them. 24. flyers and bobbin rails properly after spindle oiling. Running the spindles with defective false twister. 27. Not keeping the creel zone clean. 40. 35. Not cleaning the light roller lapping. Making too much spindles idle unnecessarily with out informing the concerned to rectify the defects and running the machine as it is. Not positioning the condenser and the sliver guides perfectly.21. 45. 32. Not keeping the condenser and the sliver guides clean. Not cleaning the spindles. 39. Running with defective condenser and sliver guides. Damaging the can bottom while loading on the trolley. 30. 36. 41. 43. twisting it fully and then doing piecing by which mending time is increased to a large extent and also the quality is affected. Not cleaning the waste accumulated in between the cans. Not keeping the flyers clean. 28. Taking the very lengthy rove. 34.
etc. Poor starting / stopping of frame. Not positioning the front cover properly and running the machine. Not cleaning the chocked pneumafil immediately. flyers in their stand. Cross creeling of slivers. 49. Not cleaning the waste accumulated at the covered place at backside. 55. while releasing and pressing the top arms. 62. Not putting the empty bobbin over the idle spindle. Following random can replenishment. 57. Inching the machine for a long time. Running the spindles with defective top rollers. Not keeping the idle spindles. 56. 61. 69. 68. top rolls. 59. Cleaning the spindle rail by keeping the machine idle. Not keeping the rollers beam clean. Under. Not cleaning the waste accumulated at hopper. 67. keeping them over floor or can etc. Non co-operation among the tenters in stopping the machine immediately when break occurs. nose bar. Running the machines by keeping the clearer covers / doors open. 65. Not patrolling the allocation and standing idle at a particular place. 53. 66. bottom roller necks. 60.utilizing the can trolleys capacity. 48. Adjusting the ratchet wheels. 51. Making the stop motion and the safety devices ineffective and running the machine. 50. Leaving the waste inside the pneumafil. 54.46. 52. 58. 64. Not keeping the pneumafil pipes in position. 63. Handling the flyers with oily /greasy hands. Running the idle spindle with flyer. Feeding the broken sliver end along with the running sliver end at the sliver guide. 26 . 47.
71. Running the machine by keeping the back doors opened. 76. 73. Piecing from top side in case of closed type flyers. Turning the can slivers and using. Running the machine with damaged pneumafil wire mesh. Not positioning the separators properly. Taking big size or very small size doffs. 72. 27 . 75. 74.70. Not cleaning the clearer waste then and there.
6. Using uncleaned empties. 9. 21. Breaking the rove while gaiting. 16. Not cleaning the flyers properly. 20. Using knife for cleaning the empties. 3. Mixing different types of wastes. Handling the bobbins with dirty /oily / greasy hands. Over twisting the rove while gaiting. 4. 5. 19. 14. 10. Not positioning the flyers properly. Using baskets for handling / storing the bobbins.SIMPLEX DOFFERS 1. 8. 15. second man distributing the empty bobbins or collected the full bobbins. Taking lengthy rove. 2. Keeping different color empties in a single bin wasting time while taking the bobbin for doffing. Using mixed color empties. Not winding the specified number of coils over the presser. Using damaged /oily /greasy empties. 13. Throwing the bobbins inside the box trolley roughly from a longer distance. Carrying full / empty bobbins in hands. 18. 11. 12. 7. Using sliver cans for collecting empty bobbins / full bobbins. Spoiling the bobbins by rough handling / carelessness. 28 . Dropping the full / empty bobbins on floor /machine or underneath the machine due to carelessness or rough handling. 17. One man moving the trolley. Not using the given waist bag. for there by consuming more time for gaiting.
Keeping the bobbins trolley in one particular place. Using damaged / oily / dirty bobbins and depositing them in the same bin where good bobbins are kept. 34. 26. Bringing too much of bobbins is trolley. Placing doffed bobbins over uncleaned top clearer covers. bringing the empty bobbins after stopping the frame. 35. 25. Bringing less number of bobbins is trolley. 30. Not cleaning the false twisters and pressers while cleaning the flyers 33. Returning to the starting point after for gaiting. Not keeping the bobbins rack. 28. Doffing with poor rating. Collecting and depositing the preparatory waste in baskets or cans or on floor and then transferring to Hessian bags.e. Lack of co-operation among the doffers.22. Empties bin. etc. 24. 31. Not bringing the empty bobbin while returning after disposing the full bobbin at ring frame section. 23. Not keeping the empty bobbins readily for doffing i. 29. 32. Placing the empty bobbins over uncleaned bobbin rails. 36. carrying the bobbins in hands and supplying to ring frames. 29 . Wide variation in rating among the doffers.. clean. 27.
16. 17. Wiping the hand waste over thigh or half. Missing the traveller while inserting the yarn. or otherwise affects the quality. 30 . 7. 15. Pulling more length of yarn while taking end. Missing hand waste and causing multiple breaks. 9. 4. 2. 6. 5. Trying to piece when there is a roller lapping.RING SPINNING FRAME SIDER 1. Trying to piece when there is a creel break. Dropping waste in alley ways. Passing away the ends down spindle due to careless patrolling. 10. Feeling the tension of yarn with middle and forefingers after piecing. 8. 3. 18. Dropping soft waste (This waste files and goes with yarn which affects quality). This practice also spoils the good waste and sometimes causes multiple breaks. Keeping the roving bobbins at one side of the frame and walking too much of distance for taking every bobbin. Changing end to other hand for cutting the excess end. 11. Trying to piece the idle spindles. Trying to piece when the bobbin has been exhausted. Taking the cop out of the spindle and then piecing the end. Piecing end with more length of yarn and making thick place.pant after piecing. Dropping bonda waste over floor or over the spindle and affecting housekeeping. 12. Trying to piece when the over head clearer is passing. 14. 13.
While attending creel break. 23. Dropping the full bobbin underneath the machine or in the alley ways while taking the bobbin from creel due to carelessness and spoiling the bobbin. Cleaning roller beam etc. 36. 34. Walking up to the end of the frame even attention is not required. Breaking the end while taking from cop. 24. While removing pneumafil waste allowing cotton to fly which result in deterioration in the quality. Missing the end while taking from cop. While patrolling. 31 . with good soft waste. 26.out. Not giving any importance for drafting zone cleanliness. Standing at a particular place and awaiting an end break. 33.e. 28. 30. 27. Not lifting the cop slightly for taking end easily when the cop size is small and wasting time in getting the end.. 20. Not cleaning the roller clearers when there is heavy accumulation. 35. 21. Carrying too many bobbins in hands and sometimes dropping the bobbin in the alley ways and underneath the machine and spoiling. While attending creel break or run.19. 32. 37. Doing double gaiting i. Because of this break. Not cleaning the traveler while piecing even when there is waste accumulation. 31. 25. holding the ring rail with fingers and taking more time. standing idle till the end comes out and not cleaning or piecing the nearest broken end. 29. Pulling the end up to the waist. over piecing. yarn is over twisted. Patrolling the stopped frame (waiting for doffing) unnecessarily and wasting time. Straining unnecessarily by over stretching or bending while piecing. taking the end from bobbin and holding till the fibers come out from the roller nip and then piecing the yarn. 22. head or ear chest or shoulder and breaking.
48. piecing the lengthy rove with the running out rove. Wasting too many layers of rove while changing the bobbin. 41. 45. 46. Awaiting and standing idle till the bobbin gets exhausted. 56. 53. 39. Not cleaning the bobbin when there is defect. Using knife for stripping the bobbins. Making more waste unnecessarily from the cop and also the bobbin while rectifying the defects. Not cleaning the rove guide rod when there is a heavy waste. While changing the bobbin. 50. 43. 55. Wasting time in cleaning the clearer before attending the break. Not tieing the waist bag.38. 42. Dropping the cop in the alley way of underneath the machine after using it for the first round of piecing after doffing. while attending creel break. Using knife for cleaning roller lappings. 40. 54. 44. Dropping the empty bobbin in the alley ways are or underneath the machine during bobbin changing. Keeping all the travellers in one box at the machine end and wasting time in bringing the traveller when it is needed for a particular spindle. 49. 32 . thus leading to a lengthy thick place. Taking rest outside for every few cycles or for every cycle. Hurrying to the bobbin trolley and wasting time in selecting good bobbins from the trolley and sometimes dropping the bobbins down or underneath the trolley. Not utilizing the small bobbin trolley for carrying the bobbins inside the alley way. due to poor eyesight. 52. 47. Finding it difficult in getting the yarn end. 51. 57. Using knife for cleaning the bobbins. Not using the waist bag properly for keeping the waste. Wasting too many layers of rove while attending creel break.
cleaning the lapping with other hand. Stopping the spindle first for taking the end. holding end in one hand. Trying to piece without cleaning the travellers waste. 68. again stopping the spindle for passing the yarn through traveller. releasing the spindle by holding the end after passing through lappet guide. 64. Leaving the end inside the pneumafil while piecing and missing the piecing or otherwise causing heavy thick place.e. Wiping of the front rolls unnecessarily with one hand holding the cop and with the other hand. (Plastic empties get melted). without 65. Getting end from the cop by taking the cop out and. Not cleaning the spindle waste even if the waste is observed.. apron – cut. making too many attempts and then cleaning the traveller. Wetting/Trying the travellers in the mouth and using them. Keeping the front top rollers clearer over roving and breaking the rove during cleaning the lapping. Leaving the end well before the roller nip missing piecing. 66. 33 . Making too many attempts in piecing without cleaning the light apron lapping or roller lapping. 63. 61. 70. dropping waste over adjacent ends which affects quality or markes multiple break and the same time over twisting of that particular end. tape cut etc. 69.58. 62. 59. Not informing the concerned or raising the indication blade in time for rectifying the defects like defective spindles. 73. Holding the cop bottom for stopping the spindle and spoiling the cop and the empty inner side. 67. Missing the traveler while inserting and bringing another traveller. Trying to piece with out cleaning the bottom roller lapping. Over piecing during the first round of piecing after doffing cleaning the residual layers of yarn over the cop) (i. 72. 71. 60. breaking the end while inserting the cop and again taking the cop out for taking the end. Not cleaning the arbour waste while cleaning the roller lapping.
During power failure. 75. Not caring about the tape position over the spindle wharves even if it is in twisted condition.). cleaning and doing the piecing. standing idle with out cleaning the machine. Breaking the roving end while passing through the guides due to rough and hurried handling. Sometime leaving it as is and mending the break in the next cycle. 83. 88.( In this case both yarn and bobbin gets damaged. Not caring about the position of the rove guides / condensers. 80. 78. 76. Not keeping the pneumafil pipe in position. Lifting the cop unnecessarily from the spindle even when the yarn is available at the nose itself. Over. Piecing the yarn with out passing through the traveller. 81. Cleaning the heavy arbour lapping with hand and not using the hook provided for the purpose and wasting time. While passing the rove through second pair of rolls. 91. 86. Removing cop with out stopping the spindle by holding the top side. leaving the rove to fall down for sometime. 89. cutting the rove and then passing through the middle pair of rolls. 87. Not cleaning the pneumafil holes and leaving them as they are. 79. breaking the rove due to carelessness and making second attempt for guiding the rove through the second pair of rolls. Passing the yarn through lappet guide after the piecing is over. 77. Walking around the motor side while patrolling even when it not necessary.74. Working at poor rating. then taking the cop out. Cleaning the cop over the spindle itself after passing the yarn through traveller and lapper guide and breaking the yarn.twisting the roving end with both hands before passing the roving through condenser. 84. 85. Passing end through front rolls for piecing. 82. After passing the rove through back roll. 90. 34 .
110. Cleaning the machine with pads or cloth or gunny sheets. 101. Unnecessarily taking the bobbin from creel while attending creel break. Piecing the adjacent spindle end with this spindle and leaving this spindle idle. 109. Pulling the rove from inner side of the bobbin and breaking the rove few 103. 93. Many times bobbins fall down and get spoiled. Making fingers wet by touching the tongue or with sweat every time before taking the end from cop. 95. Crossing the roves while creeling. While cleaning roller beam. 102. 96. 98. breaking end due to carelessness. pulling-out few coils and taking end. Keeping the waist bag tied at back side. Not keeping the bottom and top roll clearers in position. Retracking the cycle unnecessarily for finding breaks. Making too many attempts for passing the yarn through lappet guide. 97. taking end and creeling. 108. 106. Sometimes they break ends also. times. Not noticing the waste collected underneath the lappet. then removing the bobbin out. that is threading to the adjacent spindle. 99. Not noticing the creel while attending the creel break and not cleaning the accumulated waste in the creels. 111. 35 . Making too many attempts for passing the yarn through traveller. 104. Not properly placing reserve bobbins / empty bobbins over creel. 100. 94. First passing yarn through traveller and then passing through lappet guide. Finding it difficult in getting the end from cop due to poor eye sight. Leaving the yarn waste inside the Pneumafil tube. While attending creel break.92. Breaking the yarn while passing it through traveller. 105. 107. breaking unnecessarily the adjacent end and doing piecing.
Not attending the breaks purposely at shift end and at shift beginning. 116. the concerned. cops. Piecing without cleaning the defective portion of the cop. 121. 114. Not releasing the top arm of the idle spindles. Releasing the top arm unnecessarily and keeping the spindle idle. Keeping extra clearers. Making an attempt to adjust the top arm roll pressure with out informing 117. 124. 126. Using sliver can for distributing full roving bobbins and collecting empty bobbins. 125. Not cleaning the traveller clearers.112. 119. 122. 115. 120.. Keeping the reserve travellers over roller beams / off-end /gear end etc. Pushing the bottom roller lapping waste to roller neck. Mixing hand waste along with bonda’s and Pneumafil waste. Adjusting the ratchet wheel while the frame is running. 118. 127. Keeping the windows and doors opened in a humidified shed. 123. wastes etc. Storing too many bobbins unnecessarily over creel in finer count frames. unnecessarily over roller beam or machine. Running the spindles / frame which are generating defective cops with out informing the concerned. 113. 36 . Pushing the top roll lapping waste to arbours.
19. 16. 20. waiting unnecessarily and standing idle till the other doffer arrives. 6. 15. Breaking the end while inserting the empties and increasing the starting breaks. 14. Working at poor rating 37 . Removing cop roughly and making slough off. Not bringing sufficient empties. Lack of co-operation between doffers.RING FRAME DOFFER 1. Breaking the end while piecing. 12. Breaking the end while doffing and increasing the starting break. Pressing individual empties after inserting the empties. 11. 5. 3. Using uncleaned empties. Not cleaning the spindles while inserting the bobbin even when there is a heavy spindle waste. 13. 10. Using damaged empties. Dropping the empties / cops in the alleyway or underneath the machine due to carelessness. Doing over piecing. Rough handling of containers / baskets. 2. Breaking the end while positioning the lappets. Not stopping the frame properly and thus leading to more back-wind length. Using mixed color empties. 18. 17. 4. Doffing many cops continuously and breaking the ends at a time creating cops entanglement. 9. Keeping the doff basket over floor and pushing it with leg while doffing 21. 8. Not inserting the empties properly causing bottom slough off. 7. Not arranging empty bobbins properly and wasting time while inserting the empties.
Not using the trolley provided for carrying the baskets/containers and carrying them with hands. 39. 31. 27. Using different types of empties. 34. Leaving loose empties.22. Not cleaning the loose ends / wastes from the spindle while attending the starting breaks which leads to multiple breaks. 38. 40. Doffing with dirty / oily / greasy hands. 23. 24. 29. 43. Using different count cops for gaiting the ends. 38 . 41. 35. Dropping waste over floor and not tieing the waist bag. etc. Not collecting the fallen empties / cops immediately. Dropping the cops underneath the machine or over the machine after gaiting the ends. Putting the cops used for gaiting the starting ends in a different count doff basket. Pushing the light roller lapping to arbour. 36. Using damaged baskets / containers. Dragging the basket / container over floor. Using dirty / greasy / fluff accumulated baskets / containers for doffing. Using dirty / greasy empties. 32. Mixing the fallen spoiled empties / cops (greasy. 37. Engaging doffers working at wide range of rating. 30. (using bamboo / cane baskets) 26. 42. 28. Using single hand for inserting the empties in the older method. Not piecing all the starting breaks. 25. Making an attempt to piece the end without noticing the creel run out / break. 33.) along with good cops. Keeping the doff basket/bag far away from the ring frame and wasting time in transferring the cops from container to doff basket/bags. Wandering here and there and observing the spindles unnecessarily after starting the frame without mending the starting breaks.
Piecing end with more length of yarn and making thick place. 59. taking the end from bobbin and holding till the fibers come out from the roller nip and because of this break. Standing at a particular place and awaiting for an end break. pushing with leg and bending every time for taking empties. Winding too much of length of yarn over the empty while gaiting ends. 63. 65. 49. or otherwise affects the quality. 46. 47. Missing the traveller while inserting the yarn. 55. Trying to piece when there is roller lapping. 57. Trying to piece the idle spindles. Wiping the hand waste over thigh or half-pant after piecing. Cleaning hands with good wastes. Keeping more length of yarn in hand while gaiting ends. 51. Trying to piece when the over head cleaner is passing. 58. 39 . Holding the cop in left hand and gaiting ends. 45. While attending creel break or run-out. holding the ring rail with fingers and taking more time. Keeping the empties basket over floor. Holding the cop in foot fingers and gaiting ends. 62. 61. Dropping soft waste. Changing end to other hand for cutting the excess end. 54. Dropping bonda waste down or over the spindle and affecting house-keeping. 64. 56. Keeping the empty basket over floor at a particular place and bringing the empties in hands every time.44. This practice also spoils the good waste and sometimes causes multiple breaks. 52. Dropping waste in alley ways. 53. (This waste flies and goes with yarn which affects quality) 60. While patrolling. 50. 48. yarn gets over twisted. Feeling the yarn tension with fingers for every piecing. Missing hand waste and causing multiple breaks.
Leaving the end well before the roller nip and missing the piecing. 84. head or ear or chest or shoulder and breaking. 86. 74. 85. 81. 70. Missing the end after getting from the cop while gaiting. Not cleaning the roller clearer even when there is heavy accumulation. 73. cleaning the lapping with other hand. Using knife for stripping the bobbins. 68. Wiping of the front rolls unnecessarily with one hand holding the cop end with the other hand. Trying to piece without cleaning the traveller waste. 72. 78. Leaving the end inside the pneumafil while piecing and missing the piecing or otherwise causing heavy thick place. 79. Breaking the end while getting the end from the cop for gaiting. Making too many attempts in piecing without cleaning the light apron lapping or roller lapping.66. Passing end through front rolls for piecing. 77. Trying to piece without cleaning the bottom roller lapping. 80. 82. 83. 40 . 67. 75. 69. 76. Missing the traveller while inserting and bringing another traveller. Straining unnecessarily by over stretching or bending while piecing. Pulling the end up to the waist. Not cleaning the traveller while piecing even when there is waste accumulation. Not keeping the pneumafil pipe in position. making too many attempts and then cleaning the traveller. 71. dropping waste over adjacent ends which affects quality or makes multiple breaks and at the same time over twisting that particular end. Not cleaning the pneumafil holes and leaving them as they are. Not using the waist bag properly for keeping the waste. Using knife for cleaning the bobbins. holding end in one hand. Using knife for cleaning roller lappings. While removing pneumafil waste allowing the waste to fly which results in deterioration in the quality.
87. Removing cop without stopping the spindle by holding the top side. (In this case
both yarn and bobbin gets damaged.) 88. Trying to clean the cop on the spindle itself.
89. Piecing the yarn without passing through the traveller.
90. Passing the yarn through lappet guide after the piecing is over. 91. Making too many attempts for passing the yarn through lappet guide.
92. Making too many attempts for passing the yarn through traveller. 93. Breaking the yarn while passing it through traveller. 94. First, passing yarn through traveller and then passing it through lappet guide.
95. Making the fingers wet by touching the tongue or body sweat every time before taking the end from cop. 96. Leaving the yarn waste inside the pneumafil.
97. Keeping the waist bag tied at back side. 98. Piecing the adjacent spindle end with this spindle and leaving the end idle. 99. Doffing the cops too early / very late.
100. Positioning the lappets after starting the frame. 101. Positioning the separators after starting the frame.
OPEN END SPINNING
1. Pulling too much of yarn from cone / cheese while piecing. 2. Making too much of sliver waste.
3. Transferring slivers unnecessarily. 4. Dividing a single can sliver into parts & transferring to different creel cans.
5. Not cleaning the defective portion of the cone / cheese. 6. Mending breaks with out cleaning the rotor. 7. Using fingers for cleaning the rotor.
8. Joining the slivers while mending sliver break or replenishing can.
9. Keeping side doors opened while running the machine. 10. Dragging the can over floor. 11. Following random can changing –method. 12. Not exhausting the can slivers fully. 13. Dropping the waste inside the can.
14. Not cleaning the droppings funnel properly.
15. Dropping the dropping wastes inside the can / over floor. 16. Not piecing the yarn properly while attending the break. 17. Over twisting the sliver end while inserting. 18. Piecing with dirty / oily / greasy hand. 19. Not cleaning the thread path (tube) and again repiecing it. 20. Not cleaning the waste wound on cradle. 21. Making delay in pressing the cradle.
22. Not giving priority for external elements. 23. Hurried pressing of cradle. 24. Not stacking the full cans and the sliver cans at proper places.
25. Not giving priority for the sliver break.
26. Throwing the sliver and other wastes in between cans.
27. Using good wastes for cleaning hands, cans and machines. 28. Keeping the department’s windows and doors open and affecting relative
humidity. Not maintaining the humidification plant properly.
29. Not creeling the empty cheese /cones /in time where automatic doffing is
functioning. 30. Not giving priority for the external elements, particularly for signals.
31. Bringing the cans by keeping the rotor idle for replenishment. 32. Not Keeping reserve starters and cans ready. 33. Keeping the cheeses / cones over machines or floors.
34. Collecting the doffed cones /cheeses immediately using the trolleys provided. 35. Not placing the count boards where too many counts cones are stacked.
36. Not affixing the suitable labels or the markings to the cones / cheeses.
37. Dumping the cones and cheeses and not stacking them properly. 38. Using damaged cones or cheeses.
39. Damaged cones /cheeses edges while doffing. 40. Not collecting the section waste in time.
41. Dropping the waste here and there and not tieing waist bag. 42. Going to the frame end for depositing the wastes for every occasion. 43. Not keeping the department tidy.
9. 23. 18. 12. Feeling the tension of yarn with middle and fore fingers after piecing. 2. Stripping more than one-eighth size cop and regaiting end. Leaving hand waste in air which goes along with the running yarn. 44 . 11. 3. Using knife for cleaning the cheeses / strips. 17. Keeping more wastes in hand while knotting. Missing the traveller while inserting the yarn. 4. Not tieing the waist bag. Keeping the waist bag over shoulder. Dropping the hand waste over floor. 13. Keeping the reserve cheeses /cones over guide rolls / roller stand / roller beam / gear end / off end. 6. Doing double gaiting . Not keeping the knotter clean. Passing away the ends down spindle with out attending the spindle . 7. Standing at a particular place and awaiting for an end break. Transferring waste from left hand to right hand and placing it in waist beg. 20. Trying to piece when the cones / cheeses have been exhausted. 16. Taking the cop out of the spindle and then piecing the end. 14. 5. 21. Making more hand waste. Pulling more length of yarn while taking end.RING DOUBLING TENTER 1. Not cleaning the defective portion of the cop / and running the spindle. 22. 10. 8. Doing foot for stopping the spindle. Using defective knotter. 15. Not passing the yarn properly through the passage. 19.
42. Breaking the end while taking from cop /cheese /cone. 39. 38. Breaking end due to carelessness ( while cleaning the roller beam) 43. Retracking the cycle unnecessarily for finding breaks. (In this case both the yarn and cop get damaged). Taking rest outside for ever few cycles or after every cycle. Patrolling the stopped frame (waiting for doffing) unnecessarily and wasting time. 36. Not lifting the cop slightly for taking end easily when the cop size is small and wasting time in getting the end. Cleaning the machine with pads or cloth or gunny sheets. 33. Keeping the traveller in the mouth and using them. 45. 40.24. 31. 27. Missing the traveller while inserting and bringing another traveller. 26. 34. head or ear or chest or shoulder and breaking. Walking up to the end of the frame even when attention is not required. 44. Walking around the motor side while patrolling even when it is not necessary. 30. 25. Adjusting the ratchet wheel while the frame is running. Not cleaning the traveller while piecing even when there is waste accumulation. Removing cop without stopping the spindle by holding the top side. Pulling the end up to the waist. 29. 41. 32. During power failure standing idle with out the cleaning the machine. Not caring about the tape position over the spindle wharves even if it is in twisted condition. 28. Not cleaning the spindle waste even if the waste is observed. 46. Lifting the cop unnecessarily from the spindle even when the yarn is available at the nose itself. Making too many attempts for passing the yarn through traveller. Not attending the breaks Purposely at shift end and at shift beginning. Keeping the waist bag tied at back side. 35. 37. Straining unnecessarily by over stretching or bending while piecing. 45 .
61. 57. 71. Unnecessarily taking the cheese / cone from creel while mending creel break. Hitting the bottom roll with top roller for cleaning the bottom roller Lapping. 46 . Not keeping the machine clean. 51. 54. Keeping the empties hear and there. 63. Poor rate of patrolling. Not Using the Knotter for knotting and putting knots manually with hands. Hitting the top roll against floor or machine for cleaning the top roller lapping. Leaving snarl ends. 50. 68. Leaving loose Knots. 52. Not keeping the indicator in position in the time for tape – cut. Mixing the wastes. Transferring the ends from one hand to the other unnecessarily. Rejecting the chesses even for very minor defects. Awaiting & standing idle till the cheese / cone gets exhausted.. 60. Using sliver cans for distributing the cheeses / cones. Keeping the reserve at a distant place and wasting time in bringing the cheeses every time 55. Using fluffs accumulated cheese / cone with out cleaning. 48. Pulling more length of yarn from cheese / cone. 53. 49. 56. 58. 62. Putting bigger knot and leaving lengthy ends when knotting with hands. 65. Leaving bigger Knots 67. 64.47. 69. Not cleaning the cheese / cone holder. 70. doffing etc.. 66. Cleaning the machine parts with good wastes. Not trimming the knots when it is specified. Carrying the cheeses / cones over handled and not using the given trolley. 59. Keeping too many reserve cheeses / cones and allowing fluff accumulations.
Not segregating the damaged empties. Generating too many cheese / cone remnants 75. 47 .72. 74. Not keeping the rejected cheeses / cones neatly and handling them roughly. Not cleaning the defective portion of the adjacent cop (Doubling defect). 73.
Pulling too much of yarn after knotting. 7. 8. Not cleaning the entangled cops at a time and wasting time for every cop. Pulling more length of yarn from cone. 20. 21. Failing to pass the yarn properly through the yarn passage in the first attempt and making additional attempts. 2. Making more hand waste. Leaving snarl knot. Following groups doffing method. Leaving hand waste with the yarn. Trying to find end from the nose of the fresh cop. 14. Waiting till a couple of cops are exhausted and then start replenishing. 9. 15. 16. Not cleaning the drum brush. 13. 3. 6. 4. Not cleaning the thread path. 19.CONE WINDING WINDER 1. 48 . 5. 11. taking end from cone. Not keeping the hopper clean. Changing the drums after checking the weight of cones and producing defective cones. 12. Leaving loose end. Transferring cop end to left hand. 10. 17. 18. pulling out and then getting end from left hand for knotting. Running different color empties on the same side of the winding machine and making the winder to drop the empties in containers. Carrying manually 4 to 7 cones for weight checking and dropping one or two cones over floor. Using mixed color empties for the same count. Using knife for stripping the cops. Dropping hand waste in alley ways/hopper/over cops etc.
30. 33. Winder pulling more length of yarn even in case of short length back wind cops. Empties overflow and get scattered over the floor. 24. cone holder problem. Not cleaning the knotter when the waste gets accumulated.. Using a defective knotter and making lot of knotter failures. 36. Not informing the concerned regarding the defects like stop motion fault. Not positioning ends properly in knotter and making knotter failure. 25. Making an attempt to mend the break or change the cop while over-head cleaner is passing. Finding it difficult to get the end yarn from the cop due to poor eyesight. 26. 37. Pulling knotted yarn upto ear or chest while leaving for winding (after starting the drum).. Not caring about the correct tension weights. Transferring ends unnecessarily from one hand to the other hand. Making too many attempts for creeling cop in the skewer. 49 . Not cleaning the light drum lappings. 35. 31. Not operating the starting handle properly in the first attempt and making additional attempts. Transferring cop from one hand to the other hand unnecessarily. pulling out few coils and then taking end from the cop. Dropping the empties down instead of leaving it over the running conveyor. 41. 34. 27. Rotating the cone with fingers too many times. 23. 29. 28. 40. Taking end with left hand from the cop. Not exchanging the empties collecting tray in time. Dropping full cops/empties in alley ways or underneath the machine. 32. 38.22. Winding 2 to 3 coils over four fingers unnecessarily after passing the yarn through the passage. etc. 39.
While leaving the yarn for winding. Breaking the cop end while positioning the ends in knotter.42. not leaving it properly inside the groove and making additional attempts. 60. Making hand waste immediately after inserting the cop. 55. Cleaning the thread path while the yarn is running. Using fluffs accumulated cops without cleaning. 63. Wasting time in collecting cops even when a service man is provided. 59. Depositing hand waste in waist bag after every knot. some times after starting the drum. 50 . Working at a very high pace and taking rest by standing at the side of the machine or disturbing other winders. Missing the cone end while positioning the ends in knotter. 43. 46. 54. 62. Holding the starting handle for a long time. 57. 58. 53. 45. Mixing the defective / part cops with the good cops and rejecting the same cops again. 49. Not passing the yarn below the tension weight in the first attempt and making additional attempts for this purpose. Throwing the yarn over cone without knotting. Throwing the yarn over empty cone after starting the drums. Not working efficiently after achieving the standard production. 56. Not keeping the slub catcher clean. Standing idle till the shift end as soon as the production accounting is over. 48. Passing the yarn below the stop motion wire after knotting. 61. 51. Dumping the cops at a particular place of the hopper and walking for taking every cop. Not cleaning the defective portion of the cone and winding it as it is. 52. 44. 47. 50. Breaking the yarn while leaving for winding and again knotting. Stripping the cop before changing the cop and starting the drum.
Transferring the cop end from right hand to left hand after insertion. Not checking the tare weight and using as it is. 81. Keeping the weighing balances far away from the winding spot. 65. 51 . 83. 72. 75. 70.. Taking too much of time for cone weight checking. Giving unproductive jobs like repairing empty cones. passing the yarn through left hand again transferring to right hand. weighing cones and stacking at packing. 69. Not keeping tension unit clean. 73. Using damaged weighing balances. Using compressor air for cleaning the machine and thread path by keeping the cops and cones in open air. Doffing too heavy or too light cones. Not keeping the weighing balances clean. Carrying only one or two cones for checking cone weights running excessive length of yarn without checking weight and not rewinding the same. Making hand wastes after positioning the ends in the knotter. Providing the lesser number of balances for cone weight checking. Too many winders standing in queue at a time for cone weight checking. Dropping the cones over floor while weight checking. Keeping the cop containers in the machine alley and taking cop from the container by turning every time. bringing cops. Depositing the empty bobbins inside the crates and not using the conveyor for this purpose. 77. 74. Collecting the cones in Hessian bags and carrying them over shoulder or head. 67. 76.64. Putting knots using fingers and not using the knotters for this purpose. Not inspecting the zero error on weighing balance. 82. Not collecting the fallen empties and cops immediately. 78. 79. 66. 71. to winders and affecting machine productivity. disposing empties etc. 68. 80.
104. 88. 98. Working with dirty and stained hands. 101. Using compressor air for cleaning while the cones are running.84. Making an attempt to clean the running cones/drums. 93. Putting bigger knots. 52 . Keeping the cones over uncleaned hopper. Running the machine at lesser effective winding speed than the standard speed. 95. Using damaged empty cones. 102. 96. Mixing the damaged empties with good empties. Wearing loose full-hand shirts and working on the machine. 92. 90. 89. Checking the cone weights which are going for doubling. 97. 87. 103. Holding the running cone and feeling with fingers unnecessarily while the cone is running. 106. Making count mix-up. Moving the cop carrier along with winder while going for mending breaks. Not keeping cop carrier wheels or bearings clean and not maintaining them properly. 94. Not passing the yarn through the slub-catcher and winding. 86. Using damaged plastic crates or baskets. 99. 100. Keeping the cones over hopper horizontally. 85. Holding the cone holder some time after starting the new cone. Handling cops/cones and empty bobbins roughly and damaging them. 105. Making the finger wet either by touching the tongue or sweat for taking end from cop/count. Not tying waist bag. Not using the cop carrier. 91. Dragging cop crates or baskets over floor or carrying them over shoulder or head.
Using the wax rounds which are accumulated with dust and fluffs without cleaning. Not cleaning the cones with brush while it is running and taking more time for cleaning the cones after doffing. Winding the high-twist yarn which are to be steamed with out steaming. 122. Using knife for cutting the drum lappings and not using the hooks provided for this purpose. 112. 124. Damaging the drum shafts and cone spindles while cleaning wastes wound on them. 115. Disposing the cones without marking the ticket number. Distributing spoiled doffs to all winders and affecting productivity. Spending too much of time for adjusting the dress.107. 110. 125. Spoiling the good wax rolls. Bringing too much of wax rounds and keeping them over hoppers or window sills. 117. Not keeping the conveyor and conveyor pulleys clean. cutting the yarn with knives and making then wastes. 114. 113. Using empty cone with different count label. 108. 120. 53 . Rejecting too much of strips and bottoms and accumulating them. Running the cone without wax which has to be waxed. Spoiling the cone labels while inserting it or handling it. Running the cone holder without empty cone. 111. Rejecting too many strips and bottoms. 127. 116. Not lubricating the mechanical hand knotters in time and not maintaining them properly. Not making the wax rounds to rotate when it is not rotating. 126. 109. 123. Not cleaning the drum shaft and cone spindle lap wastes immediately. Mixing the winding count cops along with reeling count cops and conditioning them. 118. 119. 121.
cops. 6. 19. Using knives for cleaning the drums. Accumulating the rejected cops. 12. 4. Not moving the container along with the winder while creeling. Rubbing the strips over machine frame and cleaning. Dragging the empties container. Wasting too much of yarn while cleaning cops and cones. 5. 14. 17. 7. Keeping the container over the bigger container and dragging them. Moving the container along with the winder while going for rectifying the signal faults. Not cleaning the knotter arms immediately when it is essential. Keeping the container on right hand side and transferring cops a from right hand side to left hand side for unwinding the backwind length. 9. 11. 18. Not keeping the reserve empty cones/cops readily in magazine creel.AUTOCONER WINDER 1. 13. Keeping the container on right hand side & turning for getting cops from container (few winders) 8. Breaking the end while making end. 55 . 20. 3. Not holding the middle of the cop while making end. Not giving priority for signals. Keeping the hand faraway from magazine creel while making end. 16. 15. Leaving too much of yarn inside the suction tube. Not inspecting the knotters arms. 10. etc. Keeping the cops in armpit and creeling them. 21. Not attending the sorting table in time. Creeling the rejected cops without rectifying the defect. 2. 22. Starting the signal drums without rectifying the defect properly.
35. 32. 41. Doing early doffing when doffing the cone manually. Dropping the cops or empties underneath the machine and not collecting them immediately. Not attending the faulty start-up drums immediately. Leaving very small problematic drums idle. 37. Not keeping the yarn clearer clean.. Dragging the cop’s crate. 25. Making an attempt to move the doffing carriage/splicing carriage when there is some struck up or jam without rotating the handle in clock-wise direction. 33. 29.g. 26. Not adjusting or arranging the cones while collecting them in trolley/containers. Making the doffed cone to fall down while pushing towards the conveyor. Not operating the top side rod immediately when there is some problem in the splicing carriage. 38. 40. Creeling different count cops in the same magazine and causing count mixup. 34. 27. Starting the machine without checking the pilot spindles. Not using the given devices (e. Not depositing the waste inside the waist bag and dropping them over floor or leaving them inside the suction tube. 39. 28.23. 24. Not attending the conveyor drums immediately. 31. Lifting the cone holder too much and causing the automatic doffing mechanism to actuate the auto doffer and not pressing the button immediately and causing the auto doffer to doff the part cone. 30. 56 . Johnson bud) for cleaning the yarn clearers. Starting the machines after power failure without releasing the doffing carriage/splicing carriage locks. Using damaged empty cones. Not keeping the splicing carriage wheels clean. and cleaning them with hand or waste. 36.
reversing shaft. Using the dust and fluff accumulated wax without cleaning. 49. 52. 50. 53. Not changing over the knotters/splicer meter knob according to the shift. 55. 48. 43. Generating too much of part and rejected cops. Creeling the double gaited/ring cut cops without rectifying the defects or unwinding defective portion. Throwing or dropping the damaged wax rounds or the pieces of wax underneath the machine or above the machine or inside the plastic crates or on any other containers. Running the count which is to be waxed without wax. Not winding the tail end or not leaving the sufficient length of yarn for tail end in case of export cones or weaving cones while doing the doffing manually. 44. Bringing too much of wax rounds and wasting them. Not filling water in wet splicer and not releasing the air from the tube in time. 54.42. Not collecting the suction waste as per schedule or as instructed in time. 45. Mixing the strips and bottoms along with the empties and disposing them as they are. Not checking the pilot drums before switching on the machine. driving shaft etc. Keeping the wax rounds over machine or cops or over window sills. 57 .. Not keeps the cradle holder. clean. 47. 51. 46.
17. 58 . Using different color empties for the same count and running them at a time. i.e. Not cleaning the light drum lappings immediately and producing the cheeses continuously over the same drum. 16. 3. 9. 7. 15. Not passing the yarn in the first attempt itself properly through the yarn passage and making additional attempts. loading the empty cheeses and then starting the drums one by one. Trying to find out the end from the nose of a fresh cop. Producing cheeses on the drums where the stop motions and the cradles are not functioning effectively. 2.DOUBLER WINDING WINDER 1. 14. Putting the not manually and not using the knotter. 10. Generating more hand waste. 4. Following group doffing method. Using knife for cleaning the cops or bottoms. 12. Standing idle at a particular place till a couple of cops are exhausted and then starting replenishments. Not cleaning the entangled cops at a time and wasting time for every cop in cleaning. Then wasting time in segregating the empties color wise. 8. Not keeping the thread path clean. 5. Throwing the hand waste over alleyways or over the cops or over the machines. Not collecting the cops or empties which are fallen over the floor or underneath the machine immediately. 11. Leaving hand waste along with the running yarn. Pulling more length of yarn from cheese. 18. 13. Pulling the knotted end upto ear or shoulder or head while leaving for winding. Dropping cops and empties in the alleyways or underneath the machine. doffing all cheeses by stopping the machine. 6.
Using the knotter without cleaning even when there is a heavy accumulation of waste. Stripping the few layers of yarn from the run out bobbins before starting the drums and affecting the machine productivity. 33. Throwing the end over running cheese without putting knot. 34. 22. 25. Cleaning the thread path while the yarn is running. Not cleaning the defective portion of the cheese and running as it is. Pulling more length of yarn from the cop even when there is only a little quantity of backwind yarn. Breaking the yarn while leaving it for winding after knotting or splicing. Changing the cops quickly and going away from the spot or chit chatting with the neighbour winders and affecting their work. 59 . 24. 23. Unwinding the back wind yarn with left hand by holding the cop with right hand. 37. Making too many attempts for creeling the cops. 26. 29. Breaking the ends while positioning them inside the knotter. 28. 20. Operating knotter before positioning the ends properly inside the knotter and making knotter failures. 36. 27. Using defective knotters. Transferring end from one hand to other hand unnecessarily. Changing cop from one hand to other hand unnecessarily. 35. 32. 31. Not doing any work after taking the standard production. 21. Mixing the spoiled cops or part cops with the good cops and wasting time in getting good cops.19. Holding the cheeses while they are running and feeling the speed unnecessarily. 30. Finding it very difficult to get the ends from the cheese and the cop due to poor eye sight and taking end by cutting few threads or pulling out few coils of yarn.
Collecting the cheeses in gunny bags and carrying them over shoulder or head or in waist. 48. Mixing damaged empties with good empties. Making count mix-up. 54. 51. 47. empties. Winder wasting time in getting cops from spinning even when a service man is provided for this purpose. 46. cheese centres and the containers roughly and damaging them. Working with dirty/oily hands. 60 . empty cheeses centres. 43. Cleaning the alleyways and machine with compressed air by keeping the cops and the cheeses in the open air. 39. 53. cones and disposing the full chesses and empties to the winder and affecting the machine productivity. Pulling the yarn after positioning the ends inside the knotter. 41. 55. Dragging the cop containers over floor or carrying them in hands or over shoulder or over head or in waist. Handling the cops. 56. 40.38. Not working after the production accounting is over. Not using the waist bag for dropping the waste. 49. Using the fluff and dust accumulated cops without cleaning. Giving the indirect jobs like bringing cops. Using damaged containers. Running the machine at lesser speed than the standard speed. Using damaged cheese centres. 44. Pulling more length of yarn after creeling the cop and thereby not only wasting time and also generating more hard waste. Wearing loose full hand shirts and working on the machine. 50. Making the fingers wet either by touching the tongue or sweat every time for taking the ends from the cop. Not tieing the waist bag and wasting time in dropping the waste. 42. 52. 45. generating more wastes and wasting time.
Bringing too much of cones or cops to the winding machine and keeping them in open air. 61. Distributing the spoiled/part cops to all winders and affecting the machine productivity. 67. 65. 69.57. 58. 63. Putting big knots or knots with waste. Putting knot and starting the drum for the yarn which is to be spliced. 59. Holding or touching the cheeses while it is running. 71. Stacking the cheeses without the winder’s ticket number. Throwing the cheeses inside the trolley while doffing by keeping the trolley at a distant place. 62. Stacking the cheeses in a dirty place. Using fluff dust accumulated cones without cleaning. 61 . 74. (Fluff and dust get accumulated over these cops/cones). 76. Throwing the damaged cheese centres here and there. Damaging the drum shaft and the cradles while cleaning the waste from them. Not applying the lubricants to the knotters and not maintaining them properly. 72. Not unwinding the singles or four ply from the cheeses and running it as it is. Using the cheese centres which are coming with few layers of yarn without cleaning. Doffing the cheeses and disposing them without affixing count label or putting the respective marking. Holding and pressing the cradles for some time immediately after starting the new cheeses. 60. 68. 75. Wasting time in frequently adjusting the dress. Not cleaning the waste wound on the drum shaft and the drum shaft and the cradles. 73. 70. 64. Cleaning the cheese or drums while they are running. Not stacking the cheeses or cones properly and dumping them in a particular place. 66.
Not cleaning the few layers of yarn left over the empty cone and disposing them with the yarn. 62 . top roller and bottom roller properly while gaiting the end. yarn guide. tension bracket. Using knife for cleaning the drum lappers and damaging the drum grooves. 79. Not cleaning the waste accumulated at top roller and bottom roller with hand and using knife for this purpose and damaging the rollers. Not keeping the machines and surroundings clean. Not covering the stacked cheeses and keeping them in open air for long period. Not passing the yarn through slub catcher. 82. 78. 81. 84. dropper bin. Not pulling the yarn while leaving it for winding and allowing loose ends or snarls and producing defective cheeses. 80.77. Cleaning good remnants with knife and waste them. Not exhausting the supply cones fully and generating remnants. 85. 83.
Making more hand waste. (Yarn slips). 22. Poor rate of patrolling. Not maintaining the knotters properly. Not keeping the knotter clean. Damaging the pot by rough handling. 17. Not passing the yarn properly through flyer. 20. 19. Dropping waste over floor. Putting big knots. Not winding the yarn over the wire tail-end properly. 14. 24. 5. Damaging the empties by rough handling. Applying break for longer period. 18. Not inserting twist for the untwisted portion of yarn while piecing. 16. stop motion wire. 15. 9. 4. 10. Using damaged/defective knotters. Not keeping the flyer unit clean. Not keeping the work spot/machine clean. Winding too much of yarn over the threading wire. 2. Using bad wire and taking more time for inserting it. 13. Not keeping the traverse guide clean. 12. 11. Not cleaning the defective portion of the cheese/cone. 6. Leaving the knot with loose ends. 63 . 8. Dropping the wastes inside the pot.TWO FOR ONE TWISTER WINDER 1. 23. Not positioning yarn properly inside the knotter. Carrying cheese/cones over hands. 3. 21. Altering the tube setting while mending break. 7. thread guide.
26. Leaving the hand waste along with the running yarn while leaving the yarn by carrying more hand waste. Not covering the doffed cones and leaving them in open air for long time. (Fluff and dust get accumulated). Disposing the doffed cones without label or marking. 64 . 27. Affixing wrong labels or putting wrong marking for the doffed cones and disposing them. 38. Not giving priority for the awaiting drums and doing some internal work like cleaning. Working without waist bag. 28. 36. Causing snarls while leaving the knotted end. Following group doffing method.25. 31. Not informing the concerned immediately when small problems or repairs occur. Unwinding good cones/cheeses and making them waste. Not exhausting the feed cones or cheeses fully. 30. 37. Not keeping the empty cones and reserve feed cheeses readily and bringing them by stopping the drums. 35. Not cleaning the few layers of yarn over the exhausted cone or cheese and disposing them as they are. 33. 34. 32. Not cleaning the dust/fluff accumulated cones and cheeses and using them as they are. 29.
Generating short length hanks by carelessness. particularly the brush while the reel is running. Using lesser or more number of threads than the specified for tieing. Rotating the reel in the opposite direction for finding the ends. Not keeping the brush. 9. Breaking the ends while doffing. 15. Making more hand waste. 20.. 19. 22. 10. Making mistakes at the time of grouping. 3. Taking too much of time for finding the end from the hank. 7. Not making up for the short length hanks. 23. 11. 16. 21. Cleaning the reel. 65 . 4. Dropping the trimmed wastes over brush (which goes along with the yarn while running). Returning to the other end after interlacing for trimming. Rough handling of doff baskets/containers.REELING REELER 1. clean. 14. 12. Running too much of length while making up for short length. 8. Not tieing the off end and tail end with the interlacing thread properly while tieing. 2. Throwing the yarn over the running reel without knotting or splicing. Depositing empties in the doff basket and mixing the cops and the empties. 5. creel board hopper etc. 17. Breaking the ends during interlacing. 18. Not dividing the hank uniformly while putting the cross ties. 13. Splicing the ends when knotter is given. Cutting few threads and taking the end from the hank. Using unconditioned cops (when it is essential). 6. Not trimming the excess length of tie when it is essential.
43. 66 . Not rectifying the hank entanglement defects and mixing them with good hanks. Not positioning the ends properly inside the knotter. Not keeping the knotter clean. Not keeping the tie yarns at the hip. 40. 38. Using very lengthy tie yarn (cutting the tie yarn more than the specified length). 41. 47. Rough handling of wooden staves. Missing the tie yarn or ends while tieing after interlacing. Causing count mix-up. Storing excessive cops/hanks for next shift. 46. 33. 25. 45.24. 37. Making more waste while cleaning the cop. 42. 32. 27. 29. Not tieing the waist bag. Not stripping the cop bottoms. 26. Dropping the waste over floor. Taking too much of time for interlacing. Using knife for cleaning the cops/bottoms. Not tieing the waist bag in the right side of the hip. Starting the interlacing from the centre and returning to the centre again after completing first half. Wasting tie yarns. Inserting the fingers inside the hank after taking the tie yarn from the hip. 31. 30. 28. 39. Counting slowly while grouping and wasting time. 36. 35. Keeping the hanks/knots over floor or over reels. Keeping the hank too tight and doing interlacing. Using a defective knotter. 34. Doing the knotting and bagging operations by keeping the reel idle (externally). 44.
50. 67 . 55. 54. (Poor rating & wrong work method). Dropping the trimmed waste and hand waste on creel board/hopper. 58. 65. 63. 62.. 59. 61. 68. Mixing the different color empties. Cleaning the cops/cops bottoms etc.48. 69. Keeping the cops over floor or gunny sheet and not using the given basket/container. Missing the end while gaiting. Not gaiting the ends properly which results in re-gaiting and short length. 64. 49. and running the reel as it is. 53. 60. Making lot of unnecessary movements. Mixing the defective/rejected cops with good cops and again rejecting the same cops. damaged staves/leather straps etc. Using cop for positioning the rack. Taking too much of time for positioning the worm and worm wheel rack and creel board. Using fluff accumulated/spoiled cops without cleaning.. by keeping the reel stopped (externally). Not informing the concerned regarding the belt slackness. Dragging the baskets/containers/bags over floor. 56. 51. Keeping the cops/empties over floor or on the creel board. 66. Using damaged baskets/containers. Finding it difficult in taking the tie yarn from hip. Changing the cop end from one hand to the other unnecessarily. Leaving the spot or not watching the reel when the reel is running. Running the reel without inserting leather straps. while grouping. Carrying the doff baskets/containers/bags in hands or over shoulder/head or at hips and not using the given trolley. 52. One reeler looking after two reels and generating short length hanks. 57. 67. Not collecting the grouped hanks and moving over staves simultaneously.
74. 73. Not keeping the trench. Using blades for trimming interlacing threads and tie yarns. Not keeping the reels and surroundings clean. clean. 71. 72.. pulleys etc. Sloughing-off the cop and pull out the yarn for taking end. side shafts.70. 68 . Not cleaning the strips and mixing with empty bobbins.
(one man holding the gum paper. 7. Preparing the packing materials for every bag/carton. Stenciling the packages after packing. 18. Stitching very closely while stitching the bag manually. 16. Dumping the cones on uncleaned floor or on dirty Hessians. 5. Not keeping the light/heavy cones readily near the balance for making up the package weight. Tearing the sealed side of alkathene bag and inserting the open side of the alkathene bag while covering the cones. Using dirty alkathene covers. 2. Damaging the cone label while putting the inserts. Using too many stencils for stenciling common details. Not keeping the packing spot clean. Not using the floor level balances for weight checking. 9. 15. second man holding the water trough. Throwing the cones while packing or transferring from one place to another. Not mending cone tail end. 12. 17. 6. 14. 20. 11. 3. 8.CONE PACKING CONE PACKER 1. Two to four men are engaged for pasting gum paper while preparing cartons. 69 . Keeping the cones in open air. Two to three packers working on a single package and making unnecessary delays. Not fixing the discs/inserts properly. 19. 4. 10. Using damaged Hessian bags/cartons for packing.(Fluffs get accumulated) 13. Not stacking the cone bags and cartons properly. Cutting Hessian cloth and alkathene sheet approximately by measuring with hands and wasting time as well as materials. third man applying water for gum paper and the fourth man holding the carton).
34. 40. Damaging the cones while hammering the nails. 29. 35. Not cleaning the used brushes and keeping them with stenciling solutions. Packing loose bags. 26. 30. 43. Stitching all the three sides manually in bag packing. Using bigger size and heavy Hessians for packing. Using damaged stencils. Getting packing materials for every carton/bag from a distant place. 37. Using very small brushes or hand wastes for applying the stenciling solution while stenciling. 31. Using baskets covered with Hessian cloths for handling the cones at packing. Not segregating the too heavy and too light cones and mixing them with goods cones. Using damped packing materials. Using improper design of fixtures at packing and wasting time. 27. Breaking the wooden cases while hammering the nail. 38. Using cotton thread for stitching.21. 39. Keeping the stitched bags and other prepared materials here and there. Not keeping the stencil pads clean. 28. Not sticking the labels properly. Preparing too much of stenciling solution and wasting them. 32. 24. Not cleaning the fluff/dust accumulated cones and packing them with fluff and dusts. 36. 23. 42. Tieing the cone bag with coir rope for tight packing. 22. 25. Using bigger size and heavy alkathene bags and sheets. Wasting hoop irons and nails in case of case packing. 70 . Not maintaining the cone weights at winding and rejecting too much of cones at packing. 33. 41.
53. Not lubricating the packing trolleys and other trolleys as specified and not keeping the material handling equipments clean. 49. Damaging the cones while putting the disks/inserts. Using the balance without adjusting the zero error. Stenciling wrong bag number or weights. 51. Dragging the cone bags and carton over floor or carrying them in hands. 55. 71 . Not mending the tail end and packing the cone without tail end or without joining the sufficient length of tail end. Not keeping the weighing balance clean. 58. Damaging the cones while stitching the bag with nails. Packing with dirty/stained hands. Staining the cone with gum while pasting the label. 54. 47. Using sticky nature of alkathene bag and finding it difficult for opening it. Using damaged material handling equipments. 50. Using the weighing balance without checking the tare weight. 48. 45. Wasting the lead seals and iron strings. 56. Throwing the hoop iron pieces and nails here and there. 46.44. 52. 57.
Not maintaining the pressing/baling machines well. Using damaged/spoiled packing materials. 18. Dumping too much of knots over table. Using damaged stencils. 11. 5. Standing idle when the baling machine/pressing machine is working. 21. handling them roughly and spoiling.. Not keeping the balance. Handling the knots/bundles with dirty/oily/greasy hands. 20. Not stacking the bundles neatly and dumping them here and there. 2. (This leads to wastage in packing materials). Bringing excessive quantities of materials. 7. Not handling over or not replacing the excess materials at shift end. 19. Not keeping the low weight and excess weight knots readily at the time of weighing and wasting time. Not keeping stencils/brushes clean. Mixing the hanks by carelessness. Lack of co-operation among bundling & baling operatives. 12. 72 . 3. 8. clean.BUNDLING & BALING ATTENDANT 1. 6. 4. 10. 14. table. Cutting excessive length of thread at the time of bundling and stitching. bin etc. Using too many stencils for stenciling a common detail. 9. Not keeping the materials ready and going out of the spot frequently for bringing the materials. 15. 17. Cutting the packing materials by approximate measurements. Spoiling the alkathene bags by rough handling. Not scutching the hanks well. 13. Not mending the breaks in the hank. 16.
33. Scutching the hank unnecessarily too many times. 29. Cleaning the face. Wasting time in placing the dressed knots far away from the pole every time. 30. 35. 24. 23. Keeping the knots on right hand side. Not inspecting the inter-lacing thread. 32. Walking over the knots. Using the knots for cleaning the floor and the table. 34. Taking only few knots from floor or from the stack at the time of scutching and wasting time. causing mix-up and wasting time in segregating them count wise. 39. 28. 41. Using single hand for moving the dressed knots towards bundling presser and wasting time. Taking too much of time for arranging the knots over table after scutching. Arranging the dressed knots for every two or three knots and wasting time. 37. 42. Taking the knot with foot fingers. 36. 31. Breaking the ends while scutching the hank. hands and other parts of the body with knots. Keeping the knots far away from the scutching poles and wasting time in getting the knots every time. 40. Throwing the bundles over dirty/ dust accumulated floors. taking the knot with right hand and transferring to left hand for scutching. tie yarn and the loose ends while scutching and knotting. 25. 27. 26. Wearing rings in fingers and scutching the hanks (some times breaking the end because of rings). Stacking the knots over dirty/stained floors. Using very lengthy thread for tieing the bundles. Making too many body movements unnecessarily during scutching or bundling.22. 73 . 38. Breaking the ends while arranging the knots inside the bundling press. Keeping different count knots very nearer.
47. Operating the pressing levers with hands and not using the rod or handle provided for this purpose. Handling the knots roughly and causing entanglement.43. Using single needle in stitching the bale. 74 . 50. Not operating the presser levers simultaneously while the presser is running and taking separate timings for this purpose. Not arranging the threads simultaneously while the presser is running and taking separate timings for this purpose. 45. Dragging or rolling the bales over floor for a longer distance. 48. 49. bringing one or two at a time and wasting time. 44. going from one side to other side of the bale unnecessarily for getting the needle. 46. Finding it difficult to insert the thread inside the needle. Not bringing all the four threads towards front side simultaneously.
15. 19.. 23. Not repairing the damaged equipment / tools in time and using them as they are. Handling the materials with dirty / oily / greasy hand. Cleaning individual parts instead of mass cleaning using cleaning trough. 10. etc. wastes.. tools. 75 . Not keeping the tools and equipments ready. Not using the right tools / equipment for lubrication and cleaning. 18. 3. 22. Not removing the cops while cleaning in ring spinning. Omitting some lubricating parts while lubrication and cleaning. 4. Lubricating unnecessary parts. 9. 11. Wasting the lubricants. Not cleaning the parts before lubrication. 20. Using hard waste for taking kerosene from barrel / can. 12. 6. grease etc. Spilling the lubricants over floor / machine. 8. Cleaning the roller necks with hand and wasting time. Not using the waist bag. Using bobbin bottom for removing the old travellers. Not informing the concerned immediately for rectifying the defects / replacing the parts. 21. 7.CLEANING GANG 1. Not cleaning the oily / greasy floor immediately. Frequently going out of spot for bringing equipments. 5. 16. 17. Not cleaning the grease nipples / bearings after lubrication. oil. 2. tools. 13. Not cleaning the creels. 14.. Applying excessive lubricants. Not using the clearer roll cleaning machine for roller clearers and cleaning them with hands. roughly. Handling the equipments.
Scratching or nicking bearing surfaces. floor. Making the fluffs fly by using compressed air etc. over window sills. sheets or HDPE 28. 46. 44. 30. Spinning the uncleaned bearings. Wasting time in applying the grease to the greasing point without grease nipples. Removing grease or oil from new bearings. 32. Using cotton waste or dirty cloth to wipe bearings. Applying the grease for the bearing without cleaning. 47.. machine parts by rough handling / careless cleaning etc. Damaging the machine. Using incorrect kind or amount of lubricants. 40. 31. Using same container for cleaning and final rinsing of bearing. Oiling the oil holes without rectifying the air bubbles and wasting the oil. Not cleaning the spot after cleaning. 29. 45. Poor cleaning of machines. with alkathene sheets while cleaning. Piecing the ends with dirty moist hands. 76 . 36. Cleaning the moving parts while running. Using good materials for cleaning.. 39. Leaving the oiling point and the greasing point without cap or grease nipple respectively. Lack of co-operation among workers.. 38. and affecting the near by running machines. 42. Exposing bearings to moisture or dirt. 25.24. 35. 34. Keeping the cleaning equipments / spare parts etc. 41. 27. machine etc. 43. Not covering the bobbin / cans / laps etc. 26. 33. Cleaning or spinning the bearings with compressed air. Handling the bearings with dirty moist hands. 37. Removing new bearings from their packages unnecessarily.
Wasting time in cleaning the cleaning parts again and again. 50. 77 .48. 53. 51. Using incorrect equipments or tools for cleaning the oil tubes and damaging them. Cleaning the cleaned areas or the nearer areas with compressed air and causing the dust and fluff to accumulate over the cleaned parts and wasting time in cleaning these portions again. Not checking the oil levels. Not cleaning the oil tubes. 49. 52. Allowing lubricants to remain exposed and get contaminated with dust and fluff.