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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.
Enjoying additional time for taking tea.36. empty bobbins. 37. spares. bobbins. 43. Dumping the materials. Using sharp knives/saw toothed wires or blades for cleaning the roller lapping. 39. tubes. Making a heavy thick place or thin place while piecing. saw toothed wires. etc. for cleaning the waste. 47.. 44. 48. 53. 4 . etc. Using the machine for production without rectifying the defects. 46. 41. Not following the educated/trained new methods and switching over to the original or old method gradually or immediately. and not using the equipment/tools provided for cleaning. Not using the safety devices properly while working. smoking. 50. Going to the next section for taking tea and wasting time. 55. Damaging the empty bobbins/cheeses/cones/rolls/drums/shafts by using sharp knifes. 38. 52. cops. 40. Running the machine without mounting the motor properly.. in a corner or any place and keeping them as they are for a long time unnecessarily. adjusting dress etc. Not informing the concerned immediately after the breakdown and standing idle or else running only the remaining machines. Taking more than the stipulated time for personal needs. 51. Using a part of the machine for production. Generating too much of waste while piecing. Running the machines with less number of belts. hooks. drinking water. 42. Removing the can spring. top cover from a good can and using it for carrying the samples to quality control department. Cleaning the parts while the machine is running which are to be cleaned after stopping the machine. 45. Interchanging the machinery parts without the permission of the concerned person. Running the machines with defective belts or ropes. tools etc. Cleaning the running machinery parts while the machine is running. spitting. 54. Damaging the can spring covers by rough handling. 49..
Not maintaining the oil level of the spindle bolsters at optimum level. doors. Keeping the ceiling too above than the recommended one. 59. Not cleaning the fans. 73. 68. 69. 65. Running the machine at very slow speed. Cleaning the machine parts by keeping it idle which can be cleaned while the machine is running. Unqualified workers trying to rectify the electrical repairs. Improper planning of lighting arrangements. 58. clean. Using higher horse power motor. 72. 62. 66. 63. 70. windows and ventilators of the well humidified shed open while the plant is running. Keeping the doors. 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. Winding defective motors and using them. motors. 61. Running the empty machines unnecessarily. windows. pillars etc. etc.56. Running the machine beyond the optimum speed. Not overhauling the motors as per the recommended schedule. 60. starters. Not replenishing the spindle oil in right time. 5 . ventilators. 57. lightings. 64. 67. Improper winding of motors. Not keeping the roofs. Depositing the wastes here and there and not using the equipments provided for them. 71.
6 . After removing the hoop irons and Hessians. Wasting time in unloading. Keeping the mixing area and the path congested. 8. 9. disposing materials etc. Working at very low rating particularly at the time of opening and preparing stack mixing. dust cotton etc. 4. keeping the bale over floor.. Few attendants just standing near the lorry and watching others. 17. Not maintaining the materials handling equipments properly. 12. 19. Mixing the unopened roving waste with the stack mixing. 2. 3. 5. 10. Not removing the foreign materials. 15. 14. taking tufts of cotton from bale with one hand and distributing over mixing and taking too much of time for distributing the cotton. Dragging the cone bags and cartons over floor. Handling the materials handling equipments and other equipments roughly. 11. 18. Moving bales over floor to a considerable distance and not using the trolley. 13. Not stacking the hoop irons while opening the bale. 6. 7. Throwing the Hessian cloth without removing the adhered cotton. Not planning properly before starting the work and wasting time in bringing materials. Cutting the hoop irons while opening the bale. Standing idle over stack mixing and waiting till the bale is opened and transferred to the mixing. Two or three men moving a single bale placed in hand-truck on a plain road. while opening the bale and preparing the mixing. Hessian bits.GODOWN & MIXING ATTENDANT 1. Two or four men working at a single bale for removing the hoop irons/Hessian cloth and wasting time. Not opening the wastes (lap bits and slivers) and fibers while preparing the mixing. Taking too much of time in cleaning the Hessian (poor rating and method). 16.
Stacking the bales inside the go down after unloading and again bringing them out for weight checking and then taking them inside the godown. 26.20. Spraying the oil mixer improperly. Neatly arranging the bales near lorry after unloading and then taking them to the godown or for weighment. 23. Waist bags are not used during mixing operation. Preparing the oil mixer after finishing the first layer of mixing (other mixing attendants standing idle). 21. Not folding the hoop irons after removing. 22. 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. 24.
Taking cotton or synthetic blends from the top side and feeding layer by layer. 8 . Not mixing the wastes properly. 16. Not cleaning the waste accumulated at lattice/beater bearings etc. 7. Not removing the foreign materials from the fibers. 2.BLOW ROOM BACK ATTENDANT 1. 12. 19. spoiling the fallen cotton or fibers by walking over them. 5. Not opening the wastes properly. 4. 10. 6. Not keeping the surroundings clean. Not keeping the stack mixing tidy. Feeding the cotton or synthetic blends tufts without opening. Not taking the specified quantities from each bale and feeding to the lattice/conveyor in case of bale mixing. Not maintaining the trolley properly. Moreover. 8. 13. 15. 18. Not using the broom given for collecting the fallen/scattered cotton or fibers and wasting time by collecting them with hands. 14. 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. 3. Not segregating the good waste fallen under the machine and disposing them along with the droppings. Mixing the good waste with the sweeping waste. 17. Using defective trolley/damaged sheets for carrying cotton from mixing to MBO. Not feeding the cotton or synthetic blends uniformly. during roof cleaning with broom sticks or machine cleaning with compressed air. 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. 11. 9. Not disposing the lap rods immediately and keeping them here and there. Keeping the mixing open.
Not following the instructed methods for mixing the usable waste along with the bale fibers while following the bale mixing method. 21. 23.20. Feeding the mixing without removing the roving bits coming along with the mixing. 24. 22. Feeding the fibers without removing the dirty wastes and the sweeping wastes. Not keeping the lattice or conveyor and the mixing trolleys properly filled-in while going for personal needs. 26. 9 . Cleaning the lattice and beater bearings with hands for removing the wastes and wasting time. Not removing the other mixing fibers or wastes coming along with the running mixing. Not using the lap waste uniformly. accumulating them for a long time. 25.
Not replenishing the roving bobbins in time which leads to lap licking at carding. Not covering the laps with alkathene sheets or HDPE sheets when roof cleaning or machine cleaning is done. 12. 17. Stacking the laps near the opened door/window. Not segregating the white waste while collecting the wastes. Not cleaning the droppings and other wastes in time 2. 8. 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. 9. Not adjusting the lap weight regulator immediately and allowing too much of rejected laps. etc from the laps placing them as they are. Not recording the correct lap weight differences in the register/note book. 15. 7. 14. 10 . (Atmospheric air destroys the top layers of lap). 13. 5. 6. 3. Not removing foreign matters. 16. Keeping the lap rods stand far away from the scutcher. Using compressed air for cleaning the laps stack area and spoiling the top layers of laps. 4. Not covering the laps with alkathene sheet or HDPE sheet when they are stored for long time. Not informing the concerned immediately when the white waste is falling. Placing the lap in the stack without checking weight. Not applying grease / oil to the respective parts in time. 10. Mixing the droppings of different mixings. oily/greasy cotton.BLOW ROOM FRONT ATTENDANT 1. Stacking the laps over unclean floor / platforms. 18. 19. Not carrying about the calendar roll pressure. 11. Not informing the MBO tenter immediately whenever there is some problem at front side.
Using dirty/oily/greasy alkathene sheets or HDPE sheets for covering the laps. Running the machine without cleaning the chocked/lapped wastes. Not removing the air compressor’s condensed water in time. 37. 26. Keeping the full bobbins or empty bobbins over dirty floor or machines or sills of the windows. 11 . 23. 40. Not keeping the scutcher and grid bars clean. Not putting the correct markings or labels when is essential. Handling the lap rods and spindles roughly and damaging the parts or else causing accidents. 29. 31. 35. Inserting the lap rod inside the lap spindle while the lap is running. Mixing the rejected laps with the good laps. 39. Cleaning the oily/dirty/greasy hand over lap. Not adjusting the lap starting end properly and leading to generate more lap bit wastes at carding. 33. Not keeping the weighing balances clean. 28. 25. Using different weight lap rods at a time and getting confused in maintaining the lap weight. Carrying the lap in hands for a long distance and not utilizing the trolleys provided for this purpose. 36. Using rusty or dirty lap rods or lap spindles. 34. 30. 38. Stacking the laps far away from the scutcher even when it is not necessary. 21. Carrying the lap over head or shoulders. 22. Trying to clean the wastes without dismantling when it is essential and wasting lot of time. 24. Using oily / greasy lap rods or lap spindles. Not carrying about the weighing balance accuracy and using it even when it needs some adjustments. 32. Not keeping the cages clean which leads to (single or doubles) defective laps.20. 27.
12. Cleaning hands with good wastes (lap bits. floors.CARDING TENTER 1. 2. sliver wastes etc. 8. Not segregating the white wastes while collecting the wastes and mixing them with saleable waste. 10. Removing the old markings with knives/saw toothed wires or blades and damaging the cans. 9.) 12 . Not removing the oily/greasy cotton and foreign matters from the lap while patrolling or lap changing. 18. 13. Not keeping the svival wheel/caster wheels clean. 15. with compressed air while the cards are running. Not doffing the can in time and running more than the specified length. Running the cards without the safety guards and machine covers. Over twisting the slivers while piecing. Unwinding the lap and spreading it over floor. 19. Bringing the laps from blow room to carding over shoulder or on head even if trolley is provided. Doffing well before time in order to makeup for the back feed shortage at drawing /sliver lap. Not informing the concerned immediately when the white waste is generated. etc. 20. 17. Storing the wastes in bamboo baskets/cans/trolleys and transferring them to Hessian bag at shift end. Not cleaning the flat strips properly. 4. Cleaning the roofs. Not attending the lap lickings in time and allowing single. 6. 5. 3. Not segregating the sweeping wastes and disposing them as they are. 16. 7. 11. 14.. Spoiling the top layer of the lap due to poor handling.. Keeping the waste cans/Hessian bag/trolley far away from the cards and wasting time in depositing the waste. Feeding the lap bits/sliver bits along with the running lap. machines.
36. 23. Not piecing the sliver end with the can sliver end. Going in between a very close machine side alley way where the belts etc. Not removing the thin/thick sliver which comes at the time of break mending or starting of card. Running the cards at slow speed unnecessarily. 28. 32. Not keeping the central dust extraction units clean. Not collecting the suction wastes. Not changing the count boards immediately after count changing. 30. 27. Not cleaning the wastes accumulated in at sides of cylinder. etc. Keeping the reserve laps over dirty floors.21. 24. 40. Not keeping the reserve laps and empty cans readily.. 13 . 39. 37. Not keeping the lap rods properly in a particular place and throwing them here and there while changing the lap. Collecting the under casing waste. 31. 34. while the card is running. 25. 41. trench waste etc. 22. open while cleaning the department with compressed air or cleaning the roofs with broom sticks. Not stripping the cards in time. Causing count mix-up due to carelessness. 35. 42. laps. Making the safety/stop motion devices ineffective and running the cards. 38.. Generating more lap bit wastes. 33. 29. Keeping the sliver full cans. Stopping more than three cards at a time for stripping. Not doffing the cans at shift end and also not keeping the reserve cans and laps to the sufficient level at shift end. Not stripping the cylinder/doffer in time when they are loaded. are running. cylinder droppings. 26. Not keeping the scrapper blades clean. Not cleaning the under casing wastes immediately when a defective web is produced.. front wastes in time and cleaning them only after heavy accumulation.
. 55. Not stacking the full cans and empty cans and reserve laps in the specified areas and keeping them here and there. 51. Not positioning the lap rod properly in the lap stand slot. Not removing the count label immediately after replenishment which goes along with the running lap. 53. etc. Not keeping the calendar rolls. 46. 57. 14 . Roughly handling the cans while loading and unloading. Throwing the alkathene papers/HDPE sheets etc. Keeping the reserve lap’s top layer in hanging condition. Not using the given face mask. Using damaged cans. 44. 49. 50. Not mending the defective can springs and using as they are.43. trumpets. 45. 56. 54. Not trimming the lap ends while changing the lap. Not keeping the Humidification ducts clean. Keeping the front doors open. 52. Dropping the wastes over floor. coiler tubes. 47. Depositing the flat strips inside the bin and transferring them to the Hessian bag. clean.. 48. here and there.
brushes. Not piecing the broken sliver end with the can sliver end. Interchanging the detatching roller bearings. Running more than the specified length of slivers in the can by re-setting the meter. 7. 15. Making heavy thick place while feeding the new lap. Not attending the lap lickings in time and allowing single. 16. Wasting the last few layers of lap unnecessarily. Running the machines without rectifying the earth faults. Not using the trolleys provided for transporting the cans. 10. 5. Collecting the noils in bamboo basket/trolley/can and transferring them to Hessian bag. Not cleaning the clearer waste in time and allowing the waste to go along with the material. Feeding small bits along with the running lap. Over twisting the slivers while piecing them. 17.. etc. Damaging the cans due to rough handling. tools. Keeping the equipment. 15 . Dropping the waste inside the can and not keeping the inside portion of can clean. 19. Interchanging the top detatching rolls by which quality is affected. Making too much of waste while attending lap licking. over the table.COMBER TENTER 1. 11. 2. 22. 4. 18. Damaging the spring tops by rough handling. 13. 20. 9. 8. Not exhausting the lap fully and generating remnants. Wasting top few layers of lap unnecessarily. 14. Dumping the noil waste bags near the machine. 6. 3. 21. 12. Making the stop motion ineffective and running the machine.
27. 44. 26. Not placing the can properly while doffing by which the sliver falls down from the can and gets spoiled. Damaging the clearer cloth by cleaning with sharp fillet brush. Running the machine by keeping the table calender roller being lifted. empty cans unnecessarily near the machine and not keeping them in their respective places. Not applying the varnish as specified and affecting the working performance. 41. Not keeping the draw box region clean. 36. Removing the waste from the moving parts particularly detatching rolls region while the machine is running. 40. Not keeping the top comb clean. 33. Damaging the top comb needle by rough handling.. Not cleaning the light roller lapping immediately. Running the machine either by lifting the top comb or without top comb. 32. Applying too much of chalk powder/viboothi etc. 30. 29. etc. while it is running. Cleaning the machine with compressed air/pad/Hessian cloth.23. 16 . Using knives or saw toothed wire or hooks for cleaning roller lapping and damaging the rolls. 24. 28. Keeping too many sliver cans. 31. Damaging the half lap nails by carelessness. Making too much of waste while attending table break or front break. 37. 34. 25. 35. Not cleaning the accumulated waste from aspirator tube in time. Stopping the machine for a long time for roller varnishing. Not collecting the noil waste in time leading to too much accumulation of waste at back side. Not straightening the bent needles nails with the tools provided. 42. Not keeping the empty spools over stand properly and keeping them here and there. 39. 43. Operating the machine with dirty/oily/greasy hand. 38.
47. 53. 50. 59. 62. Not keeping the reserve laps and cans readily and bringing them by keeping the machine idle. Not lubricating the top roll and feed roll bearings as specified. 58. Carrying the laps in hand or on shoulders or over head. Not cleaning the oily /greasy floors immediately. 49. Running the machine with defective top rolls. Not tieing the marking thread (identification thread) around the can properly. 55. Not joining the required length of sliver for a table break. Not keeping the trumpets clean 54. 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. Inching the machine for a long time. 52. Using damaged springs and cans. 60. 46. Not depositing the wastes variety wise. 57. 51.. Cleaning the machines and the floors or roofs with compressed air or brooms by keeping the cans and laps in open air. Not cleaning the embedded wastes from the cylinder assembly using the hook immediately while the defective web is produced.45. Using knives/thin rods etc. Not keeping the top roll. 56. 48. 61. Not attending the noil chocking immediately. Not cleaning the spilling and excess oil greases from the machine immediately. 17 .
Congested stacking of cans. 6. Taking the slivers from can and dividing them into parts and then creeling. 16. 23. 14. 19. Following random can replenishment method. Not collecting the laps from stand immediately. Crossing the slivers over creel while creeling. Generating sliver waste unnecessarily while piecing the broken sliver ends. 20. Not cleaning the creel roll clearers. clean.SLIVER LAP / RIBBON LAP / SUPER LAP TENTER 1. Bringing the reserve spools by keeping the machine idle. etc. 3. spool tray. 17. Not placing the spools perfectly and damaging the spools.. Not keeping the reserve cans readily for replenishment and wasting time in bringing the cans which leads to a loss in machine productivity. 2. 21. 12. Not lubricating the bearings properly. Running the machine with low pressure and producing loose laps. 18. Not keeping the cans. 11. Not putting the specified markings. 5. Over twisting the sliver while piecing by which not only the quality is affected but also the rolls get damaged. 7. Making the stop motion ineffective whenever earth problem is there and not informing the concerned to rectify the fault. etc. Poor starting of lap. Guiding more than one sliver through a single creel calendar roll. 8. Transferring the slivers from can to floor and then creeling it. spools. 22. 4. Not cleaning the empty spool properly and using it as it is. 9. Keeping the cans far away from creel by which the slivers get stretched. 13. Not stacking the lap properly. 15. Not cleaning the waste accumulated at lap guide. 10. 18 . lap rack.
trolleys. Damaging the can bottom while loading the can on trolley. Not cleaning the light roller lappings immediately. etc. Cutting the laps and placing them aside and creeling the new laps unnecessarily. 44. Not exhausting the supply cans completely and leaving some coils of sliver inside the can. Keeping too many sliver/empty cans unnecessarily near the machine and not keeping them in their respective places. Mixing the waste of different mixings and types. Not removing the thin/thick slivers and running them by keeping the creel roll being lifted. 38. Not attending the lap licking in time and allowing singles. Handling the cans. 19 . Piecing with dirty/oily/greasy hand. 41. 28. 34. Inching the machine for a long time. 27. 39.. Not keeping the cans clean. with good waste. Cleaning the machine. 43. Making too much of waste while attending lap licking. 29. 35. hand. 25. etc. Cleaning the machine with compressed air while the machine is running. 47. Doing external can replenishment. Stacking the different count sliver cans in the same place and making mix-up. roughly. 36. Carrying the laps in hand or on shoulder or over head. Not keeping the reserve laps / readily and bringing them by keeping the machine idle. Making too much of waste while attending table break/front break. 42. 26. 45. Dropping the wastes inside the empty cans. 46. 40. 30.. Bringing/disposing a single can only at a time by dragging and not using the trolley provided for the purpose. 33. front zone covers. 37. 32. Making heavy thick places while feeding new lap.24. 31. Running the machine without rectifying the earth faults.
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. Not keeping the clearers clean. Not collecting the pneumafil wastes as specified then and there. Not stacking the laps and empty spools at the racks and stacking those floors or machines. Running the laps without the presser plates. 54. 20 . 52. 53. 56. 51.48. 50. 57. Not keeping the machine and surroundings clean. 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. etc. Not cleaning the defective laps then and there and accumulating them. Not keeping the drafting zone selvedge guide in position. 49. 55.
14. Generating sliver wastes unnecessarily while piecing the broken sliver ends. 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. Running the machine by keeping the front zone cover being lifted. 15. Not removing the thin / thick slivers and running them by keeping the creel roll being lifted. 11. 8. Taking the slivers from can. 9. Not changing the count board immediately after count changing and making confusion afterwards and also making mix-ups. Transferring the sliver from can to floor and their creeling. Congested stacking of cans. Inter changing the top rollers which affects the quality seriously. 21. Guiding two slivers through a single creel calendar roll.DRAW FRAME TENTER 1. 13. 12.fluffs get accumulated inside the bearing which reduced the life of top roll and the bearings. Running the machine with low pressure. 18. Mixing the wastes of different mixing and types. Not keeping the rollers clearers clean and in correct position. Over twisting the sliver while piecing by which not only the quality is affected but also the roller are damaged. 6. 16. 4. 21 . 3. Applying too much of chalk powder / viboothi etc. Making the stop motion ineffective whenever earth problem is there and not information the concerned to rectify the fault. Not piecing the broken sliver end with the delivery can sliver end. Running the machine by keeping the creel calendar roll being lifted. dividing them into parts and creeling them. 20.. 17.. 19. 7. Over the rolls. Cleaning the machine with compressed air while the machine is running. 10. 5. 2. Not keeping the top roll bearing zone clean . Not keeping the drafting zone clean.
Damaging the casters / svival wheels while loading the cans on trolley. 33. Cleaning the machine hand etc.e. Not applying varnish when the working is poor. Not putting the correct markings. and running the frame.. 41.. guides. 23. 26. 37. etc. 38. 40. Not keeping the cans clean.) 43. 24. Handing the cans. Dropping the wastes inside the empty cans. Transporting one or two can only in a trolley and underutilizing its capacity... Doing external can replenishment. 44. Pressing the delivery can slivers frequently while running. Not maintaining the can wheels properly. 22 . 30. 31. Clean. 25. 36. Stacking different count sliver cans in the same place and making mix-up. 29.22. (i. roughly. 39. pasting of tapes or twisted sliver etc. 27. Damaging the can bottom while loading on the trolley. Not keeping the funnel. trolley. trumpets. Using damaged cans. Bringing or disposing a single can only at a time by dragging and not using the trolley provided for the purpose. 32. 35. Tieing the top roll strippers with twine etc. 28. front zone covers etc. condenser. 34. Not mending the defective springs. 42. Stopping the machine for applying varnish even when the working performance is good. Using the sharp wire. Re-setting the full can length indicator and running the machine without doffing. Not exhausting the supply cans completely and leaving some coils of slivers inside the cans. Piecing with dirty / oily / greasy hand. fillet-brush or knives for cleaning the clearers and roll respectively and damaged them. with good waste.
48. 47. 46. 49. Not collecting the wastes as per the schedule or in time. Running single delivery.45. 23 . Using defective rolls. Not rectifying the defects immediately when a defective sliver is produced. Not positioning the doff roll end bushes properly and using as they are.
with good waste. 20. trolleys. 11. Not keeping the can clean. Over twisting the sliver while piecing by which not only the quality is affected but also the rolls get damaged. 17. 16. 13. Doing external can replenishment. Not exhausting the supply can completely and leaving some coils of sliver inside the can. 6. dividing them into parts and then creeling it. 14. 8. 10. Generating too much of sliver waste while mending the sliver break. 2. Not keeping the roller clearers clean and incorrect position. 5.. Taking the sliver from can. 18. Running the machine with low pressure. Not rectifying the single or thick sliver and running them as it is.SIMPLEX TENTER 1. Not keeping the reserve cans readily and bringing the cans by keeping the Machine idle. 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. etc. Not keeping the drafting zone clean. 3. 12. 7. Cleaning the machine with compressed air/ pad /Hessian cloth while the machine is running. Handling the can. Dropping the waste inside the empty cans. roughly. front zone covers etc. 24 . 15. Congested stacking of cans. Transferring the slivers from can to floor and creeling. Cleaning the machine. 4. Piecing with dirty / oily / greasy hand.. 9. hand. 19. Mixing the waste of different mixing and types.
44. Making too much spindles idle unnecessarily with out informing the concerned to rectify the defects and running the machine as it is. Not keeping the condenser and the sliver guides clean. Damaging the can bottom while loading on the trolley. Not keeping the flyers clean. 45. Not cleaning the defective portion of the bobbin. Not positioning the condenser and the sliver guides perfectly. Not cleaning the air filter condensed water in compressor in time. Not making the correct marking on bobbin. Not cleaning the spindles. 25. Running with defective condenser and sliver guides. flyers and bobbin rails properly after spindle oiling. 31. 39. Running the spindles with defective false twister. 28. Taking the very lengthy rove. 35. Not cleaning the waste accumulated in between the cans. 32. Stacking different count sliver cans in the same place and making mix-up. Not winding the specified number of coils over the presser while piecing. twisting it fully and then doing piecing by which mending time is increased to a large extent and also the quality is affected. 29. 42. 22. Bringing or disposing a single can only at a time by dragging and not using the trolley provided for the purpose. 23. 27. 24. Not keeping the creel zone clean. 38. Not cleaning the presser & false twister perfectly while cleaning the flyer. Not cleaning the adjacent bobbin where double rove is there. 41. 40. 26. 30. 34. 37. Using sharp wire-fillet brush or knives for cleaning the clearers and rolls respectively and damaging them. Not keeping the spindle rails and bobbin rails clean. Not piecing the rove as specified. 43. 25 . Running the spindle without apron. Not cleaning the light roller lapping.21. 36. 33. Not releasing the idle spindle top arms and running the machine.
63. 55. 62. Not cleaning the waste accumulated at the covered place at backside. Not putting the empty bobbin over the idle spindle. Feeding the broken sliver end along with the running sliver end at the sliver guide. Not keeping the rollers beam clean.46. 61. Running the machines by keeping the clearer covers / doors open. Not cleaning the waste accumulated at hopper. 65. 57. Running the idle spindle with flyer. 69. 49. 66. 53.utilizing the can trolleys capacity. 50. nose bar. flyers in their stand. 60. etc. Following random can replenishment. 52. Not cleaning the chocked pneumafil immediately. Not keeping the idle spindles. Cross creeling of slivers. top rolls. Leaving the waste inside the pneumafil. Under. 58. Poor starting / stopping of frame. 59. 68. keeping them over floor or can etc. Non co-operation among the tenters in stopping the machine immediately when break occurs. 48. 54. Running the spindles with defective top rollers. Making the stop motion and the safety devices ineffective and running the machine. Adjusting the ratchet wheels. while releasing and pressing the top arms. Inching the machine for a long time. 67. bottom roller necks. 26 . 47. 64. Cleaning the spindle rail by keeping the machine idle. 51. Not keeping the pneumafil pipes in position. Not patrolling the allocation and standing idle at a particular place. Not positioning the front cover properly and running the machine. 56. Handling the flyers with oily /greasy hands.
75. Piecing from top side in case of closed type flyers. 73. 72. 27 . Not positioning the separators properly. 76. Taking big size or very small size doffs. Running the machine by keeping the back doors opened. 74. 71. Turning the can slivers and using.70. Not cleaning the clearer waste then and there. Running the machine with damaged pneumafil wire mesh.
11. 2. Throwing the bobbins inside the box trolley roughly from a longer distance. 17. second man distributing the empty bobbins or collected the full bobbins. Using damaged /oily /greasy empties. Using sliver cans for collecting empty bobbins / full bobbins. 13. Not using the given waist bag. for there by consuming more time for gaiting. Not cleaning the flyers properly. 16. Dropping the full / empty bobbins on floor /machine or underneath the machine due to carelessness or rough handling. Keeping different color empties in a single bin wasting time while taking the bobbin for doffing. Not positioning the flyers properly. Over twisting the rove while gaiting. 19. 18. 21. 15. Spoiling the bobbins by rough handling / carelessness. Using uncleaned empties. 9. Using baskets for handling / storing the bobbins. Mixing different types of wastes. 7. 10. 14. Breaking the rove while gaiting. Using mixed color empties. Taking lengthy rove. 28 . One man moving the trolley. Using knife for cleaning the empties. Not winding the specified number of coils over the presser. 4. 8. 12.SIMPLEX DOFFERS 1. 20. Carrying full / empty bobbins in hands. 6. 5. 3. Handling the bobbins with dirty /oily / greasy hands.
32. Bringing less number of bobbins is trolley. carrying the bobbins in hands and supplying to ring frames. 29 . clean. Collecting and depositing the preparatory waste in baskets or cans or on floor and then transferring to Hessian bags. etc. Lack of co-operation among the doffers. 36. Doffing with poor rating. Empties bin. Using damaged / oily / dirty bobbins and depositing them in the same bin where good bobbins are kept.22. 25. 35.. Not keeping the bobbins rack. Bringing too much of bobbins is trolley. Not keeping the empty bobbins readily for doffing i. 24. 30. 27. 26. Not bringing the empty bobbin while returning after disposing the full bobbin at ring frame section. Placing doffed bobbins over uncleaned top clearer covers. Returning to the starting point after for gaiting.e. Wide variation in rating among the doffers. Not cleaning the false twisters and pressers while cleaning the flyers 33. Placing the empty bobbins over uncleaned bobbin rails. 23. Keeping the bobbins trolley in one particular place. 31. 29. 34. 28. bringing the empty bobbins after stopping the frame.
4. 16. 14. 2. 9. Trying to piece when the over head clearer is passing. Wiping the hand waste over thigh or half. Dropping waste in alley ways. or otherwise affects the quality. 11. Dropping soft waste (This waste files and goes with yarn which affects quality). Trying to piece the idle spindles. 6.pant after piecing. Missing the traveller while inserting the yarn. Feeling the tension of yarn with middle and forefingers after piecing. Missing hand waste and causing multiple breaks. 13. 17. Trying to piece when there is a roller lapping. 3. Pulling more length of yarn while taking end. 30 . Passing away the ends down spindle due to careless patrolling. Piecing end with more length of yarn and making thick place. This practice also spoils the good waste and sometimes causes multiple breaks.RING SPINNING FRAME SIDER 1. 12. Trying to piece when there is a creel break. 18. 5. Trying to piece when the bobbin has been exhausted. Dropping bonda waste over floor or over the spindle and affecting housekeeping. 7. 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. Taking the cop out of the spindle and then piecing the end. 8. 15. 10.
taking the end from bobbin and holding till the fibers come out from the roller nip and then piecing the yarn. 21. 32. While attending creel break. 29. 24. 25. 37. Carrying too many bobbins in hands and sometimes dropping the bobbin in the alley ways and underneath the machine and spoiling. 34.19. Walking up to the end of the frame even attention is not required. 27. Standing at a particular place and awaiting an end break. 31. While removing pneumafil waste allowing cotton to fly which result in deterioration in the quality. Doing double gaiting i. yarn is over twisted. 35. 31 . 33. Pulling the end up to the waist. Not cleaning the traveler while piecing even when there is waste accumulation. 26. Not cleaning the roller clearers when there is heavy accumulation. 23. standing idle till the end comes out and not cleaning or piecing the nearest broken end. While patrolling. Not giving any importance for drafting zone cleanliness. 22. Breaking the end while taking from cop. Missing the end while taking from cop. with good soft waste. 36. over piecing.out. Not lifting the cop slightly for taking end easily when the cop size is small and wasting time in getting the end. Patrolling the stopped frame (waiting for doffing) unnecessarily and wasting time. head or ear chest or shoulder and breaking.. 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. 30. 28. 20. Cleaning roller beam etc.e. Straining unnecessarily by over stretching or bending while piecing. Because of this break. holding the ring rail with fingers and taking more time. While attending creel break or run.
47. 41. 50. 44. Not cleaning the rove guide rod when there is a heavy waste.38. 55. Finding it difficult in getting the yarn end. 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. 56. Using knife for stripping the bobbins. thus leading to a lengthy thick place. 51. Using knife for cleaning the bobbins. 57. piecing the lengthy rove with the running out rove. 32 . Making more waste unnecessarily from the cop and also the bobbin while rectifying the defects. Dropping the cop in the alley way of underneath the machine after using it for the first round of piecing after doffing. 54. 39. 43. Not using the waist bag properly for keeping the waste. Not utilizing the small bobbin trolley for carrying the bobbins inside the alley way. 49. Wasting time in cleaning the clearer before attending the break. 42. Awaiting and standing idle till the bobbin gets exhausted. 40. 45. Not cleaning the bobbin when there is defect. Wasting too many layers of rove while attending creel break. Dropping the empty bobbin in the alley ways are or underneath the machine during bobbin changing. While changing the bobbin. 46. Not tieing the waist bag. while attending creel break. Using knife for cleaning roller lappings. 53. 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. 52. Wasting too many layers of rove while changing the bobbin. due to poor eyesight. 48. Taking rest outside for every few cycles or for every cycle.
73. Stopping the spindle first for taking the end. Not cleaning the spindle waste even if the waste is observed. Not informing the concerned or raising the indication blade in time for rectifying the defects like defective spindles. 61. again stopping the spindle for passing the yarn through traveller. releasing the spindle by holding the end after passing through lappet guide. Wiping of the front rolls unnecessarily with one hand holding the cop and with the other hand. 68. Making too many attempts in piecing without cleaning the light apron lapping or roller lapping. without 65. Keeping the front top rollers clearer over roving and breaking the rove during cleaning the lapping. making too many attempts and then cleaning the traveller. cleaning the lapping with other hand. holding end in one hand. 64. Trying to piece with out cleaning the bottom roller lapping. Holding the cop bottom for stopping the spindle and spoiling the cop and the empty inner side.. Wetting/Trying the travellers in the mouth and using them. 63. dropping waste over adjacent ends which affects quality or markes multiple break and the same time over twisting of that particular end. 71. 70. 62. Leaving the end inside the pneumafil while piecing and missing the piecing or otherwise causing heavy thick place. 67.58. Not cleaning the arbour waste while cleaning the roller lapping. 66. tape cut etc. 60.e. 33 . Leaving the end well before the roller nip missing piecing. 69. breaking the end while inserting the cop and again taking the cop out for taking the end. 59. (Plastic empties get melted). 72. Missing the traveler while inserting and bringing another traveller. apron – cut. Getting end from the cop by taking the cop out and. Over piecing during the first round of piecing after doffing cleaning the residual layers of yarn over the cop) (i. Trying to piece without cleaning the travellers waste.
91. 82.twisting the roving end with both hands before passing the roving through condenser. After passing the rove through back roll. During power failure. Working at poor rating. 87. 81. Not keeping the pneumafil pipe in position. cleaning and doing the piecing.74. then taking the cop out. 34 . 88. 90. 80. Lifting the cop unnecessarily from the spindle even when the yarn is available at the nose itself. Removing cop with out stopping the spindle by holding the top side. 76. 79. Over. Cleaning the heavy arbour lapping with hand and not using the hook provided for the purpose and wasting time. 83. Piecing the yarn with out passing through the traveller. Cleaning the cop over the spindle itself after passing the yarn through traveller and lapper guide and breaking the yarn. Walking around the motor side while patrolling even when it not necessary. 89. Passing end through front rolls for piecing. breaking the rove due to carelessness and making second attempt for guiding the rove through the second pair of rolls.( In this case both yarn and bobbin gets damaged. 78. 77. 85. Passing the yarn through lappet guide after the piecing is over. 75.). Sometime leaving it as is and mending the break in the next cycle. standing idle with out cleaning the machine. 84. While passing the rove through second pair of rolls. 86. Not caring about the tape position over the spindle wharves even if it is in twisted condition. Not cleaning the pneumafil holes and leaving them as they are. cutting the rove and then passing through the middle pair of rolls. Breaking the roving end while passing through the guides due to rough and hurried handling. leaving the rove to fall down for sometime. Not caring about the position of the rove guides / condensers.
Retracking the cycle unnecessarily for finding breaks. Making fingers wet by touching the tongue or with sweat every time before taking the end from cop. 110. 108. Many times bobbins fall down and get spoiled. Finding it difficult in getting the end from cop due to poor eye sight. 105. Sometimes they break ends also. Piecing the adjacent spindle end with this spindle and leaving this spindle idle. 106. 102. that is threading to the adjacent spindle. pulling-out few coils and taking end. 107. 104. breaking unnecessarily the adjacent end and doing piecing. 95. Not properly placing reserve bobbins / empty bobbins over creel. Making too many attempts for passing the yarn through lappet guide.92. 99. While cleaning roller beam. 96. then removing the bobbin out. Crossing the roves while creeling. breaking end due to carelessness. Keeping the waist bag tied at back side. 98. 100. Not noticing the waste collected underneath the lappet. 94. Not keeping the bottom and top roll clearers in position. Making too many attempts for passing the yarn through traveller. First passing yarn through traveller and then passing through lappet guide. Leaving the yarn waste inside the Pneumafil tube. 93. times. taking end and creeling. Pulling the rove from inner side of the bobbin and breaking the rove few 103. 97. 101. Cleaning the machine with pads or cloth or gunny sheets. 35 . 111. 109. Breaking the yarn while passing it through traveller. Not noticing the creel while attending the creel break and not cleaning the accumulated waste in the creels. While attending creel break. Unnecessarily taking the bobbin from creel while attending creel break.
the concerned. Not cleaning the traveller clearers. Pushing the bottom roller lapping waste to roller neck. 121. Releasing the top arm unnecessarily and keeping the spindle idle.112. Making an attempt to adjust the top arm roll pressure with out informing 117. 122. unnecessarily over roller beam or machine. 123. Using sliver can for distributing full roving bobbins and collecting empty bobbins. Mixing hand waste along with bonda’s and Pneumafil waste. Pushing the top roll lapping waste to arbours. 118. 127.. 116. Not releasing the top arm of the idle spindles. 113. 114. 120. 115. Piecing without cleaning the defective portion of the cop. 119. Adjusting the ratchet wheel while the frame is running. 125. Not attending the breaks purposely at shift end and at shift beginning. Keeping extra clearers. Keeping the reserve travellers over roller beams / off-end /gear end etc. 124. Storing too many bobbins unnecessarily over creel in finer count frames. cops. 36 . Keeping the windows and doors opened in a humidified shed. Running the spindles / frame which are generating defective cops with out informing the concerned. 126. wastes etc.
Not inserting the empties properly causing bottom slough off. 6. 12. waiting unnecessarily and standing idle till the other doffer arrives. Rough handling of containers / baskets. Doffing many cops continuously and breaking the ends at a time creating cops entanglement. 13. Breaking the end while inserting the empties and increasing the starting breaks. 5. Keeping the doff basket over floor and pushing it with leg while doffing 21.RING FRAME DOFFER 1. 7. 14. 19. 18. 15. Dropping the empties / cops in the alleyway or underneath the machine due to carelessness. Working at poor rating 37 . Using damaged empties. Breaking the end while piecing. Breaking the end while positioning the lappets. Not arranging empty bobbins properly and wasting time while inserting the empties. Lack of co-operation between doffers. 11. 2. Not stopping the frame properly and thus leading to more back-wind length. 20. Removing cop roughly and making slough off. 3. Pressing individual empties after inserting the empties. Not cleaning the spindles while inserting the bobbin even when there is a heavy spindle waste. 17. Not bringing sufficient empties. 4. 9. Doing over piecing. Using uncleaned empties. 10. Breaking the end while doffing and increasing the starting break. Using mixed color empties. 8. 16.
25. (using bamboo / cane baskets) 26. Dropping the cops underneath the machine or over the machine after gaiting the ends. Using different types of empties. 28. Using damaged baskets / containers. Not piecing all the starting breaks. Doffing with dirty / oily / greasy hands. Using single hand for inserting the empties in the older method. Using different count cops for gaiting the ends. Making an attempt to piece the end without noticing the creel run out / break. Keeping the doff basket/bag far away from the ring frame and wasting time in transferring the cops from container to doff basket/bags. 39. 31. etc. Not collecting the fallen empties / cops immediately.22.) along with good cops. 35. 33. 24. 38. 42. Using dirty / greasy / fluff accumulated baskets / containers for doffing. 36. 41. 29. Pushing the light roller lapping to arbour. 32. Not using the trolley provided for carrying the baskets/containers and carrying them with hands. 40. 37. 43. Using dirty / greasy empties. Engaging doffers working at wide range of rating. 23. 27. Putting the cops used for gaiting the starting ends in a different count doff basket. Leaving loose empties. Dragging the basket / container over floor. 34. Mixing the fallen spoiled empties / cops (greasy. Not cleaning the loose ends / wastes from the spindle while attending the starting breaks which leads to multiple breaks. Dropping waste over floor and not tieing the waist bag. 30. Wandering here and there and observing the spindles unnecessarily after starting the frame without mending the starting breaks. 38 .
39 . 53. 49. Dropping waste in alley ways. Winding too much of length of yarn over the empty while gaiting ends. 63. 57. 62. Keeping more length of yarn in hand while gaiting ends. holding the ring rail with fingers and taking more time. While patrolling. 64. Missing hand waste and causing multiple breaks. 48. Trying to piece when the over head cleaner is passing. Cleaning hands with good wastes. pushing with leg and bending every time for taking empties. Trying to piece the idle spindles. Changing end to other hand for cutting the excess end. 54. Dropping bonda waste down or over the spindle and affecting house-keeping. Trying to piece when there is roller lapping. Standing at a particular place and awaiting for an end break. 65. 46. or otherwise affects the quality. Wiping the hand waste over thigh or half-pant after piecing. taking the end from bobbin and holding till the fibers come out from the roller nip and because of this break. 47. Holding the cop in left hand and gaiting ends.44. Feeling the yarn tension with fingers for every piecing. 56. 51. Keeping the empty basket over floor at a particular place and bringing the empties in hands every time. 45. 59. 58. (This waste flies and goes with yarn which affects quality) 60. While attending creel break or run-out. This practice also spoils the good waste and sometimes causes multiple breaks. Holding the cop in foot fingers and gaiting ends. 55. Dropping soft waste. 61. 50. Missing the traveller while inserting the yarn. 52. yarn gets over twisted. Keeping the empties basket over floor. Piecing end with more length of yarn and making thick place.
Using knife for cleaning the bobbins. Not cleaning the roller clearer even when there is heavy accumulation.66. 84. Straining unnecessarily by over stretching or bending while piecing. Not using the waist bag properly for keeping the waste. making too many attempts and then cleaning the traveller. 76. While removing pneumafil waste allowing the waste to fly which results in deterioration in the quality. 74. 77. Breaking the end while getting the end from the cop for gaiting. Trying to piece without cleaning the bottom roller lapping. 79. Not cleaning the pneumafil holes and leaving them as they are. 86. Leaving the end inside the pneumafil while piecing and missing the piecing or otherwise causing heavy thick place. 40 . Pulling the end up to the waist. Making too many attempts in piecing without cleaning the light apron lapping or roller lapping. Missing the traveller while inserting and bringing another traveller. Not cleaning the traveller while piecing even when there is waste accumulation. Trying to piece without cleaning the traveller waste. Not keeping the pneumafil pipe in position. holding end in one hand. 67. 75. 68. 70. Leaving the end well before the roller nip and missing the piecing. 85. 83. Using knife for stripping the bobbins. Using knife for cleaning roller lappings. 71. 72. 80. head or ear or chest or shoulder and breaking. 78. 82. Missing the end after getting from the cop while gaiting. cleaning the lapping with other hand. 81. Passing end through front rolls for piecing. 73. Wiping of the front rolls unnecessarily with one hand holding the cop end with the other hand. dropping waste over adjacent ends which affects quality or makes multiple breaks and at the same time over twisting that particular end. 69.
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.
14. Keeping the reserve cheeses /cones over guide rolls / roller stand / roller beam / gear end / off end. 17. 5. Transferring waste from left hand to right hand and placing it in waist beg. Dropping the hand waste over floor. Pulling more length of yarn while taking end. Keeping more wastes in hand while knotting. 22. Using knife for cleaning the cheeses / strips. 9. 13. Doing foot for stopping the spindle. 10. 16. 7. 8. Standing at a particular place and awaiting for an end break. Doing double gaiting . 4. Not tieing the waist bag. 21. Feeling the tension of yarn with middle and fore fingers after piecing. Making more hand waste. 23. Passing away the ends down spindle with out attending the spindle . Using defective knotter. Not passing the yarn properly through the passage. Stripping more than one-eighth size cop and regaiting end. 12. Taking the cop out of the spindle and then piecing the end. Not cleaning the defective portion of the cop / and running the spindle. 3. Missing the traveller while inserting the yarn. 11. Trying to piece when the cones / cheeses have been exhausted. 15. Leaving hand waste in air which goes along with the running yarn.RING DOUBLING TENTER 1. 6. 2. 18. Not keeping the knotter clean. Keeping the waist bag over shoulder. 20. 44 . 19.
29. During power failure standing idle with out the cleaning the machine. 44. 40. Taking rest outside for ever few cycles or after every cycle. 33. 32.24. Walking up to the end of the frame even when attention is not required. Not caring about the tape position over the spindle wharves even if it is in twisted condition. Retracking the cycle unnecessarily for finding breaks. head or ear or chest or shoulder and breaking. Patrolling the stopped frame (waiting for doffing) unnecessarily and wasting time. 41. (In this case both the yarn and cop get damaged). Cleaning the machine with pads or cloth or gunny sheets. 36. 38. 26. 37. Removing cop without stopping the spindle by holding the top side. 25. Breaking end due to carelessness ( while cleaning the roller beam) 43. 39. Adjusting the ratchet wheel while the frame is running. 27. Keeping the traveller in the mouth and using them. 45 . 30. 45. Not cleaning the traveller while piecing even when there is waste accumulation. Straining unnecessarily by over stretching or bending while piecing. Missing the traveller while inserting and bringing another traveller. Not lifting the cop slightly for taking end easily when the cop size is small and wasting time in getting the end. 46. 28. 35. Walking around the motor side while patrolling even when it is not necessary. Not cleaning the spindle waste even if the waste is observed. Breaking the end while taking from cop /cheese /cone. Not attending the breaks Purposely at shift end and at shift beginning. 34. Lifting the cop unnecessarily from the spindle even when the yarn is available at the nose itself. Keeping the waist bag tied at back side. 42. 31. Making too many attempts for passing the yarn through traveller. Pulling the end up to the waist.
Cleaning the machine parts with good wastes. Not trimming the knots when it is specified. Poor rate of patrolling. 60. Keeping the reserve at a distant place and wasting time in bringing the cheeses every time 55. doffing etc. Unnecessarily taking the cheese / cone from creel while mending creel break. 52. Putting bigger knot and leaving lengthy ends when knotting with hands. 50. 69. 68.. Not cleaning the cheese / cone holder. 57. Hitting the top roll against floor or machine for cleaning the top roller lapping. Leaving snarl ends. 56. Pulling more length of yarn from cheese / cone. 62.47. Using fluffs accumulated cheese / cone with out cleaning. Transferring the ends from one hand to the other unnecessarily. 53. Not keeping the machine clean. Hitting the bottom roll with top roller for cleaning the bottom roller Lapping. 51. Carrying the cheeses / cones over handled and not using the given trolley. Mixing the wastes.. Leaving bigger Knots 67. 71. 65. Not Using the Knotter for knotting and putting knots manually with hands. 54. 48. 59. Keeping too many reserve cheeses / cones and allowing fluff accumulations. 66. 58. 64. Keeping the empties hear and there. Not keeping the indicator in position in the time for tape – cut. Leaving loose Knots. Awaiting & standing idle till the cheese / cone gets exhausted. Rejecting the chesses even for very minor defects. 49. Using sliver cans for distributing the cheeses / cones. 70. 61. 63. 46 .
Generating too many cheese / cone remnants 75. 74.72. Not cleaning the defective portion of the adjacent cop (Doubling defect). Not segregating the damaged empties. 73. Not keeping the rejected cheeses / cones neatly and handling them roughly. 47 .
Using mixed color empties for the same count. Leaving hand waste with the yarn. 6. 14. Not keeping the hopper clean. Running different color empties on the same side of the winding machine and making the winder to drop the empties in containers. Not cleaning the entangled cops at a time and wasting time for every cop.CONE WINDING WINDER 1. Dropping hand waste in alley ways/hopper/over cops etc. pulling out and then getting end from left hand for knotting. Pulling too much of yarn after knotting. Not cleaning the drum brush. 19. 3. 2. Leaving loose end. 17. 12. 7. Waiting till a couple of cops are exhausted and then start replenishing. 13. 48 . Leaving snarl knot. Carrying manually 4 to 7 cones for weight checking and dropping one or two cones over floor. Trying to find end from the nose of the fresh cop. 10. 9. 5. Following groups doffing method. 20. Failing to pass the yarn properly through the yarn passage in the first attempt and making additional attempts. Changing the drums after checking the weight of cones and producing defective cones. Pulling more length of yarn from cone. 8. Using knife for stripping the cops. 4. 21. Not cleaning the thread path. 11. 16. Making more hand waste. Transferring cop end to left hand. 18. 15. taking end from cone.
Winder pulling more length of yarn even in case of short length back wind cops. cone holder problem. Finding it difficult to get the end yarn from the cop due to poor eyesight. 26. Transferring ends unnecessarily from one hand to the other hand. 27. Pulling knotted yarn upto ear or chest while leaving for winding (after starting the drum). Dropping the empties down instead of leaving it over the running conveyor. Not cleaning the light drum lappings. Not informing the concerned regarding the defects like stop motion fault. Making too many attempts for creeling cop in the skewer. 34. 41.. etc. 23. pulling out few coils and then taking end from the cop. Using a defective knotter and making lot of knotter failures. Not operating the starting handle properly in the first attempt and making additional attempts. 32. Dropping full cops/empties in alley ways or underneath the machine. 40. 37. 33. 36. 25. 39. Not caring about the correct tension weights. 28. 49 .22. Not positioning ends properly in knotter and making knotter failure. Empties overflow and get scattered over the floor. 31. 38. Not exchanging the empties collecting tray in time. Not cleaning the knotter when the waste gets accumulated. 29. Winding 2 to 3 coils over four fingers unnecessarily after passing the yarn through the passage. Making an attempt to mend the break or change the cop while over-head cleaner is passing. 30.. Rotating the cone with fingers too many times. Taking end with left hand from the cop. Transferring cop from one hand to the other hand unnecessarily. 35. 24.
Breaking the cop end while positioning the ends in knotter. 49. Depositing hand waste in waist bag after every knot. 46. 43. 53.42. 58. Standing idle till the shift end as soon as the production accounting is over. Throwing the yarn over empty cone after starting the drums. Cleaning the thread path while the yarn is running. 48. 45. 44. Working at a very high pace and taking rest by standing at the side of the machine or disturbing other winders. Passing the yarn below the stop motion wire after knotting. not leaving it properly inside the groove and making additional attempts. Missing the cone end while positioning the ends in knotter. 55. 60. 57. Throwing the yarn over cone without knotting. 50. Dumping the cops at a particular place of the hopper and walking for taking every cop. Holding the starting handle for a long time. While leaving the yarn for winding. 61. 51. Mixing the defective / part cops with the good cops and rejecting the same cops again. Making hand waste immediately after inserting the cop. 52. Breaking the yarn while leaving for winding and again knotting. 54. 50 . Not cleaning the defective portion of the cone and winding it as it is. Wasting time in collecting cops even when a service man is provided. Not passing the yarn below the tension weight in the first attempt and making additional attempts for this purpose. Stripping the cop before changing the cop and starting the drum. 47. some times after starting the drum. 63. 59. Using fluffs accumulated cops without cleaning. 62. 56. Not keeping the slub catcher clean. Not working efficiently after achieving the standard production.
. 65. 51 . 78. 66.64. Taking too much of time for cone weight checking. Not collecting the fallen empties and cops immediately. 83. Not keeping the weighing balances clean. Depositing the empty bobbins inside the crates and not using the conveyor for this purpose. disposing empties etc. Providing the lesser number of balances for cone weight checking. 72. Using damaged weighing balances. passing the yarn through left hand again transferring to right hand. 70. 77. Not checking the tare weight and using as it is. Carrying only one or two cones for checking cone weights running excessive length of yarn without checking weight and not rewinding the same. Not keeping tension unit clean. 80. Making hand wastes after positioning the ends in the knotter. 74. bringing cops. Not inspecting the zero error on weighing balance. Using compressor air for cleaning the machine and thread path by keeping the cops and cones in open air. Giving unproductive jobs like repairing empty cones. 68. 71. Transferring the cop end from right hand to left hand after insertion. 82. 73. weighing cones and stacking at packing. Keeping the cop containers in the machine alley and taking cop from the container by turning every time. to winders and affecting machine productivity. Doffing too heavy or too light cones. Putting knots using fingers and not using the knotters for this purpose. Too many winders standing in queue at a time for cone weight checking. Dropping the cones over floor while weight checking. 81. 69. 79. 75. 76. Collecting the cones in Hessian bags and carrying them over shoulder or head. 67. Keeping the weighing balances far away from the winding spot.
Making an attempt to clean the running cones/drums. 89. 91. Moving the cop carrier along with winder while going for mending breaks. 97. Not keeping cop carrier wheels or bearings clean and not maintaining them properly. 99. Making the finger wet either by touching the tongue or sweat for taking end from cop/count. Mixing the damaged empties with good empties. Making count mix-up. Checking the cone weights which are going for doubling. 101. 100. 95. 96. 103. Not using the cop carrier. 93. Not tying waist bag. 90. Putting bigger knots. Working with dirty and stained hands. 94. 92. Running the machine at lesser effective winding speed than the standard speed. 102. Not passing the yarn through the slub-catcher and winding. Holding the running cone and feeling with fingers unnecessarily while the cone is running. Wearing loose full-hand shirts and working on the machine. Using damaged plastic crates or baskets. 104. 106. Using damaged empty cones. Holding the cone holder some time after starting the new cone. Handling cops/cones and empty bobbins roughly and damaging them. 87. Dragging cop crates or baskets over floor or carrying them over shoulder or head.84. 85. 98. 105. Using compressor air for cleaning while the cones are running. 52 . 86. Keeping the cones over uncleaned hopper. 88. Keeping the cones over hopper horizontally.
119. 114. Bringing too much of wax rounds and keeping them over hoppers or window sills. Not cleaning the cones with brush while it is running and taking more time for cleaning the cones after doffing. 110. Running the cone holder without empty cone. Rejecting too many strips and bottoms. 121. Rejecting too much of strips and bottoms and accumulating them. cutting the yarn with knives and making then wastes. 53 . Using empty cone with different count label. Running the cone without wax which has to be waxed. Damaging the drum shafts and cone spindles while cleaning wastes wound on them. Using the wax rounds which are accumulated with dust and fluffs without cleaning. 109.107. 111. 113. Spending too much of time for adjusting the dress. Not cleaning the drum shaft and cone spindle lap wastes immediately. 124. Using knife for cutting the drum lappings and not using the hooks provided for this purpose. 125. 108. Not making the wax rounds to rotate when it is not rotating. Distributing spoiled doffs to all winders and affecting productivity. 116. Not lubricating the mechanical hand knotters in time and not maintaining them properly. 127. 122. Spoiling the good wax rolls. 123. Winding the high-twist yarn which are to be steamed with out steaming. Disposing the cones without marking the ticket number. 117. 120. 118. 112. 115. 126. Not keeping the conveyor and conveyor pulleys clean. Spoiling the cone labels while inserting it or handling it. Mixing the winding count cops along with reeling count cops and conditioning them.
20. 21. Not moving the container along with the winder while creeling. 16. Not cleaning the knotter arms immediately when it is essential. 4. Keeping the container on right hand side & turning for getting cops from container (few winders) 8. Dragging the empties container. Creeling the rejected cops without rectifying the defect. Rubbing the strips over machine frame and cleaning. Breaking the end while making end. Wasting too much of yarn while cleaning cops and cones. 3. Keeping the hand faraway from magazine creel while making end. Using knives for cleaning the drums. Not holding the middle of the cop while making end.AUTOCONER WINDER 1. Accumulating the rejected cops. Leaving too much of yarn inside the suction tube. Keeping the cops in armpit and creeling them. 11. Keeping the container on right hand side and transferring cops a from right hand side to left hand side for unwinding the backwind length. 12. 18. 5. 6. 2. Not giving priority for signals. 7. Moving the container along with the winder while going for rectifying the signal faults. Not keeping the reserve empty cones/cops readily in magazine creel. 13. 15. 9. etc. Not inspecting the knotters arms. Keeping the container over the bigger container and dragging them. 17. 14. Starting the signal drums without rectifying the defect properly. 10. cops. 22. 55 . 19. Not attending the sorting table in time.
Using damaged empty cones. Dropping the cops or empties underneath the machine and not collecting them immediately. 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. Dragging the cop’s crate. Not attending the faulty start-up drums immediately. Johnson bud) for cleaning the yarn clearers. Not attending the conveyor drums immediately. 31. Creeling different count cops in the same magazine and causing count mixup. 40. 26. Not depositing the waste inside the waist bag and dropping them over floor or leaving them inside the suction tube. 29. 33. and cleaning them with hand or waste. Not operating the top side rod immediately when there is some problem in the splicing carriage. 37. Making the doffed cone to fall down while pushing towards the conveyor. Leaving very small problematic drums idle. Not adjusting or arranging the cones while collecting them in trolley/containers. 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..g. 36. 35. 56 . Starting the machines after power failure without releasing the doffing carriage/splicing carriage locks. 25. 34. Doing early doffing when doffing the cone manually. 39. Not keeping the yarn clearer clean. 24. Not keeping the splicing carriage wheels clean. Starting the machine without checking the pilot spindles. 32. Not using the given devices (e. 28. 27. 38.23. 30. 41.
. Mixing the strips and bottoms along with the empties and disposing them as they are. 50. 51. Not filling water in wet splicer and not releasing the air from the tube in time. 48. 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. 43. 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. reversing shaft.42. Not changing over the knotters/splicer meter knob according to the shift. Not collecting the suction waste as per schedule or as instructed in time. 55. driving shaft etc. Creeling the double gaited/ring cut cops without rectifying the defects or unwinding defective portion. Not keeps the cradle holder. Running the count which is to be waxed without wax. Not checking the pilot drums before switching on the machine. Using the dust and fluff accumulated wax without cleaning. 49. 57 . 54. 52. Keeping the wax rounds over machine or cops or over window sills. 44. 46. 47. clean. Bringing too much of wax rounds and wasting them. 45. Generating too much of part and rejected cops. 53.
Not cleaning the entangled cops at a time and wasting time for every cop in cleaning. Dropping cops and empties in the alleyways or underneath the machine. Then wasting time in segregating the empties color wise. 10. Using knife for cleaning the cops or bottoms. Not cleaning the light drum lappings immediately and producing the cheeses continuously over the same drum. 5. 16. Producing cheeses on the drums where the stop motions and the cradles are not functioning effectively. 9. 58 .DOUBLER WINDING WINDER 1. Generating more hand waste. loading the empty cheeses and then starting the drums one by one. 6. Trying to find out the end from the nose of a fresh cop. 18. doffing all cheeses by stopping the machine. i. 8. 7. Using different color empties for the same count and running them at a time. 3. 12. Standing idle at a particular place till a couple of cops are exhausted and then starting replenishments. 13. 14. Throwing the hand waste over alleyways or over the cops or over the machines. 4. Not collecting the cops or empties which are fallen over the floor or underneath the machine immediately.e. 11. Not keeping the thread path clean. Pulling more length of yarn from cheese. Putting the not manually and not using the knotter. Following group doffing method. Pulling the knotted end upto ear or shoulder or head while leaving for winding. 2. 15. Not passing the yarn in the first attempt itself properly through the yarn passage and making additional attempts. 17. Leaving hand waste along with the running yarn.
24. Changing the cops quickly and going away from the spot or chit chatting with the neighbour winders and affecting their work. 26. 59 . Breaking the yarn while leaving it for winding after knotting or splicing.19. Mixing the spoiled cops or part cops with the good cops and wasting time in getting good cops. 23. 35. Using defective knotters. 31. 20. Transferring end from one hand to other hand unnecessarily. 28. Unwinding the back wind yarn with left hand by holding the cop with right hand. Stripping the few layers of yarn from the run out bobbins before starting the drums and affecting the machine productivity. Changing cop from one hand to other hand unnecessarily. 27. 36. 32. 22. Pulling more length of yarn from the cop even when there is only a little quantity of backwind yarn. 21. Cleaning the thread path while the yarn is running. 30. Not cleaning the defective portion of the cheese and running as it is. Throwing the end over running cheese without putting knot. 29. Breaking the ends while positioning them inside the knotter. 34. Making too many attempts for creeling the cops. Holding the cheeses while they are running and feeling the speed unnecessarily. 37. 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. Not doing any work after taking the standard production. Using the knotter without cleaning even when there is a heavy accumulation of waste. 33. Operating knotter before positioning the ends properly inside the knotter and making knotter failures. 25.
45. 48. Using damaged cheese centres. 42. Not tieing the waist bag and wasting time in dropping the waste. Collecting the cheeses in gunny bags and carrying them over shoulder or head or in waist. 46. Mixing damaged empties with good empties. generating more wastes and wasting time. 56. 60 . 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. Handling the cops. Using damaged containers. Making count mix-up. 55. Wearing loose full hand shirts and working on the machine. 39. Making the fingers wet either by touching the tongue or sweat every time for taking the ends from the cop. Working with dirty/oily hands. 47. 51. Not working after the production accounting is over. Winder wasting time in getting cops from spinning even when a service man is provided for this purpose. Using the fluff and dust accumulated cops without cleaning. cheese centres and the containers roughly and damaging them. empties. Running the machine at lesser speed than the standard speed. Pulling more length of yarn after creeling the cop and thereby not only wasting time and also generating more hard waste. 54. Cleaning the alleyways and machine with compressed air by keeping the cops and the cheeses in the open air. 44. empty cheeses centres.38. Dragging the cop containers over floor or carrying them in hands or over shoulder or over head or in waist. 40. 53. 41. Giving the indirect jobs like bringing cops. 50. 52. 43. 49. Not using the waist bag for dropping the waste.
63. Putting big knots or knots with waste. Stacking the cheeses without the winder’s ticket number. Distributing the spoiled/part cops to all winders and affecting the machine productivity. Doffing the cheeses and disposing them without affixing count label or putting the respective marking. 61 . Holding or touching the cheeses while it is running. Not unwinding the singles or four ply from the cheeses and running it as it is. Throwing the cheeses inside the trolley while doffing by keeping the trolley at a distant place. (Fluff and dust get accumulated over these cops/cones). Cleaning the cheese or drums while they are running. Using the cheese centres which are coming with few layers of yarn without cleaning. 67. Throwing the damaged cheese centres here and there. 65. 61. 64. 69. 75. 72. 73. Holding and pressing the cradles for some time immediately after starting the new cheeses. 66. Stacking the cheeses in a dirty place. 68. Bringing too much of cones or cops to the winding machine and keeping them in open air. Not cleaning the waste wound on the drum shaft and the drum shaft and the cradles. Using fluff dust accumulated cones without cleaning. Not stacking the cheeses or cones properly and dumping them in a particular place. 70. 74. 71. Wasting time in frequently adjusting the dress.57. Not applying the lubricants to the knotters and not maintaining them properly. 59. 60. 58. 62. 76. Putting knot and starting the drum for the yarn which is to be spliced. Damaging the drum shaft and the cradles while cleaning the waste from them.
yarn guide. Cleaning good remnants with knife and waste them. 78. 62 . Not covering the stacked cheeses and keeping them in open air for long period. 83. Not exhausting the supply cones fully and generating remnants. 82. Not pulling the yarn while leaving it for winding and allowing loose ends or snarls and producing defective cheeses. Not passing the yarn through slub catcher. Not keeping the machines and surroundings clean. 80. Using knife for cleaning the drum lappers and damaging the drum grooves. 79. dropper bin. top roller and bottom roller properly while gaiting the end. 84.77. 81. Not cleaning the waste accumulated at top roller and bottom roller with hand and using knife for this purpose and damaging the rollers. tension bracket. Not cleaning the few layers of yarn left over the empty cone and disposing them with the yarn. 85.
3. Not keeping the traverse guide clean. Not cleaning the defective portion of the cheese/cone. 18. 15. 17. 7. 23. 14.TWO FOR ONE TWISTER WINDER 1. (Yarn slips). Leaving the knot with loose ends. 8. 9. Not winding the yarn over the wire tail-end properly. 24. 4. 63 . Carrying cheese/cones over hands. 16. 2. Applying break for longer period. stop motion wire. 12. Not positioning yarn properly inside the knotter. Using damaged/defective knotters. Dropping the wastes inside the pot. Poor rate of patrolling. Dropping waste over floor. 21. Not maintaining the knotters properly. 20. Not keeping the flyer unit clean. Using bad wire and taking more time for inserting it. 19. 6. Not keeping the knotter clean. 13. Damaging the pot by rough handling. Not passing the yarn properly through flyer. Not inserting twist for the untwisted portion of yarn while piecing. Making more hand waste. thread guide. 11. Altering the tube setting while mending break. Winding too much of yarn over the threading wire. Damaging the empties by rough handling. 5. Not keeping the work spot/machine clean. Putting big knots. 10. 22.
28. Not giving priority for the awaiting drums and doing some internal work like cleaning. 33. Causing snarls while leaving the knotted end.25. 38. Disposing the doffed cones without label or marking. 35. 36. 37. Working without waist bag. 27. Not keeping the empty cones and reserve feed cheeses readily and bringing them by stopping the drums. (Fluff and dust get accumulated). 26. 34. 29. 64 . 31. Not cleaning the dust/fluff accumulated cones and cheeses and using them as they are. 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. 32. Affixing wrong labels or putting wrong marking for the doffed cones and disposing them. Not exhausting the feed cones or cheeses fully. Following group doffing method. Not cleaning the few layers of yarn over the exhausted cone or cheese and disposing them as they are. Unwinding good cones/cheeses and making them waste. 30. Not informing the concerned immediately when small problems or repairs occur.
6. Making more hand waste. Cutting few threads and taking the end from the hank. Breaking the ends while doffing. Returning to the other end after interlacing for trimming. 21. creel board hopper etc. Rough handling of doff baskets/containers. 19.REELING REELER 1. particularly the brush while the reel is running. 13. 15. 22. clean.. 2. Dropping the trimmed wastes over brush (which goes along with the yarn while running). 3. Throwing the yarn over the running reel without knotting or splicing. Cleaning the reel. Making mistakes at the time of grouping. 65 . 16. Using lesser or more number of threads than the specified for tieing. Running too much of length while making up for short length. Taking too much of time for finding the end from the hank. Using unconditioned cops (when it is essential). Not trimming the excess length of tie when it is essential. 12. 9. Not tieing the off end and tail end with the interlacing thread properly while tieing. Not keeping the brush. 14. 17. 5. 8. Not making up for the short length hanks. Splicing the ends when knotter is given. Not dividing the hank uniformly while putting the cross ties. 20. 18. Depositing empties in the doff basket and mixing the cops and the empties. Breaking the ends during interlacing. 4. 23. 11. 10. Rotating the reel in the opposite direction for finding the ends. Generating short length hanks by carelessness. 7.
Doing the knotting and bagging operations by keeping the reel idle (externally). Storing excessive cops/hanks for next shift. 31. 29. 34. 39. Making more waste while cleaning the cop. 43. Wasting tie yarns. Causing count mix-up. 46. 38. Not positioning the ends properly inside the knotter. 37. Taking too much of time for interlacing. Keeping the hanks/knots over floor or over reels. Counting slowly while grouping and wasting time. Using a defective knotter. 26. Using knife for cleaning the cops/bottoms. Not keeping the tie yarns at the hip. Dropping the waste over floor. Starting the interlacing from the centre and returning to the centre again after completing first half. 32. 36. 41. Not stripping the cop bottoms. Not tieing the waist bag in the right side of the hip. 25. Missing the tie yarn or ends while tieing after interlacing. 35. 44. 47. Rough handling of wooden staves. Keeping the hank too tight and doing interlacing. 30. Not keeping the knotter clean. 27. 33. Using very lengthy tie yarn (cutting the tie yarn more than the specified length). 28. 42.24. Inserting the fingers inside the hank after taking the tie yarn from the hip. Not tieing the waist bag. 40. 66 . 45. Not rectifying the hank entanglement defects and mixing them with good hanks.
50. by keeping the reel stopped (externally). 53. 67. 66. Running the reel without inserting leather straps.. 64. 57. 62. (Poor rating & wrong work method). 59. Not informing the concerned regarding the belt slackness. 56. Using fluff accumulated/spoiled cops without cleaning. Using cop for positioning the rack. Cleaning the cops/cops bottoms etc. Mixing the defective/rejected cops with good cops and again rejecting the same cops. 68. 60.48. Carrying the doff baskets/containers/bags in hands or over shoulder/head or at hips and not using the given trolley. 51. 69. Not gaiting the ends properly which results in re-gaiting and short length. Leaving the spot or not watching the reel when the reel is running. Mixing the different color empties. Using damaged baskets/containers. Making lot of unnecessary movements. 58. 65. Missing the end while gaiting. 67 .. and running the reel as it is. 55. Keeping the cops over floor or gunny sheet and not using the given basket/container. while grouping. Keeping the cops/empties over floor or on the creel board. 63. 49. One reeler looking after two reels and generating short length hanks. 52. 61. Finding it difficult in taking the tie yarn from hip. 54. Not collecting the grouped hanks and moving over staves simultaneously. Taking too much of time for positioning the worm and worm wheel rack and creel board. Dropping the trimmed waste and hand waste on creel board/hopper. Changing the cop end from one hand to the other unnecessarily. damaged staves/leather straps etc. Dragging the baskets/containers/bags over floor.
Using blades for trimming interlacing threads and tie yarns. pulleys etc. side shafts. 72. 73. Not keeping the reels and surroundings clean. Not cleaning the strips and mixing with empty bobbins. 71. Sloughing-off the cop and pull out the yarn for taking end.. 68 . Not keeping the trench. 74. clean.70.
(one man holding the gum paper. 10. 11. 12. 2. Two to three packers working on a single package and making unnecessary delays. Using damaged Hessian bags/cartons for packing. Not mending cone tail end. 7.CONE PACKING CONE PACKER 1. 9. Not keeping the packing spot clean. 20. third man applying water for gum paper and the fourth man holding the carton). Stitching very closely while stitching the bag manually. 8. second man holding the water trough. Damaging the cone label while putting the inserts. Stenciling the packages after packing. 14. Not keeping the light/heavy cones readily near the balance for making up the package weight. Preparing the packing materials for every bag/carton. Not stacking the cone bags and cartons properly. Two to four men are engaged for pasting gum paper while preparing cartons. Not fixing the discs/inserts properly. 3. Throwing the cones while packing or transferring from one place to another. Using too many stencils for stenciling common details. Tearing the sealed side of alkathene bag and inserting the open side of the alkathene bag while covering the cones. 5. 15. 17. Keeping the cones in open air. 18. 6.(Fluffs get accumulated) 13. 16. 69 . 19. Cutting Hessian cloth and alkathene sheet approximately by measuring with hands and wasting time as well as materials. Not using the floor level balances for weight checking. Using dirty alkathene covers. 4. Dumping the cones on uncleaned floor or on dirty Hessians.
29. 39. Using damaged stencils. 31. Stitching all the three sides manually in bag packing. Using improper design of fixtures at packing and wasting time. Getting packing materials for every carton/bag from a distant place. 38. Using damped packing materials. 25. Not maintaining the cone weights at winding and rejecting too much of cones at packing. Using cotton thread for stitching. 24. Using bigger size and heavy Hessians for packing. 26. Using very small brushes or hand wastes for applying the stenciling solution while stenciling. Using baskets covered with Hessian cloths for handling the cones at packing. 32. 70 . Not segregating the too heavy and too light cones and mixing them with goods cones. 23. 40. 37. Packing loose bags. 36. 34. Wasting hoop irons and nails in case of case packing. Breaking the wooden cases while hammering the nail. 28. Not cleaning the fluff/dust accumulated cones and packing them with fluff and dusts. Not sticking the labels properly. Preparing too much of stenciling solution and wasting them. Using bigger size and heavy alkathene bags and sheets. 30. Not keeping the stencil pads clean. 35. 41. 22. Damaging the cones while hammering the nails. Tieing the cone bag with coir rope for tight packing. 27. Not cleaning the used brushes and keeping them with stenciling solutions.21. 42. 33. 43. Keeping the stitched bags and other prepared materials here and there.
Not keeping the weighing balance clean. 45. Damaging the cones while putting the disks/inserts. 50. 51. 52. 53. 57. 55. Not mending the tail end and packing the cone without tail end or without joining the sufficient length of tail end. 46. 47. 48. Dragging the cone bags and carton over floor or carrying them in hands. Using damaged material handling equipments. Not lubricating the packing trolleys and other trolleys as specified and not keeping the material handling equipments clean.44. 49. 58. 71 . Stenciling wrong bag number or weights. Using the balance without adjusting the zero error. 56. Using sticky nature of alkathene bag and finding it difficult for opening it. Packing with dirty/stained hands. 54. Using the weighing balance without checking the tare weight. Throwing the hoop iron pieces and nails here and there. Wasting the lead seals and iron strings. Damaging the cones while stitching the bag with nails. Staining the cone with gum while pasting the label.
bin etc. Handling the knots/bundles with dirty/oily/greasy hands. 11. 9. Cutting excessive length of thread at the time of bundling and stitching. 16. Not mending the breaks in the hank. 21. Lack of co-operation among bundling & baling operatives. Using damaged stencils. Mixing the hanks by carelessness. Not keeping the balance. Spoiling the alkathene bags by rough handling. 72 . 13. Standing idle when the baling machine/pressing machine is working. 10. 17. 12. 4. table.. Dumping too much of knots over table. (This leads to wastage in packing materials). 8. 7. Not keeping the low weight and excess weight knots readily at the time of weighing and wasting time. Not stacking the bundles neatly and dumping them here and there. 3. 5. 14. 18. Not keeping stencils/brushes clean. Not maintaining the pressing/baling machines well. Cutting the packing materials by approximate measurements. Using damaged/spoiled packing materials. 19. Not handling over or not replacing the excess materials at shift end. Bringing excessive quantities of materials. 20. Not scutching the hanks well. Not keeping the materials ready and going out of the spot frequently for bringing the materials. Using too many stencils for stenciling a common detail. 2. clean. 15. handling them roughly and spoiling.BUNDLING & BALING ATTENDANT 1. 6.
38. Cleaning the face. Walking over the knots. 33. Wearing rings in fingers and scutching the hanks (some times breaking the end because of rings). 37. 32. Throwing the bundles over dirty/ dust accumulated floors. Breaking the ends while scutching the hank. taking the knot with right hand and transferring to left hand for scutching. 27. 35. Keeping the knots on right hand side. hands and other parts of the body with knots. 26. 34. tie yarn and the loose ends while scutching and knotting. Taking too much of time for arranging the knots over table after scutching. 39. Keeping different count knots very nearer. 41. Stacking the knots over dirty/stained floors. Arranging the dressed knots for every two or three knots and wasting time. Using very lengthy thread for tieing the bundles. 28. 31. Not inspecting the inter-lacing thread. 36. 29. Taking only few knots from floor or from the stack at the time of scutching and wasting time. Keeping the knots far away from the scutching poles and wasting time in getting the knots every time. Using the knots for cleaning the floor and the table. Using single hand for moving the dressed knots towards bundling presser and wasting time. 40. Wasting time in placing the dressed knots far away from the pole every time. causing mix-up and wasting time in segregating them count wise. Scutching the hank unnecessarily too many times. 30. 42. Breaking the ends while arranging the knots inside the bundling press.22. 23. 24. 73 . Making too many body movements unnecessarily during scutching or bundling. 25. Taking the knot with foot fingers.
Not arranging the threads simultaneously while the presser is running and taking separate timings for this purpose. 49. Finding it difficult to insert the thread inside the needle. Using single needle in stitching the bale.43. Operating the pressing levers with hands and not using the rod or handle provided for this purpose. 50. going from one side to other side of the bale unnecessarily for getting the needle. 74 . Handling the knots roughly and causing entanglement. bringing one or two at a time and wasting time. 45. Dragging or rolling the bales over floor for a longer distance. Not operating the presser levers simultaneously while the presser is running and taking separate timings for this purpose. 47. 46. 44. Not bringing all the four threads towards front side simultaneously. 48.
grease etc. 4. 13. Not repairing the damaged equipment / tools in time and using them as they are. Not cleaning the grease nipples / bearings after lubrication. 2. tools. 23. 21. 8. 6. 7. Spilling the lubricants over floor / machine. etc. Not using the waist bag.. 18. 5. Cleaning individual parts instead of mass cleaning using cleaning trough. 75 . Applying excessive lubricants.CLEANING GANG 1. Not using the clearer roll cleaning machine for roller clearers and cleaning them with hands.. Not cleaning the oily / greasy floor immediately.. 11. 20. Lubricating unnecessary parts. Not cleaning the parts before lubrication. Not using the right tools / equipment for lubrication and cleaning. Not removing the cops while cleaning in ring spinning. roughly. wastes. 9. Handling the materials with dirty / oily / greasy hand. Cleaning the roller necks with hand and wasting time. 19. 12. Handling the equipments. 22. 15. 16. Omitting some lubricating parts while lubrication and cleaning. 14. Frequently going out of spot for bringing equipments. Wasting the lubricants. Not informing the concerned immediately for rectifying the defects / replacing the parts. Using bobbin bottom for removing the old travellers. 3. Using hard waste for taking kerosene from barrel / can. oil. Not keeping the tools and equipments ready. tools. 10. Not cleaning the creels. 17.
24. 36.. 42. 31. Poor cleaning of machines. Oiling the oil holes without rectifying the air bubbles and wasting the oil. 25. Piecing the ends with dirty moist hands. 32. 35. Not cleaning the spot after cleaning. 46. machine parts by rough handling / careless cleaning etc. 26. 45.. Removing grease or oil from new bearings. Not covering the bobbin / cans / laps etc. Leaving the oiling point and the greasing point without cap or grease nipple respectively. 39. Cleaning the moving parts while running. Applying the grease for the bearing without cleaning. Wasting time in applying the grease to the greasing point without grease nipples. 47. Keeping the cleaning equipments / spare parts etc. Spinning the uncleaned bearings. 33. Using same container for cleaning and final rinsing of bearing. Handling the bearings with dirty moist hands. Using good materials for cleaning. machine etc. 38. Cleaning or spinning the bearings with compressed air. 40. Using incorrect kind or amount of lubricants. 30. 27. 34. Damaging the machine.. Using cotton waste or dirty cloth to wipe bearings. Exposing bearings to moisture or dirt. 44. with alkathene sheets while cleaning. 41. Scratching or nicking bearing surfaces. Lack of co-operation among workers. 29. 43. sheets or HDPE 28. floor. Making the fluffs fly by using compressed air etc. 37. 76 . over window sills. and affecting the near by running machines. Removing new bearings from their packages unnecessarily.
52. Wasting time in cleaning the cleaning parts again and again. 77 . 50. Not cleaning the oil tubes. Using incorrect equipments or tools for cleaning the oil tubes and damaging them. 53. 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. 51. Allowing lubricants to remain exposed and get contaminated with dust and fluff. 49. Not checking the oil levels.48.
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