TRAINING SCHEDULE FOR SHOP FLOOR LEVEL TECHNICIANS OF SPINNING MILL

Training is an art which helps each and every living things to get perfect and through knowledge of
subject.

Training is a clean root where everybody applying the positive brain to achieve all prospect in life.
Training is a miracle art where the intensive or extensive efforts result in success.

Training is very essential because through proper training you can achieve better result with well
discipline way. This increases your knowledge. Basic theoretical knowledge of the subject, Concentration
with proper sense and conviction is a must criteria for teachers and trainees. Training helps to achieve
work norms, productive work culture, team building skills, proper attitude, rightful perception, better
understanding of the subject, work ethics, improving own habits, problem solving, concept of
communication etc. etc. Shop-floor training is always result oriented.

Through training one can achieve * improving product quality * Increasing production * Controlling the
waste * Maintenance management * Controlling the product cost * Better utilization of the machine
* Capacity utilization of the machine * Communication skill development * Time management
* Performance Appraisal * Industrial safety management * Fabric inspection.

TRAINING SYSTEM: (1) FRESHER TRAINING (2) REFRESHER TRAINING

FRESHER TRAINING: (1) CLASS ROOM TRAINING (2) SHOP FLOOR TRAINING.

CLASSROOM TRAINING:

(a) Introduction about : the History of the Company; Manufacturing Process; Different Production
Department; About Finished product.

(b) Introduction about Super Seniors, and HOD; * Name and Post of Super Seniors * Name of
Department and their main responsibilities * Name of Head of the Department * Name of Labour officers
and their unit.

(c) About Discipline of the Company: * Duty timing * Lunch time/ Good work time * Duty overtime * About
Hooter * Pick-up Vehicle time at specific destination * Importance of Attendence * Importance of Identity
card * Leave Rules * Card punching at mill gate * Colony and Canteen administration.

(d) Department Administration : * About your work * Diuscipline of the Department * Machine Charge
System * Material Handling * Waste generation * Quality means and its importance for the company *
House keeping * Work Load of the Department * Respect to Jobbers and Staff.

REFRESHER TRAINING: (1) SHOPFLOOR TRAINING (2) CLASS ROOM TRAINING.

SHOPFLOOR TRAINING:

(1) RING FRAME SIDER: * Piecing method * Machine cleaning method * Gaiting method * Bobbin
creeling method * How to reduce idle spindles * Adopting cyclic petrolling * Roller lapping removing
method * Removing defective yarn * Inserting ring traveler * To avoid roller piecing * To avoid double
lepata,
(2) RING FRAME DOFFER: * Keeping reserve bobbins * Doffing method * Cleaning method * Inserting
ring traveler * Keeping waste bag * Avoid to ends down while gaiting * Avoid too many breaks while
doffing * Roller lapping removing method.

(3) SINGLE/DOUBLE WINDER:

(A) KNOTTING METHOD: How to use hand’s knotter, splicer, peg knotter and increase knotting speed.

(B) YARN REALISING METHOD: How to release yarn after knotting to avoid snarling, parallel yarn and
T.P.I. variation.

(C) MACHINE CLEANING: The true method of machine cleaning without damaging the yarn quality.

(D) TAIL END: True method of keeping tail end in each cone.

(E) MATERIAL HANDLING: How to handle the material in the working time.

(F) HOUSEKEEPING: How to maintain good house keeping as per Japanese Five S formula.

(G) SLIP KNOT: How to avoid slip knots, Problem in finishing Department and make better quality.

(H) HARD WASTE: How to reduce more hard waste and hard waste in finishing material.

(I) DOFFING METHOD: To introduce new doffing method in cheese winding to avoid hard waste in T.F.O.
material.

(J) OBSERVATION: To observe the work method of every worker and talk with him about true work
method. If, any worker is not following up the true work method while he is working and also inform him
about bobbin feeding, signal attending, information about each part of the machine in Auto coner and
cyclic patrolling method of doubling tenter.

2: CLASS ROOM TRAINING

(A) GENERAL MOTIVATION: * Market condition, competition and complaint. * How to survive our unit in
this condition and what we can do for attaining the same. * Our responsibilities towards job/work allotted.
* Maximum attendance.

(B) INTRODUCTION OF PRODUCTS MANUFACTURED: * What mistakes are made during the work
period * How and to which extent market suffers because of our mistake * Reputation of the unit is
questioned/ at stake because of the faulty product. * The reason for all these are nothing else but the
wrong work method.

(C) REASONS OF CLOSING THE TEXTILE MILL: * Old management, Old machinery, Old workers, old
working methods

* Production and market graph shown: Low Production – Higher Demand ; Production – Demand ;

High Production – Less Demand.

It is compulsory to give/manufacture best quality product.

(D) ABILITIES OF SKILLED WORKERS: * Knowledge of machine and material * Speed of work *
Interest in the work * Scientific work method * Discipline * Object of Winding machine * Passage of yarn
through the machine * Knowledge about each part and its function in detail.

(E) COUNT AND BLEND: * Mixed Count creating defects in cloth. * Mixed lots will also create defects in
cloth.

(F) MARKET COMPLAINT: * Hard Waste * Slip Knots * Snarling * Parallel Yarn.

How, why and where the defects occurred and its remedy.

(G) WHAT IS BONDA AND WASTE: * How to reduce Bonda * How many losses generate by more
bonda. (to be shown on board by calculating)

(H) OBJECT OF RING DOUBLING AND TWO-FOR-ONE MACHINE

(I) MOTIVATION * House-Keeping and Material Handling * How we can be beneficial to our unit * Current
problems of the unit * Duties of finishing operators including what to do and what not to do.

DURATION OF TRAINING: * Class Training – 30 days ; Junior Trainee – 60 days ; Senior Trainee – 90
days.

PROCEDURE OF PROMOTION:

1. After completion of 30 days training period, production people along with the S.Q.C. people check the
performance of each and every trainee as per the norms. If trainee achieves the norms he be promoted
as junior trainee.

2. After completion of 60 days training period, production people along with the S.Q.C. people again
check the performance of each and every junior trainee as per the norms. If junior trainee achieves the
norms he be promoted as senior trainee.

3. After completion of 90 days training period, production people along with the S.Q.C. people finally
check the performance of each and every senior trainee as per the norms. If senior trainee achieves the
norms he be promoted as skilled worker.

FORMS TO BE FILLED:

1: APPLICATION FORM- must have * Name * Father’s Name * Present Address * Permanent Address

* Qualificvation with documentary evidence * Marital Status i.e. Married or Unmarried * Name of the
Department * Experience * Reference * Signature of the person.

APPRAISAL REPORT

(a): Personal Information: Name; Address – Present and Permanent ; Date of Birth and Age ;
Qualification; Languages Known.

(b) Job Status: Code Number ; Designation ; Department ; Experience.

(c) Performance Assessment ( By Grade A, B, C and D) : * Regularity * Work Speed * Quality Awareness
* Knowlkedge of Machine * Work Method * Behaviour/Attitude
Grade: A = Excellent ; B = Good ; C = Average ; D = Poor

Remarks:

TRAINING NORMS

(1) Height of the trainee: 5’4” to 5’7” ; (2) Health: Normal (3) Age: 18 to 24 Years

(4) Qualification – For Male – 10th or 12th Standard pass; For Female – 8th to 10th Standard pass.

Note: All trainees know all type of colours. They should not be colour blind. Also they should not consume
Tobacco, Gutka, Bidi and/or Cigarettes.

Designation Category Symbol of Batch Or Ribbon Training Days Attendance

1 Class Training D Red Batch 30 Below 49%

2 Junior Trainee C Yellow Batch 60 50 to 69%

3 Seniuor Trainee B green Batch 90 70 to 89%

4 Skilled Worker A Above 90%

BASE FOR APPRAISAL NORMS:

* Regularity 15% ; * Work Speed 25% * Quality Awareness 25% * Knowlkedge of Machine 10%

* Work Method 20% * Behaviour/Attitude 5% = Total 100 %

BASE FOR OBSERVATION

1. LATTICE FEEDER ( MIXING DEPARTMENT)

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: Observation based on working of Blow room line. Grade Based on reserve Box Filling. Whether
Reserve Box is Always full or not.

QUALITY: * House Keeping * Machine Cleaning * Detect Awareness * Fenning

A = Adopting all good points ; B = Adopting 3 good points; C = Adopting 2 good points;

D = Adopting 1 or less good point.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc. etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD: * Taking material from Mixing * Feeding Lattice * Method of Cleaning * Removing dirty and oily
material * Taking out waste-in time. * Using Softwaste.
A = Adopting all points ; B = Adopting 4 - 5 points; C = Adopting 3 points;

D = Adopting 2 or less point.

2. SCUTCHER TENTER

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: Observation based on working of Blow room line. Grade Based on Actual Number of Lap
Produce/ required Number of Lap Production.

QUALITY: * House Keeping * Machine Cleaning * Detect Awareness * Fenning

A = Adopting all good points ; B = Adopting 3 good points; C = Adopting 2 good points;

D = Adopting 1 or less good point.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD: * Weighting the Lap * Setting if the Lap weight is not proper * Method of Cleaning

* Removing Dirty and Oily material * Taking out waste in time * Doffing method * Stop Motion Checking *
Lap transportation.

A = Adopting all points ; B = Adopting 6 - 7 points; C = Adopting 4 - 5 points;

D = Adopting 3 and/or less points.

3. CARDING OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: Observation Based on Production of Machine.

Particular: A B C D

Efficiency: Above 80% 70-79% 60-69% Below 60%

QUALITY: * Sliver piecing Quality * House Keeping * Machine Cleaning * Detect Awareness * Fenning

A = Adopting all good points ; B = Adopting 3 - 4 good points; C = Adopting 2 good points;

D = Adopting less than 2 good point.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD * Checking feeding unit function * Can Transportation * Sliver piecing method * Method of
Cleaning * Removing single and double sliver * Taking out waste in time. * Doffing method * Stop Motion
checking.

A = Adopting all good points ; B = Adopting 6 - 7 good points; C = Adopting 4 - 5 good points;

D = Adopting 3 and less good point.

4. DRAWING OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: OBSERVATION BASED ON PRODUCTION OF MACHINE.

Particular: A B C D

Efficiency: Above 80% 70-79% 60-69% Below 60%

QUALITY: * Sliver Piecing Quality * House Keeping * Machine Cleaning * Defect Awareness * Fenning

A = Adopting all good points ; B = Adopting 3 – 4 good points; C = Adopting 2 - 3 good points;

D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc. etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD: * Arranges cans at the Creel properly * While Creeling at the back and mending at front
produces more waste. Sliver Piecing method * Method of cleaning * Removing single and double sliver. *
Lapping removing method * Doffing method * Stop Motion Checking * Can transportation.

A = Adopting all good points ; B = Adopting 7 - 8 good points; C = Adopting 5 - 6 good points;

D = Adopting 4 and less good point.

5. SPEEDFRAME OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED:

PARTICULAR A B C D

PIECING AT FRONT Below 20 sec. 21 – 25 Sec. 26 – 30 sec. Above 31Second

Time for Taking out 5 Bobbins Below 20 sec.21 – 24 Sec.25 – 28 sec. Above 29Second
QUALITY;

* Sliver piecing quality * Rove Piecing quality * House Keeping * Machine Cleaning * Defect awareness *
Fenning.

A = Adopting all good points ; B = Adopting 4 - 5 good points; C = Adopting 2 - 3 good points;

D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc. etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD;

* Arrange cans at the Creel Properly * While Creeling at the back and mending at front produces more
waste. * Rove piecing method * Method of cleaning * Removing single and double roving * Lapping
removing method * Doffing method * Gaiting method * Machine start and stop.

A = Adopting all good points ; B = Adopting 7 - 8 good points; C = Adopting 5 - 6 good points;

D = Adopting 4 and less good point.

6. RINGFRAME PIECER

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED

PARTICULAR A B C D

PIECING PER MINUTE 11 and above 8 – 10 5–7 4 and Below

GAITING PER MINUTE 11 and above 8 – 10 5–7 4 and Below

QUALITY * Piecing quality * Cleaning * Housekeeping * Yarn and bobbin defect * Quality of Rove piecing
* Fenning

A = Adopting all good points ; B = Adopting 4 - 5 good points; C = Adopting 2 - 3 good points;

D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc. etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD:

* Piecing method * Bobbin Creeling method * Cleaning machine in-time * Cleaning method *
Inserting ring traveler * Generating more waste * Keeping waste bag * Idle spindles *
Adopting cyclic patrolling. Removing defective yarn * Roller lapping removing method.

A = Adopting all good points ; B = Adopting 8 - 10 good points; C = Adopting 6 - 9 good points; D =
Adopting less than 5 good point.

7. RING FRAME DOFFER

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED

PARTICULAR A B C D

PIECING PER MINUTE 11 and above 8 – 10 5–7 4 and Below

GAITING PER MINUTE 11 and above 8 – 10 5–7 4 and Below

DOFFING PER MINUTE Above 50 bobbins 46 - 50 bobbins 41 - 45 bobbins Below 40bobbins

QUALITY

* Piecing Quality * Cleaning * Houseekeeping * Yarn and bobbin Defect * Quality of gaiting *
Fenning

A = Adopting all good points ; B = Adopting 5 - 6 good points; C = Adopting 3 - 4 good points;

D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc. etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD:

* Keeping reserve bobbin * Doffing method * Gaiting method * Cleaning method * Inserting ring traveler *
Generating more waste * Keeping waste Bag * Too many ends down while gaiting * Too many breaks
while doffing * Removing defective yarn * Roller lapping removing method

A = Adopting all good points ; B = Adopting 8 - 10 good points;

C = Adopting 6 - 9 good points; D = Adopting less than 5 good point.

8. ORDINARY WINDING MACHINE OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: Number of Bobbin change ( Knots per Minute).

A: 8 and above B: 6 to 7 C: 4 to 5 D: 3 and below

QUALITY

* Cone Defects * Cleaning * Housekeeping Yarn and bobbin Defect * Quality of knot ( Big or small) * Snarl

A = Adopting all good points ; B = Adopting 5 good points; C = Adopting 3 good points;

D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD:

* Arranging bobbins properly in Basket * Taking care about Count mix * Allowing required yarn while
knotting * Creeling bobbins in systematic manner * Not spoiling bobbin layer while finding the ends * Not
spoiling cone layers while finding the ends * Doffing cone in time * Keeping tail end properly * Cleaning
machine with given aids * Cleaning machine in time * Cleaning drum without damaging groove * Fanning
practice * Using knotter * Releasing yarn properly after knotting * Using proper tension weight. * Using
waste bag.

A = Adopting all good points ; B = Adopting 12 - 14 good points; C = Adopting 9 - 11 good points; D =
Adopting 8 and less than 8 good point.

9. DOUBLING OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: Number of Bobbin change ( Knots per Minute).

PARTICULAR A B C D

Knotting Time below 10 sec. 11 – 14 Sec. 15 – 18 sec .Above 19 sec.

GAITING PER MINUTE 12 and above 10 – 12 8–9 7 and Below

CREELING TIME below 15 seconds 16 – 18 Sec. 19 – 21 sec. Above 22 sec.

DOFFING PER MINUTE Above 50 bobbins 46 - 50 bobbins 41 - 45 bobbins Below40bobbin

QUALITY

* Bobbin Defects * Cleaning * Housekeeping * Yarn and bobbin Defect * Quality of knot ( Big or small) *
Snarl * Parallel Yarn

A = Adopting all good points ; B = Adopting 5 – 6 good points;

C = Adopting 3 – 4 good points; D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD:

* Keeping reserve cheese ready * Clean cheese before creeling * Cleaning machine in-time * Cleaning
method * Taking too much yarn while knotting * Generating more waste * Keeping waste bag * Using
knotter * Adopting Cyclic Patrolling * Removing defective yarn – parallel yarn * Fenning practice.

A = Adopting all good points ; B = Adopting 8 – 10 good points;

C = Adopting 6 – 9 good points; D = Adopting 5 and less than 5 good point.

10. DOUBLER WINDING MACHINE OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: Knotting Speed in seconds

A: 8 and Below B: 9 – 11 C: 12 – 14 D: 15 and above

QUALITY

*feed Package Defects * Cleaning * Housekeeping * Supply package Defect * Quality of knot ( Big or
small) * Snarl

A = Adopting all good points ; B = Adopting 5 good points; C = Adopting 3 good points;

D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD:

* Arranging supply package properly * Taking care about count mix * Allowing required yarn while knotting
* Removing single or extra yarn * Using proper tension weight * Not spoiling cone layer while finding the
ends * Doffing package in time * Using waste bag * Cleaning machine with given aids * Cleaning machine
in time * Cleaning drum without damaging groove * Fanning practice * Using knotter * Releasing yarn
properly after knotting.

A = Adopting all good points ; B = Adopting 10 – 12 good points; C = Adopting 7 – 9 good points; D =
Adopting 6 and less than 6 good point.

11. TWO – FOR – ONE OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED:

PARTICULAR A B C D

KNOTTING TIME(in seconds) Below 18 19 – 22 23 – 25 Above 27

CREELING TIME (in Seconds) Below 21 22 – 25 26 – 29 Above 30

QUALITY

* Cone Defects * Cleaning * Housekeeping * Yarn and Bobbin Defect * Quality of knot ( Big or small) *
Snarl * Parallel

A = Adopting all good points ; B = Adopting 5 good points; C = Adopting 3 good points;

D = Adopting less than 2 good points.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD:

* Keeping reserve cheese ready * Clean cheese before creeling * Cleaning machine in-time *
Cleaning method * Taking too much yarn while knotting * Generating more waste * Keeping
waste bag * Using knotter * Adopting cyclic patrolling. Imparting more or less twist while knotting * Using
tail end.

A = Adopting all good points ; B = Adopting 8 – 10 good points; C = Adopting 6 – 8 good points; D =
Adopting 5 and less than 5 good point.
12. AUTOCONER OPERATIVES

ATTENDENCE: A – Above 90% ; B – 70 to 89% ; C – 50 to 69% ; D – Below 49%

SPEED: Number of Bobbins Feed in Magazine in one minute.

A: 25 and Above B: 20– 24 C: 16 – 19 D: 15 and below

QUALITY

* Cone Defects * Cleaning * Housekeeping * Yarn and Bobbin Defect

Here, grade based on Visual Observation.

MACHINE KNOWLEDGE ( TOTAL 10 QUESTIONS):

* Function about the main Machine and parts * Function about Process i.e. Count, Marking etc.

A = Able to answer 9 and/or 10 questions ; B = Able to answer 7 and/or 8 questions;

C = Able to answer 5 and/or 6 questions; D = Able to answer less than 4 questions.

METHOD:

* Arranging Bobbins properly in basket * Taking care about count mix * Allowing more yarn in suction *
Attending signal in time * Spoiling cone layer while finding the ends * Doffing cone in time * Keeping tail
end properly * Cleaning machine with given aids bag * Cleaning machine in time * Cleaning drum without
damaging groove * Fanning practice

A = Adopting all good points ; B = Adopting 9 – 10 good points; C = Adopting 7 – 8 good points; D =
Adopting 6 and less than 6 good point.