Dept Process Audits Jan 16 Onwards

ANNEXURE : 2 unit -I 1/13/2016
COMMON PROCESS CONTROL AUDIT
(1) MERCERISING (Weekely) No. of Abnormal %age of

YES NO observations observations deviation
1. HANDLING & LOADING OF HANKS(uniformity in spreading of hanks, YES 3 0 0
no overlapping, no entanglement, balanced loading)
2.ARE ALL THE SETTINGS AS PER NORMS ? YES 2 0 0
3. IS THE SPECIFIED CYCLE TIME AS PER NORMS. YES 2 0 0
4. IS CAUSTIC CIRCULATION SYSTEM IS WORKING EFFICIENTLY. YES 1 0 0
5. ARE THESE PARAMETERS UP TO THE MARK.

...... CONC. OF CAUSTIC LYE YES 1 0 0
....... SHRINKAGE POWER OF CAUSTIC . YES 1 0 0
...... TEMPERATURE OF CAUSTIC. NO 1 1 100
.......PROPER DIPPING OF HANKS. YES 2 0 0
...... QUANTITY OF WETTING AGENT. NO 2 2 100
....... WASHING TEMPERATURE. YES 1 0 0
...... %age STRETCH. YES 2 0 0
No. of Abnormal %age of

(2) BLEACH LINE: YES NO observations observations deviation
KIER BOILING
6. IS LOADING OF HANKS BEING DONE IN A PROPER WAY? 0 0 0

NA
7. ARE TEMPERATURE & PRESSURE OF KIER UP TO THE MARK ? YES 1 0 0
8. UNIFORM DISTRIBUTION OF WEIGHTS AFTER LOADING NA 0 0 0
9. EXACT WEIGHMENT OF CAUSTIC & OTHER CHEMICALS. NA 0 0 0
10. IS THE LID LOCK IN SATISFACTORY CONDITION. YES 2 0 0
BLEACHING
11. IS LOADING OF HANKS BEING DONE IN A PROPER WAY ? NA 0 0 0

........ CONC. OF AVAILABLE CHLORINE. YES 1 0 0
........ PH OF BLEACHING LIQUOR. YES 1 0 0
........ CONC. OF HCL IN FINAL ACID. NA 0 0 0
........PH OF FINAL RFD MATERIAL . NA 0 0 0
....... ADEQUATE FLOW OF BLEACHING LIQUOR. YES 1 0 0
...... QUANTITY OF CHEMICALS USED. NA 0 0 0
13. IS THERE ANY LEAKAGE FROM BLEACH TANK. NO 3 0 0

14. TROLLIES & PULLIES ARE IN GOOD CONDITION. YES 4 0 0
(3) DUMPER No. of Abnormal %age

15. IS THE LOT IN THE BATH RUN AS PER THE PROCESS YES 1 0 0
SPECIFIED ?
16. IS TEMPERATURE INDICATOR WORKING EFFICIENTLY ? YES 1 0 0
17. ARE PULLIES IN GOOD WORKING CONDITION ? YES 1 0 0
18. IS WHITENESS OF DUMPER WHITE UP TO THE STANDARD ? YES 1 0 0
(4) ROLL DYEING:
19. IS THE LOADING OF HANKS ON TO THE POLES IN A PROPER WAY ? YES 1 0 0
20. IS THE LOT IN THE DYEING BATH RUN AS PER THE PROCESS YES 6 0 0
SPECIFIED ?
21 .IS THERE ANY LEAKAGE FROM THE DYEING TANK ? NO 6 0 0
.... M/L RATIO OF DYEING BATH YES 6 1 16.66

.......ROTATION OF ROLLERS ( forward & reverse) YES 6 0 0
....ALLIGNMENT OF ROLLERS YES 6 0 0
.. IS COLOUR BEING CARRIED IN A CLOSED CONTAINER. NA 0 0 0
VAT DYEING
..... COLOUR DISSOLUTION IN A STANDARD WAY NA 0 0 0
......CONC. OF CAUSTIC & SODIUM HYDROSULPHITE . NA 0 0 0
....... TEMPERATURE OF DYEING NA 0 0 0
....... SPECIFIED CYCLE TIME FOR DYEING NA 2 0 0
.....IS OXIDATION BEING DONE AS PER STANDARD NORMS. NA 0 0 0
..... IS SOAPING BEING DONE IN A STANDARD WAY. NA 0 0 0
REACTIVE DYEING
...... COLOUR DISSOLUTION IN A STANDARD WAY. NA 0 0 0
...... CONC. OF SALT & SODA YES 6 0 0
...... TEMPERATURE OF DYEING YES 6 1 16.66
..... SPECIFIED CYCLE TIME FOR DYEING YES 6 1 16.66
..... IS SOAPING BEING DONE IN A STANDARD WAY. YES 1 0 0
23. ARE TEMP. INDICATORS SHOW ACTUAL TEMP? YES 6 0 0
24. IS THE COMPLETE INFORMATION REGARDING THE PROCESS YES 6 0 0

SPECIFIED ON DRUG SLIP ?
(5) HYDROEXTRACTOR No. of Abnormal %age

25.PROPER LOADING OF MATERIAL IN HYDROEXTRACTOR. NA 0 0 0

26.IS THE CYCLE TIME SPECIFIED FOR HYDROEXTRACTION BEING NA 0 0 0
FOLLOWED.
27.IS THE SPEED AS PER NORMS. NA 0 0 0
(6) STEAM DRYER
28.IS SPEED OF STEAM DRYER UP TO THE MARK ? NA 0 0 0
29. ARE POLES IN GOOD WORKING CONDITION ? YES 15 0 0
30. IS DRESSING OF HANKS BEFORE LOADING UP TO THE MARK ? NA 0 0 0
31. IS THERE ANY STAIN & BROKEN END IN DRIED MATERIAL ? NO 2 0 0
32. IS PRESSURE OF STEAM IN STEAM DRIER UP TO THE MARK ? YES 1 0 0
33. IS TEMPERATURE OF STEAM DRIER AS PER STANDARD NORMS ? YES 2 0 0
(7) CABINET DYEING
34. IS THE LOT IN THE CABINET MACHINE RUN AS PER PROCESS YES 1 0 0
SPECIFIED ?
35. IS THE LOADING OF HANKS ON TO THE RODS IN A PROPER WAY ? YES 1 0 0
36.IS THERE ANY LEAKAGE FROM THE CABINET ? NO 2 1 50
37. IS THERE ANY STAIN & BROKEN END IN PROCESSED MATERIAL ? NA 0 0 0
38. IS THE WATER BEING FILLED TO CORRECT LEVEL ? YES 1 0 0
39. IS THERE ANY SHARP OR POINTED TIP IN TROLLIES USED NO 2 0 0

FOR UNLODING ?
(8) USE OF PPE'S

40. ARE PERSONS ARE USING PPE'S PROPERLY AS PER THEIR YES 15 6 40
WORK REQUIREMENT ?
(9) CALIBRATION OF WEIGHING BALANCES
41. ARE CALIBRATION IS DONE REGULARLY ? NO 1 1 100
42. ARE THE CALIBRATION RECORDS ARE MAINTAINED ? NO 1 1 100
ANY SPECIAL ABNORMALITY NOTICED : NIL
SHIFT OFFICER : __________________

AUTHORISED SIGNATORY
PDC OFFICER : _________________
MGR (DYG) : _________________
V P (O) : _________________
ANNEXURE : 2 unit - 1 1/13/2016

(1) PACKAGE DYEING MACHINE: No. of Abnormal %age of
1. IS THE LOT IN THE DYEING MACHINE RUN YES 8 0 0
AS PER THE PROCESS SPECIFIED?
2. ARE ALL THE PROGRAMMES FED IN THE YES 4 0 0

PROGRAMMER?
3. IS THE PROGRAMMER WORKING? YES 7 0 0
4. IS WATER BEING FILLED TO CORRECT LEVEL? NA 0 0 0
5. IS THE FLOW REVERSAL CYCLE TIMING AS YES 1 0 0

PER SPECIFICATION?
6. IS THEIR ANY LEAKAGE FROM THE:

--- BODY OF MACHINE NO 11 0 0
--- STEAM LINE NO 5 0 0
--- WATER LINE NO 5 0 0
--- AIR LINE NO 3 0 0
--- DRAIN VALVE NO 11 0 0
7. ARE THE FOLLOWING PARTS OF THE MACHINE No. of Abnormal %age
IN PROPER WORKING CONDITIONS: YES NO observations observations observations
--- DOOR LOCKING SYSTEM YES 2 0 0
--- ADDITION VAT YES 8 0 0
---- INJECTOR PUMP YES 1 0 0
---- CARRIERS YES 12 0 0
GASKET YES 4 0 0
8. ARE ALL THE SAFETY DEVICES WORKING? YES 5 0 0
9. ARE ALL THE VALVES OPERATIONAL BOTH YES 1 0 0

IN AUTO AND MANUAL MODE?
10. IS THE CONDENSATE BEING RECOVERED? NC 0 0 0
11. IS THE BACK COOLING WATER BEING NC 0 0 0

RECOVERED?
12. ARE THE CARRIER PLACED ON RUBBER MATS? YES 12 1 8.33
13. IS THEIR ANY DENT/DEFORMATION IN THE NO 12 1 8.33

SPINDLES/CARRIERS.
14. ARE THE SPINDLES SECURED TIGHTLY? YES 8 1 12.5
15. ARE ALL THE HOLES OF SPINDLE CLEAR? YES 3 0 0
16. DIFFERENTIAL PRESSURE IN HTHP DYEING MACHINES IS YES 7 0 0

ACCORDING TO STANDARD NORMS.
17. PH OF DYEING BATH IS ACCORDING TO STANDARD NORMS. YES 3 0 0
18. IS THERE ANY DIFFERENCE IN TEMP SHOWN BY PROGRAMMER NC 0 0 0

& ACTUAL TEMP. IN DYEING VESSEL. (STD- NOT BE MORE THAN -4 0C).
COLOUR PASTING METHOD:
19. IS THE COLOUR BEING CARRIED IN CLOSED NO 4 4 100
CONTAINER ?
20. IS THE COLOUR BEING DISSOLVED USING YES 1 0 0

MECHANICAL STIRRER?
21. IS THE DISSOLVED COLOUR BEING ADDED AFTER no 1 1 100

FILTRATION?
22. IS CLEANING SCHEDULE FOR PD MACHINES FOLLOWED YES 33 28 84.84

PROPERLY.
(2) BERTA HYDROEXTRACTOR:
1. ARE THE BASKETS OPERATIONAL? YES 1 0 0
2. ARE ALL SPINDLES OPERATIONAL? YES 1 0 0
3. IS THE SPEED IS AS PER NORMS? YES 1 0 0
4. IS THE SPECIFIED CYCLE TIME BEING YES 1 0 0

FOLLOWED?
(3) RF DRYER: No. of Abnormal %age

1. ARE THE BELT SPEED AND ELECTRODE NA 0 0 0

SETTING AS PER NORMS?
2. IS THE PLACEMENT OF THE PACKAGES YES 2 0 0

AS SPECIFIED?
3. IS THE CURRENT DRAWN WITHIN LIMITS? NA 0 0 0
(4) WEIGHING BALANCE: 2
1. DOES THE BALANCE SHOW THE WEIGHT YES 3 0 0

CORRECT?
2. IS THE CORRECT WEIGHING PROCEDURE YES 3 0 0

WEIGHER?
3. SPOONS FOR WEIGHMENT ARE IN GOOD WORKING CONDITIONS. YES 30 0 0

36
0 0
(5) USE OF PPE'S
1. ARE PERSONS USING PPE'S PROPERLY AS PER THEIR YES 8 4 50
WORK REQUIREMENT ?
1. ARE CALIBRATION DONE REGULARLY ? NO 2 2 100

Any Special Abnormalty Noticed:
SHIFT OFFICER : __________________
PDC OFFICER : __________________

Authorised signatory
MGR (DYG) : __________________ Mgr (PDC)
V P (O) : __________________
ANNEXURE - 3
SUMMARY OF PROCESS AUDIT
1. Unit Auditied : Unit - I

2. Date of Auditing : 13 Jan 15
3. Auditied by : Mr.Narinder Rana

Archana Pandey
4. No. of Key Areas Auditied : 9
5. Audit Result :
Key Area No. of Parameters No. of Observations Abnormal observation % Abnormal

1. Mercerising 5 18 3 16.66
2. Bleach Line 8 13 0 0
3. Dumper 4 4 0 0
4. Roll Dyeing 6 64 3 4.68
5. Hydroextractor 3 0 0 0
6. Steam Dryer 6 20 0 0
7. Cabinet M/C 6 7 1 14.28
8. Use of PPE's 1 15 6 40
9. Calibration of balance 2 2 2 100
LIST OF ABNORMAL FINDINGS :

1.Quantity of mercerising wetting agent for J1- nil & for J2 - 60 ml, pipe found chocked, informed to
fitter immediately.
2. Dia tester is not in regular use.
3. Foaming was observed & hank dipping time in caustic was 12 & 14 sec
4. Temperature of caustic lye was found on slightly higher side 34.4 deg C.
5. Water spray system on bleaching tank was found partially chocked.
6. Damaged buckets for carrying caustic lye to KIER may cause accident.
7. Safety box on KIER was found broken. Needs to be repaired.
8. The Dumper operator was adding chemicals without measurement as no. graduated device is given.
9. No PPE's found in safety box on Roll dyeing. Operators complained about not getting the PPE's.
10. In RD 33 , the total run time in salt was inappropriate. Operator was not using timer for the same.
It is found that timer is not in proper use by all.
11. In RD 30 operator was doing coldwash at a m:L:R of 1:12-13.
12. Leakage was found from cabinet no. 1 during red shade dyeing
13. Use of PPE's are not perfect.
14. Calibration of weighing balances are pending.
ANNEXURE 3
1. Unit Audited :- UNIT -1

2. Date of Auditing:- 1/13/2016
3. Audited By:- Mr.Lucky
Archana Pandey
4. No. of Key Areas audited:- Four

5. Audit Result :
Key area No. of parameters No. of Observations Abnormal observation % Abnormal
1. Package dyeing machine 21 172 36 20.93
2. Berta Hydroextractor 4 4 0 0
3. R.F Dryer 3 2 0 0
4. Weighing Balance 3 36 0 0
5. Use Of PPE'S 2 8 4 50
6. Calibration of balances 2 4 4 100

LIST OF ABNORMAL FINDINGS:-
rvations 1. Spindle of carrier of PD-10were found inadequate (improper gapping betwwen the packages.
2. Labelling on new buckets for keeping chemicals on HTHP platform is required.
3. Gaskets from spindle locks of FONGS machine were found missing. (5 out of 12)
4. Poor house keeping in basement area of HTHP machines.
6. Lift wire was found below the level. Repaired immediately.
7. Safety box on HTHP platform was found broken.
8. Color is not being carried in closed container for some PD machines
9. Calibration of pressure gauges on HTHP PD machines are due.
10. Use of PPE's not upto the mark.
11. Machine cleaning schedule was not perfectly followed.
SHIFT OFFICER : __________________
PDC OFFICER : _________________

Authorised Signatory
MGR (DYG) : _________________ Mgr (PDC)
V P (O) : _________________


...... TEMPERATURE OF CAUSTIC. YES 1 0 0
...... QUANTITY OF WETTING AGENT. NO 1 1 100

KIER BOILING

NA
7. ARE TEMPERATURE & PRESSURE OF KIER UP TO THE MARK ? NA 0 0 0
BLEACHING
11. IS LOADING OF HANKS BEING DONE IN A PROPER WAY ? YES 1 0 0

........ CONC. OF AVAILABLE CHLORINE. NA 0 0 0
........ PH OF BLEACHING LIQUOR. NA 0 0 0
........ CONC. OF HCL IN FINAL ACID. YES 1 0 0
........PH OF FINAL RFD MATERIAL . YES 1 0 0
....... ADEQUATE FLOW OF BLEACHING LIQUOR. NA 0 0 0
...... QUANTITY OF CHEMICALS USED. NA 0 0 0

YES NO
SPECIFIED ?
18. IS WHITENESS OF DUMPER WHITE UP TO THE STANDARD ? YES 1 0 0
(4) ROLL DYEING:
SPECIFIED ?
.... M/L RATIO OF DYEING BATH YES 9 1 11.11

.......ROTATION OF ROLLERS ( forward & reverse) YES 15 0 0
....ALLIGNMENT OF ROLLERS YES 15 1 6.67
.. IS COLOUR BEING CARRIED IN A CLOSED CONTAINER. NO 4 4 100
VAT DYEING
......CONC. OF CAUSTIC & SODIUM HYDROSULPHITE . YES 1 0 0
....... TEMPERATURE OF DYEING YES 1 0 0
REACTIVE DYEING
...... CONC. OF SALT & SODA YES 9 0 0
...... TEMPERATURE OF DYEING YES 9 0 0
..... SPECIFIED CYCLE TIME FOR DYEING YES 3 0 0


25.PROPER LOADING OF MATERIAL IN HYDROEXTRACTOR. YES 1 0 0
26.IS THE CYCLE TIME SPECIFIED FOR HYDROEXTRACTION BEING YES 1 0 0

FOLLOWED.
(6) STEAM DRYER 2

30. IS DRESSING OF HANKS BEFORE LOADING UP TO THE MARK ? YES 1 0 0
(7) CABINET DYEING
SPECIFIED ?
35. IS THE LOADING OF HANKS ON TO THE RODS IN A PROPER WAY ? YES 1 0 0
37. IS THERE ANY STAIN & BROKEN END IN PROCESSED MATERIAL ? NA 0 0 0

FOR UNLODING ?
(8) USE OF PPE'S

40. ARE PERSONS ARE USING PPE'S PROPERLY AS PER THEIR YES 12 5 41.67
WORK REQUIREMENT ?
SHIFT OFFICER : __________________

PDC OFFICER : _________________
MGR (DYG) : _________________
V P (O) : _________________
ANNEXURE - 3

2. Date of Auditing : 15 Feb 16
3. Auditied by : Mr. Manoj Singhal

Archana Pandey
5. Audit Result :

1. Mercerising 5 12 1 8.33
3. Dumper 4 4 0 0
4. Roll Dyeing 6 97 6 6.18
7. Cabinet M/C 6 7 1 14.8
8. Use of PPE's 1 12 5 41.66

1.Quantity of mercerising wetting agent for J1- nil
2. Foaming was observed & hank dipping time in caustic was 13 sec
3. approximate Chemical weighment at Roll dyeing machine
4. Color was carried in open containers at roll dyeing
5. Leakage is observed from cabinet dyeing machine no. 1
6. Poor house keeping near bleachline area
ANNEXURE - 4
REVIEW OF LAST AUDIT UNIT - S.T - 1
1. Date of Last Audit : 1/13/2016

2. Review Date : 2/15/2016
3. Auditied By : Mr. Manoj Singhal
Archana Pandey
4. Review Results :
Key Area No. of NC Cleared or Not
1. Mercerising 3 2 cleared
2. Bleach Line 0 0
3. Dumper 0 0
4. Roll Dyeing 3 cleared
5. Hydroextractor 0 0
6. Steam Dryer 0 not cleared
7. CabinetM/C 1 not cleared
8. Use of PPE's 6 not cleared
9. Calibration of balance 2 not cleared
ABNORMAL FINDINGS: -
EXE. (DYG) : _________________
MGR (DYG) : _________________
V P (DYG) : _________________


...... TEMPERATURE OF CAUSTIC. YES 1 0 0
...... QUANTITY OF WETTING AGENT. YES 1 0 0

KIER BOILING

NA
7. ARE TEMPERATURE & PRESSURE OF KIER UP TO THE MARK ? YES 2 0 0
BLEACHING
11. IS LOADING OF HANKS BEING DONE IN A PROPER WAY ? NA 0 0 0

........ CONC. OF AVAILABLE CHLORINE. NA 0 0 0
........ PH OF BLEACHING LIQUOR. NA 0 0 0
........ CONC. OF HCL IN FINAL ACID. NA 0 0 0
........PH OF FINAL RFD MATERIAL . YES 3 0 0
....... ADEQUATE FLOW OF BLEACHING LIQUOR. NA 0 0 0
...... QUANTITY OF CHEMICALS USED. YES 1 0 0

YES NO
SPECIFIED ?
18. IS WHITENESS OF DUMPER WHITE UP TO THE STANDARD ? NA 0 0 0
(4) ROLL DYEING:
SPECIFIED ?
.... M/L RATIO OF DYEING BATH YES 10 1 10

.......ROTATION OF ROLLERS ( forward & reverse) YES 12 0 0.00
....ALLIGNMENT OF ROLLERS YES 12 1 8.33
.. IS COLOUR BEING CARRIED IN A CLOSED CONTAINER. NO 1 1 100
VAT DYEING
......CONC. OF CAUSTIC & SODIUM HYDROSULPHITE . YES 3 1 33.33
....... TEMPERATURE OF DYEING YES 3 0 0
..... IS SOAPING BEING DONE IN A STANDARD WAY. NA 0 0 0
REACTIVE DYEING
...... CONC. OF SALT & SODA YES 7 3 42.86
...... TEMPERATURE OF DYEING YES 7 0 0
..... SPECIFIED CYCLE TIME FOR DYEING YES 7 0 0


25.PROPER LOADING OF MATERIAL IN HYDROEXTRACTOR. YES 1 0 0
26.IS THE CYCLE TIME SPECIFIED FOR HYDROEXTRACTION BEING YES 1 0 0

FOLLOWED.
(6) STEAM DRYER

30. IS DRESSING OF HANKS BEFORE LOADING UP TO THE MARK ? YES 3 0 0
(7) CABINET DYEING
SPECIFIED ?
35. IS THE LOADING OF HANKS ON TO THE RODS IN A PROPER WAY ? NA 0 0 0
37. IS THERE ANY STAIN & BROKEN END IN PROCESSED MATERIAL ? NO 1 0 0

FOR UNLODING ?
(8) USE OF PPE'S

40. ARE PERSONS ARE USING PPE'S PROPERLY AS PER THEIR YES 10 7 70
WORK REQUIREMENT ?
SHIFT OFFICER : __________________

PDC OFFICER : _________________
MGR (DYG) : _________________
V P (O) : _________________
ANNEXURE : 2 unit - 1 3/12/2016

(1) PACKAGE DYEING MACHINE: No. of Abnormal %age of
1. IS THE LOT IN THE DYEING MACHINE RUN YES 7 0 0
AS PER THE PROCESS SPECIFIED?
2. ARE ALL THE PROGRAMMES FED IN THE YES 5 0 0

PROGRAMMER?
3. IS THE PROGRAMMER WORKING? YES 5 0 0
4. IS WATER BEING FILLED TO CORRECT LEVEL? YES 1 0 0
5. IS THE FLOW REVERSAL CYCLE TIMING AS YES 2 0 0

PER SPECIFICATION?
6. IS THEIR ANY LEAKAGE FROM THE:

--- BODY OF MACHINE NO 7 0 0
--- STEAM LINE NO 5 0 0
--- WATER LINE NO 5 0 0
--- AIR LINE NO 5 0 0
--- DRAIN VALVE NO 7 0 0
7. ARE THE FOLLOWING PARTS OF THE MACHINE No. of Abnormal %age
IN PROPER WORKING CONDITIONS: YES NO observations observations observations
--- DOOR LOCKING SYSTEM YES 3 0 0
--- ADDITION VAT YES 7 0 0
---- INJECTOR PUMP NA 0 0 0
---- CARRIERS YES 9 1 11.11
GASKET YES 3 0 0
8. ARE ALL THE SAFETY DEVICES WORKING? YES 5 0 0
9. ARE ALL THE VALVES OPERATIONAL BOTH YES 10 3 30

IN AUTO AND MANUAL MODE?
10. IS THE CONDENSATE BEING RECOVERED? NC 0 0 0
11. IS THE BACK COOLING WATER BEING NC 0 0 0

RECOVERED?
12. ARE THE CARRIER PLACED ON RUBBER MATS? YES 9 1 11.11
13. IS THEIR ANY DENT/DEFORMATION IN THE NO 9 2 22.22

SPINDLES/CARRIERS.
14. ARE THE SPINDLES SECURED TIGHTLY? YES 10 5 50
15. ARE ALL THE HOLES OF SPINDLE CLEAR? YES 9 1 11.11
16. DIFFERENTIAL PRESSURE IN HTHP DYEING MACHINES IS YES 10 0 0

ACCORDING TO STANDARD NORMS.
17. PH OF DYEING BATH IS ACCORDING TO STANDARD NORMS. NA 0 0 0

18. IS THERE ANY DIFFERENCE IN TEMP SHOWN BY PROGRAMMER NC 0 0 0
& ACTUAL TEMP. IN DYEING VESSEL. (STD- NOT BE MORE THAN -4 0C).
COLOUR PASTING METHOD:

19. IS THE COLOUR BEING CARRIED IN CLOSED NO 2 2 100
CONTAINER ?
20. IS THE COLOUR BEING DISSOLVED USING NA 0 0 0
MECHANICAL STIRRER?
21. IS THE DISSOLVED COLOUR BEING ADDED AFTER no 1 1 100

FILTRATION?
22. IS CLEANING SCHEDULE FOR PD MACHINES FOLLOWED NO 36 36 100

PROPERLY.
(2) BERTA HYDROEXTRACTOR:
1. ARE THE BASKETS OPERATIONAL? YES 1 0 0
2. ARE ALL SPINDLES OPERATIONAL? YES 1 0 0
3. IS THE SPEED IS AS PER NORMS? YES 1 0 0
4. IS THE SPECIFIED CYCLE TIME BEING YES 1 0 0

FOLLOWED?
(3) RF DRYER: No. of Abnormal %age

1. ARE THE BELT SPEED AND ELECTRODE NA 0 0 0

SETTING AS PER NORMS?
2. IS THE PLACEMENT OF THE PACKAGES YES 1 0 0

AS SPECIFIED?
3. IS THE CURRENT DRAWN WITHIN LIMITS? NA 0 0 0
(4) WEIGHING BALANCE:
1. DOES THE BALANCE SHOW THE WEIGHT YES 3 0 0

CORRECT?
2. IS THE CORRECT WEIGHING PROCEDURE YES 3 0 0

WEIGHER?
3. SPOONS FOR WEIGHMENT ARE IN GOOD WORKING CONDITIONS. YES 20 0 0
(5) USE OF PPE'S

1. ARE PERSONS USING PPE'S PROPERLY AS PER THEIR YES 5 3 60
WORK REQUIREMENT ?
1. ARE CALIBRATION DONE REGULARLY ? NO 2 2 100

Any Special Abnormalty Noticed: Oligomer cleaning schedule is not followed regularly
SHIFT OFFICER : __________________
PDC OFFICER : __________________

Authorised signatory
MGR (DYG) : __________________ Mgr (PDC)
V P (O) : __________________
ANNEXURE - 3

2. Date of Auditing : 12 Mar 16
3. Auditied by : Mr.Hemant
Archana Pandey
5. Audit Result :

1. Mercerising 5 11 0 0
3. Dumper 4 3 0 0
4. Roll Dyeing 6 97 7 7.22
7. Cabinet M/C 6 5 0 0
8. Use of PPE's 1 10 7 70

1. Mercerised material of running 3/21 was found dry.
2. Material of 12/36 mercerised in previous day evening shift was found dry kept below the shower.
3. Too much foam formation observed in caustic lye.
4. Dry soda ash is added in KIER-2 (6/57, 9/47, 3/24)
5. Poor house keeping in bleachline area.
6. Water collection after souring does not seems to be done regularly (pH in pit -3-4)
7. For operating the valve for water collection near pit (bleachline), worker needs to cross the guide rails
which is a risky task & may cause accident.
8. Safety box on KIER was found broken. Needs to be repaired.
9. Shade no. 8154 (vat)was dyed at M:L:R 1:10 in RD-8
10. In few drug slips of reactive dyeing & vat dyeing chemical quantity was not as per standard.
11. Polypax TDS is given without entry in chemical store
12. Chemical in two similar measuring cylinder were kept on Roll dyeing area without labelling.
13. White material was kept in 021 trolley.
16. Alignment of roller of RD-33 was not appropriate. Need maintenance.
ANNEXURE - 4
REVIEW OF LAST AUDIT UNIT - S.T - 1
1. Date of Last Audit : 2/15/2016

2. Review Date : 3/12/2016
3. Auditied By : Mr. Hemant
Archana Pandey
4. Review Results :
Key Area No. of NC Cleared or Not
1. Mercerising 1 cleared
2. Bleach Line 0 0
3. Dumper 0 0
4. Roll Dyeing 6 5 cleared
5. Hydroextractor 0 0
6. Steam Dryer 0 0
7. CabinetM/C 1 not available
8. Use of PPE's 5 not cleared
9. Calibration of balance 2 not cleared
ABNORMAL FINDINGS: -
1.Quantity of mercerising wetting agent for J1- nil
2. Foaming was observed & hank dipping time in caustic was 13 sec
3. approximate Chemical weighment at Roll dyeing machine
4. Color was carried in open containers at roll dyeing
5. Leakage is observed from cabinet dyeing machine no. 1
6. Poor house keeping near bleachline area
SHIFT OFFICER : __________________ Authorised Signatory
PDC OFFICER : _________________
EXE. (DYG) : _________________
MGR (DYG) : _________________
V P (DYG) : _________________
ANNEXURE 3
1. Unit Audited :- UNIT -1

2. Date of Auditing:- 3/12/2016
3. Audited By:- Mr. Vikas Sood
Archana Pandey
4. No. of Key Areas audited:- Four

5. Audit Result :
Key area No. of parameters No. of Observations Abnormal observation % Abnormal
1. Package dyeing machine 21 172 52 30.23
2. Berta Hydroextractor 4 4 0 0
3. R.F Dryer 3 1 0 0
4. Weighing Balance 3 26 0 0
5. Use Of PPE'S 1 5 3 60
6. Calibration of balances 2 2 2 100

servations LIST OF ABNORMAL FINDINGS:-
1. On carrier of PD-7, 2kgs SSM wound packages & 1.5 kgs random wound packages both were loaded
that may cause column density variation. Bolts were also different.
2. Oligomer cleaning is not done regularly
3. PD-27,28,31 has some mechanical problem during drain. Operator runs it in manual mode.
4. Chanelling is observed in PD-6, loose bolts are found.
5. Almost all filtration units are damaged. Color is being added without fiteration.
6. Rubbers from Fong's spindle locks were missing (9/15).
7. Color is not being carried in closed container for some PD machines
8. Calibration of pressure gauges on HTHP PD machines are due.
9. Use of PPE's not upto the mark.
10. Color / chemicals filling date is not being updated.
11. Less no. of fongs spindle lock were found causing mix bolt uses.
SHIFT OFFICER : __________________
PDC OFFICER : _________________

Authorised Signatory
MGR (DYG) : _________________ Mgr (PDC)
V P (O) : _________________
ANNEXURE-4 FOR PROCESS AUDIT
REVIEW OF LAST AUDIT :
1. Date of last audit:- 15/2/16
2. Review Date :-12/3/16
3.Audited By:- Mr.Vikas Sood

Archana Pandey
4.Review Result :
Key area No. of NC Cleared or not

( Y/N)
1. Package dyeing machine 36 not cleared
2. Berta Hydroextractor 0 0
3. R.F Dryer 0 0
4. Weighing Balance 0 0
5. Use Of PPE'S 4 not cleared
6. Calibration of balances 4 not cleared
LIST OF ABNORMAL FINDINGS: PRESENT STATUS

STATUS

Dept Process Audits Jan 16 Onwards

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Dept Process Audits Jan 16 Onwards

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ANNEXURE : 2 unit -I 1/13/2016

COMMON PROCESS CONTROL AUDIT

(1) MERCERISING (Weekely) No. of Abnormal %age of

2.ARE ALL THE SETTINGS AS PER NORMS ? YES 2 0 0

3. IS THE SPECIFIED CYCLE TIME AS PER NORMS. YES 2 0 0

4. IS CAUSTIC CIRCULATION SYSTEM IS WORKING EFFICIENTLY. YES 1 0 0

5. ARE THESE PARAMETERS UP TO THE MARK.

No. of Abnormal %age of

6. IS LOADING OF HANKS BEING DONE IN A PROPER WAY? 0 0 0

8. UNIFORM DISTRIBUTION OF WEIGHTS AFTER LOADING NA 0 0 0

9. EXACT WEIGHMENT OF CAUSTIC & OTHER CHEMICALS. NA 0 0 0

10. IS THE LID LOCK IN SATISFACTORY CONDITION. YES 2 0 0

11. IS LOADING OF HANKS BEING DONE IN A PROPER WAY ? NA 0 0 0

12. ARE THESE PARAMETERS UP TO THE MARK.

13. IS THERE ANY LEAKAGE FROM BLEACH TANK. NO 3 0 0

(3) DUMPER No. of Abnormal %age

16. IS TEMPERATURE INDICATOR WORKING EFFICIENTLY ? YES 1 0 0

17. ARE PULLIES IN GOOD WORKING CONDITION ? YES 1 0 0

18. IS WHITENESS OF DUMPER WHITE UP TO THE STANDARD ? YES 1 0 0

(4) ROLL DYEING:

19. IS THE LOADING OF HANKS ON TO THE POLES IN A PROPER WAY ? YES 1 0 0

21 .IS THERE ANY LEAKAGE FROM THE DYEING TANK ? NO 6 0 0

22. ARE THESE PARAMETERS UP TO THE MARK.

.... M/L RATIO OF DYEING BATH YES 6 1 16.66

23. ARE TEMP. INDICATORS SHOW ACTUAL TEMP? YES 6 0 0

24. IS THE COMPLETE INFORMATION REGARDING THE PROCESS YES 6 0 0

(5) HYDROEXTRACTOR No. of Abnormal %age

25.PROPER LOADING OF MATERIAL IN HYDROEXTRACTOR. NA 0 0 0

27.IS THE SPEED AS PER NORMS. NA 0 0 0

(6) STEAM DRYER

28.IS SPEED OF STEAM DRYER UP TO THE MARK ? NA 0 0 0

29. ARE POLES IN GOOD WORKING CONDITION ? YES 15 0 0

30. IS DRESSING OF HANKS BEFORE LOADING UP TO THE MARK ? NA 0 0 0

31. IS THERE ANY STAIN & BROKEN END IN DRIED MATERIAL ? NO 2 0 0

32. IS PRESSURE OF STEAM IN STEAM DRIER UP TO THE MARK ? YES 1 0 0

33. IS TEMPERATURE OF STEAM DRIER AS PER STANDARD NORMS ? YES 2 0 0

(7) CABINET DYEING

35. IS THE LOADING OF HANKS ON TO THE RODS IN A PROPER WAY ? YES 1 0 0

36.IS THERE ANY LEAKAGE FROM THE CABINET ? NO 2 1 50

37. IS THERE ANY STAIN & BROKEN END IN PROCESSED MATERIAL ? NA 0 0 0

38. IS THE WATER BEING FILLED TO CORRECT LEVEL ? YES 1 0 0

39. IS THERE ANY SHARP OR POINTED TIP IN TROLLIES USED NO 2 0 0

(8) USE OF PPE'S

(9) CALIBRATION OF WEIGHING BALANCES

41. ARE CALIBRATION IS DONE REGULARLY ? NO 1 1 100

42. ARE THE CALIBRATION RECORDS ARE MAINTAINED ? NO 1 1 100

ANY SPECIAL ABNORMALITY NOTICED : NIL

SHIFT OFFICER : __________________

MGR (DYG) : _________________

COMMON PROCESS CONTROL AUDIT

2. ARE ALL THE PROGRAMMES FED IN THE YES 4 0 0

3. IS THE PROGRAMMER WORKING? YES 7 0 0

4. IS WATER BEING FILLED TO CORRECT LEVEL? NA 0 0 0

5. IS THE FLOW REVERSAL CYCLE TIMING AS YES 1 0 0

6. IS THEIR ANY LEAKAGE FROM THE:

9. ARE ALL THE VALVES OPERATIONAL BOTH YES 1 0 0

10. IS THE CONDENSATE BEING RECOVERED? NC 0 0 0

11. IS THE BACK COOLING WATER BEING NC 0 0 0

12. ARE THE CARRIER PLACED ON RUBBER MATS? YES 12 1 8.33

13. IS THEIR ANY DENT/DEFORMATION IN THE NO 12 1 8.33

14. ARE THE SPINDLES SECURED TIGHTLY? YES 8 1 12.5

15. ARE ALL THE HOLES OF SPINDLE CLEAR? YES 3 0 0

16. DIFFERENTIAL PRESSURE IN HTHP DYEING MACHINES IS YES 7 0 0