Operator Evaluation Programme in Spinning Mill

(From Mixing to Yarn Conditioning)

Prepared by R.Senthil Kumar, Assistant professor (SRG), Department of Textile Technology, KCT, Coimbatore-49. sen29iit@yahoo.co.in

MIXING 1) Cotton is available in ------ and ---- form (Bale and boras) 2) One Indian bale and imported bale weight is ------- and ----- kgs(175,225) 3) Cotton is graded by its ------ length (staple) 4) ELS means ----- (Extra Long staple) 5) Bales are strapped with ------- (iron hoops) 6) Cotton bale is sorted by ------ number and ---- number (lot, Bale) 7) Arrangement of bale according to variety and quality in godown is termed as ----( Bale management system) 8) Other than cotton mixed in bale is called as ---- (contaminant) 9) Normal trash % in Indian cotton is ------% (7 to 8) 10) Mixing attendant should wear ---- and ----- (mask and head cap) 11) Mixing of processed fibre is termed as ------ waste mixing (soft ) 12) Bale is transported to mixing area from godown is done by using -----( trolley) 13) Opening of bale strip is done by using -------(bale cutter) 14) Bale covered by ------ or ----- (cloth or hessian cloth) 15) Automatic mixing done by ---- machine( blendomat) 16) Arranging of bales in mixing area is termed as ------ down area(lay) 17) Cotton godown is a ------- free area (fire ) 18) Bale lot number and variety is identified by --------- and ---- (bale number and placards) 19) Waste should be stored in ----- bags (waist) 20) Iron strip to be removed and ----- and kept in separate place(folded) 21) Iron bits in cotton will spoil wire points in ---- machine or cause fire in --machine(carding, blow room) 22) Flat waste, droppings, yarn waste are called as ----- waste ( salable) 23) ---- waste to be checked and sorted thoroughly and good fibres to be removed (sweeping) 24) ----- waste to be opened by ----- opener and used in mixing(roving, rove opener) 25) Adding color to mixing is called as ----- (tinting) 26) Samples of cotton to be collected from the ----- portion of the bale(centre)

27) ----- by --- mixing to be done according to variety in manual mixing. 28) Manual mixing is called as ------ mixing or --- mixing(bin, stack) 29) Polyester is a----- fibre(synthetic) 30) --------- is a contaminant(jute) Multiple choice questions 1) Bale is covered with ----a) Hessian cloth b) Poly propylene c) polyester cloth d) Paper 2) Jute thread in cotton is a ------a) Contaminant b) Dust c) trash d) Part of cotton 3) Bale is strapped with ----a) String b) iron hoops c) plastic strap d) cotton rope 4) Approximate Indian bale weight is ------ kgs a) 175 b) 230 c) 250 d) 200 5) ------ waste is mixed with bale cotton during mixing a) Soft waste b) sweeping waste c) hard waste d) roving ends 6) Yarn waste is called as --------a) Soft waste b) hard waste c) sweeping waste d) contaminant waste 7) Bale is identified by -----a) Variety and lot number b) lot number c) Bale number d) All (a, b, c) 8) Arrangement of bale to blendomat is called as ----a) Bale arrangement b) lay down c) lay plan d) laying 9) Bale strips are cut by using ----a) Bale cutter b) cutting player c) crow bar d) chisel 10) Adding colour to mixing is termed as ---a) Tinting b) dyeing c) spraying d) conditioning 11) Adding oil and water to manual mixing is termed as ----a) Conditioning b)spraying c) weighing d) mixing 12) Object of mixing is -------a) Mixing different varieties of cotton b) Mixing bale of same variety

c) Mixing polyester and cotton d) Mixing soft waste with bale 13) Contaminants during mixing to be collected and stored in ------a) Waist bags b) waste can c) crates d) bin Match the following 1) Package of cotton : Contaminent (5) 2) Transport of cotton from godown: lot number and bale number(4) 3) Identification of bale : soft waste (2) 4) Blower waste from spinning: bale trolley(3) 5) Jute fibre/thread mixed with cotton : Bale form or boras (1) On line test (on field test) 1) Why you should wear mask and head cap during mixing? Avoid inhalation of fine dust and prevent hair fall in mixing 2) What are the contaminants in mixing? Jute , cloth bits, poly propylene , gutka cover 3) Why should you wear waist bag during mixing or lay down time? To collect the contaminants 4) Which instrument used to cut the iron strips in bale? Bale cutter 5) After cutting iron strips from bale what are the procedures to adopt to store it? Fold it and keep separately 6) Do ou know the impact of iron part mixing with cotton It will damage the wire points in carding and cause fire in blow room 7) Why the contaminants to be removed during mixing? It will cause dye shade variation in cloth and spoil the yarn quality 8) Name some contaminants in cotton Jute , cloth bits, poly propylene , gutka cover 9) Name few varieties of cotton

DCH 32, Suvin, H4, Shankar 4, LRA ON line study 1) Time taken to transport bale from godown to mixing or lay down area 2) Work load for mixing attendant 3) Time taken to open the bale 4) Time taken to fold the iron hoops and fold it, plucking cotton from hessian cloth cover of the bale 5) Time taken to dispose the iron hoops to the specified area 6) Time taken to complete one lay 7) Time taken to put one mixing ( manual mixing) 8) Knowledge of Location of fire extinguisher 9) Knowledge about operation of fire extinguisher. 10) Knowledge about higher officials. Match the following 1) Package form of cotton : Contaminant (5) 2) Transport of cotton from godown: Lot number and bale number(4) 3) Identification of bale : Soft waste(2) 4) Blower waste from spinning : Bale trolley (3) 5) Jute fibre or thread : Bale or boras(1)

Blow Room 1) The main function of blow room is ------- and ------ (opening and cleaning) 2) First machine in Blow room line is ------- (MBO) 3) The blow room line in the factory suits for ----- system (CHUTE Feed) 4) Contaminants in cotton in blow room eliminated by ----- (Vision shield) 5) Suction fan in blow room eliminates ----- (micro dust) 6) The Level of cotton in ERM is controlled by ----- ( photo cell) 7) Iron strips and bits is eliminated in blow room by ---- detector(magnetic detector) 8) In case of fire or smoke in blow room it is indicated by ----- alarm(fire) 9) The hank(Wt/unit length) is adjusted by adjusting ----- setting in MBO(evener roller) 10) The machine that stores large quantity of cotton and releases slowly to next machine is ---(unimix) 11) ------------- to be started first while stating the blow room line(beaters) 12) -------- colour indicates the fibre transport duct(white) 13) ------ colour indicates the waste transport duct(red) 14) Iron particles in fibre is removed by ----- detector(magnetic ) 15) Fire is sensed by ---- alarm(fire) 16) Over feed of cotton causes ------ of beater(chocking) 17) Make of machine in blow room is ------ (LMW) 18) ----- is used to bypass the machine in blow room(Two way distributor valve) 19) ------ machine makes automatic mixing(blendomat) 20) ------ switch used to sudden stop of all machine in blow room(Emergency) 21) The part below the beater is called as ----- (grid bars) 22) Beater in blow room does the ----- function(opening and cleaning) 23) The objective of blow room is ------(opening and cleaning) 24) One blow room line can feed ----- cards (8) 25) The mixing bale opener has got ----- lattices(3) 26) ----- lattice feed the material in MBO( feed lattice)

27) ----- lattice has got spikes in MBO(elevating lattice) 28) Beaters are running ------ in blowroom(continuously) 29) ERM beater will have ----or---- type of beater(pin or saw tooth) 30) At a time we can process ----- type of Varity or count in a particular blow room line(only one type) ON FIELD TEST 31) Sequence of machine in blow room line 32) Number of blow room line 33) Count processed in each line 34) Identification machine in each line 35) Panel board operation and sequence of operation 36) Sequence of operation of machine during the start of the shift 37) Identification of fibre transport duct and waste carrying duct. 38) Sensors in blow room and their function and their location 39) Beaters in blow room 40) What is chocking in blow room 41) Function of contaminant clearer 42) Make of blow room 43) Count processed in blow room 44) By pass point in blow room 45) Processing sequence for polyester or synthetics 46) Safety switches and door stop motions 47) Operation procedure of blendomat 48) Basic programming knowledge of blendomat 49) Function of emergency switch 50) Location emergency switch 51) Number of blow room line and count processed in each line 52) What is chocking? 53) Procedure to test transport ducts 54) Condenser cage functioning 55) Adjustment procedure in evener roller setting in mixing bale opener and hopper feeder

56) Number of cards the particular blow room line feed 57) Communication method to carding in case of chocking and in case of chocking 58) Knowledge of reserve lay 59) Basic knowledge of operation of fire extinguisher and location 60) Micro dust filters and functions On field study 61) Make of blow room 62) Count processed in blow room 63) Machine sequence in each line 64) By pass arrangement in each line 65) Operation procedure of by pass arrangement 66) Identification of fibre transport duct and waste transport duct 67) Compressor air usage 68) Function of photo cell in blow room 69) Knowledge of fire alarms 70) Blendomat functioning and operational procedure 71) Operation of emergency switch 72) Method adopted during count or lot change 73) Placard and cunt board 74) Method to feed MBO in case of manual feed 75) Method of taking cotton from bin to feed MBO 76) Procedure to follow during quality check 77) Cleaning procedure Online time study 78) Time to start the blow room line 79) Time to clean the line 80) Time taken during count change 81) Production details 82) Procedure to adopt at the start and end of the shift 83) Hand over procedure during the end of the shift

CARDING 1) Make of card ----2) Feed material---- (blow room fibre) 3) Delivery material ------ (sliver) 4) Carding machine parts------ ( Cylinder, Lickerin, Doffer, Flats) 5) Card can size---- (50x 40 inches) 6) Colour code for card can ----7) Stop motion in card-----( double feed, sliver break) 8) Signals in card and identification -----( Sliver break, double feed) 9) Length of sliver in card can---10) ----- can used for reserve can(empty) 11) ----- changes the full can after doffing(full can stop motion) 12) The changing of doffed can is known as-----(auto can changing) 13) Types of waste in card ----(lickerin droppings, flat waste, cylinder flies) 14) ------ regulates the weight variation in carding( Auto leveler) 15) ----- Cleaning is available in front zone(CCD) 16) Feed roll cleaning is done by using----(hand brush) 17) Pre signal for doffing is -----(blinking lights) 18) Flat monitor signal used to indicate ---- (flats revolving) 19) production, Time, Sliver breaks/shift, Efficiency in card is indicated by ----- (Card commander (PLC) information) 20) ----- controls the level of fibre in chute(Pressure switch) 21) In case of double feed --- is used to rectify the fault(Pressure switch operation for feed roller-Reverse switch for feed roller) 22) Doffer can be operated by --------- speeds(two speeds, (slow or fast) 23) ------ speed used for doffer during the time of -------(slow, Piecig) 24) ----- is used during the time of piecing (Web doffing control switch) 25) Sliver hank variation is indicated by ---------(deviation of draft)

26) Machine stoppages indicated in ------(efficiency of machine) 27) ------ switch used in case of Emergency( Emergency stop) 28) usable waste is stored in ------( separate cans) 29) During piecing -------- operation used for web transport from doffing unit(Pneumatic air supply switch) 30) ----- is fitted over the web doffing device(Scrapper blade ) 31) ----- is used to lift the scrapper blade( spring controlled lever) 32) Count processed in card is identified by ----- (placard) 33) The doffed can is stored near ---- (draw frame) 34) Empty can storage is near the ----(reserve can system0 35) Card can is fitted with -------(Caster wheel) 36) Number of cards supplied by one chute is ----- (8) 37) ---- is to be started first while starting the card(cylinder) 38) The part that placed the sliver in can is called as ----- (coiler) 39) The part that revolves around above the cylinder is called as -----(flats) 40) The waste removed by the flats is called as ----- ( Flat strips) 41) The waste removed by likerin is called as ----- (likerin droppings)

On field test 42) Operation sequence of card 43) Knowledge push buttons in card commander 44) Knowledge of emergency switch 45) Slow fast operation of doffer 46) Interference detail of card commander information 47) Chute duct control systems 48) Double feed sensors 49) Knowledge of reverse switch for feed roller in case of double feed 50) Method of sliver piecing in case of break 51) Full doff change pre signal 52) Flat monitor signal

53) Machine operating efficiency/shift 54) Scrapper blade lifting lever and procedure 55) Feed roller cleaning procedure 56) Automatic waste evacuation system and basic knowledge 57) Count change procedure 58) Work load / tenter 59) Duties and responsibilities of card tenter 60) Knowledge of fire extinguisher an operational procedure On field time study 61) Colour code/count 62) Time taken to piece the sliver break 63) Time taken to repair the double feed 64) Time taken to store the full doff can 65) Time taken to store the empty can 66) Time taken to clean the card 67) Time taken during count change

Draw Frame 1. ___________ Can is the feed material for breaker draw frame. (card) (a) Card (b) simplex (c)draw frame (d) waste 2. What is the output of breaker draw frame? Answer: Breaker draw frame can 3. _________ Number of doublings usually carried out in draw frame. (8) (a) 10 (b) 2 (c) 4 (d) 8 4. __________ is the make of draw frame (a) LMW (b) Rieter (c) Trutzscler (d) Toyota 5. Drafting arrangement in RSB draw frame is -----a) 3 over 3 b) 3over 5 c) 4 over 4 d) 5 over 3

6. Model of RSB draw frame is ---------a) RSB 851 b) RSB 750 c) RSB 550 d) RSB 815

7. Rollers are loaded in RSB draw frame is by -------a) spring b) pneumatic c) dead weight d) self weight 8. -------- done to avoid roller lapping a) Varnishing b) buffing c) roller berkolising d) heating 9. If the draw frame is fed by card sliver it is called -------- drawframe a) Breaker b) finisher c) first d) even 10. If the draw frame is fed by breaker draw frame sliver it is called as ------ draw frame a) Breaker b) finisher c) second d) even 11. The feed portion of draw frame is called as -----(creel) 12. The feed stop motion is governed by-----(photo cell and creel calendar rollers) 13. The slivers are passed thro ---- system in draw frame (tounge and groove) 14. ------ zone contains top and bottom roller( drafting ) 15. The top roller is made up of ---- (rubber cots) 16. The drafted web is passed thro ---- from the front roller( symmetric funnel tube) 17. The top roller pressure is released by ------ (pressure release lever) 18. The pressure is released during the time of -----(gaiting or roller lapping) 19. The material after the funnel tube is passed through ----(coiler trumpet) 20. ------ light indicates the coiler chocking(yellow) 21. ----- light indicates the sliver break(red light) 22. -----light indicates the doffing (blinking signal) 23. -----light indicates the mass variation out of control ( green) 24. ----- controls mass variation in draw frame( potentio meter) 25. ------- controls the feed and delivery in draw frame (auto leveler) 26. ----- indicates the production details in draw frame( hank meter) 27. One tenter attends ----- draw frame in a shift ( 8) 28. The finisher draw frame cans are stored near to the --- (simplex) 29. The empty can form the simplex is stored near the ---- (reserve can system) 30. The breaker draw frame full can is stored near the ----- finisher draw frame( creel zone of)

31. The ---- button is used during the time of piecing or during the time of mending a break (inching) 32. On field test 1) check the knowledge of color codes in draw frame (Breaker and finisher can) 2) Check the knowledge of stop motions Creel, lapping, full can 3) where is drafting zone? 4) identidy drafting roller 5) Top roller pressur release system 6) method of lifting in top arm lever 7) Method of roller lifting 8) identification of botton clearer 9) dismantling procedure of bottom clesrer 10) Cleaning procedure for bottom clearer 11) method of varnishing of top roller 12) Method of top roller greasing 13) Method of piecing in draw frame 14) knowledge of magazine creel 15) Knowledge of emergency switch 16) Where is the auto leveler? 17) Auto leveler mal functioning 18) Checking of main drive belt in the stepped pulley 19) Changing of driving belt in main driving arrangement to change the speed 20) waste removal from suction duct 21) Where do you put the soft waste after mending? 22) disposal of card can after emptying. 23) storing of finisher draw frame can 24) Method of can arrangement at creel 25) piecing method in creel zone 26) Cleaning procedure of tunnel tube in front zone 27) where is scanning roller

28) how to release the scanning roller 29) Where is sliver guide condenser in the drafting zone 30) where is trumpet in draw frame? 31) Where is coiler calendar roller? 32) can size of draw frame 33) How to release the coiler calendar roller? 34) Capacity of draw frame full can 35) Method of sliver insertion in colier after a break 36) What is inching motion? 37) when you use the inching motion 38) What do you do when the auto leveler alarm works? 39) Checking of stop motion in creel zone 40) importance of creel stop motion 41) Caster wheel cleaning 42) What is caster wheel? 43) check the cleaning of drafting zone by the operator 44) Check the cleaning of coiler zone 45) Reserve can in the delivery side 46) Count processed in draw frame 47) Knowledge about the process details 48) Knowledge about material handling. 49) Knowledge about house keeping 50) Knowledge of operation of picker gun or stick 51) Production information details and knowledge 52) Efficiency of operator in terms of hank meter 53) Knowledge about hank meter operation 54) Top Roller interchange procedure 55) top roller cleaning procedure 56) Knowledge of work load On field study 57)Time for mending creel breaks

58) Time for arranging cans at back side 59) time for mending breaks in case of roller lapping (top and bottom) 60) method of rectifying top roller lapping (Knife not to be used) 61) Repeated piecing attempt 62) Time to mend break in case of trumpet chocking 63) Time taken to interchange the top rollers 64) time taken to dispose the empty can (Card can) 65) time taken to store the finisher draw frame can at specified area 66) Procedure to adopt during count change 67) Basic knowledge of operation of fire extinguisher 68) Knowledge about higher officials 69) procedure during start and end of shifts.

UniLap 1) Unilap is fed by ------ sliver(breaker draw frame or carded can) 2) The material in unilap is wound in ---- (spools) 3) After doffing ----- to be done( reset of doff meter) 4) Number of sliver at feed side is ---- (48) 5) Control switch in unilap are ----- (inching, continuous running, Pressure on/off switch, Manual doff switch) 6) Red signal indicates in unilap ---- (sliver break at creel) 7) Knife should not be used to remove the lapped cotton in detaching roller or top roller. True or False. (Answer: True) 8) Where are the places you will clean in Lap Former during the shift? Drafting Zone Creel zone Lap winding zone

9) ________ cleaning to be done once in 2 hours. (Answer: Drafting Zone) a) Drafting zone b) lap winding zone c) Creel zone d) Gear end

10) _______ is used for cleaning in Drafting zone. a) Brush b) Picker gun c) stick d) both b and c

11) Drafting rollers are loaded by __________ system a) Pneumatic b) Spring loaded c) Dead weight d) magnetic 12) ________ number of top rollers present in the drafting zone. (Answer: refer respective unit) 13) ________ is the feed hank of the Unilap (Answer: refer respective unit) 14) ________ is the delivery hank of the Unilap (Answer: refer respective unit) 15) _________ is the approx. weight of full lap. (Answer: refer respective unit) 16) __________ is the weight of the empty spool. (Answer: refer respective unit) 17) ______ is the function of black switch in the machine. (Answer: Inching motion) 18) Top clearer cloth rotation over the drafting zone should be observe frequently. True or False. Answer: True 19) Lap should be transported by _________ (answer: lap trolley) 20)_________ No. of Reserve spools should be there while machine running.(Answer:3 - 4)

On field Test: 1. Check the awareness for colour code in can, lap, etc.. 2. Ask the tenter to show how to arrange the can in creel. 3. Check the tenters knowledge of machine switch operations. 4. Check the knowledge of doffing of lap by manual method. 5. Method of piecing in the creel zone. 6. Check for identification of parts such as top roller, bottom roller, creel, spool, gear end, off end, lap trolley, spool holding disc, etc

COMBER 9) Object of comber is ------(remove the short fibres) 10) Comber waste is termed as ----- (NOIL) 11) Number of heads in comber is ---- (8)

12) Comber is fed by ----(ribbon lap) 13) Number of lap fed in ribbon lap is ---(6) 14) Number of doubling in sliver lap is ----(refer your unit) 15) Sliver lap is fed by --- (card sliver) 16) Ribbon lap is fed by ----( sliver lap) 17) Blue button in comber is used to -------(release pressure on detaching roller) 18) Inch button in comber to be used only during -----(piecing) 19) No. of Detaching roller per head is _________ (Answer: a)2) a) 2 b) 4 c) 1 d) 3 12) Feeding laps should have uniform size to minimize the down time. True or false Answer: True. 13) Laps feeded to comber should be transported from lap former using________ a) Lap trolley b) Lap holder c) hand d) shoulder 14) Top Comb should be kept in _________ during cleaning (Answer: top comb stand) 15) Lap stop motion sensor will ________ the machine during exhaustion of the lap. (Answer: stop) 16) Knife should not be used to remove the lapped cotton in detaching roller or top roller. True or False. (Answer: True) 17) No. of top rollers in the drafting zone is ____ (Answer: 3) 18) Where are the places you will clean in comber during the shift? Drafting Zone Detaching zone Table zone Coiler zone Feeding zone

19) ________ cleaning to be done once in 2 hours. (Answer: drafting Zone) a) Drafting zone b) Top comb c) Unicomb d) Gear box 20) _______ is used for cleaning in drafting zone, detaching zone and feeding zone. a) Brush b) Picker gun c) stick d) both b and c

21) Glass flap over the Unicomb zone should be closed while machine running. True or False.

Answer: True 22) Name the below part as shown in the diagram.(Answer: top comb)

23) Name the parts in the below shown diagram. (Top and bottom detaching rollers)

24) __________ will automatically eject outwards if it fill fully. (Answer: Can) a) Can b) Lap c) Coiler d) top comb

25) What is Noil? Noil is short fibre waste removed in comber process. 26) Empty can should always be there behind the running can, otherwise machine will not run. Why? Empty can stop motion will stop the machine in the absence of reserve empty can in the delivery zone. 27) Noil is resalable or reusable. True or False. (Answer: True) 28) Improper handling of top comb results __________ (Answer: Comb damage) 29) Running without top comb produces ___________ quality sliver. (Answer: Bad) 30) _________ should be cleaned often with water to free from dirt and avoid frequent lapping during the shift. (Answer: Detaching top rollers and top rollers) 31) Can castor wheels should be cleaned before keeping in the can plate. True or False.

Answer: True. 32) Laps should be handled without any damage to web. True or False. Answer: True 33) _________ % noil is running in your unit. (Answer: Refer respective unit) 34) _________ will take the sliver from drafting zone to coiler zone in the comber machine. Answer: Conveyor belt 35) Where is web condenser? Web condenser is there immediately after the drafting zone. 36) ________ system loads the drafting rollers. a) Pneumatic b) Dead weight c) Magnet d) Spring load 37) ________ system loads the detaching rollers. (Answer: Pneumatic or Air) 38) What are the various stop motions there in comber? Answer: Empty lap stop motion, calendar roller stop motion in each head, drafting zone stop motion, coiler calendar roller stop motion

39) What do you do if lap licking or roller lapping occurs frequently? Answer: Use heating lamp or talc powder or inform production foreman/officer. 40) Noil should be separated from sliver waste. True or False. Answer: True.

On Field test 1) Identify cylinder in comber 2) Identify top comb in comber 3) Identify detaching roller in comber 4) Where is draw box in comber? 5) Identify aspirator drum in comber 6) Give the function of red, black and green button in comber. 7) Where is table calendar roller trumpet? 8) Identify the signals in comber 9) Sliver stop motion signal 10) Where is diverter plate in ribbon lap machine 11) Trumpet chocking signal

12) Pressure release system 13) Method of releasing the detaching roller 14) Method of releasing the nipper 15) Identify stop motions in sliver lap machine 16) Identify stop motions in ribbon lap machine 17) Where do you store the reserve spool in lap machines? 18) Piecing method in sliver lap creel zone 19) Magazine creel in sliver lap machine 20) Air usage in sliver and ribbon lap machine 21) Piecing method in ribbon lap machine creel zone On Field time study 22) Time taken for piecing creel breaks in sliver lap machine 23) Time taken to repair roller lapping in sliver lap machine 24) Time taken to replace a exhaust can in sliver lap machine 25) Time taken to take a full can from carding deparment to sliver lap machine 26) Time taken to dispose the empty can to carding department from sliver lap machine 27) Time taken to store the sliver lap to ribbon lap machine 28) Time taken to take the empty spools from ribbon lap machine and to load the spool magazine in ribbon lap machine 29) Knowledge of operation of push buttons in sliver lap and ribbon lap machine 30) Method of operation of manual doffing in sliver and ribbon lap machine 31) Time taken to mend the breaks in ribbon lap machine 32) Time taken to replace the empty spool by full lap in creel side of the ribbon lap machine 33) Time taken to place the ribbon lap to comber at individual position of comber creel 34) Time taken to collect the empty spool from comber and to load the spool magazine of ribbon lap machine 35) Time taken to mend the full lap in comber by replacing the empty spool 36) Time taken to mend the breaks at table calendar zone in case of chocking or replenishing time 37) Time taken to mend the sliver break at draw box zone

38) Time taken to replace the doff can in comber 39) Time taken to mend the break in case of roller lapping in detaching roller zone 40) Time taken to lift the nipper and reposition the nipper after replenishing 41) Time taken to store the comber can in specified area 42) Time taken to store the empty comber can from draw frame near comber 43) Knowledge about pressure switch 44) Varnishing methods.

SIMPLEX 1. What is the output material of the simplex machine? Roving bobbin 2. What is the feed material for simplex machine? Draw frame sliver 3. What do you observe in your machine while shift change over? Count /hank of delivery and feed Roving bobbin colour Cleaning of the drafting zone, creel, spindle, bobbin rail, spindle rail No. of idle spindles Machine is running or not House keeping Amount of Roving Waste Over head blower functioning Deformed or slough off bobbins any Hank meter reading

4. Where is top roller? (on field identification test) 5. Where is bottom roller? (on field identification test) 6. Where is flyer? (on field identification test) 7. Where is creel?(on field identification test) 8. Where is bottom apron and top apron?(on field identification test)

9. Where is spacer? (on field identification test) 10. How do you transfer the can from draw frame department to back of the simplex? By using the can trolley. 11. What is floating condenser? In the front zone of the drafting zone one condenser floats in the support of roving is called floating condenser. 12. What do you do if can plate in the feed can is slanting and it creates sliver breakage/stretch? Do not process that can in simplex and also in draw frame until can plate corrected. (It increases the roving C.V % lowers the roving quality).

13. What do you do if fibre sticks to the back bottom roller forms a layer? One should clean the back bottom roller and do not allow to form the fibre layer and should inform about this to production or R&D officers.(it creates increase in count C.V%). 14. What do you do if back top roller is missing? Leave the spindles idle respective to that top roller and immediately inform to production/maintenance persons. (It affects the count C.V% severely) 15. What do you do if apron (bottom or top) is missing? Leave the spindles idle respective to that top roller and immediately inform to production/maintenance persons.(it affects the roving quality). 16. What do you do if top roller cot found damaged / cut? Remove the top roller and put any reserve top roller or inform to maintenance/production persons. 17. What do you do if the feed can side get damaged? Avoid using the sides damaged can it distorts and damage the sliver while unwinding. 18. What do you do if can castor wheels not rotating properly? Clean the can castor wheels or inform to the production officer. 19. How do you put the cans in simplex either batch wise or complete replenishment? Mostly batch wise. 20. What are the things to monitor while hank changes or lot changes?

Feed sliver hank and colour Roving bobbin colour and any markings Spacer colour Floating condenser colour Wheel changes (draft, twist, lifter, etc)

21. How do you piece the sliver in the creel side? Remove the one portion of sliver of one end and remove the one portion of sliver of another end and combine both and slightly twist. 22. What is the piecing and attending time of a sliver break occurring at creel side? Within 30 - 45 seconds 23. What is the can changing time during batch wise can replacement in the creel? Depends on no.of cans/batch .

24. What to do if the roving coming from drafting roller is too loose/too tight? Adjust the ratchet wheel or to inform the fitter immediately to correct. 25. How many lays put over the flyer finger before wounding the roving on empty bobbin? As mentioned by production officer/foreman. 26. How much time taken by a person to take 30 bobbins doff? 3-4 minutes (good) 27. How do you mend the sliver while lot change? Run the old sliver completely and insert the new sliver up to the drafting zone and freshly wind over the empty bobbin. 28. How to lift the Top arm loading lever? One should lift the top arm loading lever using the knob by applying the uniform pressure. 29. What is the frequency of time to clean the drafting zone in a shift? Thrice in a shift using the picker gun and brush. 30. What is the frequency of time to clean the Bobbin rail and spindle rail in a shift? During every doff. 31. What is the frequency of time to clean creel zone in a shift?

Twice in a shift. 32. What do you do if you sense abnormal sound/noise in the machine? Immediately stop the machine and inform to production/maintenance person. 33. What are the functions of the black/red/green button in the machine? Black Inching motion Red stop Green run the machine

34. What do you understand from the signal light (red/orange/green)? Red- to stop the machine Orange for doffing Green ready to start 35. Knife should be used for removing roving layers in roving bobbin. True or false True 36. Exhaust trench grills should be kept clean for good suction. True or False True 37. Where is creel stop motion sensor? (on field identification test) 38. Sweeping to be done while changing the cans batch wise. True or False (Answer: True) 39. Top roller clearer cloth rotation should be proper for effective cleaning. True or False (Answer: True) 40. If one bobbin running found slough off, what do you do? Leave that spindle idle and remove that bobbin immediately 41. Where is false twister? (on field test) 42. What should be done if running roving is loose or tight? (on field test) 43. Where do you put the sliver waste during mending at creel side? Put in the allotted sliver waste box or can 44. Roving waste should be minimum while attending roving breakage near flyer. True or False (Answer: True) 45. Damaged empty roving bobbin should not be used and kept separately.

True or false (Answer: True) 46. Bobbins should be arranged in __________ (bobbin rack) 47. Bobbins should be handled properly to avoid slough off or damage. True or False (Answer: True) 48. Bobbin should not be thrown into the bobbin trolley. True or False (Answer: True) 49. While attending end breakage at front side, using of nylon hose for inserting roving inside the flyer minimizes the time. True or False (Answer:True) 50. Mention the preparatory department Maistry/foreman.(on field test) Get Answer from respective unit 51. Mention the production officer name (on field test) Get Answer from respective unit 52. Check for Fire extinguisher operation (on field test) First locate the fire extinguisher, then take it to the respective place and release the lock in the neck and take the extinguisher near the fire accident area and knock over the top knob, it will extinguish fire. 53. Check for basic knowledge about humidification system.(on field test) To ask the tenter to show Exhaust trench, Supply air duct and ask them to answer whether humidification plant is running or not. 54. Over head Blower should not run during the doff. True or False (Ans: true) 55. Check the method of doffing. (on field test) Get help from training officer for observing this. 56. Check the efficiency of doffing w.r.t standard unit time.(on field test) Get help from production dept of respective unit. 57. Check the production for one doff per standard unit time (on field test) Get help from production dept of respective unit. 58. 1 roving bobbin = ________ kgs (approximately 1-2 kgs) 59. 1 roving bobbin = ------------- metres (approx 5000 metres) 60. Check for hank meter operations such as speed, length, etc (on field test) 61. Mark the machine parts (spindle, bobbin, creel, gear end, off end, flyer) in the below diagram.

62. Show and name top roller, bottom roller and top arm lever in the below diagram.

63.where is false twister cup in the below diagram?

64.what is travelling OHB in the below diagram?

65.What is wrapping of roving over presser arm?

Ring Spinning

1. What is the feed material for ring frame machine? Roving bobbin or Simplex bobbin 2. What is the output material of ring frame machine? Ring cop 3. ________ is the model of the ring frame machine (respective unit). 4. Ring frame machine has ___________ number of spindles per frame.

5. While changing count, is it necessary to change the traveller? Yes or No Yes 6. Traveller is necessary for spinning the yarn. True or False True 7. What do you observe in your machine while shift change over? Count /hank of delivery and feed Roving bobbin colour Cleaning of the drafting zone, creel, spindle, spindle rail No. of idle spindles Machine is running or not House keeping Amount of Roving Waste and Pneumafil waste Over head blower functioning Deformed or slough off bobbins any Hank meter reading

8. Where is top roller? (on field test) 9. Where is bottom roller? (on field test) 10. Where is flyer? (on field test) 11. Where is creel?(on field test) 12. Where is bottom apron and top apron?(on field test) 13. Where is spacer? (on field test) 14. Where is ring?(on field test) 15. Where is traveller? (on field test) 16. Where is broken end collector? (on field test) 17. Where is lappet? (on field test) 18. Where is lappet hook? (on field test) 19. Show the gear end in the machine.(on field test) 20. Show the off end in the machine.(on field test) 21. Show the tin roller in the machine.(on field test) 22. Where do you check hank reading in the machine.(on field test) 23. Show the spindle tape running in the machine.(on field test)

24. Show the drafting zone in the machine.(on field test) 25. One Spindle tape drives _______ spindles. (answer -4) (a) 2 (b) 4 (c) 6 (d) 8 26. Show the Balloon Control Ring in the machine. (On field test) 27. Traveller will not rotate in the ring while end breakage .True or False (Answer-false) 28. When top roller gets lapped with cotton, you have to use the knife to remove the lapped cotton. True or false (Answer False) 29. How do you fix the spacer in the drafting zone? (On field test) 30. Spindle tape running out of spindle wharve is not acceptable. True or false (Answer True) twist variation occur lower yarn quality 31. If fibre forms a layer in the bottom roller while normal running what do you do? Cleaning to be done using stick or picker gun. 32. Waist bag is necessary for ring frame tenter. True or false (Ans: True) 33. Where do you put the fibre waste collected during roller lapping? Waist bag 34. How much length of yarn you will unwind from cop while piecing? 1 to 1.5 feet. (Approx) 35. After attending the end breakage, you should not lift the pieced yarn by finger. True or False (Ans :True) 36. What are the responsibilities of the ring frame sider or tenter? Count running in the machine Process details such as lot, colour codes, traveller details Feed bobbin hank Feed bobbin running simplex and bobbin storage place Awareness about Idle spindles Machine switch operations Doffing procedures Empties colour Piecing procedure after doffing (during start of the doff)

End breakage attending procedure Traveller reserve to be kept Number of sides looking Having waist bag, stick Count board information update while changes occur

37. What do you do if your machine is having more idle spindles? Should inform to Production officer/foreman/fitter to correct 38. Spindle tape is running crosswise in the spindle will produce low quality yarn. True or false (Ans:True) 39. Spindle is running with huge vibration and noise will create end breakage. True or false (Ans: True) 40. What do you do if machine is having higher end breakage? Inform production officer/foreman/maistry to correct 41. If the traveller is loading with fibre in many spindles, what will you do? Inform production officer/foreman/maistry to correct 42. If roving bobbin get exhausted and spindle is running idle, what will you do? Put the reserve bobbin and piece and run 43. Removing roving bobbin with 1 or 2 layers from the creel creates good fibre waste. True or false (Answer: True) 44. Roving waste in spinning should be very minimum. True or false Answer: True 45. Drafting zone cleaning is essential for good quality yarn. True or false. Answer: True 46. Over end piecing during start of the doff is wrong which create huge breakage in winding and heavy yarn waste in winding. True or False Answer: True 47. Number of piecing /min pieced by sider (on field test) 48. Method of piecing (on field test) To see how much length of yarn taken from cops (should be minimum) To see how much time taken to unwind yarn from cop and piecing

Check the pieced area by R & D person (Pieced area should be minimum to get minimum breaks in winding)

49. What do you in case of broken end collector chocking with fibre? Take the broken end collector outside and clean the chocked fibre using stick and again fit and run. 50. Number of cops/doffer/doff - Time (on field test) 51. Doffing method: (on field test) Operation of machine switches during doffing Preparation for doffing with empties All the persons ready at time to be checked Check for lagging among the doffers Empties arrangement in the crates Time taken by doffer from empties box to the machine Check for communication among the doffers Doffing the full cops and putting the empty cops check for exact insertion While running after doff check for any empty cop in wrong position Piecing procedure during the start immediately after doff Check for over end piecing (to avoid)

52. Check for lagging among persons - doffing time/doff (on field test) 53. What do you observe while count change? Count to be changed Colour codes Variety, lot wise etc Wheel change done or not to be ensured Traveller to be changed if necessary Count board to be changed Old ring cops to be disposed to proper area After run for 5-10 min stop and inform to R &D for count check up.

54. What should be done while lot change?

Traveller if count also changed Old roving bobbins, old ring cops to be disposed to respective places Count information board update Colour codes -empties Wheel changes if necessary to be noted After run for 5-10 min stop and inform to R &D for count check up.

55. Where is Over head blower? 56. Over head blower (OHB) gets stopped due to some repair. After repair you have to run over head blower with all ring frames respective to that OHB to avoid huge end breakage and low quality yarn. True or false True. 57. What do you do if you find apron(top or bottom) is missing? Leave the spindle idle and inform to fitter/foreman 58. What do you do if you find top roller damage? Leave the spindle idle and inform to fitter/foreman 59. Top arm pressure lever should be lifted with uniform pressure. True or false True 60. Top roller clearer roller should be always kept over top rollers. True or false True 61. Top roller clearer roller is not rotating in some spindles. What will you do? Try to make it run by cleaning otherwise inform to fitter 62. Test basic knowledge about Humidification system (on field test) 63. Allot full work load for a sider and observe the end breakages, idle spindles, piecing yarn area and machine cleaning (for 1 doff) 64. Check the observation of full doff time.(on field test) 65. Allot full work load to the doffing team and observe the doffing procedures, end breakages after doff, any over end piecing done, etc. (on field test) 66. Check for cleaning ability of slight slough off roving bobbin and running in ring frame (on field test) 67. When roving bobbin is going to exhaust in a set, what do you do?

Inform to spinning foreman and put it during doff time to avoid idle spindles. 68. Machine is not running due to electrical problem, what do you do? Inform to production persons/officers 69. What is the name of the spinning foreman? 70. What is the name of the production officer/manager? 71. What do you do in case fire accidents occur? Stop the machine. Extinguish using fire extinguisher or water. Inform to officers immediately. 72. Where is fire extinguisher in your department? (on field test) 73. How to operate fire extinguisher? (on field test) 74. If spindle wharve is having some yarn wound, what do you do? Remove the yarn (because it increases the load on spindle in turn increases power consumption). 75. What is the spacer colour in the ring frame?(on field test) 76. Where is traversing motion?(on field test) 77. Where is emergency switch? (on field test) 78. Where is pneumafil waste box?(on field test) 79. Check the Over Head Blower air outlets for air blow is mustfor effective machine cleaning. True or false (ans: True) 80. Where is 500 no. spindle in this ring frame? (on field test) 81. How do you stop the spindle for attending the end breakage? Using knee break or finger 82. Leaving knee break in contact with the spindle in normal running condition should be avoided. true or false (ans: True) 83. Leaving knee break in contact with the spindle for a long time should be avoided. true or false (ans: true) 84. Spindle button in spindle is important for empty cop gripping. True or false True 85. Knife should not be used for removing fibres in spinning. True or false True

86. Exhaust trench grills should be kept clean for good suction. True or False True 87. Doffed cops to be kept near the respective count running winding machine or allotted place. True or false Ans: True 88. Cops with different colour found in your machine to be kept in _________(Answer: separate allotted box) 89. Machine underside should be kept clean and free from empties or any cops. Yes or No (Answer: yes) 90. Ring cut occurred in ring cop in a spindle in your machine. What do you do? Remove the roving bobbin and respective ring cop separately and immediately inform the production/R&D officers. 91. Blue colour empties is running in your machine. Will you put red colour empties? Yes or No. (Ans: No) 92. Breaks occur in the creel are more, what do you do? Check for respective bobbin holder rotation is free or not and inform to fitter/production officer.

Cone Winding

1. _________ is the feed material for cone winding. (Ans: ring cop) 2. _________ is the output material for cone winding (Ans: Cone) 3. ________ is the cone weight running in particular machine (on field) 4. Ring cops feeding for the particular winding machine should be kept with proper count and lot information .True or False (Ans: true) 5. Where is cop feeding magazine? (on field identification test) 6. Where is yarn clearer? (on field identification test) 7. Where is cone drum? (on field identification test) 8. Where is splicer? (on field identification test) 9. Where is waxing roll? (on field identification test)

10. Waxing roll should be used in winding machine as per instruction from winding officer only. True or False (Answer: True) 11. What are the responsibilities of winding tenter? Should know Count, lot, process details Ring cop, empty cone colour codes Should know Cone weight and its tolerance limits Basic functions in microprocessor screen Able to read fault messages in screen and to inform officers Aware about Changes takes place in previous shift Should inform about any count mix or lot mix Should check shade variations Should check for any visible fault in splice area in the yarn Have waist bag to put yarn waste Inform about abnormal breaks, deformed cop, rejected cops

12. Where is yarn cutter? (on field identification test) 13. What do you do if you find different colour cop not respective to that count in you crate box? Handover the cop and inform to winding officer 14. Too much cop rejections lower the production of the winding machine. True or false (Ans: True) 15. Over end piecing done in ring spinning create breakage in cone winding. True or False (Answer: True) 16. Where is your feed ring cop location in winding department? (on field test) 17. ___________ Metres of length of yarn present in one cone. 18. _________ is the empty paper cone weight. 19. (+) ______ GMS tolerance is acceptable in cone weight. 20. Cone weight is varying too much, what is the problem? In next process yarn waste will be more due to differences in exhaustion. 21. Hands should be clean while touching cone. True or False Answer: True 22. Every empty cone should have ________.

(a) Cone label (b)colour (c)mark (d)number 23. Cone tip should have colour if necessary. True or false Answer: True 24. Check Winding m/c switch operations (on field identification test) 25. Check for the different signal lamp and its meaning (on field test) 26. Check for knowledge about passage of material (on field test) From cop feed magazine through yarn guide, yarn tensioner, fault detector, yarn cutter to winding drum 27. Check the method of cone covering using hand without stains(on field test) 28. Observe the tenter work while doffing time and empty cone feeding time (on field test) 29. Knowledge about air requirement to run autoconer, compressor, etc(on field test) 30. Cones should be arranged properly in the space allotted. True or False Answer: True 31. Cones should be handled properly and transferred through cone trolley. True or False (answer: true) 32. What is cone slough off? (Answer: layers come out due to poor material handling methods) 33. What is shade variation? Answer: if different count or lot gets mixed then shade of the yarn or cone varied. 34. Shade variation is acceptable quality problem. True or False. Answer: False. It is a serious quality problem leads to cone rejection. 35. How do you find the shade variation in the cone? By showing the cone in the Ultra violet rays in the dark room, shade variation is visible to eyes clearly. 36. Where do you check the shade variation? ( on field test) 37. Full cones should be keep in _________ (cone trolley) 38. Where is cone trolley? (on field identification test) 39. What are the things to note down while count change? Colour codes- ring cop, cone label, cone tip Cone weight Settings change

Check for previous lot cops any in the machine or around the machine

40. Knowledge about operating fire extinguisher.(on field test) 41. Location of fire extinguisher.(on field identification test) 42. Basics about humidification plant (on field test) To check whether exhaust trench having suction and supply fan is running or not, looking the hygrometer for correct RH% 43. Underground trench grills should not have any blockage. True or False Answer: True 44. Rejected cops are ________ quality ring cops. (a) Low (b) High (c) too low (d) both a and c 45. If cone wound is too loose or too tight what do you do? Answer: Inform immediately to winding officer. 46. Air cleaning using hose should not be done while machine is in running. True or False Answer: True 47. What is hard waste? Yarn waste is hard waste 48. Hard waste is usable waste. True or false. (Answer: False) 49. Usage of knife in winding is prohibited. True or False. (Answer: true) 50. What is rewinding? Feeding the cone and winding carried out to produce cone is called rewinding 51. Check the winding tenter efficiency by allotting drums as per work load per standard unit time. (On field test) Answer: get the help of your respective unit production manager in carrying out this test 52. Check the winding tenters awareness in following things such as cone label, tip, weight, location of the delivered cone, cops coming frame No., count, etc (On field test)

Answer: get the help of your respective unit production manager in carrying out this test 53. Check their ability in understanding basic settings in screen and button operation. (On field test) Answer: get answer from respective unit 54. How do you manually run the drum? (On field test) Ask the winding tenter to run the drum manually for preparing sample. 55. What is the name of the winding Officer? (On field test) Answer: get answer from respective unit 56. Hard waste should be minimum. True or false (Answer: true) 57. How many drums are there in a machine? (On field test) Answer: get answer from respective unit 58. How many machines are there in the winding department? (On field test) Answer: get answer from respective unit 59. What is the Autoconer model? (On field test) Answer: get answer from respective unit 60. Where is Over head blower (OHB)? (On field test) OHB is travelling equipment on the machine which is having side pipes which blow and suck the dust present on the machine. 61. What do you do if OHB is not functioning? Inform to OHB mechanic or winding officer

Yarn Conditioning & Packing

Yarn Conditioning: 1. What is the feed material for yarn conditioning machine? Cone 2. How do you keep the cone in the yarn conditioner? Keep the cones in the cone trolley and insert the cone trolley into the yarn conditioner through rails 3. How do you set the temperature in the yarn conditioner? (on field test) Hint: Temperature setting in the microprocessor screen 4. 5. 6. Check for basic switch operations in yarn conditioner. (on field test) How many cones can you keep inside the yarn conditioner once? (on field test) Check the material handling method of yarn conditioner operator (on field test) Hint: Use cone trolley for keeping cones inside conditioner 7. If temperature set is higher than the recommended, what happened to yarn? Answer: yarn quality gets lowers. 8. What is the time frequency for yarn conditioning? (on field test) Hint: Time to keep one doff in conditioner (varies for hosiery and warp) 9. Where do you take the cone for conditioning? Answer: Cones kept in the allotted place as instructed by winding officer. 10. Polythene covers should be removed from cone before conditioning. True or false Answer: True 11. Check for the safety measures to followed during cone trolley insertion and removal from yarn conditioner (on field test) Hint: Cone trolley to be moved in rally provided in yarn conditioner 12. Conditioned cone should not have any yarn colour change. True or false Answer: True 13. Location of fire extinguisher (on field test) 14. Basic operation of fire extinguisher (on field test) 15. Check the follow up of conditioning operation such as correct time follow up, speed of material transportation (on field test) 16. Knowledge of count, lot, colour codes (on field test) 17. What is the name of winding officer? (on field test)

18. Yarn conditioning is done to improve ___________ (yarn strength) 19. Knowledge of Time and temperature setting for different yarns (hosiery and warp) (on field test) 20. Check the ability to open and closing of door. (on field test)

Packing:

1. All the cones should be covered with polythene covers. True or False (Answer: true) 2. Cones of respective count should have same cone tip colour and colour code. True or false (answer: True) 3. _________ should be provided in the packing area for easy identification.(b) (a) Label (b) count board (c)cone bag (d) poster 4. __________ Details should be checked in the carton board. (d) (a)count (b) No. of cones (c) lot (d) all the above 5. Check the knowledge of carton weight, full carton weight, tolerances (on field test) 6. Check the method of packing and placement of cones inside the carton (on field test) 7. Check the material handling ability (on field test) 8. Check the knowledge of count, lot, colour code details of all the cones.(on field test) 9. Knowledge on where to get the carton, polythene covers, twines, etc (on field test) 10. Check the ability to observe the weighing of the carton bags (on field test) 11. Cone cartons to be kept in ___________ ( allotted place instructed by winding officer) 12. Carton should not have any damage or stains. True or false (Ans: true)

13. Placement of cone in carton should be proper and should not have damage to cones. True or false (answer: True) 14. Any visible stains in cones while packing should be kept ________ (separately) 15. Weighing balance should be checked with standard weight for calibration. True or False (Answer: True) 16. ________ should be used to transfer cone cartons from one place to another. Answer: Carton Trolley 17. Straps should be compactly hold the carton. True or False (True) 18. __________ is the empty weight of carton. (Answer: refer your mill packing dept) 19. Carton should be stiff enough to put the cones inside. True or False (True) 20. ___________ is the colour of carton. (answer: Brown) 21. __________ is the carton weight tolerance (Answer: refer your mill packing dept) 22. What will you do if you find one cone with wrong colour code? Answer: Keep separately and informed to winding officer. 23. Cones must be covered with polythene cover before placing in the carton. True or false (True) 24. _________ is the weight of one polythene cover used for covering cone.(Answer: approx 5 gms) 25. ____________ is used to check the cone weight. (Answer: Weighing Balance) 26. What is tare weight? Answer: Weight of materials (empty cone, polythene cover, carton and strap) other than yarn. 27. What is net weight? Answer: Only Yarn weight 28. Net weight = Total weight - ___________ (Answer: tare weight) 29. How do you calibrate the weighing balance? Answer: By using standard weight bars check the correct functioning of weighing balance 30. Cartons should have uniform dimensions. True or false (answer: True) 31. Cartons should have Mill name. true or false (answer: true)

32. Cartons should not have carton number. True or False (Answer: False) 33. Sharp hooks should not be used to transfer cone bags or cartons. True or False (Answer: True) 34. _________ number of cones are there in a carton bag. (Answer: refer mill packing department) 35. What is Carton? Carton is Thick brown cone packing box