L All Vocational Ed Textile Sector: Textile S.No ... · HAND SPINNING OF COTTON CARPET YARN. ... CARPET YARN DYEING WITH NATURAL DYES ... • Preparation of project cum feasibility

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L_All_Vocational_Ed_Textile

Sector: Textile

S.No Specialization Page No.1 Carpet Technology 2-122 Chemical Processing 13-293 Khadi Manufacturing 30-434 Spinning 44-615 Weaving 62-81

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NATIONAL VOCATIONAL EDUCATION QUALIFICATION FRAMEWORK

SECTOR: TEXTILE

SPECIALIZATION: CARPET TECHNOLOGY

S.No. Certificate Level Vocational Hours1. Level-I 200 hrs2. Level-II 250 hrs3. Level-III 350 hrs4. Level-IV 350 hrs5. Level-V 500 hrs6. Level-VI 550 hrs7. Level-VII 750 hrs

CERTIFICATE LEVEL – I

1. HAND SPINNING OF WOOLEN CARPET YARN.(Carpet / CAR 104)Practical Competencies Underpinning Knowledge (Theory

• Identification of wool fibre• Operation of Gandhi & Ambar

charkha for producing woolen yarn

• Measurement & control ofCount & Twist

• Measurement & control of yarn realisation

• Practice Do’s & Don’ts

• Study of wool fibre• Study of tools and materials required

for manufacturing hand spun woolenyarn.

• Study of feed material required formanufacturing hand spun woolen yarnof the desired count

• Study of different product setting parameters

• Study on yarn realisation• Do’s & Don’ts

2. HAND SPINNING OF COTTON CARPET YARN.(Carpet / CAR 105)

PRACTICAL THEORY• Identification of cotton fibre• Operation of Gandhi & Ambar

charkha for producing cottonyarn

• Measurement & control of Count& Twist

• Measurement & control ofyarn realisation


• Study of cotton fibre• Study of tools and materials required for

manufacturing hand spun cotton yarn.• Study of feed material required for

manufacturing hand spun cotton yarn of thedesired count

• Study of different product settingparameters• Study on yarn realisation

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• Do’s & Don’tsCERTIFICATE LEVEL – II

1. HAND KNOTTED WOOLLEN CARPET MANUFACTURING(Carpet / CAR 101)

Practical Competencies Underpinning Knowledge (Theory• Identification of various tools &

equipment & material.• Safe working practices.• Warping• Preparation of warp beam &

mounting on the loom• Warp setting• Knot setting• Knotting on the loom on the basis of

design• Measurement & control of pile

height, knot density, waste, dimension etc

• Study of sequence of operations• Methods of transferring the

design to carpet.• Defects in manufacturing carpet

and remedial measures.

2. TIBETAN CARPET MANUFACTURING(Carpet / CAR 102)






• Inspection & Mending of the defects

• Study of sequence of operations• Methods of transferring the design to

carpet.• Defects in manufacturing carpet


3. FLAT WOVEN DHURRIE MANUFACTURING(Carpet / CAR 103)

Practical Competencies Underpinning Knowledge (Theory• Identification of various tools &equipment & material.• Safe working practices.• Warping on the loomPractice of weaving according to the designon flat looms to make dhurries

• Study of sequence of operations• Methods of transferring the design

to carpet.• Defects in manufacturing carpet

and remedial measures

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• Inspection & Mending of defectsCERTIFICATE LEVEL – III

1. HAND TUFTED CARPET MANUFACTURING(Carpet / CAR 106)


equipment & material.• Safe working practices.• Stretching of the primary fabric on

loom• Inspection & Analysis of

primary, secondary & third backing fabric including yarn used for tufting

• Maintenance of tufting gun• Transferring the design from

trace paper to fabric• Practice of tufting on tufted

loom• Inspection & Mending of the

defects

• Study of sequence of operations• Study of primary, secondary &

third backing fabric including yarn used for tufting

• Study of various tufting guns• Methods of transferring the



2. BROAD LOOM CARPET MANUFACTURING(Carpet / CAR 107)


equipment & material.• Safe working practices.• Warping out side the loom• Beam setting on the loom• Weft preparation• Machine setting• Practice of weaving on

broadloom.• Inspection & Mending of defects

• Study of sequence of operations• Methods of transferring the design to

carpet.• Defects in manufacturing carpet


.

3. MANUFACTURE OF FABRIC RELATED TO CARPET(Carpet / CAR 112)


equipment & material.• Safe working practices.• Operation of looms• Practice of beam gaiting• Practice of loom setting

• Study of sequence of operations• Parts of the loom & its function• Motion of the loom & Mechanism

behind• Specification of fabrics related to

carpet/ home furnishing

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• Practice of Design setting• Practice of repairing of thread

breaks• Inspection & Mending of defects

• Theory of loom/setting• Theory of cloth setting• Basics of Fabric Design• Study of fabric defects

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CERTIFICATE LEVEL – IV

1. CARPET YARN DYEING(Carpet / CAR 108)


equipment & material.• Safe working practices.• Wool/Silk/Art. Silk identification.• Operation of dyeing machine.• Dye stuffs identification• Practice of Dyeing of wool• Practice of Dyeing of silk• Practice of Dyeing of Art. Silk• Shade Matching• Checking of colour fastness to

washing, rubbing etc.

• Study of wool/silk/art silk Fibre• Study of Sequence of operations• Importance of machine parameters of

dyeing.• Different type of machines used for

Carpet Yarn Dyeing• Function of dyes, chemicals &

auxiliaries• Recipe, Colour Fastness and

shade matching

2. CARPET FINISHING - I (Carpet / CAR 109)


equipment & material.• Safe working practices.• Practice of washing of handknotted

woolen carpet using chemicals and herbal products

• Practice of washing of hand tufted woolen carpet using chemicals and herbal products

• Monitoring & control of neutralization & moisture content

• Practice of after wash process like drying

• Monitoring & control of residual moisture content

• Scope & objective of washing• Recipes• Function of all ingredients• Defects of carpets and their

remedial measures.• Eco-friendliness

3. CARPET YARN DYEING WITH NATURAL DYES(Carpet / CAR 217)

Practical Competencies Underpinning Knowledge(Theory

• Identification of various tools &equipment &

material.• Safe working practices.

• Study of Fibres: Wool/silk/art.Silk

• Study on availability of harvestedRaw materials for extraction of

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• Collection of harvested Rawmaterials for extraction of Naturaldyes.

• Practice of Extraction of dyestuffsfrom various harvested raw materials

• Measurement and control of dye concentration, pH of extracteddye.

• Dyeing of wool with extractednatural dyes

• Dyeing of silk with extractednatural dyes

• Dyeing of Art. Silk withextracted natural dyes

• Control of parameters toobtain reproducible shades.

• Testing of Colour Fastness

Natural dyes.• Sequence of Natural dye

extraction• Theory of dyeing with natural dyes• Importance of mordants &

auxiliaries.• Study on fastness properties of

natural dyes

4. CARPET FINISHING-II(Carpet / CAR 218)


equipment & material.• Safe working practices.

Practice for• Singeing• Shearing• Stretching• Sorting• Clipping• Carving• Embossing• Binding• Colour cut• Packaging

• Study of sequence of operations• Study of finishing methods relevant to

type of carpets• Basics of packaging of carpets

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CERTIFICATE LEVEL – V

1. HAND KNOTTED SILK CARPET MANUFACTURING(Carpet / CAR 210)






• Study of sequence of operations• Methods of transferring the



2. NATURAL FIBRES FOR CARPET(Carpet / CAR 211)


equipment & material.• Safe working practices.• Identification of fibres.• Operation of related spinning

techniques• Operation of related Process of dyeing• Operation of related process of

Weaving

• Description of different unconventional Natural Fibres, their properties & end use applications.

• Study on sequence of operation on yarn spinning

• Study on operation in dyeing• Study on operations in related

chemical treatments• Study on process of weaving of

natural fibre based yarns

3. SPINNING OF WOOLEN CARPET YARN(Carpet / CAR 213)

Practical Competencies Underpinning Knowledge (Theory• Identification of various tools

& equipment &material.

• Safe working practices.• Identification of wool Fibre• Operation of woolen

spinning line• Operation of Semi-

Worsted spinning line.

• Study of wool fibre• Study of sequence of operation of

woolen spinning line• Study of the different machine

setting parameters• Study of different product

setting parameters• Study on yarn realisation• Do’s & Don’ts

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• Production of woolen yarn (s)of desired counts

• Production of semiworsted yarn (s) ofdesired counts

• Measurement & control ofCount & Twist

• Measurement & control ofyarn realisation


4. ENTREPRENEURSHIP AND EXPORT MANAGEMENT(Carpet / CAR 214)


equipment & material.• Safe working practices.• Preparation of various export

documents• Survey & data basing• Preparation of project cum

feasibility report for setting up a small scale company

• Types of export documents• L/C and its types• Regulatory requirements of various

countries• Basic requirements for

entrepreneurs• Basics of production, financial

marketing management• Govt. schemes for development of

entrepreneurship & employment promotion schemes

• Managing people

5. MINOR PROJECT I

6. PERSONALITY DEVELOPMENT

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CERTIFICATE LEVEL – VI

1. SPINNING OF COTTON CARPET YARNPractical Competencies Underpinning Knowledge (Theory

• Identification of various tools &equipment & material.

• Safe working practices.• Identification of cotton Fibre• Operation of cotton spinning line• Production of cotton yarn (s) of

desired counts• Measurement & control of Count &

Twist of cotton yarn• Measurement & control of yarn

realisation• Practice Do’s & Don’ts

• Study of wool fibre• Study of sequence of operation of

cotton spinning line• Study of the different machine

setting parameters• Study of different product

setting parameters• Study on yarn realisation• Do’s & Don’ts.

2. CARPET BACKINGPractical Competencies Underpinning Knowledge (Theory


• Safe working practices.• Analysis of latex and/or adhesive

material• Analysis of backing fabrics• Measurement & Monitoring of

drying and adhesion• Setting of backing process• Testing for delamination & tuft

withdrawal force

• Study of sequence of operations• Study of backing materials

including latex and/ or adhesive materials

• Study of overall backing system including quality assurance

3. DESIGNING OF FABRIC RELATED TO CARPETPractical Competencies Underpinning Knowledge (Theory


• Safe working practices.• Development of dobby and

Jacquard with respect to design.• Drawing & Drafting• Pegging of lattice• Card punching• Dobby/ Jacquard design

development

• Study of Basics of fabric structure• Types of fabric for various end

uses.• Basics of Cloth setting• Trend of design in backing fabrics

related to carpet/ home textiles• Basics of weaving process• Study of dobby and Jacquard with

respect to design.

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4. MODERN CARPET YARN MANUFACTURINGPractical Competencies Underpinning Knowledge (Theory


• Safe working practices.• Identification of different parts of

DREF 2000 or such machine• Setting of process & machine

parameter involved.• Practice to produce woolen or such

yarn in DREF 2000 or such machine• Measurement & Control of Count of

Yarn

• Fibres and its uses• Types of fibres including wool fibre

required for DREF machine• Sequence of operation in DREF or

such Technology• Technique of manufacturing yarn

through DREF or such machine• Do’s & Dont’s

5. MAJOR PROJECT

6. ADVANCE SKILLS

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CERTIFICATE LEVEL – VII

1. CARPET DESIGNING CADPRACTICAL COMPETENCY UNDERPINNING KNOWLEDGE (THEORY)

• Development of Colour wheel• Use of crayons, colour pencil,

Skecth & water colour, poster colour

• To create different type & style design plate in these areas: Textile: Jamdani, Phulkari,

Kantha, Paithani, Banaras Carpet: Kirman, Herati,

Tabriz, Prayer Rug, Mir, Tufted and Modern Carpet Design

• System Practice on CAD out of above mentioned creations

• Exhibition of developed design for market testing

• To study historical aspects & colour themes involved in areas Textile: Jamdani, Phulkari,

Kantha, Paithani, Banarasi Carpet: Kirman, Herati, Tabriz,

Prayer Rug, Mir, Tufted and Modern

CAD• Different tools of CAD Software &

its Application for Textile & Carpet Designing

• Study of Colour, Motif & Market trend

2. FUNDAMENTALS OF I. T. & ITS APPLICATION IN CARPET INDUSTRYPRACTICAL COMPETENCY UNDERPINNING KNOWLEDGE (THEORY)

• Practical of BasicCommand/ Functions/Statements for computeroperation.

• Basic/ Some other relevant software practice.

• Practical for developing small programme for computation relevant to Carpet & Textile

• Practical for Cost Calculation• Practical for MIS reporting• Cost output using Carpcost

• Basics of Information Technology• Commands/ Functions of a

particular programming language C++/Visual Basic

• Web technology, HTML,Protocols, HTTP, www

• Basics of networking• Use of Software (Carpcost)

3. MAJOR PROJECT

4. PRODUCT DEVELOPMENT

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SECTOR: TEXTILE

SPECIALIZATION: CHEMICAL PROCESSING


Certificate Level – I

1. ALL TYPES OF PROCESSES INVOLVED IN CHEMICAL PROCESSING OF THE TEXTILES

2. OPERATION AND MAIMTENANCE OF SINGING MACHINE, MERCERISING MACHINE AND DRYING MACHINE (TCP146,TCP147).(TCP146)Practical Competencies Under pinning Knowledge (Theory) Cleaning of the machine and the

surroundings Putting petrol in the gas generating

plant and generating gas. Alternatelyoperate the gas valve fitted to LPGcylinder

Light up the flames and adjust the height

Run the yarn in the machine Clean burners, brushes and gas

generator. Practicing the work considering

safety of man and machine Mock drill for fire fighting and first

aid.

Basic knowledge about variousaspects of gassing machine function and operation to get optimum production

Importance of gassing of yarn Details of the machine Importance of discipline and

punctuality Ill effects of absenteeism Productivity and quality Knowledge of chemicals used Quality of work Safety precautions First aid and fire fighting

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(TCP147)

Practical Competencies Under pinning Knowledge (Theory) Cleaning of the machine and the

surroundings Bring the hanks for mercerising Straighten the hanks and load the

machine with swivels Prepare the caustic soda solution

of necessary strength Start the machine and monitor the

stretch After completing the time, drain

out the caustic liquor and wash the hanks with dilute acid forneutralizing, followed by washing

Remove the hanks and feed to drying chamber.

Practicing the work considering safety of man and machine

Mock drill for fire fighting and first aid.

Basic knowledge about variousaspects of mercerising machine and operation to get optimum production

Importance of mercerising of yarn Details of the machine Importance of discipline and


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Certificate Level – II

1. GREY FABRIC MARKING AND COUNTING GREY FABRIC STITCHING(TCP106,TCP107).

(TCP 106,)

Practical Competencies Under pinning Knowledge (Theory) Cleaning of the table and the

surroundings To receive grey cloth To count and sort the cloth To stamp the cloth as necessary Preparing the fabric in suitable

lots and delivering to stitching. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of marking and counting

Importance of marking and counting the fabric

Importance of discipline and punctuality

Ill effects of absenteeism Productivity and quality Knowledge of chemicals used Quality of work Safety precautions First aid and fire fighting

(TCP 107)

Practical Competencies Under pinning Knowledge (Theory) Cleaning of the stitching machine,

table and the surroundings To receive grey cloth To open a piece and take out

inside loose end To pick up loose top end of the

second piece and to join these two ends and feed them to stitching machine

To stitch two ends together ensuring that the joined fabrics are straight and in one line.


Importance of stitching the fabric instraight line and making longer length offabric batch


Ill effects of absenteeism Productivity and quality Knowledge of chemicals used Quality of work Safety precautions First aid and fire fighting

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2. BLEACHING PROCESS(TCP109,TCP182).

(TCP109,)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine Weighing the chemicals,

preparing solution and diluting them to required strength.

Cleaning of the Mixers/machine and the surroundings

Submitting the solution for testing the strength and quality of chemicals in the laboratory

Handling the chemical containers Controlling the stirring operation. Monitoring chemical pipelines

and water lines. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of Colour preparation and chemical preparation

Importance of preparing uniform chemical solution, weighing and paste preparation

Details of the stirring machines, chemical pipelines and storage conditions


Ill effects of absenteeism Productivity and quality Knowledge of colours and chemicals used Quality of work Safety precautions First aid and fire fighting

(TCP182)

Practical Competencies Under pinning Knowledge (Theory) Inspecting the fabrics after each

process in bleaching and finishing section for the quality and working.

Checking whiteness, feel, finish, lustre, width consistency.

Recording and maintaining the records.

Classifying the fabrics as per sort and the quality and reporting the findings.

Practicing considering safety and health aspects.


Basic knowledge about variousaspects of Quality of bleaching and finishing operations and the fabrics.

Importance of quality at each stage in bleaching and finishing department.

The quality norms and normal defects Importance of discipline and

punctuality Ill effects of absenteeism Productivity and quality Safety precautions First aid and fire fighting

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Certificate Level – III

1. INTRODUCTION TO DIFFERENT KINDS OF DYES AND SYSTEMS OF DYEINGDYE BATH PREPARATION AND CALCULATIONS

2. COLOUR MIXER/ CHEMICAL PREPARATION (TCP 112, TCP 260).

(TCP 112,)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine Weighing the colours and

chemicals, preparing colour pastes and diluting them to required strength. Sieving wherever needed.


Submitting the solution for testing the strength and quality of chemicals in the laboratory



first aid.






(TCP 260)

Practical Competencies Under pinning Knowledge (Theory) To maintain cleanliness around the

work place To refer the sample and verify with

the colour charts and shade cards. If practicable, check the shade

in spectrometer and colourmatching computer

Verify the dyestuffs in stock and study the combinations to get theshade.

If dyestuff in stock is notsuitable, indent for correct dyestuff.

Basic knowledge about variousaspects of colour matching before dyeing in bulk

Importance of matching the shade to customer requirement

Operation of a colour matching spectrometer and computer

Shade cards provided by dye stuffmanufacturers and standard colours.

Dyeing with different group of dyes. Importance of discipline and

punctuality

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Dye a small sample as per your calculations and compare the shade with the original sample. Find outthe difference.

Correct the dye liquor to get thecorrect shade.

Record all the activities and work out the dye recipe and the cycle timings to get the required shadeand fastness properties

Practicing the work consideringsafety of man and machine

Mock drill for fire fighting and first aid

Ill effects of absenteeism Productivity and quality Knowledge of colours and

chemicals used Quality of work Safety precautions First aid and fire fighting

3. YARN DYEING IN HANKS FIBRE DYEING IN MACHINE JIGGER MACHINE OPERATION (TCP 113,TCP114,TCP 156).

(TCP 113,)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine To maintain cleanliness around

the work place To bring and put the boiled and

hydro-extracted yarn on sticks To prepare dye solution using

required colours and chemicals, bring it to required temperature and stir well before putting the yarn into Vat. Ensure that colours are properly dissolved.

Monitor the time and temperature of dyeing while ensuring continuous rotation of hanks.

Maintain the level of liquor constant through out.

After dyeing take out the yard and allow the liquor to drain out, and then oxidise, wash, sour ifneeded, soap and wash again.


Basic knowledge about variousaspects of hank dyeing.

Importance of Hank dyeing Dyeing with different group of dyes. Importance of discipline and

punctuality Ill effects of absenteeism Productivity and quality Knowledge of colours and chemicals used Quality of work Safety precautions First aid and fire fighting

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(TCP114)


the work place To Put loose fibres into stainless

steel cages uniformly Insert the cage into the machine

and operate as per instructions while maintaining time, temperature and dye solution feeding

Take out the cage after dyeing and allow the liquor to drain.

Oxidise, wash, after treat as needed

Prepare washing liquor and insert the cage again and wash.

Hydro-extract the fibres to dry Mock drill for fire fighting and

first aid.

Importance of fibre dyeing Procedures for dyeing cotton in loose form Shade cards provided by dye stuff

manufacturers and standard colours. Dyeing with different group of dyes. Importance of discipline and


(TCP 156)

Practical Competencies Under pinning Knowledge (Theory) End to End stitching of fabric

pieces Operation of panel board Cleaning of the machine and the

surroundings Oiling and greasing of the

machine Mounting the batch Monitoring the water, chemicals

and dye feeding. Temperature control of dye bath Stocking dyed batches properly Adjusting and maintaining speed of

running and reversing Sampling out for shade matching. Practicing the work considering

safety of man and machine Mock drill for fire fighting and

first aid.

Importance of dyeing of fabrics inopen width

Basic knowledge about various aspects of Jigger and Jumbo Jigger machine, function and operation to get optimum production.

Details of the machine Importance of discipline and

punctuality Ill effects of absenteeism Productivity and quality Knowledge of colours and chemicals

used Quality of work Safety precautions First aid and fire fighting

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Certificate Level – IV

1. HT-HP DYEING OPERATION JET DYEING MACHINE OPERATION(TCP 158,TCP159,,TCP184, TCP 185)

(TCP 158,)

Practical Competencies Under pinning Knowledge (Theory) Mounting of cheeses in the cheese

carrier Operation of panel board Cleaning of the machine and the


machine Monitoring the dyeing and

washing cycles, water, chemicals and dye stuff additions, temperature, time and pressure.

Unloading the dyed materials and sending for further process.



Importance of dyeing of yarns incheese form.

Basic knowledge about various aspects ofyarn dyeing in cheese form and Beam form.

Details of the machines Importance of discipline and


(TCP159)

Practical Competencies Under pinning Knowledge (Theory) Mounting of beam on beam

carrier. Operation of panel board Cleaning of the machine and the


machine Monitoring the dyeing and washing

cycles, water, chemicals and dye stuffadditions, temperature, time and pressure.

Unloading the dyed materials and sendingfor further process.

Practicing the work considering safetyof man and machine


Basic knowledge about variousaspects of yarn dyeing in cheeseform and Beam form.

Importance of dyeing ofyarns in beam form.

Details of the machines Importance of

discipline and punctuality



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(TCP184)




machine Preparing beam, mounting beam

in HTHP dyeing machine. Monitoring the water, chemicals

and dye feeding. Temperature and Pressure control

of dye bath Stocking dyed batches properly Adjusting and maintaining speed

of running and reversing Sampling out for shade matching. Practicing considering safety and

health aspects. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of HTHP Beam Dyeing machines, function and operation to get optimum production.

Importance of dyeing of woven polyester and blends in open width in beam form at high temperature and high pressure



(TCP 185)




machine Threading of fabric to jet dyeing

machine Monitoring the water, chemicals

and dye feeding. Temperature and Pressure control of

dye bath Stocking dyed batches properly Adjusting and maintaining speed of

running and reversing Sampling out for shade matching.

Importance of dyeing of Loosewoven and knitted fabrics in loose rope form in Jet dyeing machine.

Basic knowledge about various aspects of Jet Dyeing machines, function and operation to get optimum production.




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2. HYDRO EXTARCTOR TRAINING (TCP 117, TCP 118,TCP 119, TCP 161)

(TCP 117)


the work place. Unloading the cake from hydro-

extractor on the table next to the feeding lattice.

To open the hydro – extracted wetcotton into small tufts by handbefore feeding them to Wet cottonOpener

Setting the speed and settings of the machine

Working the machine and delivering the opened materials to driers.


Basic knowledge about variousaspects of Opening of wet cottons after hydro-extractor

Importance of Wet cotton Opening Importance of discipline and


( TCP 118)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine To maintain cleanliness around the

work place To Put dyed or bleached hanks

into Hydro-extractor Set the speed and time of the

machine Take out the hanks after hydro-

extracting Hang the hanks for drying. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of drying of hanks using hydro-extractor

Importance of hydro-extracting Importance of discipline and


used Quality of work Safety precautions

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First aid and fire fighting

(TCP 119)


the work place To clean the inside portion of the

dryer and remove burnt cottons To feed loose bleached or dyed

fibres or hanks into drying chamber

Setting the fans, speed and temperature of the heating coils in the machine

Monitoring the Moisture content. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of hot air drying of fibres and yarns

Importance of drying with hot air and the controls in the hot air chamber


Ill effects of absenteeism Productivity and quality Quality of work Safety precautions First aid and fire fighting

( TCP 161)

Practical Competencies Under pinning Knowledge (Theory) To maintain cleanliness around

the work place To clean the inside portion of the

dryer and remove burnt cottons To feed loose bleached or dyed

fibres into drying range after wet cotton opening

Setting the speed and temperature of the machine

Monitoring the Moisture content Delivering the dried fibres for

baling press. Practicing the work considering


first aid.

Basic knowledge about variousaspects of drying of fibres using continuous drying range

Importance of continuous drying range and the controls


Ill effects of absenteeism Productivity and quality Quality of work Safety precautions First aid and fire fighting

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Certificate Level – V

1. PRINTING PASTE PREPARATION (TCP123)

(TCP123)

Practical Competencies Under pinning Knowledge (Theory) Weighing the colours and

chemicals, preparing colour pastes, and bringing them to required strength. Sieving wherever needed.

Preparation of gum, starch and binding pastes and mixing the colour



and water lines. Practicing the work considering


first aid.

Importance of preparing uniformchemical solution, weighing and paste preparation




2. SCREEN PRINTING MANUAL TECHNIQUE (TCP120, TCP121)

(TCP120)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine Laying of fabric for printing Placing of flat screens on the table as

per their positions Applying colour paste Cleaning of the table and the

surroundings Monitoring the application of

colour pastes, temperature and time.


Basic knowledge about variousaspects of Screen printing and maintenance of screens.

Importance of Screen printing and maintenance of Screens.

Details of the Printing table Importance of discipline and


used Quality of work

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Safety precautions First aid and fire fighting

( TCP121)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine Fixing the Nylon mesh fabric for

preparing screen Coating the mesh cloth with

photo sensitive materials Exposing the coated mesh to the

image to be printed Cleaning of the surroundings Monitoring the application of

coating, exposure time and light. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of Screen preparation, screen printing and maintenance of screens.


Details of the Screen preparation Importance of discipline and



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Certificate Level – VI

1. INTRODUCTION TO VARIOUS AUTOMATED PRINTING PROCESSES

2. SCREEN PRINTING MACHINE OPERATION (TCP 162, TCP163, TCP164, TCP165)

(TCP 162)Practical Competencies Under pinning Knowledge (Theory) Placing of screens on the machine

as per their positions Setting of Doctor blades Preparing the batch for feeding to

the machine Operation of panel board Cleaning of the machine and the


machine Monitoring the application of




Basic knowledge about variousaspects of Flat bed Screen printing and maintenance of screens.

Importance of Flat bed screen printing, maintenance of screens and Doctor blades.



(TCP 163)Practical Competencies Under pinning Knowledge (Theory) Placing of Rotary screens on the

machine as per their positions Setting of Doctor blades Preparing the batch of fabrics for

feeding to machine Operation of panel board Cleaning of the machine and the






Basic knowledge about variousaspects of Rotary Screen printing and maintenance of screens.

Importance of Rotary screen printing, maintenance of rotary screens and Doctor blades.




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(TCP 164)

Practical Competencies Under pinning Knowledge (Theory) Understanding the design in hand Cleaning the copper rollers and

preparing for engraving Coating copper roller with

chemicals Applying the design and

engraving. Practicing the work considering


first aid.

Basic knowledge about variousaspects of engraving on copper rollers, preparation of rollers for printing

Importance of engraving the copper rollers and clarity of printing.



(TCP 165)

Practical Competencies Under pinning Knowledge (Theory) Mounting of Engraved rollers on

the machine and setting their positions

Setting of Doctor blades Threading the fabric through the

machine Operation of panel board Cleaning of the machine and the






Basic knowledge about variousaspects of Roller printing and maintenance of engraved rollers.

Importance of Roller printing, engraved copper rollers, and maintenance of rollers and Doctor blades.




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Certificate Level – VII

1. INTRODUCTION TO FINISHING PROCESS. TYPES OF FINISHES. VARIOUS TYPES OF EQUIPMENTS USED FOR THE FINISHING OF TEXTILES.

2. FINISHING MACHINERY OPERATION AND MAINTENANCE (TCP171, TCP172, TCP173)

(TCP171)




machine Temperature control of steam

bowls Feeding of the fabric to the

machine Nip pressure control (Bowls Nip) Adjusting and maintaining speed Locating metal particles in the

fabric by using metal detectors Examining the delivered cloth for

lustre, feel and width uniformity. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of Calender machine, function and operation to get optimum production. Different types ofcalender viz Swissing, Chasing, Shreiner and Embossing

Importance of Callendering of fabrics Details of the machine Importance of discipline and


(TCP172, )




machine Heating and cooling of cylinder

and rubber felt. Feeding of the fabric to the

machine Pressure control of the felt on

Basic knowledge about variousaspects of Pre shrinking machine, function and operation to get optimum production.

Importance of Pre shrinking of fabrics


punctuality Ill effects of absenteeism Productivity and quality Knowledge of chemicals used

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cylinder Adjusting and maintaining speed Examining the delivered cloth for

feel and width uniformity. Practicing considering safety and

health aspects. Mock drill for fire fighting and

first aid.

Quality of work Safety precautions First aid and fire fighting

(TCP173)

Practical Competencies Under pinning Knowledge (Theory) Operation of panel board Cleaning of the machine and the

surroundings and oiling and greasing of the machine

Preparing finishing mix recipe Feeding of the fabric to the clips

in the machine. Adjusting the required width of cloth.

To open steam valve of damping box and that of steam pipe and coils underneath the Stenter

To put the end of cloth from the Stenter through draw roller to the Plaiter or to wrap round the batching roll

Adjusting and maintaining temperature, speed and mangle pressure

Maintaining required moisture content in dried fabric

Verifying the finish uniformity at the delivery.



Basic knowledge about variousaspects of Stenter machine, function and operation to get optimum production. Different types of hot air stenters viz Clip Stenter, Belt Stenter and Pin Stenter

Importance of finishing and drying of fabrics

Details of the machine Maintaining the quality Importance of discipline and


30


SECTOR: TEXTILE

SPECIALIZATION: KHADI MANUFACTURING



1. INTRODUCTION TO VARIOUS TYPES OF FIBRES. INTRODUCTION TO SPINNING SYSTEMS. OVERVIEW OF ALL THE TYPES OF CHARKHAS AND HAND LOOMS USED IN THE LOCALITY

2. TRAINING ON TRADITIONAL CHARKHA (Relevant topic to be taken from the table)

(KHA 101)Practical Competencies Underpinning Knowledge (Theory)

1. Safety precautions (use of various equipments in safe manner)

2. Ergonomics of plying of roving belni andcharkha

3. Familiarization with tools and equipments

4. Piecing of broken end, Tying of mala thread (with appropriate tension for spindle drive)

5. Maintenance of charkha & roving belnilike cleaning, oiling, greasing

6. Winding – preparation of different packages – hank, cone etc.

7. One-day field visit to a reputed khadi institution(s) having good spinning and weaving and fabric conversion facilities and

1 Process involved in spinning Blow- room– carding – drawing – roving – spinning -Brief information.

2 Natural & manmade -Particularly cotton & polyester Physical characteristics

3 Information about cotton to cloth and Garment - How it is produced - Pictorialpresentation.

4 What is yarn – Definition of yarn count

5 Type of charkhas used in khadi sector – Detailed information.

6 Health & Hygiene

31

sales outlet. 7 Communication skills, discipline, morality, attitude, etc


1. HANDS ON VARIOUS TYPES OF TEXTILE FIBRES

2. SPINNING ON NEW MODEL CHARKHA SPINNING ON E-CHARKHA (Relevant topic to be taken from the table)


1. Safety precautions (use of various equipments in safe manner)

2. Ergonomics of plying of roving belni andcharkha



5. Maintenance of charkha & roving belnilike cleaning, oiling, greasing


7. One-day field visit to a reputed khadi institution(s) having good spinning and weaving and fabric conversion facilities andsales outlet.

1 Process involved in spinning Blow- room– carding – drawing – roving – spinning -Brief information.

2 Natural & manmade -Particularly cotton & polyester Physical characteristics

3 Information about cotton to cloth and Garment - How it is produced - Pictorialpresentation.

4 What is yarn – Definition of yarn count

5 Type of charkhas used in khadi sector – Detailed information.

6 Health & Hygiene

7 Communication skills, discipline, morality, attitude, etc

32


1. INTRODUCTION TO VARIOUS TYPES OF SPINNING ADVANCED SYSTEMS IN THE LOCAL INDUSTRY

2. INTRODUCTION TO DIFFERENT PARTS OF SPINNING MACHINE ADVANCE SPINNING (COTTON & MUSLIN)

(KHA 204)

Practical Competencies Underpinning Knowledge (Theory)

1 Safety precautions (use of various equipments in safe manner)

2 Ergonomics of plying of roving belni and charkha

3 Familiarization with tools and equipments

4 Piecing of broken end, Tying of mala thread (with appropriate tension for spindle drive)

5 Maintenance of charkha & roving belni like cleaning, oiling, greasing

6 Winding – preparation of different packages – hank, cone etc.

7 One-day field visit to a reputed cotton & muslin khadi producing institution(s) having good spinning and weaving and fabric conversion facilities and sales outlet and one-day visit to Central Sliver Plant of KVIC.

1 Processes involved in spinning – i.e. Blow room –carding – combing – Drawing – roving – spinning –Brief information about each process

2 Natural & Man-made fibres –particularly different varieties of cotton – deshi, medium staple, longer staple cotton and polyester etc. – Physical characteristics and chemical properties etc.

3 Information about cotton & muslin production. (Yarn –cloth and garment etc.) – Pictorial presentation as well as theoretical study.

4 Study about cotton & muslin charkha –

Top rollers & aprons – rubber cots, shore hardness, life and its effect on yarn quality.

Study about rings, travellers and spindle used in cotton / muslin charkha.

5 Spinning methodology – Drafting, Twisting and winding.

6 What is yarn – Definition of yarn – Yarn numbering in Metric system – Yarn count, strength and CSP (count strength product) and other useful parameters – their corresponding standards etc.

7 Simple calculations to find out draft, twist, delivery, spindle speed and theoretical production from the cotton & muslin charkha driving mechanism.

8 Type of charkhas used in khadi sector for cotton and muslin spinning – Detailed information.

9 Health & Hygiene

10 Communication skills, discipline, morality, attitude, etc

33


1. ADVANCE SPINNING (WOOLEN) ADVANCE SPINNING (SILK) (KHA 203, KHA205)

(KHA 203)

Practical Competencies Underpinning Knowledge (Theory)1. Safety precautions (use of

various equipments in safe manner)

2. Ergonomics of plying of roving belni and charkha



5. Maintenance of charkha & roving belni like cleaning, oiling, greasing


7. One-day field visit to a reputed wool khadi producing institution(s) having good spinning and weaving and fabric conversion facilities and sales outlet and one day visit to nearby woolen manufacturing industry.

1. Processes involved in spinning – i.e. scouring – carding – combing – Gill box (drawing) – roving (bobbiner machine) –spinning – Brief information about each process.

2. Grading of wool3. Natural & Man-made fibres –

a. particularly different varieties of wool –deshi, merino, cross breed etc and acrylic, polyester etc. – Wool fibre structure, Physical characteristics and chemical properties etc.

4. Information about wool production. (Yarn –cloth and garment etc.) – Pictorial presentation as well as theoretical study.

5. Study about woolen charkha –6. Top rollers & aprons – rubber cots, shore

hardness, life and its effect on yarn quality.7. Study about rings, travellers and spindle

used in woolen charkha.8. Spinning methodology – Drafting, Twisting

and winding.

9. What is yarn – Definition of yarn – Yarn numbering in Metric system – Yarn count, strength and CSP (count strength product) and other useful parameters – their corresponding standards etc.

10. Simple calculations to find out draft, twist, delivery, spindle speed and theoretical production from the wool charkha driving mechanism.

11. Type of charkhas used in khadi sector for wool spinning – Detailed information.

12. Health & Hygiene

13. Communication skills, discipline morality, attitude etc.

34

(KHA205)

Practical Competencies Underpinning Knowledge (Theory)


2 Practice for manual reeling and operating winding and twisting machines


4 Piecing of broken end in winding and twisting with hand knotter, Tying/stitching of tape in twisting machine (with appropriate tension for spindle drive)

5 Maintenance of reeling, winding and twisting machine like cleaning, oiling,greasing

6 Winding – preparation of hank

7 Twisting - 2 ply 3 ply 4 ply etc

8 Warping – preparation of warp in sectional warping machine.

9 Weft preparation – winding on pirns.

10 One-day field visit to a reputed silk khadi producing institution(s) havinggood reeling, twisting and weaving and fabric conversion facilities and salesoutlet.

1 Brief introduction to sericulture – rearing ofsilk worms and production of cocoons.

2 Processes involved in reeling – i.e. grading& selection of cocoons, sorting of cocoons,boiling, hand reeling, re-reeling– winding on bobbins, twisting – Detailed information about each process.

3 Brief about spun silk

4 Natural & Man-made fibres –5 particularly different varieties of silk –

mulberry, tussur, endi, muga etc and cotton, polyester etc. – Physical characteristics and chemical properties, renditta etc.

6 Information about silk production. (Yarn –cloth and garment etc.) – Pictorial presentation as well as theoretical study.

7 What is yarn – Definition of yarn – Yarn numbering in denier system – Yarn count, strength and other useful parameters – theircorresponding standards etc.

8 Simple calculations to find denier, twist, delivery, spindle speed and theoretical production for silk reeling, winding and twisting machines.

9 Type of reeling, winding and twisting machines used in khadi sector for silk yarn production – Detailed information.

10 Health & Hygiene11 Communication skills, discipline, morality,

attitude, etc

35


1. WARPING TECHNIQUES PREPARATIONS FOR WARPING CALCULATIONS RELATED TO WARPING(WPN 103)Practical Competencies Under pinning Knowledge (Theory) Understanding the Warping machine

and its creel. Understanding the pattern and

creeling the cones in their respective places.

Taking the ends out, passing through the tension guides and taking up to front and tying all ends of the section together after drawing in the reeds,

Pulling the yarns together on the swift. Setting the section width. Setting the section length by considering the minimum length of yarns on cones.

Leasing Winding the required number of

sections. Attending the breaks and putting

weaver‟s knot. Transferring the warp sheet from

swift to a weaver‟s beam Using of safety gadgets like caps,

masks, gloves and shoes. Always tying the sider‟s bag and

collecting the hard wastes in it. Mock drill for fire fighting and first

aid.

Details of Sectional Warpingmachine, Creeling pattern and the quality requirements

Importance of Sectional warping, creeling the cones as per pattern, setting the length per section and section width.

Importance of maintaining uniform tension all the time.

Knowledge of colour codification Knowledge of yarn count, cone

weight and the weaver‟s knot. Precautions to be taken while

working Importance of cleanliness and

personal safety Importance of discipline at work Fire fighting and first aid Safety gadgets in a cotton factory

2. METHOD OF FINDING REED COUNT PREPARATIONS FOR WEAVING

36

3. ADVANCE WEAVING (COTTON/ BLENDS)(KHA 208)

Practical Competencies Underpinning Knowledge (Theory)1 Safety precautions (use of

various equipments in safe manner)

2 Ergonomics of plying of frame loom


4 Yarn sorting (count wise)

5 Yarn wetting process

6 Yarn sizing (by hand & hank sizingmachine)

7 Yarn winding as D.F. bobbin, core,etc.

8 Sectional warping

9 Denting & Drafting.

10 Pirn winding

11 Plain weaving, different types of knots.

12 Cloth testing – ends, picks, mending cloth defects, etc.

1. Khadi vis-à-vis Textile Industry.2. Khadi (Fabrics) Production3. Brief on khadi yarn production:4. Hand Spinning5. Type of Yarn used in Khadi (Cotton/

Polyvastra)6. Count range of Khadi Yarn7. Characteristics of Khadi Yarn8. Hank winding (reeling)9. Weaving Preparatory: -10. Sizing11. Yarn sizing.12. Material used in size solution13. Sizing process14. Weft preparation15. Pirn winding16. Warp preparation17. Winding of Yarn on Bobbin, cone, etc.,18. Warping –using sectional warping machine.19. Sectional warping methods20. Warp beam preparation21. Loom: -22. Description of looms and functions of

its parts including semi-automatic loom–

23. Working of different types of primary, secondary and auxiliary motions ofweaving.

24. Loom timings25. Elementary weaves and weaving the

same with different types of yarns forvarious end uses.

26. Development of designs on ‘Point’ paper.27. Extra warp and extra weft weaving.28. Knowledge of Jala, dobby and

jacquard weaving29. Weaving calculations including costing

of the fabrics30. General 31. Usual defects in khadi cloths32. Care to be taken while weaving33.Counting ends & picks, mending defects

37


1. INTRODUCTION TO WOOLEN AND SILK MATERIAL. PROPERTIES OF WOOL AND SILK FIBRES AND YARN.

2. ADVANCE WEAVING ( WOOLEN) ADVANCE WEAVING (SILK) (KHA 207,206)


1 Safety precautions (use of variousequipments in safe manner)



4 Wool Yarn sorting (count wise)


6 Sectional warping.


8 Pirn winding.



1 Khadi vis-à-vis Textile Industry.

2 Khadi (Fabrics) Production

a. Brief on Wool yarn production:

Wool Yarn hand Spinning Type of Yarn used in Khadi (Wool

/ Cotton/ Polyvastra) Count range of Woolen Yarn Characteristics of Woolen Yarn Hank winding (reeling)

b. Weaving Preparatory: -

Scouring Yarn scouring.

Material used in YarnScouring

Scouring process Warp preparation

Winding of Yarn onBobbin, cone, etc.,

Warping –using sectional warping machine.

Sectional warping methods Warp beam preparation c.

Loom: -

Description of looms and functionsof its parts including semi-automatic loom – Working ofdifferent types of primary,secondary and auxiliary motionsof weaving.

Loom timings Elementary weaves and weaving

the same with different types of yarns for various end uses.

Development of designs on ‘Point’paper. Extra warp and extra weftweaving.

38

Knowledge of Jala, dobby and jacquard weaving

Weaving calculations including costing of the fabrics

d. General:

Usual defects in khadi Woolen Care to be taken while weaving Counting ends & picks, mending

defects





4 Yarn sorting (count wise)


6 Sectional warping


8 Pirn winding



1 Khadi vis-à-vis Textile Industry.

2 Khadi (Fabrics) Production

e. Brief on Silk Yarn production:

Silk Reeling/ Hand spinning Type of Yarn used in Khadi Silk Count range of Silk Yarn Characteristics of Silk Yarn Hank winding (reeling)

f. Weaving Preparatory: -

Weft preparation Pirn winding

Warp preparation Winding of Yarn onBobbin, cone, etc.,

Warping –using sectional warping machine.

Sectional warping methods

Warp beam preparation g.

Loom: - Description of looms and

functions of its parts including semi-

automatic loom –

Working of different types of primary,secondary and auxiliary motions of

39

weaving. Loom timings

Elementary weaves and weaving thesame with different types of yarns forvarious end uses. Development of designs on

‘Point’ paper. Extra warp and extra weft weaving. Knowledge of Jala, dobby andjacquard weaving

Weaving calculations including costing ofthe fabrics

h. General:

Usual defects in khadi cloths Care to be taken while weaving

Counting ends & picks, mending defects

40


1. YARN BLEACHING IN HANK FORMCOLOUR PREPARATION DYEING TECHNIQUESDYEING OF YARNDYEING OF FABRICDYEING OF WOOLEN FABRICDYEING OF SILK FABRIC (TCP 105, TCP112, TCP113)

(TCP 105)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine Cleaning of the machine and the

surroundings To put the hanks on sticks To prepare the vat with bleach

liquor of required strength To heat the bleach liquor with the

help of steam and treating the yarns for specified time

Washing and neutralizing the bath Squeezing the hanks in a pair of

squeezing rollers Drying the hanks in open air. Mock drill for fire fighting and

first aid.

Basic knowledge about variousaspects of bleaching depending on the typeof fibres in the yarn

Knowledge of bleaching hanks by hand Importance of ecology, effluent treatment

and norms for discharging water out. Importance of discipline and


(TCP112)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine Weighing the colours and

chemicals, preparing colour pastes and diluting them to required strength. Sieving wherever needed.


Submitting the solution for testing the strength and quality of chemicals in




Importance of discipline and

41

the laboratory Handling the chemical containers Controlling the stirring operation. Monitoring chemical pipelines


first aid.



(TCP113)


the work place To bring and put the boiled and

hydro-extracted yarn on sticks To prepare dye solution using

required colours and chemicals, bring it to required temperature and stir well before putting the yarn into Vat. Ensure that colours areproperly dissolved.

Monitor the time and temperature ofdyeing while ensuring continuous rotation of hanks.

Maintain the level of liquor constant through out.

After dyeing take out the yard and allow the liquor to drain out, and then oxidise, wash, sour ifneeded, soap and wash again.


Basic knowledge about variousaspects of hank dyeing.

Importance of Hank dyeing Dyeing with different group of dyes. Importance of discipline and



42

2. PRINTING TECHNIQUESPRINTING OF YARNPRINTING OF FABRIC (TCP123, TCP126, TCP120)

(TCP123)

Practical Competencies Under pinning Knowledge (Theory) Weighing the colours and

chemicals, preparing colour pastes, and bringing them to required strength. Sieving wherever needed.




and water lines. Practicing the work considering


first aid.

Importance of preparing uniformchemical solution, weighing and paste preparation



Ill effects of absenteeism Productivity and quality Knowledge of colours and chemicals


(TCP 126)

Practical Competencies Under pinning Knowledge (Theory) Weighing the colours and chemicals,

preparing colour pastes, and bringing them to required strength. Sieving wherever needed.


To bring prepared and dried yarn to the machine

Preparing yarn in adequate lots To put yarn on arms of the machine

and straighten it on the arms To put colour pastes in colour pans

according to number of colours to be printed

To work the machine by hand and printing the yarns.

Taking out the yarns from arms and

Basic knowledge about variousaspects of printing yarn.

Importance of printing yarns with fast colours by hand

Preparation of colour solution, weighing and paste preparation




43

putting for drying on sticks To deliver yarns for After-process. Practicing the work considering

safety of man and machine Mock drill for fire fighting and first

aid.

(TCP 120)

Practical Competencies Under pinning Knowledge (Theory) Safety of man and machine Laying of fabric for printing Placing of flat screens on the table as

per their positions Applying colour paste Cleaning of the table and the

surroundings Monitoring the application of



Basic knowledge about variousaspects of Screen printing and maintenance of screens.


Details of the Printing table Importance of discipline and



3. FINISHING OF FABRICS IN THE COTTAGE INDUSTRY

44


SECTOR: TEXTILE

SPECIALIZATION: SPINNING



1. INTRODUCTION TO VARIOUS TYPES OF GINNING PRINCIPLES

2. GINNING MACHINE AND OPERATIONS MAINTENANCE OF GINNING MACHINE POST CLEANING OF COTTON LINT AND SEED (GIN103, GIN104, GIN105)

(GIN 103)Practical Competencies Under pinning Knowledge (Theory) Cleaning the area of work Wearing safety gadgets like Mask,

cap etc. and working in a safe way Feeding kapas to ginning machine Collecting the seeds and putting them

in bags Segregating foreign matters and

keeping them at specified place Supplying ginned cottons for next

process Mock drill for fire fighting and first

aid.

Importance of removing seeds fromkapas

Importance of cleanliness and personal safety

Types of contaminations and their sources

Identifying specified places for keeping seeds, contaminations and good length

Fire fighting and first aid Safety gadgets in a ginning factory

(GIN104)Practical Competencies Under pinning Knowledge (Theory) Cleaning the area of work Wearing safety gadgets like Mask,

Importance of cleaning ginned cottonimmediately after ginning.

45

cap etc. and working in a safe way Feeding ginned cotton to opening

cum cleaning machine Operating the cleaning machine. Collecting the droppings and

putting them in bags Segregating foreign matters and

keeping them at specified place Supplying clean ginned cottons for

baling. Mock drill for fire fighting and

first aid.

Parts of a cleaning machine and precautions to be taken while operating the machines.



Identifying specified places for keeping dropping, contaminations and good cotton


(GIN 105)Practical Competencies Under pinning Knowledge (Theory) Cleaning the area of work Wearing safety gadgets like Mask,

cap etc. and working in a safe way Regulating the feeding of cleaned

ginned cotton to press. Operating the press machine after

required quantity of cotton is filled. Monitoring the pressure and bale

dimensions Weighing the bales and marking the

press number and bale parameters on bales.

Recording the production Mock drill for fire fighting and

first aid.

Importance of pressing ginned cottoninto bales.

Parts of a baling press and precautions to be taken while operating the machines.


Identifying specified places for keeping bales, packing materials


46


1. IDENTIFICATION OF COTTON GRADE. PROCESSES IN BLOW-ROOM AND END PRODUCT.

2. BLOW ROOM OPERTION AND MAINTAINANCE MATERIAL HANDLING(SPG101, SPG102, SPG116, SPG117, SPG118, SPG138)

(SPG101)Practical Competencies Under pinning Knowledge (Theory) Cleaning the area of work Wearing safety gadgets like Mask,

cap etc. and working in a safe way Opening the bales and removing the

bale hoops, Hessian and cleaningthe sides

Gently opening the cotton byhand and searching for the foreign matters if any.

Supplying clean cotton to blow room

Keeping the contaminations in a specified place


Importance of removingcontaminations from cotton

Importance of cleaning sides of cotton bales before opening



Identifying specified places depending on the type of contaminations

Fire fighting and first aid Safety gadgets in a cotton factory

(SPG102)Practical Competencies Under pinning Knowledge (Theory) Cleaning the area of work Wearing safety gadgets like Mask,

cap etc. and working in a safe way Opening the bales and removing the

bale hoops, Hessian and cleaningthe sides

Gently opening the cotton byhand and spreading on the floor in the mixing bin for making stack mixing.

Identifying the lot number and bale numbers before opening them.

Supplying clean cotton to blow room

Removing contaminations and keeping them in a specified place


Importance of Stack mixing andprecautions to be taken while mixing

Gently cutting the bale hoops and removing Hessian.




Fire fighting and first aid Safety gadgets in a Cotton factory

47

(SPG116)Practical Competencies Under pinning Knowledge (Theory) Opening the bales removing the

bale hoops and covering cloth, cleaning the sides of the bales.

Laying the bales as per the plan given.

Running the Bale Plucker. Keeping the machine

surroundings always clean Using of safety gadgets like caps,

masks and shoes and verifying the safety stop motions

Controlling the feed as per indent from the next machine

Cleaning the machine along with the maintenance person

Removing contaminations frombale‟s layers.

Mock drill for fire fighting andfirst aid.

Details of Bale Plucker, importanceof laying cotton bales for mixing, opening the bale hoops and removing covering cloth, cleaning the sides of bales.

Importance of Bale Plucker and precautions to be taken while working

Importance of indenting from next machine, and feed regulations.





(SPG117)Practical Competencies Under pinning Knowledge (Theory) Opening the bales and making

small tufts before feeding on the lattice.

Running the bale breaker machine Removing the droppings as per the

prescribed frequency Keeping the machine



Controlling the feed as per indent from the next machine

Cleaning magnets periodically Cleaning the machine along with the

maintenance person Removing contaminations from

feed lattice Mock drill for fire fighting and

first aid.

Details of bale breaker machine,importance of opening the cotton by hand into smallest stuff, controlling the feed as per indent from the next machine.

Importance of Mixing bale breaker and precautions to be taken while working

Importance of indenting from next machine, and feed regulations.





48

(SPG118)Practical Competencies Under pinning Knowledge (Theory) Cleaning the oiling spots and

ensure that oil flows to the required spot of oiling

Cleaning the parts after oiling Ensuring that no oil is leaking out Auditing the machine conditions for

oil leakage and spilling Planning for oil and grease

requirement and giving requisition.

Using of safety gadgets like caps, masks, helmet, safety belt, gloves and shoes.

Verifying the safety stop motions and getting them attended

Maintaining records of oiling and oilchanges


Importance of lubricating variousmachines and mechanisms used in Blow room.

Functions of different lubricants and their relevance to the mechanism, andexpected life span of the lubricants

Details of all oiling spots of machinery in blow room, standard lubricatingpractices, maintenance of oil storingarea, Checking of oil for viscosity,normal life of oil at various mechanisms

Understanding the Oil and lubrication catalogue and indenting them.

General management knowledgeof coordinating with workshop, electrical department, stores and production

Precautions to be taken while working Importance of cleanliness and

personal safety Fire fighting and first aid Safety gadgets in a cotton factory

(SPG138)Practical Competencies Under pinning Knowledge (Theory) Running out the mixing and

starting new mixing. Setting the length of lap. Adjusting the calender and lap

roller pressures Weighing the laps and adjusting the

weights Keeping the machine



Cleaning the machine along with the maintenance person


Details of Scutcher, importance ofLap preparation, Lap weight regulation, Lap length setting, removing droppings and cleaning the machine along with maintenance people

Importance of Scutcher and Lap preparation

Precautions to be taken while working



49


1. CARDING PROCESS, OBJECTS, PRINCIPLES AND CALCULATIONS

2. CARDING OPERATION AMD MAINTENANCE OF CARDING MACHINERY (SPG 120, SPG 139, SPG 240)

(SPG 120)Practical Competencies Under pinning Knowledge (Theory) Removing of old wires

from flats and making them bare.

Checking the level of flat surface and ends

End milling of flats Levelling the flat surface Clipping the Tops Clipping the flat tops and

dressing Transporting the flats for

mounting on cards Using of safety gadgets

like caps, masks, gloves and shoes.

Maintaining records of maintenance


Details of wires for different end uses,different types of wires, checking the ends and surface of bare flats, end milling, levelling the surface, clipping and dressing of flats

Importance of mounting and different wires used for mounting flats

The grinding apparatus and grinding stones Dressing of grinding stone Understanding the Wire catalogue and

indenting for wires General management knowledge of

coordinating with workshop, electrical department, stores and production

Precautions to be taken while working Importance of cleanliness and personal safety Fire fighting and first aid Safety gadgets in a cotton factory

(SPG 139)Practical Competencies Under pinning Knowledge (Theory) Running bare card before feeding

cotton Feeding lap Collecting the web and

condensing to feed to the calender roller and produce a sliver

Operating the control panel Studying the signals and taking

actions Inserting empty cans and taking out

doffed cans Keeping the machine


Importance of carding, various partsin a card and their functions.

Salient features of high speed and super high speed cards


Knowledge about humidity conditions and the working of cards

Normal defects in card web and actions needed to correct them


Fire fighting and first aid Safety gadgets in a Spinning mill.

50



(SPG 240)Practical Competencies Under pinning Knowledge (Theory) Removing old wires from

cylinder, doffer and flats and making them bare.

Checking the bearings and eccentricity of shafts

Grinding bare cylinder and doffer

Mounting the wires. Grinding the cylinder and doffer Checking the flat level and ends,

and deciding the milling Milling the flat ends Levelling the flat surface Clipping the flat tops and

dressing Using of safety gadgets like caps,

masks, helmet, gloves and shoes. Maintaining records of

maintenance Mock drill for fire fighting and first

aid.

Details of wires for different end uses,different types of wires, barecylinder grinding, mounting andgrinding after mounting, dressing of flats. Standard maintenancepractices, normal life of various wires and quality standards expected in the materials produced.

The grinding apparatus and grinding stones

Dressing of grinding stone Understanding the Wire catalogue

and indenting for wires General management knowledge of

coordinating with workshop, electrical department, stores and production

Precautions to be taken while working Importance of cleanliness and

personal safety Fire fighting and first aid Safety gadgets in a cotton factory

51


1. COMBING PROCESS, OBJECTS, PRINCIPLES, COMBER CALCULATION

2. SLIVER LAP TENTER TRAINING RIBBON LAP TENTER TRAINING (SPG 125, SPG 126,

(SPG 125)Practical Competencies Under pinning Knowledge (Theory) Understanding the mixings, hanks

and the colour codification used. Creeling the required number of cans

and taking the sliver forward Installing the lap spool in lap

forming unit Adjust the lap length Running the machine and

producing the laps to be fed to ribbon lap machine

Bringing back the empty spools from ribbon lap machine.

Keeping the work area and surroundings always clean

Using of safety gadgets like caps, masks and shoes.

Mock drill for fire fighting andfirst aid.

Concepts of Sliver lap, therequirement of combers, the mixings and hanks

Precautions to be taken while feeding the cans and producing the laps.


Identifying specified places for keeping laps depending on the type of mixing and hanks



and the colour codification used. Creeling the Sliver laps and

taking the drafted web forward on the table to the lap forming unit

Installing the lap spool in lap forming unit

Adjust the lap length Running the machine and

producing the laps to be fed to Combing machine

Bringing back the empty spools from combing machine.


Using of safety gadgets like caps,

Concepts of Ribbon lap, therequirement of combers, the mixings and hanks

Precautions to be taken while feeding the Sliver laps and producing thelaps.


Identifying specified places for keeping laps depending on the type of mixing and hanks


52

masks and shoes. Mock drill for fire fighting and

first aid.

3. COMBER MACHINE OPERATION AND MAINTENANCE (SPG 142, SPG 127, SPG253)


and the colour codification used. Creeling the laps and starting the

machine Taking the combed web, condensing

and converting into sliver, taking the slivers forward on the table to the draw box unit

Installing the empty cans Running the machine and producing

the sliver to be fed to draw frame Checking the quality of noil and

cleaning the noil box from time to time

Cleaning the top combs at fixed interval


Using of safety gadgets like caps, masks and shoes.


Concepts of Combers, therequirement of combed sliver, the mixings and hanks

Precautions to be taken while feeding the laps and producing the sliver.

Importance of maintaining Relative Humidity and Temperature


Identifying specified places for keeping laps depending on the typeof mixing and hanks


( SPG 127)Practical Competencies Under pinning Knowledge (Theory) Cleaning the combing segment,

heating and removing the old needles

Selecting the required needle and fitting them in the template depending on the row

Aligning the needles Soldering with out disturbing the

alignment Delivering the combing segment to

be fit in half lap or to be used as

Importance of combing, the role ofcombing needles, the specifications of combing segment and the top combs.

Details of Needles, the gauge and the needles per inch in each row.

Aligning and soldering Precautions to be taken while

aligning and mounting the needles Importance of cleanliness and

personal safety

53

Top comb as needed. Mock drill for fire fighting and

first aid.

Fire fighting and first aid Safety gadgets in a Spinning factory

(SPG253)Practical Competencies Under pinning Knowledge (Theory) Understanding the combing cycle

and settings components referring to the index wheel. Operating a comber and setting the Noil level and piecing.

Erection, levelling and setting of parts including automatic doffing, length counter, drafting zone and setting detaching roller and top roller pressure

Auditing the machine conditions Planning for spares and giving

requisition. Using of safety gadgets like caps,

masks, gloves and shoes. Verifying the safety stop motions

and getting them attended Maintaining records of

maintenance. Mock drill for fire fighting and

first aid.

Details of Combers and comberpreparatory, mechanisms adopted and importance of each, salient features and the comer timings.

Understanding the machine catalogue and indenting for spares

Standard maintenance practices, normal life of various spares and quality standards expected in the materials produced.

General management knowledge of managing subordinates, coordinating with workshop, electrical department, stores and production




54


1. PROCESS OF DRAWING AND ROVING AND THEIR OBJECTS. PRODUCTION CALCULATIONS.

2. DRAW FRAME OPERATION AND MAINTENANCE (SPG 123,SPG 252)

(SPG 123)Practical Competencies Under pinning Knowledge (Theory) Checking the stop motions, the

mixing being worked and thecolour codesodes used.

Creeling the cans in the back and running the machine

Inserting empty can in the coiler Doffing full can Keeping the machine




Importance of draw frame, variousparts in a draw frame and their functions.


Knowledge about humidity conditions and the working of cards

Normal defects in draw frame sliver and actions needed to correct them



(SPG 252)Practical Competencies Under pinning Knowledge (Theory) Assembling and dismantling of

various mechanisms and setting them to get the required quality.

Operating a Draw frame and setting the auto leveller

Erection, levelling and setting of parts including auto levellers, automatic doffing, length counter, drafting zone and setting toproller pressure

Off line maintenance of different modules




Importance of various parts andmechanisms used in Draw frames.

Auto levellers and their functioning and setting.

Salient features of high speed draw frames and their significance. Standard maintenance practices, normal life of various spares and quality standards expected in the materials produced.




55



first aid.



3. SPEED FRAME OPERATION AND MAINTENANCE (SPG 128, SPG254)

(SPG 128)Practical Competencies Under pinning Knowledge (Theory) Collecting empty bobbins from

ring frames and cleaning them Arranging the bobbins in each

frame by referring to thecolour codesode in practice

After stopping the machine and aligning the flyers, lifting the flyers and removing the full bobbins

Putting empty bobbins on the spindle tube and lapping the rove gently

Attending the breaks Delivering the full bobbins to ring

frame section Mock drill for fire fighting and

first aid.

Details of working of a speed frame Importance of speed frames and

taking the doff Precautions to be taken while doffing

and restarting the machines Importance of cleanliness and

personal safety Fire fighting and first aid Safety gadgets in a Spinning factory

(SPG254)

Practical Competencies Under pinning Knowledge (Theory) Understanding the speed frame

mechanisms and settings components. Operating a speed frame and setting the coils and tension.

Erection, levelling and setting of parts including automatic doffing, drafting zone and top roller pressure



Details and importance of variousparts and mechanisms used in speed frames.

Functions of different spares and their expected life span



General management knowledge of

56



maintenance Mock drill for fire fighting and

first aid.

managing subordinates, coordinating with workshop, electrical department, stores and production




57


1. INTRODUCTION TO RING SPINNING, PROCESS OF MANUFACTURING YARN, PRODUCTION CALCULATIONS

2. RING FRAME OPERATION AND MAINTENANCE (SPG 130, SPG 131, SPG 132, SPG 135)

(SPG 130)Practical Competencies Under pinning Knowledge (Theory) Collecting empty bobbins from

winding section and cleaning them

Arranging the bobbins in crates fordoffing for each machine by referring to the colour code in practice

Removing the full cops andputting empty cops, pressing them and piecing the ends after restartingof the machine

Delivering the full doffs to winding after weighing.

Cleaning the spindle rails and drafting area


Details of working of a Ring frame. Importance of ring frames and taking

the doff Precautions to be taken while doffing

and restarting the machines Importance of cleanliness and


(SPG 131)Practical Competencies Under pinning Knowledge (Theory) Stopping the ring frame after

taking the doff Removing the bobbins from the

creel Checking the condition of machine

parts and getting them replaces if found bad.

Cleaning the spindles, tin rollers, jockey pulleys, creels, bobbin holders etc., by using long brushes

Lifting the ring rail and cleaning the poker bars and poker tubes

Lifting the top arms, relieving the bottom aprons from the apron bridgebar and cleaning the drafting rollers, cradles, top arms

Opening the covers and cleaning the

Details of Ring frame parts and themethod of opening and cleaning them

Importance of cleaning the machines Precautions to be taking while

cleaning Checking the parts for their condition Importance of cleanliness and


58

gears, builder motion, etc After cleaning the machine,

removing the ring travellers and putting new travellers.


(SPG 132, )Practical Competencies Under pinning Knowledge (Theory) Turning the wooden rollers to the

required size and putting the pins. In case of stationary clearers,

cutting the wood to the shape required

Cutting the clearer cloth (Flannel) and mounting on the wooden rollers after applying glue.

Tying the roll till it dries In case of synthetic clearer tube,

mounting them on the wooden rollers with suitable fixing solution coating.

In case of top clearer cloth guided byrollers, preparing a loop by stitchingthe ends of clearer cloth


Details of Clearer rollers and clearersin various parts of machines and the method of preparing clearers.

Importance of clearer rollers and clearers

Precautions to be taking while fixing the clearer cloth

Checking the wooden parts for their condition



(SPG 135)Practical Competencies Under pinning Knowledge (Theory) Cleaning the old rings with

suitable solvent to remove carbon deposits

Checking the condition of the rings

Buffing the rings lightly to remove the burrs and make the ring reusable


Details of ring profile and thetolerance, buffing of the inside edge of flanges.

Importance of buffing of the rings to have longer life.

Precautions to be taking while buffing.


Fire fighting and first aid. Safety gadgets in a Spinning factory.

59


1. INDTRODUCTION TO OPEN END SPINNING AND DOUBLING, OBJECTS, PRINCIPLES, MANUFACTURING PROCESS AND PARAMETERS, PRODUCTION CALCULATION

2. OPEN END MACHINE OPERATION AND MAINTENANCE ( SPG 136, SPG 256,)

(SPG 136)Practical Competencies Under pinning Knowledge (Theory) Checking the rotors and cleaning

before creeling a can Feeding sliver to opener roller. Taking an end from the already

wound cheese and inserting in the rotor to piece the ends

Attending to breakages Doffing the full cheeses Removing the dusts collected

from time to time Following the safety precautions

while working. Mock drill for fire fighting and

first aid.

Basics of Open-end machine, therotors and opening rollers, the condition of take-up rollers.

Precautions to be taking while creeling the cans and piecing



(SPG 256)Practical Competencies Under pinning Knowledge (Theory) Understanding the Open-end

machines, mechanisms and settings components.

Erection, levelling and setting of parts, setting the feed, opener roller, selecting the rotor diameter and groveangle depending on the type of yarnand the counts spun and changing the rotors, feeding angle to the rotor, andwinding mechanism.

Operating an Open-end machine and studying the mechanical problems.




Details of Open-end machines,various mechanisms adopted

Importance of various parts and mechanisms used in Open-end machines.






60



first aid.



3. TWO FOR ONE MACHINE OPERATION AND MAINTENANCE (DBL 103, DBL 104)

(DBL 103)

Practical Competencies Under pinning Knowledge (Theory) Creeling the assembly wound

cheeses in the twisting pot and takingthe ends up through the hollow spindle and the tension capsule andflyer, and winding on to deliverycones.

After the cones are built up, doffing them and putting new empty cones by verifying the colour codes and the labels.

Cleaning the delivery rollers and Cone holders, sides of the machines, spindle pots, magnets and spindle brakes.

Bringing assembly cheeses from winder and returning the empty tubes.

Inserting staggered knots in case ofany break in the yarn while working.


Details of working of a Two for onetwisting machine, doffing the full cones and restarting the machine with fresh empty cones

Importance of Two-for-One Twisting machine and working them.

The concept of knotless yarns Precautions to be taken while

inserting new feed packages, doffing and restarting the ends.



(DBL 104)

Practical Competencies Under pinning Knowledge (Theory) Understanding the Two-for-One

Twisting machines, mechanisms and settings components.

Erection, levelling and setting of parts like tension capsules, magnets, flyers, guides and cone holders. Changing the capsules depending on the type of yarn and the counts spun.

Details of Two-for-One twistingmachines

Importance of various parts and mechanisms used in Two-for-One Twisting machines.


Understanding the machine catalogue

61

Setting the tangential belts or the 4 spindle drive depending on the system in the machine

Operating a Two-for-One twisting machine and studying the mechanical problems.

Auditing the machine conditions, Planning for spares and giving requisition.

Using of safety gadgets like caps, masks, gloves and shoes.

Maintaining records of maintenance.


and indenting for spares Standard maintenance practices,

normal life of various spares and quality standards expected in the materials produced.





62


SECTOR: TEXTILE

SPECIALIZATION: WEAVING



1. WINDING MACHINE OPERATION AND MAINTENANCE (WDG 106, WDG 112)

(WDG 106)

Practical Competencies Under pinning Knowledge (Theory) Understanding the winding

machine and operating it. Feeding cops in the magazine

and taking ends to the yarn trap. Practicing to wind correct

weight of cones with correct sizeby maintaining correct tensions and setting the weight and length on the MIC.

Attending the stuck drums by taking both the ends andre- putting it

Using of safety gadgets likecaps, masks, gloves and shoes.

Always tying the sider‟s bag andcollecting the hard wastes in it.

Mock drill for fire fightingand first aid.

Details of Automatic windingmachine

Importance of automatic winding, the stop motions and the quality requirement


Knowledge of colour codification Knowledge of yarn count, cone weight,

various types of knots and splices. Concepts of length measurements on

winding. Precautions to be taken while



63

(WDG 112)

Practical Competencies Under pinning Knowledge (Theory) Understanding the winding

machine and operating it. Erection, levelling and setting of

parts including Knotter assembly, cone holders, Electronic yarn clearer units, MIC data feeding, Length setting for attending breaks, reversing of drums etc.



masks, gloves and shoes. Maintaining records of


first aid.

Details and Importance of automaticwinding machine, knotters, splices, length counters, electronic yarn clearers stop motions, the quality requirements the mechanisms and standard maintenance practices

Knowledge of yarn count, cone weight, Length tolerance, various types of knots and splices.

Keeping tools in correct places in cupboards or tool cabins



Importance of discipline at work Fire fighting and first aid Safety gadgets in a cotton factory

64


1. WARPING MACHINE OPERATION AND MAINTENANCE (WPN 103, WPN 106, WPN 110)

(WPN 103)Practical Competencies Under pinning Knowledge (Theory) Understanding the Warping machine

and its creel. Understanding the pattern and

creeling the cones in their respective places.

Taking the ends out, passing through the tension guides and taking up to front and tying all ends of the section together after drawing in the reeds,

Pulling the yarns together on the swift. Setting the section width. Setting the section length by considering the minimum length of yarns on cones.

Leasing Winding the required number of

sections. Attending the breaks and putting

weaver‟s knot. Transferring the warp sheet from

swift to a weaver‟s beam Using of safety gadgets like caps,

masks, gloves and shoes. Always tying the sider‟s bag and

collecting the hard wastes in it. Mock drill for fire fighting and first

aid.

Details of Sectional Warpingmachine, Creeling pattern and the quality requirements

Importance of Sectional warping, creeling the cones as per pattern, setting the length per section and section width.


Knowledge of colour codification Knowledge of yarn count, cone

weight and the weaver‟s knot. Precautions to be taken while



(WPN 106)Practical Competencies Under pinning Knowledge (Theory) Understanding the salient features of

super high speed warping machine and its Controls.

Understanding the pattern and creeling the cones in their respective places.

Taking the ends out, passing through the tension guides and taking up to front and tying all ends together after drawing in the reeds, pulling the

Details of Super High speedWarping machine, Creeling pattern and the quality requirements

Importance of Super High speed warping, creeling the cones as per pattern, setting the length.


Knowledge of colour codification

65

yarns together and tying on the warp beam

Setting the length by considering the minimum length of yarns on cones.

Attending the breaks and puttingweaver‟s knot.

Doffing the full beam and sending tosizing after recording the weight


Maintaining the beam record. Mock drill for fire fighting and first

aid.

Knowledge of yarn count, coneweight and the weaver‟s knot.

Precautions to be taken whileworking



(WPN 110)Practical Competencies Under pinning Knowledge (Theory) Understanding the Warping

machine and operating it. Erection, levelling and setting of parts

including hydraulic doffing assembly,Beaming head, MIC data feeding,Length setting, creel etc.



masks, gloves and shoes. Maintaining records of

maintenance. Mock drill for fire fighting and first

aid.

Details of Warping machines, stopmotions, hydraulic systems for doffing, the creel, the quality requirements and the maintenance practices

Importance of warping machine, the mechanisms and standard maintenance practices

Keeping tools in correct places in cupboards or tool cabins




66


1. INTRODUCTION TO SIZING, OBJECTS OF SIZING, SIZING PROCESS FLOW , SIZING CALCULATIONS

2. SIZE PASTE PREPARATION TECHNIQUES (WPN 107)

(WPN 107)Practical Competencies Under pinning Knowledge (Theory)

Cleaning of the machine and thesurroundings.

Understanding the recipe and the stages of their mixing in the cooking vessel.

Breaking starches and other big lumps.Preparing a paste with water after weighing in specified quantities of water separately.

To open the steam valve and cooking the materials; after completing the cooking, adding hot water to make up the volume. Alternately using a high pressure cooking vessel for cooking the starch

To supply cooked size to sizing machines To clean the starch tubs, stirrer and sieves Checking to ensure that no grit is left in

the cooked mixing. Practicing considering safety of man and

machine Mock drill for fire fighting and first aid.

Basic knowledge aboutvarious aspects preparing mixes and cooking the starch

Importance of cooking the sizing solution


punctuality Ill effects of absenteeism Productivity and quality Knowledge of colours and


3. SIZING MACHINE OPERATION AND MAINTENANCE (Relevant topic to be taken from the table) (WPN 102, WPN 109, WPN 111)

(WPN 102)Practical Competencies Under pinning Knowledge (Theory) Understanding the features

ofSizing creel and sow box and itsControls.

Using of hoists for creelingthe beams.

Taking the warp sheet out from each warp beam, passing through the tension guides and sow box, passing on the drying

Importance of sizing, creeling thebeams and monitoring the sow box.

Details of Creel of a sizing machine, method of creeling, using hoists, monitoring the sow box and size pick up

Importance of maintaining uniform and required viscosity, temperature and squeezing roller pressures.


67

cylinders and handing over to front Sizer to take forward.

Checking viscosity of size in sow box and monitoring it.

Checking pressure of squeezing rollers and monitoring it

Removing the lappers if anyon sizing and squeezingrollers





( WPN 109)Practical Competencies Under pinning Knowledge (Theory) Understanding the features of

Multi-cylinder Sizing machine, steam pressure and temperaturein individual cylinders, stretch Controls and moisture controls.

Leasing the sheets, drawingends through reeds, adjustingthe expanding comb and setting the beam width, setting length and doffing thebeam after set length.

Removing the condensates from the drying cylinders from time to time.

Removing the migrationsand lappers if any

Using of safety gadgets like caps, gloves and shoes.


Details of a Multi cylinder sizingmachine, using of hoists, monitoring the pressure in drying cylinders, dryingtemperature, stretch and speed and moisturecontent.

Importance of sizing, leasing, denting, setting expanding comb, controllingmoisture content.

Importance of monitoring and maintainingpressure and temperature of individual cylinders, speed and stretch control.




(WPN 111)Practical Competencies Under pinning Knowledge (Theory) Understanding the features of

Sizing machine, Sizecooking plant, steam connections, water connections, drains, exhaust,

Details of sizing machine, hoists,water and steam pipe lines, valves, drains and covering of flannel cloth and rubberrollers.

Importance of sizing, leasing, denting,

68

hoists Leasing the sheets,drawing ends through reeds, adjusting the expanding comb and setting the beam width, setting length and doffing thebeam after set length.





setting expanding comb, controllingmoisture content.

Importance of maintenance of monitoringdevices for pressure, temperature of individual cylinders and sow box, Variable speed drive, paired wheel drivefor stretch and speed control.




69

Certificate Level - IV

1. INTRODUCTION TO WEAVING, OBJECTS OF WEAVING , PROCESS FLOW, PRODUCTION CALCULATIONS , REED COUNT CALCULATION ETC

2. DRAWING –IN OPERATION AND REACHING (Relevant topic to be taken from the table)(WPN 102, WPN 109, WPN 111)

(WPN 102)Practical Competencies Under pinning Knowledge (Theory) Understanding the features

ofSizing creel and sow box and itsControls.

Using of hoists for creelingthe beams.

Taking the warp sheet out from each warp beam, passing through the tension guides and sow box, passing on the drying cylinders and handing over to front Sizer to take forward.

Checking viscosity of size in sow box and monitoring it.

Checking pressure of squeezing rollers and monitoring it

Removing the lappers if anyon sizing and squeezingrollers



Importance of sizing, creeling thebeams and monitoring the sow box.

Details of Creel of a sizing machine,method of creeling, using hoists, monitoring the sow box and size pick up

Importance of maintaining uniform and required viscosity, temperature and squeezing roller pressures.




( WPN 109)Practical Competencies Under pinning Knowledge (Theory) Understanding the features of

Multi-cylinder Sizing machine, steam pressure and temperaturein individual cylinders, stretch Controls and moisture controls.

Leasing the sheets, drawingends through reeds, adjusting

Details of a Multi cylinder sizingmachine, using of hoists, monitoring the pressure in drying cylinders, dryingtemperature, stretch and speed and moisturecontent.

Importance of sizing, leasing, denting, setting expanding comb, controlling

70

the expanding comb and setting the beam width, setting length and doffing thebeam after set length.





moisture content. Importance of monitoring and maintaining

pressure and temperature of individual cylinders, speed and stretch control.




(WPN 111)Practical Competencies Under pinning Knowledge (Theory) Understanding the features of

Sizing machine, Sizecooking plant, steam connections, water connections, drains, exhaust,hoists Leasing the sheets,drawing ends through reeds, adjusting the expanding comb and setting the beam width, setting length and doffing thebeam after set length.





Details of sizing machine, hoists,water and steam pipe lines, valves, drains and covering of flannel cloth and rubberrollers.

Importance of sizing, leasing, denting, setting expanding comb, controllingmoisture content.

Importance of maintenance of monitoringdevices for pressure, temperature of individual cylinders and sow box, Variable speed drive, paired wheel drivefor stretch and speed control.




71

3. PIRN WINDING MACHINE OPERATION AND MAINTENANCE (WVG 103, WVG 112)

(WVG 103)Practical Competencies Under pinning Knowledge (Theory) Understanding the weft

requirements, the required dimensions of cop.

Practicing the safety systems by wearing head cover and masks

Understanding the works to be done in the weft winding machines.

Feeding the cones and taking the ends through tensioners and the thread guide

Running the machine and attending the breaks

Removing the hard wastes. Mock drill for fire fighting and

first aid.

Basics of weft preparation,maintaining tension and cop content

Knowledge about the working of the machines in a safe and hygienic manner

Marking, Colour codification and channelisation

Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

(WVG 112)Practical Competencies Under pinning Knowledge (Theory) Understanding the requirements

of the weft yarns, the pirn size and the count.

Feeding of empty bobbins to the magazine

Replacing the feeding cones as and when required

Tying knot by using suitable knotter while attending breaks

To observe for the proper formation of bunches

Practicing the safety systems by wearing head cover and masks

Understanding the works to be done in the weft winding machines.

Collecting the hard wastes. Mock drill for fire fighting and

first aid.

Basics of automatic pirn windingmachine and operating with uniform tension control

Knowledge about the working of the automatic pirn winding machines in a safe and hygienic manner

Basic disciplines in the industry Colour codification followed count

wise or material wise Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

72


1. WEAVING PROCESS, MOTIONS OF LOOMS, TYPES OF SHED FORMATION, TYPES OF LOOMS AND CALCULATIONS

2. PLAIN LOOM FITTER TRAINING AUTO LOOM FITTER TRAINING OILER TRAINING (WVG 127, WVG 128, WVG 129, WVG 130, WVG 136,WVG 137)

(WVG 127)Practical Competencies Under pinning Knowledge (Theory) To prepare new slays and repair

old slays depending on the loom specifications.

To help the carpenter and the shuttle man.

To help the fitter in line levelling. To assist the supervisor in

maintaining proper stock of necessary accessories for the day.

To check the supply of new accessories.


Importance of Slay and preparingslay as needed.

Basics of carpentry. Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

(WVG 128)Practical Competencies Under pinning Knowledge (Theory) To prepare and repair wooden

parts like picking sticks, slay boards, shuttles, heald frames etc.

Preparing blocks for machine foundation, levelling, displays etc as needed.

Maintaining the spares. Mock drill for fire fighting and

first aid.

Importance of wooden parts in aweaving mill and their specifications.

Basics of carpentry. Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

(WVG 129)Practical Competencies Under pinning Knowledge (Theory) To attend to the repairs of

shuttles. To attend the shuttle truing

machine and make the shuttles true.

To help the carpenter when required.

To arrange and get the spares. Mock drill for fire fighting and

Basics of shuttle and its design. Importance of shuttle in a loom and

its specifications and balancing. Basics of carpentry. Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

73

first aid.

(WVG 130)Practical Competencies Under pinning Knowledge (Theory) To bring oil and grease from the

stores as per gradation and number.

Store the oils and lubricants in a safe place in dedicated racks.

Clean the oil path and oil the parts ofthe loom as per schedule.

Wipe the surface of the oiled portion with a clean cloth while ensuring that there are no leakages of oils.

Cleaning the floor and the surroundings of the oiled area and the places of keeping oil cans or containers with clean cloths to prevent oil stains on the fabrics.


Importance of lubrication and oiling Precautions to be taken for oiling and

lubrication Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

(WVG 136)Practical Competencies Under pinning Knowledge (Theory) To repair and maintain the Drop-

Boxes To prepare and repair pattern

lattices and maintaining them properly.

To check cloth patterns. To maintain the required spares for

Drop-Box maintenance of all the looms.


Basics of Drop-Box and theirmaintenance.

Importance of Drop-Box in a loom for producing checks and weft designs.

Maintenance practices for Drop-box Precautions to be taken during

maintenance. Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

74











75


1. INTRODUCTION TO WEAVES, DESIGN, DRAFT AND PEG PLAN. BASIC WEAVES AND THEIR DERIVATIVES

2. TEXTILE DESIGNING COMPUTER AIDED TEXTILE DESIGNING(FAD 121)

3. SHEDDING MECHANISM, SETTING FOR TAPPETS, DOBBIES, JAQUARDS AND ELECTRONIC JAQUARDS (WVG 119, WVG 120, WVG 121, WVG 122, WVG 123, WVG 124, WVG 125, WVG 126)

(WVG 119)Practical Competencies Under pinning Knowledge (Theory) Checking the condition of the

parts before starting the loom and cleaning them.

Checking the pattern and the weave, fitting of heald frames in different shafts, pegging to get the required weave or design.

Running the looms, attending to breaks and un-weave and correct the damages in the fabric.

To maintain optimum possible production with good quality in respect of patterns, proper picks, broken threads, clear selvedge, cloth cover, starting marks etc.

Doffing the cloth after completing the set length.


Basics of Dobby loom operations. Knowledge about the working of the

Dobby looms in a safe and hygienic manner.

Knowledge about the shade differences and the weave of the fabric

Pegging the Dobby to get the required design or weave.


(WVG 120)Practical Competencies Under pinning Knowledge (Theory) Checking the condition of the

parts before starting the loom and cleaning them.

Checking the design and the weave, arranging the punched cards as per the design requirement

Basics of Jacquard loom operations. Knowledge about the working of the

Jacquard looms in a safe and hygienic manner.


76

Running the looms, attending to breaks and un-weave and correct the damages in the fabric.

To maintain optimum possible production with good quality in respect of design, proper picks, broken threads, clear selvedge, cloth cover, starting marks etc.

Doffing the cloth after completing the set length.


Arranging the punched cards to get the required design on the fabric.


(WVG 121)Practical Competencies Under pinning Knowledge (Theory) Understanding the design in hand

Translating the design on to a point paper

Studying the gaps in shades and inserting a bond by suitable interlacement

Programming the card punching machine

Punching the card for each weft insertion in the design for one repeat

Numbering the cards and lacing them and make a continuous lattice.

To handover the lattice of punched cards to the Jacquard line man


Knowledge about the working of theJacquard and the role of punched cards in getting the required design on the fabric.

Programming the card punching as per the design

Knowledge about the shadedifferences and the weave of the fabric


(WVG 122)Practical Competencies Under pinning Knowledge (Theory) To prepare the harness for the

loom under gaiting To repair the harness as needed in a

running loom. To help the line man and the

lattice man To check the working of dobbies

and attend to them as needed.

Importance of harness in a loom andits effect on fabric quality.

Basics of preparing harness Servicing of Dobbies Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

77

Cleaning and ensuring proper working of dobbies


(WVG 123)Practical Competencies Under pinning Knowledge (Theory) Understanding the design in hand To prepare lattice To remove pegs and to re-peg

according to design To help the comber-board man

and the line man To help in bringing the stores To maintain the stock of pegs and

the boards To prepare cards according to pattern

if paper cards are provided Mock drill for fire fighting and

first aid.

Importance of lattice in a dobby loomand its effect on fabric quality.

Basics of preparing lattices for dobby looms

Servicing of Dobbies Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

(WVG 124)Practical Competencies Under pinning Knowledge (Theory) To attend the repairs and oiling of

dobbies. To tie the harness and to adjust

for proper working To prepare broken harness and

lattice To check designs To attend the folding department as

far as dobby damages are concerned.

To overhaul the dobbies as needed.


Importance of harness, tying theharness.

Overhauling of Dobbies Servicing of Dobbies Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

78

(WVG 125)Practical Competencies Under pinning Knowledge (Theory) To bring the cards and cutting

them to design To lace the cards in sequence. To maintain the stocks of cards. To mark the design numbers on

the point paper and lattice card and to tie the point papers.

To keep the card-cutting machine in proper condition.

To operate the card RepeatingMachine and Lacing Machine


Basics of the Card cutting and lacing Importance of card cutting and lacing. Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting

(WVG 126)Practical Competencies Under pinning Knowledge (Theory) To tie and dress the harness as

required To lease the harness and adjust

for proper working To repair and replace broken

harnesses. To insert the lingoes To repair the jacquards, keep them

properly cleaned and oiled. To mount the card lattice and tie it

properly. To work the jacquard and check

the design. To help the card cutter and lacer as

required. To attend the grey folding

department for corrective actions. To maintain the stocks of spares Mock drill for fire fighting and

first aid.

Basics of Jacquard working andmaintenance and tying harness.

Importance of Dressing the harness and maintaining the Jacquards in weaving for getting the required design on the fabric.


79


1. INTRODUCTION TO SHUTTLELESS LOOMS, CLASSIFICATION OF SHUTTLELESS LOOMS, WORKING PRINCIPLES

2. (WEAVER AND FITTER TRAINING ONLY ON - ANY ONE OF THE LOOM)RAPIER LOOMS OR PROJECTILE LOOMS OR AIR JET LOOMS OR WATER JET LOOM OR MULTY PHASE LOOM (WVG 132, WVG 133, WVG 134, WVG 135, WVG 136, WVG 137)

(WVG 132)Practical Competencies Under pinning Knowledge (Theory) To understand the material being

woven on the loom and the weft in different positions of the weft feeder.

Attending the breaks and restarting the looms, while removing any half pick or full double pick.

Keeping the machine always clean and periodically cleaning the shed area with a vacuum cleaner.


Knowledge about the working of theRapier Looms





Attending the breaks and restarting the looms, while removing any half pick or full double pick.



Knowledge about the working of theGripper / Projectile Looms





Knowledge about the working of theAir Jet Looms

Knowledge about the shade differences and the weave of the

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Maintaining the air pressure as needed

Attending the breaks and restarting the looms, while correcting any half pick or full double pick.



fabric Basic disciplines in the industry Communication and data presentation Safety precautions in a weaving mill First aid and fire fighting



Maintaining the Water pressure as needed

Attending the breaks and restarting the looms, while correcting any half pick or full double pick.

Keeping the machine always clean


Knowledge about the working of theWater Jet Looms













(WVG 137)Practical Competencies Under pinning Knowledge (Theory)

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To understand the looms in theshed and the salient features and precision needed in their settings and timing.

To erect and level the looms, assemble the parts and tune the loom.

To attend the mechanical repairs as needed.

To audit the machine condition and indent for spares well in advance.

Maintain the stocks of essential spares in a safe custody and account of them.


Importance of a loom, variousmechanisms, and the precisionneeded in their fitting and timings for producing fabrics of require quality and get trouble free working.

Standard Maintenance Practices andProductive maintenance

Precautions to be taken during maintenance.


Documents

L All Vocational Ed Textile Sector: Textile S.No ... · HAND SPINNING OF COTTON CARPET YARN. ... CARPET YARN DYEING WITH NATURAL DYES ... • Preparation of project cum feasibility