Sewing Machine Operator

Industrial Sewing Machine Operator Participant Guide Get the bobbin out. The bobbin is a small spool that is located under the sewing needle in your machine. It supplies the underside portion of the machine stitch, but doesn‘t come prepared with thread. Remove the covering above the bobbin and take it out of its case; it should be empty of thread. Put in your thread. Place your spool of thread on the top of the sewing machine, on the spool pin. The spool should be turned so that the thread is released counter-clockwise. Pull the thread out. Tug at the thread to pull it out, and wind it around the bobbin winding tension disc at the top of the sewing machine. If you have a newer sewing machine, there will likely be a diagram at the top guiding you through this process. Begin winding the bobbin. Hold the bobbin up and wrap the thread around it 2-3 times. Put the bobbin on the bobbin pin. This is a small pin that is likely on the top of your machine. Slide the pin over to lock the bobbin in place for winding. Start the bobbin winder. As you hold the longer thread entering the bobbin, start winding the bobbin for a few seconds by pushing the floor pedal or press the bobbin winding button. Doing this will make sure the thread is securely wrapped around the bobbin. Then, cut off the excess thread on the short tail end that is sticking out. Finish winding the bobbin. Apply pressure to the floor pedal again or flip the winder back on and allow it to completely fill the bobbin with thread. Likely, your winder will stop on its own when the bobbin is full; the bobbin should still be able to spin easily when full. Remove the bobbin. Slide the bobbin pin over and remove the bobbin. The thread will still be attached to the thread spool as well as the bobbin, so cut the excess with a pair of scissors, leaving a 2–3 inch (5.1–7.6 cm) tail. You‘re ready to start threading your machine now! Page | 251

Industrial Sewing Machine Operator Participant Guide Perform a test run to ensure machine is operating correctly Report defective machines, tools and/or equipment to the responsible person Find the thread guides. The thread guides are the metal devices that help regulate tension. They are various loops that you run the thread through before looping it into your needle. They keep the thread from getting tangled and distribute the tension evenly from the spool to your fabric. Find the tension discs and regulator. The tension discs and tension regulator together are called the tension assembly. The tension discs squeeze the thread as it passes between them, while the tension regulator controls the amount of pressure on the discs. The tension regulator is elementary: when adjusted to a higher number (turned clockwise), the discs move closer together, increasing the pressure. Turned to a lower number (counterclockwise), the discs move apart, decreasing pressure.  On older machines there are only two tension discs, controlled by a screw or knob. On newer models there are three discs controlled by a dial or keypad on the front of the machine.  Unless you have a newer machine that makes automatic upper-tension adjustments, using a thicker thread without resetting the dial will increase the pressure and cause the upper thread flow to decrease. Find the bobbin. The flat bobbin-case spring exerts pressure on the thread as it comes out of the bobbin case. You can either have a loading drop in bobbin (you won‘t have a bobbin case), or bottom loading with a bobbin case in a compartment below the needle. The amount of pressure on the bobbin is regulated by a small screw at the rear of the spring.  Both the spring and screw are easy to locate when the machine has a separate bobbin case. When the machine has a drop-in bobbin with a built-in bobbin case, locating the tension screw can be more challenging but a little bit of searching will prove it‘s there.  In either case, to increase the resistance, use a small screwdriver to turn the screw clockwise (to a higher number) or counterclockwise (to a lower number). Turn the screw in small increments and never more than a quarter-turn between tests. Understand tension. Tension is what keeps your bottom and top stitches in equal tension with one another. In other words, it is what keeps your front and back stitches looking the same. Both the top and bottom tension must work together in order to create consistent stitching. If your top and bottom stitches aren‘t even, it may be due to your tension not being right on the top or bottom.  Most domestic sewing machines are of the \"lockstitch\" variety. That means an upper thread and a lower thread \"lock\" together. When they don‘t ―lock‖ together properly, you could have an issue with the tension. Page | 252

Industrial Sewing Machine Operator Participant Guide Sew a test seam. Using a small swatch of fabric, run a couple of seams down the middle of the square. Observe the top and bottom surface of the seams, using a magnifying glass if need be.  Remember you want your stitches to look even on both sides of your fabric. If the thread is so tight it‘s causing the fabric to bunch around it or if the stitching is loose and falling apart, you might have an issue with the tension.  If your stitches look perfect and your sewing machine is sewing wonderfully, don‘t touch your tension knobs! Identify your problem. You‘ve sewn a test seam or two and you‘ve inspected the seams. A perfect stitch will have threads locked midway between the two layers of cloth, with no loops on the top or bottom of the seam and no puckers in the cloth.  An easy way to think of the thread balance is tug of war. You have your top thread and your bobbin thread pulling on each side. If they‘re both pulling equally, the seam will be even and consistent. If one side is pulling too much, the thread from the other side will be visible.  If the bobbin thread shows on the top side of the seam and the top thread is straight, the upper tension is too tight. If top thread shows on the underside of the seam and the lower thread is straight, the upper tension is too loose. Inspect your machine. There are multiple problems that could be causing issues with your sewing machine that aren‘t the tension. Make sure to check these possible causes before adjusting your tension knobs.  Incorrectly threaded machine: Is all of the thread running through the thread guides? Is thread unwinding freely from the spool or is it catching? Is the bobbin inserted correctly? Page | 253

Industrial Sewing Machine Operator Participant Guide  Dirty machine: Thread ends can get lodged between tension discs, around the bobbin case, and under the throat pale. This can cause an increase in resistance and restrict the thread flow. Check all of these areas to ensure they‘re clear.  Damaged machine parts: Bent needles and bobbins and rough or damaged surfaces on the needle eyes, thread guides, tension discs, take-up lever, throat plate, presser foot, bobbin case, or in the bobbin area can all cause problems. Give your machine a general inspection and remember that even the tiniest damage can distort tension. Pay attention to your needles, threads, and fabrics. Different thread sizes on the top and in the bobbin can throw off your basic tension settings. A needle that is too large or too small can also unbalance your stitches. If you‘re getting puckers on a lightweight fabric, trying shortening the stitch length to 1.75mm. All of these small details can wreak havoc on your project so make sure you‘re detail-oriented when setting up your machine for a project.  Polyester thread is a a true all-purpose thread, and it‘s a good choice for most sewing projects. Wool thread, on the other hand, is very thick and if you were to use it, you'd have to adjust your tension.  Common heavy duty fabrics include canvas and burlap while cotton and polyester are common fabrics with a standard weight. If you‘re switching between heavy fabrics and something of a lighter weight, you‘d have to adjust your tension to keep the stitches even.  Needles come in various sizes for different purposes. There are thicker needles designed for denim that won‘t break when they‘re being used and thin needles that won‘t damage thin, delicate fabrics. When buying needles, you can consult someone in the store to help you find the best option for your fabric. Safe machinery, tools and equipment Machinery, tools and equipment must be made safe before maintenance starts. Page | 254

Industrial Sewing Machine Operator Participant Guide Safe isolation  Ensure machinery, tools & equipments has stopped and isolate electrical and other power supplies. Most maintenance should be carried out with the power off. If the work is near uninsulated, overhead electrical conductors, eg close to overhead travelling cranes, cut the power off first  Lock off machines if there is a chance the power could be accidentally switched back on  Isolate machinery, tools and pipelines containing pressured fluid, gas, steam or hazardous material. Lock off isolating valve. Other factors you need to consider  Release any stored energy, such as compressed air or hydraulic pressure that could cause the machine to move or cycle  Support parts of machinery, tools that could fall, eg support the blades of down-stroking bale cutters and guillotines with blocks  Allow components that operate at high temperatures time to cool  Place mobile machinery, tools in neutral gear, apply the brake and chock the wheels  Safely clean out vessels containing flammable solids, liquids, gases or dusts, and check them before hot work is carried out to prevent explosions. You may need specialist help and advice to do this safely  Avoid entering tanks and vessels where possible. This can be very high-risk work. If required, get specialist help to ensure adequate precautions are taken  Clean and check vessels containing toxic materials before work starts Page | 255

Industrial Sewing Machine Operator Participant Guide Dos and don’ts of machinery, tools and equipment maintenance Do ensure maintenance is carried out by a competent person (someone who has  the necessary skills, knowledge and experience to carry out the work safely)  maintain machinery, tools and equipment regularly – use the manufacturer‘s maintenance instructions as a guide, particularly if there are safety-critical  features   have a procedure that allows workers to report damaged or faulty equipment  provide the proper tools for the maintenance person schedule maintenance to minimise the risk to other workers and the maintenance person wherever possible make sure maintenance is done safely, that machines and moving parts are isolated or locked and that flammable/explosive/toxic materials are dealt with properly Don’t…  ignore maintenance  ignore reports of damaged or unsafe equipment  use faulty or damaged equipment Operate machines safely and in accordance with guidelines Safety is important to everyone and it is your responsibility to maintain a safe working place. To maintain a safe environment, learn these safety rules and practice them at all times. Page | 256

Industrial Sewing Machine Operator Participant Guide Safety Rules:  When in doubt, ask the instructor.  Report any injuries or accidents immediately to the instructor. Also, Report a breakage to a tool or m/c to the instructor. If the equipment does not operate properly, notify the instructor immediately.  Wipe up any oil specified on the floor immediately to prevent anyone from slipping. Keep aisles clear at all times.  Operate only the machines you have been trained to operate and when the instructor or supervisor/ assistant is present.  Operate machines only with permission.  Always inspect the m/c before starting to work. Be sure it is clean and threaded correctly, with no loose threads on the pulley belt and all guards in place.  Make only adjustments you have been trained to perform  When sewing on a power m/c, wear low shoes & close-fitting clothing. Avoid loose fitting sleeves, sweaters, jewelry, ties, and ribbons when operating the machine. If your hair is long, tie it back.  Always practice proper posture to reduce fatigue, help prevent accidents and increase efficiency. If possible, adjust the chair height so that your feet rest flat on the floor.  Do not pull your chair forward or toward while operating the machine.  Use both hands to raise & lower the machine head.  Always keep your head above the table.  Keep your feet off the treadle when you are setting or threading the needle. Turn the motor off:  Before cleaning, oiling or adjusting the machine.  Before removing or replacing the pulley belt and run the machine out. Wait until all motion has stopped.  In case of an emergency or when in doubt.  Before unplugging the machine. Page | 257

Industrial Sewing Machine Operator Participant Guide  When unplugging the machine, hold onto the plug, not the cord.  Do not use your hand to stop and start the hand wheel. Use your hand only to set the hand wheel.  Before operating the m/c., close the slide bed cover and be sure the needle is properly set and the bobbin is properly placed.  When operating the machine, do not be careless. Do not talk with your colleagues. Keep your attention on your work and hands. Keep your hands at a safe distance from the needle. Keep your hands, scissors, and other sharp objects away from the belt.  Keep the machine and work station clean with tools in the side drawer.  Use the proper needle for the job.  Do not stitch over pins or put them in your mouth.  When the m/c is not in use, lower the foot and needle.  Three-way plugs are a safety feature on the machines. Do not cut off the ground prong.  Unplug the machine at the end of the day.  Know the location of the main power switch, outlets, and fuses in case of an emergency.  Do not remove any safety devices from the machines.  Turn off the iron at the end of the work.  Always place the iron on the iron pad to avoid scorching the ironing board cover.  Always place the industrial iron flat on the iron pad to avoid knocking it over.  When trimming or cutting, put all trimmings in the wastebasket.  Scissors should be handed to another person with the handles toward the person. Never toss or throw scissors or equipment.  Do not eat, drink, or smoke in the work area. Safety instructions All safety devices must be in position when the machine is ready for work or in operation. The operation without the specified safety devices is not allowed. Read the Instruction Manual before you use the machine. Page | 258

Industrial Sewing Machine Operator Participant Guide In addition, keep this Instruction Manual so that you may read it at any time when necessary. Use the machine after it has been ascertained that it conforms to safety rules standards valid in your Country. General maintenance and inspection work and also repair, remodeling and adjustment works must only be done by appropriately trained technicians or personnel.  For personal protection, wear safety glasses. Tampering with the live parts and devices is prohibited.  For the following, turn off the power switch or disconnect the power plug of the m/c from the receptacle: 1. For threading needle(s), looper, spreader etc. and reo placing bobbin. 2. For replacing part(s) of needle, presser foot, throat plate, looper, spreader, feed dog, needle guard, folder, cloth guide etc. 3. For repair work. 4. When leaving the working place or when the working place is unattended. 5. When using clutch motors without applying brake, wait until the motor stops totally.  If you should allow oil, grease, etc. used with the machine and devices to come in contact with your eyes or skin or swallow any of such liquid by mistake, immediately wash the contacted areas and consult a doctor. Optimize the positioning and layout of materials to ensure a smooth and rapid throughput. Material positioning and optimizing can be defined as: ― Art and science of conveying, elevating, positioning ,transporting, packaging and storing of materials‖ Page | 259

Industrial Sewing Machine Operator Participant Guide Starting from the time, the raw material(such as fibres for spinning unit or yarns for weaving/ knitting unit and fabrics for wet processing or garmenting units) enters the mill gate and goes out of the mill gate in the form of finished products; it is handled at all stages within mill boundaries such as within and between raw material stores, various section of production department, machine to machine and finished product stores. A material may be handled even 50 times or more before it changes to finished product. It has been estimated that average material handling cost is roughly 10-30% of the total production cost depending upon product to process. By saving in the material handling cost, the cost of production can be reduced considerably. Material handling involves the movement of materials, manually or mechanically in batches or one item at a time within the machinery, tools. The movement may be horizontal, vertical or the combination of these two. Material movement adds to the cost but not to the product value. The ideal mill would have an absolute minimum of materials handling and more use of mechanical material handling equipments. The shortage of labour and increasing wages cost demand the most efficient use of labour. Proper material handling offers benefits for:.  improving productivity .  increasing the handling capacity.  reducing man-power  increasing the speed of material movement  reducing materials wastage  promoting easier and cleaner handling  eliminating idle time of machines, equipment and workers  reduce fatigue incurred by the workers  increasing safety and minimising accidents  locate and stock material better and in less space.  minimising production cost, etc. Page | 260

Industrial Sewing Machine Operator Participant Guide PRINCIPLES OF MATERIAL POSITIONING In general, principles of material handling are as under: i. Minimize the movements involved in a production process. ii. Minimize the distance moved by adopting shortest routes. iii. In order to speed up the material movements, employ mechanical aids in place of manual labour. iv. For moving optimum number of pieces in one unit; use the principles of containerization, unit load or palletization. v. Appropriate, standard, efficient, effective, flexible, safe and proper sized material positioning equipments should be selected. vi. In order to minimize back tracking and duplicate handling; change in sequence of production operations. vii. If possible, utilize gravity for assisting material movements wherever possible. viii. To reduce damage to the materials during handling and economize material positioning process; design trolleys, packages, containers and drums etc. ix. Handling equipments are so arranged that these should minimize distances moved by products and at the same time handling equipments should not interfere with other machine or operation. x. To avoid any interruption in handling; material handling equipments should periodically be checked, repaired and maintained. SELECTION OF MATERIAL HANDLING EQUIPMENTS There are two most important aspects for analyzing or solving a material handling problem are: engineering aspect, and economic aspect. Engineering factors include: the condition of existing building and machinery, tools layout, production processes and equipments, nature of materials and products to be handled, usefulness and effectiveness of existing material positioning equipment. Page | 261

Industrial Sewing Machine Operator Participant Guide The economic factors include the cost of material handling equipment, operating costs, repair and maintenance costs and taxes etc. The choice of a particular equipment depends upon specific requirements or the condition of an industry. For selection of Material handling equipment, the following factors should betaken into account: i. Type/shape of materials to be transported: The size of material, its shape, weight, delicacy and its chances of getting damaged during handling etc. should be considered. ii. Mill building and layout The route of material movement, width of doors and aisles, inequality in floor levels, height of the ceiling, strength of floor and walls, columns and pillars etc. to a great extent influence the choice of a material handling equipments. iii. Machine production Different machines have different outputs per unit time. The material handling equipment should be able to handle the maximum output. iv. Type of material flow pattern: A horizontal flow pattern will need trucks, over heads bridge cranes, conveyors etc, whereas a vertical flow pattern will require elevators, conveyors, pipes etc. v. Types of production: The selection of the material handling equipments depends a great extend on type of production such as: mass production and batch production. Conveyors are more suitable for mass production on fixed routes and powered trucks for batch production. Page | 262

Industrial Sewing Machine Operator Participant Guide vi. Other factors Some other factors also considered during selection of material handling cost are: cost of material handling equipment, handling costs, life of the equipment and amount of care and maintenance required for the equipment. MATERIAL POSITIONING EQUIPMENTS A wide range of material handling equipments is available in the market; which are suitable to the most of the industrial requirements. Material handling equipments are classed as: 1. Industrial trucks: manual and powered 2. Cranes: overhead bridge crane, jib crane and gantry crane. 3. Hoists : chain type manual, electrical and pneumatic,. 4. Conveyors: belt conveyors, roller conveyor, drag conveyor, bucket conveyor, pipeline (pneumatic) conveyor, chain or cable conveyor 5. Monorail 6. Slides and chutes. 7. Lift 8. Tractors and trailers etc. In the textile mills, there are many types of materials viz. raw materials, purchased components, material in process, finished goods, packing material, maintenance and repair supplies, scrape and waste etc. These materials are of various size, shape and specific features. For this purpose, mostly special and some general type material positioning equipments are used in textile industries. Page | 263

Industrial Sewing Machine Operator Participant Guide Check the equipment prior to making the stitching, including: Correct controls  Correct attachments  Changing needles  Changing threads  Changing awls  Correct timing Operating the machine Connecting the machine Push plug into the receptacle at the right end of the machine. Then connect plug to your socket outlet. Changing the needle plate Your machine comes with the General Purpose Needle Plate attached. The Straight Stitch Needle Plate may be purchased at your sewing center and can be attached as follows: * Raise needle and presser foot. * Open slide plate. * Lift up needle plate from right corner and slide out from under foot. * To replace needle plate, slide it under pin and push it firmly to the left * Press down until it snaps into place. Page | 264

Industrial Sewing Machine Operator Participant Guide Fabric, thread and needle table The needle and thread you choose will depend upon the fabric being sewn. The table below is a practical guide to needle and thread selection. Always refer to it before beginning a sewing project. Be sure to use the same size and type of thread in both needle and bobbin. The fabrics can be of any fiber cotton, linen, silk. wool, NEEDLES synthetic, rayon, blends. they are listed as examples of weight Fabrics Thread Type Size Light Weight Batiste Cotton- 2020 11/80 Chiffon Crepe wrapped Polyester 100% Polyester *Mercerized Size 50 Nylon Medium Corduroy Cotton- 2020 14/90 Weight Flannel wrapped Gabardine Polyester Gingham 100% Linen Muslin Polyester Wool Crepe *Mercerized Size 50 Nylon Medium Bonded Cotton- 2020 16/100 Heavy Wovens wrapped 2020 18/110 Canvas Polyester Coating 100% Denim Duck Polyester Sailcloth *Mercerized Size 40 *\"Heavy Duty\" Knits Bonded Knits Cotton- Ball-Point 2045 Size 11/80, Double Knit wrapped 14/100, 16/110 Jersey Polyester Polyester Tricot Nylon Threading the machine To thread your machine correctly, follow the steps below: Page | 265

Industrial Sewing Machine Operator Participant Guide * Raise take-up lever to highest position by turning hand wheel toward you. * Raise presser foot to release thread tension. * Place spool of thread on spool pin * Slide spool cap firmly over rim of spool to prevent thread tangling. * Lead thread from spool and snap into thread guide and with only one hand pass the thread under the guide and through the slot, as illustrated * Thread the tension discs by leading the thread down and around the tension Hold the spool lightly and pull the thread up, lifting the spring and allowing the thread to slip into thread guard. * Slip thread into take-up lever as illustrated * Pass thread through guides * Thread needle from front to back, pulling 4\" (10 cm) of thread through eye. Raising the bobbin thread Once the needle has been threaded and the bobbin placed in the bobbin case, the bobbin thread must be brought up through the hole in the needle plate. 1. Hold needle thread loosely with left hand. Turn hand wheel slowly toward you, lowering needle into hole in plate. 2. Continue to do this until needle rises above needle plate. Pull gently on needle thread and bring up bobbin thread in a loop. 3. Open loop with fingers to find end of bobbin thread. 4. Draw needle thread through left side opening in presser foot. Pull both threads to back of machine. Page | 266

Industrial Sewing Machine Operator Participant Guide Needle position selector Needle Position Selector positions the needle in left, in center or right. Stitch length selector The stitch length indicator is numbered O to 5. The lower the number, the shorter the stitch. Shorter stitches are best for lightweight fabrics; longer ones for heavy fabrics. To adjust the length of your stitches, turn the dial so that desired stitch length is positioned under ( * ) symbol. * To shorten stitch length, turn dial toward a lower number. * To lengthen stitch length, turn dial toward a higher number. Reverse stitch button The reverse stitch button with the (???) symbol, is located in the center of the stitch length selector. * For reverse stitching, push in the button and hold in place. The machine will stitch in reverse only as long as you keep the button pushed in. Adjusting thread tension When an even amount of tension is exerted on both threads, a smooth even stitch, known as a balanced stitch, is produced. Correct tension is important because too much or too little will weaken your seams or cause your fabric to pucker. Make a test sample with the fabric and thread you plan to use and examine it. A perfect, well balanced stitch. Page | 267

Industrial Sewing Machine Operator Participant Guide (1), will have the needle and bobbin threads locked between the two layers of fabric with no loops on top or bottom and no puckering. Too much tension will produce a tight stitch (2) which will cause the fabric to pucker. * To decrease tension, turn the dial to a lower number. Too little tension will produce a loose stitch (3) which will cause loops in your seam. * To increase tension, turn the dial to a higher number. The following accessories furnished with your sewing machine are designed to simplify your sewing projects and increase the versatility of your machine. The letter in a circle adjacent to the illustrated part is reproduced on the part itself to help you select the correct attachment for the type of work you are doing. 1. Special purpose presser foot is used for decorative and zig-zag sewing. (only for machines with 5, 6, 8 and 10 stitches) 2. General purpose needle plate and presser foot are on your machine when delivered. Use together for alternating between straight and zig-zag stitching. 3. Buttonhole presser foot is used with the General Purpose Needle Plate to make four-step buttonholes. (only for machines with 5, 6, 8 and 10 stitches) 4. Zipper foot is used for inserting zippers and stitching corded seams. (only for machines with 5, 6, 8 and 10 stitches) 5. Friction free spool holder is used to hold various size spools and allows thread to unwind smoothly. The spool does not turn. 6. Small thread spool holder for use with small diameter spools of thread. Page | 268

Industrial Sewing Machine Operator Participant Guide 7. Needlepack includes an assortment for sewing various types of fabrics. 8. Feed cover is used to prevent the feed from moving the fabric when darning or free motion embroidery. 9. Transparent bobbins for easy viewing of thread supply 10. Blindstitch hem presser foot is used to position the hem for blind stitch hemming. (only for machines with 5, 6, 8 and 10 stitches) 11. Twin needle and spool pin are used to stitch two parallel rows of decorative stitching simultaneously. When using twin-needle for decorative stitching, set stitch width lever to zig-zag mid range. (Optional for some markets). 12. Felt for twin needle spool pin. (Optional for some markets). Stitch the correct materials in the right sequence as required by the production specification Garments manufacturing follows a flowchart where in each steps definite works are completed to carried out a complete garments. Here I will show you all of the garments manufacturing steps that you must follow to make a garment. 1. Design/ Sketch: For the production of knit garments, or woven garments a sketch of a particular garment including its design features is essential to produce on paper so that after manufacturing of that garment could be verified or checked whether could be done manually or with the help of computer. Page | 269

Industrial Sewing Machine Operator Participant Guide 2. Pattern Design: Hard paper copy of each component of the garment of exact dimension of each component is called pattern. The patterns also include seam allowance, trimming allowance, dirts, and pleats, ease allowance, any special design etc affairs. Pattern design could also be done manually or with the help of computer. 3. Sample Making: The patterns are used to cut the fabric. Then the garment components in fabric form are used to sew/assemble the garment. Sample garment manufacturing is to be done by a very efficient and technically sound person. 4. Production Pattern: The patterns of the approved sample garment are used for making production pattern. During production pattern making, sometimes it may be necessary to modify patterns design if buyer or appropriate authority suggests any minor modification. 5. Grading: Normally for large scale garments production of any style needs different sizes to produce from a set of particular size of patterns, the patterns of different sizes are produced by using grade rule which is called grading. 6. Marker Making: All the pattern pieces for all the required sizes are arranged n the paper in such a way so that maximum number of garments could be produced with minimum fabric wastag4e. Markers are made for 6, 12, 18, 24 etc. pieces. Marker is also useful to estimate fabric consumption calculations. Page | 270

Industrial Sewing Machine Operator Participant Guide 7. Spreading: It is the process of arranging fabrics on the spreading table as per length and width of the marker in stack form. Normally height of the lay/fabric is limited upto maximum six inches high. But 4 inch to 5 inch height of the lay is safe. 8. Fabric Cutting: On the fabric lay/spread the marker paper is placed carefully and accurately, and pinned with the fabric to avoid unwanted movement or displacement of the marker paper. Normally straight knife cutting machine is used to cut out the garment component as per exact dimension of each patterns in stack form, care must be taken to avoid cutting defects. 9. Sorting/ Bundling: After cutting the entire fabric lay, all the garments components in stack form is shorted out as per size and color. To avoid mistake in sorting, it is better to use code number on each pattern. 10. Sewing or Assembling: It is the most important department/ section of a garment manufacturing industry. Sewing machines of different types are arranged as a vertical line to assemble the garments. Sequence of types of sewing machine arrangement depends on sequence of assembling operations. Number of sewing machine per line varies from 20 nos to 60 nos depending on the style of the ga4rmnet to be produce. Production pr line pr hour also varies from 100 to 150 pieces depending on specific circumstances. Number of sewing machine arrangement per line may be upto 60 depending on design and out put quantity of garment. Page | 271

Industrial Sewing Machine Operator Participant Guide 11. Inspection: Each and every garment after sewing passes through the inspection table/ point, where the garments are thoroughly and carefully checked to detect/find any defect if present in the garment. The defects may be for example variation of measurement, sewing defect, fabric defects, spots etc. if the defect is possible to overcome, then the garment is sent to the respective person for correction. If the defect is not correctionable, then the garment is separated as wastage. 12. Pressing/ Finishing: After passing through the inspection table, each garment is normally ironed/ pressed to remove unwanted crease and to improve the smoothness, so that the garments looks nice to the customer. Folding of the garment is also done here for poly packing of the garments as per required dimension. 13. Final Inspection: It is the last stage of inspection f the manufactured garments on behalf of the garment manufacturing organization, to detect any defective garments before packing. 14. Packing: After final inspection, the garments are poly-packed, dozen-wise, color wise, size ratio wise, bundled and packed in the cartoon. The cartoon is marked with important information in printed form which is seen from outside the cartoon easily. 15. Despatch: The cartoons of the manufactured garments are delivered or placed in the despatch department or finished product godown, from where the garments lot is delivered for shipment. Page | 272

Industrial Sewing Machine Operator Participant Guide Ensure stitched product conforms to shape and size requirement and stitched products meets specification in terms of labels and trimmings CHECK OUT THESE TECHNIQUES FOR SEWING THE PERFECT DRESS! 1. PICK THE PROPER SIZE When choosing your size there are three main measurements to take: bust, waist, and hips. All commercial patterns will have you start with those measurements to get a basic idea of what size you should pick, but there are other measurements to keep in mind depending on your project. For example, if you're sewing a dress with a very full skirt, your hip measurement isn't necessary because the shape will be plenty wide enough to accommodate your size. With a project like that it's more important to select your size based on the bust, or more probably the waist. It is also helpful to take your upper bust measurement when sewing a dress with a form-fitting bodice. Fitting your upper bust first, and then making a small or full- bust adjustment, will help ensure your bodice fits well across the chest and shoulders. It's often easier to make one bust adjustment then it is to try and fit the shoulders, chest, back and bust all at once. 2. MAKE A MUSLIN VERSION After taking your measurements you can test the size you selected by sewing a practice version in muslin fabric. It is important to do this because you don't want to risk cutting into to your fashion fabric and putting in a ton of hard work, only to find out the dress size doesn't fit you well. Page | 273

Industrial Sewing Machine Operator Participant Guide Sewing a muslin first will not only help you identify fitting issues, but it will help you get familiar with sewing a new pattern. Once the muslin is adjusted, you'll be able to breeze through your final version with no problems. 3. CHOOSE THE APPROPRIATE PATTERN FOR THE DESIGN It's really important to pick the right fabric for the dress you plan to make. Fabrics have varying degrees of stretch and drape that will effect how your dress takes shape.Quilting cotton is an excellent choice for a vintage day dress, but it would make a very poor choice for a couture vogue gown that needs a fabric with fluid, dramatic drape.If you're unsure of what fabric is most suitable for your pattern, check the back of the envelope for recommendations. 4. USE PROPER STRUCTURE AND FINISHING TECHNIQUES The insides of your dress are just as important as the outside and deserve the same attention to detail. Make sure you take the time to clip curves, grade your seams and reduce bulk when your pattern calls for it. Use the correct type of interfacing and read the instructions when applying it to your fabric. If your pattern suggests hand sewing on a hem or neckline for a neat finish, it will be worth your time to do that. Also, never underestimate the power of well pressed seam! The ironing board is your friend and will make all the difference in the appearance of your finished dress. Inspect stitched products against specifications The inspections are done to control the quality is means by examining the products without the products any instruments. To examine the fabric, sewing, button, thread, zipper, garments measurements and so on according to specification or desired standard is called inspection. There are so many facilities for inspection in every section of garments industries. The aim of inspection is to reduce the time and cost by identifying the faults or defects in every step of garments making. Page | 274

Industrial Sewing Machine Operator Participant Guide Flow Chart of Garment Inspection Confirmation of Quantity ↓ Confirmation of accessories ↓ Size spec inspection ↓ In side Inspection ↓ Out side Inspection ↓ Final Inspection ↓ Packing Inspection Procedure of Garments are Described Below: 1. Confirmation of Quantity: First step of garment inspection start with confirmation of Quantity with the vendors packing list by counting all Pecs. Of each box. If Qty is not matching to the packing list and written in the box then this discrepancy is informed to the vendor. Page | 275

Industrial Sewing Machine Operator Participant Guide 2. Confirmation of Accessories: Next step is the confirmation of accessories, here we confirm brand tags, demerit tags, Price tags, or other tags, wash care labels, woven labels, or other labels and accessories as required by the buyer. 3. Size Spec inspection: After confirmation of accessories all pcs are checked as per size spec based on the instruction sheet which is given by the buyer side. If any measurement problem is noticed then we check the original sample and inform the buyer same time. 4. In Side Inspection: At this stage garment is checked from reverse side to ensure that there is no fabric defect, poor stitching, and stains etc in the garment. 5. Out Side Inspection: At this stage garment is checked from outside to ensure that there is no color variation, weaving defect, fabric defect, printing defect, holes, poor stitching, bad smell , dying defect and stains etc in the garment. 6. Final Inspection: Final Inspection stage is the most important part of inspection process, here garment is rechecked to confirm that inspection is done properly without missing any checking step if any defect is noticed we put it into rejection bin or send it for repay. Page | 276

Industrial Sewing Machine Operator Participant Guide 7. Packing: All ―Grade-A‖ goods are put back into poly bags as per the original packaging and then they are send for needle inspection. So, depending on the quality of defect some garments are send for repair and some are rejected. Identify mark and place rejects in the designated locations The fast changing economic conditions such as global competition, declining profit margin, customer demand for high quality product, product variety and reduced lead-time etc. have a major impact on manufacturing industries. The demand for higher value at lower price is increasing and to survive, apparel manufacturers need to improve their operations through producing right first time quality and waste reduction. It is important to identify, quantify and eliminate sources of variation in an operational process, to optimize the operation variables, improve and sustain process performance with well-executed control plans. The industry can gain higher productivity and profitability with improved quality product by minimizing the need for reworks. It also minimizes cost and improves internal throughout time. In garment business, it is quite usual that few rejected garments are left after shipment due to the unacceptable, and sometimes unrepairable, defects that occur during the manufacturing process. This may happen due to low quality raw materials or faulty process or employee's casual behavior (machine and/or human error). It is important, therefore, that the factory has evolved well defined check points to control the quality and reduce the rejection percentage. Reworks in the garments industry are quite common but they hamper the smooth normal production. Page | 277

Industrial Sewing Machine Operator Participant Guide In the apparel manufacturing industry, main raw material is fabric; others are different types of trimmings and accessories. Operational wastages in the apparel manufacturing process are- top surface rework, printed label rework, sewing fault rework, pinhole rework, fabric rework, improper fly shape, and other reworks. The defects can be categorized as follows. Sewing Defects: These defects are usually caused by errors arising from wrong functioning of sewing machines. Seaming defects: These defects are usually caused by errors arising from the interaction of the operator and machine in the handling of garment. Placement Defects: These defects are usually caused by errors arising in marking and cutting as well as sewing operations in the sewing room or a combination of all these. Fabric defects: These defects are usually caused by errors arising from the fabric processing like knitting and dyeing. Embroidery defects: These defects are usually caused by errors arising from the embroidery processing of the garments. Page | 278

Industrial Sewing Machine Operator Participant Guide CHAPTER - 11 Maintain Health, Safety and Security Along with covid protocol This unit provides performance criteria, knowledge & Understanding and Skills & Abilities required complying with health, safety and security requirements at the workplace and covers procedure stop prevent, control and minimize risk to self and others. Comply with health and safety related instructions applicable to the workplace Safe work practices are generally written methods that define how tasks are performed while minimizing risks to people, equipment, materials, environment, and processes. Safe Work Procedures are documented procedures for performing tasks. Safe Work Procedures are documented procedures for performing tasks. The purpose of a safe work procedure is to reduce the risk to health and safety in the workplace and reduce the likelihood of an injury by ensuring that employees know how to work safely when carrying out the tasks involved in their jobs. Safe work procedures may also be called safe work method statements (SWMS). The purpose of a safe work procedure is to reduce the risk to health and safety in the workplace and reduce the likelihood of an injury through improving employees know how to work safely when carrying out the tasks involved in their jobs. Page | 279

Industrial Sewing Machine Operator Participant Guide What are the different types of Workplace safety procedures and instructions?  Handling chemicals – these involves procedures on how to handle chemicals in workplace where these are used.  Lifting and moving objects – are procedures that pertain to how objects are to be lifted and moved safely and without strain to the person or worker.  Working at heights – these are procedures that underscore what a worker must observe to keep himself safe while working in an elevated structure or environment.  Slips, trips and falls – are procedures that pertain to safety procedures that should be in place to prevent slips, trips and fall accidents in the workplace.  Housekeeping – are procedures that pertain to how housekeeping activities should be done while keeping in mind safety, health and well-being of workers in a facility or workplace.  Electrical equipment – these are safety procedures that pertain to the installation, repair and maintenance of electrical equipment. The following steps should be followed to ensure a sound safe work procedure is developed:  Observe the task/activities: t is important to observe the task/activity being performed the preferred way to ensure safest method is documented.  Review associated legislative requirements: Some task/activities are governed by legislative requirements. These must be considered when developing a safe work procedure to ensure any legal requirements are included.  Record the sequence of basic job steps: write down the steps that make up the task/activity.  Record potential hazards of each step: Next to each step identify what may have potential to cause injury or disease  Identify ways of eliminating and controlling the hazards: list the measures that need to be put in place to eliminate or control any likely risk. Page | 280

Industrial Sewing Machine Operator Participant Guide  Test the procedure: Observe staff/student following the safe work procedure  Obtain approval: Before the safe work procedure can be used it must be approved by each approver nominated.  Monitor and review: Make sure the activity is supervised to ensure the documented process is being followed. Consultation and participation – Management or the owners of a business/organisation must consult with employees about OHS matters that can directly affect them in the carrying out of their duties.  Emergency situations/incidents – Any situation that may arise unexpectedly that could cause injury or harm to any person in a workplace.  Employee and employer responsibilities – Employees must take reasonable care to ensure the safety of themselves and others, and comply with all OHS requirements.  Hazard identification and risk control – Identifying any hazard as a source of potential harm to people, or damage to property, and reducing risk.  Occupational Health and Safety (OHS) – OHS concerns the health and safety of all people in a workplace, including employers, employees and visitors  Safe work practices and procedures – These provide practical guidance to business on how to fulfil their duty to provide a safe and healthy workplace.  Workplace accidents, injury or impairment – Unexpected events that cause physical harm or damage to people or property. Page | 281

Industrial Sewing Machine Operator Participant Guide Use and maintain personal protective equipment as per protocol Making the workplace safe includes providing instructions, procedures, training and supervision to encourage people to work safely and responsibly. Even where engineering controls and safe systems of work have been applied, some hazards might remain. These include injuries to:  the lungs, e.g. from breathing in contaminated air  the head and feet, e.g. from falling materials  the eyes, e.g. from flying particles or splashes of corrosive liquids  the skin, e.g. from contact with corrosive materials  the body, e.g. from extremes of heat or cold PPE is needed in these cases to reduce the risk. What do you have to do?  Only use PPE as a last resort  If PPE is still needed after implementing other controls (and there will be circumstances when it is, eg head protection on most construction sites), you must provide this for your employees free of charge  You must choose the equipment carefully (see selection details below) and ensure employees are trained to use it properly, and know how to detect and report any faults Page | 282

Industrial Sewing Machine Operator Participant Guide Selection and use You should ask yourself the following questions:  Who is exposed and to what?  How long are they exposed for?  How much are they exposed to? When selecting and using PPE:  Choose products which are CE marked in accordance with the Personal Protective Equipment Regulations 2002 – suppliers can advise you  Choose equipment that suits the user – consider the size, fit and weight of the PPE. If the users help choose it, they will be more likely to use it  If more than one item of PPE is worn at the same time, make sure they can be used together, eg wearing safety glasses may disturb the seal of a respirator, causing air leaks  Instruct and train people how to use it, eg train people to remove gloves without contaminating their skin. Tell them why it is needed, when to use it and what its limitations are. Other advice on PPE  Never allow exemptions from wearing PPE for those jobs that ‗only take a few minutes'  Check with your supplier on what PPE is appropriate – explain the job to them  If in doubt, seek further advice from a specialist adviser Maintenance PPE must be properly looked after and stored when not in use, eg in a dry, clean cupboard. If it is reusable it must be cleaned and kept in good condition. Think about:  using the right replacement parts which match the original, eg respirator filters  keeping replacement PPE available  who is responsible for maintenance and how it is to be done  having a supply of appropriate disposable suits which are useful for dirty jobs where laundry costs are high, eg for visitors who need protective clothing Employees must make proper use of PPE and report its loss or destruction or any fault in it. Page | 283

Industrial Sewing Machine Operator Participant Guide Monitor and review  Check regularly that PPE is used. If it isn‘t, find out why not  Safety signs can be a useful reminder that PPE should be worn  Take note of any changes in equipment, materials and methods – you may need to update what you provide. Page | 284

Industrial Sewing Machine Operator Participant Guide Carry out own activities in line with approved guidelines and procedures On industrial basis there are certain areas or sequence through which garments are manufactured.  Your duties include operating industrial appliances to gather pieces of clothes, evaluating them for errors and presenting findings to the department supervisor.  In order to ensure safety of workers, you are responsible for supervising the work environment to create a clean and healthy condition, following proven safety rules.  To ensure smooth flow of work, you should implement preventative maintenance measures outlined by manufacturers, accordingly.  You must understand that production involves many processes and as such are ready and willing to work with other people to fasten production speed.  Always on top of production activities, you should control machine functions and processes, manipulating devices and gadgets to enhance production output quality.  Other things you do include communicating with their supervisors and other team members, keeping them informed about production activities and developments.  In order to produce good quality products, the machine operator uses his/her expertise to select the best raw materials to be used for production.  You must analyzes production details and information to arrive at the best and most convenient solution to issues at hand.  Abreast with the physical activities required for production, You must keep yourself fit and healthy by engaging in exercises to be stronger and more agile to move around.  You must monitors production processes, materials, and surroundings by closely observing the performance of production equipment, events, and environment to avoid surprises or casualties. Page | 285

Industrial Sewing Machine Operator Participant Guide  Other tasks you must perform include evaluating the substance of products and their characteristics, such as shapes, sizes, volumes, delivery time, production cost, resources, and other elements needed for smooth production.  Your role also include fixing or setting them up production appliances accordingly to perform the exact sewing function needed in tune with job order and specification to have good production quality Maintain a healthy lifestyle and guard against dependency on intoxicants Being healthy should be part of your overall lifestyle, not just a New Year‘s resolution. Living a healthy lifestyle can help prevent chronic diseases and long- term illnesses. Feeling good about yourself and taking care of your health are important for your self-esteem and self-image. Maintain a healthy lifestyle by doing what is right for your body. Step 1 Maintain a healthy weight. Determine whether you are overweight by checking your body mass index. If you are overweight, it can lead to a higher risk of chronic disease such as cardiovascular disease, diabetes, stroke and certain cancers. Step 2 Stick with healthy food from each food group. This means staying away from food high in saturated fats, sodium and added sugars. Eat more whole grains, lean proteins such as chicken or legumes and beans, low-fat or non-fat dairy, and increase your fruits and vegetables. Page | 286

Industrial Sewing Machine Operator Participant Guide Step 3 Visit your doctor for an annual physical exam. Depending on your age, certain lab tests and screenings, such as mammograms, colonoscopies and heart tests, are necessary. Stay up to date on your health screenings to identify whether there are medical problems to address. Step 4 Make sure your relationships are positive and healthy ones. Surround yourself with people who support you and who you feel good around. Your partner in life, friends and others who are in your life should respect you. If you find yourself in an unhealthy relationship, take steps to improve it or move on. Step 5 Engage in physical activity for at least 30 minutes every day. Take an exercise class, join the gym or just take a brisk walk outside. Making the time for physical activity is a necessity and not a luxury. Step 6 Know when and how to de-stress. Taking care of your mental health is just as important as taking care of your physical health. Make sure that you have positive ways of dealing with stressors in your life. This might be exercising, meditating, yoga or just doing deep-breathing exercises. If stress becomes so severe that it is interfering with your sleep or ability to cope, talk to your doctor or a counselor. Page | 287

Industrial Sewing Machine Operator Participant Guide Step 7 Do not smoke. Smoking can cause preventable diseases such as lung cancer and other cancers. Stay away from secondhand smoke, since this can also be hazardous to your health. Follow environment management system related procedures Environmental management system (EMS) refers to the management of an organization's environmental programs in a comprehensive, systematic, planned and documented manner. It includes the organizational structure, planning and resources for developing, implementing and maintaining policy for environmental protection. More formally, EMS is \"a system and database which integrates procedures and processes for training of personnel, monitoring, summarizing, and reporting of specialized environmental performance information to internal and external stakeholders of a firm.‖ The most widely used standard on which an EMS is based is International Organization for Standardization (ISO) 14001. Alternatives include the EMAS. An environmental management information system (EMIS) is an information technology solution for tracking environmental data for a company as part of their overall environmental management system. Page | 288

Industrial Sewing Machine Operator Participant Guide The goals of EMS are to increase compliance and reduce waste:  Compliance is the act of reaching and maintaining minimal legal standards. By not being compliant, companies may face fines, government intervention or may not be able to operate.  Waste reduction goes beyond compliance to reduce environmental impact. The EMS helps to develop, implement, manage, coordinate and monitor environmental policies. Waste reduction begins at the design phase through pollution prevention and waste minimization. At the end of the life cycle, waste is reduced by recycling. To meet these goals, the selection of environmental management systems is typically subject to a certain set of criteria: a proven capability to handle high frequency data, high performance indicators, transparent handling and processing of data, powerful calculation engine, customised factor handling, multiple integration capabilities, automation of workflows and QA processes and in-depth, flexible reporting. An environmental management system (EMS):  Serves as a tool, or process, to improve environmental performance and information mainly \"design, pollution control and waste minimization, training, reporting to top management, and the setting of goals\"  Provides a systematic way of managing an organization‘s environmental affairs  Is the aspect of the organization‘s overall management structure that addresses immediate and long-term impacts of its products, services and processes on the environment? EMS assists with planning, controlling and monitoring policies in an organization.  Gives order and consistency for organizations to address environmental concerns through the allocation of resources, assignment of responsibility and ongoing evaluation of practices, procedures and processes Page | 289

Industrial Sewing Machine Operator Participant Guide  Creates environmental buy-in from management and employees and assigns accountability and responsibility.  Sets framework for training to achieve objectives and desired performance.  Helps understand legislative requirements to better determine a product or service's impact, significance, priorities and objectives.  Focuses on continual improvement of the system and a way to implement policies and objectives to meet a desired result. This also helps with reviewing and auditing the EMS to find future opportunities.  Encourages contractors and suppliers to establish their own EMS.  Facilitates e-reporting to federal, state and provincial government environmental agencies through direct upload Identify and correct (if possible) malfunctions in machinery and equipment and Report any service malfunctions that cannot be rectified Preventive maintenance is defined as the regular performance of equipment maintenance practices in order to avoid future equipment problems. An important first step in any preventive maintenance program is learning to identify the causes of equipment failure. By providing managers and service technicians with the knowledge to identify causes of gearbox failure (a crucial link in the power transmission chain), they can establish an effective preventive maintenance program. Analyzing Problems Effective lubrication is extremely critical to all gearboxes and will help prevent gear and bearing failures. Many gear and bearing failures result from insufficient or interrupted lubrication. Page | 290

Industrial Sewing Machine Operator Participant Guide Maintaining proper lubrication includes using the appropriate lubricant, keeping oil clean and free of foreign materials, and maintaining a sufficient supply of lubricant. Since selecting a lubricant is based on many independent factors including gear type, load type, speed, operating temperatures, input power and reduction ratio – choosing a lubricant should be left up to a gear lubrication specialist. This is especially true considering the technical sophistication found in gearing today, along with increased speeds and loads, and the specialized lubricants and additives now available. When lubrication problems occur they can cause several gear problems. Failures, like scoring and galling, are generally caused by oil film breakdown resulting in metal-to-metal contact, and high temperatures resulting in tooth surface damage. If a gear continues to operate without adequate lubrication, damage will progress until the gear‘s tooth profiles are degraded to the point where replacement is the only remedy. Further, foreign materials present in the lubricant can cause abrasive wear. Maintenance professionals have several important tools at their disposal for diagnosing gearbox lubrication problems, including oil analysis. By analyzing particulate content and concentration in the oil, engineers are able to monitor the condition of an operating gearbox. Further analysis of the oil yields vital information about the condition of the lubricant used in the equipment. Analysis of the oil used for lubrication could alert engineers to possible problems within the lubrication system. Lubrication problems can also be detected by examining wear patterns on gears. Gear tooth ―pitting‖ is characterized by a large number of very small pits, distributed evenly over the working surface of a gear. The appearance of such pitting is usually an indication of gear overload, but may also be indicative of lubrication problems caused either by some corrosive medium within a lubricant, or by improper lubricant additives. Page | 291

Industrial Sewing Machine Operator Participant Guide Vibration – the motion of a body about a reference point caused by an undesirable mechanical force – is another key indicator in the diagnosis of machine faults. Each machine fault generates a specific vibration profile, and a single vibration measurement provides information concerning multiple components. The frequency of the vibration is determined by the machine geometry and operating speed. By analyzing shaft vibration, engineers are able to determine whether the cause of the machine fault is imbalance, misalignment, general looseness or wear, bearing defects, gear defects, or some other unforeseen problem. Imbalance is the force created by a rotating body when its center of mass is offset from its center of rotation. Imbalance can cause other faults to appear. Misalignment is the deviation from a common centerline during operation and can occur as offset (shafts are meeting square, but not on a centerline), angular (shafts are meeting at an angle from one another), or both. Gear damage caused by misalignment is visible as a fracture originating at one end of a gear tooth, occurring on a diagonal line. Misalignment is also a common cause of broken teeth on helical and bevel gears. Wear is another fault determinable by vibration analysis, and can cover a broader range of gear damage – from scoring and galling, to abrasive wear, to plastic yielding. Left alone, any of these machine faults can do enough damage to necessitate shutting down a process making a shaft vibration analysis even more important. ESTABLISHING A PREVENTIVE MAINTENANCE PROGRAM While identifying the cause of equipment failure can sometimes be as simple as looking closely at the damage, discovering the root cause of such a problem is often considerably more difficult. Most mines do not have the sophisticated equipment needed to identify shaft vibration anomalies or analyze oil samples for foreign materials. Without these resources, how then can they establish a preventive maintenance program? Page | 292

Industrial Sewing Machine Operator Participant Guide Outsourcing preventive maintenance functions to an outside service provider is certainly an option. Outsourcing these duties allows mines to focus on their own core competencies, letting experts, with access to both a strong knowledge base and a wide range of necessary equipment, handle maintenance and repair duties. When selecting a preventive maintenance provider, several key services should be included in any agreement. Any agreement should cover breakdowns, scheduled maintenance, parts reconditioning, service upgrades, reverse engineering, alignment and balancing, and on- or off-site diagnostic services. Providers should be thoroughly skilled in performing gearbox failure root cause analysis. Troubleshooting is another necessary service, as part of a comprehensive preventive maintenance program. Such troubleshooting duties include engineering assistance in the identification, and swift resolution of operational problems. Other important services that were covered previously include vibration and oil analysis. These two monitoring techniques are paramount in identifying equipment anomalies before they become a problem. Any good preventive maintenance contract should include a strong warranty on all equipment serviced. Such warranties often offer many of the services already mentioned, and are ultimately a benefit to the refurbished equipment. Also, as important as any warranty is the proper installation of a gearbox, which can assure years of trouble-free operation, if adequate preventive maintenance procedures are performed. CONCLUSION While identifying the cause of equipment failure is only the first step in establishing an overall preventive maintenance program, it is an important step. Page | 293

Industrial Sewing Machine Operator Participant Guide The information gathered will ultimately serve as the foundation for planning future preventive maintenance - a particular necessity when working with critical equipment. Such information will also help service technicians avoid making the same mistakes after initial equipment repairs. PREVENTIVE MAINTENANCE CHECKLIST: Equipment Repair  Breakdowns  Scheduled Maintenance  Parts Reconditioning  Service Upgrades  Reverse Engineering  Alignment and Balancing  On or Off-Site Services Oil Analysis  In Service Condition Monitoring of Lubricant and Operating Equipment  Wear Particle Analysis  Monitor Mechanical Condition of Wearing Parts  Monitor Lubricant Viscosity  Measure Concentration of Contaminants Page | 294

Industrial Sewing Machine Operator Participant Guide Vibration Analysis  On-Site Diagnostic Assistance  Phone Support  Preventive Maintenance Program Support  Turnkey Preventive Maintenance Services  System Design and Calculations Troubleshooting  Engineering Assistance in the Identification, and Swift Resolution of Operational Problems  Analysis of operational problems including: o System o Component o Sound o Vibration o Failure Failure Analysis  Determine Root Cause of Gear and Bearing Failures  Evaluate Entire System  Identify Root Cause and Permanent Corrective Action  Operational Loads  Component Design  Maintenance Practices  Failed Components Store materials and equipment in line with manufacturer’s and organizational requirements and Safely handle and move waste and debris All businesses must store goods and materials safely, especially warehouses, factories, shops, food, agricultural and construction businesses. As well as ensuring you fulfill your legal duty to protect the health and safety of those affected by your business, the right approach to storage can also help you reduce pollution, unnecessary wastage and other costs. This guide explains how to assess and reduce the key risks of storing goods and materials, including hazardous substances. Page | 295

Industrial Sewing Machine Operator Participant Guide Using shelves, racks and pallets safely Shelving and racking must be installed and maintained properly. Ensure that:  floors are sound and level  you follow the manufacturer's installation instructions  where shelving or racking needs to be fixed to a wall, the wall can support the load  special safety ladders are provided to avoid people climbing on shelving  units are spaced correctly to allow easy access for staff and, if necessary, mechanical-handling equipment such as forklift trucks  shelves and racks are properly aligned and goods don't overhang shelves  correct maximum loads for racking are displayed  personal protective equipment is used where necessary  items are stacked correctly - put the heaviest at the bottom where possible Page | 296

Industrial Sewing Machine Operator Participant Guide If you use pallets with racking units, you should avoid:  using a pallet which can't cope with its load  poorly designed or constructed pallets  using damaged pallets  using the wrong type of pallet for the racking system used or the material or substance stored  poor handling of pallets You must use any mechanical-handling equipment, such as forklift trucks, safely. Anyone operating a forklift needs to be fully-trained, and people in areas where forklifts operate must be aware of the warning alarms, signs and notices. Storing dangerous or hazardous materials You must ensure chemicals and dangerous substances are stored and handled in a way that minimizes their risks and limits people's exposure to them. You can control risks by:  storing chemicals according to the manufacturer's instructions  keeping the minimum quantity of hazardous substances necessary  storing incompatible substances separately  taking steps to prevent release or leakage of dangerous substances  keeping a spill kit near to storage areas, and ensuring staff are trained in what to do in the event of a spill  cleaning up any leaks or spills that occur  using appropriate precautions when handling substances - for example, wearing protective clothing or ensuring adequate ventilation. Page | 297

Industrial Sewing Machine Operator Participant Guide  ensuring employees who store and handle dangerous substances are properly trained  checking containers used for short-term storage are properly labelled If you store chemicals or dangerous substances that could create a fire or explosion, you must ensure that flammable substances are correctly stored in suitable containers and are not stored near to a source of ignition such as a heater. You should also:  place stores of liquid above ground where they're unlikely to be damaged, eg away from traffic routes  avoid overfilling containers  supervise deliveries  maintain gauges, valves and pipework  monitor oil use - unexpectedly high use may indicate a leak  have procedures for dealing with emergency leakages  use a secondary containment system such as a drip tray or bund (a storage area designed to prevent liquids escaping) Storing waste and food Because of the potential dangers they pose to the environmental and health, there are special storage requirements for waste and food. All businesses must store waste safely and securely. There are additional rules for special (hazardous) waste. Page | 298

Industrial Sewing Machine Operator Participant Guide Food and catering businesses must ensure food is correctly stored to comply with food hygiene requirements. For example, you must:  observe temperature controls in all storage areas, including display cabinets  store dried food off the floor  observe use-by dates  ensure all areas are clean  avoid overloading refrigerated units - if they become too full, air doesn't circulate properly, causing food to deteriorate  follow any storage instructions on food packaging Minimize health and safety risks to self and others due to own actions You must assess the risks posed by storing goods and materials, determine how likely they are to occur and take steps to minimize them. You can reduce your risk of storing goods by:  marking all exit routes and keeping them clear  organizing storage areas and to allow people and vehicles - such as forklift trucks - to move goods safely  storing flammable substances far from any source of ignition such as a heater  storing dangerous substances, such as chemicals, appropriately  installing collision barriers in vulnerable areas  clearing up all spills immediately to reduce the risks of slips, trips and pollution Page | 299

Industrial Sewing Machine Operator Participant Guide  storing liquids in areas away from drains to avoid leaks or spills reaching water sources  checking that shelving and racking units are safe and appropriate for the materials they hold  providing any personal protective equipment staff need to store or move materials and training them on how to use it  keeping the minimum amount of materials necessary in processing and production areas  taking unused materials back to storage areas rather than leaving them lying around  segregating any materials which could contaminate each other or be dangerous if stored close together  considering how you'll ensure the security of high-value goods  using appropriate safety signage Seek clarifications, from supervisors or other authorized personnel in case of perceived risks To avoid any unpleasant surprises, The Company must lay down risk assessment minimization procedures. These procedures must be periodically reviewed to ensure that executive management controls risks through means of a properly defined framework. This document provides an insight into the risk management framework for a Textile Company. Risk Identification & Mitigation Risks can be identified in the following categories: 1. Business Risks: These are strategic risks that may threaten the existence or the smooth running of the business in the future. Page | 300