Project Report on Textile Industry

A project report on Textile Industry Promoting Tourism

SUBMITTED TO :- DR. JSR RAO

SUBMITTED BY:- 148129000 ( BTS ) NAWAZ SHARIF ANSARI

PREFACE I am going to make a project on How Textile Industry Promotes Tourism and in order to know the Production of the small sector, the Material, Designs, Special Costume in a Region, Manufacturing process and Layout. This project also gives the some important information of textile industry those brands, different product, New business, New technologies, New partnership. Because technologies also shape corporate destines. The report is made with clear objective of study of “textile industry” it’s working. The report will give the details of Production .My report provides you all the information related to the Production. I hope this report fulfils need of the educational requirements.

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I am heartily thankful to the IGNOU, which has given us the golden opportunity to prepare or analyze project report of “textile industry”. We are also thankful to honorable professor Dr. JSR RAO who has leaded us to enlighten ourselves in preparation of this project.

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NO 1 2

PARTICULAR PREFACE ACKNOWLEDGEMENT

PAGE NO. 2 3

3

OVERVIEW OF TEXTILE INDUSTRY

5

4

TYPE OF PRODUCTION SYSTEM

6

5

MANUFACTURING PROCESS OF TEXTILE INDUSTRY

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6

FACILITY LOCATION

15-19

7

FACILITY LAYOUT/PLANT LAYOUT

20-22

8

INDUSTRIAL SAFETY MEASURES IN TEXTILE INDUSTRY

23-27

9

BIBLIOGRAPHY

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OVERVIEW OF TEXTILE INDUSTRY 4 | Page

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Modernization Is A Continuous Process And There Should Be Concerted Efforts To Modernize Both Machinery And Manufacturing Processes Regularly. It Is General Experience That Units Which Maintained The Process Of Modernization Systematically Could Manage To Sustain Their Growth In The Long Run. Modernization In Fact Is Needed To Increase Production, Reduce The Cost Of Production, Rationalize Labour, Reduce Maintenance And Power Cost Per Unit Of Production Etc. Due To A Number Of Factors, The Vast Majority Of The Textile Units In India Never Tried To Regularly Modernize Their Units. As A Result The Indian Textile Industry Had Been Suffering From Technological Obsolescence Since The Beginning Of The 20th Century. Textile Industry Is One Of The Leading Textile Industries In The World. Though Was Predominantly Unorganized Industry Even A Few Years Back, But The Scenario Started Changing After The Economic Liberalization Of Indian Economy In 1991. The Opening Up Of Economy Gave Much Needed Thrust To Textile Industry, Which Has Now Successfully Become One Of The Largest In The World. Indian Textile Industry Largely Depends Upon The Textile Manufacturing And Export. Its Play A Major Role In The Economy of The Country. Indian Textile Industry Is Also The Largest In The Country In Terms Of Employment Generation. Indian Textile Industry Can Be Divided Into Several Segments, Some Of Which Can Be Listed As Below:     

Cotton Textile Silk Textile Woolen Textile Readymade Textile Hand-Crafted Textile Jute And Coir

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In the production system there are following types of production system can be used for the conversion of raw material into the finished goods. There is the different type of techniques used in the production process.      

Project Job shop Batch production ( disconnected line) Assembly line Continuous flow Cell manufacturing (group technology)

The textile industry using the JOB-SHOP or BATCH PRODUCTION techniques for the production. The Weaving Process Is Characterized By Long Planning Horizons And Relatively Slow Speed Of Machines, Very Long Setup Times, Very Large Production Batches, And Mixed Order And Stock-Based Production. On The Contrary, The Warp Making Process Is Characterized By Short Planning Horizons And High Speed Of Machines, Short Setup Times, Small Production Batches And Only Orders-Based Production. The Above Phases Pose The Most Complex Production Scheduling Problems. JOB-SHOP techniques:In the job shop machinery used mostly general purpose to produce the goods. Highly skilled labor is needed for this type of production system to handle and operate the machinery. Production Is Characterized By Processing Of Small Batches Of A Large Number Of Different Products Most Of Which Require A Different Set Or Sequence Of Processing Steps. In the job shop technique i.e., print shop…

Textile production systems may be treated as a succession of local problems, one per each production phase. The coherence of these local problems should be taken into account by “material requirements planning” or “just-in-time” approaches.

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INTRODUCTION:Products are the goods and services produced and processes are the facilities, skills, and technologies used to produce them. Production function or operation function is the primary function of an industrial enterprise. It is also known as conversion process or transformation process which transforms some of the inputs (raw material and components) into outputs which are useful for the consumers.

INPUTS

CONVERSION PROCESS

OUTPUTS

MANUFACTURING PROCESS OF TEXTILE INDUSTRY 7 | Page

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FIBER PREPARATION:Raw Cotton Contains Cotton Fiber Along With Small Plant Parts And Field Trash That Are Not Removed By The Ginning Process. At This Stage, The Cotton Fiber Has A Coating Of Oils And Waxes That Make It Hydrophobic. Raw Fiber Is Suitable For Making Nonwovens To Be Used In Industrial Products In Which Absorbency And Aesthetics Are Not Important. In Some Cases, Nonwoven Fabrics Made With Raw Fiber Can Be Wet Processed In the Same Manner As Woven And Knitted Fabrics

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SPINNING:Most Spinning Is Done Using Break Or Open-End Spinning, This Is A Technique Where The Staples Are Blown By Air Into A Rotating Drum, Where They Attach Themselves To The Tail Of Formed Yarn That Is Continually Being Drawn Out Of The Chamber. Other Methods Of Break Spinning Use Needles And Electrostatic Forces. This Method Has Replaced The Older Methods Of Ring And Mule Spinning. It Is Also Easily Adapted For Artificial Fibers. The Spinning Machine Takes The Roving, Thins It And Twists It, Creating Yarn. In Mule Spinning The Roving Is Pulled Off A Bobbin And Fed Through Rollers, Which Are Feeding At Several Different Speeds. This Thins The Roving At A Consistent Rate. If The Roving Was Not A Consistent Size, Then This Step Could Cause A Break In The Yarn, Or Could Jam The Machine. The Yarn Is Twisted Through The Spinning Of The Bobbin As The Carriage Moves Out, And Is Rolled Onto A Cop As The Carriage Returns. Mule Spinning Produces A Finer Thread Than The Less Skilled Ring Spinning.

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MULE SPINNING SPINNING

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RING

WEAVING:Weaving Is A Method Of Fabric Production In Which Two Distinct Sets Of Yarns Or Threads Are Interlaced At Right Angles To Form A Fabric Or Cloth. The Other Methods Are Knitting, Lace Making, Felting, And Braiding Or Plaiting. The Longitudinal Threads Are Called The Warp And The Lateral Threads Are The Weft Or Filling. (WEFT OR WOOF IS AN OLD ENGLISH WORD MEANING "THAT WHICH IS WOVEN".) The Method In Which These Threads Are Inter Woven Affects The Characteristics Of The Cloth.

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Cloth Is Usually Woven On A Loom, A Device That Holds The Warp Threads In Place While Filling Threads Are Woven Through Them. A Fabric Band Which Meets This Definition Of Cloth (Warp Threads With A Weft Thread Winding Between) Can Also Be Made Using Other Methods, Including Tablet Weaving, Back-Strap, Or Other Techniques Without Looms.

DYEING:The Most Commonly Used Processes For Imparting Color To Cotton Are Piece Dyeing And Yarn Dyeing. In Piece Dyeing, Which Is Used Primarily For Fabrics That Are To Be A Solid Color, A Continuous Length Of Dry Cloth Is Passed Full-Width Through A Trough Of Hot Dye Solution. The Cloth Then Goes Between Padded Rollers That Squeeze In The Color Evenly And Removes The Excess Liquid. In One Variation Of This Basic Method, The Fabric, In A Rope-Like Coil, Is Processed On A Reel That Passes In And Out Of A Dye Beck Or Vat. Yarn Dyeing, Which Occurs Before The Cloth Is Woven Or Knitted, Is Used To Produce Gingham Checks, Plaids, Woven Stripes And Other Special Effects. Blue Dyed Warp Yarns, For Example, Are Combined With White Filling Yarns In Denim Construction.

PRINTING:Colored Designs On Cotton Cloth Is Similar To Printing On Paper. Long Runs Of The Same Fabric Design Are Produced On A Roller Print Machine Operating At Speeds Between 50 To 100 Yards A Minute. As Many As Of 10 Different Colors Can Be Printed In One Continuous Operation. 11 | P a g e

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A Typical Printing Machine Has A Large Padded Drum Or Cylinder, Which Is Surrounded By A Series Of Copper Rollers, Each With Its Own Dye Trough And Doctor Blade That Scrapes Away Excess Dye. The Number Of Rollers Varies According To The Fabric Design, Since Each Color In The Design Is Etched On A Separate Roller. As The Cloth Moves Between The Rotating Drum And Rollers Under Great Pressure, It Picks Up Color From The Engraved Area Of Each Roller In Sequence. The Printed Cloth Is Dried Immediately And Conveyed To An Oven That Sets The Dye. Automatic Screen-Printing Is Another Principal Method For Imparting Colored Designs To Cotton Fabrics. Although Slower Than Roller Printing, It Has The Advantage Of Producing Much Larger And More Intricate Designs, Elaborate Shadings And Various Handcrafted Effects.

FINISHING:Finishing, As The Term Implies, Is The Final Step In Fabric Production. Hundreds Of Finishes Can Be Applied To Textiles, And The Methods Of Application Are As Varied As The Finishes. Cotton Fabrics Are Probably Finished In More Different Ways Than Any Other Type Of Fabrics. Some Finishes Change The Look And Feel Of The Cotton Fabric, While Others Add Special Characteristics Such As Durable Press, Water Repellency, Flame Resistance, Shrinkage Control And Others. Several Different Finishes May Be Applied To A Single Fabric.

CUTTING:The Fabric Is Then Cut With The Help Of Cloth Cutting Machines Suitable For The Type Of The Cloth. These Can Be Band Cutters Having Similar Work Method Like That Of Band Saws; Cutters Having Rotary Blades; Machines Having Reciprocal Blades Which Saw Up And Down; Die Clickers Similar To Die Or Punch Press; Or Computerized Machines That Use Either Blades Or Laser Beams To Cut The Fabric In Desired Shapes.

Sewing: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. 12 | P a g e

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Sequence Of Types Of Sewing Machine Arrangement Depends On Sequence Of Assembling Operations. Number Of Sewing Machine Per Line Varies From 20 No.S To 60 No.S 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 Up To 60 Depending On Design And Output Quantity Of Garment.

PRIMARY ACTIVITIES            

Raw Product Storage Waste Bailing Opening Carding Spinning Warping Slashing Weaving Inspection Packaging Warehousing Shipping

SECONDARY ACTIVITIES         13 | P a g e

Unloading Fork lifting Unwrapping Cutting Ties Waste Bailing Feeding Removing Lint Movement Of Card Cans IGNOU

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Movement Of Drawing Cans Spinning Yarn Warp Filling Winding Yarn Onto Beam Supplying Beams Preparing Loom Beams Storing Loom Beams Hoisting Producing Fabric Rolls Inspecting Fabric Cutting Fabric Wrapping Loading

SUPPORT ACTIVITIES            

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Eating Relaxing Storage Personal Hygiene Supervision Maintenance Air Washing/Conditioning Lint Removal Quality Control Testing Training Monitoring

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FACILITY LOCATION Plant location may be understood as the function of determining where the plant should be located for maximum operating economy and effectiveness. The selection for locating a plant is most important factor which influences the industry. Any industry has ttry to locate their plant near by the market place, where transportation facility available, labour force, raw material, power…etc 15 | P a g e

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Popularly Termed As The Textile State Of India, Gujarat Has One Of The Most Flourishing Textile Industries In The Country. Also Said To Be The Manchester Of The East And The Denim Capital Of India The Textile Industry In Gujarat Contributes Almost 3% Towards The GDP Of India. India Holds A Major Portion Of Global Textile Market Share. Textiles In Gujarat Are Responsible For Contributing A Major Share Of India's Art And Crafts. It Is Also Among The Oldest Industries In The State. Due To Its Perfect Combination Of Skilled Labor, Vast Variety Of Raw Materials, Seamless Blend Of Yarns And The Use Of Traditional Techniques The State Produces The Finest Range Of Textiles.

One Of The Major Factors Behind The Success Of The Textile Industry In Gujarat Is That The State Has Managed To Preserve Its Old Tradition And Culture. The Textile Industry In Gujarat Involves Quite A Sizable Chunk Of The Population. Brands Like Arvind Mills, Parag And Praful Belong To Gujarat. More Than 90% Of The Polyester Used In India Is Produced In Surat. The Two Major Textile Manufacturing Cities In Gujarat Are Ahmedabad And Surat. Both These Cities Together Account For Almost 50% Of The Total Textiles Produced In Gujarat.

Textiles in Gujarat BANDHEJ:Bandhej Is The Name Given To The Tie And Dye Fabric Of Jamnagar, Mandvi And Bhuj. The Art Of Bandhej Is Known For Its Typical Designs And Patterns. These Are Often Used In Wedding Outfits When They Are Called Gharchola Odhni And Sarees.He Tie-Dyed Fabrics Or The Bandhej Of Gujarat Are Certainly The Best Of Its Kind Produced In India Also Lso Known As Bandhani Or Bandhni.The Cost Of The Bandhej Of Gujarat Rests Not Only On The Quality Of The Fabric, But Also On The Number Of Times It Has To Be Tied And Dyed As Well As The Intricacy Of The Pattern. MATANI:Matani Or More Popularly Called Matani Pechedi Or Mata-Ni-Pachedi Are Made By The Vaghris For The Purpose Of Various Rituals. They Employ A Combination Of Block Printing For The Outline Of The Pattern As Well As The Painting Of The Mordants.The Matani Is Actually A Tribute To The Mother Goddess Durga.Matani Reflects A Passion Among The Gujaratis For Colors And A Vision For The Intricate Designs And Forms. It Is The Expression Of An Artistic Personality As Well As Rich Cultural Heritage. 16 | P a g e

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PATOLA:The Patola Silk from Patan Is Very Popular And One Of The Largest Selling Fabrics In The Country. The Sarees Are A Mark Of Tradition And Grandeur Depicting Gujarat As A Land Of Prosperity And Wealth. This Is Unique To Patan And Is Known For Its Utmost Delicate Designs Woven With Great Expertise And Quality. Gujarat Patola Exhibits A Passion For Color And A Deep Sense For Design And Form. They Convey A Message Of The State's Rich Cultural Heritage.

SIZE OF THE INDUSTRY:

The Indian Textile Industry Today Has Approximately 1200 Medium To Large Scale Textile Mills In India. 20%Of These Mills Are Located In Coimbatore (Tamilnadu).

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The Industry Has 34 Million Cotton Textile Spindles For Manufacturing Cotton Yarn Which Account For 70 Percent Of India's Textile Exports. (China Has 40 Million Cotton Spindles.)

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Of The Indian Textile Yarn Exports, Almost 80 Percent Come From Coarser Yarns (Counts Below 40's). Consequently, There Is A Need To Upgrade The Technology.

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The Domestic Knitting Industry Is Characterized By Small Scale Units With Facilities For Dyeing, Processing And Finishing. The Industry Is Concentrated In Tirupur (Tamilnadu) And Ludhiana (Punjab). Tirupur Produces 60 Percent Of The Country's Total Knitwear Exports.

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Knitted Garments Account For Almost 32 Percent Of All Exported Garments. The Major Players Include Nahar Spinning, Arun Processors And Jersey India.

EMPLOYMENT OPPORTUNITIES:The Indian Textile Industry of India is vast and growing with presence of several national and international brands. The main segments of the Indian textile industry are Man-made Textiles, Cotton Textiles including Handlooms, Silk Textiles, Woolen Textiles, Handicrafts, Coir, Readymade Garments, and Jute. 17 | P a g e

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Job opportunities are diverse in nature in the textile industry ranging from production, designing, distribution and sales. The need for manpower for the textile industry is growing to keep up with the growing demand; fresher’s are finding numerous job opportunities in the textile industry of India. The Indian textile industry offers opportunities to fresher's from various academic backgrounds as nature of job is diverse. A textile engineer must have an engineering background; either B.E. or B.Tech is preferred 

Indian Textile Industry Covers 61 % Of The International Textile Market And 22 % Of The Global Market

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Indian Textile Industry Is Known To Be The 3rd Largest Manufacturer Of Cotton Across The Globe.

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This Industry Of India Claims To Be The 2nd Largest Manufacturer As Well As Provider Of Cotton Yarn And Textiles In The World

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India Holds Around 25 % Share In The Cotton Yarn Industry Across The Globe

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India Textile Industry Contributes To Around 12 %Of The World's Production Of Cotton Yarn And Textiles.

Size Of The Industry Geographical Distribution Output Per Annum

Percentage In World Market Market Capitalization

1200 Medium To Large Scale Textile Mills In India Tamilnadu, Andhrapradesh, Punjab, Karnataka, Maharashtra 16% Per Annum Growth Rate And 1000 Million Kg Per Annum 7% Share In The Global Market 4% To The Share Of GDP

The need for the selection of the location may arise under any of the following conditions:1) When the business is newly started; 2) The existing business unit has outgrown its original facilities and expansion is not possible; 3) A lease expire and the landlord does not renew the lease; 18 | P a g e

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4) Other social or economic reasons; for example inadequate labour supply, shifting of the market.

STEPS IN LOCATION:in choosing a plant location, the entrepreneur would do well to proceed step by step, the step being; 1) Within the country or outside; 2) Selection of the region: Availability of raw material  Nearness to the market  Availability of power  Transport facilities  Suitability of climate  Government policy  Competition between stat

3) Selection of the locality or community;  Availability of labour  Civic amenities for workers  Finance and research facility  Availability of water and fire-fighting facility 19 | P a g e

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 

Local taxes and restrictions Personal factors

4) Selection of the exact site.  Soil, size, and topography  Disposal of waste

FACILITY LAYOUT/PLANT LAYOUT Plant layout is the physical arrangement of industrial facilities. It involves the allocation of space & the arrangement of equipment in such a manner that overall operating costs are minimized. There Are Three Classic Approaches To Laying Out The Equipment And Processing Functions Within A Manufacturing Facility.

1) FIXED POSITION FACILITIES:- Comes The Closest To Meeting Our Goal Of Moving The Product As Little As Possible As It Undergoes Production Processing. In These Facilities, The Product Occupies A Constant Fixed Position In The Center Of The Manufacturing Area. Rather Than Physically Moving The Product Through Different Processing Points, The Workers And The Equipment Necessary For Manufacturing Steps Are Brought To The Product. A Good Example Of A Fixed Position Manufacturing Layout Is A Shipyard, Where The Ship Under Construction Occupies A Fixed Position In The Drydock. Certain Aerospace Industries Also Operate With Fixed Position Manufacturing Arrangements.

2) PROCESS LAYOUTS:- Are Those In Which Equipment And Workstations Are Arranged According To The Type Of Process They Perform. Saws Would Be One Part Of The Manufacturing Area; Drill Presses Would Be In Another; Welding Stations Would 20 | P a g e

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Be In A Third; And Paint Booths Would Be In A Fourth Area. Process Layouts Are Used Primarily In Job Shops, Where The Facility Produces A Variety Of 9 Different Products And Each Requires A Different Series Of Processing Steps To Be Performed In A Different Sequence.

Process Layouts Require The Most Movement Of Products From Workstation To Workstation Since The Equipment Is Arranged Without Regard To The Processing Needs Of Any One Product. Job Shops Can Attempt To Reduce This Unnecessary Handling, However, By Assessing Movement Between Various Workstations For Each Product. They Can Then Determine The Total Number Of Product Movements Between Workstations For All Of Their Products And Arrange The Different Process Areas To Reduce The Total Number Of Product Movements. Process Layouts Do Have The Advantage, However, Of Maximizing The Efficiency Of Machinery Usage. All Products Requiring Drilling, For Example, Are Moved To The Same Drill Press. Therefore, The Total Number Of Drill Presses Required Is Kept To A Minimum.

3) PRODUCT LAYOUTS:-On The Other Hand, Are Geared To Production Line Operations Which Manufacture Only One Product Or A Limited Series Of Products Which Undergo Approximately The Same Processing Steps In Approximately The Same Sequence. In These Cases, Equipment And Manual Workstations Are Arranged To Mirror The Required Flow Of These Specified Products Through The Steps In The Manufacturing Process. If The First Production Process Following Reception Of Incoming Raw Materials Is Cutting Boards Into Door Frame Components, The First Piece Of Equipment Located Adjacent To The Receiving Dock Will Be A Saw. If The Next Process Step Is To Assemble These Components Into A Door Frame, Then Adjacent To The First Cutting Station Will Be A Frame Assembly Area. While Product Layouts Do Require Handling Of Products From Step To Step In The Manufacturing Process, They Minimize The Unnecessary Movement Of Products Between Related Steps By Ensuring Their Close Proximity.

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Unlike Process Layouts, However, Product Layouts Maximize The Need For Expenditures On Equipment. Studies Have Shown That Savings In Process Efficiency Far Outweigh These Additional Machine Costs. If Cutting Stations Are Required At Several Steps Along The Processing Route, Product Layouts Would Require Purchasing Separate Saws For Each Step To Allow The Uninterrupted Flow Of Work Along The Line.

IMPORTANCE OF THE LAYOUT: Economies in handling  Effective use of available area  Minimization of production delay  Improved quality control  Minimum equipment investment  Better production control  Better supervision  Improved utilization of labour  Improved employee morale  Avoidance of unnecessary and costly charges

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INDUSTRIAL SAFETY MEASURES IN TEXTILE INDUSTRY Introduction:There Are Numerous Health And Safety (H&S) Issues Associated With The textile Industry. These Include: Chemical Exposure From The Processing and Dyeing Of Materials; Exposure To Cotton And Other Organic Dusts, Which Can Affect The Throat And Lungs; Musculoskeletal Stresses; Noise exposure, Which Can Lead To Hearing Loss; Temperature And Ventilation, Which Can Lead To Fatigue And Dehydration If Temperatures Are Too High; And Working Hours And Breaks, Including Access To Food, Drinks And Bathroom Facilities. This Booklet Reviews Some Key Areas Of H&S In textile Dyeing Such As The Information Present In Material Safety Data Sheets (MSDS), Fire Hazard Training And Various Other Components Of H&S. Health And Safety Regulations Have Been In Place In Textile Industries Across Europe And The USA Since The 1970s. In England, The Health And Safety At Work Act Was Introduced In The Early 1970s And The Health And Safety Executive (HSE) Was Formed And Given Responsibility For Providing The Framework For Workplace H&S. Different Countries Have Different Standards On H&S Practices And This Booklet Takes Some Of The Key Elements Of These That Are Applicable To Promoting A Safe Working Environment In The Textile Industry In Bangladesh. 23 | P a g e

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CHEMICAL SAFETY      

Hazardous Chemicals and their Symbols Material Safety Data Sheet Risk Assessment of Chemicals Health Effects of Dyes and Chemicals Chemical Storage and Disposal of Waste First Aid

LABORATORY SAFETY PROTOCOL  Laboratory Safety Protocol  Factory Floor Safety Protocol

RESPONSIBILITY  Role of The Management  Role of The Factory Staff

HAZARDOUS CHEMICALS AND THEIR SYMBOLS   

Substances used directly in work activities (e.g. adhesives, solvents, cleaning agents); Substances generated during work activities (e.g. fumes from soldering and welding); Naturally occurring substances (e.g. dust); and Biological agents such as bacteria and other micro-organisms.

MATERIAL SAFETY DATA SHEETS Material Safety Data Sheets (MSDS) Exist To Provide Workers With The Proper Procedures For Handling Or Working With Particular Substances And Should Therefore Be Supplied For Each Individual Substance. MSDS Includes Information As Physical Data (Melting Point, Boiling Point And Flash Point), Toxicity, Health Effects, Reactivity, Required Storage Conditions, Disposal Methods, Protective Equipment, First Aid, And Spill Or Leak Procedures. When A Substance Is Bought, The Manufacturer Should Provide The Purchaser (The Textile Factory) With The MSDS For It. The MSDS Should Be Received By The Factory The First Time Goods Are Delivered. They Should Be Available In The Manager’s Office, The Storeroom Or An Appropriate Place Where People Can Have Easy Access To Them When Needed. Staff Members Who Regularly Handle Such Chemicals Should Be Aware Of The Contents Of The MSDS And Should Be Provided With Training To Advise Them Of The Aspects That May Impact On Their Health If Chemicals Are Not Handled Correctly. RISK ASSESSMENT OF CHEMICALS 24 | P a g e

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An inventory and risk assessment of all chemicals and dyes that are present at the factory must be undertaken by the management. The MSDS simplify this process by providing much of the information required in this risk assessment. The risk assessment should consider how chemicals are stored and handled. The information in the inventory and risk assessment must be made available to all workers. The factory management team should remove unnecessary risks and protect against those that remain. The steps involved in undertaking a risk assessment include: • Reference to the supplier’s MSDS; • Observations at the factory (on the production floor, in the laboratory and in the chemical store); • Consultation with employees and supervisors; and • Assessing feedback and results from monitoring of potential health risks.

HEALTH EFFECTS OF DYES AND CHEMICALS There is no evidence to suggest that the majority of the dyestuffs currently used in textile dyeing and finishing are harmful to human health at the levels of exposure that workers generally face in the factories. However, with long-term or accidental over exposure, there can be potential health hazards and all dyes and chemicals must therefore be treated with care. The most common hazard of reactive dyes is respiratory problems due to the inhalation of dye particles. Sometimes they can affect a person’s immune system and in extreme cases this can mean that when the person next inhales the dye their body can react dramatically. This is called respiratory sensitization and symptoms include itching, watery eyes, sneezing and symptoms of asthma such as coughing and wheezing.

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ROLE OF THE MANAGEMENT The Management Should Regularly Check And Document The National Laws And Regulations Concerning Workplace Safety. The Management Should Then Develop A Protocol Through Which To Implement These Laws. It May Also Be Necessary To Consider The Requirements Of Certain Buyers, Who May Have Codes Of Conduct That Include Aspects Of H&S, Corporate Social Responsibility And Environmental Responsibility. The Protocol Given In This Document Should Provide A Good Basis For This And If Implemented Correctly Could Improve The Safety Of The Working Environment In Most Factories. 26 | P a g e

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PROVIDE BASIC NEEDS Employees Should Be Given Access To Safe Drinking Water As Well As A Clean Area For Meals. Meals Should Be Taken In A Separate Area Away From The Factory Production. The Factory Staff Should Also Have Access To A Sufficient Number Of Toilets Of Adequate Quality, This Is A Legal Requirement And Contained In Most Codes Of Conduct Provided By Buyers. 

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There Should Also Be Signs Saying “No Food And Drink” In Areas Such As The Laboratory, Store Room And Factory Floor, And Any Other Areas Where It Is Not Safe To Consume Food, For Example Because Of The Risk Of Contamination By Chemicals. Hazardous Chemicals Should Be Clearly Marked In An Appropriate Language And With Clear Symbols That People Have Been Trained To Recognise And Understand. Heavy Objects Should Be Marked As Such To Avoid Musculoskeletal Accidents. Substances Or Items That Present A Fire Hazard Should Be Clearly Labelled With The Universally Recognized Symbol. Signs Should Be Placed Near Inflammable Substances Stating That It Is Not Permitted To Smoke Or Have Open Fires. Showers And Eye Washes Should Be Made Available And Clearly Marked.

ROLE OF THE FACTORY STAFF Each Employee Should Have Sufficient Appropriate Training And Experience So That They Can Perform All Their Required Job Activities. Where Relevant Each Employee Should: • Be Aware Of The Contents Of MSDS And Of Potential H&S Hazards. • Follow All Protocol In The Safe Handling And Disposal Of Dyes And Chemicals. • Be Aware Of The Fire Protocol, Where Fire Extinguishers Are And Where The Nearest Exit Is And Where Assembly Points Are. • Be Aware Of Where The First Aid Kit Is. • Wash Hands Before Meals, When Leaving The Work Area And At The End Of The Shift. This Will Prevent Accidental Ingestion Of Chemicals Or Contact With Eyes. • Maintain Correct Posture When Lifting Or Carrying Heavy Objects. • Report All Accidents And Sicknesses To The Manager As Soon As They Occur. 27 | P a g e

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• Report Any Defects Or Problems With The Machinery That Might Lead To Potential Accidents.

BIBLOGRAPHY BOOK:- 1) operation and supply management 12th edition 2) Production and operation management (k.aswathappa Himalaya publishing house)

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