Textile Spinning Mills, Back Process Job Description of a section Officer

byKAYES •
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Total activities of a Production Officer performed in spinning Back Process Control

An Officer of a section is generally the head of that section. It may be back process section, Ring Section, Finishing section. He performed all kind of activities for his section. He receives information and apply it his section according to the information and rules and regulation that he has given. A production officer performed different kind of activities into his section as well as back section. In my point of view the total activities of a production officer in back process control can be described by dividing as follows.
  1. Theoretical work
  2. Technical work
  3. Daily work
  4. Schedule work
  5. Special work 

  1. Theoretical Work:
This is a very important work for a Production Officer. He should know everything theoretically. He has to have a vast Idea about his work and its related things as much as possible like Production process, line diagram, m/c specification and its work everything from after receiving cotton bale to finished goods. A production Officer must have the following knowledge, Let’s discuss it with example-

  • Process Knowledge
  • Machine Knowledge
  • Calculative Knowledge
  • Miscellaneous.
  • Process knowledge:

After receiving bale from godown he should have or collect information about –
    • No. of bale per mixing and weight per bale
    •  Finished time of a mixing in BDT
    • Category (mic, +b), Staple length

The received bale is arranged in BDT laydown and BDT plucks fibre tufts from BDT and transfer it to the carding through different machine with two different lines. The output Product of carding is Sliver. This sliver forming in carding is the basic stage or Principle stage in a spinning mill. The process diagram of Blow room of Youth Spinning Mills ltd is given bellow-



The output of carding is sliver and is directly feed to Breaker draw frame by doubling a number of carding slivers can and formed sliver called precomb drawn sliver or PCD sliver. These sliver goes for card and Comb process according to the requirement. For Kard (KH) process, the PCD sliver is directly feed to the Finisher draw frame and then simplex. For Comb (CH) process, the PCD sliver is transfer to the Lap Former (L/F) by the doubling a number of PCD sliver and formed Lap. The number of doubling may 24 to 28. This lap is feed into Comber and formed Combed Sliver. A comber consists of 8 head and each head contain one Lap. This comb sliver is feed into finisher draw frame and then Simplex.

  • Knowledge about machine specification and their work:
A production Officer should have an idea about the machine their specification and work. Back process consists of two section Blow Room section (B/R) and Back Section.


    • B/R: There are some machines arranged in Blow Room. The machine of Blow Room and their specification is given bellow.

      •  BDT
      • LVSA
      •  MFC
      • MPM
      • CXL3
      • CVT1
      • Loptex
      • SCFO
      • Dustex

    • Back:

      • Carding
      • Breaker D/F
      • Finisher D/F
      • Lap former
      • Comber
      • Simplex

  • Knowledge of Calculation:
A production Officer must be able to calculate the following things

      • Production per unit (per hr, per shift, per day and per machine) of all machines.
      • Doffing time, Block finished time, Laydown finished time.
      • Count of product (Sliver, Roving, Yarn)
      • Weight of per unit sliver and weight of a full can.
      • Weight of a roving package.
      • Different waste percentage like Doffing-1 and 2, Noil%, Sliver waste%, Roving waste%, roving%, Pneumafil%, Hard waste% etc from B/R to Finishing.


  • Miscellaneous:
Some other basic things or parameter is very important to know for a Production Officer as follows,

      • Machine Speed
      • Count of Sliver, Roving, Yarn
      • No. of doubling
      • No. of elements and capacity of the elements (can, belt, bobbin, cap etc and their different color)
      • Man power set up including off day, leave etc
      • Avg. temperature and RH%
      • Study the massage of machine shows into the monitor.
      • Miscellaneous
Technical Work:
The 2nd necessary thing of Production Officer is technical work. Though it is the 2nd necessary things, but this is the main and principal work. The production officer performs his all kind of activities in the floor technically. He takes information from the management, run his floor according to the information and give feedback to them about the floor. He technically does the following activities.
  • Process
  • Man power setup
  • Problem and solution
  • Miscellaneous

  • Process:
The works of a production officer begin when his shift is started. After entering his section first of all he has to take information about process from log book, board or other place where it has written. Besides that the previous shift officer give a brief about the information of process and floor. Then he move to the floor to see the process and floor condition and make a plan for 8 hr to run the process. If any information is changed or added, he will be informed it from the management directly or through Shift In-charge.

Different process of different fibre and one or two or more fibre lot may run for different process. These processes are separated by different marking like –
    • Belt of different color for sliver can
    • Different Color can
    • Different color of Cap and Bobbin for Simplex roving
    • Different color Chalk mark

If we consider one fibre into the process, In Bangladesh Maximum export oriented mill have two processes. These are Kard Hossiary (KH), Comb Hossiary (CH). Except these Kard Woven(KW) and Comb Woven(CW) also made.
The Production Officer will calculate the ring production and find out how much material per hour is needed for each process. Then he divided the material and machine of back process according to his calculation for each process. He can also consider per shift (8hr) of per day instead of per hr during calculation to make the plan. Then these separated processes are marking by different mark to prevent mixing. In spinning this type of mixing (mixing into different process) is called lot mixing. When he makes the plan he has to consider the information that has given from the management directly or through Shift In charge or previous shift officer.
He has to have a look about breakdown of any m/c that hoe the breakdown of a m/c can be minimized due to the process material (Sliver, Empty Can, Bobbin) or process surplus. In that case he should study the dead line by calculation and thinking and explain it Shift In Charge or management in advance.
  • Man Power set up:
At Present Manpower is the heart of any mill, farm, or any other organization in Bangladesh as well as in the World. The other two principle elements are machine and material. To get quality and Production by processing machine and material, skilled manpower is very essential. The more skilled manpower, the more production and quality as well as productivity. But the reality is that there is no mill that has 100% skilled manpower. In a mill some are skilled, semi-skilled and some are unskilled. He has to work with all of them. Here I will discuss about worker setup as manpower setup in the back process of a spinning mill.
            A number of workers have been given to the production officer. He divides the work and machine to the worker according to the efficient, non-efficient and un-efficient. He select some worker to run some machine permanently for 8 hr. They are also dividing as App. Operator, Asst. Operator, Jr. Operator, Operator, and Sr. Operator etc. according to their experience and performance. Some are doffing roving in Simplex called doffer. They are also dividing as App., Asst., Jr. Etc. according to their experience and performance. Some are Floor Cleaner Called FC. He keeps also some worker for reliever. The reliever runs the machine when the permanent worker of that machine is in leave or spending off day. Sometimes he has to change worker from the machine. It is totally depends on the situation. He arrange weakly holiday called “off day” among the worker that every day the number of present worker is remain same. He has to provide or supplied sufficient and necessary material to the worker to run the floor smoothly.

  • Problem and Solution:
Different kind of problem has created during run the floor. The production has to take necessary steps to solute the problem. The problems can be divided as follows
1.     Problem in Machine
2.     Problem in Process
3.     Power Shortage Problem
4.     Problem of workers
5.     Miscellaneous

    1. Problem in Machine: Various kind of problem is seen in machine during running it. Each problem must have a cause. It may either Electrical or Mechanical, Utility, Quality or other’s. There is a massage or notification shows in the monitor when that machine is in problem. A production should have a minimum idea about the problem either it electrical, Mechanical, Utility or other’s by seeing massage or notification of that machine. After understanding the problem he will inform the responsible person for the problem of that machine. If the breakdown time is so long as more than 30 to 40 minutes or the after effect of the breakdown is important, He will inform it to the management or Shift In-charge. In that case he may or must write a note to the Factory In-charge through Production In-charge or directly to the Production In-charge by mentioning the problem, cause of problem and breakdown time in details. There is a breakdown format where machine no., cause, and breakdown time is recorded daily in every shift.
    2. Problem in Process:Many problems are seen during the process. If carding speed is comparatively more than breaker Draw frame, access carding full can is gradually stored in the floor and the empty can is decrease. So that carding machine may stopped due to empty can short. The same problem may occurred for Breaker Draw frame to Finisher Draw frame and Finisher Draw frame to Simplex.On the other hand, the machine (except carding) is stopped due to lack of material or sliver short. This kind of problem is seen if Breaker draw frame speed is more than carding as well as Finisher draw frame to Breaker draw frame and Simplex to Finisher draw frame. Another problem is that the quality of the product is related to the process speed or machine speed. The more speed the less quality and vice versa. So a speed should be selected where optimum production and quality and productivity is obtained and decrease or minimize breakdown period. Sometimes marking material ( belt, cap, bobbin etc) for separating the product in process is short. In that case the production Officer should provide it in to the process any how even though it may discuss with management.
    3. Power Shortage Problem: Sometimes machines are stopped due to power shortage. It may happened if Power Generation Plant shows any problem. Sometimes Generator may stopped due to low gas pressure, Generator maintenance, Generator overhealling, or other mechanical or Electrical problem. Due to the shortage of power, the production should run the machine according to process priority by calculating load that how much load will be given by PGD (Power Generation Deartmant) and how much load that he will be required. He should communicate with the Shift Incharge and with the management about this.
    4. Problem of Worker’s: Various kinds of problem among the worker are seen in a spinning mill, Every mill must have a rules and regulation, Instruction, Discipline etc. by considering of those problems. Some important problem among them and their solution according to that rules and regulation are given bellow.
      • Absent for long time: Some workers may absent for long time without information. There is a time limit about their absenteeism. If his/her absenteeism is exceeded from that time limit without information, he will be fired. The time limit may 10 days to 3 months. It depends on the mill management and authority. If the worker comes before the expiration of time limit, the production officer will ask him the cause and may give him leave of that absence or not according to the rules of the mill and the cause that is given by the worker. If the worker is in absence for more than 4 to 5 days or absent regularly without any reason, then the PO will take him to the management or communicate with the management about his or absenteeism.
      • Quarreling and Complain: Sometimes they are quarrelling each other and complain to the Production Officer against the opponent. The Production Officer Should here the both voice and Investigate the matter. He should give a punishment to the criminal by giving note, updating the performance sheet or reprimand him. If the problem is serious, the Production Officer must inform it to the management.
      • Leave tendency without any reason: Some worker have a tendency to get leave. There is a rules that how many leave a worker can spend per unit month. It may 2/3 days leave per months or 5 leave per three months etc. the Production should take necessary steps to control it.
      • Getting accident: Accident may happened at any time at any place during working in a mill. If a worker fall in accident, the Production Officer should sent him/her in to mill medical center immediately and communicate with the management. He must write a report regarding the worker’s accident by mentioning details.
      • Doing Indiscipline work: Sometimes Workers are doing indiscipline work such as-
          • Ø Coming late tendency
          • Ø Gossiping for long time
          • Ø Sleeping at Night shift
          • Ø Spend more time from allotted during eating
          • Ø Etc
    • Miscellaneous:
      •  Process Look after: Give Instruction to the worker properly about the and look after to prevent lot mixing, improve productivity and maintain quality uniformly.
      • Out looking: The out looking of a section, mill or any organization is expressed the performance and quality of the product and the responsible person. Like that the performance of a production Officer is depends on the out looking of his section. He can keep the section beautiful by the following ways.
        • Ø Keep the section net and clean and give direction to the Floor Cleaner in that ways
        • Ø  Arrange the empty can and full can in the selected place
        • Ø Arrange empty can and full can in different shape like “ I , Square or rectangle ” shape.
        • Ø Keep belt, bobbin, cap in Color wise in different place
        • Ø Give direction to the operator, worker to clean their machine
        • Ø Etc

3.     Daily work
In eight hours, there are some works that a production Officer should have to do daily. Every day he has to do the following work-
Ø Read out the logbook
Ø Make formet in Production khata to collect production data of different machine
Ø Collect breakdown data
Ø Write logbook mentioning floor condition, and given information
Ø Maintain attendance khata to give attendance of worker.
Ø Give attendance to the workers time card by signature
Ø Updating the white board
Ø Making Plan and setup worker according to the plan and the no. of worker are present
Ø Look at the process condition and take discision what to do according to the indormation and plan.
Ø Guiding the worker and Inspect their work
Ø Keep the section net clean
Ø Etc

4.     Schedule work: There are some work that a Production Officer Should have to do afeter a shedule time as follows

1.     Preparing time card at the end of the month:
2.     Make monthly attendence sheet of previous month mentioning total no. of Off day, total leave, total absent, total working days.
3.     Make attendence khata for next month
4.     Evalute the worker performance, wastage grade etc in every three month by giving a grade A+, A, B, C, D and make average the grade of three month for one year.
5.     Give a summery to the management about present strength of your no. of worker and asked for the worker you have lacking.

5.     Special work:

Worker appraisal is a special worker for a Production Officer. It means the evaluation of the total performance for a year of a worker. It includes wastage percentage, no. of leave, absent, work and m/c related knowledge etc.

      Lot Change is another special work. Other special work is Research related assignment work, train to the worker about their work and rules of the company etc.

6.     Conclusion: In conclusion it can be said that A Production Officer is only the responsible person for his section. He will take discussion about his floor according to the rules and regulation and information. He will report to the Management through the In-charge.

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