Flag Maintenance Technician

Milliken & Company is a global manufacturing leader whose focus on materials science delivers tomorrow’s breakthroughs today. From industry-leading molecules to sustainable innovations, Milliken creates products that enhance people’s lives and deliver solutions for its customers and communities. Drawing on thousands of patents and a portfolio with applications across the textile, flooring, chemical and healthcare businesses, the company harnesses a shared sense of integrity and excellence to positively impact the world for generations. Discover more about Milliken’s curious minds and inspired solutions at Milliken.com and on Facebook, Instagram, LinkedIn and Twitter.

RESPONSIBILITIES: 

1. Flag maintenance.  (WIAJ05.01) 

2. On-loom style change.  (WIAJ05.02) 

3. New pattern style change.  (WIAJ05.03) 

4. New warp start-up.   (WIAJ05.04) 

5. Prepare machines for rereed.  (WIAJ05.05) 

6. Start machine after reed change.   (WIAJ05.06) 

7. Follow-up on chronic machine problems.  (WIAJ05.07) 

8. Putting machines in and out of production. 

9. Relief weave.   (WIAJ05.08) 

10. Remove demerits if requested.  (WIAJ05.09) 

11. Doff fabric.    (WIAJ05.10) 

12. Warp Out Verification Process. (WIAJ05.13) 

13. Bad Warp Verification Process. (WIAJ05.14) 

14. Use A-frame Crane. (WIAJ11.06) 

15. Responsible for following and implementing training received per the locations ISO 14001 EMS, SPI 4.4.4 Training Calendar. 

16. Maintain a working knowledge of department specific combustible dust hazards and protocol as listed in WIAJ01.01 

WIAJO5.01 FLAG MAINTENANCE 

PURPOSE:  To ensure first quality fabric and production of assigned areas. 

1. At the beginning of shift, review daily communication sheet (FMAJ56) with the previous shift.  If a machine has had three flags for the same defect in the last 48-hour period or 4 times in 5 days, the loom should be on FMAJ56.         

2.  Check all flags on job assignment. 

3.  Fix machines that do not take an excessive amount of time    first. 

4.  Disposal of waste oil:  take waste oil in a container and set       next to the designated waste oil drum. 

5.  Initial and date the roll map after defect has been fixed. Record the corrective action in log book, then initial and date.  Recheck the loom after 20 minutes to make sure the defect has not reappeared and initial roll map in appropriate area.  (Use FMAJ45)  

6.  Check BARCO plant monitoring program for any out-of-control machines and work on high stop machines (WIAJ05.07). 

7.  Clear flag when complete. 

WIAJO5.02 ON-LOOM STYLE CHANGE (PICK AND FILLING CHANGE) 

1. Look for blue style change form (FMPIN19) on loom. 

2.  Obtain filling needed as noted on spec: Put on fill board. 

3.  Input pick level in microprocessor. 

4.  Discard old filling card and spec. 

5.  Put filling card on machine (MIC 1787) and place new spec on clipboard. 

6.  Place a Roll Tracking Sheet (FMAJ45) on the clipboard. For Printers Blanket refer to SPI25. 

7.  If style requires 2 filling yarns, filling card will be hung on creel position running specific filling type. 

8.  Weave fabric on new style and complete blue sheet (FMPLN19). 

9.  Change style in BARCO. 

10. Take headend and blue sheet (FMPLN1)

WIAJO5.03 NEW PATTERN STYLE CHANGE 

  1.  If blue style change form (FMPLN19) is on loom, or given by              manager, then follow steps below: 

  2.  Cut pattern behind reed. 

  3.  Set air nozzles. 

  4.  Set reed width and profile to style specification sheet. 

  5.  Set cams to specification sheets. 

  6.  Remove harness guides and reed. 

  7.  Remove module from machine. 

  8.  Clean machine. 

  9.  Oil and grease machine as trained. 

  10.  Lay new pattern module in. 

  11.  Tighten pattern down. 

  12.  Secure reed. 

  13.  Tie ends of new warp to fabric threaded in machines. 

  14.  Time lenos. 

  15.  Set harness height. 

  16.  Input settings in the microprocessor. 

  17.  Replace guards. 

  18.  Obtain filling needed as noted on new spec. 

  19.  Dispose of old filling card and spec. 

  20.  Place filling card on machine (MIC1787) and place new spec on clipboard. 

  21.  Place a new Roll Tracking Sheet (FMAJ45) on the clipboard.  

  22.  For printer’s blanket, check the spacing of the colored ends and adjust to match spec.  Refer to SPI25. 

  23.  If style requires 2 filling yarns, filling card will be hung on creel position running specific filling type. 

  24.  Adjust air flow. 

  25. Complete style change checklist (FMDI9/10).  Get technician trainer to check demerits on loom and correct all deficient items.  Get trainer technician to recheck after corrections are made.  Do not move on to next step until the loom scores zero demerits. 

  26.  Weave fabric on new style and complete blue sheet. 

  27.  Obtain head end for Lab and change style in BARCO. 

  28. Take headend, blue sheet (FMPLN19), and style change checklist (FMDI9/10) to lab for approval. 

  29.  Start machine if approved by lab. 

WIAJ05.04 NEW WARP START UP 

This task includes a cleaning activity that is intended to reduce accumulation of lint buildup on equipment and surrounding areas.  The cleaning itself will disturb lint in and around the equipment and presents a risk of combustible dust.  Routine cleaning as scheduled reduces that risk by limiting the amount of accumulation.  Dust removed from the machine must be swept up and sent to the dust collection system via the vacuum return system.  Tools used to sweep the dust (brooms and dust pans) must be spark-proof. 

Cleaning methods and controls should be conducted in a manner consistent with plantwide dust and lint control procedures. 

1. Go to a loom that is warped out. If printers blanket; complete New Warp Start-up Checklist (FMAJ46) – SPI25. 

2. Obtain an air hose and proper equipment and clean machine.  Oil and grease machine as trained. 

3. Replace leno's using the forward and reverse options on the loom to position the lenos. 

4. After the warp is tied, clean reed if warp is filament or if needed on a spun warp.  Slack off warp then zero out warp tension.  Put temple caps down. Tighten warp back to set tension. 

5. Run an inch of picks in fabric. Abrasive styles require black filling yarn to be used when running the fabric. Certain Contract Jacquard styles require a test weave and black filling to be run. 

6. If machine is a printer’s blanket style, check spacing of the colored ends; adjust to match spec.  Refer to SPI25. 

7. Check for doubles, misreeds, and end outs. 

8. Run warp-tie to back of take-up.  If a doff is not required, cut out the warp tie and sew a seam. 

9. If the style does require a doff, follow WIAJ05.10. 

WIAJ05.05 PREPARE FOR REED CHANGE 

PURPOSE:  To have ready for rereed. 

1.  Review daily communication sheet (FMAJ56) for rereeds. 

2.  Place loom at zero degrees manually. 

3.  Loosen reed. 

4.  Remove temple caps. 

5.  Take-off PRA. 

6.  Slack off on warp tension. 

7.  Cut warp ends and tie behind reed. 

WIAJ05.06 START MACHINE AFTER REED CHANGE 

PURPOSE:  To put machine back into production as soon as possible. 

1.   Place reed in position and slide until contacts set screw. 

2.   Tighten reed down. 

3.   Tie down warp and pull over until knots are over sand drum. 

4.   Tighten warp tension. 

5.   Put PRA back 5mm from end of reed. 

6.   Replace temple caps. 

7.   Put picks in fabric and check for defects. 

WIAJ05.07 FOLLOW-UP PROGRAM/CHRONIC MACHINES 

PURPOSE:  Prevent off-quality and increase production. 

1.  Check chronic machine report in barco for any out of control machines on your set or with the daily communication sheet (FMAJ56) 

2.  Work on high stop machines. 

3.  Check these machines during shift to see if these machines have been corrected. 

4.  Communicate with technician using daily communication sheet (FMAJ56) on following shift. 

5.  Communicate with PI any chronic machine problems. 

WIAJO5.08 RELIEF WEAVING 

1.  Repair warp breaks.       (WIAJ04.03) 

2.  Repair filling breaks.    (WIAJ04.04) 

3.  Repair leno breaks.       (WIAJ04.05) 

4.  Repair catchcord breaks.  (WIAJ04.06) 

5.  Creel where necessary. 

6.  Refer to SPI 25 for printer’s blanket styles. 

WIAJ05.09 REMOVE DEMERITS 

PURPOSE:  To maintain optimum operating condition of machine by correcting demerits found by machine inspector. 

1.  Obtain demerit list from maintenance leader. 

2.  Obtain materials needed to make repairs. 

3.  Go to machine checked by machine inspector. 

4.  Make Barco declaration.  (FMPI13) 

5.  Put up orange flag. 

6.  If necessary, stop machine, and attach lockout/tagout device. 

7.  Remove demerits found and recorded by machine inspector (e.g. broken, loose, missing, worn parts, settings, lubrication, cleanliness). 

8.  Remove lockout/tagout device if being used. 

9.  Start machine. 

10.  Make Barco declaration. 

11.  Remove orange flag. 

12.  Go to next machine, until list is completed. 

13.  Sign and date demerit sheet. 

14.  Return to maintenance leader. 

DOFFING FABRIC: 

1. AGV approaches and stops one loom before the machine to be doffed; yellow light is solid and AGV readout says "PRESS CONTINUE".  Weave machine should be stopped and lamp tree light is solid orange. 

2. Enter “79” for doff arrival. 

3. Obtain marker and Inspection Seam Map (MIC 17299-1). 

4. Write the following information on the Inspection Seam Map (MIC 17299-1):         

Enter "Admin 77" 

A. Barco Piece Number        

B. SAP Material Number       

C. Yards                     

D. Initials of associate doffing the roll and date. 

5. Follow instructions per SAP SPI “Doffing the Weave Machine”. 

6.  Press the CONTINUE button on AGV, it moves forward to the machine to be doffed. 

7.  Remove tube from AGV and press and hold CONTINUE button on AGV until readout says “R FLAP IN POSITION" or "L FLAP IN POSITION. Green "FLAP IN POSITION" AGV light will quit flashing. 

8.  Flaps are lowered on machine take-up side. 

9.  Doff roll onto AGV and press CONTINUE button on AGV. 

10.  The flaps raise to secure roll on AGV. 

11.  AGV readout says "STAY AWAY AGV IS MOVING" and AGV moves away. 

12.  Place tube in machine take-up - wrap fabric around tube. 

13.  Check tube guides. 

14.  Restart weave machine. 

Milliken is an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to actual or perceived race, color, creed, religion, sex or gender (including pregnancy, childbirth or related medical condition, including but not limited to lactation), sexual orientation, gender identity or gender expression (including transgender status), ancestry, national origin, citizenship, age physical or mental disability, genetic information, marital status, veteran or military status or any other characteristic protected by applicable law.