Experienced Textile Engineer with over 6 years in weaving production and quality control, specializing in denim and finishing testing. Currently working as Deputy Manager Weaving at Diamond Fabrics Limited, Sapphire Group. Skilled in fabric analysis, yarn and fabric testing, and ensuring quality compliance in greige, denim, and finished fabrics. Experienced in managing air-jet loom production and addressing weaving defects to maintain high production standards.
➢ Managing daily yarn testing of different counts and materials to be used in running articles and new orders both (warp and weft).
➢ Successfully streamlined the fabric testing workflow and reduced the turnaround time by 20%.
➢ Successfully increased the daily fabric testing capacity by 15%.
➢ Administrated woven fabric quality related issues i.e., fabric damage, reed marks, temple marks, nozzles marks, miss pick, SM, RM, shade issue of running and new orders in PICANOL Omniplus Summum Air jet loom,and OPTIMAX Rapier shed on daily basis to ensure and maintain 100% quality standards for our customers.
➢ Managing fabric testing of export customers like VD, Vlisco etc and their feedback to the Sr. General Manager Weaving.
➢ Managing feedback of fabric testing of Inter-company articles (export) from Denim QA lab before and after finishing processes like PFGD and Dyeing operations.
➢ Negotiations with Denim and Finishing team regarding strength issues of corduroy and VD (export) articles.
➢ Managing record keeping of yarn and fabric testing results in weaving lab.
➢ Daily negotiations with marketing team about quality related issues of running orders.
➢ Discussions and planning of new orders with marketing team related to their specifications and possible outputs related to quality assurance.
➢ Established a robust customer feedback loop to gather and analyze feedback on fabric quality from our clients.
➢ Experience of SAP business software regarding record keeping and worked on establishing new modules on SAP of better inspection of raw materials within the system.
➢ Co-ordination with PPC team to make sure timely testing measures of raw materials before running orders.
➢ Successfully strengthen supplier quality assurance processes by implementing rigorous testing and evaluation procedures for incoming materials
➢ Daily negotiations with supply chain team for timely demand of daily yarn arrivals for both denim, corduroy and greige weaving orders.
➢ Successfully improved customer satisfaction and build stronger relationships with our clients by addressing customer concerns promptly and making necessary adjustments to our processes.
➢ Managing damage control related to quality assurance and maintenance related faults in weaving shed.
➢ Daily cross checking of new and running articles in weaving shed.
➢ Experience in waste management in weaving shed to minimize cost to its minimum range.
➢ Daily feedback from folding (inspection department) of sensitive buyers like VD and their possible issues to troubleshoot early on time minimizing rejection.
➢ Discussions with marketing team about fabric swatch analysis and their possible parameters like possible efficiency%, possible RPM and rejection before booking of orders.
➢ Experience of article planning of different qualities w.r.t loom type i.e Rapier, Airjet etc
➢ Directly reporting to Sr. General Manager and General Manager Weaving about quality related issues related to weaving.
➢ Deep understanding of weaving lab testing equipment like tensile tester, tear tester, yarn twist tester, etc.
➢ Monitored different woven fabric qualities of variety of weaves and constructions efficiently to achieve higher quality standards in local and export market.
➢ Administrated woven fabric quality related issues i.e., fabric damage, reed marks, temple marks, nozzles marks, miss pick, SM, RM, shade issue of running and new orders in TSUDAKOMA ZAX-9100 and TOYOTA JAT810 Air jet loom shed on daily basis to ensure and maintain 100% quality standards for our customers.
➢ Preparing loom article change instructions indicating changes in loom shedding mechanism i.e., Tappet or Dobby according to construction and weave design.
➢ Expertise in preparing complicated Dobby designs as per reference sample from the customer and setting it up on loom function.
➢ Daily troubleshooting to maintenance related faults in weaving shed.
➢ Air consumption management on all looms and entire weaving shed.
➢ Daily check and balance of damage loom parts and their replacement in the weaving shed.
➢ Directly reporting to GM about all the technical issues and daily task updates related to weaving.
➢ Managed quality change planning of looms according to their availability as per construction, order width and loom type i.e., 190CM, 210CM, and 230CM for narrow orders and 280CM & 340CM looms for wider orders.
➢ Expertise in Drawing in Mechanisms of different qualities w.r.t no. of frames, heald wire type, body denting, selvedge denting and reed count to ensure accurate quality specifications.
➢ Daily negotiations with the marketing team of various technical issues of new orders before starting production.
➢ Monitoring sensitive feedback of customers from folding inspection department and take corrective actions immediately to resolve all technical issues. Lubrication management on different parts of the loom.
➢ In-depth knowledge of Tsudakoma and Toyota loom software and their functions in order to run proper fabric qualities.
➢ Motivation and training of staff and workers.
➢ Expertise in weaving calculations i.e., per day production, warp consumptions, weft consumptions, cloth roll calculations, warp & weft contraction, count conversions etc.
Monitored mechanical faults related to woven fabrics in loom shed and took corrective measures to control them
➢ Responsible of management and execution of production targets.
➢ Gained in-depth knowledge of Tsudakoma and Toyota Loom Settings of different constructions.
➢ Expertise in adjustment of loom back rest height, back rest position, frame height lever height, tension controls of let-off and take-up motions.
➢ Order piece length management according to total order and no. of looms running.
➢ Cost saving from warp and weft yarns by calculating correct amount of input on machine by past results and experience.
➢ Managed yarn testing of daily arrivals of different counts i.e., USTER-06 testing, CLSP (count lea strength product), TPI (twist per inch) and making fabric appearance reports from inspection department before using a yarn received from spinning mills.
➢ Experience of swatch analysis of different weaves like 1/1 Plain, Half Panama, Full Panama, 2/1 & 3/1 Twills, 4/1 Satin, Rib Stop, Herring Bone, 2/2 Matt, Broken Twill, Bedford Cord, Canvas, Oxford, Basket Weave, Cavalry Twill, Cellular Weave, Pointed Twill, Basket Weave, Bird Eye Dobby and other complicated dobby weaves with their peg plan, lifting and design mechanisms, yarn count, warp & weft contractions, fiber material, twist, ply and selvedge specifications.
➢ Managed record of keeping quality specification data of different constructions.
➢ Expertise in fabric testing i.e., tear testing, tensile testing, fabric thickness, shade matching etc.
➢ Knowledge of basic testing equipment i.e., James Heal Elma Tear (digital), Elendorf Tear Tester (analog), Mesdan Tensile Tester, Zwick/Roell Tensile Testing Machine, Mesdan Light Lab and Mesdan Lab Splice Scanner-2 and TPI Testing Machine.
➢ Experience of Microscopic Analysis of Lycra and Spandex yarns.
➢ Managed Contract Finalization of new orders and setting up their program and loom specifications including selvedge specification requirements of different local and export buyers.
➢ Supervised and coordinated activities of my team and workers of quality department i.e., Quality In charge, Quality Supervisors, Quality Checkers and Testing Clerks.