Textile process controller

Textile process controllers perform textile process operations, technical functions in various aspects of design, production and quality control of textile products, and cost control for processes. They use computer aided manufacturing (CAM), and computer integrated manufacturing (CIM) tools in order to ensure conformity of entire production process to specifications. They compare and exchange individual processes with other departments (e.g cost calculation office) and initiate appropriate actions. They analyse the structure and properties of raw materials used in textiles and assist to prepare specifications for their production, analyse and interpret test data.

Textile process controllers typically do the following tasks:

• Plan and coordinate the production process, ensuring that production schedules are met and products are produced according to specifications
• Monitor the production process to ensure that quality standards are met and identify areas where improvements can be made
• Develop and implement production policies and procedures to optimize production efficiency and minimize waste
• Train and supervise machine operators and other production staff, ensuring that they follow proper procedures and safety guidelines
• Analyze production data and prepare reports for management, highlighting areas for improvement and making recommendations for changes to the production process
• Ensure that the production process meets environmental and safety standards

The following job titles also refer to textile process controller:

textile process controllers
quality assurance supervisor
textile process supervisor
textile process coordinator
textile process inspector
textile process checker

Textile process controllers typically work in manufacturing facilities. The job requires standing for long periods of time, as well as the ability to lift and move heavy objects. You may need to work irregular hours, including evenings and weekends, to meet production deadlines. The work environment can be noisy, hot, and dusty, so you will need to wear protective clothing and equipment.

To become a textile process controller, you will typically need a high school diploma or equivalent, along with experience working in a manufacturing environment. Some employers may prefer candidates with a degree in engineering or a related field. You will need to have strong organizational and communication skills, as well as the ability to analyze data and make decisions. On-the-job training will be provided to help you learn the specific processes and procedures used by your employer.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Textile process controller is a Skill level 3 occupation.

These occupations, although different, require a lot of knowledge and skills similar to textile process controller.

textile quality technician
textile operations manager
textile chemical quality technician
textile sourcing merchandiser
clothing CAD technician

These occupations require some skills and knowledge of textile process controller. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of textile process controller with a significant experience and/or extensive training.

textile quality manager
textile technologist
textile chemist
textile product developer
textile, leather and footwear researcher

This knowledge should be acquired through learning to fulfill the role of textile process controller.

• Health and safety in the textile industry: The requirements, rules and applications of health and safety measures in the textile industry.
• Staple spinning machine technology: Technologies, operations, monitoring and maintenance of machines during the yarn spinning process.
• Properties of fabrics: The influence of chemical composition and molecular arrangement of yarn and fibre properties and fabric structure on the physical properties of textile fabrics; the different fibre types, their physical and chemical characteristics and different material characteristics; the materials used in different processes and the effect on materials as they are processed.
• Textile printing technology: Addition of colour partially, according to the designed pattern, onto textile based materials. Processes for adding coloured patterns onto textile materials using printing machines and techniques (rotary of flat bed screen printing or others, heat transfer, inkjet, etc.).

These skills are necessary for the role of textile process controller.

• Control textile process: Plan and monitor textile production to achieve control on behalf of quality, productivity and delivery time.
• Maintain work standards: Maintaining standards of work in order to improve and acquire new skills and work methods.
• Use textile finishing machine technologies: Use textile finishing machine technologies that enable the coating or laminating of fabrics.
• Convert textile fibres into sliver: Convert textile fibres into drafting sliver by working in the fibre opening, carding and drafting process.
• Test physical properties of textiles: Evaluating the physical properties of textiles by using testing methods, normally in accordance with a standard; it includes fibre identification and trouble shooting.
• Set-up weft knitting machines: Prepare weft knitting machines. Activities related to preparing for weft knitting process, knitting to specification and keeping the work area clean and safe.
• Evaluate textile characteristics: Evaluate textiles and their properties in order to manufacture products in conformity with specifications.
• Check quality of products in textile production line: Check characteristics of textile products like yarns, woven, knitted, braided, tufted or nonwoven textiles, finished cloths, ready-make-garments and determine the product quality along different stages of the textiles or clothing production line.

This knowledge is sometimes, but not always, required for the role of textile process controller. However, mastering this knowledge allows you to have more opportunities for career development.

• Knitting machine technology: Manufacturing technologies which use loop forming techniques to convert yarns into fabrics in order to form knitted fabrics.
• Nonwoven machine technology: Manufacturing of nonwoven fabrics according to specification. Development, manufacture, properties and evaluation of nonwoven fabrics.
• Textile chemistry: Chemical processing of textiles such as the reactions of textiles to chemicals.
• Research and development in textiles: Development of new concepts through the use of scientific and other methods of applied research.
• Braiding technology: Development, manufacturing requirements, properties and evaluation of braided fabrics.
• Textile finishing technology: Processes used for changing the properties of textile materials. This includes operating, monitoring and maintaining textile finishing machines.

These skills and competences are sometimes, but not always, required for the role of textile process controller. However, mastering these skills and competences allows you to have more opportunities for career development.

• Use weft preparation technologies: Prepare bobbins to be used in textile processing.
• Manufacture nonwoven staple products: Perform the operation, monitoring and maintenance of machines and processes to manufacture nonwoven staple products, keeping efficiency and productivity at high levels.
• Manufacture knitted textiles: Perform the operation, monitoring and maintenance of machines and processes to manufacture knitted products keeping efficiency and productivity at high levels.
• Manufacture woven fabrics: Perform the operation, monitoring and maintenance of machines and processes to manufacture woven fabrics.
• Manufacture staple yarns: Perform the operation, monitoring and maintenance of machines and processes to manufacture staple fiber yarns.
• Manufacture non-woven filament products: Perform the operation, monitoring and maintenance of machines and processes to manufacture nonwoven filament products, keeping efficiency and productivity at high levels.
• Process man-made fibres: Converting synthetic granule into man-made-fibres such as filament yarns or staple fibre yarns.
• Covert slivers into thread: Convert slivers into yarns or threads by combing processes converting drafting card sliver to combed sliver. Form short fibre to yarn using yarn and thread processing technologies, mostly ring spinning or open-end spinning (rotor spinning) or alternative spinning techniques. Work in the drafting or drawing process converting sliver into roving and converting roving into yarn, through further drafting and twisting processes. Work on winding machines to reel the yarn from bobbins onto spools or cones.
• Use warp knitting technologies: Use warp knitting machine technologies that enable the formation of fabrics. Able to set machines for warp knitting, colour and pattern for monitoring and controlling the warp knitting process on electronic automatic warp knitting machines equipped with multifunction microprocessor and software.
• Use weaving machine technologies: Operate machines that enable weaving processes turning threads into fabrics. Setup weaving machine programmes for the machine to produce fabrics with the adequate pattern, colour and fabric density.
• Use warp preparation technologies: Use warping, sizing, drawing-in and knotting technologies that enable the formation of warps.
• Manufacture braided products: Perform the operation, monitoring and maintenance of machines and processes to manufacture braided products while keeping efficiency and productivity at high levels.
• Manufacture texturised filament yarns: Perform the operation, monitoring and maintenance of machines and processes to manufacture texturised filament yarns.
• Conduct textile testing operations: Prepare for textile testing and evaluation, gathering the test samples, conducting and recording tests, validating data and presenting results.

3119 – Physical and engineering science technicians not elsewhere classified

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References

1. Textile process controller – ESCO
2. Featured image: By Basotxerri – Own work, CC BY-SA 4.0