Textile machinery operators tend machines that manufacture textile goods used in all types of consumer and industrial products. Pants, skirts, and socks are familiar examples of textile products, but many are surprised to find that textile products are used in such things as tires and roads. There are many phases in the textile production process, and operators' duties and responsibilities depend on the product and the type of machinery in use.
The textile production process begins with the preparation of manufactured or natural fibers for spinning. Machinery operaters control equipment that cleans, cards, combs, and draws the fiber; spins the fiber into yarn; and weaves, knits, or tufts the yarn into textile products. They are responsible for numerous machines that they must start, stop, clean, and monitor for proper functioning.
Fibers are cleaned and aligned through carding and combing. To prepare the fiber for the spinning process, very short fibers and any foreign matter are removed and the fibers are drawn into a substance called sliver. During this process, different types of fibers may be combined to give products the desired textures, durability, or other characteristics. This is how 50 percent cotton, 50 percent polyester blends, for example, are created. Operators constantly monitor their machines during this stage, checking the movement of the fiber, removing and replacing cans of sliver, repairing breaks in the sliver, and making minor repairs to the machinery.
The full cans of sliver are then taken to the spinning area. Spinning draws and twists the sliver to produce yarn which is then wound onto conical structures called bobbins. This is an automated version of the old fashion spinning wheel.
Some workers oversee machinery that makes manufactured fibers. These fibers, used in many textile products, are created from materials that, unlike cotton, wool, and flax, are not fibrous in their natural form. To make this fiber, wood pulp or chemical compounds are dissolved or melted in a liquid which is then extruded, or forced, through holes in a metal plate, called a spinneret. The sizes and shapes of the holes in the spinneret determine the shape and the uses of the fiber. Workers adjust the flow of fiber base through the spinneret, repair breaks in the fiber, or make minor adjustments to the machinery. Because this fiber is created by a chemical process, the majority of these workers are employed by chemical companies, not textile mills.
When the yarn is ready, it is taken to be woven, knitted, or tufted. Each of these processes produces a different type of textile product and requires a different type of machine. For example, woven fabrics are made on looms that interlace the yarn. Knit products, such as socks or women's hosiery, are produced by intermeshing loops of yarn. Carpeting is made through the tufting process, in which the loops of yarn are pushed through a material backing. Although the processes are now highly automated, these concepts have been used for many centuries to produce textile products.
Even though operators work with many different kinds of machines, many of their responsibilities are similar. Each operator oversees numerous machines repairing breaks in the yarn, monitoring the supply of yarn, and making minor repairs to the machinery. As increasingly sophisticated machinery is used in textile mills, more processes will be controlled by computers, making it possible for each operator to monitor a larger area or number of machines. Because of the complexity of many machines, operators often specialize in a particular type of machine. In addition, operators prepare the machinery prior to a production run and help maintain the equipment. For example, they may adjust the timing on a machine, thread the harnesses that create patterns in textile goods, or repair machinery.
Once the yarn has been woven, knitted, or tufted, the resulting fabric is ready to be dyed and finished either at the textile mill or at a plant specializing in textile finishing. Because of the variety of consumer preferences, manufacturers must print and dye textiles in thousands of different designs and colors. Depending upon the end use of the yarn, it may be dyed before or after it is woven, knitted, or tufted. Some fabric is treated before it is dyed to remove other chemical additives that could affect the quality of the dyed product.
In addition to dyeing and printing, products are often finished by treating them to prevent excessive shrinkage, to provide strength, or to give a silky luster. In the production of hosiery and socks, for example, the stocking or sock is placed on a form and then exposed to steam and heat to give it shape.
Although employment of textile workers will decline, many job opportunities will arise from the need to replace workers who leave their jobs.
Most textile machine operators work in a textile mill or a chemical plant. Working conditions depend upon the age of the facility or equipment and its degree of modernization. Newer facilities offer better ventilation and climate control that reduce potential problems caused by airborne fibers and fumes often encountered in older facilities. Workers in areas with high levels of these airborne materials often use protective glasses and masks that cover their nose and mouth.
Although some of the newer machinery has reduced the level of noise, workers in some areas still must wear ear protection. Because many machines operate at high speeds, workers must be careful not to wear clothing or jewelry that could get caught in moving parts. In addition, extruding and forming machine operators may wear protective shoes and clothing when working with some types of chemical compounds.
The average workweek for textile production workers is 40 hours. Because most textile and fiber mills operate 24 hours a day, night and weekend shifts are common. However, many employers use a rotating schedule of shifts so operators don't consistently work nights or weekends. Operators are on their feet moving between machines during most of their shift.
Although workers have traditionally worked under close supervision, new management philosophies are placing an increasing emphasis on teamwork, which will allow operators greater interpersonal contact and more initiative.
Textile machinery operators held about 284,000 jobs in 1992. The majority of these workers were employed in weaving, finishing, yarn, and thread mills. Other employers with a substantial number of these workers were knitting mills and manufactured fiber producers.
North Carolina was the leading State in the employment of textile workers, accounting for about 30 percent of the total. Georgia and South Carolina combined accounted for another 30 percent. Most of the remaining workers were employed in other southern States and in the northeast.
Physical stamina and manual dexterity are important skills for these jobs. Education and training, however, are becoming increasingly important for working with complex machinery and advanced manufacturing methods.
A high school diploma in addition to extensive technical training is becoming a prerequisite for entry to many jobs. This training may be obtained, in part, at a formal training institution such as a technical school. Extensive on-the-job training by more experienced workers or representatives of machinery manufacturers is also common.
As the textile industry becomes more highly automated, operators will need to understand the complex machinery and be able to diagnose problems. Because textile machinery is increasingly controlled electronically, many operators will need good computer skills.
Self-direction and interpersonal skills will become increasingly important for textile machinery operators. Business attitudes promoting teamwork and fewer levels of management offer operators greater responsibility and the opportunity to take more initiative in running the production facility.
Textile machinery operatives can advance in several ways. Some workers become instructors and train new employees. Others advance by taking positions requiring higher skills and greater responsibility. First-line supervisory positions usually are filled from the ranks of skilled operators.
The textile industry will continue to undergo change. Greater productivity through the introduction of laborsaving machinery and changing business practices are expected to help the industry better compete in the global marketplace. However, these changes mean that employment of textile machinery operators is expected to decline through the year 2005.
The industry will update existing and introduce new technology that is expected to significantly increase productivity. New machinery, such as faster shuttleless and air jet looms, and computer-integrated manufacturing processes increase productivity by producing goods at a faster rate. They also allow each operator to monitor a larger number of machines. Many factories are also reorganizing production floors to further increase productivity and to give workers more responsibility.
Employment declines due to productivity increases, however, will likely be partially offset by increased demand for textile mill products. As apparel production increases in North America, the demand for textile goods produced in the United States may increase. This increased demand will help to keep jobs in the textile industry.
Although employment will continue to decline in the years ahead, many job opportunities will arise from the need to replace workers who leave their jobs. Because the industry is highly automated, persons with technical skills will have better opportunities than others.
Average weekly earnings for production workers in the textile and manufactured fiber industries were $353 in 1992, compared to $469 for production workers in all manufacturing industries. Moreover, earnings vary significantly depending upon the type of mill and by shift, job specialty, and seniority. Average weekly earnings for production workers in the chemical industry, where most extruding machine operators are found, were $623 in 1992.
Benefits usually include paid holidays and vacations, health and life insurance, a retirement plan, and sick leave. Some firms provide on-site daycare facilities. Additionally, employees often receive discounts in company-owned outlet stores.
Metalworking and plastics-working machine operators perform similar duties and have the same entry and training requirements as extruding and forming machine operators and tenders; textile machine operators and tenders; and textile bleaching and dyeing machine operators. Setters and setup operators in other industries, for example, in metal fabrication and plastics manufacturing, perform duties comparable to those of textile machine setters and setup operators.
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Reprinted with Permission of U. S. Department of Labor