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Text File | 1995-10-24 | 11.8 KB | 248 lines

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Textile Machinery Operators

(A list of D.O.T.  codes is available on request.  See page 468.)

Nature of the Work

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.

Working Conditions

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.

Employment

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.

Training, Other Qualifications, and Advancement

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.

Job Outlook

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.

Earnings

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.

Related Occupations

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.

Sources of Additional Information

   Information about job opportunities in textile and manmade fiber
production is available from local employers or local offices of the
State employment service.

   For general information on careers, technology, or trade regulations
in the textile industry, write to:

   American Textile Manufacturers Institute, Inc.  1801 K St.  NW.,
Suite 900, Washington, DC 20006.

   Institute of Textile Technology, P.O.  Box 391, Charlottesville, VA
22901.


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