Basavarajappa K

A professionally qualified and well-experienced graduate in Textiles seeking for a good opportunity where excellence will be criteria for performance. Working as an GM with working experience 30 Years, handled successfully in setting up Yarn Dyeing plant and fabric dyeing, finishing and up gradation of systems and ISO 9002 implementation in different complex mills.

Plant manufacturing & quality head (General Manager) at DCM Shriram Rayons Limited (2022-07 – Present)

• Production planning and control and MIS (Management information system)
• Physical lab
• Chemical lab
• Viscose dept
• Spin bath
• Spinning production
• Twisting
• Coning
• Weaving
• Dipping & finishing
• Quality Assurance and quality control
• Packing
• Daily production - 35 MT
• Utilizing methodologies such as 5S, TPM, QC, Kaizen, Lean production, Workplace Safety tools, and others, to spearhead projects aimed at enhancing cost efficiency, quality, productivity, and safety.
• Reporting to: Vice President and Chief Operating Officer
• Successfully implemented IATF -16949 In DCM Shriram Rayons (Technical textiles and Automative fabrics sector)

Senior Manager Yarn Dyeing at Grasim Industries Limited, Aditya Birla Group (2015-11 – 2022-06)

• Viscose dope dyeing & yarn dyeing production.
• R &D, Process & Quality control, Quality Assurance
• Safety
• After treatment and finishing
• Textile coning
• Twisting
• New product development
• Fancy yarn production
• Viscose Air texturization
• Rayon Textile Out Sourcing production & quality
• Reporting to: Joint President (Operations)
• Dope Dyeing Qualities Manufacturing: 75/12 Color yarn (Newly Developed); 75/24 Color yarn (Newly Developed); 120/09 Color yarn (Newly Developed); 120/24 Color yarn; 150/40 Color yarn; 225/40 Color yarn; 300/50 Color yarn; 300/90 Color yarn (Newly Developed); 450/90 Color yarn; 600/90 Color yarn
• Twisting: 110/2 BRT for Embroidery; 120/2 BRT for Embroidery; 150/2 BRT for embroidery
• Machines: TFO & Cop winders
• Fancy yarn (Viscose Air texturization – ATY production)
• Daily production: 3.0 Ton
• ATY Yarn Qualities: 75 Plain; 130 Plain; 150 Plain; 115 Slub; 160 Slub; 180 plain; 220 Slub; 245 Slub; 300 Plain; 300 Slub
• Fancy yarn production: Splendor, daily production – 0.700 Ton/day, Denier - 130 & 150; Radium, daily production – 0.500 Ton/day, 300 Radium, 150 Radium; Titan, 170 Denier; Neptune, 170 Denier
• Remarks: Launched in the market.
• Covering yarn: Daily production – 250 kg; 60 Denier + Spandex; 75 Denier + Spandex; 110 Denier +Spandex; 120 Denier +Spandex; 150 Denier + Spandex

Plant Head at Threads India Limited, Lohia group (2014-02 – 2015-10)

Lead the overall operations at Bangalore plant.

• Lab matching
• Planning
• Dyeing Production
• Soft winding
• Cone winding - Nylon
• Stretching.
• packing
• HR
• Commercial activities
• Reporting to: Executive Director.
• Machineries handled: Weavtex horizontal machines; Dalal dyeing machines; Harish Soft winder; Peass metlar; Propeller soft winding machine; Auto Taining machines; UT machines (UTM); Cop banding machines; Stretching machines; Rashmi winder; Texmil winder; Conorapid soft winder
• Qualities - Sewing Threads Manufacturing: 2/20 Spun Poly; 2/25 Poly Poly; 3/20 Spun Poly; 3/22 Spun Poly; 3/25 Spun Poly; 4/20 Spun Poly; 3/60 Spun Poly; 3/65 Spun Poly; 2/70 Spun Poly; 2/20 HT Yarn; 2/12 Poly Poly; 3/12 Poly; 4/12 Poly; 2/16 Poly; 3/16 Poly; 2/29 Spun Poly; 3/29 Spun Poly; 2/36 Poly; 2/45 Poly; 2/50 Spun poly; 150/0 Tex; 300/0 Tex
• Nylon - (Sewing Thread manufacturing): 210/2 ply; 210/3 ply; 210/4 ply; 210/6 ply; 210/9 ply; 210/12ply; 110/3 ply
• Ensuring the lab matching of lab dips nearly 20-30 shades development per day.
• Ensuring the effective grey yarn feedback from winding incharge
• Looking after complete production of dyeing and ensuring the repeatability and reproducibility or right first time 92% from lab to bulk.
• Ensuring effective and smooth in-time deliveries to the customer.
• Matching of the shades within the tolerance limit-DE-value 1.0
• Familiarized in computer color matching.
• Ensuring the quality parameter like wash fastness (ISO-105 EO-3), water fastness (IS0105 EO-1), Rubbing fastness (ISO-X-12), chlorine fastness and light fastness as per customer requirement and maintaining the periodical records.
• Ensuring cost reduction in process by right color Combination
• Reputed Clients: Gokul Das, Shahi, Texport, Cottonworld, Page garments, Madhura garments, A.I enterprises, Stanfab apparels, Roverco

Deputy General Manager at GM Fabrics (2010-04 – 2014-02)

Headed the Yarn Dyeing Operations at Tarapur Plant.

• Lab matching
• Planning
• Production - Winding
• Packing
• Qualities of Yarn worked with: Viscose SFY; Viscose embroidery yarn; Viscose Chennile yarn; Cotton Yarn; 150/40 Roto; Spun poly; Dull & Semidull poly; Poly Air Textuized yarn

Senior Manager at Aditya Birla Nuvo Limited (2008-03 – 2010-02)

Reporting to Vice President, Indian Rayon - A leading multinational company and biggest viscose yarn producer in India accredited with ISO-9001, ISO-14001, OHSAS-18001(Health- safety) OEKO-TEX STANDARD 100-Certificate and RC-14001-2005 (Responsible care —first in India to receive the certificate. Complete responsibility of Viscose yarn manufacturing and Dope dyed yarn department as Head of the department.

• Lab matching
• Planning
• Production-42.5 ton - Winding - Packing.
• Quality of Materials: 40 /24 Brt; 50/24 Brt; 60/24 Brt; 75/24 Brt; 75/40 Brt; 100/40 Brt; 110/24 Brt; 120/09 Brt; 120/12 Brt; 120/24 Brt; 120/40 Brt; 150/40 Brt; 180/40 Brt; 225/40 Brt; 300/70 Brt; 450/90 Brt; 600/90 Brt
• Dope dyed yarn: 120/24 Color yarn; 150/40 Color yarn; 225/40 Color yarn; 300/50 Color yarn; 300/90 Color yarn; 450/90 Color yarn; 600/90 Color yarn
• Ensuring the effective grey yarn feedback from winding in charge
• Looking after complete production of dyeing and ensuring the repeatability and reproducibility or right first time 85-90% from lab to bulk.
• Ensuring the daily production target of 42.5 ton
• Ensuring effective and smooth in-time deliveries to the customer.
• Matching of the shades within the tolerance limit-DE-value 1.0
• Familiarized in computer color matching.
• Ensuring the quality parameter like wash fastness (ISO-105 EO-3), water fastness (IS0 105 EO-1), Rubbing fastness (ISO-X-12), chlorine fastness and light fastness as per customer requirement and maintaining the periodical records.
• Ensuring cost reduction in process by right color Combination
• Successfully developed nearly -300 new shades in viscose and get ensured the Repeatability and reproducibility RFT 85-90%
• Successfully solved problems in viscose dyeing in 120\2 viscose (embroidery).
• Reputed Clients Worked For: LEMONTECH-UK, TECHNO-ITALY AND SPAIN, TESSIBE ITALY, TEXYA —TUNISIA, MOHAMED AND MOHAMED —EGYPT, TOP RAYON-MOROCCO, RAMADHAN-LIBYA, FILTRADING SRL-ITALY, ETS BERRADA-MOROCCO-SOUTH AFRICA, WUPPERTALLER GARN-GERMANY, NOMURA TREADING JAPAN, ETS-HAMMAMI KAMAL -TUNISIA, FILOTEX-GERMNY, HATEM-EL-BADRY-EGYPT, NASTROFACEA SRL-ITALY.MAVELTEX MOROCCO (S.A), A.C.TER KUILE BV —NETHERL, LAINERE DE PICARDE FRANCE, STROUD RILEY-SOUTH AFRICA AND KUFNER TEXTILES.

Dyeing Manager at GM Fabrics (2003-02 – 2008-02)

Was looking over the Yarn Dyeing operations at Tarapur Plant

• Reporting to: Director (Textiles)
• Area: Furnishings, Hosiery
• Machine capacity: 1500kg
• Daily production: 6.0 -7.0TON
• Machine: FONGS HTHP Yarn dyeing machines (fully Auto)
• Lab matching
• Planning
• Production - Winding - Packing.
• Had the complete responsibility of planning, lab matching, production, winding and packing.
• Experienced in SSM winding machine, PSM Soft winders and RJK AND ALIDHRA Final winding machine. Ensuring the lab to repeatability and reproducibility (Right first time) up to 85%
• Effective feedback of dyed yarn to weaving section.
• Succesfully Erected and set up the yarn dyeing plant in as Head of the dept.
• Completely eliminated the unevenness in 120\2viscose yarn dyeing and vat dyeing.
• Set up the process for sensitive poly airtex material in for following deniers: 240 denier airetex for weft; 109 denier airtes for weft; 51\550 poly for warp
• 150\144\2 flat yarn-Eliminated completely uneven dyeing and barrines in this yarn.
• Set up the process for for 120\2 viscose material meant for embroidery and extensively worked in following qualities: 20 viscose, 120\2 vis, 150\2 vis, 15 viscose slub, 15 viscose slub +120 viscose, 10viscose slub, 10 cotton slub, 20 cotton, 30 cotton, 40 cotton, 16 cotton, 8 cotton slub, 16 single cotton slub, 3 NM viscose, 5NM viscose, 7 NM Viscose Boucle yarn

Technical Assistant at Forbes Gokak Mills Limited (1995-10 – 2003)

• Campbell knitwear Limited (Oct 1995 – Jan 1997) - Worked in the fabric dyeing soft flow machines with production of 10 ton per day.
• Forbes Gokak Mills Limited, Forbes Group (Feb 1997 – Jan 2003) - A leading yarn Exporters in India -ISO 9002 Company
• Area: Hosiery Yarn
• Machine capacity: 2.4 Tons., Daily Production: 10 Tons
• Machines: Dalal HTHP yarn dyeing machines (semi auto)
• Reporting to: Production manger(dyeing)
• Manage the entire operations of dyeing department, soft package winding, final winding. Inline quality control with targeted production of 10 ton
• Was responsible for allocation of workers, plan and ensure the targeted production.
• To practically implement the suggestions of our dyeing team headed by production manager and general manger for cost reduction, time management and successfully train the workers and team members to implement new development in process.
• To monitor all the quality reports of grey yarn in soft winding & ensure right quality yarn is wound for dyeing and after dyeing ensure maintenance of periodical records.
• To investigate root cause for re-dyeing of NON-RFT shades and identify the mistakes and educating to avoid such mistakes and corrective action.
• To conduct the production meetings of the team to communicate the management expectations and apprise the quality issues.
• Significant contributions: As production Asst under MR WD HUNTER FROM SCOTLND who was TECHNICAL CONSULTANT AND HEAD OF THE DEPT For a period of TWO YEARS who trained us in the following aspects: To choose the right color combination of shade for dyeing; Use the computer color matching to effectively to judge the tone of shade and quality and control; To be innovative in development of new process to reduce the cost and Time, this led to improved production.
• Qualities of greige Yarn & dyed Yarn manufacturing: 8 k (karded), 8C(Combed), 10k, 10C, 12K, 12C, 16K, 16C, 20K, 20C, 24K, 24C, 24C Socks quality, 30K, 30C, 32K, 32C, 40K, 40C, 60C, 2\60 Gassed, 2\40gassed, 2\40mercerised, 2\60 mercerised, 2\20Cotton, 16k, for Terry towel end uses, 2\20poly, 20 poly, 2\20p\c, 2\40p\c, 2\20p\v, 2\20 Acrylic
• REPUTED CUSTOMRES: GAP, MARK & SPENCERS, WALL MART, COOGI AUSTRALIA, SHAHI EXPORTS, WELL SPUN, VIRAT INDUSTRIES, CANTERBURRY AUSTRALIA, GALADHARA TEXTILES DUBAI
• Working Knowledge: Having experience in wet processing of polyester, viscose, acrylic, cotton polyester/cotton, polyester/viscose (PV) Yarns.
• Familiar to various qualities of polyester and viscose chenille yarn, embroidery, yarn, bright yarn, airtex yarn dyeing.
• Experience in SSM soft winding, PSM winding machine.
• Familiar in Shade Matching & Dyeing of reactive, vat, disperse, direct, cationic, basic dyes, acid dyes and pigment dope dyes.
• Testing Area - Physical Testing: Water Fastness (ISO - 105E01); Wash Fastness (ISO - 105C03); Rubbing Fastness (ISO - 105X12); Perspiration Testing; Marks and Spencer Testing
• Chemical Testing: Dyes Testing; Chemical Strength Evaluation; Solid Content Checking
• ETP Department: Our company has its own ETP plant; We are strictly maintaining CETP Norms (PH, TSS, Oil and grease, BOD, COD); Above ETP process parameters are better than ETP norms of India; We are giving much attention on 7 principles of Ecology and main components of Ecosystem as well as 4 pillars of Ecosystem - Water, land, climate change resilience and communities
• Utility Department: We are strictly controlling consumption of water, steam, electricity; We are producing the electricity by using Mustard husk which is easily available nearby our factory area; So, Mustard husk cost comparatively much lower against coal; Steam consumption also in the range of Industrial average; Own power plant of 10 MW

B. Tech in Textile Technology – Bangalore University (1991 – 1995)