Trining for quality improvement

TRAINING FOR QUALITY IMPROVEMENT

MAA Garment & Textiles FactoryPO Box 1976, Quiha, Mekelle, Ethiopia.

Mohammad Mizanur RahmanFabrics Finishing Expert (Manager)

Cell: +251 962 600 055Email: [email protected]

PRESENTED BY

mailto:[email protected]

TRANSLATIONS BY

Subagadis Hagos Tesfay

Finishing Department Head

M/C WISE QUALITY CHECK POINTS

1. Slitting M/c (Corino) 2. Dryer M/c 3. Stenter M/c 4. Compactor M/c

1. Slitting M/c (Corino) A. Cutting on Slitting Mark B. Crease Mark from Padder C. Pick up % D. Any visible problems E. Dirty Spot F. Elongation %

QUALITY CHECK POINTS

2. Dryer Machine A. Even dry B. Over dry C. Elongations/ Compaction % D. Any Visible Problem


3. Stenter Machine A. GSM B. Width C. Hand Feel D. Shade E. Shrinkage F. Spirality


G. Color Variations H. Width Variations I. GSM Variations J. Crease Mark K. Middle Loose L. Dye Un level

4. Compactors Machine A. GSM B. Elephant Skin C. Crease Mark D. Light Mark E. Any Visiable Problems F. Shrinkages


QUALITY PROBLEMA. Wrong SlittingB. Crease MarkC. Width VariationD. Middle LooseE. Pin Hole in selvedgeF. White MarkG. Light MarkH. Softener MarkI. ShrinkageJ. SpiralityK. Dirty SpotsL. Shade VariationM. Elephants Skin N. Lycra Fabrics

i. GSM Variation with in rollii. Within roll 1st & last GSM variationiii. GSM low after dyeingiv. Roll to roll GSM variationv. GSM up down after Finish

QUALITY SOLUTIONSDefect, Causes & Remedies:-1. Crease Mark:A. Causes:

i. From Padder (If proper not open uncurler Roller)ii. Pin out from stenter m/ciii. If not use leading cloth in time in stenter m/c rather than ropesiv. From Dyeing (If ropes stage dyeing)v. High Yarn Tensionvi. If edges not proper stitch and knots pass from corino

B. Remedies:i. Slitting, Stenter & Compacting starting time reject fabrics Stitch.ii. Operator all time actively follow upiii. Dyeing time up to mark use Anti-Creasing Agent iv. Yarn tension less from knitting

QUALITY SOLUTIONS2. Width Variation.A. Causes:

i. Stenter M/c setup change within one batchii. Grey fabric of the same lot, knitted on different makes of

Knitting Machines, having varying number of Needles in the Cylinder.

iii. Pin selvedge controller auto not proper workiv. If not proper stitch before stenter m/c

B. Remedies:i. Same setup width Full batch Finishii. The whole lot of the grey fabric should be knitted on the same

make of knitting machinesiii. selvedge controller should work auto iv. proper stitch each rolls v. Stenter m/c running time must be actively work

QUALITY SOLUTIONS3. Wrong Slitting.A. Causes-

i. If auto cutter sensor not proper workii. Proper Not sewingiii. If drop needle not visible iv. Operator not active

B. Remedies-i. Auto cutter sensor should be in proper Working conditionii. Proper Stitching with drop needleiii. Operator carefully M/c operating

QUALITY SOLUTIONS4. Folder/ Dia Mark.A. Causes-

i. Mainly Lycra & High GSM fabricsii. High pressure of the fabric Take Down rollers of the Knitting

machine on the grey fabric is one of the main causes

B. Remedies-i. Adjust the gap between the two rolls as per the thickness

of the fabric sheet ii. Fabrics cutting/open from knitting (option)iii. After knitting fabrics keeping relax stage

QUALITY SOLUTIONS5. Middle Fabric Loose.

A. Causes-i. If actual width not finishii. Adjust Fan pressure bottom and topiii. Delivery tension not adjustediv. Blower Speed More

B. Remedies-i. Should be Actual with finishii. Adjusted delivery tensioniii. Adjust Blower Speed

QUALITY SOLUTIONS6. Pin Hole in selvedge.

A. Causes-i. Selvedge Auto controller not proper workii. Operator not activeiii. Needle ledge (pins) damage

B. Remedies-i. Selvedge Auto controller proper workii. Operator carefully M/c operatingiii. Needle ledges should be inspected regularly and

replace if damage

QUALITY SOLUTIONS7. White Mark.

A. Causes-i. If any friction.ii. After slitting if selvedge dry.iii. If not proper wash in dyeing.iv. Soda & Salt Effectv. Softener Not Proper Mixation vi. pH not control

B. Remedies-I. After slitting urgently dryII. Proper wash in dyeingIII. Softener pH control

QUALITY SOLUTIONS8. Shrinkage.A. Causes-

i. If Actual width not finishii. High Stresses & strains exerted on the fabric, during

Knitting, Dyeing &Processing & the fabric not being allowed to relax properly

iii. Not Proper Count Useiv. Not Right Stitch Lengthv. Tension on fabric during finishing

B. Remedies-i. Should be Actual width finishii. Give maximum overfeed to the fabric, during the

processing, on the Stenter,& Compactoriii. Proper Count Useiv. Right Stitch Lengthv. Minimize tension during processes (corino, stenter)

QUALITY SOLUTIONS9. Spirality.A. Causes-

i. Need proper Angle.ii. Appropriate Yarn TPI/ High TPI. of the Yarniii. Knitting more feeder useiv. Uneven Fabric tension on the Knitting machinev. Unequal rate of Fabric feed on the Stenter & Compactorvi. If not actual width finish

B. Remedies-i. Auto use Weft straightener (Mahlo)ii. Use the yarns of the recommended TPI level for Knittingiii. Ensure uniform rate of feed of the dyed fabric on both the edges

while feeding the fabric to the Stenter & Compactor machinesiv. Actual width finishv. Knitting feeder use less

QUALITY SOLUTIONS10. Color Variation in Finishing.A. Causes-

i. Stenter M/c not same speed runsii. If Suddenly m/c Stopiii. Squeeze Roller Pick up % side to side Different iv. If Stenter m/c side to side Temperature Differencev. Stenter m/c Circulation not proper

B. Remedies-i. Should be m/c run same speedii. Stenter m/c Circulation properiii. Check pickup %

QUALITY SOLUTIONS11. GSM Variation :A. Causes-

i. Roll to roll variation in the, process parameters, of the fabric, like; Overfeed &Width wise stretching of the dyed fabric, on the Stenter & Compactor Machine.

ii. Roll to roll variation in the fabric stitch length.

B. Remedies-i. Make sure that all the fabric rolls in a lot, are processed

under the same process parameters.ii. The Knitting Machine settings, like; the Quality Pulley

diameter etc. should never be disturbed.

QUALITY SOLUTIONS12.Dark Mark:

A. Causes-i. Mainly crease mark is the dark Color fabrics showing

dark line.ii. Dark Shade mainly showingiii. If not properly use anti Creasing & Wetting agent.iv. If fabrics not properly open stage in the dyeing

nozzle.v. Rope stage in dyeing.

B. Remedies-i. Up to mark use anti crease & wetting agent.ii. Ensure the open stage dyeing & not rope.

QUALITY SOLUTIONS13. Elephants Skin:

A. Causes-i. Mainly coming from compactor machine.ii. If over compaction.iii. If taplon/ Glass fiber not proper setting

B. Remedies--i. Before compactor m/c run then everything checks.ii. Up to mark feed the over feed.iii. Taplon/ Glass fiber properly set.iv. Again compactor under overfeed.

QUALITY SOLUTIONS

14. Light Mark:

A. Causes-i. If Not Properly M/c Cleanii. Color Changes Must be proper clean iii. After Clean if directly run the Fasbricsiv. Compact Teflon if damages

B. Remedies--i. Every Machine should be Properly cleanii. Color Changes then 1st run reject fabrics.iii. Taplon/ Glass fiber properly set.iv. If Teflon damages then must be replaces

Lycra Fabrics issue

LYCRA FABRICS PROBLEMS

1. GSM Variation with in roll2. Within roll 1st & last GSM variation3. GSM low after dyeing4. Roll to roll GSM variation5. GSM up down after Finish

Defect, Causes & Remedies:-


1.GSM Variation with in rollA.Causes- i. Not proper Relaxation after Knitted ii. Lycra not proper feeding in knitting iii. Proper temperatures in heat set iv. Both side pinning speed not same v. Running time overfeed changes in stenter B. Remedies-

i. After knitting need proper Relaxationii. After Slitting also need relaxationiii. Heat set time both side pinning need to be

sameiv. Running time Overfeed/ Speed should be

same

2. With in roll 1st & Last GSM VariationsA.Causes- i. Not proper Relaxation after Knitted ii. Lycra not proper feeding in knitting iii. If any tension iv. Temperature not same each chamber v. Running time overfeed changes in stenter B. Remedies-

i. After knitting need proper Relaxationii. After Slitting also need relaxationiii. Temperature should be same each chamberiv. Running time Overfeed/ Speed should be

same


LYCRA FABRICS PROBLEMS3. GSM low after Dyeing A.Causes- i. If use maximum overfeed in Heat set ii. Lycra property not heat recovery iii. Low temperature lycra iv. More Enzyme use in dyeing v. Over time running in dyeing stages with high temperatureB. Remedies-

i. In heat set time use maximum 60% overfeedii. Before heat set should be knows lycra property iii. Use Regan able Enzyme %iv. Within short time need to be dyeing finish

LYCRA FABRICS PROBLEMS4. Roll to Roll GSM Variation A.Causes- i. Not same knitting Machine ii. Knitting m/c to m/c Stitch length/ Lycra Tension Differences iii. If differences time heat setB. Remedies-

i. Same knitting M/c together Heat set & dyedii. All knitting m/c need to be conform same Stitch length/

Lycra tensioniii. Follow same heat set parameteriv. Full batch same parameter use

LYCRA FABRICS PROBLEMS5. GSM Variation after FinishingA.Causes- i. If speed/overfeed variations in M/c ii. Padder pressure & pick up % variations iii. Not proper relaxation iv. Heat set not goodB. Remedies-

i. Speed /Overfeed should be same in finishing time

ii. Padder Pressure & Pick up % must be equal iii. After finish must be Proper relax iv. Should be proper Heat set.

OUR EXPECTATION GOOD QUALITY WITH QUANTITY.

Thanks

Trining for quality improvement

Engineering

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