An investigation on the inspection of grey & finished knit fabric in wet processinge

PROJECT ONAn investigation on the inspection of grey & finished knit fabric in wet processing... 10% check will give buyer some ideas of his product quality 25% check maybe necessary

PROJECT ON

An investigation on the inspection of grey &

finished knit fabric in wet processing

WELCOME TO OUR PRESENTATION

WELCOME TO OUR PRESENTATION

SOUTHEAST UNIVERSITY

SOUTHEAST UNIVERSITY

Number of units: 4 (Four) units

Part-A: Knitting unit

Part-B: Dyeing unit

Part-C: Garments unit – 3 floors

Part-D: Printing unit

Total area: 271,000 square feet

Name of the Company: Aman Tex Ltd

Number of units: 4 (Four) units

Part-A: Knitting unit

Part-B: Dyeing unit

Part-C: Garments unit – 3 floors

Part-D: Printing unit

Total area: 271,000 square feet

After fabric is received, inspection should be done to determine its acceptability from a quality view point; otherwise extra cost in garment manufacturing may be returns and dissatisfaction due to poor fabric quality Either way fabric inspection after the fabric production process will release the burden responsibility at the marking, spreading and cutting section As a result a spreader will

be concentrating more in spreading rather to worry about fabric inspection and detecting faults

Aim of the project

6 To maximize the production.

7 To minimize the production cost.

6 To maximize the production.

7 To minimize the production cost.

Inspection Machine

Fabric inspection is usually done on fabric inspection machines such as those shown in the Figure These machines are designed so that fabric rolls can be mounted behind the inspection table under adequate light and rerolled as they leave the table This inspection m/c is either power driven or the inspector pulls the fabric over the inspection table The defects are tracked, marked and recorded on an inspection sheets

Fabric inspection is usually done on fabric inspection machines such as those shown in the Figure These machines are designed so that fabric rolls can be mounted behind the inspection table under adequate light and rerolled as they leave the table This inspection m/c is either power driven or the inspector pulls the fabric over the inspection table The defects are tracked, marked and recorded on an inspection sheets

Fabric Inspection

When, why, where

Producer likes to know the quality of his products (says quality for 500,000 yds fabric)

Buyer wants to assure the product quality he ordered

10% check will give buyer some ideas of his product quality

25% check maybe necessary for new supplier

3% check maybe enough for a proven record supplier

Producer likes to know the quality of his products (says quality for 500,000 yds fabric)

Buyer wants to assure the product quality he ordered

10% check will give buyer some ideas of his product quality

25% check maybe necessary for new supplier

3% check maybe enough for a proven record supplier

Fabric inspection must be selected randomly

The fabric sample must be selected from different place, different lot and different time

Inspector must use a packing list and select different bales on different place

The samples should be selected from early, middle and late production

Inspection Standards

1 Ten Point System

 Oldest and most used in woven finished fabric

2 Four point System

 Widely adopted and used in knitted fabric

3 The Graniteville’78 System

 major and minor types, used in garment pieces

1 Ten Point System

 Oldest and most used in woven finished fabric

2 Four point System

 Widely adopted and used in knitted fabric

3 The Graniteville’78 System

 major and minor types, used in garment pieces

AMAN TEX LTD (KNIT COMPOSITE) - All inspection 4 point system

Grey Fabric Inspection

Grey fabric inspection is the

process of identifying

knitting faults in the knitted

fabric just after the grey

fabric production in the

knitting machine

Four Point System

Four Point System is adopted by American Apparel Manufacturers Association (AAMA) for piece goods knitted fabric Fabric defects is penaltized by maximum of

4 points

In this system fabric faults are identified with defect points in the scale of 4 I.e maximum defect point is 4

Four Point System

Grey Fabric Inspection Repot of Aman Tex Ltd

Grey Fabric Inspection Faults

Grey Fabric Inspection Faults

1 Needle Mark

Causes:

slightly bends

Causes:

1 When a needle breaks down.

2 If a needle or needle hook is

slightly bends

3 If needle does not catch yarn

Remedies:

as from broken latch.

Remedies:

 Needle should be straight as well

as from broken latch.

Grey Fabric Inspection Faults

2 Needle Broken

Causes:

•High Yarn Tension

•Bad Setting of the Yarn Feeders

•Old & Worn out Needle set

Causes:

•High Yarn Tension

•Bad Setting of the Yarn Feeders

•Old & Worn out Needle set

Remedies:

Ensure uniform & the right Yarn

tension on all the feeders

Keep the recommended gap,

between the Yarn Feeders & the

Needles

Periodically change the complete set

of needles

Remedies:

Ensure uniform & the right Yarn

tension on all the feeders

Keep the recommended gap,

between the Yarn Feeders & the

Needles

Periodically change the complete set

of needles

Grey Fabric Inspection Faults

3 Hole Mark

Causes:

Yarn breakage or yarn cracks

If the yarn count is not correct on

regarding structure, gauge, course and

density

Badly knot or splicing

Yarn feeder badly set

If yarn tension too high

Causes:

Yarn breakage or yarn cracks

If the yarn count is not correct on

regarding structure, gauge, course and

density

Badly knot or splicing

Yarn feeder badly set

If yarn tension too high

Remedies:

Yarn strength must be sufficient to

withstand the stretch as well as uniform

Use proper count of yarn

Correctly set of yarn feeder

Knot should be given properly

Remedies:

Yarn strength must be sufficient to

withstand the stretch as well as uniform

Use proper count of yarn

Correctly set of yarn feeder

Knot should be given properly

Grey Fabric Inspection Faults

4 Pin Hole

Causes:

Improper tension

Same drive for both knit & tuck stitch

Curved needle latch

Causes:

Improper tension

Same drive for both knit & tuck stitch

Curved needle latch

Remedies:

Different drive have to maintained

Needle has to change

Needle has no change

Remedies:

Different drive have to maintained

Needle has to change

Needle has no change

Grey Fabric Inspection Faults

5 Star Mark

Causes:

Yarn tension variation during production

Buckling of the needle latch

Low G.S.M fabric production

Causes:

Yarn tension variation during production

Buckling of the needle latch

Low G.S.M fabric production

Grey Fabric Inspection Faults

6 Drop Stitches

Causes:

Defective needle

If yarn is not properly fed during loop

formation i.e not properly laid on to the

needle hook

Take-down mechanism too loose

Insufficient yarn tension

Badly set yarn feeder

Causes:

Defective needle

If yarn is not properly fed during loop

formation i.e not properly laid on to the

needle hook

Take-down mechanism too loose

Insufficient yarn tension

Badly set yarn feeder

Remedies:

Needle should be straight & well

Proper feeding of yarn during loop

Needle should be straight & well

Proper feeding of yarn during loop

Grey Fabric Inspection Faults

7 Bariness

Causes:

Use of irregular yarn having higher

long term irregularities

Using different count thread

Causes:

Use of irregular yarn having higher

long term irregularities

Using different count thread

Remedies:

Remove irregular yarn

Use proper yarn count

We can use it for white fabric

Remedies:

Remove irregular yarn

Use proper yarn count

We can use it for white fabric

Grey Fabric Inspection Faults

8 Loop

Causes:

If needle latch is hard or curve

If yarn tension is loose

Causes:

If needle latch is hard or curve

If yarn tension is loose

Remedies:

Clean or change the needle

Set proper yarn tension

Remedies:

Clean or change the needle

Set proper yarn tension

Grey Fabric Inspection Faults

9 Lycra Out

Causes:

Cause by If lycra is missed

or Lycra attach with the yarn

Causes:

Cause by If lycra is missed

or Lycra attach with the yarn

Grey Fabric Inspection Faults

10 Seat Up

Causes:

If needle latch is not work properly

Causes by thick yarn

Improper/large knot

Causes:

If needle latch is not work properly

Causes by thick yarn

Improper/large knot

Remedies:

Make sure all the latches of needle

are closed with feeding yarn after a

drop stitch

Remedies:

Make sure all the latches of needle

are closed with feeding yarn after a

drop stitch

Finished Fabric Inspection

Finished inspection is done

after dyeing and finishing

process to find out the dyeing

and finishing faults, calculate

the number of faults ,grading

and taking decision to accept

or reject a finished fabric roll.

In AMAN Tex, 4 point system

is followed for finished fabric

inspection

Finished Fabric Inspection Repot of Aman Tex Ltd

Grey Fabric Inspection Faults

10 Roll to roll variation

9 Batch to Batch Shade variation

8 Softener Mark

2 Dye spot

Finished Fabric Inspection

Faults

1 Uneven Dyeing

Sources & Causes:

Uneven pretreatment (uneven scouring & bleaching)

Improper color dosing

Using dyes of high fixation property

Uneven heat-setting in case of synthetic fibers

Lack of control on dyeing m/c

Sources & Causes:

Uneven pretreatment (uneven scouring & bleaching)

Improper color dosing

Using dyes of high fixation property

Uneven heat-setting in case of synthetic fibers

Lack of control on dyeing m/c

Effects:

 Dyeing process loss

Fabric waste in garments section

More time

Waste of chemical & dyes

More water & steam

Effects:

 Dyeing process loss

Fabric waste in garments section

More time

Waste of chemical & dyes

More water & steam

Remedy:

By ensuring even pretreatment

By ensuring even heat-setting in case of synthetic fibers

Proper dosing of dyes and chemicals

Proper controlling of dyeing m/c

Remedy:

By ensuring even pretreatment

By ensuring even heat-setting in case of synthetic fibers

Proper dosing of dyes and chemicals

Proper controlling of dyeing m/c

Finished Fabric Inspection

Faults

2 Dye spot

Sources & Causes:

Improper Dissolving of dye particle in bath

Improper Dissolving of caustic soda particle in bath

Sources & Causes:

Improper Dissolving of dye particle in bath

Improper Dissolving of caustic soda particle in bath

Effects:

Body fabric rejected in the garments section

More dye & caustic

More fabric damage

Less production

Cost highly

Effects:

Body fabric rejected in the garments section

More dye & caustic

More fabric damage

Finished Fabric Inspection

Faults

3 Soda Spots

Sources & causes:

Soaping start before wash

CaCO3 or MgCO3 in soaping bath

Sources & causes:

Soaping start before wash

CaCO3 or MgCO3 in soaping bath

Remedy:

Remove hardness water

Use sequestering agent

Remedy:

Remove hardness water

Use sequestering agent

Finished Fabric Inspection

Faults

4 Fabric hole

Sources & causes:

More acid of knit fabric in the dyeing section

Highly acidity

Temperature highly

Sources & causes:

More acid of knit fabric in the dyeing section

Highly acidity

Temperature highly

Effects:

Damage of the knit fabric

Fabric strength, stiffness & comfortable loss

Waste of acid

Loss Time & Temperature

Effects:

Damage of the knit fabric

Fabric strength, stiffness & comfortable loss

Waste of acid

Loss Time & Temperature

Remedy:

Use standard Acid

Proper dosing of Acid

Proper Control of dyeing m/c

Temperature Control

Proper acid addition

Remedy:

Use standard Acid

Proper dosing of Acid

Proper Control of dyeing m/c

Temperature Control

Proper acid addition

Finished Fabric Inspection

Faults

5 Compacting hole

Sources & Causes:

More steam pressure

Low roller RPM

Uneven roller

Sources & Causes:

More steam pressure

Finished Fabric Inspection

Faults

6 Crease Mark

Sources & Causes:

Poor opening of the fabric rope

Shock cooling of synthetic material

If pump pressure & reel speed is not equal

Due to high speed m/c running

Sources & Causes:

Poor opening of the fabric rope

Shock cooling of synthetic material

If pump pressure & reel speed is not equal

Due to high speed m/c running

Remedy:

•Maintaining proper reel sped & pump speed

•Lower rate rising and cooling the temperature

•Reducing the m/c load

•Higher liquor ratio

Remedy:

•Maintaining proper reel sped & pump speed

•Lower rate rising and cooling the temperature

•Reducing the m/c load

•Higher liquor ratio

Finished Fabric Inspection

Faults

7 Dark Colored oil Spots

Sources & Causes:

Often encountered when the goods are given

silicone finishing agent treatment in soft flow

machine using SILICONES which are NOT jet

stable

Sources & Causes:

Often encountered when the goods are given

silicone finishing agent treatment in soft flow

machine using SILICONES which are NOT jet

Finished Fabric Inspection

Faults

8 Softener Mark

Sources & Causes:

Improper mixing of the Softener

Improper running time of the fabric during

application of softener

Entanglement of the fabric during application of

softener

Sources & Causes:

Improper mixing of the Softener

Improper running time of the fabric during

application of softener

Entanglement of the fabric during application of

softener

Remedies:

Maintaining proper reel sped & pump speed

Proper Mixing of the softener before addition

Prevent the entanglement of the fabric during

application of softener

Remedies:

Maintaining proper reel sped & pump speed

Proper Mixing of the softener before addition

Prevent the entanglement of the fabric during

application of softener

Finished Fabric Inspection

Faults

9 Batch to Batch Shade variation

Sources & Causes:

Fluctuation of Temperature

Improper dosing time of dyes & chemicals

Batch to batch weight variation of dyes and chemicals

Dyes lot variation

Improper reel speed, pump speed, liquor ratio

Improper pretreatment

Sources & Causes:

Fluctuation of Temperature

Improper dosing time of dyes & chemicals

Batch to batch weight variation of dyes and chemicals

Dyes lot variation

Improper reel speed, pump speed, liquor ratio

Improper pretreatment

Remedies:

Use standard dyes and chemicals

Maintain the same liquor ratio

Follow the standard pretreatment procedure

Maintain the same dyeing cycle

The pH, hardness and sodium carbonate content

supply water should check daily

Remedies:

Use standard dyes and chemicals

Maintain the same liquor ratio

Follow the standard pretreatment procedure

Maintain the same dyeing cycle

The pH, hardness and sodium carbonate content

supply water should check daily