Process control of weaving process

Introduction : Process control is defined as a statistical & engineering tools or discipline that deals with architecture structure , mechanism and algorithm sequence of finite instruc

Process control of Weaving

Name : MAZADUL HASAN SHESHIR

ID: 2010000400008

Batch: 13th Batch (Session 2009-2013) Department: Wet Processing Technology Email: mazadulhasan@yahoo.com

Blog: www Textilelab.blogspot.com

Southeast University

Department of Textile Engineering

PREPARED BY © right

Introduction : Process control is defined as a statistical & engineering tools or

discipline that deals with architecture ( structure ) , mechanism and algorithm (sequence of finite instruction ) for controlling the output of a specific production process Quality is formed during production process So, if a production process

is not controlled, the target production quality or reference parameter may not achieved

INTRODUCTION

Process control is performed by six steps :

1 Step-1: Draw process flow chart showing real change in products geometry

2 Step-2 : Segregate or highlight the part of the flow chart where any change is

taking place

3 Step-3 : Find the set points or control points value at each step

4 Step-4 : Determine which output variables have gone out of the range of

standard / reference values beyond tolerance

5 Step- 5 : Identify cause which is responsible

6 Step-6 : Make recommendation as what to do

PROCESS CONTROL

PROCESS FLOW CHART OF WEAVING

Fabric Sample :Denim Fabric

Construction :( 73 × 43 / 15 × 10 ) × 55 Structure :Twill

Interlacing Pattern :2/1

Yarn Type :Cotton Yarn

GSM :230

Process Control of Warping Section

Input Variable of Warping Input Quantity Required Quantity

Strength / tenacity 11 13

Breaking elongation (%) 8 8.5

Minimum Staple length of Yarn 2.5 2.7

Contamination Moderate Moderate Yarn type Cotton Cotton Yarn hairiness Moderate Low

Yarn micronaire value 3.5 4

Output Variable of

Warping

Output Quantity

Required Quantity

Process Control

Yarn uniformity (CV % ) 10 12 Uniformity of warped yarn depends on the

uniformity of the input raw yarn By controlling the uniformity of raw yarn warped yarn uniformity also can be

controlled Broken or loose ends 10 5 To reduce yarn breakage lower strength /

tenacity yarn has to remove Density of

package(yarn/inch)

132 130 To maintain the yarn density of warp

beam perfect count of V – reed have to be

used Beam barrel diameter (

inch)

12 13 To maintain the warp beam diameter ,

beam barrel diameter also have to control

during selection of warp beam Width of warp beam 58 60 To produce the actual wide of the fabric

the warp beam diameter also have to be perfect It is control during selection of

warp beam Coarse knots 10 5 To reduce coarse knot actual quantity &

type of yarn twist have to be maintain

Process Control of Sizing Section

Output Variable of

Sizing

Output Quantity

Required Quantity

Process Control

Count of sized yarn 8 10 To maintain sized yarn count proper

amount of sizing percentage have

to be maintained Uniformity of sized yarn Moderate Good Uniformity of sized yarn can be

maintained by properly sizing Percent of size 3 1.5 Percent of size can be maintained

by controlling the immersion roller Strength & uniformity

of sized yarn

13 15 Strength & uniformity of sized yarn

can be maintained by maintaining the proper sizing recipe & heat of

drying chamber Unwindability Low Moderate Unwindability can be reduce by

properly drying sized yarn Density of sized beam

( yarn / inch )

73 75 Density of sized beam can be

maintained by controlling the width

of headstock Broken , missing ,

crossed sticky ends

5 3 Broken , missing , crossed sticky

ends can be reduced by controlling the yarn tension during sizing

Process Control of Drawing-in & trying Section

Output Variable of

Drawing in & trying

Output Quantity

Required Quantity

Process Control

Cross ends 5 3 Cross ends can be reduce by carefully

drawing - in Extra ends 10 5 Extra ends can be reduce by

conforming sufficient yarn strength

Process Control of Looming Section

Output Variable of

Warping

Output Quantity Required

Quantity

Process Control

Construction 73 × 43 / 15 ×

10

75 × 45 / 16 ×

12

Construction of the fabric can be maintained by using proper reed

count &pattern card GSM 230 235 GSM of the fabric can be maintained

by using proper fabric construction

& yarn count Salvage Structure Plain Plain Salvage Structure can be maintained

by using proper type of selvedge & the salvage forming pattern card Broken ends / picks 5 3 Broken ends / picks can be reduce

by controlling the RPM of the loom Double ends /

double picks

5 3 Double ends / double picks can

reduce by carefully drawing – in

Output Variable of

Warping

Output Quantity Required

Quantity

Process Control

End out / miss

picks / knot

6 4 End out / miss picks / knot can be

reduce by properly adjusting the ends / picks after broken Hole ( per lot ) 10 8 Holes in the fabrics can be removed

by reducing the no of naps in the

yarn Reed streak 3 2 Reed streak can be removed by

maintaining or replacing the reed Stop marks ( Per lot ) 8 5 Stop marks can be reduce by

reducing the machine stoppage time

during production Dirt amount Moderate Low Dirt amount can be reduce by

controlling the dirt contamination & carefully handling the machine

Conclusion:

By this experiment we have learn about process quality control of weaving section Which has increased our practical knowledge about process quality control It will be helpful for our future practical knowledge.

CONCLUSION: