Process control of weaving

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

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

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

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: