Fabrics faults and remedy

Methodology of textile faults.For Yarn manufacturing technology: We study different types of yarn faults, causes and its remedy.. Knitting faults, causes and its remedy:on feed into mach

Southeast university

DEPERTMENT OF TEXTILE ENGINEERING

Company profile

 Name of the Company: Alim Knitwear ltd

 Year of Establishment: 2005-2006

 Certified Achievement: ISO 9001:2000, (Certified), Oeko-Tex Standard 100 (Certified)

 Manufacturing products: Export oriented knit fabrics dyeing and readymade garments

 Owner and directors of the factory: Alim mondal.

 Factory Address: Nayapara, Kashimpur, Gazipur, Bangladesh

 Total Employees: 4500

 Number of units: 3 (Three) units

 Part-A: Garments unit – 3 floors

 Part-C: Dyeing unit

 Part-D: Printing unit

 Total area: 0.5 acres

 Corresponding Bank: 1) United Commercial Bank Limited Dhaka, Bangladesh

2) Dutch Bangla Bank Ltd Dhaka, Bangladesh

 Factory Supervisor: Md Mamun ( PM in garments section)

 Another Name of the Company: GMS composite Knitting industries ltd.

 Owner and directors of the factory: GMS composite Knitting industries ltd.

 Factory Address: Ssaradagong, Kashimpur, Gazipur, Bangladesh

 Total Employees: 4500

 Number of units: 3 (Three) units

 Part-A: Garments unit – 3 floors

 Part-C: Dyeing unit

 Part-D: Printing unit

 Part-E: knitting unit.

 Factory Supervisor: Md Saiful Islam

Object of training

 To know about garments faults & remedy we

justify each & every garments.

 To knowing that we give max customers

satisfaction.

 To know about different fabric inspection.

 To know about different quality parameters of

fabric, different trims & accessories

 To know about buyers AQL.

 To know about major or minor fabric faults.

Methodology of textile faults.

For Yarn manufacturing technology:

We study different types of yarn faults, causes and its remedy

1 Slub Lack of adequate fibre

control in the drafting Zone.

Proper fibre control of drafting zone

3 Kitty yarn Improper ginning i.e Seeds

broken during ginning

proper ginning i.e Seeds broken during ginning

1 Slub

2 Kitty yarn

Faults name Causes Remedy

4 Foreign matters Improper handling

of travelers

Improper preparation of mixing

proper handling of travelers

proper preparation

of mixing

feed on the spindles

Less twist in the yarn

proper bobbin feed

Closer roller settings

Proper Mixing of cotton of widely differing staple lengths

Proper roller settings

Spinning faults and remedy percentage diagram

Sl = slub yarn

Oi = oily slub

Ki = Kitty yarn

Fo = Foreign matter

Co = cork screw yarn

Ov = over twisted yarn

So = soft yarn Cra = cracker

Knitting faults, causes and its remedy:

on feed into machine Proper yearn selection and proper roller

Faults name Causes Remedy

3 Crease mark Its create when fabric passing

through squeeze rollers in the dyeing process Its mainly Occurs

in tubular knits fabric

Proper adjustment of squeeze rollers.

4 Hole caused by broken needle Change the needle.

5 Needle Line Caused by broken needle

forming distorted stitches Replace the needle

Faults name Causes Remedy

6 Runner Usually caused by broken

needle Change the needle.

7 Slub (Knit fabric) Usually caused by a thick or

heavy place in yarn Replace the yarn cone to a more uniform yarn cone

Different Causes of Fabric Barre

Knitting faults and remedy percentage diagram:

Bro = broken color

Mis = missing yarn

Mix = mixing yarn

Dyeing, printing and finishing faults and remedy

 Classification of Defects

 A defect is defined as minor Defect that is not likely to reduce the Usability of the product, but nevertheless may negatively influence the sales.

 The minor defects can be untrimmed thread-ends, slight dirt in a

non-noticeable zone which can be removed, etc

 A defect that, if conspicuous on the finished product, would cause the item to

be a second (A "second" is a garment with a conspicuous defect that affects

the salability or serviceability of the item

Faults name Causes Remedy

1 Barre Its horizontal shaded band

across the width of the fabric It causes by the yarn mixing

proper yarn selection.

2 Bleeding improper dye selection or poor

dye fastness proper dye selection.

3 Crocking It is the rubbing off of the

color

It may rub onto another fabric

proper dye selection.

barre Bleeding Crocking

Faults name Causes Remedy

4 Shading It is generally due to uneven

tension on the fabric To maintain the proper tension

5 Stained caused by a foreign substance,

dirt, grease, and oil or sizing residue on the fabric being dyed.

To using different spot remover chemical

Faults name Causes Remedy

7 Creasing Causes unleveled penetration

of dyes To use proper dyes and chemical or leveling agent

8 Flushing/Wicking Caused due to Low viscosity

of print paste To use high viscosity of printing past

9 Bleeding Caused due to Low viscosity

Faults name Causes Remedy

10 Crack or miss alignment in

transfer printed fabric. Incomplete transfer of design from paper to fabric Proper transfer of design.

11 Unwanted marks on fabric. Causes by the contact with oil or

grease covered exposed machine parts, careless handling

To using spot cleaner

12 Decolorized patch on fabric Caused due to chemical spillage on

fabric Localized excess bleaching

Localized excess enzyme wash

To using spot cleaner

Crack Unwanted mark Decolorized patch

on fabric

Dyeing and printing faults and remedy percentage diagram

Un = unwanded mark Flu = flushing

Crak = crack or miss aligment

Garments faults and remedy

1 Misprints or off registration not properly cleaning of Printing

screens Properly Cleaning of printing screen

2 Grease/ Oil / dirty stains Oil stains generally come from

sewing machines; machines such as over lock and flat lock machines are more prone to have oil stains

To use spot cleaner chemical

3 Needle damage using the wrong needle Repairing or older the garments

4 Open or broken seams improper handling of the cut piece

or machine Repairing or alter the garments.

Misprint Grease/ oil/ dirty stain. Needle damage Open or broken seam

Faults name Causes Remedy

5 Broken stitch improper handling of cut pieces or

improper machine usage Repairing or alter the garments

6 Skipped or dropped stitches improper handling of cut pieces or

improper machine usage

Repairing or alter the garments

7 Neck shape caused by defective cut pieces Repairing or alter the garments or

use proper cut piece of garments

8 Sewing thread not matching To use improper sewing thread To use proper sewing thread

Broken stitch Skipped stitch Neck shape Sewing thread not

matching

Faults name Causes Remedy

1 Seams not aligned at crossing of

seams improper handling of the cut piece. Repairing or older the garments

2 Stripes not matching from improper handling of cut

pieces

Repairing or older the garments

3 Misplaced label improper placement of labels when

sewing Repairing or alter the garments or proper placement of the label

Seam not aligned at

crossing of seams Stripes not matching Misplaced label

Garments faults and remedy diagram

Dir = dirty stain

Bro = broken stitch

Skip = skip stitch

Sw = sewing thread not

match

Miss = misplace label

Nec = neck shape

Po = pocket disposition

Un = uncovered seam

Brok = broken seam