Spinning machine of cotton spinning mill which made by textile machine manufacturers for manufacturing fiber and yarn. There are a lot of machines are used in spinning factory like lapping machine, simplex machine, porcupine Opener, mono cylinder beater, draw frame, lap former, comber machine etc.
List of Spinning Machine for Cotton Spinning Mill:
Textile machine manufacturers make different types of machine for cotton mill-
Coconut fiber making machine for industrial automation
Ball Fiber Making Machine for garment industry
Polyester Fiber Making Machine for textile manufacturing
Water jet loom polyester fiber making machine for apparel industry
Cotton fiber making machine for textile manufacturing
Maize Fiber making machine for textile industry
Recycled cotton fiber making machine for textile industry
Polypropylene staple fiber making machine for textile industry
Non woven fabric making machine for apparel industry
Woven fabric making machine for textile manufacturing for apparel industry
Coir Fiber rope making machine for apparel industry
Automation of Cotton Spinning Mill :
For producing technology in textile industries of yarn ring frame is one of the best important component during the last two and half decades components of ring spinning machines have been greatly improved, drive systems and robotics have enabled large gains in productivity, flexibility and quality. Most of the technical spreads in ring spinning were aimed at improving the performances on the present technology. These are all achieved to the automation.
Fiber Making MachinPalm Fiber Making Machine
Advantages of Spinning Machines:
The advantages of the spinning machines made by textile machine manufacturer-
Very trustworthy system of these electrical machines
Maximum machine is controlled by servomotor
Expensive to implement
Enhancing manufacturing by textile machine manufacturers capacities.
Textiles equipment are made by textile machine manufacturer
Accurate result for cotton on
Automatic Doffe system
Reduced Manpower from the industry
Increase more productivity than manual system.
Flowchart of Wool Finishing Process:
Finishing process of Wool in textile world is given below-
Design a system and plan, by which production may be carried out in order to meet promised delivery date consistent with minimum cost and quality standard.
Ensure efficient utilization of production facilities.
Coordinate production activities of different departments.
Maintain an adequate and not excessive stock of raw materials; work -in-progress and of finished goods to meet production requirements and delivery schedules at the most economical level.
Ensure production of right product in right quality at the right time.
Maintain flexibility in manufacturing jobs, to accommodate rush jobs or to meet
Contingences manner.
Ensure smooth flow of materials by eliminating, bottlenecks, if any, in production.
Establish targets and check them against standards.
PPC guides production department by preparing and manufacturing orders.
Spining Plan:
In spinning, preparation of spin plan is an important component of PPC work. First we have to decide the type, quantity and quality of yarn. Then an allocation of various machinery is calculated in the spin plan. Product Detail:-
20s Carded yarn
Blends of cotton and manmade fiber or other (e.g. 65/35 PV,70/30 PC,93/7 CV…….etc)
Process flow: blowing…..Carding…..1st Passage…..2nd Passage…Roving….Ring
Mill Details:
Blow room with chute feed to cards
Marzoli
Reiter
Trutzschler
Cards:
Marzoli CX300(8 heads)
Reiter C4-A and C4 (7heads)
Trutzschler TC 03 (6 heads)
Draw frames:
DO6: 6 machines
RSB 851 : 5 machines
SB2 : 2 machines
VOULK : 4 machines
Melanjor : 1 machine
Unilap:
Vouk (RD300/2T): 1 machine
Comber:
Vouk (CM400/S) : 5 machines
Fly frames:
F1/1A:5 machines
F5:2 machines
F1/1:2 machines
Ring frames:
G5/1 (14 machines having 768 spindles)
G5/11 (16 machines having 1008 spindles)
CSM (6 machines having 1088 spindles )
Winding machines:
Murata (7-II)…..5 machines having 60 spindles
Murata (V-SS)……5 machines having 60 spindles
Schalafhorst……….2 machines having 60 spindles
Steamer machine:
Mill works for 6 days a week; 24 hours a day.
Production Required:
100% cotton carded or mélange 20s: 4000kg/day
(The above production figures are arrived based on orders)
Process Parameters:
The following table gives the process parameters for the counts that have been given under Production required.
Machine
Count
Speed
Hank
TM
Efficiency
Other Factors
Card
20s
130 m/min(truszschler)
0.12
–
90
Doffer speed;27″ ;1.5Tension draft
Draw frame
20s
400m/m
0.13
–
85
Fly frame
20s
1000 rpm(F1/1A)
0.9
1.47
85
120 spindles per machine
Ring frame
20s
11000rpm (G5/11)9000 rpm (G5/1)
—
4.64
88.085
1008 Spindles per m/c768 Spindles per m/c
Winding machine
20s
1000 m/min
–
–
75
60 drums
Waste Levels:
Ring frames:
Pneumafil – 4.0% (reusable)
Hard waste – 0.2%
Fly frames:
Roving waste– 0.3% (Reusable)
Sliver waste – 0.2%
Draw frames:
Sliver waste- 0.2% (reusable)
Suction waste – 0.8%
Cards:
Card waste – 4.8%
Sliver/web – 0.2% (Reusable)
Blow room:
Blow room waste: 4.0%
Reusable waste: 0.2% (Reusable)
(All percentages on ring frame production)
Balancing Machine :
Ring Frames (G5/11):
Production per spindle per 8 hours for balancing machine (in grams):
7.2*Spindle Speed(rpm)
——————————* Efficiency
Count *TPI
Production per spindle per 8 hours (g):
20s: 169.40grams.
Number of spindles allotted
= 7669.3spindles
Number of ring frames = 7.6 8
Fly frames for balancing machine :
Production per fly frame per day:
20s: 4.5*120*3 = 1620.0 Kg
Number of fly frames allotted:
Production in ring frame+Ring frame waste+ Roving waste
———————————————————————
Production per fly frames per day
= 2.7 3 Fly frames.
Finisher draw frames:
Production per shift per machine (kg)
(0.286*L*eff*Nd
———————-
Ne
(0.286*400*0.85*1)
= ———————
0.12
=810.3 kg
Production of Finisher Draw frame per day per machine:
20s: 810.3*3 = 2430.9 Kg
Number of finisher draw frames allotted:
Breaker draw frames:
Production per shift per machine (kg) for balancing machine
(0.286*L*eff*Nd)
=————————
Ne
(0.286*400*0.85*1)
=————————–
0.12
= 810.3kg
Production of Breaker Draw frame per day per machine:
20s: 762*3 = 2430.9 Kg
Number of Breaker draw frames allotted:
Production in FD frame +FD frame waste +bDF waste
—————————————————————-
Production per BD frame per day
Production in BD frame per day =2*2430.9= 4861.8 Kg.
Roving waste = 4214.2*0.3/100
=12.6 kg
Sliver waste = 4214.2*0.2/100
=8.4 kg
Suction waste = 4214.2*0.8/100
=33.7 kg
So, Number of finisher D frames allotted
4680+12.6+8.4+33.7
=————————–
2430
= 2.02 2 FDF
Carding Spinning Machines:
Production per shift per machine (kg)
(0.286*L*eff*Nd)
=———————
Ne
(0.286*130*0.9*1)
=———————–
0.12
=278.8 kg
Production of Carding per day per machine:
20s: 278.8*3 = 836.5 Kg
Number of carding machine allotted:
Production in BD frame + Bd frmae waste +Card waste
—————————————————————–
Production of carding per day
Production in BD frame per day =2*2430.9= 4861.8 Kg.
Sliver waste = 4214.2*0.2/100
=8.4 kg
Suction waste = 4214.2*0.8/100
=33.7 kg
Card waste = 4214.2*4.8/100
=202.3 kg
So, Number of carding machine allotted
4861.8+8.4+33.7+202.3
= —————————–
836.5
= 6.1 6 Card, since we do have excess quantity in draw frames no need to approximate to 7 carding machines.
Bales required:
Blow room waste = 4214.2*(1 + 4/100) =168.6 kg
Reusable waste = 4214.2 *(1+0.2/100) =8.5 kg
Total card production =6*278.8
5019 kg +8.5 +168.6
=————————-
230
=22.6, approximate to 23 bales
Autoconer winding spinning machines:
Production per drum per day = 0.2836*m/min*eff*Nd/Ne
= 10.6 kg
TOTAL production per machine per day =10.6*60*3
=1908 kg
Hard Waste = 4214.2*(1+2/100) = 84 kg
No of autoconer required
Ring production – Winding waste
= —————————————–
Winding m/c kg per day per m/c
4214.2 -84
=————-
1908
= 2.16 ≈3 Winding machines
Conclusion:
Number of machines calculated above for achieving production balance in cotton spinning (short staple plant) is summarized below:-
Ring spinning unit =8064 spindles i.e. 8 G5/1 machines (1008 spindles)
Simplex frame, 3 Roving (120 spindles)
Draw frames,(2 passage), 4 single delivery drawing frames
Carding machines, 6 Cards
Blow room, cleaning line of machines with chute feed system.
Winding, 3 machines (60 drums)
Balancing machine is the key factor for quality production.
[1] Ovi Islam, B.Sc in Textile Engineering- PUB Email: [email protected]
[2]Wondwossen Seyoum, Planning Head in Saygindima Textile Share Company. BSc, in Textile and Leather Engineering
Automation System software for Weaving is developed by automation engineer for textile company. The computer on which weaving software is installed, collects the data from the Machine Terminals through the network device and generates various reports. The software gets the data from the looms and generates customized reports, which can be easily interpreted. The software cab transfer the data to an ERP system. The software can be installed on various computer on the plant.
We have largest Garment and Textile ERP software collections in Bangladesh. We sale customized ERP for the factories. We are agent of all Garment and Textile ERP software company. We will forward you to the best ERP software company based on your requirements. We are trouble shooter of fashion industrial software like Willcom, Barudan, Lectra, Gerber, iEcho, Datacolor, Shedomaster, Datalog, Qc etc. For any queries, please Contact Us.
Data log is online logger for Online Monitoring System facilitates for continuous monitoring of each machine separately and all together. The data is processed and useful reports generated help in the unified running of all operations.
Essential Feature or Weaving Automation:
Weaver Planning with data loger
Report should transfer by email
Integrated information solutions should cover all types of LOOMS
Easy identification the machines
Efficiency & Speed information report on the machine by weaving software
Shift wise Trend Graph
Long stop report can be entered on the machine
Modular design of logger & hence easy to add new machines
Computer Network operation run under automation technology
Beam Runout Reports by weaving software
ERP Interface for textile weaving company
File conversion facility by using data log system
Snap Study on Running / Stopped Looms
Score Board to Display the Efficiency of the shed by using data log system software
Combination of loom types e.g. jacquard loom
Should generate graphical report by using data logger
Viewing of Production, Stoppage report is installed by programmer
User friendly software on the computer installed by engineer
Exception reports for the software systems
SMS Alerts facility in textile weaving automation
Various reports of textile weaving on Production, Stoppage, Efficiency, etc
Software for spinning mill is online monitoring system which facilitates nonstop monitoring of production and power at each machine. The computerized data is processed for generating reports that help in continuous running of all operations and identify weak areas, help industries continuously to improve productivity, save costs, translating into higher profits.
We have largest Garment and Textile ERP software collections in Bangladesh. We sale customized ERP for the factories. We are agent of all Garment and Textile ERP software company. We will forward you to the best ERP software company based on your requirements. We are trouble shooter of fashion industrial software like Willcom, Barudan, Lectra, Gerber, iEcho, Datacolor, Shedomaster, Batch, Qc etc. For any queries, please Contact Us.
Software Developer List:
Datalist
Datalog of Spinning Mill:
Data log is logger Online Monitoring System software for spinning mill that facilitates continuous monitoring of each machine separately and all together. The data is processed and useful reports generated help in the unified running of all operations.
Automation System
Feature of Software for Spinning Mill:
Auto report generation in automation companies
Display of key data for spinning wool and spinning wheel for automation companies
Reports of production, stoppage and efficiency
Generate Doff wise & Doff prediction reports
Automated systems Software for automation companies
Comparison reports for factory automation
Snap study, exception reports for automation companies
Generate Trend Graph of spinning process in computer software system
Accurate data for costing and analysis
Operator wise report for factory automation
Supervisor wise report for factory automation
Machine wise report for factory automation
Department wise report for factory automation
Ring Frame & Speed Frame makes different report
Network based computers is essential for data log system
ERP Interface is necessary for data log system
File conversion/ transfer into excel
Please contact us by submitting a comment below on Leave a Reply box
Mechanical sewing machine is migrating into computerized sewing machine rapidly. A short description is given here about mechanical vs digital sewing machine. Singer use mechanical engineering for mechanical mahine and janome use computerized technology for manufacturing there product and vice versa. Garments owner purchase sewing machines to progress the efficiency of several sewing tasks. There aere two types of machines are available, mechanical and computerized, which operate differently and contain varying features. Both types can do the basic function of making uniform stitches in fabric using two sources of thread. The decision to purchase one of these machines is heavily based on the customers required functions, skill level, frequency of use.
Mechanical Sewing Machine:
Mechanical sewing machine e.g. singer sewing machine operate on electricity but contain mechanical gears and parts. All of the levers, switches, knobs, and dials require manual control from the user. For adding accessories and parts must be purchased and installed manually. The quality of sewing machine stitches are different also.
Mechanical Sewing Machines
Computerized Sewing Machine:
Computerized sewing machine contain microprocessors which is digital technology to control the different program. The Stitches are stored on memory. The computer receive the user’s settings for simple setup and operation. The processes are automatically controlled by the machine after the user inputs the desired instruction. The user can download program from internet and can installed for better work. The latest sewing machine are called portable sewing machine. The latest sewing machine is treated as best sewing machine on the market.
Computerized Sewing Machines
Standard Operating Procedures of Sewing:
Sewing: It is the process of joining the cut parts by formation of Seams to produce a wearable garment having an acceptable level of Quality Standard described by the Buyer.
Importance of Sewing: Sewing is the Backbone of the apparel manufacturing industry, involving utilization of machines and physical manpower. If the sewing department is functioning properly and production methods are followed correctly, it provides an edge in the industry to survive.
Sewing Department: The following sections constitute the Sewing department:
CPU (Small parts are joined together which are sent to assembly)
Input Section (Front and Back Parts are prepared)
Output Section (Assembly operations comprise the output section)
Each sewing line consists of 1 Input Supervisor, 1 Output Supervisor (Line Manager), 2 Roving Q/C’s and one End Line Q/C to maintain production as well as quality of the output.
Sewing Machine SOP
Case Study About mechanical sewing machine and Computerized Sewing Machine
Manufacturing System
The manufacturing systems can be divided into 2 types, basically
Push system – Anticipates future demands or needs and what we do today is determined by what we think will be needed at some time in the future. In push system, a schedule is prepared in advance for a series of workstations, each workstation pushes its completed work to next station. The orders are evaluated at supplying location. In this, the stock available at the supplier and the distribution to various retailers is taken into account. It is helpful for accomplishing scheduled production in a non-stop flow. It has redesigned, fixed assembly line, single purpose portable sewing machine with high output capacities. The inventory between stages is high.
Pull system – Replacing stock after consumption has occurred what we do today is to replace what was used yesterday.
Pull system is not a preferred system in the company as the labor is cheap and the country does not has a solid retail market, so most manufacturing is done for export purpose.
Disadvantages of Pull system in the sub-continent
In the sub-continent countries especially Bangladesh, where the retail market is more-or-less absent, the pull system carries the following disadvantages.
Limited ability to adapt to changes in product or product mix (ex. portable sewing machine are of limited capacity and the tooling necessary for products is not always feasible in a given FMS), and the style variation is very frequent so it loses grounds on that account.
Substantial pre-planning is required which is a lacking in the country.
The installation and implementation is expensive, and costs millions of dollars
Technological problems of exact component positioning and precise timing necessary to process a component
Sophisticated manufacturing systems
Advantages of Push systems
The push system helps to cope up with the frequent style changes, which is one of the feature of export based garment manufacturing.
The work can be done for small lot sizes, and in garments industry, there are many cases in which we get to see small orders for a style or small color wise order of the same style.
The push system also helps us to meet the short delivery deadlines, which is a major concern with export-based garments and it helps to fulfill this requirement in most of the cases.
Manufacturing System in Auto Group Ltd.
In Auto Group Ltd, there are 15 lines (5lines per floor), these are all assembly lines having around 40 workstations per line and all these operations are assembly related and these lines are assembly lines.
Apart from the assembly lines, there are preparatory-section which work on a modular basis, especially for cuff and collar preparation. The preparatory section consists of the first 4-6 workstations of every line and also, there is another section in the corner of every floor for the same purpose.
In all, we can say that the manufacturing system followed is a blend of two manufacturing systems, namely
Progressive Bundling Unit (PBU)
Assembly line
Progressive Bundling Unit (PBU)
In PBS production, sewing operations are broken down by management into a number of distinct Progressive bundling and separate operations depending on the complexity of the garment.
Management assigns an expected sewing time or “standard” (in minutes) for each operation such that the amount of effort required to sew a standard minute is equivalent across tasks.
Workers are paid based on individual piece rates according to the standard set for the operation they undertake. In addition to the piece rate standard, workers also receive an hourly wage, or variance pay, when work is interrupted.
The advantages of the PBU system can be listed as under:
Helps to cope up with frequent style changes
Helpful for small lot sizes also
Allows the garment manufacturer to meet short delivery deadlines
The disadvantages faced on following the PBU system are:
Greater amount of WIP
Single operator single skill
Individual piece rates and incentives
Shop floor supervision
Productivity effected by rate of absenteeism
Worker performs repetitive motions
Assembly Line
An assembly line is a manufacturing process in which interchangeable parts are added to a product in a sequential manner to create a product. It can also be called a process where discrete parts are put together to make a finished product. The assembly line operations are a high volume operation that produces products that are very similar in features and performance. Items are produced in a continuous manner, with usually only one possible routing.
It is a very productive production system, and at the same time, the layout is product oriented. Typically, it is a line of dissimilar portable sewing machine is grouped in the line (sometimes more than one to balance flow). Line balancing is a key in the assembly line system as the amount of output varies by varying the sequence of operations and the material flow. Though the assembly line carries a disadvantage of being very inflexible, as the Computerized Sewing Machine layout cannot be altered very often, yet it is most commonly used in the garments industry.
As a part of internship work, I was supposed to cover 2different styles of shirts in the sewing floor from entering the floor to the dispatch to the finishing section. The study in the style included the time study, the method study (process charts and LH/RH charts for each operations). Based on the time study data, the calculations were done to find out the line efficiency, throughput time and the inventory level.
The sewing department covered the most part of the study and it required many calculations to come up with the right data and figures to support and suggest the appropriate changes to the company. The method study also helped to make suggestions on reducing the idle time and the delays from processes.
For the purpose of study, I covered the 2different styles of shirts
Men’s Long Sleeve Hidden B/D Collar Shirt (HAGGAR-PROMINENT APPAREL LTD.)
Men’s Long Sleeve Point Collar Shirt (CAPITAL MERCURY, CARHARTT)
Men’s L/S Hidden B/D Collar Shirt
The style was introduced in many stages as it had a very big order size but the color variation was also frequent. Since the fabric is check/stripe, therefore, the problem of shade variation is not very common. Considering this fact, the order was introduced in the line with a very big bundle size of 279 pieces per bundle. This size was actually determined by the number of lays spread in the spreading/cutting department.
In all, one line engages nearly 85 people and only about 32 of them are operators, the rest all are engaged in either the quality inspection, thread trimming or simply as a helper.
Line Efficiency
Line efficiency= Actual pieces/day x100
Ideal pieces/day
Actual pieces/hour= minimum number of pieces in the line
Ideal pieces per day= No. of operators X Available minutes in a day
SMV of the garment
Now, for this particular style, the minimum number of pieces in the line is 78 pieces
Therefore, actual number of pieces in a day (9hours)= 78X9= 702 pieces
Operators required= 46
Therefore, the operator time taken in a day = 46X5400min= 24840min
Hence, the ideal pieces/day= 24840 = 1489 pieces
16.68
Line efficiency= 702 X100 = 47.15%
1489
From this calculation, it is very clear that the line efficiency is very less and has to be immediately taken into account.
SOP for Sewing: First of all PP Meeting is conducted. This meeting conducted in presence of GM, PM, QM, TM, Line Manager, Maintenance Manager, IE and respective Merchandiser.
After PP Meeting, Red Tag Sample and Trim Chart is provided by the merchandiser along with the Tech Pack and the Technical sheet. The I.E. Department provides the Style bulletin containing the details of Machinery and Manpower allocation.
Cut Parts are received from Cutting.
Pilot run / 1st Bulk is done. It is checked for Quality / Measurement and Shrinkage Issues, Washing issues and also the product safety issues are also discussed .In case of any issue, immediate meeting is conducted and attended by GM, PM, QM and TM to sort out the issue.
Once, all the quality / measurement issues are resolved, approval for bulk cutting is provided and accordingly Bulk Sewing commences.
The Roving Q/C checks randomly 7 pcs from random work stations. In case of any Quality issues, it is immediately highlighted to the Line manager as well as the Technical manager. These issues are sorted immediately.
The End Line Q/C checks 100 % garments for Quality and 2Pcs every Hour for Measurement. Any issues are immediately highlighted to the PM, QM and TM for sorting out the issue.
All the Q/C Pass pcs are sent for wash. Washing is done Style/ Color/ Lot/ Recipe wise. 100 % pcs are checked for Hand feel, Washing Standard and Measurement. If any issues are encountered, rewash is done to achieve the acceptable quality standard.
After washing, garments are issued to finishing (Size/ Lot wise).
Reports in Sewing Section: Ten reports are being made in the Sewing Section:
Quality assurance -QA is consists of quality measuring system by quality equipment when production process is completed. Here, we have described some quality assurance system of dyeing and finishing unit
Quality Assurance Tools and Techniques:
Various types of machineries and equipment are used by quality assurance analyst or quality manager during testing. Following equipment’s are the main instruments for testing of quality assurance. All of the qc tool is not contrived by same manufacturing companies. Various qc tool manufacturing companies certified by iso 9001 are liable to provide such types of equipment’s for the textile factory. ISO 9001 standard qc tool or quality assurance tester list for quality assurance is given in this post
Some Online Quality assurance tools and techniques :
Applicable test: The applicable QA test for pretreatment performance is as follows-
Pick up percentage test.
Barium activity number of mercerized fabric.
pH test.
Absorbency test.
Size test.
Whiteness test.
Desized wash test.
Test procedure: Pick up percentage test:The pick percentage test procedure is as follows-
Machine / solution used :N/A
Machine / solution manufactured by:N/A
Person responsible:QA checker or inspector
Frequency:After change of padder, every month following maintenance and/or whenever required.
Procedure 1 :Make 3 polythene bag (previously weight denoted BL, BA, BR) L, C and R thus will be use to hold the sample taken during the pickup check. L, C & R represent the position from where the sample is taken. Looking down the machine from the face end in the same direction as the fabric is running, left hand side of the machine will designed as L, center C & right hand side is R.
Procedure 2:Stop the machine when seam level the nip of the padder and cut three samples from the fabric each approximately 3 square inch.
Procedure 3 :Place the sample into the bag and seal the bag tightly to prevent the moisture loss. Then weigh each of the bag with the sample inside and record the weight (WL, WC, WR).
Procedure 4 :Take the sample out of the bags. Dry the entire sample and the bag on an oven.
Procedure 5 :When dried take the bag out of the oven and allow them to cool, then take the sample out of the oven and immediately place them in a correct bag.
Procedure 6 :Aloe further cooling of the samples (for 5 min) and reweight the bag with the sample inside and record the weight (DL, DC, DL)
Procedure 8 :In case of non conformity :Inform mechanical maintenance personnel / relevant area in charge for corrective action.
Barium activity number of mercerized fabric test: The procedure for barium activity number test on mercerized cloth is given bellow-
Machine / solution used :N/A
Machine / solution manufactured by:N/A
Person responsible:QA lab assistant
Frequency:As and when required
Procedure Take one unmercerized sample and 3 more sample from left, center and right so that the sample weight is approximately 5 gm. Check the pH if the value is not natural than washed the sample with 10 g/l natural soap and 2 g/l soda ash.boi the sample for one hour and checked the pH of washed liquid. Than dry the sample.
Procedure After drying take accurately 2 gm portion of each of the sample and cut them into 3mm square. Place the cut portion in 250 ml volumetric flask. Add 30 ml of 0.25 N barium hydroxide solutions in each of flask and keep them for 2 hours. Stir the content at some interval.
Procedure After 2 hours pipette out 10 ml of solution from the flask and titrate with 1 N HCl. Not down the reading.
Performance standard:128-140
In case of non conformity :Inform mechanical maintenance personnel / relevant area in charge for corrective action.
pH test: The details of pH test procedue is given bellow-
Machine / solution used :Universal indicator solution, flame able liquid, mixable with water, color scale range for pH 4-10
Procedure :2-3 drop of water are spayed over the fabric, and then added 1-2 drop of pH solution over it. The resulted color is than compared with the scale. Performance standard:pH 7-8 for reactive. pH ≤ 7 for disperse.
In case of non conformity :Hot wash
Absorbency test:
Machine / solution used :N/A
Machine / solution manufactured by:N/A
Person responsible:QA lab assistant
Frequency:Every thousand meter
Procedure :A full width mercerized fabric is taken. 3 samples are cut from that piece, one from left, one from right and one from center. The size of the sample is (1.3-2.5) cm. Each of the sample is up to 5 cm showing every single cm. the samples are than dipped in the solution (0.5 gm reactive dyes is dissolve in 200 cc water) for 1 min. generally one or less than one cm is dipped in the solution and it is expected that the minimum performance standard.
Performance standard:Minimum 3 cm
In case of non conformity :adding with wetting agent or rewash or rebleach.
Size test:
Machine / solution used :Lodin solution
Machine / solution manufactured by:N/A
Person responsible:QA lab assistant
Frequency:Every thousand meter
Procedure :1. Preparation of iodine solution- Dissolved 10 gm of potassium iodide in 100 ml of water, add 0.65 gm of iodine and shack till complete dissolution. Fill with water with 800 ml mark and then with ethanol up to 1 liter.
Application: Put a drop of the solution take 1 ml solution and dissolve in 99 ml of distill water. Drop method- Take 0.1 N iodine solution and dissolved on 99 ml of distill water
Application 2: Put a drop of the solution on the fabric and compare the color with the scale.
Performance standard:6 min (degree of desizing)
In case of non conformity :Re-scouring
Whiteness test:
Machine / solution used :Spectrophotometer
Machine / solution manufactured by:Date color international
Person responsible:QA lab assistant
Frequency:Every 100 meter
Procedure :Measure the whiteness and compare the result.
Performance standard:Whiteness chart is given bellow-
In case of non conformity :Re-bleaching
Width test:
Machine / solution used :Measuring tape
Machine / solution manufactured by:N/A
Person responsible:QA lab assistant
Frequency:Every thousand meter
Procedure :Manual measurement
Performance standard:In case of mercerizing CVC / PC (142, 144) cm, cotton (144-148) cm, otherwise as per customer specification.
In case of non conformity :Stretching.
Desized wash test:
Machine / solution used :Dyeing padder
Machine / solution manufactured by:Werner Mathis AG Switzerland
Person responsible:QA lab assistant
Frequency:Every yarn dyed fabric
Procedure :Take one square feet sample. Use desizing recipe and pad the sample fabric under the following condition. Temperature 70°C, pH 7 padder pressure 2.5 bar, batching time 12 hr. Hot wash the padded sample with water at 90 °C for 2 min. Dry. Take a part of the dried sample and padded with 0.5 g/l OBA at room temperature with padder pressure being 2.5 bar. Dry again. Prepare the desized washed sample sheet (with greige fabric, desized washed fabric and the OBA treated one). Finally compare the sheet with the original swatch (if the fabric is soft finished)
Performance standard:Match with original.
In case of non conformity:During processing, after washing checked the shade if it does not match go for topping.
Applicable test for solid dyed fabric are as follows- Shade check, Listing, Wash fastness, Crocking fastness.
Shade check:
Machine :Spectrophotometer
Machine manufactured by :Data color international.
Person responsible:QA lab assistant
Frequency:Every thousand
Procedure :1.Collect sample from dyeing after every thousand meter. 2. Measure the sample by spectrophotometer. 3. Print out the result. 4. Make shade continuity card. 5. Samples are also compared visually with approved lab dip.
Performance standard:E value 1.0-1.5
In case of non conformity:Inform QA executive who take the following necessary action:
Listing:
Machine / solution used :N/A
Machine / solution manufactured by:N/A
Person responsible:QA lab assistant
Frequency:Every thousand meter
Procedure :1.A full width sample is cut into 7 pieces and sewed in the following manner and checked with one another in the light specified by the customer. A full width sample is cut into5 pieces and sewed in the following manner and checked with one another in the light specified by the customer.
In case of non conformity :If listing problem occur, the responsible person in production should be informed generally increasing or decreasing padder pressure solved the problem.
Wash fastness test (for dark shade only):
Machine used :Gyro wash
Machine manufactured by:James . H . Heals and company, England
Person responsible:QA lab assistant
Frequency:Every order
Procedure :Method BS 1006 ref:C06 C2S
Performance standard:For color change – 4C
For color staining- 4S
In case of non conformity :Re wash
Crock fastness (for dark shade only):
Machine used :Crock meter
Machine manufactured by:Na
Person responsible:QA lab assistant
Frequency:Every order
Procedure :Method BS 1006 ref: X 12
In case of non conformity :Re-wash or spiral finish with softener which improve crock fastness
7 QC Tools :
Quality assurance and quality control also maintain 7 qc tools techniques. The techniques are listed below-
