Download - Process control of weaving process
Process control of Weaving
Name : MAZADUL HASAN SHESHIRID: 2010000400008Batch: 13th Batch (Session 2009-2013)Department: Wet Processing Technology Email: [email protected]: www. Textilelab.blogspot.com Southeast UniversityDepartment 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 FabricConstruction :( 73 × 43 / 15 × 10 ) × 55Structure :TwillInterlacing Pattern :2/1Yarn Type :Cotton YarnGSM :230
Process Control of Warping Section
Input Variable of Warping Input Quantity Required QuantityYarn Count 15 16
CV % 10 12Strength / tenacity 11 13
Breaking elongation (%) 8 8.5Minimum Staple length of Yarn 2.5 2.7
Contamination Moderate ModerateYarn type Cotton Cotton
Yarn hairiness Moderate LowYarn micronaire value 3.5 4
Twist factor 4 4.5
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
controlledBroken or loose ends 10 5 To reduce yarn breakage lower strength /
tenacity yarn has to removeDensity 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 beamWidth 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 beamCoarse 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 maintainedUniformity of sized yarn Moderate Good Uniformity of sized yarn can be
maintained by properly sizingPercent of size 3 1.5 Percent of size can be maintained
by controlling the immersion rollerStrength & uniformity
of sized yarn13 15 Strength & uniformity of sized yarn
can be maintained by maintaining the proper sizing recipe & heat of
drying chamberUnwindability Low Moderate Unwindability can be reduce by
properly drying sized yarnDensity 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 cardGSM 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 cardBroken ends / picks 5 3 Broken ends / picks can be reduce
by controlling the RPM of the loomDouble 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 brokenHole ( 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 productionDirt 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: