Escolar Documentos
Profissional Documentos
Cultura Documentos
By: Qurat-ul-Ain
ME-Textiles
NED University
Introduction
to produce top quality woven goods in
high volume
must have their planning and
organization under control.
Additional criterion is thorough
familiarity with the entire production
process, from fibre to fabric, to
ensure that fabric production is
profitable.
Introduction(Cont)
optimum production steps
planning stage that defines process parameters,
sequences of operations and working conditions, all
of which are relevant to profitability.
optimal installation of the weaving machines, with
appropriate transport routes and equipment.
Additionally, capacities must be planned and the
necessary infrastructure and resources created,
including buffer store, air conditioning, lighting,
personnel, quality control etc.
Yarn quality
80% of weaving machine stoppages
originates from bad yarn quality.
Not only the uniformity of the yarn is
important; damaged packages are a sign of
poor transport quality, and on the weaving
machine they not only impair productivity but
also cause waste.
If there are no yarn reserves in the weft
packages the result will be a weft stoppage.
Yarn quality.(Cont)
Thread breaks in weaving are the
largest cost factor in the entire
production process, because they
always involve a machine stoppage
Every stoppage prevented directly
improves the company's profits.
Weaving preparation
Faultlessly produced warp beams and
precision work on the sizing machine, in
combination with the right sizing agent
and size application, are the conditions
that have to be fulfilled.
According to an old German proverb in
the textile industry, "well sized is half
woven"
Yarn Breakages:
Yarn Breakages..(Cont)
In order to control end breakage rate
different quality control measures are taken
in each process.
Analysis shows that no more than one stop
per 100,000 m of weft yarn should occur. As
soon as two or more stops per 100,000 m of
yarn are available in the high production
weaving mill, costs will increase as a result
of a reduction in efficiency.
Loom stoppages:
The loom stoppages occur due to the
following reasons.
1. Breakages of warp yarn
2. Breakages of weft yarn
3. Malfunctioning of some important of
mechanisms of loom or basic loom motion.
4. Temperature and humidity of weaving
depart
Ensure that the yarn coming from spinning must have the
suitable characteristics of strength, hairiness, thick places,
thin places, neps, and elongation according to the standards
for different yarn counts.
Twist in yarn
Tensile strength
a)Single yarn strength
b)Lea strength
Elongation
Hairiness
Yarn imperfection ( thin, thick places and neps)
Air conditioning:
Air conditioning serves to create an optimal
climate for weaving.
Correctly adjusted relative humidity is crucial for
the running characteristics.
Good air conditioning also fulfils other tasks:
it purifies the ambient air by extracting dust,
by cooling air,creates the right working conditions.
Cleaning:
Efficient and effective cleaning is important in
achieving flawless fabric production.
For staple fiber yarns, the air conditioning system is
not enough, travelling cleaners are used.
blow off advisable.
for thorough cleaning of weaving machines, using
vacuum cleaners and compressed air.
Cleaning (Cont):
Compressed air is efficient but simply blows the
dust somewhere else.
For this reason, suctioning off is a far more effective
method.
Central vacuum systems have the advantage that
they simultaneously remove dust and waste.
Heavy soiling increases wear on machine
components and causes stoppages.
With scheduled cleaning work, unnecessary costs of spare parts, stoppages and maintenance can be
avoided
Downtime
The duration of a stoppage is not only
important with regard to productivity; it also
crucially influences fabric quality.
Stop marks, can be prevented if the
machine is restarted quickly.
Too long stoppage, the width of fabrics may
be reduced.
Downtime(Cont)
Complicated yarn breaks or multiple breaks
must be avoided at all costs.
The weaver's workload can be calculated
from the downtime and the number of
stoppages. From this data it can be seen
how many weaving machines one weaver
can look after, which in turn provides
information on personnel costs.
Long-term stoppages
Include style and warp changes,
machine servicing and repairs.
can be reduced to a minimum by planning
with foresight, teamwork and personnel
training are indispensable.
Keeping sufficient quantities of spare and
wearing parts in stock to cover consumption
will help minimize long-term downtimes and
save costs by avoiding rush orders
Efficiency
Two types of efficiencies.
Efficiency(Cont)
The plant efficiency reflects the productivity
of the weaving facility and can be improved
by reducing short-term (yarn breaks) and
long-term (organizational) stoppages.
Depending on the style mix, increasing
efficiency by one percent results in an
increase in earnings of up to 1000 Euros or
more per weaving machine and year.
Lighting
Correct lighting of production facilities
Machine maintenance
Maintenance must be carried out in accordance
with the manufacturers' instructions.
Unnecessary repairs and long-term stoppages can
thus be avoided, and spare parts costs reduced.
Maintenance is carried out on the basis of
checklist,
making a record of the condition of parts and of
parts replaced.
Machine maintenance
(Cont)
The record file will identify deficiencies and
excessive wear of individual weaving machines.
Lubrication and greasing require special care
and must be carried out by qualified personnel
in accordance with the manufacturer's
instructions.
Machine cleaning must not be neglected under
any circumstances
Preparation of materials
Good planning benefits
The production process,
Helping to avoid unnecessary waiting time.
Adequate quantities of warp beams and weft
material at intermediate storage points, close to the
weaving machines, production losses can be
minimized.
The weft yarn should be acclimatized for at least 24
hours under the climatic conditions in the weave
room.
Cloth inspection
Immediate inspection after weaving, avoids
the production of further faulty goods.
Avoiding defects is the prime objective.
If they occur, it is vitally important to detect
and remedy them quickly.
Document all defects, so that a subsequent
inspection can be carried out efficiently.