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# Process control of weaving process

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### Process control of weaving process

1. 1. Process control of Weaving
2. 2. Name : MAZADUL HASAN SHESHIR ID: 2010000400008 Batch: 13th Batch (Session 2009-2013) Department: Wet Processing Technology Email: mazadulhasan@yahoo.com Blog: www. Textilelab.blogspot.com Southeast University Department of Textile Engineering PREPARED BY ©right
3. 3. 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
4. 4. 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
5. 5. PROCESS FLOW CHART OF WEAVING
6. 6. Fabric Sample :Denim Fabric Construction :( 73 × 43 / 15 × 10 ) × 55 Structure :Twill Interlacing Pattern :2/1 Yarn Type :Cotton Yarn GSM :230
7. 7. Process Control of Warping Section
8. 8. Input Variable of Warping Input Quantity Required Quantity Yarn Count 15 16 CV % 10 12 Strength / tenacity 11 13 Breaking elongation (%) 8 8.5 Minimum Staple length of Yarn 2.5 2.7 Contamination Moderate Moderate Yarn type Cotton Cotton Yarn hairiness Moderate Low Yarn micronaire value 3.5 4 Twist factor 4 4.5
9. 9. 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
10. 10. Process Control of Sizing Section
11. 11. 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
12. 12. Process Control of Drawing-in & trying Section
13. 13. 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
14. 14. Process Control of Looming Section
15. 15. 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
16. 16. 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
17. 17. 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: