This document provides training on quality improvement for a garment factory. It discusses quality check points and potential problems for various machines in the production process, including slitting, drying, stenting, and compacting machines. Specific defects like crease marks, width variations, and shrinkage are analyzed in terms of their causes and recommended solutions. The document also covers quality issues unique to lycra fabrics, such as GSM variations, and proposes remedies. The overall goal is to maintain good quality while meeting production quantities through establishing standard operating procedures and active operator monitoring at all stages.

1. TRAINING FOR
QUALITY
IMPROVEMENT
MAA Garment
& Textiles
Factory
PO Box 1976, Quiha, Mekelle, Ethiopia.

2. Mohammad Mizanur Rahman
Fabrics Finishing Expert (Manager)
Cell: +251 962 600 055
Email: mizan5379@yahoo.com
PRESENTED BY

3. TRANSLATIONS BY
Subagadis Hagos
Tesfay

4. M/C WISE QUALITY CHECK
POINTS
1. Slitting M/c
(Corino)
2. Dryer M/c
3. Stenter M/c
4. Compactor M/c

5. 1. Slitting M/c (Corino)
A. Cutting on Slitting Mark
B. Crease Mark from Padder
C. Pick up %
D. Any visible problems
E. Dirty Spot
F. Elongation %
QUALITY CHECK POINTS

6. 2. Dryer Machine
A. Even dry
B. Over dry
C. Elongations/ Compaction %
D. Any Visible Problem
QUALITY CHECK POINTS

7. 3. Stenter Machine
A. GSM
B. Width
C. Hand Feel
D. Shade
E. Shrinkage
F. Spirality
QUALITY CHECK POINTS
G. Color Variations
H. Width Variations
I. GSM Variations
J. Crease Mark
K. Middle Loose
L. Dye Un level

8. 4. Compactors Machine
A. GSM
B. Elephant Skin
C. Crease Mark
D. Light Mark
E. Any Visiable
Problems
F. Shrinkages
QUALITY CHECK POINTS

9. QUALITY PROBLEM
A. Wrong Slitting
B. Crease Mark
C. Width Variation
D. Middle Loose
E. Pin Hole in selvedge
F. White Mark
G. Light Mark
H. Softener Mark
I. Shrinkage
J. Spirality
K. Dirty Spots
L. Shade Variation
M. Elephants Skin
N. Lycra Fabrics
i. GSM Variation with in roll
ii. Within roll 1st & last GSM variation
iii. GSM low after dyeing
iv. Roll to roll GSM variation
v. GSM up down after Finish

10. QUALITY SOLUTIONS
Defect, Causes & Remedies:-
1. Crease Mark:
A. Causes:
i. From Padder (If proper not open uncurler Roller)
ii. Pin out from stenter m/c
iii. If not use leading cloth in time in stenter m/c rather than ropes
iv. From Dyeing (If ropes stage dyeing)
v. High Yarn Tension
vi. If edges not proper stitch and knots pass from corino
A. Remedies:
i. Slitting, Stenter & Compacting starting time reject fabrics Stitch.
ii. Operator all time actively follow up
iii. Dyeing time up to mark use Anti-Creasing Agent
iv. Yarn tension less from knitting

11. QUALITY SOLUTIONS
2. Width Variation.
A. Causes:
i. Stenter M/c setup change within one batch
ii. Grey fabric of the same lot, knitted on different makes of Knitting
Machines, having varying number of Needles in the Cylinder.
iii. Pin selvedge controller auto not proper work
iv. If not proper stitch before stenter m/c
A. Remedies:
i. Same setup width Full batch Finish
ii. The whole lot of the grey fabric should be knitted on the same make of
knitting machines
iii. selvedge controller should work auto
iv. proper stitch each rolls
v. Stenter m/c running time must be actively work

12. QUALITY SOLUTIONS
3. Wrong Slitting.
A. Causes-
i. If auto cutter sensor not proper work
ii. Proper Not sewing
iii. If drop needle not visible
iv. Operator not active
A. Remedies-
i. Auto cutter sensor should be in proper Working condition
ii. Proper Stitching with drop needle
iii. Operator carefully M/c operating

13. QUALITY SOLUTIONS
4. Folder/ Dia Mark.
A. Causes-
i. Mainly Lycra & High GSM fabrics
ii. High pressure of the fabric Take Down rollers of the Knitting
machine on the grey fabric is one of the main causes
A. Remedies-
i. Adjust the gap between the two rolls as per the thickness of the
fabric sheet
ii. Fabrics cutting/open from knitting (option)
iii. After knitting fabrics keeping relax stage

14. QUALITY SOLUTIONS
5. Middle Fabric Loose.
A. Causes-
i. If actual width not finish
ii. Adjust Fan pressure bottom and top
iii. Delivery tension not adjusted
iv. Blower Speed More
A. Remedies-
i. Should be Actual with finish
ii. Adjusted delivery tension
iii. Adjust Blower Speed

15. QUALITY SOLUTIONS
6. Pin Hole in selvedge.
A. Causes-
i. Selvedge Auto controller not proper work
ii. Operator not active
iii. Needle ledge (pins) damage
A. Remedies-
i. Selvedge Auto controller proper work
ii. Operator carefully M/c operating
iii. Needle ledges should be inspected regularly and replace if
damage

16. QUALITY SOLUTIONS
7. White Mark.
A. Causes-
i. If any friction.
ii. After slitting if selvedge dry.
iii. If not proper wash in dyeing.
iv. Soda & Salt Effect
v. Softener Not Proper Mixation
vi. pH not control
B. Remedies-
I. After slitting urgently dry
II. Proper wash in dyeing
III. Softener pH control

17. QUALITY SOLUTIONS
8. Shrinkage.
A. Causes-
i. If Actual width not finish
ii. High Stresses & strains exerted on the fabric, during Knitting,
Dyeing &Processing & the fabric not being allowed to relax
properly
iii. Not Proper Count Use
iv. Not Right Stitch Length
v. Tension on fabric during finishing
A. Remedies-
i. Should be Actual width finish
ii. Give maximum overfeed to the fabric, during the processing, on
the Stenter,& Compactor
iii. Proper Count Use
iv. Right Stitch Length
v. Minimize tension during processes (corino, stenter)

18. QUALITY SOLUTIONS
9. Spirality.
A. Causes-
i. Need proper Angle.
ii. Appropriate Yarn TPI/ High TPI. of the Yarn
iii. Knitting more feeder use
iv. Uneven Fabric tension on the Knitting machine
v. Unequal rate of Fabric feed on the Stenter & Compactor
vi. If not actual width finish
A. Remedies-
i. Auto use Weft straightener (Mahlo)
ii. Use the yarns of the recommended TPI level for Knitting
iii. Ensure uniform rate of feed of the dyed fabric on both the edges while
feeding the fabric to the Stenter & Compactor machines
iv. Actual width finish
v. Knitting feeder use less

19. QUALITY SOLUTIONS
10. Color Variation in Finishing.
A. Causes-
i. Stenter M/c not same speed runs
ii. If Suddenly m/c Stop
iii. Squeeze Roller Pick up % side to side Different
iv. If Stenter m/c side to side Temperature Difference
v. Stenter m/c Circulation not proper
A. Remedies-
i. Should be m/c run same speed
ii. Stenter m/c Circulation proper
iii. Check pickup %

20. QUALITY SOLUTIONS
11. GSM Variation :
A. Causes-
i. Roll to roll variation in the, process parameters, of the fabric, like;
Overfeed &Width wise stretching of the dyed fabric, on the Stenter
& Compactor Machine.
ii. Roll to roll variation in the fabric stitch length.
A. Remedies-
i. Make sure that all the fabric rolls in a lot, are processed under the
same process parameters.
ii. The Knitting Machine settings, like; the Quality Pulley diameter
etc. should never be disturbed.

21. QUALITY SOLUTIONS
12.Dark Mark:
A. Causes-
i. Mainly crease mark is the dark Color fabrics showing dark
line.
ii. Dark Shade mainly showing
iii. If not properly use anti Creasing & Wetting agent.
iv. If fabrics not properly open stage in the dyeing nozzle.
v. Rope stage in dyeing.
B. Remedies-
i. Up to mark use anti crease & wetting agent.
ii. Ensure the open stage dyeing & not rope.

22. QUALITY SOLUTIONS
13. Elephants Skin:
A. Causes-
i. Mainly coming from compactor machine.
ii. If over compaction.
iii. If taplon/ Glass fiber not proper setting
B. Remedies--
i. Before compactor m/c run then everything checks.
ii. Up to mark feed the over feed.
iii. Taplon/ Glass fiber properly set.
iv. Again compactor under overfeed.

23. QUALITY SOLUTIONS
14. Light Mark:
A. Causes-
i. If Not Properly M/c Clean
ii. Color Changes Must be proper clean
iii. After Clean if directly run the Fasbrics
iv. Compact Teflon if damages
B. Remedies--
i. Every Machine should be Properly clean
ii. Color Changes then 1st run reject fabrics.
iii. Taplon/ Glass fiber properly set.
iv. If Teflon damages then must be replaces

25. LYCRA FABRICS
PROBLEMS
1. GSM Variation with in roll
2. Within roll 1st & last GSM
variation
3. GSM low after dyeing
4. Roll to roll GSM variation
5. GSM up down after Finish

26. Defect, Causes & Remedies:-
LYCRA FABRICS
PROBLEMS
1. GSM Variation with in roll
A. Causes-
i. Not proper Relaxation after Knitted
ii. Lycra not proper feeding in knitting
iii. Proper temperatures in heat set
iv. Both side pinning speed not same
v. Running time overfeed changes in stenter
B. Remedies-
i. After knitting need proper Relaxation
ii. After Slitting also need relaxation
iii. Heat set time both side pinning need to be same
iv. Running time Overfeed/ Speed should be same

27. 2. With in roll 1st & Last GSM Variations
A. Causes-
i. Not proper Relaxation after Knitted
ii. Lycra not proper feeding in knitting
iii. If any tension
iv. Temperature not same each chamber
v. Running time overfeed changes in stenter
B. Remedies-
i. After knitting need proper Relaxation
ii. After Slitting also need relaxation
iii. Temperature should be same each chamber
iv. Running time Overfeed/ Speed should be same
LYCRA FABRICS PROBLEMS

28. LYCRA FABRICS PROBLEMS
3. GSM low after Dyeing
A. Causes-
i. If use maximum overfeed in Heat set
ii. Lycra property not heat recovery
iii. Low temperature lycra
iv. More Enzyme use in dyeing
v. Over time running in dyeing stages with high temperature
B. Remedies-
i. In heat set time use maximum 60% overfeed
ii. Before heat set should be knows lycra property
iii. Use Regan able Enzyme %
iv. Within short time need to be dyeing finish

29. LYCRA FABRICS PROBLEMS
4. Roll to Roll GSM Variation
A. Causes-
i. Not same knitting Machine
ii. Knitting m/c to m/c Stitch length/ Lycra Tension Differences
iii. If differences time heat set
B. Remedies-
i. Same knitting M/c together Heat set & dyed
ii. All knitting m/c need to be conform same Stitch length/ Lycra tension
iii. Follow same heat set parameter
iv. Full batch same parameter use

30. LYCRA FABRICS PROBLEMS
5. GSM Variation after Finishing
A. Causes-
i. If speed/overfeed variations in M/c
ii. Padder pressure & pick up % variations
iii. Not proper relaxation
iv. Heat set not good
B. Remedies-
i. Speed /Overfeed should be same in finishing time
ii. Padder Pressure & Pick up % must be equal
iii. After finish must be Proper relax
iv. Should be proper Heat set.

31. OUR EXPECTATION GOOD
QUALITY WITH QUANTITY.