Quality Workship by Uster PDF

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Summary

1 day Workshop on process optimization with Quality in mind Uster Technologies India Murali Ganesh Agenda Subject Duration Preparatory Process Key indicators and check points 09 to 13:00 (Tea break 10 to 11:00) Lunch break 13:00 to 14:00 Spinning, Winding and new innovations 14:00 to 17:00 (Tea brea...

Description

1 day Workshop on process optimization with Quality in mind

Uster Technologies India

Murali Ganesh

Agenda

Subject

Duration

Preparatory Process • Key indicators and check points

09.30 to 13:00 (Tea break 10.45 to 11:00)

Lunch break

13:00 to 14:00

Spinning, Winding and new innovations

14:00 to 17:00

•

(Tea break 15:30 to 15:45)

Key indicators and check points

1

The most common challenges of the spinning mills

Productiv ity

Yield – waste

Systems

Quality & Costs

2

Automati on

Raw material

Energy

Labour

Manage ment

Producti on targets

Yarn demand

Competit ion

Quality

Claims

Consisten cy

Quality & Costs

Homoge nity

Requirement for better yarns at lower costs

Yarn quality

Manufacturing costs Year 1970

3

1980

1990

2000

2010

Remaining problems that the quality managers are facing in spinning mills today • No consistency from yarn batch to yarn batch • Foreign fiber claims • No systematic quality management in the mill • Number of outlier bobbins or cones too high • Raw material variation not under control • Knowledge of fiber quality characteristics and bales handling • Knowledge for what purpose the yarn is used • Claims cannot be traced back to specific events in the mill • Frequent changes of operators • Shortage of skilled personnel and textile technologists • Continuous pressure to reduce the costs (sacrificing the quality) 4

USTER® QUANTUM 3 Basics of yarn clearing Claims and their origin

Remaining thicks/thins, 16%

Fabric appearance, 15%

Contamination, 14%

Barré, 13%

Hairiness – pilling , 12% Breaks in knitting / weaving, 21%

5

Murali Ganesh Uster Technologies

White specs, 9%

Key Quality Indicators and check points

Murali Ganesh, Uster Technologies

Key Quality Indicators and Check points Raw Material

Gin Raw material Sourcing

Fiber quality

Bale Storage

Handling Bale Quality and size

7

Murali Ganesh Uster Technologies

Key Quality Indicators and Check points Laydowns – Mixing Recommendations Mixing Recommendations

Fiber fineness (Mic)

Fiber length and uniformity

Impurities

Color

•

Avg. Mic between laydown...