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DESIGING
DYEING HOUSE
NEW SPINING
POST SPINING
MENDING
FINISHING
INSPECTION
WAREHOUSE
QC LABORTARY
DESIGNING
Designing department acts as the heart and soul of the whole process
of fabric making. This department receives feedback from the market and
after analyzing various factors the designs are developed. There are mainly
two seasons i.e. Fall/Winter and Spring/Summer. New designs according to
the market trends are developed along with improving some of the old
designs. The procedure of designing is briefly explained here.
New shades are developed by HOD (Designing) in tune with the current
trends and count, blend & twist / inch are also decided by HOD.
The inputs for this procedure are blend composition, twist, count &
shade. As per the end product required, the loom setting(ends/inch X
picks/inch X reed width in inches on loom) is decided. To establish a basic
design, feeler sample is made & after approval from sales, design pattern
are developed and finished accordingly.
The cut samples from blanket sample are shown to VP(Sales) &
HOD (Designing) and selected according to trend.
Master card :
Feeler manufacturing
For feeler manufacturing yarn requirement and yarns are taken from
store and if single yarn is available, it is made 1,2, or 3 ply according to the
requirement. If yarn is not available, arrangement for yarn manufacturing is
made and piece ticket is issued. After finishing, feelers are checked for fel
and finish and if rejected, it is kept separate and sold separately.
Production Plan:
The master card made is checked with the folder and duly signed by
HOD. After this the master card is sent to Q.C.Lab sends the master card to
PPC (Production Planning & Control).
PRODUCTION PLANNING & CONTROL
If designing can be considered as the heart & soul of the Mill, the
production planning & control dept acts as the nervous system of the Mill.
This deptt plans the production and issues the various plans to different
departments and also controls the whole production process.
The master cards from Q.C. Lab helps in issuing indents to Spinning,
Recombing & Dye House. The process completion dates are put on the
indents, which helps the PPC to monitor the process.
The warp and weft piece tickets are issued to weaving which contains
the full plan to weave the fabric. The colour, pattern and design are
contained in the piece tickets and the operator of loom understands the
details and manufacture the fabric accordingly.
The fabric production stage is monitored so that the target dates are
achieved in addition to the maintaining of quality and fool proof
production.
The Dye House unit is a major operational unit in the company. The product
is given its proper and required shade in the Dye House. The raw wool
received as raw material is of white or natural colour and dye house dyes the
wool into the required shade according to the market demand and the
customer's order.
Top dyeing :
The tops are dyed and the below given procedure is followed :
Hydroextraction :
Backwashing :
The shade of the dyed material is again checked and if found correct
the material is sent to recombing department for further processing.
Yarn dyeing:
The yarn in the shape of cones is dyed, the various stages in yarn
dyeing are as given below
Shade checking:
The yarn is checked for the shade required with matching the shade
and if the shade is rejected the material is reprocessed.
Hydroextractor:
R.F. Drying :
The yarn is dried in R.F. dryer machines which dries the yarn and
make them ready for spinning or further processing.
Dye House also dyes fabric which requires specific shades. These
fabrics are woven as white fabric and dyed afterwards. This process is also
called piece dyeing. The various stages in this process are :
Shade checking:
The shade is checked after dyeing the fabric and if found incorrect the
material is dyed again.
If the shade matches with the required shade, the material is sent to
hydroextractor machine.
Hydroextractor:
Hydroextractor machine extracts the extra colour & water from the
dyed material. To Finishing : The dyed fabric is sent to Finishing Dept for
drying and checking of any defects. If found defective the fabric is sent back
to Dye House for reprocessing.
NEW SPINNING
Spinning
Spinning may be defined as " A set of operations the textile fabric
must undergo to be converted into yarn."
BLENDING:
PRE-COMB GILLING :
The carded sliver contains some impurities which should be
removed before further processing. These impurities include :
The Procedure :
Slivers are fed at the back of the Gill box through which the slivers
enter the back rollers and after processing by the Gill box passes on to the
delivery can through front rollers. The front and the back rollers revolve at
different speeds, later being slow. This difference in speeds of two rollers
pull the sliver and thus the weight per unit length of the sliver is reduced
as required. This process is called Drafting.
COMBING :
The sliver at this stage may contain neps, vegetable matter and short
or broken fibres. These faults are removed this stage.
The procedure :
A number of slivers are fed to the machine. These slivers pass
through various rollers which feeds the sliver into the combing section. In
the combing section, the sliver is passed through a comb, containing pins,
which in turn combs the sliver. The combed sliver passes through the
crimping unit to give crimp to the wool and at the end the sliver is collected
in a can through a coiler unit.
In this stage the recombed top sliver is given two gilling. The
purpose of two gilling is:
- To remove the wavy pattern of the combed sliver formed due to the
overlapping of the successive combed fibres.
- To even out the irregularities in weight per unit length of the sliver.
- To collect the sliver in the form of a ball. It is called wool top.
SPINNING
The function of ring frame is to process the roving and produce the
desired count of yarn within the spinning process.
THE PROCESS :
The main stages in this section are listed below :
- DRAFTING
- TWISTING
- WINDING
- LIFTING & BUILDING
The output of spinning process is YARN.
POST SPINNING
Assembly Winding :
Assembly winding is the process in which two single yarns are wound
together on to a parallel cheese.
The Process :
Two cheeses or cones of single yarn are placed in supply pegs and
yarn from both the cones or cheeses are wrapped round the cheese on the
cheese holder. If one end breaks or runs out the winding stops. This motion
prevents any single end being wound on to the cheese. When the end breaks
these are joined by splicing.
Two-for-one Twister:
The function of this stage is to
Twist the assembly wound yarn
Wind the twisted yarn on to a cone or
cheese.
The process:
The T.F.O. twists the assembly wound yarn and winds the yarn on to
cheese or cone. In each revolution of the spindle. T.F.O. inserts two turns in
the yarn. This is how it is known as 'TWO FOR ONE' twister.
The yarn from supply package is passed through the spindle top. The
formation of balloon is prevented by balloon limiter. In this process one
full package is made out of one full assembly wound cheese and the end
breakage is negligible and hence the knots are negligible.
Autoclave :
The yarn is steamed after twisting to set the twist and to avoid
snarling. This also improves the strength of the yarn. After steaming the yarn
is set for conditioning . At the end of this section each cone is checked
completely for any defects and the approved cones are stored in cone store.
WEAVING
Weaving interlaces warp and weft yarns in a certain definite pattern to
form cloth, Weaving transforms the yarn into fabric on a loom which
interlaces two sets of threads i.e.
WEFT : Which lies at right angles to the warp-crossing the fabric from
selvedge to selvedge.
The five basic functions which a loom has to perform to weave the cloth
are listed below :-
Shedding;
The warp threads which runs down the length of the cloth are to be
set to make way for the weft thread to pass in between them. The warp
threads are separated vertically and the way for weft is made. This vertical
separation of warp is known as shedding.
Picking :
This is the process of giving the shuttle (or rapier or projectile with
weft) the propelled motion across the race plate through the separated warp
is known as shedding.
Beating Up:
The weft yarn inserted in warp threads need to be pushed on the cloth
side before the next weft yarn is inserted. This pushing of the weft yarn into
the 'fell' of the cloth by means of Reed mounted on the oscillating sley is
called beating up.
Taking Up :
The weaved fabric is wound on the cloth beam on the other side of
the machine and this winding is known as taking up. The rate of taking up
controls the number of picks of weft threads per inch.
This section is very important as this section corrects any kind of defects in
the fabric. No machine is used for Mending. The fabric from Greasy Perch is
checked on the perches and the defects are removed. The fabric is again
checked on the perches by the Inspectors after Mending and the approved
fabric is sent to Finishing.
PICKING :
Picking is the process in which all kemps, straws, heir etc. are
removed from the surface by picking.
BURLING:
This process consists of removing all the slubs etc. by following the
below given procedure :
Scouring :
Steaming :
Blowing steaming through the fabric two or three minutes helps in
relaxation of strains and then a permanent set. This process of steaming is
done to improve the finishing of the fabric. The fabric is then allowed to
cool before further reprocessing.
Crabbing :
This process has the same objects as of steaming, but hot water is
used instead of steam. The cloth is unwound and run at full width through
the trough containing hot water. Finally the cloth is passed to the hollow
steaming roll where on it is wound.
INSPECTION
The fabric from finishing is inspected in this section before
delivering it to the Warehouse. The fabric is received by the Inspection
Department and checked on perches to inspect the fabric on both the sides
and putting flags on the defective portions. The Cloth Inspector puts two
types of flags (yellow & white colour thread) on the selvedge indicating the
defective portion of the fabric.
Yellow flag :
The yellow coloured flag indicates major defects like hole, loom
repair, yarn bar, lever missing, float bunch and patch etc. The yellow flag
indicates to cut the fabric at that portion.
White flag:
The pieces which require remending, are tied with white tags and
with relative details and sent to Mending Department. Not O.K. pieces
which require re-processing are tied with yellow tags with relative details
and sent to Finishing Section.
Cutting Instructions ;
Process Damage :
The fabric which got damaged in process and which is not
saleable in thans, suit lengths, coat lengths or pant lengths is shown to the
committee and a record is kept of them. These are sent to the Warehouse
with a damage stamp on them.
WAREHOUSE
The material from Inspection Department is received in Warehouse
and a record is kept. The badly finished or wrong product is sent back to
Finishing for reprocessing with a note after recording the same in records.
Then the material is kept on racks according to the quality (after sorting for
quality)
The Procedure :
After printing the challan, the material is checked with the challan
for :
♦ Quality
♦ Shade
♦ Length and weight
♦ Road transport
♦ Railways
♦ Messenger delivery
♦ Post parcel
♦ Through courier
♦ Air cargo
Q.C. LABORATORY
Some of the important tests which are carried out in Q.C.LAB are briefed
below :
BLEND (Composition):
Chemical tests are used to find out the blend of the fabric. One ingredient is
dissolved in the chemicals and the residual is dried and wighed, which in
turn gives the percentage of ingredients. Thus, the blend or composition is
found by chemical testing.
This test checks the staining effect of the product. The fabric to be tested is
sandwiched in between light shaded fabric in the machine and the staining
effect is tested.
BREAKING STRENGTH:
The breaking strength of the fabric is tested in this test. The sample of the
fabric to be tested is fitted into the machine and the fabric is pulled from
both the ends and the breaking strength is noted by recording the point
where the fabric breaks. A minimum limits is fixed as per standards and
the results are matched to the fixed standard and report is prepared.
SEAM SLIPPAGE :
In this test, the fabric is stitched at one end and the breaking strength of the
fabric is noted around that end. The machine used in the breaking strength
test is used in this test and the procedure is also almost same.
The colour fastness of the fabric is noted in this test and the sample is tested
for the extent it loses colour in the test.
SHRINKAGE:
The shrinkage property is tested in this test. The fabric of different blends
are tested by different methods e.g. All wool is tested for shrinkage by
soaking it in cold water only.