ETHIOPIAN TEXTILE DEVELOPMENT

INSTITUTE

Textile Industry Development Institute

2014
PURPOSE OF QUALITY CONTROL
The purpose is how to control quality
parameters’ of spinning mills at every stage of
process from raw material to packing for
producing best quality yarn to meet customers
satisfaction. Now let us understand the
following:-
I. Meaning of quality---Conformity to
requirement
II. How it. is achieved---By prevention
III.What is the standard---As benchmarked
IV.How it is measured----By non-conformance
WHY WE SHOULD CONTROL QUALITY
The prime reason is to meet our customer
requirement of yarn or fabric at an economical
cost to enable mills to operate profit. The quality
control will help us
I. Reduce breakages and stoppages to maintain
high operating efficiency and work
assignment.
II. Reduce waste & seconds.
III.Use the least expensive raw cotton & fiber
IV.To take advantage of machinery capabilities of
speed, draft and package size.
 PROCESS CAPABILITY OF PROCESS
Any manufacturing process unit has a process
capability measured in terms of minimum
variability between individual units of
production,
Types :--
I. Natural variations
II. Introduced variation
Process capability is assessed by parameters
such as :--
I. The quality of raw material

II. The level of technology

III.Mechanical condition of the machines

IV.The competence and the commitment of the

personnel
Continuous improvement in the above
parameters will improve the capability of the
process by way of reduction of minimum
variability. As a result Management will achieve
optimum techno-economic advantage leading to
customer’s satisfaction, market capitalization and
great satisfaction to mills personnel and enhance
their confidence level.
THE NATURAL FIBER COTTON
Cotton is the most important natural cellulosic
fibers. Cotton fiber grows in the seed hair pod
(ball) of cotton plant grown & cultivated in
warm climates. Cotton is very nearly pure
cellulose.
Physical Properties: Cotton is a strong fiber
having a tenacity of 2 to 5gms/denier (18 to 45
gms/tex).Wet cotton is about 20% stronger than
dry cotton.
THE NATURAL FIBER COTTON
Cotton breaks at an elongation of less than10% and elastic
recovery of cotton are only 75% at 2% elongation. Cotton is
relatively stiff fiber. Its Specific gravity is 1.54 & the moisture
regain is 7 to 9%. At 100% relative humidity, cotton has
25~30% moisture absorbency. Charges of static electricity do
not build up readily on the cotton clothes.
 End use – It is a versatile fiber & its application is wide.
Cotton fabrics feel cool in wearing & due to its good
moisture absorption nature it is used for under wear of
men’s & women’s, clothing, sheeting, furnishing, yarn,
thread, rope, surgical & many other industrial purposes.
 It can be blended with viscose, polyester, jute fiber for the
production of shirting, suiting, garments & furnishing
including carpets, up holster & many industrial purposes.
CLASSIFICATION OF COTTONS BASED ON
2.5% SPAN LENGTH VALUES

S.NO Class 2.5% Span length mm

1 Extra long staple 32.5&above

2 Long staple 27.5 to 32

3 Medium long 25.5 to 27

staple
4 Medium staple 20.5 to 24.5

5 Short staple 20.0 & below

THE QUALITY OF RAW MATERIAL
(COTTON)
Sampling:- Ideally each cotton bale should
undergo to the following tests which is
collectively called as ‘Bale Management’ and it
is must to sustain in export market. In case it is
not possible, we are to select bales randomly
from a lot as given hereunder & collect samples
from 3 or 4 places of a bale. This is called Lot
Management
SAMPLING PROCEDURE FOR SELECTION OF
BALES FROM A LOT

S.NO Lot Size Bale Sample Size

1 Upto 50 2

2 51 to 100 4

3 101 to 150 7

4 151 to 300 12

5 301 to 500 20
Selection:-
• The most important fiber quality is fiber
length. The other qualities are fiber strength,
fiber fineness, maturity & colour.
 The selection of cotton is of prime importance. A
table is furnished below with examples as
guidelines along with testing
instruments/accessories needed

Sr Instrument 2.5% span 50% span UR Colour Micronaire

1 HVI with 29mm 13.7mm 47 Ivory 4.0

to colorimeter

10
GUIDELINES
1. Longer Staple Length: - If the fiber length is longer, it gives stronger
yarn. Also it produces finer count yarn which will fetch higher prices.
2. More bundle strength:- Stronger fiber gives stronger yarn & higher
productivity can be achieved as processing speed can be higher.
3. More trash:- Higher percentage of trash will increase waste % in Blow
room & card . It will cause less yarn realization & causing financial loss.
4. Less Maturity :-Immature, weak, neppy cotton creates more
imperfections in yarn. Also it may cause dye variation in fabric & more
end breakages in spinning.
5. More honey dew:- Higher sugar content will create stickiness of fiber &
create processing problem ,licking in the machine.
6. More moisture:- If the cotton absorbs more moisture it becomes wet. It
causes loss of yarn realization.
7. Less uniformity ratio:- If the uniformity ratio is poor, uneven yarn may
be produced & more end breakages. This may lead to reducing
productivity & profitability.
VALUE RATING

Uniformit Microna
Maturity
S.NO y Rating ire Rating Rating
value
Ratio% Ug/inch
1 50 Good 3 Fine 0.80 Good
2 45 Average 4 Averag 0.75 Averag
e e
3 43 poor 5 Coarse 0.65 Poor
FIBER STRENGTH

Pressley Stelometer
S.NO Rating
1000 lbs/sq.in Gms/tex

1 75 30 Good

2 60 24 Average

3 45 18 Poor
 COTTON TESTING INSTRUMENTS
Bundle Cage Maturit Honey Moisture Nep
Tests---- Trash%
strength loss% y% dew% % count

Electroni
Trash Trash Chemica AFIS
Instrumen Stelomet Flow c
analyze analyze l nep
ts er meter Moisture
r r analysis tester
meter

Sr nos

1 ,2,3,4
24 4 1.2 81 0.75 7 70
up to

10
CONCLUSION

From the above test results Management shall

decide which lot of cotton will be suitable to the
industry for taking mixing of spinning for
particular count considering techno-economic
advantage/disadantage
 BLOW ROOM

A) Total Cleaning Efficiency% of Blow room line = Trash in mixing—trash in chute x100
Trash in mixing

B) Individual beater-----This is important to know each beater’s contribution in the Blow room line.
INSTRUMENT TRASH ANALYSER
S. no. Cleaning points/beaters Cleaning eff% Good fibre loss

1 Uniclean 15-20
2 Unimix 15-20
3 ERM 25-30
4 Step cleaner 30-35
5 Axi flo 15-20
6 Uniflex 15-20
7 Saw tooth opener 25-30

Trash Allowable in Cotton Mixing for Producing Good Quality of Yarn

20s =5% 30s=4% 40s=3.5% 60s=3% 70s=2.5% 80s=2%
Trash% in cotton or sliver can be checked by Trash Analyzer
BLOW ROOM
CLEANING EFFICIENCY

No of beating Cleaning
S.NO Trash% in cotton
points Efficiency
1 5.1& above 5 60
2 3.1 to 5 4 55
3 1.0 to 3.0 3 50
i) More the trash, more the cleaning efficiency % of
blow room
ii) In modern Blow room care has been taken by
manufacturers to remove maximum trash
without damaging fibre, and without loss of good
fibre.
iii) Blow room cleaning efficiency 50 to 60 % seems
alright.
iv) Individual cleaning efficiency of beaters ranges
from 15% to 25%
v) Total waste dropping in blow room = same
percentage of trash, that is if trash is 4%, dropping
should be 4%.
vi) filter room loss (micro dust) should be 0.7% to
1.0% apx
WASTE % IN CARDS

Licker
S.N Type of in Flat
Mixing Others Total
O card droppi strips
ng
1 20s to VHP 2.0 3.5 1.5 7.0
40s
2 Above VHP 1.8 3.0 1.2 6
40S
1. Card waste---If individual study is possible
then it should be taken—It should be 5-7%
2. Card to card waste variation should be +_0.5%
3. If the above is not possible then overall waste
% should be taken.
4. Card cleaning efficiency is 85~92% &
combined cleaning efficiency is 93- 98%
 If fibre rupture takes place in any beater or in
card there will be deterioration in quality
leading to bad working in RF and OE causing
poor yarn strength.
 So it is advisable to check fiber rupture study
to all individual beaters of Blow room and as
well as in Card
 2.5% 50% UR
Sr Beaters
span span %
1 Uniclean
2 Unimix
3 ERM
4 Step
cleaner
5 Axi flo
6 Uniflex
1 to Card
6
Note:
• If 2.5 % span length is dropped by 4% or more
compared with that of mixing then fibre rupture could
be suspected in blow room.
• In that case it is required to recheck settings,
speeds, material transport fan blade condition, fan
speed. To Change some of the parameters and to
take trials.
• Possibility of more immature fibre in mixing.
• Very dry cotton used without conditioning.
• In card, very close setting between feed plate and
licker results fiber rupture.
• Carding is the ‘Heart of Spinning’. So good quality
sliver produced means ‘Half Spinning’ has been
achieved.
TRASH IN CARD SLIVER

Trash % in mixing 2.0 to 3.4 3.5 & above

HP Card 0.15 to 0.4 0.25 to0.5

VHP Card 0.10 to 0.35 0.07 to

0.30
NEPS IN CARD WAVE

Mixing Good Average

20s to 40s 50 75
50s & finer 75 100

Neps in mixing ,chute, card sliver & combed

sliver can be measured in Afis Tester
 COTTON REQUIRES PRODUCING GOOD QUALITY OF YARN.
CARDED YARN

Length Micronaire Uniformity Strength

Count
(mm) value ratio % (gms/tex)
20s 26-28 mm 3.8-4.2 47 18
30s 27-29 mm 3.8 -4.0 48 22
40s 29-31 mm 3.8-4.0 48 24
60s 31-33 mm 3.6-3.8 48 26
80s 32-34 mm 3.4-3.6 49 28
COMMON QUALITY TESTS ON
MATERIAL/PRODUCT
• These are common to mostly all the
sections except Blow room .The probable
reasons for ‘out-ranged’ values are given
along with the table in the form of
‘Analysis .It will help the department
personnel to rectify/trouble shoot the
problems
A) Wrapping & CV by Wrap Reel. Wrap Block &
Auto sorter [ Sliver to yarn all types]
B) Evenness & hairiness by Evenness Tester attached
with hairiness module[Sliver to yarn all types]
C) SingleYarn strength (R.K.M) by Tensorapid [All
types of yarn]
D) Classimat tests by Classimat Tester [All types of
yarn]
E) Yarn Appearance Test by Yarn Appearance Board
F) Twist Test by Twist Tester
G) Elongation of yarn is test by Tensojet
WRAPPING BY AUTO SORTER
Nomina
Actual
Sr Section Schedule Sample size l Ct CV%
ct
ct
1 Card All cards once 5 yds x 10 sliver
daily
2 Draw Frames All D.F every 2 5yds x 10 samples
Br hrs
3 Draw Frames All D.F every 2 5 yds x 10 samples
Fr hrs
4 Combers All combers once 5 yds x 10 samples
daily

5 Speed Frames All S. Frames once 15 yds x10 samples

daily
6 Ring frames All R.Frames once 120 yds x 10
daily samples
6 Open End All OE once daily 60 yds x 10
samples
7 Auto Coner All counts once 120 ydsx10
daily samples
ALL M/CS ARE MOST MODERN –SO BE SURE ON DATA – FEED
INTO M/C, IF FOUND OK THEN THE FOLLOWINGS HOLD
BETTER
I. Card wrapping variation –check blow room feeding—chute
feed 80% on & 20% off
• Unimix empty, lay down empty, some problem in
autoleveller in individual card
I. Draw frame breaker—normally more card variations create
problem on breaker draw frame. Correct card variation first,
check top roll pressure, sliver entry, stop motion etc
II. finisher Drawing---If breaker is erratic, it reflects on
finisher---correct breaker, check Auto leveller, scanning
roller, top roller pressure, sliver entry, stop motion etc
III. Roving;:--Top roll pressure, stretching, and bad sliver from
finisher drawing.
IV. Ring frame.-Top roll pressure, roving stretch on creel, Auto
coner and TFO has nothing to do with count variation, if
found by chance-check RF and back machines
EVENNESS BY EVENNESS TESTER WITH SPECTROGRAPH
ATTACHED WITH HAIRINESS MODULE
Sample
Sr Sec Schedule U% CV% Thin Thick Neps Hairiness
size
1 Card Once daily As per NA NA NA NA
Tester

2 DF-br Twice --do-- NA MA NA NA

daily
3 DF-fr Twice daily --d0-- NA NA NA NA

4 SF Once daily 5 NA NA NA NA
bobbins
5 RF 6 machines 10
daily bobbins
6 OE 2-m/c daily 10
cheeses
7 AC Weeky 10cones

8 TFO Weekly 10
cheeses
ANALYSIS
• Card---high U%--Check Blow room feed, jerky
chute & card feed roll, any lapping anywhere,
damaged wires specially doffer, redirecting roll,
calendar roll, damaged apro doff belts, pulleys
• Breaker drawing—high U% --check types of card
sliver, damaged/eccentric top/bottom rolls,belts
.Analyze spectrograph and conclude and take
action
• Finisher-Drawing:-Same as breaker also check
auto leveller A%.
• Roving—Check the sliver fed, top arm,top/bottom
rolls.aprons, false twister, gearings, belts, also
analyze spectrograph. Also check Stretch % in
roving
ANALYSIS
• RF—a) high U%--check any mechanical fault,
like rollers, aprons, cots, nose bar, spliced bottom
aprons, wide spacer, quality of roving as well.
High imperfections—normally card & other
preparatory machines contribute more of these
Good draft zone cleaning daily by over head
cleaner and operator with hand pickers keeps
imperfections under control. Also top roller
clearer cleaning by Roller Clearer Cleaning
machine.
• OE :- High U %--check feed roll, feed plate lap,
opening roll damage ,take up roll cots ,naval,
draw tube etc. check sliver ,condenser etc
ANALYSIS
 Auto coner—Normally Autoconer increases
U% , imperfections & hairiness, it only
reduces objectionable thick and weak/thin
places in the yarn. By trials mills to come to a
limit where action can be taken against any
sort of mechanical fault on m/c drum, yarn
passage etc.
 TFO---U% & imperfections normally 75% of
ring yarn and , if more then check mechanical
condition of machine parts.
UN EVENNESS STANDARD
Type of sliver U%
Card sliver 3.5
Drawing slivrer with Auto
2.0
leveler
Drg sliver without Auto
leveller 2.5

Roving combed 4.0

Roving carded 4.5
100% COTTON KNITTED YARN CARDED & COMBED

40sC 30S
Count 20s/1KH 30s/1KH
H CH
Count cv% 1.2 1.2 1.3 1.2
U% 9.5 10 1O 9.0
Total IPI 80 110 75 40
RKM 16 17 18 18
Elongation 5.7 5.35 5.2 5.0
Hairiness 7.5 7.0 5 3.5
 YARN ELONGATION TEST BY TENSOJET, CSP BY LEA STRENGTH
TESTER & SINGLE YARN STRENGTH BY TENSORAPID

CV
Lea 120 Single yarn Elong
% of
yds CV breaking ation
Sr Sec Ne CSP RKM CV% elon
Breaking % In gms (100 %
gatio
in lbs cops)
n
1 RF
2 OE
3 AC
4
5
6
 YARN CSP FOR WARP COUNT

Carded Count Good Average Poor

20s 2050 1850 1650
30s 2200 2000 1800
40s 2250 2050 1850
Combed 30s 2050 1850 1650
40s 2050 1850 1650
60s 2100 1900 1700
RKM VALUE

50% Fiber Micron

Averag
Count Good Poor span strengt aire
e
length h value
20s 16 14 12 13.5 19 4.4
30s 16.5 14.5 13 15.2 21 4.1
40s 17 15 13 15.4 22 3.8
YARN TEST BY CLASSIMAT TESTER
SAMPLE SIZE > 100 KM

Total
Tota Tota Total Thick
Thin
M/ l l Objectionable
Sr Sec Ne Objection Remarks
C Thic Thi A4,B3,B4,C2,C3,C4,
able
k n D2,D3,D4
H2,I1,I2
1 RF

2 OE

3 AC

4
CLASSIMAT FAULT /100 KM

Count range Short thick fault Long thick fault Long thin fault
Carded _______________ _______________ ______________
A B C D E F G H I
15_25 700 70 20 5 4 10 4 1070 15
35_45 2300 200 25 4 2 5 2 450 6
55_65 6300 300 30 6 4 12 4 740 16
COMBED YARN

Yarn Appearance Test-----It needs a board

winder, black boards, ASTM photographs of all
grades Yarn is being wound on these boards
parallely by winder and compared ‘visually’ with
ASTM boards photo and graded accordingly
Sr no Section Grade- Grade-B Grade Grade
A -C -D
1 RF

2 OE

3 AC

4 TFO
TWIST TESTING— BY YARN TWIST
TESTER
Sr Sec Sample Mechanica Actual Remark
size l
TPI
1 RF 10
bobbins
2 TFO 10 cones
3 Doubl 10
e yarn bobbins
Common Studies on m/cs and Process:-

A) Snap study & working efficiency %

B) End Breakage % study cause wise

C) Idle spindle % study cause wise

D) Material content study

Snap study - two hourly one round—for 8 hours/
every shift Date………..
Here the observer should note down whether m/c is
stopped or working. Stoppage to be noted reason wise:-
Like maintenance, breakdown, operator attending,
cleaning etc
Efficiency
Sr Sec 8.00am 10.00am 12.00 am 2.00 pm 4.00 pm 6.00 pm
%
1 Blow room
2 Card
3 DF—Br
4 DF—Fn
5 SF
6 RF
7 OE
8 AC
9 TFO
10
 BREAKAGE STUDY FORMAT –REASON-
WISE
Speed Frame
Breaks no. of % breaks/100
Sr Reason for breakage Remarks
times spdl hours
1 Sliver run out
2 Undrafted
3 Slubs
4 Between nip & false
twister
5 Between arm
6 Between press finger &
bobbin
7 Floating fluff
8 Too tight roving tension
9 Too slack roving tension
10 Bad sliver joint
11 Others
Total breaks
END BREAKAGES STANDARD IN FLY FRAME

Breakages/ 100
Count
spindles/hr
20s to 39s 5%

40s to 59s 4%

60s & above 3%

RING FRAME:-BREAKAGE STUDY FORMAT
TIME
START………….END………….DURATION…………DATE…………M/
C NO……..
% of breakage/100
Sr Reason of breakage No of times Remarks
spdl/ hour
1 Roving run out
2 Slubs in roving
3 Lapping top/bottom roll
4 Bad top/bottom roll
5 Lappet,ring,bc ring off centre
6 Traveller fly out
7 Traveler clearer too close/wide
8 Low tension balloon collapse
10 High tension
11 Undrafted roving
12 Thin yarn
13 Thick yarn
14 Floating fluffs
15 Others
16 Unknown
Total
Note:- Once in a month full doff breakage study of a
ring frame should be taken to ascertain traveller
selection. At different doff position breakages to be
noted e.g. 1/4,1/2,3/4 & full position.
i) More breaks at the start--------lighter traveller---
yarn breaks due to balloon collapse.
• More breaks at the end -----------heavier traveller
–more yarn tension
END BREAKAGES STANDARD IN RING FRAME

Count 40s Breakages/ 100

spindle/hr
20s to 39s 4%

to 59s 3%

60s above 2%
 OPEN-END BREAKAGE STUDY FORMAT
% breaks/100
Sr Reasons No of times Remarks
Rotor/ hour
1 Sliver run out
2 Entangled sliver
3 Thick/thin sliver
4 Feed/opening roll lap

5 Suction tube blockage

6 Take up roll danaged

7 Thick yarn
8 Thin yarn
9 Foreign fibre
10 Trash in yarn
11 Soft yarn
12 Bad sliver joint
Total

Done By……………………………….Rogue Rotors nos………………………….

End Breakages Standard in Rotor Spinning
 End
Mixing
breakages/100spindle/hr
Waste cotton 50%
100% Virgin cotton 20 %
 TFO BREAKAGE STUDY FORMAT
% breaks/100
S.No Reasons No of times Remarks
spdl hours
1. Cheese run out
2. Single yarn
3. Lappet hook off
centered
4. Pressure capsule wrong
5. Spindle tape damage
6 Jockey pulley off
centered
7 Drum pullet damaged
8 Balloon collapse
9 High tension
Total

Done By………………………………………..
TFO END BREAKAGES STANDARD

TFO End Breakages Standard

Parameters Good Average Poor

Breaks/100 spindle/hr 10 15 20
Twist variation ( cv%)
3 4 5
cotton yarn

End breakages standard at cheese winding

Parameter Good Average Poor

Breaks/100 km 2 5 10
Auto corner Breakage

From the ‘Print-out’, at the end of shift, the yarn breakage report is revealed. Quality control dept
should note it down in their breakage register. In ideal condition it should be around 60 per 100 km of
yarn cleared. The clearer setting has also a great impact on yarn breakage.
Closer clearer setting gives adverse working in warping/sizing/weaving.

Winding breaks standard

Parameters Good Average Poor

Clearer cuts/100 km 50 90 150
Rewinding breaks 2 4 7
Std Speed Frame idle spindle = Nil
Date…………….Time start…………End………. M/c nos………………..

Sr Cause Nos % Idle spdl Remark

1 Sliver shortage
2 Damaged top/bottom aprons
3 Damaged nose bar/spacer
4 Damaged condenser
5 Damaged false twister
6 Damaged top/bottom roll
7 Damaged flyer/press finger
8 Other mechanical problems
9
Total

Done by………………………………..

Std Ring Frame Idle spindle = 0.1%

Idle spindle format in ring frame

Date……………….Time start…………End…………….M/cs nos……………..

Sr Causes Nos % Idle spdl Remarks

1 Roving run out/bobbin holder
Dmaged/missing parts
2 Roving condenser
3 Top/bottom aprons
4 Top/bottom rolls
5 Nose bar/spacer/suction tube
6 Lappet/hooks
7 BC rings/separator
8 Rings
9 Traveller clearer
10 Finger brake
11 Spindle tape
12 Jockey pulley
13 Drum pulley
14 Spindle/bolster
15 Traveller fly out
16
17
Total
Done By…………………………………

Std Open End Idle rotors = Nil

Idle spindle format in open end

Date……………Time start………..End………….M/c mos……………

Sr Cause Nos % Idle rotors Remarks

1 Run out/entangled sliver
Damaged/missing parts
2 Feed plate/roll
3 Opening roll/rotor/naval
4 Take up roller cots

5 Cradle adaptor
6 Traverse guide
7 Signal lamp
8 Push nutton
9 Others
Total
Done by………………………

Std Auto corner Idle Drum =Nil

Auto corner idle spindle format

Date……..Time start………..End…………..M/c no

Sr Reason Nos % Idle drums Remarks

1 Elec/mech problems
magazine
2 Problems in splicing unit
3 Damaged drum
4 Cradle/adaptor
5 Others

Total

Done By…………………………….

Std TFO Idle Spindle = 0.1%

TFO Idle Spindle format
Date…………Time start…………….End………………M/c no

Sr Reasons Nos % Idle spindle Remarks

1 Cheese run out
Damaged/missing parts
2 Pot/flyer
3 Pressure capsule
4 Lappet hook
5 Seperator
6 Traverse guide
7 Package adaptor
8 Cradle
9 Spindle tape
10 Jockey pulley/drum
Total

Done By………………………………
Can / Bobbin content study

Quality control department can find out the incidence of over filling or under filling of cans and
bobbins by using some formula which is guideline.
2
i) Can content in Kg………… .1.5 X height of can X Diameter of can ( In inches)
1000
2
ii) SF bobbin content in Kg………….3 X Lift X doff diameter squire (In inches)
1000
2
iii)RF bobbin content in grames…….3.25 X Lift X ring diameter squire (In inches)
Mechanical condition of machinery

i) To achieve higher and higher quality standard, the mechanical condition of the machinery
should be up to the mark.
ii) This is done by good maintenance practice of spinning dept as well as the engineering &
utility dept.
iii) A good maintenance practice is highly dependent on spare parts procurement. The
management should focus on it.
iv) Above all a good team work and cooperation between responsible departments can do a
splendid job.
COMPETENCE AND COMMITMENT OF
PERSONNEL
i) This is the ‘Human capital’. A training dept.
has been provided to enhance personal
competence.
ii) Quality control dept.is also included in that.
They also need training time to time & job
rotation.
iii) The proficiency of quality personnel like
observer, examiner, lab asst. is very important
to provide management impartial and true
quality reports,
THE QUALITY CONTROL DEPARTMENT

The followings are basic needs of the dept.

i) Good quality control dept with sufficient
space for m/cs, instruments, and personnel
ii) Dress code for personnel

iii) Air conditioning at 65% relative humidity and

temperature 20 to 22 degree Celsius.
Quality checking plan

The following quality control activities are initiated in spinniang mills.

1. Mixing & Blow Room:-

a) Trash% checking of all lots of cotton from bales whenever it arrives in the factory go down
b) Neps checking of mixing once in a fortnight.
c) Cleaning Efficiency of Blow room & combined cleaning Efficiency once in a fortnight.

2. Carding

a) Wrapping of all cards once in a day.

b) Count cv% of wrapping
c) U% of card sliver once in a day
d) Trash% checking of all card slivers once in a fortnight.
e) Neps Removal Efficiency of all cards once in a fortnight.
f) Cleaning efficiency of cards once in a fortnight.
1. Draw frame

a) Wrapping of breaker &finisher draw frames every 2 hrs

b) CV% of wrapping.
c) U% of all Draw Frames once daily.
d) A% checking of all Auto leveller of Rieter Draw Frames once in a fortnight

2. Unilap

a) Wrapping once in a week

3. Comber

a) Combed sliver wrapping checking once in a day.

b) Combed sliver U% checking once in a day
c) Comber noil testing once in a week.
d) Neps Removal Efficiency of all combers once in a fortnight.
1. Speed frames

a) Wrapping of all speed frames once in a day.

b) CV% of wrapping.
c) U% of roving of all speed frames once in day.
d) Breakages of all roving machines once in a week.
e) Stretch % checking of all roving once in a fortnight

2. Ring frame

a) Wrapping of all Ring Frames once in a day

b) CV% of wrapping
c) TPI checking of all counts once in a fortnight
d) RKM of all Ring Frames counts once in a week.
e) RKM CV% once in a week
f) U% & imperfections of all Ring frames counts once in a week.
. g) Elongation of all Ring Frames counts once in a week.
h) Hairiness of all Ring Frames counts once in a week.
i) Breakages % of all Ring Frames once in a week.
ii) Idle spindle% of all Ring Frames once daily.
1. Autoconer

a) Wrapping of cones count wise once in a day.

b) U% & imperfection checking of cones countwise once in a week.

2. Open end

a) Wrapping of cones machine wise once in a week.

b) U% & imperfection of cones machine wise once in a day
c) RKM & Elongation of cones machine wise once in a week

3. T.F.O

a)Wrapping of cones count wise once in a day

b) U% of cones count wise once in a week.
c) RKM& Elongation once in a week.

4. Packing

a) Count wise 2 cartoons/bags/ one pallet checking every day.

1. Moisture regain by Xorella of all counts once in a week.

Some special jobs of Quality Control Department

i) Process improvement Trials----with due discussion with production & maintenance dept. the
QC should initiate trials to improve quality, by altering m/c parameters like-- speeds, settings,
drafts, using different accessories etc and the results to include it in monthly report.
ii) At least two sets of trial to be conducted every month. It does not matter if results are ‘bad.’
But if ‘good’ then it can be implemented in planned manner. Taking trials is a continuous
process. It makes the people more technology oriented and makes the job interesting.
iii) Time and motion study-----to be carried out regularly on operators, maintenance staffs, packing
staffs etc
Ring frame pneumafil suction pressure—by water manometer---normally maintenance forgets, ignores
it.So time to time all the Ring frames to be checked at gear end/middle/suction end to be recorded and
reported to maintenance to attend if suction is low
WEEKLY, BI WEEKLY & MONTHLY QUALITY REPORT

A format to monthly report is shown below. The QC dept

should compile if from day to day, weekly & bi weekly
test reports. A monthly quality meeting should be held
with the management along with production,
maintenance, engineering, HRD personnel. The meeting
should be effective/friendly & not a fault finding tool.
The departmental personnel should take the report
sportingly and promise a time frame to rectify the faults
observed from the reports and improve upon it.
 Month Jan Feb March April May June July August Sept Oct Nov Dec

Count
Count cv%

RKM
RKMcv%
Elongation
Elongation cv%

Hairiness
Hairiness cv%
U%
Thin places/km

Thick places/km

Neps /km
Total Imperfection

Ring line cotton length

OE line cotton length

Trash in cotton Ring

line

Trash in cotton OE lines