FAULT ANALYSIS

DIFFERENT FAULTS OF CIRCULAR KNITTED FABRIC

HOLE
 Theoretical Causes:
 1. Bad needles
 2. Broken needles
 3. Takedown mechanism too tight
 4. High tension on yarn
 5. Bad yarn
 6. Needles too tight in their slots
 7. Dial height too high or low
 8. Badly tied knots
 9. Needle timing set wrong
 10. Improper stitch setting
 11. Yarn threaded wrong
 12. Yarn too dry
 13. Weak places in yarn, which
break during loop formation Original cause
 14. Yarn feeder badly set Due to badly tied knots (T.C-8)
 Original cause Original cause
Needle break due to deposited dust (T.C-2) Needle break for slub (T.C-2)
 Original cause Original cause
Due to high tension on yarn(T.C-4) Weak places in yarn (T.C-13)
DROP STITCH
 Theoretical causes:
 Insufficient yarn tension
 Yarn jumping away from the needle hook
 Badly set yarn feeder
 Yarn feeder wrongly threaded in
 Bad take up
 Very dry material
 Dial loop length not properly

related to cylinder loop length .

Original cause
Latch of needle remains close.
So yarn jumps over hook. (T.C-2)
RUN
Theoretical causes
1.Broken needle
2.Damaged needle hook

Original cause Original cause

Due to needle break (T.C-1) Due to needle break (T.C-1)
NEEDLE LINE

 Theoretical causes:

 Broken needle
 Defective needle
 Dirt in needle slot
 Bad trick walls
 Needles too tight or loose in tricks
 Needles not getting enough oil
 Needles getting too much oil
 Bent needle
 Damaged needle latch
 Damaged needle hook
 Damaged dial or cylinder

Original cause
Due to defective needle (T.C-2)
THICK THIN PLACE

Theoretical causes:
*One feed of yarn being much coarser
than that normal to the fabric.
*One feed of yarn whose diameter is
noticeably smaller than that normal
to the fabric.
* High yarn tension.

Original cause
Due to Coarse yarn insertion(Thick place)
MISSING YARN
Theoretical causes:
1. Any yarn missing from a double yarn course from the same/similar positive feed.
2. Wrong yarn feeder setting.
3. Faulty positive feed system.

Original cause Original cause

Due to cotton yarn Missing (T.C-1) Due to spandex yarn missing (T.C-1)
OUTSIDE DIRT

Theoretical causes:

1.Because of foreign matter that is contamination

by some substance other than fibre.
2.Because of foreign fibre that is fibres
other than that common to a fabric.

Original cause
Deposited dust (T.C-2)
OIL MARK

Theoretical causes:
*Oil leakage
*Over lubrication

Original cause
Oil leakage (T.C-1)
 PRESS OFF
Theoretical causes:
1. If an empty needle (generally
after a drop stitch) with closed latch
runs into the yarn feeder and removes
the yarn out of the hooks of the
following needles
 2. Due to yarn breakage

Original cause
Due to drop stitch and empty needle
running into the yarn feeder(T.C-1)
Original cause
Due to yarn breakage
(yarn feeder was jammed by
deposited dust). (T.C-2)
KNOT
Theoretical causes:
 Badly tied yarn

Original cause
Due to badly tied yarn
(T.C-1)
Different Faults of Flat Bed Knitted Fabric
HOLE

Theoretical causes:
1. Bad needles
2. Broken needles
3. High tension on yarn
4. Bad yarn
5. Needles too tight in their slots
6. Needle timing set wrong
7. Yarn threaded wrong
8. Yarn too dry
9. Weak places in yarn, which
break during loop formation Original cause
10. Yarn feeder badly set
11. Badly tied knots Weak places in yarn, which break during
loop formation. (T.C-9)
Original cause
Due to badly tied knots & weak places (T.C- 11&9)
NEEDLE LINE
Theoretical causes:

*Broken needle
*Defective needle
*Dirt in needle slot
*Bad trick walls
*Needles too tight or loose in tricks
*Damaged needle latch
*Damaged needle hook

Original cause
Defective needle (T.C-2)

RUN
Theoretical causes:

1.Broken needle
2.Damaged needle hook

Original cause
Broken needle (T.C-1)
DROP STITCH

Theoretical causes:

 Insufficient yarn tension
 Yarn jumping away from the needle hook
 Badly set yarn feeder
 Yarn feeder wrongly threaded in
 Bad take up
 Very dry material

Original cause
Latch of needle remains close.
So yarn jumps over hook(T.C-2)
VERTICAL LINE (OIL MARK)

 Theoretical causes:

 Due to bad lubrication

 Defective mechanical or
automatic lubricating device

Original cause
Due to bad lubrication (T.C-1)
DEFECTIVE TUCK
Theoretical causes:
1.Insufficient sliding ability of yarn ( stiff yarn )
2.Defective needle
3.The course density is not set correctly

Original cause
Defective needle(T.C-2)
SIDE PROBLEM
Theoretical causes:
* Due to insufficient yarn tension
Carriage movement timing exceeds
*needle bed width

Original cause
Carriage movement timing exceeds needle bed width (T.C-2)
PLY MISSING

Theoretical causes:
** Yarn breakage

Original cause
One of the yarn is broken during knitting (T.C-1)