Process Control in Cotton Mixing

 Process Control in Cotton Mixing

These two lectures answer the following questions:

1. How can I decide about cotton mixing for denim.

2. How can I decide about cotton mixing for making knitted fabric.

3. What is information required for an optimum cotton mixing.

4. What is an ideal cotton mix.

5. What are the steps to create an optimum cotton mix.

6. What are the four components of yarn quality. How each of these is
affected by fiber quality.

7. What values of yarn quality parameters can be obtained from a cotton mix
of particular fiber attribute.

8. For some pre specified values of yarn characteristics, what are the average
values of fibre attributes that we should in cotton mix.

9. What are the various problems due to cotton mixing vairations, case study
of fabric barre.

CONSULTING

SCOPE OF CONSULTANCY
The Scope of the consultancy could cover one or several of the below
mentioned areas as per mutual agreement.

1)NEW PROJECT MANAGEMENT

2)OPERATION PROCESSES AND PRODUCTIVITY ENHANCEMENT
3)QUALITY ASSURANCE
4)NEW PRODUCT DEVELOPMENT
5)VENDOR DEVELOPMENT(OUT SOURCED YARNS)

NEW PROJECT MANAGEMENT

1. Assistance in planning production output, and machinery balancing with

plant personnel and machinery suppliers.
2. Selection of machinery and finalizing layout for smooth material and men
movement.
3. Co-Ordination with civil (structural), H plant and WCS suppliers, and
machinery suppliers for technical specification finalization.
4. Complete Planning and erection of machines as per agreed upon time
bound plan.
5. Successful commissioning and hand over of the plant.
6. Optimization of process parameters for achieving the required quality.
7. Assistance in requirement of workers and their training(optional at
additional cost)

OPERATION PROCESSES AND PRODUCTIVITY ENHANCEMENT

1. Review of current productivity at all stages and suggestion to improve

the same.
2. Review of manufacturing cost and help optimize the same.
3. To review machine utilization in all departments and suggestions to
maximize the same.
4. Manpower allotment review and suggestions to right size the same.
5. Review of maintenance practices, replacement schedules, and
maintenance cost.
6. Energy consumption study at various departments and suggestions for
savings.
7. Review of process parameters at all stages of manufacture and
optimization of the same based on the test results, and
intermediate/yarn/fabric quality. These include production speeds, settings,
and methods of operation.
8. Machinery Audit of all machines types in various departments
9. In depth study of process wastes and help minimize them. (Yarn
Realization, Hard Wastes, Fabric Wastes).

QUALITY ASSURANCE

Raw Material:
1) Assisting in selection of cotton and optimization of mixings based on
fibre properties and yarn quality required.
2) Continual review of cotton properties, based on requirement for optimum
mixing cost.
3) Assisting in conducting various cotton mixing based trials to arrive at the
most optimum cost of mixing
4) Suggestions to modify the machine sequence/process parameters to
achieve the same.

Quality Systems:

1. Review of quality systems adopted, including various testing, audits and

studies, their frequency, and points of observations.
2. Observations of various processes for proper working (for ex., Loom stop
marks study, winding cuts study, etc).
3. Review of standards adopted for incoming materials (including packing
materials), in-process intermediate products, and final products and
customer’s requirement.

Fabric quality/Packing:

1) Improvement in fresh fabric quality through vigorous analysis of defects,

review of process at the concerned affected departments, initiating
necessary actions to over come the same.( Aim is to achieve 90% first
quality fabrics)
2) Specific attention to be given to rope based denims, and new products.

Customer complaints resolution:

1) In depth analysis of customer complaints and help in resolving the same

with active support to marketing.
2) Corrective and Preventive actions to ensure that the problems do not re-
occur.

NEW PRODUCT DEVELOPMENT

1. Development of New products based on different fibers, spinning

methods, and processes.
2. Process stabilization in all departments during commercial run of new
products.
3. Feasibility study of the products in manufacturing, review of fabric
properties as well as ability to produce the new products on continual basis
with excellent fresh packing before launch.
4. Objective co-ordination with the Production as well as Marketing
departments for launching of new products

VENDOR DEVELOPMENT

1) Third Party Audit of yarn suppliers to review the present condition of

machines and Process parameters and mixing quality used.
2) Review and suggestions to improve the performance of their processes
as well as yarn quality as per mill’s requirement.