Project To Reduce Torn-Tear

Defect in Dyeing

Presented By :- Vipin kumar

Guided by :- Mr. Birendra Dey

HOD :- Mr. Neeraj Arya
Project Selection
DEFECT’S PROPORTION IN DOWNGRADE

LENO CUT
6% OTHERS
15% TORN
38%
PULL TERRY
7%

BOWING Torn / Tear defect is Highest

5% STAIN contributor (38%) in
29% process house downgrade

Data Source – Avg Downgrade of Year 2020

 Impact Of Tear Torn

Causes Financial
Hampers Lot’s Urgency & Losses
Deaminize “A”
Dispatches
Grade Quality

Reduces Grand Quality Index

BASELINE SELECTION :
Torn (No. of pieces)
Torn (%)
Nov-20 666
Nov-20 0.29

Oct-20 606
Oct-20 0.24

Sep-20 590
Sep-20 0.21

Aug-20 487
Aug-20 0.18
300 350 400 450 500 550 600 650 700
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35

AVG BASELINE % Pieces

TORN 0.23 587
TARGET SELECTION : 0.17 % (434 pieces)
As Per – PAST TREND :
TORN Peices (%) over 2 years
0.3
0.29

0.28

0.26
0.26
0.25 0.25
0.24 0.24
0.24
0.23
0.22 0.22 0.22
0.22
0.21 0.21 0.21 0.21 0.21 0.21
0.2
0.2
0.19 0.19 0.19 0.19
0.18 0.18
0.18

0.16
- 19 - 1 9 r- 1 9 r - 1 9 - 19 - 1 9 l-1 9 - 19 - 1 9 t -1 9 - 19 - 19 - 20 - 2 0 r- 2 0 r - 2 0 - 20 - 2 0 l-2 0 - 20 - 2 0 t -2 0 - 20 - 20
n b ay n Ju g p v c n b ay n g p v c
Ja Fe M
a Ap M Ju Au Se Oc No De Ja Fe M
a Ap M Ju Ju Au Se Oc No De

Best Achieved – 0.18%(Aug 19 & Aug 20)

TARGET SELECTION : 0.17 %
As Per – CALCULATION : Total Torn Contribution

Average Production Batches per day – 90 Batches ( Aprrox)

• Pieces damaged by Sample stage in Dyeing (1 sample 43
per Batch) – 90 Pieces % Uncontrollable
• No. of pieces damaged in Sampling at Drying Stage – 90 Controllable
pieces.
______________________________________________ 57
180 Pieces (Minimum) comprising %
upto 0.09 to 0.1 % (Among 0.23%)
 Total Torn Contribution

BASELINE – 0.23 %
43
% Uncontrollable (334 pieces)

57 Controllable (252 pieces )

%

Considering proportion
of 0.23 %
0.11 % 0.12%

Targeting 60% to
control out of it

0.06%
0.18 %
Approx. (450 pieces )
TYPES
OF Window Cut Torn Hole

TORN Leno cut

DEFECT
Jaali Wrong Stitching
 Window Cutting
PROBLEM ORIGIN
• For the Sampling purpose, Windows
are been cut from the ropes by the
weaving department.
• If the Windows are neglected during
the Dyeing process, Causes torn
continually.
REMEDY
• If Greigh department does not stitch the
window, it will continue torn in the
dyeing machine which will increase the
torn downgrade.
• Either, Greigh department must properly
stitch the filter fabric on window side to limit
the Towel to tear further.
• Or, Processing department will Stich the cut
window before unloading the material in the
dyeing machine.
 Jaali (In Tub-Mat material)

PROBLEM ORIGIN REMEDY

• Tub mate material posses high GSM.
• Special care must be taken in case of
• Due to improper unloading of wet
PROBLEM ORIGIN
ROBLEM ORIGIN RP lots.
material in trolley, material get
• For High GSM material-
overlapped over each other.
• Keeping MLR ratio High
• During the feeding in softening process
• Winch speed – 75 m/min
on padder, Sudden pulling occurs In Tub-mat Material
(as per GSM)
causes tension and jaali is been
• Proper unloading of Wet material.
formed due to its own weight.
Action Plan :
Excess Dosages of Bio-polishing Chemical
• Excess Dosage of Bio-polishing increases the Torn easily.
• Now the Concentration of Bio-polish is reduced in all qualities to reduce the chances of torn.
QUALITY BEFORE (%) AFTER (%)

NORMAL 0.15 % 0.12 %

PVA / ZERO TWIST 0.13 % 0.08 %

WHITE 0.15 % 0.12 %

TUB-MAT 0.11 % 0.04 %

Product Mix size (Tub-mat & Towel size in same plan)

• For the Parties like AUCHAN & SAINSBURY, Mix sizes were planned (Towel & Tub-mat together)
• For such plan to avoid torn, We have dyed both the sizes diffrently and reduced the chance of
Torn to be occurred.

W E L S P U N
Action Plan :
Excess Tension on the Rope opener (For High GSM)

Generated new SOP of doing softener in

the dyeing machine itself for Tub-Mat &
High GSM material.

For the Tub-mat & High GSM material, Excess pressure

on rope is created due to its own weight in wet
condition which causes JAALI

W E L S P U N
SOP’s For
TUBMAT Dyeing

Meeting Awareness

W E L S P U N
 SELVEDGE CUT
PROBLEM ORIGIN Remedy
• This Problem is mainly
Observed in Shearing &
Stenter Section area • To prevent this torn, Leno edges

• Due to Clip & Pin holding on must have good strength.

the edges of the material • Avoid extra tension on the

causes Torn on the towel. fabric, wherever possible.

• Sometimes due to loose leno • Fabric must not come in contact

on the selvedge, The structure with Nuts or Pointed nooks

gets open from the edge side during its cycle run.

due to raveling of the yarns.

• Due to excessive tension on
width of material by pins
causes torn holes on edges.
 • TORN HOLE Remedy
PROBLEM ORIGIN

• This torn can occur at • Avoid unnecessary

any stage by contact of material contacts.
material with Pointed/ • Scheduled checking of
Elevated machine parts machine parts
or storage equipment.
Continuation of Torn occurred from Grey Damaged Trolley

WEILDED & PAINTED TROLLEYS

Damaged Machine parts -
Material Used to Stuck between Unloading winch & Supporter. With the Help of engineering team, This
problem resolved & Now this problem is less Occurring .

More Space between Unloading Narrow space between Unloading Winch &
Winch & Motor Supporter Motor Supporter. Causing less chances of Torn
while unloading

W E L S P U N
 LENO CUT / BREAK
PROBLEM ORIGIN Remedy
• Due to improper
condition(alignment) of pins
• High strength leno yarns
of stenter
must be used to
• To avoid unraveling of yarns
overcome this problem.
from selvedge, Leno yarns
• Avoid unnecessary
are used on edges of
abrasion on ropes in grey
selvedge which binds with
issuance , Dyeing &
ground warp.
Drying.
• Due to abrasion with Faulty
• Time to time preventive
metal parts in the towel
of stenter
fabric, leno gets damage and
yarns from selvedge end
starts to unravel.
Action Plan :
Neglecting Provided SOP’s
• Taking scheduled meeting with floor executive to let them aware about the SOP’s

Multiple sample cutting

• SOPs are been made for cutting all the samples from the same rope & same towel up to
possible extend.
• For the Tubmat material, Round shape sample cutting are indtructed.

W E L S P U N
MONTH TORN %

DEC-2020 0.29 TORN %

0.3
JAN-2021 0.22

FEB-2021 0.27 0.25

MAR-2021 0.20
0.2
APR-2021 0.20
0.15
MAY-2021 0.19

JUN-2021 0.17 0.1

JULY-2021 0.16
0.05
AUG-2021 0.24
0
SEP-2021 0.17 Dec-20 Jan-21 Feb-21 Mar-21 Apr-21 May-21 Jun-21 Jul-21 Aug-21 Sep-21
 FINANCIAL IMPACT
MONTH TORN % BASELINE DIFF. % PACK PROD. RATE IMPACT IN RS LACS
DEC.2020 0.29 0.23 0.06 2500 267 -4.01 12 lakh Rupees
JAN.2021 0.22 0.23 -0.01 2500 267 0.67 Saving
FEB.2021 0.27 0.23 0.04 2500 267 -2.67 • Average Reduction
per Month=0.02 %
MAR.2021 0.20 0.23 -0.03 2500 267 2.00 • Average Packing
APR.2021 0.20 0.23 -0.03 2500 267 2.00 Production=2500 MT
MAY.2021 0.19 0.23 -0.04 2500 267 2.67 • Difference in price
btw. A-Grade to D-
JUNE.2021 0.17 0.23 -0.06 2500 267 4.01 Grade towel=267
JULY.2021 0.16 0.23 -0.07 2500 267 4.67 Rupees
AUG.2021 0.24 0.23 0.01 2500 267 -0.67
SEPT.2021 0.17 0.23 -0.06 2500 267 4.01

AVG 0.21 0.23 -0.02 2500 MT 267 12.68