1. Process control of Weaving

2. Introduction : Process control is defined as a statistical & engineering tools or
discipline that deals with architecture ( structure ) , mechanism and algorithm
(sequence of finite instruction ) for controlling the output of a specific production
process . Quality is formed during production process . So, if a production process
is not controlled, the target production quality or reference parameter may not
achieved
INTRODUCTION

3. Process control is performed by six steps :
1. Step-1: Draw process flow chart showing real change in products geometry
2. Step-2 : Segregate or highlight the part of the flow chart where any change is
taking place
3. Step-3 : Find the set points or control points value at each step
4. Step-4 : Determine which output variables have gone out of the range of
standard / reference values beyond tolerance
5. Step- 5 : Identify cause which is responsible
6. Step-6 : Make recommendation as what to do
PROCESS CONTROL

4. PROCESS FLOW CHART OF WEAVING

5. Fabric Sample :Denim Fabric
Construction :( 73 × 43 / 15 × 10 ) × 55
Structure :Twill
Interlacing Pattern :2/1
Yarn Type :Cotton Yarn
GSM :230

6. Process Control of Warping Section

7. Input Variable of Warping Input Quantity Required Quantity
Yarn Count 15 16
CV % 10 12
Strength / tenacity 11 13
Breaking elongation (%) 8 8.5
Minimum Staple length of Yarn 2.5 2.7
Contamination Moderate Moderate
Yarn type Cotton Cotton
Yarn hairiness Moderate Low
Yarn micronaire value 3.5 4
Twist factor 4 4.5

8. Output Variable of
Warping
Output
Quantity
Required
Quantity
Process Control
Yarn uniformity (CV % ) 10 12 Uniformity of warped yarn depends on the
uniformity of the input raw yarn. By
controlling the uniformity of raw yarn
warped yarn uniformity also can be
controlled
Broken or loose ends 10 5 To reduce yarn breakage lower strength /
tenacity yarn has to remove
Density of
package(yarn/inch)
132 130 To maintain the yarn density of warp
beam perfect count of V – reed have to
be used
Beam barrel diameter (
inch)
12 13 To maintain the warp beam diameter ,
beam barrel diameter also have to control
during selection of warp beam
Width of warp beam 58 60 To produce the actual wide of the fabric
the warp beam diameter also have to be
perfect . It is control during selection of
warp beam
Coarse knots 10 5 To reduce coarse knot actual quantity &
type of yarn twist have to be maintain

9. Process Control of Sizing Section

10. Output Variable of
Sizing
Output
Quantity
Required
Quantity
Process Control
Count of sized yarn 8 10 To maintain sized yarn count proper
amount of sizing percentage have
to be maintained
Uniformity of sized yarn Moderate Good Uniformity of sized yarn can be
maintained by properly sizing
Percent of size 3 1.5 Percent of size can be maintained
by controlling the immersion roller
Strength & uniformity
of sized yarn
13 15 Strength & uniformity of sized yarn
can be maintained by maintaining
the proper sizing recipe & heat of
drying chamber
Unwindability Low Moderate Unwindability can be reduce by
properly drying sized yarn
Density of sized beam ( 73 75 Density of sized beam can be

11. Process Control of Drawing-in & trying Section

12. Output Variable of
Drawing in & trying
Output
Quantity
Required
Quantity
Process Control
Cross ends 5 3 Cross ends can be reduce by carefully
drawing - in
Extra ends 10 5 Extra ends can be reduce by
conforming sufficient yarn strength

13. Process Control of Looming Section

14. Output Variable of
Warping
Output
Quantity
Required
Quantity
Process Control
Construction 73 × 43 / 15 ×
10
75 × 45 / 16 ×
12
Construction of the fabric can be
maintained by using proper reed
count &pattern card
GSM 230 235 GSM of the fabric can be maintained
by using proper fabric construction
& yarn count
Salvage Structure Plain Plain Salvage Structure can be maintained
by using proper type of selvedge &
the salvage forming pattern card
Broken ends / picks 5 3 Broken ends / picks can be reduce
by controlling the RPM of the loom
Double ends /
double picks
5 3 Double ends / double picks can
reduce by carefully drawing – in

15. Output Variable of
Warping
Output
Quantity
Required
Quantity
Process Control
End out / miss picks
/ knot
6 4 End out / miss picks / knot can be
reduce by properly adjusting the
ends / picks after broken
Hole ( per lot ) 10 8 Holes in the fabrics can be removed
by reducing the no. of naps in the
yarn
Reed streak 3 2 Reed streak can be removed by
maintaining or replacing the reed
Stop marks ( Per lot ) 8 5 Stop marks can be reduce by
reducing the machine stoppage time
during production
Dirt amount Moderate Low Dirt amount can be reduce by
controlling the dirt contamination &
carefully handling the machine

16. Conclusion:
By this experiment we have learn about process quality control of
weaving section. Which has increased our practical knowledge about process
quality control. It will be helpful for our future practical knowledge.
CONCLUSION: