Production planning of woven Fabric
Introduction:
Production
Planning
ü Taking
order form marketing division
ü Analyzing
the orders
ü Planning
for dyeing the yarn
ü Planning
for weaving the fabric
ü Planning
for finishing the fabric
Literature Survey:
Production
Planning
Sample Taking
Sample construction
(Count, EPI, PPI)
Weaving Construction
(Fabric Design and Analysis)
Yarn consumption
Weaving
Flow
chart of Weaving
Winding:
This is a process of transfer of yarns from ring, bobbin,
hanks etc, into a convenient from of package containing considerably long
length of yarn. This simple transfer of yarn from one package (bobbin) to
another large package (cone, spool, pirn) is called winding.
Objects of winding:
ü To
improve the quality of yarn
ü To
get a suitable package
ü Make
continuous supply of yarn in the subsequent process
ü Removal
of thick &thin place from the yarn
ü Removal
of weak places from the yarn
ü Removal
of slubs
ü Removal
of knots
ü To
store the yarn
Sequence
of winding:
Yarn in ring bobbin
Guide
Tension
Yarn clearer device
Stopping device
Traversing guide
Winding
Defects of winding:
ü Formation
of patches on the yarn.
ü Incorrect
winding speed.
ü Tension
variation.
ü Dirty
package.
ü Incorrect
shape of the package.
ü Piecing
up.
ü Too
much knots in the yarn.
ü Greasy
& dirty yarn.
ü Excessive
full bobbin.
Warping:
The parallel winding of yarn from
cone or cheese packages on to a warp beam is called warping. Warping is a
process of transferring yarn from a predetermined number of single-end
packages, such as cones or cheeses, into a sheet of parallel yarns of a
specified length and width.
Objects of warping:
ü To
wound up fixed (required) length of yarn on to a warp beam.
ü To
increase the weavability of yarn.
ü To
make dynamic next process.
ü To
increase production.
ü To
increase quality of fabric.
ü To
make re-useable small packages.
ü To
make convenient yarn sheet for sizing process.
Yarn passing diagram
Sizing: The
weaving process requires the warp yarn to be strong, smooth and elastic or
extensible to a certain degree. To
achieve these properties on the warp yarns,
a protective coating of a polymeric film forming agent ( size ) is
applied to the warp yarns prior to weaving. This is called sizing or slashing.
Types of Sizing
1) Conventional aqueous sizing
(a)
Double cylinder sizing
(b)
Multi cylinder sizing
2) Non conventional sizing
(a)
Dry sizing
(b)
Solvent sizing
(c)
Hot melt sizing
(d)
Foam sizing
Main Purposes of Warp Sizing:
ü
To
increase the strength of the yarns
ü
To reduce the yarn hairiness
ü
To
increase the abrasion resistance of the yarn against other yarns
ü
To
reduce fluff and fly during the weaving machine process for high speed weaving
machines.
Before sizing & after sizing Yarn:
Appearance of size spun yarn:
Weaving:
Weaving is the interlacing of two or more threads or pieces
of material in order to create a joined structure. Weaving is the process of
making cloth, rugs, blankets, and other products by crossing two sets of
threads over and under each other. Weavers use threads to spun from natural
fibers like cotton, silk, and wool synthetic fibers such as nylon.
Process Flow Chart of Weaving:
Warp Wise Yarn Path
Weavers beam
↓
Back rest roller
↓
Feeler roller
↓
Warp stop motion or drop wire
↓
Heald Eye
↓
Reed
↓
Take Up Roller
Weft Wise Yarn Path
Bobbin Creel
↓
Pre Winder
↓
Programmable Filling Tensioned (P F T)
↓
Fixed Nozzle
↓
Movable Nozzle
↓
Filling Cutter
↓
Relay Nozzle
↓
Filling Detector
↓
Stress Nozzle
↓
Waste Cutter
Case Study: Some use full formula for production
planning
Pre calculation:
Total fabric production=
Total length+
Excess amount of fabric in %
•Total end=EPI × Width of the fabric
• Reed count = EPI- Crimp%
Reed space = Total ends ÷ Reed count
•
Yarn Consumption: Warp yarn= [{ Total ends ÷ (warp count × 840) + waste% }]
•
Weft yarn = [{ PPI ×
(reed space + waste)} ÷ weft count × 840]
Warping:
•
NO. Of cone = Total End ÷ NO. of warp beam
•
Cone length =(cone wt. in lbs × count × 840) yds
•
Set length = cone length ÷ No. of warp beam
•
Weaver’s beam: Length
of weaver’s beam = length of warp beam + sizing extension
Crimp%
calculation:
•
For 40’s yarn:
Sizing beam length = 1800 yds
Waste in head of the beam = 4 yds
Waste in tail of the beam =
9 yds
Total waste of yarn from beam after sizing = (4+ 9) yds
= 13 yds
Actual beam length = (1800 – 13) yds
= 1787 yds
1787 yds sized yarn produce 1590 yds fabric
Less amount of fabric produce due to crimp = (1787 – 1590)
yds
= 197 yds
Due to crimp 1787 yds reduce = 197 yds
Due to crimp 1 yds reduce = 197 ÷ 1787 yds
Due to crimp 100 yds reduce = (197 X 100) ÷ 1787
=
11.02 %
Actual crimp% for 40’s yarn = 11.02
Above all, we can say that we
learned this type of topics Production Planning
•
Flow chart of Weaving
•
Winding
•
Warping
•
Sizing
•
Weaving
•
Calculation formula
•
Crimp% calculation
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