Fabrics faults and remedy

Southeast university DEPERTMENT OF TEXTILE ENGINEERING August 13, 2015 AKL and GMS 1 Company prole  Name of the Company: Alim Knitwear ltd  Year of Establishment: 2005-2006  Certified Achievement: ISO 9001:2000, (Certified), Oeko-Tex Standard 100 (Certified)  Manufacturing products: Export oriented knit fabrics dyeing and readymade garments  Owner and directors of the factory: Alim mondal.  Factory Address: Nayapara, Kashimpur, Gazipur, Bangladesh  Total Employees: 4500  Number of units: 3 (Three) units  Part-A: Garments unit – 3 floors  Part-C: Dyeing unit  Part-D: Printing unit  Total area: 0.5 acres  Corresponding Bank: 1) United Commercial Bank Limited . Dhaka, Bangladesh 2) Dutch Bangla Bank Ltd. Dhaka, Bangladesh  Factory Supervisor: Md. Mamun ( PM in garments section)  Supervising teacher: Md. Abul Kalam Azad. August 13, 2015 AKL and GMS 2  Another Name of the Company: GMS composite Knitting industries ltd.  Year of Establishment: 2003-2004  Certified Achievement: ISO 9001:2000, (Certified), Oeko-Tex Standard 100 (Certified)  Manufacturing products: Export oriented knit fabrics dyeing and readymade garments  Owner and directors of the factory: GMS composite Knitting industries ltd.  Factory Address: Ssaradagong, Kashimpur, Gazipur, Bangladesh  Total Employees: 4500  Number of units: 3 (Three) units  Part-A: Garments unit – 3 floors  Part-C: Dyeing unit  Part-D: Printing unit  Part-E: knitting unit.  Factory Supervisor: Md. Saiful Islam August 13, 2015 AKL and GMS 3 Object of training  To know about garments faults & remedy we justify each & every garments.  To knowing that we give max customers satisfaction.  To know about different fabric inspection.  To know about different quality parameters of fabric, different trims & accessories.  To know about buyers AQL.  To know about major or minor fabric faults. August 13, 2015 AKL and GMS 4 Methodology of textile faults. For Yarn manufacturing technology: We study different types of yarn faults, causes and its remedy. August 13, 2015 AKL and GMS 5 Faults name Causes Remedy 1. Slub Lack of adequate fibre control in the drafting Zone. Proper fibre control of drafting zone 2. Oily slub Improper lubrication proper lubrication 3. Kitty yarn Improper ginning i.e. Seeds broken during ginning proper ginning i.e. Seeds broken during ginning 1. Slub 2. Kitty yarn August 13, 2015 AKL and GMS 6 August 13, 2015 AKL and GMS 7 Faults name Causes Remedy 4. Foreign matters Improper handling of travelers Improper preparation of mixing proper handling of travelers proper preparation of mixing 5. Soft yarn  Improper bobbin feed on the spindles  Less twist in the yarn  proper bobbin feed on the spindles  Proper twist in the yarn 6. Crackers  Mixing of cotton of widely different staple lengths Closer roller settings  Proper Mixing of cotton of widely differing staple lengths  Proper roller settings Spinning faults and remedy percentage diagram August 13, 2015 AKL and GMS 8 Sl = slub yarn Oi = oily slub Ki = Kitty yarn Fo = Foreign matter Co = cork screw yarn Ov = over twisted yarn So = soft yarn Cra = cracker Remedy % Faults name Knitting faults, causes and its remedy: Faults name Causes Remedy 1. Barre Caused by mixing yarn on feed into machine. Proper yearn selection and proper roller adjustment. 2. Broken Colour Pattern Usually caused by color yarn out of place on frame. Proper adjustment of color and yarn. August 13, 2015 AKL and GMS 9 Faults name Causes Remedy 3. Crease mark Its create when fabric passing through squeeze rollers in the dyeing process. Its mainly Occurs in tubular knits fabric. Proper adjustment of squeeze rollers. 4. Hole caused by broken needle Change the needle. 5. Needle Line Caused by broken needle forming distorted stitches Replace the needle August 13, 2015 AKL and GMS 10 [...].. .Faults name Causes Remedy 6 Runner Usually caused by broken needle Change the needle 7 Slub (Knit fabric) Usually caused by a thick or heavy place in yarn Replace the yarn cone to a more uniform yarn cone August 13, 2015 AKL and GMS 11 Different Causes of Fabric Barre August 13, 2015 AKL and GMS 12 Knitting faults and remedy percentage diagram: Remedy % Ba = barre mark Bro... Crea = creasing Un = unwanded mark Flu = flushing Crak = crack or miss aligment August 13, 2015 AKL and GMS 19 Garments faults and remedy Faults Name Causes Remedy 1 Misprints or off registration not properly cleaning of Printing screens Properly Cleaning of printing screen 2 Grease/ Oil / dirty stains Oil stains generally come from sewing machines; machines such as over lock and flat lock machines... grease covered exposed machine parts, careless handling To using spot cleaner 12 Decolorized patch on fabric Caused due to chemical spillage on fabric Localized excess bleaching Localized excess enzyme wash To using spot cleaner Crack August 13, 2015 Unwanted mark AKL and GMS Decolorized patch on fabric 18 Dyeing and printing faults and remedy percentage diagram Remedy % Bar = barre Bl = bleeding Sh = shadding... 2015 AKL and GMS 14 Faults name Causes Remedy 1 Barre Its horizontal shaded band across the width of the fabric It causes by the yarn mixing proper yarn selection 2 Bleeding improper dye selection or poor dye fastness proper dye selection 3 Crocking It is the rubbing off of the color It may rub onto another fabric proper dye selection barre August 13, 2015 Bleeding AKL and GMS Crocking 15 Faults name... 16 Faults name Causes Remedy 7 Creasing Causes unleveled penetration of dyes To use proper dyes and chemical or leveling agent 8 Flushing/Wicking Caused due to Low viscosity of print paste To use high viscosity of printing past 9 Bleeding Caused due to Low viscosity of print paste To use high viscosity of printing past Creasing August 13, 2015 Flushing AKL and GMS Bleeding 17 Faults name Causes Remedy. .. Open or broken seams improper handling of the cut piece or machine Repairing or alter the garments Misprint August 13, 2015 Grease/ oil/ dirty stain AKL and GMS Needle damage Open or broken seam 20 Faults name Causes Remedy 5 Broken stitch improper handling of cut pieces or improper machine usage Repairing or alter the garments 6 Skipped or dropped stitches improper handling of cut pieces or improper... August 13, 2015 AKL and GMS 12 Knitting faults and remedy percentage diagram: Remedy % Ba = barre mark Bro = broken color Mis = missing yarn Mix = mixing yarn August 13, 2015 AKL and GMS 13 Dyeing, printing and finishing faults and remedy       Classification of Defects Minor Defect A defect is defined as minor Defect that is not likely to reduce the Usability of the product, but nevertheless may... thread To use proper sewing thread Broken stitch August 13, 2015 Skipped stitch Neck shape AKL and GMS Sewing thread not matching 21 Faults name Causes Remedy 1 Seams not aligned at crossing of seams improper handling of the cut piece Repairing or older the garments 2 Stripes not matching from improper handling of cut pieces Repairing or older the garments 3 Misplaced label improper placement of labels... aligned at crossing of seams August 13, 2015 Stripes not matching AKL and GMS Misplaced label 22 Garments faults and remedy diagram Dir = dirty stain Bro = broken stitch Skip = skip stitch Sw = sewing thread not match Miss = misplace label Nec = neck shape Po = pocket disposition Un = uncovered seam Brok = broken seam August 13, 2015 AKL and GMS 23 Conclusion In Bangladesh the maximum dyeing industry are... Causes Remedy 4 Shading It is generally due to uneven tension on the fabric To maintain the proper tension 5 Stained caused by a foreign substance, dirt, grease, and oil or sizing residue on the fabric being dyed To using different spot remover chemical 6 Color variation in yarn Caused due to lack of agitation in the dye bath proper agitation in the dye bath Shading August 13, 2015 stained AKL and GMS . yarn Cra = cracker Remedy % Faults name Knitting faults, causes and its remedy: Faults name Causes Remedy 1. Barre Caused by mixing yarn on feed into machine. Proper yearn selection and proper roller. fabric faults. August 13, 2015 AKL and GMS 4 Methodology of textile faults. For Yarn manufacturing technology: We study different types of yarn faults, causes and its remedy. August 13, 2015 AKL and. and GMS 12 Knitting faults and remedy percentage diagram: August 13, 2015 AKL and GMS 13 Remedy % Ba = barre mark Bro = broken color Mis = missing yarn Mix = mixing yarn Dyeing, printing and