Study of Weaving Quality Monitoring Systems in Pakistan

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TEXTILE INSTITUTE OF PAKISTAN KARACHI

“THE STUDY OF WEAVING QUALITY MONITORING SYSTEMS APPLIED IN PAKISTAN”

BY

SALMAN RIAZ
MOHSIN ALI SADIQ

BSc. (Hons) TEXTILE SCIENCE

2008

TABLE OF CONTENTS

LIST OF FIGURES03

ACKNOWLEDGMENTS04

ABSTRACT05

FOREWORD06

Chapter 1- Overview09

1.1Executive Summary
1.2Introduction
1.3Research Objectives
1.4Research Methodology
1.4.1Phase 1 – Research
1.4.2Phase 2 – Investigation
1.4.3Phase 3 – Decipher
1.4.4Phase 4 – Presentation

Chapter 2-Literature Review16

2.1 An Overview of Quality Monitoring Systems
2.2 Types Of Quality Monitoring Systems

2.3 Loom Data Monitoring Systems

2.3.1 Working Principle
2.4 On-Loom Fabric Inspection
2.4.1 Working Principle:
2.5 Textile Production Problems

Chapter 3- Case Studies30

3.1 Naveena Industries
3.2 Sonic Industries, Karachi
3.2.1 Observation

Chapter 4-Conclusions & Recommendations40

BIBLIOGRAPHY43

LIST OF FIGURES

ACKNOWLEDGEMENTS

Before beginning with our final year research report, we would like to express our gratitude and appreciation to all those people who made helped us during the course of our research and made it possible.

We start by thanking Mr. Ali Imran, Weaving Manager at Naveena Industries Ltd. He specially made time for us from his busy schedule and provided us with the necessary information for our investigation. He also happens to be a Texpert of batch 1998 (graduate of TIP), so he was able to answer our queries and satisfy our curiosity very well.

We would also like to thank Mr. Muzammil Polani, Weaving Manager at Sonic Industries. He too, entertained our visit very graciously.

We also want to thank Dr. Noor Ahmed Memon, Incharge of Research Projects at TIP. His door was always open for advice, support and words of encouragement.

Last, but not the least, we would like to acknowledge Mr. Umair Saeed, Academic Coordinator and Faculty Member at TIP. He took on a mammoth task of supervising our final year research project in spite of his busy schedule and he was always available for consultancy, suggestion, motivation and sharing information.

We sum up our token of appreciation by acknowledging all the secondary resources used for our research and literature review.

ABSTRACT

Weaving Quality Monitoring Systems may be considered as a hybrid of hardware and specialized software. Its primary purpose is to bring all the working data of a loom to a central station. Quality Monitoring System (QMS) in weaving is not only useful to ensure conformity of fabric specifications demanded by the customer, but is also vital to keep a check on the weaving process as a whole. QMS also helps to identify and possibly eradicate imperfections and inefficiencies at various stages of weaving processes.

The main purpose of this study is to review and compare the Quality Monitoring Systems applied in weaving and to investigate why a particular weaving monitoring system is adopted. The research is focused on case studies of two weaving installations in Karachi, namely, Naveena and Sonic Industries.

It is found that loom data monitoring systems are preferred over the on-loom fabric inspection in both of the industries under investigation. This is due to the fact that on-loom fabric inspection adds up to loom stoppages decreasing the efficiency of weaving. On-loom fabric inspection may be a viable option by eliminating a final manual inspection. This is only feasible in countries where the labour cost is extremely high.

It is also observed that use of statistical techniques to critically analyze the data obtained by the loom monitoring systems in both of the weavings sheds was absent. Incorporation of Statistical Process Control (SPC) would further optimize the weaving process and increase weaving efficiency.

FOREWORD

Before getting into the details of...
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