Quality Circle Project

• Universal Textile Mills / Jaipuria Silk Mills Pvt Ltd

44 Gudahhati Main Road, Neralur Post, Bengaluru 562107

• www.universaltextile.com

CONTENTS

• About The Company.

• Basic Processes.

• Existing problems.

• Problem Statement.

• Problem Definition,

Analysis &

Probable Solution.

• Future Course of Action

ABOUT THE COMPANY

• Jaipuria Silks has been associated with silks for around 40 years.

• Director: Abhay Jaipuria.

• Their product are silks and linen material. They do all processing in-house: printing, dyeing, washing, ironing.

• They are working with around 30 countries.

• Major part of their products are exported to Europe and US.

• Around 30% of raw material are produced in house while rest are imported from China.

BASIC PROCESS IN THE TEXTILE

MILL

Washing

Yarn Dyeing

Winding

Warping

Weaving

Printing

Steaming

Finishing

THE EXISTING PROBLEMS

• Visual Management and Kanban problem

• Waste Management

• Quality in Core processes

• Vendor Management/Procurement

• Logistics

• Office and Accounts

FACTORS CONSIDERED FOR FINAL SELECTION OF PROBLEM

• Cost involved

• Management’s Viewpoint on issues

• Time factor

PROBLEM STATEMENTUniversal Textile Mill is facing problems in the areas of

Visual Management, Waste Management and Quality Aspects ultimately resulting in increased costs

and reduced profits.

1. VISUAL MANAGEMENT

ISSUES

1. Absence of proper identification and storage of materials.

PROBABLE SOLUTIONS

• Employing location labeling for identification and storage.

• Material Identification (colour) codes.

• Floor marking tapes showing walkways and restricted areas.

• Floor marking tapes showing specificstorage areas.

2. Absence of an Organized and Structured work environment.

PROBABLE SOLUTIONS

• Systematic Cleaning and Painting Schedule.

• Introduction of 5S.

IN ADDITION, THE FOLLOWING CAN BE CONSIDERED.

• Visual Displays:

– Recognizing performances of employees.

• CAPA for injuries.

• Weekly Rejection rates, desired targets, downtime can be displayed.

• Vision, Mission can be displayed in the shop floor.

• Visual Control:

– Signs such as Warning, Danger signs, Safety signs, etc.

2. WASTE MANAGEMENT

Textile Manufacturing

CURRENT SITUATION

• The products are exported to Europe and America. As a result, products which do not conform to the desired specifications are rejected.

• This results in rejection of even slightly defected products.

• The scrap is sold based on the weight.

TURN FABRIC SCRAP INTO YARDAGE

THREE BASIC STEPS

• Resale

• Recycle

• Conversion to Rags

GENERAL OBJECTIVES OF REDUCING TEXTILE CUTTING WASTE

• Optimum, uniform width

• Maximum practical length

• Minimum defects

• Protective packaging, with clean, increased ends at beginning and end of roll

• Minimum shade variation

TO STUDY..

• Reduce waste/costs associated with textile cuttings

• Reduce waste/costs associated with common recyclables (paper, plastic, etc.) and generate revenue

• Reduce waste/costs associated with dyes and chemicals

3. QUALITY

QUALITY ASPECTS IN DIFFERENT PROCESSES

A. Quality issues in the digital textile printing.

B. Quality issues in the digital jacquard looms for yarn weaving.

A. DIGITAL TEXTILE PRINTING

• This is the technology that consists of printing your designs on fabric, directly from your computer, with no other additional step.

QUALITY ISSUES IN DIGITAL FABRIC PRINTING

Defects Primary causes (Brain storming)

1. Specky / patchy dyeing Water drop on fabric and too much foaming

2. Dark colored spot Incompatibility and high dye stuff concentration

3. Dark or light selvedges Non uniform batching

4. Flushing/Wicking Low viscosity of print paste

5. Scrimps Fabric may creases underneath one of the screens

6. Misfits Improper alignment of the screens

MEASURING DEFECTS USING CHECK SHEET TOOL

Defect Types/

Event Occurrence

Dates

TOTALSunday Monday Tuesday Wednesday Thursday Friday Saturday

Specky / patchy dyeing 11 16 6 15 5 24 6 83

Dark coloured spot 2 5 1 2 1 11

Dark or light selvedges 3 8 1 9 21

Scrimps 1 6 1 8

Misfits 1 1 1 4 7

Miscellaneous 2 1 1 4

Flushing/Wicking/Color 8 19 10 5 11 53

Colour out 2 1 3

Machine Stop 1 1

TOTAL 25 47 20 28 10 30 31 191

Frequency 83 53 21 11 8 7 4 3 1

Percentage 43.5 27.7 10.9 5.7 4.1 3.6 2.0 1.5 0.5

Cum % 43.5 71.2 82.2 88.0 92.1 95.8 97.9 99.5 100

Sp

ecky / P

atc

hy D

ye

ng

Da

rk o

r lig

ht

Sle

ve

dg

es

Flu

sh

ing

/Wic

kin

g

Da

rk c

olo

red

Sp

ots

Scrim

ps

Mis

fits

Ma

chin

e S

top

Co

lor

out

Mis

ce

llanio

us

0%

20%

40%

60%

80%

100%

0

20

40

60

80

100

120

140

160

180

200

Cu

mu

lative

%

Defe

cts

Causes

Pareto Chart Of Quality Issues Recorded

Vital Few Useful Many Labels Cut Off % [42]

• From Pareto Analysis it was observed that “ 71.2% of quality issues were caused due to Specky / patchy dyeing & Flushing/Wicking”

• So these 2 issues will be considered for further analysis

B. JACQUARD WEAVING

• Weaving is done by employing Jacquard looms which involves the programmed raising of each warp thread over the other depending on the desired pattern.

QUALITY ISSUES IN DIGITAL JACQUARD WEAVING

Defects Primary causes (Brain storming)

1. Yarn breaking Thread inconsistency

2. Coloured Flecks Presence of coloured foreign matter in the yarn because of mixing

3. Slub (low twists yarn) Broken tooth in the chain of gear system

4. Broken pattern Wrong drawing in of threads, Incorrect shedding

5. Double end Wrong drawing

6. Gout (Foreign material) Improper loom cleaning.

MEASURING DEFECTS USING CHECK SHEET TOOL

Defect Types/

Event Occurrence

Dates

TOTALSunday Monday Tuesday Wednesday Thursday Friday Saturday

Loose Threads

1 1 2 2 6

Coloured Flecks

2 2

Slub (low twists yarn)

6 5 3 9 4 7 34

Broken pattern

2 3 4 7 16

Double end

1 1

Gout (Foreign

material)4 6 9 4 2 25

Yarn breaking

2 1 1 4

Miscellaneous

1 1 2

Hole/Cut/Tear

1 1

TOTAL 15 12 15 6 19 12 12 91

Frequency 34 25 16 6 4 2 2 1 1

Percentage 37.4 27.4 17.5 6.5 4.3 2.1 2.1 1.0 1.0

Cum % 37.4 64.8 82.4 89.0 93.4 95.6 97.8 98.9 100

Slu

b

Go

ut

Bro

ke

n p

att

ern

Lo

ose

Th

rea

ds

Ya

rn b

rea

kin

g

Colo

ure

d F

lecks

Mis

cella

ne

ou

s

Hole

/Cu

t/Te

ar

Dou

ble

En

d

0%

20%

40%

60%

80%

100%

0

10

20

30

40

50

60

70

Cum

ula

tive

%

Defe

cts

Fre

qu

en

cy

Causes

Pareto Chart Of Quality Issues Recorded

Vital Few Useful Many Cumulative% Cut Off % [42]

• From Pareto Analysis it was observed that “ 78.5% of quality issues were caused due to Slub, Gout & Brocken pattern”

• So these 3 issues will be considered for further analysis

STEPS

DONE Measuring the number of different defects over a period of

time. Using the Pareto analysis (80-20 concept) for finding the

most frequently occuring defects.

TO DO

• Then trying to find out the probable causes for those defects using Why-why analysis and Fish Bone diagram.

• Finally finding the pursuable causes and eliminating them in order to remove the overall problem.

FUTURE COURSE OF ACTION

• Generation of alternatives

• Choose the most feasible solution

• Evaluation of suggestions in terms of • Cost of implementation

• Savings

• Impact on quality

• Implementation