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Textile Process Improvement

This document summarizes a root cause analysis conducted to identify reasons for reprocessing. The investigative team analyzed issues in pretreatment, spinning, and weaving. In pretreatment, they found problems like improper desizing and bleaching, temperature variations, and chemical concentration issues. In spinning, issues included dead fiber, insufficient fiber length, and poor quality recycled fiber. In weaving, problems with sizing chemical viscosity and roller pressure were observed. To address these findings, corrective actions were proposed like ensuring proper concentration and training on pretreatment machines, monitoring padder pressure, improving absorbency uniformity, using same dyes/chemicals for samples and bulk, maintaining temperature specifications, and properly mixing chemicals.

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sayeef khan
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204 views5 pages

Textile Process Improvement

This document summarizes a root cause analysis conducted to identify reasons for reprocessing. The investigative team analyzed issues in pretreatment, spinning, and weaving. In pretreatment, they found problems like improper desizing and bleaching, temperature variations, and chemical concentration issues. In spinning, issues included dead fiber, insufficient fiber length, and poor quality recycled fiber. In weaving, problems with sizing chemical viscosity and roller pressure were observed. To address these findings, corrective actions were proposed like ensuring proper concentration and training on pretreatment machines, monitoring padder pressure, improving absorbency uniformity, using same dyes/chemicals for samples and bulk, maintaining temperature specifications, and properly mixing chemicals.

Uploaded by

sayeef khan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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ROOT CAUSE ANALYSIS (RCA)

This project has an aim to find out the reason of re-processing, and find the below

outcomes of our findings

TITLE: REASONS OF RE-PROCESSING DATE:26-06-2022

EVENT DESCRIPTION

THIS SECTION COVERS DECLARATION OF THE PROBLEM AND IDENTIFIED ALONG THE

FOLLOWING:

• INFORMATION

• PROBLEM STATEMENT

• AIM OBJECTIVES OF THE ANALYSIS AND EXPECTED OUTCOMES

• HOW WAS THE PROBLEM CAME INTO OUR OBSERVATION?

• SITUATION TYPE

• LEVEL OF SEVERITY OF THE PROBLEM

• EFFECT OF THE PROBLEM ON THE FOLLOWING FACTORY

TIMELINE LEADING UP TO THE EVENT

Date Sequence of Events

1. Collect Different information of Processing from department

From, head Mr. Moynul during this period for several time, Our

1st June 2022 teammates used to collect information and show him our

TO, findings during this time.

20th June 2022 2. In the mean time we used to communicate with Mr. Ashfaqur

Rahman Thakur and showed him our findings and took


suggestion from him

3. We took further more information from Mr. Shubasis Bose &

Mr. Mrittunjoy Chowdhury.

INVESTIGATIVE TEAM METHODS USED

NO. OF PEOPLE IN THE TEAM: 09

• MD. RIAD IBNE ZABED BADHON

• TAUFIZUL ISLAM USSAS

• SAFAYAT HOSSAIN PREOW

• SUSMOY SARKER

• NUR HOSSAIN RAHAT


• COLLECTING INFORMATION
• MD. SOHAN MIA
INDIVIDUALLY
• NAFIS FUAD RAHMAN
• SURVEY
• MD ABU SAYED

• MD. SARWAR JAHAN

DESIGNATION: TRAINEE OFFICER

QUALIFICATION: BSC. IN TEXTILE

ENGINEERING
FINDINGS OR IDENTIFICATION OF ROOT CAUSE

OBSERVATIONS 1: PROCESSING

1. LACK OF PROPER PRETREATMENT PROCESSES SUCH AS IMPROPER DESIZING

(BATCHER ROTATION WITHOUT COVER, ROTATION PROBLEM), IMPROPER

BLEACHING, PADDER PRESSURE OF THE MACHINES, CHEMICAL CONCENTRATION

AND MIXING TEMPERATURE)

2. LISTING

3. TAILING

4. DYES AND CHEMICALS ISSUES (AFFINITY, DYE PARTICLE SIZE, CHEMICAL

CONCENTRATION)

5. TEMPERATURE VARIATION ON DIFFERENT CHAMBER AND IR

6. OFF-SHADE

7. PADDER PRESSURE UNIFORMITY

8. LACK OF CONCENTRATION OF WORKER

9. FLOOR TEMPERATURE IS TOO HIGH

10.SOME PRETREATMENT MACHINERIES HAVE LESS EFFICIENCY

11.MISCOMMUNICATION

12.BAUME VARIATION
OBSERVATIONS 2: SPINNING

• DEAD FIBER

• INSUFFICIENT FIBER SPUN LENGTH

• LOW CSP

• OLD MACHINE

• HAND MIXING (KEEPING EXACT BLEND RATION IS SO TOUGH)

• POOR QUALITY OF RECYCLED FIBER

OBSERVATIONS 3: WEAVING

• IMPROPER SIZING CHEMICAL’S VISCOSITY

• UNEVEN ROLLER OR PADDER PRESSURE OF SIZING MACHINE

• AMOUNT OF FLY YARN

CORRECTIVE ACTION

THE CORRECTIVE ACTION PLANS WILL HELP US TO DEFINE THE PROBLEM AND TAKE

CORRECTIVE ACTION AS SOLUTION.

THERE ARE SOME CORRECTIVE ACTIONS GIVEN BELOW BASED ON THE FINDINGS:

1. PROPER CONCENTRATION AND MANPOWER SETTING ON EACH MACHINES DURING

PRODUCTION IS THE KEY SOLUTION OF IMPROPER PRETREATMENT PROCESS. LACK

OF PROPER CONCENTRATION IS THE IS THE MAINLY ROOT CAUSE OF

PRETREATMENT PROCESS HAMPER.

AROUND 80% OF ALL DYEING PROBLEMS WILL BE REDUCED BY ADOPTING PROPER

MANPOWER SETTING ON EACH MACHINES AND INCREASING THEIR KNOWLEDGE


AND SKILLS BY PROPER TRAINING AND EVALUATION.

2. LISTING PROBLEMS OCCURS DUE TO PADDER PRESSURE VARIATION. SO TO

REDUCE THIS LISTING PROBLEM THE CONCERNED PERSONS MUST ENSURE

CONTINUOUS FOLLOW UP OF THE PADDER PRESSURE OF ALL PRETREATMENT

MACHINES AS WELL AS PROCESSING MACHINES.

3. TAILING PROBLEMS OCCURS DUE TO UNEVEN ABSORBENCY. PRETREATMENT

PROCESS SHOULD BE MONITOR ALSO FOR AVOIDING UNEVEN ABSORBENCY

PROBLEM SO THAT IN DYEING PROCESS TAILS FAULTS MIGHT NOT OCCUR. THE

ASSIGNED PERSONS SHOULD KEEP CHECKING TAILS FAULTS ON FABRIC

CONTINUOUSLY. WHENEVER THIS PROBLEM IS SEEN DURING PROCESSING THE

ASSIGN PERSON SHOULD TAKE NECESSARY STEP IMMEDIATELY.

4. SAME BRAND DYES AND CHEMICALS SHOULD BE USED FOR BOTH SAMPLE AND

BULK

5. TEMPERATURE SHOULD BE MAINTAIN ACCORDING TO REQUIREMENT (IR &

DIFFERENT CHAMBER)

6. STRONG LYE AND WEAK LYE MIXING SHOULD BE IN PROPER WAY

SUPERVISOR ACCEPTANCE

Signature Supervisor Name & Designation Date

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