"Comparative Study On Defects and Inspection System of Woven Fabrics in Different RMG Industry in Bangladesh" 1
"Comparative Study On Defects and Inspection System of Woven Fabrics in Different RMG Industry in Bangladesh" 1
"Comparative Study On Defects and Inspection System of Woven Fabrics in Different RMG Industry in Bangladesh" 1
Introduction
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
1.1
Introduction
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
Chapter 02
Literature survey
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
them in the weft direction are irregular weft density, double pick, broken pick, weft yarn defect,
and float; defects in the warp direction are broken end, double end and warp yarn defect. Defects
with no directional dependence involve defects: stain, hole and foreign body.
List of defects in woven fabric is given bellow:
Coloured flecks
Knots
Slub
Broken ends woven in a bunch
Broken pattern
Double end
Float
Gout
Hole, cut, or tear
Lashing-In
Local distortion
Missing ends
Missing Pick
Oil and other stain
Oily ends
Oily picks
Reed mark
Slough of
Shuttle smash
Snarls
Stitches
Untrimmed loose threads
Weft bar
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
Knots
Knot is a fastening made by tying together the ends of yarn.
Causes:
Thread breaks during process of winding, warping,
sizing or weaving.
Mending:
Non Mendable.
Slub:
Slub is a bunch of yarn having less twist or no twist and has
a wider diameter compared to normal spun yarn.
Causes:
Improper carding/combing.
Broken tooth in the chain of gear system.
Mending:
The slub should be cut with the clipper from both
the ends. The resultant bare patch can be corrected
by combing with a metallic comb or by insertion of a separate thread with the help of fine
needle.
Broken pattern :
A broken pattern is the non continuity of a weave/ design/
pattern.
Causes:
Wrong drawing in of threads.
Incorrect shedding.
Mending:
Non Mendable.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
Double end :
When two or more ends gets woven as one. This defect is
characterized by a thick bar running parallel to the warp.
Causes:
Wrong drawing, taking more ends in heald eye.
Mending:
This fault can be corrected by pulling out the extra
end with the help of needle. A bare patch is formed
and can be filled by combing in both directions with
the help of metallic comb.
Float :
Float is the improper interlacement of warp and weft
threads over a certain area.
Causes:
Improper sizing (ends sticking).
Broken end entangling with the other ends.
Mending:
Only minor floats can be rectified. The floating
threads are cut with a clipper. Combing in both
directions rectifies the resultant patch.
Gout
Gout is a foreign matter accidently woven into the fabric.
Causes :
Improper loom cleaning.
Unclean environment.
Mending :
The extra foreign matter can be pulled out with a
plucker. Combing in both direction rectifies the
resultant patch.
Hole, Cut, Tear
This is self explanatory.
Causes :
Sharp edges on cloth roll.
Hard substance between layers of fabric in cloth roll.
Course temples used for fine fabric.
During removal of hard particles like, Iron particles
woven in the cloth.
Mending:
Non mendable.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
Missing Ends
Missing Ends : The fabric is characterized by a gap, parallel to
the warp. The number of ends missing may be one or more.
Causes :
Loom not equipped with warp stop motion.
Dirty drop wires or accumulation of lint may prevent
their dropping.
In electric warp stop motion, the electric bars are dirty or
corroded.
Mending:
When there are only two adjacent ends missing, the fault can be rectified by combing in
both directions using a metallic comb. This may fill the bare patch formed due to missing
ends.
Missing Picks
A narrow streak running parallel with weft threads caused due to
absence of weft.
Causes:
Faulty let-off and take-up motion.
Faulty weft-stop motion.
Fell of the cloth not adjusted after loom stoppage for
mending.
Mending:
When there are only two adjacent picks missing, the fault can be rectified by combing in
both directions using a metallic comb.
Stitches
A Single thread float.
Causes :
Two adjacent ends sticking together during shedding
for a brief period of time.
In case of synthetic yarns, ends sticking together due to
static charge during weaving.
Mending:
Stitches are cut with a clipper from both the ends. Combing in both the directions with
the help of a metallic comb may rectify the resultant bare patch formed.
Untrimmed loose threads
Any hanging threads on the face of the fabrics are termed as
loose threads.
Causes :
Tail ends not trimmed after piecing up.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
Mending:
These defects can be easily rectified with the help of clipper.
Weft bar:
An unwanted bar, running across the full width of a piece
which differs in appearance from the adjacent normal fabric.
Causes :
Difference in count, twist, colour, lustre.
Faulty let-off and take-up motion.
Mending:
Non mendable.
Shuttle smash :
Ruptued cloth structure characterised by many broken warp
ends and floating picks.
Causes :
Improper timing.
Insufficient picking force.
Slack ends in certain portion. The sagging
endsobstructs shuttle flight.
Mending:
Non mendable.
Lashing in
An extra piece of yarn woven into the fabric in the vicinity of
the selvedge.
Causes :
Defective setting of the shuttle box.
Early or late picking.
In case of auto loom, weft cutters worn out or not set
properly
Mending:
This defect can be corrected by pulling out the extra pick from the selvedge end, which
can be clipped with the help of clipper. A bare patch is formed and can be filled by
combing in both directions with the help of metallic comb.
Oil Or Stain
These are spot defects of oil, rust, grease or other stains found in
the fabric.
Causes :
Improper oiling/greasing of looms.
Oil stained Take up roller.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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Mending:
1) Keep the stained portion of the fabric over an absorbent pad. Apply the stain remover,
wetting the stain and surrounding portion thoroughly.
2) Rub gently to quicken the penetration of the stain remover.
3) Rubbing should be done towards the centre of stain to avoid spreading.
Oily Ends
These are oily warp ends.
Causes:
Improper handling and storage of material in
spinning department.
Oil-contaminated guides and oily hands during
process of warping.
Improper handling of warp beams.
Mending:
1) Keep the stained portion of the fabric over an absorbent pad. Apply the stain remover,
wetting the stain and surrounding portion throughly.
2) Rub gently to quicken the penetration of the stain remover.
3) Rubbing should be done towards the centre of stain to avoid spreading.
Oily Weft
These are oily weft picks.
Causes:
Improper handling and storing in spinning
department.
Weft package falling on oily ground.
Handling the weft with oily hands.
Weft carring baskets having oil.
Mending:
1) Keep the stained portion of the fabric over an absorbent pad. Apply the
stain remover, wetting the stain and surrounding portion throughly.
2) Rub gently to quicken the penetration of the stain remover.
3) Rubbing should be done towards the centre of stain to avoid spreading.
Local Distortion
A Distortion occurs when there is displacement of warp and/or
weft threads from their normal position.
Causes:
The emery roll is worn out.
In filament fabric having low reed picks.
Mending:
This defect can be corrected by combing in both directions using a metallic comb.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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Slough off :
A slough-off is a bunch of weft woven into the fabric.
Causes:
Improper winding of the yarn onto the weft pirn.
Improper shape and size of the pirn.
Harsh picking.
Mending:
The bulk yarn can be pulled out by means of plucker.
Combing in both direction with help of metallic
comb can fill up the resultant bare patch.
Reed Marks
A warp way crack caused by a damaged or defective reed.
Causes:
Defective or damaged reed.
Mending:
Non Mendable.
Broken pattern due to defective piles:
A broken pattern is the result of non-continuity of the
design/pattern in the pile fabric.
Causes:
Improper working of terry motion on loom.
Improper functioning of jacquard.
Missing pick.
Mending:
Non mendable.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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Selection of rolls
Select at least one roll of each color. Choose the additional roles in proportion to the total
number of roles per color received, if more than one role must be selected.
Defects classification
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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For Shipment:
(TotalAverage
Total Shipment Points per 100 Sq. Yards = Shipment Inspected
The total defect points per 100 square yard are calculated. The fabric rolls containing more than
40 points per 100 square yard are considered as B. However, a garment may use more or less
than 40 points per 100 square yards as an acceptance criteria. The standard acceptance/grading
criteria is given bellow:
Total Point
40
Above 40-60
Above60-80
Over 80
Grade
A
B
C
Rejected
Advantages
Point system has not width limitation.
Worker can easily understand it.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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Points allotted
(Penalty)
Warp defects
Up to 1
Over 1 up to 5
Over 5 up to 10
Over 10 up to 36
1
3
5
10
Weft defects
Up to 1
Over 1 up to 5
Over 5 up to width
Over width
1
3
5
10
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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The principle was established in garment cutting piece, which the short length defects
(less than 9) will normally be removed.
The system tries to balance the importance of longer defects (over 9) and put less weight
on 1-10 defects such as slub.
The system also suggests the viewing distance of 9 foot instead of normal 3-foot viewing
distance. It also tends to eliminate very small defects from the total penalty score.
Disadvantages
As this system is used on cutting pieces according to one point of view it also increases
the cost of production.
Comparative study on Defects and Inspection System of woven fabrics in different RMG Industry in Bangladesh
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