Primed Canvas Standard Quality Control (SQC) Manual SQC Manual Index: Production Flow Chart Yarn procurement and TFO / twisting. Warping and sizing.............................1 Weaving and grey fabric rolls ………………………………………….2 Priming (coating) process and stuffing………………………………………..3 & 4 Technical Specifications:-……………………………………………………………… 5 & 6 Quality Control: Part 1:-Q.C. flow chart up to weaving stage............................................7 to 8 Part 2:-Q.C process during priming................................................................9 Part 3:-Inspection systems................................................................ 10 to 15 Marking…………………………………………………………………………..…16
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Primed Canvas
Standard Quality Control (SQC) Manual
SQC Manual Index:
Production Flow ChartYarn procurement and TFO / twisting. Warping and sizing.............................1
Weaving and grey fabric rolls ………………………………………….2Priming (coating) process and stuffing………………………………………..3 & 4
Part 1:-Q.C. flow chart up to weaving stage............................................7 to 8Part 2:-Q.C process during priming................................................................9Part 3:-Inspection systems................................................................ 10 to 15Marking…………………………………………………………………………..…16
CIL Textiles Pvt. Ltd. India
PRODUCTION PROCESS
YARN PROCUREMENT BASED ON REQUIRED SPECS FROM CONSISTENT SOURCE E.G. FOR COATED BUSINESS, YARN IS ALWAYS REQUIRED IN VIRGIN GRADE WITH MINIMUM KITTIES AND DEFECTS.
TFO / TWISTING OF YARN ( IF REQUIRED)
WARPING AND SIZING PROCESS
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BEAM IS MADE AND SENT TO LOOM FOR WEAVING
GREY FABRIC ROLLS
Grey rolls are made in bigger roll length in order to obtain bigger pc length after finishing as per the requirements of the customer.
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COATING IS DONE ON ROLLS PASSED FROM GREY STAGE WITH
3 LAYERS OF ACRYLIC JESSO WITH TITANIOM DIOXIDE
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AFTER COATING , FINAL ROLLS ARE MADE FOR S.Q.C. PASSSED ROLLS ARE SENT FOR SHIPMENT
Shipment is made in duly inspected containers under the Supervision of the plant and then is sealed after stuffing.
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TECHNICAL SPECIFICATION SHEET
Technical specification for coated (primed) goods:-
QUALITY CODE TOLERANCE 6 OZ /72" 8 OZ /72" 10 OZ /72"
CHARACTERISTICS OF "C" GROUPPRODUCT CLASSIFIED UNDER GROUP 'C' FOR COATING WITH 10 % INSPECTION
CODE FIBER
CONTENTS
WEAVE YARN COUNT
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PART I
Q.C.Flow chart up to weaving
1) All yarn is ordered based on standard specs required for a particular contract. E.g. for coated business, yarn is always required in virgin grade with minimum kitties and defects.
2) Yarn sample is tested from the yarn lot received to check the required norms as shown below the. Photograph of yarn testing machines used to find strength and actual count of yarn.
TEST REPORT OF YARN
NAME OF MILL
REQUIRED COUNT
ACTUAL COUNT FOUND
C.S.P ( STRENGTH )
APPEARANCE OK/NOT OK
RESULTS OK/NOT OK
DT OF RECEIPT
SIGNATURE
3) After warping & sizing process, production starts in weaving section. Inspection of fabric on running loom is done to see the appearance of fabric and to ensure proper setting for loom .
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.
If there is any issue which needs to be corrected immediately after start of looms, it is taken care of. e.g. Reed marks , temple marks if observed has to be stopped at this stage itself. Weave pattern is checked.
4) Fabric sample is drawn from initial production for testing the parameters required through instrument shown below Tensile strength for fabric is testing with below instrument. It is done based on cutting strips of 6”x4” grab test method and also by using 5x20 cm strip of fabric.
5) Once a roll is made, it is sent for mending the defects. I.e. if there are any defects which can be
corrected by manual correction, it is done. Like hanging threads are cut, dirt marks are removed using guns. Major defects are cut. Flags are marked.( if required by customer )
6) After mending and checking by internal S.Q.C. final roll is made and if it is under the norms, it is offered for final inspection by the external S.Q.C. which is working independently from production dept. Checking is done randomly for 10 % of the lot .If ok, and then it is dispatched for next process on it. If the defects are below 40 points / 100 linier mtrs, then it is passed from grey stage.
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PART IIQ.C. Process during Coating (Priming)
1) Coating is done on rolls received duly passed after grey inspection stage.
2) 3 coating of acrylic gesso with Titanium dioxide is used.
3) It is continuously monitored during entire coating process in all 3 stages of coating i.e. 1st coating, 2 nd coating and then final 3 rd coating. In process checks for weight, width is done after each layer of coating.
4) Fabrics from each batch are checked for whiteness, texture and feel as per standards.
5) Coated roll is sent for mending, Checking, cutting and final packing by plant.
6) Again the lot already passed by coating plant is randomly checked by the external S.Q.C.
7) If the lot is given ok based on fixed norms of fewer than 40 points /100 meters, then it is ready for dispatch for exports.
8) Containers are checked before stuffing of goods.
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PART IIIInspection system
1) 4 point American system for inspection is followed.
2) A fixed format for inspection is used for both grey and coated fabric.
3) Format for inspection summary for grey goods is given below :-
Major defects are1) bad starting marks2) warp breakages3) cracks4) oily warp and weft.5) Double picks6) Knots
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4) Format for inspection for coated fabric is given below.
COATING INSPECTION REPORT
ROLL NO: - MTR -
QUALITY
NET WT -
COATED WIDTH : PCS
NAME OF THE INSPECTOR
DATE OF INSPECTION
MTRS
POINTS 1 2 3 4
DEFECT SIZE "0-3"
3-6" 6-9"
9 UP
TOTAL DEFECTS 0 0 0 0 0
POINTS 0 0 0 0
TYPE OF DEFECTS BAD STARTING MARKS ( BSM
)
TOUCH UP
LOOSE END
EXCESS CHEMICALS
CHIPS LINE
WARP BREAKAGE
EXCESS CHEMICALS LINE
CRACK
HANGING THREAD
OILY SPOTS/LINING
FLOTS
KNOTS
WARP BREAKAGE
WRINKLES
LT
5) Each defect is counted based on its size. • For defects up to 3” ,1 point is given• For defects more than 3” and up to 6” 2 points are given • For defects between 6” to 9”, 3 points are given• For defects more than 9” , 4 points are given
6) Cut table defects are cut and are not taken into point calculations.( Or FLAGS are put in if
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customer wants it in order to get bigger piece length.)
7) Defects are marked in respective column.
8) Total points are calculated and converted to defect points/100 linear mtrs .If defects points are less than 40 points/100 linear mtrs, then it is graded under “Passed” category.
9) Defects shown below are taken in point calculations, if they are small,But if size is bigger in size more than 9” and are multiple, they are cut.
A) BAD STARTING MARKS
B) TOUCH UP
C) LOOSE WARP
D) EXCESS CHEMICALS
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E) CHIPS LINE F) EXCESS CHEMICAL LINE
G) CRACK H) HANGING THREADS
OILY SPOTS/LINES J) FLOTSa.
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K) KNOTS L) WARP BREAKAGES
M) WRINKLES N) LT
10) Further apart from points system, S.Q.C. has to check weight of the fabric, appearance, whiteness, feel and weave pattern of fabric ( as per chart shown in technical sheet and base approved samples )
11) For coated fabric, sample cutting from each roll is taken for records.
12) Color test for each coated roll is performed and if it gets passed if there is no penetration on the back side of the fabric under acceptable limits, then only the roll is finally approved for exports
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Procedure for doing the color test is given below:-
Test equipments:50ml Glass Beaker Hog Hair Brush – B 36 size 10Artist Oil Color French Ultramarine Georgian Oil Color Burnt Sienne System 3 Emerald Green WaterArtist Turpentine Linseed Oil Palette knife or other suitable stirrer.
Test Methods:
Check the surface of the canvas to ensure it matches for whiteness tooth. Check also that any color applied to the surface is free – flowing j.e.does not drag under the brush .
Mix a 10% solution of artist Oil Color French Ultramarine in Turpentine using a palette knife and glass beaker. Apply by brush to the canvas surface and allow to dry .Leave to dry overnight. Check for any penetration of the color thought to the reverse side of the canvas.
Make 10% solution of artist Oil Color French Ultramarine in Linseed Oil. Apply the solution by brush to the canvas surface and allow to dry. Leave to dry three days. Check for any penetration of the color thought to the reverse side of the canvas at twenty four hour intervals.
Using a brush. Apply Georgian Oil color burnt sienna directly from the tube to the canvas surface. Check for the drying of the oil over a period of five days at 24 hour intervals.
Mix a 10% solution and system 3 Emerald Green in water using the beaker. Apply by brush to the canvas surface. After one hour check any penetration of the acrylic in to the surface, any unevenness, and that the color has dried.
( Note: all solutions are freshly made before testing the canvas.)
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9) Marking on final rolls is done as shown in example below.
10) Packaging is done with LDPE layer on the fabric and then LAMINATED HDPE on top