Reduce Cord Cord Jumper Rate

Target: according to statistics, March 2012 ~2013 February Jumper rate Monthly average is 0.6%. After research and analysis, the company set the goal as cord cord jumper rate less than 0.2%.

Feasibility analysis: in 2012, the monthly average jumper rate of the cord fabric was 0.6%, of which the cord cord jumper line at the mark line accounted for 77.83%. After calculation, the jump line rate could be controlled at 0.19% per month, if only 87% of the cord jumpers in the marking line could be solved.

Causal analysis: Group for meridian line Jumper Brainstorming was used to analyze the causes. Analysis of the end factors: improper operation, the upper garment workers did not meet the requirements of the process, the warp threads on the marking line were worn out, the weaving process caused the warp tension at the marking line to be small, the thread at the end of the cloth end was drawn, the material properties were not up to standard, the temperature and humidity affected the strength and the elongation of the products.

On the basis of the terminal factors found, the QC group discussed the verification of the above end factors by checking the schedule, through on-site inspection, on-site tracking, sampling and testing, and checking records. It was decided that the weaving process should cause the warp tension at the marking line to be small, and the warp line at the end of the cloth head should be pumped when the fabric was dipped.

Implementation of countermeasures: the group has formulated a list of countermeasures and evaluation. In the light of Warp knitting The tension is small, the group proposes to stabilize the weaving tension of the warp thread at the marking line, change the fabric organization structure at the marking line, and increase the weaving tension of the cord at the marking line; in view of the marking line warping, the group measures the stitching reinforcement, increasing the weft density of the cloth end and increasing the weft density of the white cloth. Through the evaluation of the effectiveness, feasibility, economy, reliability and timeliness of the measures, the team finally decided to stabilize the weaving tension of the warp thread at the marking line, increase the weaving tension of the cord at the marking line, and reinforce the cloth head, the tail mark line, and increase the density of the white fabric and so on. The 4 countermeasures are put forward.

After repeated experiments, the team set up tension balancing rollers to make the tension uniform and stable on the marking line, add cowskin gaskets on the marking line, try to use U tension rods to add sheets, and stitch and reinforce the cloth ends, and so on. After the implementation of the strategy, the rate of jumper line with BS marking cord varieties decreased from month to month, and the average monthly jumper rate dropped from 0.6% to 0.14%. In all aspects of the activities, effective measures have been implemented in the new standards, and the effect has been maintained well.

Benefit: through this activity, we effectively reduce the jumper rate of marking gray fabric, and satisfy the high quality requirements of the international high-end users to the maximum extent, and enhance the company's product image.

Team members' team spirit, quality consciousness, personal ability and the use of QC tools have been greatly improved, and have accumulated rich experience for further activities in the future.