Download - Yarn quality and customer satisfaction
CUSTOMER PERCEPTION ZDQC DIFFERENT AUDIT TYPES END USE BASED QUALITY REQUIREMENTS HAIR SEVERITY CO CREATION
CUSTOMERS OF SPINNING MILLS
1. WEAVERS2. KNITTERS3. GARMENT MANUFACTUERERS4. VALUE ADDITION GROUP
CURRENT SCENERIO OF TEXTILE INDUSTRY:ONLY THE QUALITY CONSCIOUS WILL SURVIVE
BUYING HOUSES ALREADY STARTED FISHING NET OPERATIONS FOR JOINT VENTURES/TIE UP ARRANGEMENTS
QUALITY
LET US NOT GIVE A CHANCE FOR THE CUSTOMER TO ASSESS OUR QUALITY.
QUALITY-LET US INTERNALISE
DEFECT IS ANYTHING THAT DISSATISFIES THE CUSTOMER
WARP BREAKS-PACKAGE /STRENGTH SPLICE QUALITY
(Appearance/Strength)
AIM AT ZERO INTERNAL COMPLAINTS
IN TQM `ZDQC’ IS A CONCEPT
DEVELOP INTERNAL AUDIT SYSTEMS-FOOLPROOF
BUYER`S EXPERTISE-LET US GIVE VALUE
DEFECT IS ANYTHING THAT DISSATISFIES THE CUSTOMER
QUALITY IS THE CUSTOMER`S PERCEPTION
Type 1 Type 2Warping Yarn ScouringSizing Yarn DyeingWeaving WarpingFabric Dyeing/Finishing Sizing
WeavingFabric Finishing
Appx 450 to 700 ends/beamSpeed : High speed – 600 m/m
Super High Speed-1000 m/m Breaks/Million Meters
0.25 to 0.4 for Single yarn 0 to 0.2 for Double yarn
Yarn strength: 18 RKM/3000 CSP – Single yarn
20 RKM/3300 CSP - Double
yarnConsistency in yarn length
NO Crushed conesNO Cut endsNO EntanglementsNO Transport damages
Preferred cone weights for single yarn Coarse Medium : Upto 3 kg 60s to 80s : 2.2 kg Above 80s : 1.8 kg
Low Hairiness
(Additional process of winding introduces more hairs. Hence basic yarn should have less hairiness)
Type 1 Type 2
Knitting Scouring
Scouring Bleaching or Dyeing
Bleaching Knitting
Dyeing/Finishing
Fabric finishing
Uniform shadeContamination free/lessDyed Vs White bleach standardsLess long term faultsLess slubs/short thick placesAbsence of wild yarn
Directly procure sewing threads fromMILLS - Polyester - CottonRequirements: Less KnotsLess SpliceNear Zero short thick place(5-6 A2,B2 faults in ply yarn - called as ELKO)
Doubling (TFO/Ring Doubling)GassingGassing, Mercerizing and bleachingGassing, Mercerizing and dyeingGrindle yarnFancy Yarn
Uniform shade/Homogenous mix QualityLess long term faultsLess fluff liberationLess NepsGood yarn strength (Stress is more
during mercerizing)
Count & : Based on 30 lea weights Count CV% : Count CV% should be below 1.2%
For 50s, 1.2% count CV% means a range
of 48.8 to 51.2
95% confidence level
2 Limits
2
48.8
x50
2
51.2
95% of the values will fall between 48.8 to 51.2
5% of the samples can take extreme values i.e. below 48.8 or above 51.2
Evenness : U% or mass variation measure
Thin : -50% of yarn diameter Thick : +50% Neps : +200% of yarn
diameter with a size less than 2mm
Evenness : Single Yarn 9 to 11.5 (20s to 80s)
Double yarn 6.5 to 8
Evenness of double yarn: Single yarn evenness
--------------------------
2
20s - 20 60s - 120 30s - 35 80s - 210 40s - 65 100s - 280 50s - 95
TODAY’S CUSTOMER REQUIREMENTS ON TODAY’S CUSTOMER REQUIREMENTS ON IMPERFECTIONS (COMBED YARN)IMPERFECTIONS (COMBED YARN)
Uster hairiness index : 20s - 7.0 40s - 5.2 80s - 4.2
Zwiegle S3 value : 40sCW - 550
HAIRINESSHAIRINESS
HAIRINESS-CONVENTIONAL HAIRINESS INDEX HAIR COUNT H3 OR S3 VALUES
NEW:HAIR SEVERITY
HAIR SEVERITY IS AN INDEX DERIVED FROM HAIR COUNT DISTRIBUTION
TWO YARNS HAVING SIMILAR HAIRINESS INDEX WILL HAVE DIFFERENT HAIR SEVERITY WHICH DECIDES THE END USE PERFORMANCE
REF
HI 3MM
4MM
5MM
6MM
7MM
>8MM
HC HS
A 4.4 123 16 2.6 0.5 0.3 0.1 143 8.9
B 4.5 163 22 2.5 0.6 0.1 0 188 12
LEA STRENGTH : Lea Tester using 120 yards lea
Terminology : Count Strength Product
CSP for Warp single yarns : 2800+ CSP for Hosiery yarns : 2300 + CSP for “Yarn dyeing” : 2500 +
YARN STRENGTHYARN STRENGTH
Single yarn strength : Based on 50cm specimen
break Instruments : Tensorapid Tensojet RKM : SYS converted to Tex could for easy
memory RKM : Single yarn strength(grams) ---------------------- Tex count
YARN STRENGTHYARN STRENGTH
RKM : Single yarn : 18RKM:Warp S.Y 15RKM:SY
Hosiery
Elongation % : Extension of yarn at the breaking point as %
Indian yarns (Single) : 4 – 4.5
Under spinning of yarn & import cotton (single) : 4.5 – 5.5
Raw material faults Objectionable faults Long thick faults Long thin faults
Today’s requirements: Any single yarn: Below 65
Any double yarn:Below 40
CLASSIMAT FAULTSCLASSIMAT FAULTS
1 A4 B4 C4 D4
A3 B3 C3 D3
A2 B2 C2 D2
A1 B1 C1 D1
+400%
+250%
+150%
+100%
+45%
H1 I1H2 I2
F G
E
- 30%
- 45%
- 75%
0.1 1 2 4 8 32
Single yarn : 8% Double yarn : 6.5%(Follows Normal Distribution)GROUP MINIMUM AVERAGE or
10 Percentile value
SINGLE YARN STRENGTH VARIATIONSINGLE YARN STRENGTH VARIATION
Shade variation/patta formation Needle breaks Fabric holes Weight shortage Fluff liberation Contamiations
NORMAL CUSTOMER COMPLAINTS IN HOSIERY YARN
Warping breaks High level of entanglements in sizing High level of warp breaks in loom Higher weft breaks Fabric neps Yarn floats in Fabric Contamination
NORMAL CUSTOMER COMPLAINTS IN WEAVING YARN
Crushed cones/cone deformation
Nose damages
Nose flowering
Ribboning
COMPLAINTS RELATED TO PACKING/CONES
Bag packing
Hollow packing
Carton packing
Carton packing covered with bags
Pallet packing
TYPE OF PACKING
4 20’ 5 57’ 9 15’
(Depends on end user & our machinery)
Practices in Indian
GinneriesJute, HairPolypropylene White &
ColourColour fabricsColour Threads
Dyed Fabric : White Polypropylene
ProjectsBleached Fabric: All colour fibers exhibitedUp to 2 colour fiber/Kg is Tolerable
Stringent requirements :0.5 Colour Fiber/20kg
Meeting Customer Requirements
Customer Satisfaction Customer Delight
Co Creation
Manufacturing Products Manufacturing Products with the Customerswith the Customers
More satisfied customer baseActive involvement of customer with
the producerReduced manufacturing costUnique experienceAvailability of more choices to the
customers
Eg: Buying a recorded musical CD Vs recording a CD with selected songs
Effect: 1st Scenario We pay for what we don’t need also
2nd Scenario We pay for a product i.e. satisfies 100% of our needs.
Challenges:
Customers arrive with own dynamic requirements
Necessity of Re-orientation to joint relation
Managers feel it as a challenge to their own Bias
Challenges:
Flexibility & Adaptability to changes
Validation of products (Eg:Windows NT 2000) has been validated by Microsoft by its 6 lac customers.
Differently we can call as tailoring the product to meet the customer requirements.
CUSTOMERS INTOLERENCE ON POOR SERVICE
GOOD SERVICE BRINGS MORE CUSTOMERS
Takes initiative
Do more than the competition
Takes responsibility
Think like a leader
Learn from the experience
Constantly strive to meet customer needs
Exceed expectations
Deliver on promises
Make it easy to do business
Be proactive
Gets to know customer`s perceptions
Response to feedback
(Exercise follows)
It reveals company`s commitments
It reveals company`s intentions
It displays a personal touch to everyone
Identify coffee stains in your company
How ,as a manager ,are going to remove these coffee stains?
GOOD RELATIONSHIP ----WHY?
LESS THAN SATISFACTORY----WHY?
UNSATISFACTORY RELATIONSHIP ----WHY?
Not working for tips
When we visit next we bring business to the hotel
Customer service-Good stories
1. Yarn Quality (30%)2. End use performance(30%)3. Quality of Packing (10%)4. Adherence to Delivery(10%)5. Quality of Sales Staff (10%)6. Quality of Agents(10%)
Customer Satisfaction Index