yarn quality and customer satisfaction
TRANSCRIPT
![Page 2: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/2.jpg)
CUSTOMER PERCEPTION ZDQC DIFFERENT AUDIT TYPES END USE BASED QUALITY REQUIREMENTS HAIR SEVERITY CO CREATION
![Page 3: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/3.jpg)
CUSTOMERS OF SPINNING MILLS
1. WEAVERS2. KNITTERS3. GARMENT MANUFACTUERERS4. VALUE ADDITION GROUP
![Page 4: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/4.jpg)
CURRENT SCENERIO OF TEXTILE INDUSTRY:ONLY THE QUALITY CONSCIOUS WILL SURVIVE
BUYING HOUSES ALREADY STARTED FISHING NET OPERATIONS FOR JOINT VENTURES/TIE UP ARRANGEMENTS
![Page 5: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/5.jpg)
QUALITY
LET US NOT GIVE A CHANCE FOR THE CUSTOMER TO ASSESS OUR QUALITY.
QUALITY-LET US INTERNALISE
![Page 6: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/6.jpg)
DEFECT IS ANYTHING THAT DISSATISFIES THE CUSTOMER
WARP BREAKS-PACKAGE /STRENGTH SPLICE QUALITY
(Appearance/Strength)
![Page 7: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/7.jpg)
AIM AT ZERO INTERNAL COMPLAINTS
IN TQM `ZDQC’ IS A CONCEPT
![Page 8: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/8.jpg)
DEVELOP INTERNAL AUDIT SYSTEMS-FOOLPROOF
BUYER`S EXPERTISE-LET US GIVE VALUE
![Page 9: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/9.jpg)
DEFECT IS ANYTHING THAT DISSATISFIES THE CUSTOMER
QUALITY IS THE CUSTOMER`S PERCEPTION
![Page 10: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/10.jpg)
Type 1 Type 2Warping Yarn ScouringSizing Yarn DyeingWeaving WarpingFabric Dyeing/Finishing Sizing
WeavingFabric Finishing
![Page 11: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/11.jpg)
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
![Page 12: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/12.jpg)
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
![Page 13: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/13.jpg)
Low Hairiness
(Additional process of winding introduces more hairs. Hence basic yarn should have less hairiness)
![Page 14: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/14.jpg)
Type 1 Type 2
Knitting Scouring
Scouring Bleaching or Dyeing
Bleaching Knitting
Dyeing/Finishing
Fabric finishing
![Page 15: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/15.jpg)
Uniform shadeContamination free/lessDyed Vs White bleach standardsLess long term faultsLess slubs/short thick placesAbsence of wild yarn
![Page 16: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/16.jpg)
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)
![Page 17: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/17.jpg)
Doubling (TFO/Ring Doubling)GassingGassing, Mercerizing and bleachingGassing, Mercerizing and dyeingGrindle yarnFancy Yarn
![Page 18: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/18.jpg)
Uniform shade/Homogenous mix QualityLess long term faultsLess fluff liberationLess NepsGood yarn strength (Stress is more
during mercerizing)
![Page 19: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/19.jpg)
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
![Page 20: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/20.jpg)
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
![Page 21: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/21.jpg)
Evenness : U% or mass variation measure
Thin : -50% of yarn diameter Thick : +50% Neps : +200% of yarn
diameter with a size less than 2mm
![Page 22: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/22.jpg)
Evenness : Single Yarn 9 to 11.5 (20s to 80s)
Double yarn 6.5 to 8
Evenness of double yarn: Single yarn evenness
--------------------------
2
![Page 23: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/23.jpg)
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)
![Page 24: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/24.jpg)
Uster hairiness index : 20s - 7.0 40s - 5.2 80s - 4.2
Zwiegle S3 value : 40sCW - 550
HAIRINESSHAIRINESS
![Page 25: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/25.jpg)
HAIRINESS-CONVENTIONAL HAIRINESS INDEX HAIR COUNT H3 OR S3 VALUES
NEW:HAIR SEVERITY
![Page 26: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/26.jpg)
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
![Page 27: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/27.jpg)
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
![Page 28: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/28.jpg)
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
![Page 29: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/29.jpg)
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
![Page 30: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/30.jpg)
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
![Page 31: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/31.jpg)
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
![Page 32: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/32.jpg)
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
![Page 33: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/33.jpg)
Single yarn : 8% Double yarn : 6.5%(Follows Normal Distribution)GROUP MINIMUM AVERAGE or
10 Percentile value
SINGLE YARN STRENGTH VARIATIONSINGLE YARN STRENGTH VARIATION
![Page 34: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/34.jpg)
Shade variation/patta formation Needle breaks Fabric holes Weight shortage Fluff liberation Contamiations
NORMAL CUSTOMER COMPLAINTS IN HOSIERY YARN
![Page 35: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/35.jpg)
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
![Page 36: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/36.jpg)
Crushed cones/cone deformation
Nose damages
Nose flowering
Ribboning
COMPLAINTS RELATED TO PACKING/CONES
![Page 37: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/37.jpg)
Bag packing
Hollow packing
Carton packing
Carton packing covered with bags
Pallet packing
TYPE OF PACKING
![Page 38: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/38.jpg)
4 20’ 5 57’ 9 15’
(Depends on end user & our machinery)
![Page 39: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/39.jpg)
Practices in Indian
GinneriesJute, HairPolypropylene White &
ColourColour fabricsColour Threads
![Page 40: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/40.jpg)
Dyed Fabric : White Polypropylene
ProjectsBleached Fabric: All colour fibers exhibitedUp to 2 colour fiber/Kg is Tolerable
Stringent requirements :0.5 Colour Fiber/20kg
![Page 41: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/41.jpg)
Meeting Customer Requirements
Customer Satisfaction Customer Delight
Co Creation
![Page 42: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/42.jpg)
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
![Page 43: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/43.jpg)
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.
![Page 44: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/44.jpg)
Challenges:
Customers arrive with own dynamic requirements
Necessity of Re-orientation to joint relation
Managers feel it as a challenge to their own Bias
![Page 45: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/45.jpg)
Challenges:
Flexibility & Adaptability to changes
Validation of products (Eg:Windows NT 2000) has been validated by Microsoft by its 6 lac customers.
![Page 46: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/46.jpg)
Differently we can call as tailoring the product to meet the customer requirements.
![Page 47: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/47.jpg)
CUSTOMERS INTOLERENCE ON POOR SERVICE
GOOD SERVICE BRINGS MORE CUSTOMERS
![Page 48: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/48.jpg)
![Page 49: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/49.jpg)
Takes initiative
Do more than the competition
Takes responsibility
![Page 50: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/50.jpg)
Think like a leader
Learn from the experience
Constantly strive to meet customer needs
![Page 51: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/51.jpg)
Exceed expectations
Deliver on promises
Make it easy to do business
![Page 52: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/52.jpg)
Be proactive
Gets to know customer`s perceptions
Response to feedback
![Page 53: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/53.jpg)
(Exercise follows)
![Page 54: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/54.jpg)
It reveals company`s commitments
It reveals company`s intentions
It displays a personal touch to everyone
![Page 55: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/55.jpg)
Identify coffee stains in your company
How ,as a manager ,are going to remove these coffee stains?
![Page 56: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/56.jpg)
GOOD RELATIONSHIP ----WHY?
LESS THAN SATISFACTORY----WHY?
UNSATISFACTORY RELATIONSHIP ----WHY?
![Page 57: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/57.jpg)
![Page 58: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/58.jpg)
Not working for tips
When we visit next we bring business to the hotel
![Page 59: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/59.jpg)
![Page 60: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/60.jpg)
Customer service-Good stories
![Page 61: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/61.jpg)
![Page 62: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/62.jpg)
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%)
![Page 63: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/63.jpg)
Customer Satisfaction Index
![Page 64: Yarn quality and customer satisfaction](https://reader035.vdocument.in/reader035/viewer/2022062412/589ebf931a28ab4a5c8b68d5/html5/thumbnails/64.jpg)