NTC Project: S06-NS02 1 Dynamic Textile Process and Quality Control Systems S06-NS02 Moon W.

Suh (NCSU) - Leader Melih Gunay (NCSU/ HueMetrix) Ravikanth Vangala (NCSU)

Code: Investigators: Students:

Project Goals
The research team proposes to develop a novel process control system for dry and wet textile processes that are either continuous or serially connected with time lags. This new process will be called dynamic process control system and will provide process averages and control limits that are relative to the conditions of the prior processes. By obtaining more accurate control limits, the root causes of the out of control situations will be determined precisely, and unnecessary corrective actions (false positives) that are detrimental to quality monitoring and improvement will be minimized. The conventional quality/process management based on Shewhart control scheme and the so-called feed-back and feed-forward control systems has had only limited success in textile manufacturing in the past. These failure mechanisms have been outlined by Suh [1]. The key missing links are the structural relationships that connect the factors in a given process stage to that of the next stage. Without implementing these relationships, the stand-alone Shewhart control systems become totally useless when the input factors have been perfectly in control and match the process averages established. Otherwise, the in-control or out-of-control decisions become either false positives or false negatives.

Abstract
A dynamic quality control system for staple spinning process has been under development as an entirely new attempt to apply the known structural equations published during the last 60 years. The first task was to research and identify all published papers and sort out clearly defined input and output parameters that are essential for controlling process performance and product qualities. The literature and structural equations found to date are indeed quite impressive in their scope and application potentials. The next task is to align and consolidate the equations to a single set at each stage in such a way that a dynamic system can be developed by combining all process steps in sequence, linking all input and outputs parameters. This task is quite challenging but most rewarding. The final step is to establish the dynamic control limits based on a set of novel variance formulae in all process steps. The same steps will be repeated in a continuous wet process later on.

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Introduction and Technical Approach

Development of textile science and engineering during the last 100 years has been truly remarkable based on the published research reports and claims. However, as Prof. John W. S. Hearle (UMIST) once said in his farewell seminar at NC State University in 1999, it is quite troublesome to find only a small fraction of what has been discovered and reported by him and others is being applied in textile manufacturing operations today. In particular, the structural models and prediction equations published to date are seldom used in quality and process control practices in the US or elsewhere. Why? Textile quality control often involves keeping output of individual processes in control though the use of Shewhart control charts [4]. Although textile producers have invested in quality control systems through Shewhart control methods, manufacturers have yet to experience a significant cost reduction or increased benefits. This is mainly due to the use of control systems that are static and inflexible for accommodating the complex, dynamic and interactive nature of textile production environment. Frequent false alarms and unwarranted process calibrations based on the single stage control algorithms, often built in the manufacturing equipment, have resulted in loss of production time, materials and consequently profit. In case of an out-of-control situation, the backtracking of the problem source naturally begins with the last machine where the problem is caught [1, 4]. This is known as feedback control often accompanies instability with a tendency for over-control or unwarranted calibration [13]. In addition, a feedback control in textiles often leads to disappointing guesswork rather than an effective corrective action due to 1-to-N nature of manufacturing processes [11]. Thus, use of a static target reference in a continuous, dynamic textile process causes frequent false alarms when the changes in process averages originate from the prior process stages. To remedy this difficulty, a dynamic EWMA control chart procedure [10, 13] can be employed. However, this procedure was somewhat effective only for short-run process control situations as it forces us to examine only the current process average against the target with no reference to the biases generated by the prior processes [3, 12] indefinitely. This undoubtedly is a terribly inefficient control process completely void of structural relationships already known for the causes and effects. Therefore, development of a new dynamic process and quality control system is one of most attractive alternatives to the current practices in dry and wet textile processes. It should be accomplished by combining the known structural models linking the process input to the output variables through time-dependent statistical models similar to EWMA and on-line computer simulations. Any prior process knowledge can be incorporated into the model in the form of prior distributions using a Bayesian approach. In textile manufacturing, prior information may be in the form of structural equations, similar process history and the expert knowledge base. The discrete textile processes may be linked through the structural equations via variance channeling as already demonstrated by Suh and Jeong [7]. Subsequently, a modified dynamic EWMA control system can be designed in order to compute the expected process averages and the associated control limits, thus generating an optimal control strategy at each process stage. These tasks require development of general theories and working models leading to Dynamic Process and Quality Control System (DTPQCS) first by surveying the published papers or wellNational Textile Center Annual Report: November 2006

NTC Project: S06-NS02 3 established scientific facts. Currently, we are in the process of developing the functional and/or structural relationships between the input and output variables of all two contiguous process stages in the staple spinning process as a foundation for DTPQCS. In the next stage, we will establish the dynamic process average and the dynamic control limits for each process stage based on the functional/structural relationships between the input and output variables involved in the previous and present process stages. Finally, as complete DTPQCS will be developed and implemented for the entire staple spinning process followed by system verification. We plan to apply the identical steps to a wet textile process to constitute the second half of this research. The on-line real-time dynamic control system will be tried in a continuous dyeing and finishing processes by considering all relevant input and output factors and variables, including the basis weight, mass uniformity, uniformity of physical properties [17], dimensional properties, speed, moisture contents, liquor ratio, dye concentration, dye injection rate, fabric speed, bath temperature, etc. [14, 16]. While the relationships among these variables have been studied in the past [15, 16], the process averages have seldom been linked in terms of structural relationships. Therefore, establishing a set of dynamic control limits for an on-line, real-time system is a significant challenge.

Work in Progress - Some Details

We made a significant progress in developing the conceptual and theoretical framework for the DTPQCS in the traditional stable yarn production process. The scientific papers published in several key journals have been searched and the relevant information extracted from many published papers. Many of the published papers are often found to be seemingly important but incongruent to each other in forming a seamless input/output structure. A major challenge, as expected, would be to sort out only the essential information and combine them into a usable form of structural equation for each and every stage. Some of the work being done is as follows: 1. We are developing an off-line dynamic control system for staple yarn spinning process by treating blending, carding, drawing, roving, spinning, and fabric formation (weaving and knitting) as continuous but disjoint processes. Since every previous process affects the following processes [5, 6, 7, 8], certain functional relationships are being surveyed, classified, analyzed and evaluated for their applicability from the vast amount of published work and literature. The measured fiber properties [9] such as strength, length, short fiber content, length uniformity, micronaire and color as well as the intermediate measurements of mass, mass uniformity at different processing stages provide the necessary input process averages and variances of the subsequent processes. Eventually, the output averages and their variances will be computed in time domain and compared against the actual values for optimal control. The data obtained would be handled as a continuous process although they are analyzed off line. 2. The key strategy is to estimate the output process averages and variances as functions of the input process averages and the variances originating from the prior process stages. Our initial approach is to take a well-known property of a fiber bundle such as mass, uniformity or strength and tracing its progress through the established relationships between various stages of yarn production. Figure 1 and Table 1 show the stages of yarn production and the several mathematical equations representing some of the most significant relationships. As seen from National Textile Center Annual Report: November 2006

NTC Project: S06-NS02 4 these, the relationships are often not in the functional forms that we could easily transfer to the discrete stages of continues yarn production. Therefore, we are mapping these equations into most compatible, congruent forms between the process stages. During this mapping, we keep in mind the assumptions that are made during the derivation of each relationship. As expected, due to the complex nature of some of these assumptions, we often had to abandon the aspiration of obtaining a clean structural equation. In order to simplify this task, we established a matrix of equations between the spinning process stages. This matrix not only allows us to derive the input and output parameters of a structural equation easily but also provides us a means to see the limitations in formulating the structural equations. Table 1, together with Figure 1, shows some of the structural and functional relationships between yarn spinning processes. The inputs and outputs of each spinning process are given on the left and right side of the process parameters, respectively. The process parameters along with the input parameters produce an output, which in fact becomes the input parameters of the following process. The sample equations cited in Figure 1 and Table 1 links only the mass features of fiber bundles in the processes. Table 1. Mass relationships in spinning processes
Eq. No. Equations Parameters/Description

WT: wi:

total width of the bales at laydown width of each bale number of laydowns the Scan Speed of Collector collector mass the scan depth the density of bale tnit collection time transfer coefficient operational layer fiber mass transferred from cylinder to doffer recycling layer fiber mass transferred from taker into cylinder flat strips

WT = wk
k =0

n: V: MC : H: d: t:
K: Q0: Q1: Q2

M C = V WT H d t

K = Q1 Q0
2 (i) Where Q0 = Q2 + QL - Qf

QL:

Qf:

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weight per unit length of the web and that of the feed respectively under steady state equilibrium conditions instantaneous deviations in the q & qp. expected residence time in the card instantaneous time since the onset of the deviation Yp.

t X = K(t) Xp ( t - ) d

q, qp :

Y, Yp : 2 (ii)

Where X = Y q

c1 :
;

Xp =

Yp qp

(t) = e- t1/c1 c1

t:

t: ___________ ____ H = (2 * t * Lf )3 / M3/2 ( For Carded Cotton Roving) ____________ ___ H = { 3 ( 1.67 * t * Lf / 6 M5 } * C ( For Combed Cotton Roving) H: Lf : M:

turns per inch weight per unit length of fiber measured as the Micronaire value of cotton. hank of roving (English System) upper half mean length in inches as measured by fibro graph = 0.95 % correction factor

(In progress)
4

National Textile Center Annual Report: November 2006

NTC Project: S06-NS02 6 Figure 1. Framework for structural and functional relationships among key spinning processes

National Textile Center Annual Report: November 2006

NTC Project: S06-NS02 7 Figure 2. Link between the standard deviations in mixing/blending and carding via the structural relationships developed

Table 2. Some functional relationships for processes in Figure 2

_ _ ________________ CV (Y) = 100 n A 1 + 0.0001CV (A)2 nA _______________ = 100 1 + 0.0001CV2 (A) n
L

n: A:

mean number of fibers in web cross-section feed web cross-section Area

L: n: BLD 2

the number of laydowns the number of bales per laydown. the between laydown variance.

total 2 = (L - 1) n BLD 2 + (Ln - 1)

(n - 1) WLD 2 (Ln - 1) 1

3. Upon identification of the most relevant structural models, the upper and lower control limits at any given process stage will be computed by incorporating the process variance National Textile Center Annual Report: November 2006

NTC Project: S06-NS02 8 generated from the current stage through the known functional or structural relationships. The process average of the current process will also be computed based on the functional relationships that reflect the biases or the amounts of the out-of-control generated from the previous process stages, if any. This concept is shown in Figure 2 above. Here, the bias Bk is introduced at the Kth stage along with new process variance k2 to generate the control limits as sum of the biases and the process variances. In addition, the process variance would be the sum of the variances inherited from the prior processes through the structural or functional relationships and the new variances introduced at that particular stage.

Summary
An extensive literature survey has been completed and is continuing. The necessary functional and structural relationships in the staple yarn spinning process have been identified, classified, and compared against each other for possible duplication and contradiction. These relationships have been analyzed partially to form continuous dynamic linkages as an integrated system in the form of input and output parameters and forward prediction equations. This is a massive undertaking as we have to comb through all scientific publications and reports available to date and sort out only the essential information, and establish the connectivity as a contiguous system in a framework of disjoint real-time domain. Efforts have been made to do try variance tolerancing and decomposition [5, 6] and this effort will also continue. Many of the available estimates have yet to be analyzed and documented. Simultaneously, a dynamic control chart procedures and a modified EWMA procedure are being examined as a working model encompassing all structural linkages to be developed. Theoretically, the most challenging tasks are in the areas of information fusing (among seemingly incompatible and/incongruent relationships) and computation of variances applying the complex set of structural equations thus finalized.

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References
1. Suh, M.W., Improving textile product and process qualities: Failure mechanisms and new directions for the future, Journal of the Textile Institute (Invited Paper), Vol. 85, No. 4, p476-483, 1994. 2. Suh, M.W., What is happening to the U.S. Textile Industry? Reflections on NAFTA and U.S. corporate strategies, Journal of Fashion Marketting and Management, Vol. 7:(2), p119-37, 2003. 3. Olorunniwo, F.O., Economic design of a partially dynamic control chart, International Journal of Quality & Reliability Management, Vol. 6, No. 3, Emerald Group Publishing Limited, 1989. 4. Bona, M. Textile quality: Physical methods of product and process control, Biella, Italy, Textilia, 1994. 5. Koo, H.J., M.W. Suh and J.L. Woo, Variance tolerancing and decomposition in short staple spinning processes, Part I Theories, Textile Research Journal, Vol. 71(1), p1-7, 2001. 6. Suh, M.W., H.J. Koo, and J.L. Woo, Variance tolerancing and decomposition in short staple spinning processes, Part II - Simulation and application to ring carded, ring combed and o-e spun yarns, Textile Research Journal Vol. 71(2), p105-111, 2001. 7. Suh, M.W. and S.H. Jeong, Sequential channeling of time-dependent variances in spun yarn manufacturing, Textile Research Journal, Vol. 72(3), p1-7, 2002. 8. Suh, M.W., Structural and probabilistic models in textiles, An Invited Paper presented to Spring 2000 Fiber Society Technical Conference MAY 17-19, 2000, GUIMARES, PORTUGAL. 9. Hearle, J.W.S., Grosberg, P. and Backer, S., Structural Mechanics of Fibers, Yarns, and Fabrics. Wiley-Interscience, New York, NY, 1969. 10. Wasserman, G.S., Short-run SPC using dynamic control chart - Computers & Industrial Engineering, 27 (1-4): p353-356, Sep, 1994. 11. Friauf, W.S., Feedback loop stability analysis, Mcgraw-Hill, 1998. 12. Chellamani, K.P. and Chattopadyhyay, D., Tools for TQM Implementation in a Spinning Mill, Asian Textile Journal, Vol. 9, Issue 11, p140, p7. 2000. 13. Crowder, S.V., Design of EWMA Schemes, Journal of Quality Tehnology, (21):3, p155-189, 1989. 14. Hall, A.J., Textile finishing, American Elsevier Publishing, 1966. 15. Lou, R., Colour appearance assessment, Journal of the Society of Dyers and Colourists 112 (3): p72-74 March 1996. 16. Johnson, A. The theory of coloration of textiles, Society of Dyers and Colourists, Second Edition, 1989.

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17. Yehia E. El Mogahzy and Yasser Gowayed., Theory and Practice of Cotton Fiber Selection, Part II: Sources of Cotton Mix Variability and Critical Factors Affecting It., Textile Res J. 65(2), 7584 (1995). 18. C.A. Lawrence, A. Dehghani, M. Mahmoudi, B. Greenwood and C. Iype, Fibre Dynamics in the Revolving-Flats Card, Part I, A Critical Review., AUTEX Research Journal, Vol 1, No.2 November 2000 AUTEX. 19. Buturovich, I.KH., Analysis of the Equalising Action of the Flat Card from the Frequency Characteristics, Tech. of Textile Industry USSR, (1), 38 43 (1968). 20. Merchant V.B., The Fundamentals of Roving Twist, Textile Institute Journal, V 53, T 58- 68, (Feb 1963).

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Project Statistics
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National Textile Center Annual Report: November 2006