Process Flow Chart of Knitting

Yarn in Package Form

Place the yarn cone in the creel

Feeding the yarn in the feeder via trip tape positive feeding arrangement and tension device

Knitting

Withdraw the rolled fabric and weighting

Inspection

Numbering

Important Parameter and their effect in fabric production

a. Stitch Length b. GSM ray S! should be less than finish S! S! increase with increase of stitch length and it is ad#usted by $%& pulley Stitch length increase with the increase of S! If fabric width increase then stitch length increase and WPI decrease For deep shade stitch length should be higher and vice"versa

 c. Count d. Gauge e. Feeder f. Design

'n(yme )evel *olour Sueded or non"sueded If shrinkage increase then S! increase

If count increase then fabric width increase S! depends on yarn count

For finer gauge finer count should be use If machine gauge increase then fabric width decrease If gauge decrease then stitch length increase

Production increase with increase no+ of feeder Feeder is setted incase of stripe fabric

*am setting Set of needle Si(e of loop shape

ualit! Control "f Knitting Section

,o produce high -uality fabric it is necessary to inspect the fabric roll after receiving from different machine+ ,his is done to assure the -uality of the fabric before dyeing+

List of e#uipments used in inspection

a+ Inspection m.c b+ 'lectronic balance c+ S! cutter

Inspection Procedure
/s the fabric is produced by the circular knitting machine it is then collected by the -uality inspector and the fabric is thoroughly inspected in front of a white light board+ %uring this inspection the holes0 oil marks0 sinker marks0 needle marks0 barre effects are checked+ If the fabric is within the acceptance level 1by four point system2 then it is sent to the batch section for dyeing or further treatment+ In case of collar and cuff no inspection is done as the collars and cuffs are made in a very precise way by fully automatic or computeri(ed machine+

ualit! Standard
Interstoff /pparels )td+ Follows the four point grading system to inspect the body 3 rib of the fabric+ It is to mention that no inspection of collar or cuff is not done here as these are produce in a very precise manner+ In the four point system the faults are found by inspection and are given points against the fault+ ,hen the total no+ is calculated+ ,he following table shows the four point system+ Si$e of defects 4 inches or less 6ver 4 inch but not over 7 inch 6ver 7 inch but not over 9 inch 6ver 9 inch Four Point Grading S!stem Penalt! Points 5 8 4 :

Following ,able shows common body and rib faults and response by inspection section at Interstoff /pparel )td+ No+ 5+ 8+ 4+ :+ =+ 7+ >+ ?+ 9+ 5@+ 55+ 58+ 54+ 5:+ 5=+ 57+ 5>+ 5?+ Faults Needle !ark Stripe <arre mark *ontamination and fly Slubs ,hick thin place <irds eye Pin holes Wrong design !iAed yarn Sinker mark !issing yarn Coles 6il line. stain *hemical %irt stain *rease )ine Bneven tension ;esponse !a#or needle line is re#ected !a#or needle line is re#ected ;e#ected /pproved for colour but not for white shade 5 point is assigned 5 point ;e#ect 5 Point 5 Point ;e#ect %iscuss with manager !a#or sinker mark is re#ected Bse : point %o %o %o %o %o %iscuss with manager

Faults % their causes in &nitting

'. (arre) ,his is basically a fabric fault which is found in the course wise+ ,his is due to
*ount variation in the same lot Shade variation in the dyed yarn Needle is too lose or tight in trick

(. *eedle mar&) ,his is a fabric fault which is found in the wales wise due to needle+
,he reasons are

<reakage of hook of needle <reakage of latch of needle *hange of alignment of latch %ue to improper schedule maintenance

C.

"il mar&) ,his is a mark in the fabric due to oiling in the machine+ ;easons are
,oo much oiling in the machine )eakage in the oiling system <ad -uality lubricant is used !iAing of one -uality lubricant with another one

D.

+oles) ,his is a fabric fault which could be due to machine or yarn

,hick thin place in the yarn ,oo much tension of yarn ,oo much speed of the machine %efective needle

,. Slubs) ,his is a fabric fault due to pro#ected fibres

!ore formation of fly from the yarn <ad -uality of yarn use ,he air circulation system by the fan is not sufficient Fly could be come from the ad#acent machine due to cleaning

F. Design -ariation)
5

$ariation of stripe in the machine Wrong cam arrangement

G. Count -ariation)
%ifferent count of yarn package in the same lot %ifferent -uality of yarn use in the same order $ariation of count in the same package in different places Bse yarn of another company for the same production

GSM -ariation)
$ariation in the stitch length Wrong position of the $%& pulley Improper tension of the fabric during production Wrong selection of yarn count

"thers Contamination) 6ther than these there may be fault in the fabric due to dust of the area0 impurities in the yarn0 badly cleaned machine0 impurities can be come from the operator hand due to splicing of yarn etc+

Collar Fault)
)oop formation Cole %ue to yarn Needle mark

6il mark

Production Calculation
'. Production . shift in Kg at /001 efficienc!

(. Production.shift in meter

C. Fabric width in meter

2
7

D. GSM Calculation

/.

3.
D

,. Length calculation

Maintenance in the &nitting section

For proper running of the machine it is necessary to maintain the machine+ ,his is done by cleaning the machine after every 5="8@ days+ ,his is basically the servicing of the machine+ ,his is done because " " " " ,o maintain the -uality of the fabric ,o reduce the fabric fault ;emoval of dust from the machine *leaning of different parts of the machine

%uring servicing the following things are checked weather they are in good condition or not+ ,hese are cleaned and also replaces if necessary+ ,hese are Needle Sinker *am boA Sinker *am *ylinder Full body