Flow Chart of Textile Engineering

The word “Textile” is come from Latin word “to weave”, “to braid”, “and “to construct”. Textile has been a fundamental part of human life since the beginning of civilization and the methods and materials used to make them have expended enormously.

Dictionary of Textile define Textile:

. A broad classification of materials that can be utilized in constructing fabrics, including textile fiber and yarns.

II. Designates the constructed fabric including woven, knitted and non-woven construction as well as lace and crocheted goods. 

III. Descriptive of processes, organizations, personal associated with the manufacturer of products from fibers or yarn.

Fig: Textile engineering students

Textile manufacturing is a major industry. It is based in the conversion of three types of fibre into yarn, then fabric, then textiles. These are then fabricated into clothes or other artifacts. Cotton remains the most important natural fibre, so is treated in depth. There are many variable processes available at the spinning and fabric-forming stages coupled with the complexities of the finishing and coloration processes to the production of wide ranges of products. There remains a large industry that uses hand techniques to achieve the same results.

Flow Chart of Textile Engineering 

Input→→→→→→→→→→ Section→→→→→→→→→ Output 

Fiber→→→→→ → Spinning →→→→→→→ Yarn 

↓ 

Yarn →→→→→→→→ Weaving →→→→→→ Grey Cloth 

↓ 

Grey Cloth →→→→ Wet Processing →→→ Dyed/Printed Fabric 

↓ 

Dyed/Printed Fabric→ → → Garment Manufacturing →→→→ End product

List of Knitting Machines | Machineries are Used for Garments Manufacturing

Knitting Machines: 

Knitted fabric differs vastly from woven fabrics. Woven fabric is formed substantially by interlacing of a series of lengthwise and crosswise threads. Knitting is the process in which fabrics are produced by set of connected loops from a series of yam in weft or warp direction is called knitting.. The basic element of a knit fabric structure is the loop intermeshed with the loops adjacent to it on both sides and above and below it. 
The knitting industry belongs to the branches of the textile industry with long tradition and the knitted goods have been known for centuries. In the early days they were made by hand but now a days various kinds of modern knitting machinery are used to produces knitted fabric. Those knitting machineries not only highly productive but also capable to produce quality fabric. Here I am giving a list of the most used knitting machines in knitting industry. 

Fig: Knitting and garment machines

Knitting are two typs; warp knitting and weft knitting. So knitting machines are also two types; warp knitting machines and weft knitting machines. 

Weft knitting machines can be classified in different way. Such as According to the frame design and needle bed arrangement or construction, according to the number of needle bed or number of needle set used, according to the end product of the weft knitting rnachine, according to the basic structure of the weft knitting, according to the types of needle used etc. 

List of knitting machines used in knitting industry: 

1. V-bed knitting machine
2. Circular knitting machine
3. Four truck single jersey circular knitting m\c
4. Mechanical Interlock circular knitting machine
5. Electronic Interlock Circular Knitting Machine
6. Interlock circular knitting machine.
7. Rib circular knitting machine
8. Jacquard Circular Knitting Machine
9. V- Bed Automatic Knitting Machine
10. Coller Cuff V- Bed Automatic Knitting Machine
11. Tricot Warp Knitting Machine
12. Linking Machine
13. Hand Socks Knitting Machine
14. Automatic Socks Knitting Machine
15. Straight bar frame knitting machine
16. Rachel warp knitting machine
17. Single truck single jersey circular knitting m\c

Garment machines: 
Clothing or garments protect the human body from extreme weather and other features for the environment. Clothes are worn for resignation of shame, safety, comfort, modesty and to reflect religious, cultural and social meaning. Ancient people used Grasses, reeds, leaves and stems to cover their body of purely the vegetable origin. And then they started to use the skin of animals as to wear as their clothes. Now a days various fashionable cloths are manufactured by using different types of machineries. In this article, I will give list of machineries used in apparel manufacturing. 

In garment manufacturing, different types of spreading machine, cutting machine, sewing machine, fusing and interlining machines are used. Now I’m giving just few widely used cutting and sewing machines list. 

List of cutting machines used in garments manufacturing: 

Cutting machines: 

1. Straight knife of Cutting Machine.
2. Round Knife Cutting Machine.
3. Band Knife Cutting Machine.
4. Die Cutting Machine.
5. Notcher Machine.
6. Drill Machine.
7. Computer Controlled Knife Cutting Machine.
8. Laser Cutting Machine.
9. Water Jet Cutting Machine.
10. Rib Cutting Machine
11. Air jet Cutting Machine.
12. Ultrasonic Cutting Machine.
13. Plasma Torch Cutting Machine

Textile Maintenance | Maintenance for Textile Machines

MAINTENANCE IN TEXTILE 
Author: Shafat Hossain Sajib

Noakhali Textile Engineering College

MAINTENANCE: 
Maintenance may be defined as the chronological activities or as the process of systematic activities done for keeping the m\c or equipments at the heat level for well run or its proper services. 

AIMS of MAINTENANCE: 

1. To maintain m\c equipment at optimum operation speed & production efficiency
2. To unsure best possible level of quality of product.
3. To minimize the idle time resulting from the machinery break down.
4. To reduce the cost.

IMPORTANCE of MAINTENANCE: 

1. To increase the life time cycle of machinery & equipment
2. In case of appropriate functioning.
3. Better or superior quality for the product.
4. Higher productivity of machines
5. Wastage reduces & control.
6. Economization of the process.

EFFECTS of MAINTENANCE:

1. Due to proper maintenance reduce undue worn out of different parts & equipment as well as corrosion of the items & increase the machines life ( these are the result of routine cleaning, lubricating, repairing, replacement, fitting, & refitting etc.)
2. For sound or congenial operation of machinery, it is required the proper lubrication, fitting, repairing, & replacement (as per necessity).
3. By the continuous operation of the machinery reduces stoppages time resulting better quality & less wastage

OPERATION INVOLVED in MAINTENANCE:

Setting: Setting is the activities to set or install the machine parts or required ancillaries. Adjustment also complementary word to setting used for appropriate setting. 

Checking: Checking means investigation of machine condition. It is very important work in case of maintenance. It is very skilled depends work as successful maintenance that depends on correct fault detection. 

Repairing: Repairing or altering of spares & equipment (if necessary) is to be detected & necessary measures are taken (repairing\altering\setting\adjustment) .

Overhauling: It is the work of maintenance, but not frequent or schedule work. It is done as per as necessary.

SYSTEM of MAINTENANCE: 
Basically there exist 2 systems on which based different types of maintenance are done. They are: 

1. Break down maintenance
2. Planned maintenance.

TYPES of MAINTENANCE: 

1. Preventive maintenance.
2. Productive maintenance.
3. Routine\schedule maintenance. (cleaning,checking, lubricating)
4. Remedial maintenance.
5. Restorative maintenance\emergency maintenance.

POWER TRANSMISSION: 
Power may be transmitted in the following ways. They are: 

1. By mechanical means
2. By electrical means
3. By electro-mechanical means
4. By hydraulic means
5. Others (aeronautics)

In them the mechanical means transmission is classified in following 

Through belt & pulley (Flat belt & flat pulley) 

• (V-belt& V-pulley)
• (Timing belt & Timing pulley)

Through gears (Straight gears such as Spur gearing) 

• (Epicyclical gearings)

Through chain-sprocket 

LUBRICANTS: 
2 types of lubricant on the basis of viscosity 

1. Oil
2. Grease

For evaluating lubricant following factors are considered 

1. Sp. gravity
2. Viscosity
3. Flash point
4. Pour point
5. CST (cent stroke behavior at 400c both for oil & grease)

EFFECT of LUBRUCANT: 

1. Corrosion (anti corrosion effectiveness)
2. Uniformity & optimum speed attainment
3. Recommended legibility of the spares & parts
4. High efficiency (due to low break down stoppage of the material)
5. Higher quality of the product
6. Low work load on the work arm
7. Less material handling

SYSTEM & PROCEDURE of MAINTENANCE: 

1. For effective maintenance a no. of pre-requirement site have to met
2. There must be a well defined organizational structure to & implement the program.
3. Proper planning, scheduling & controlling of maintenance must be designed.
4. An appropriate flow of information & data on maintenance must be devised.
5. Timely supply of the spare parts & also other materials needed must be ensured.
6. Personnel of varying skilled & competence must be engaged.

WHAT ARE THE SYSTEM & PROCEDURE of MAINTENANCE? 
The answer will depend on the aspects emphasized. It may be of two natures: 

1. Management aspects 
2. Technical aspects

In managerial aspects, system may be defined as the means which the personnel of an enterprise operate to accomplish the enterprise objects. They provide the means of translating managerial policies. Procedure will be that they are written & oral instruction which give formal sanction to a system. On the other hand of stress is given to on technical works & parameters than a system may be considered a network of related production developed according to an integrated scheme for performing a major activity or function. Procedure may be regarded as a sequence of technical operation established to ensure uniform accomplishment of recurring tasks. 

NECESSITY of SYSTEM & PROCEDURE: 
Maintenance operations are characteristics by wide range & different degree of uncertainty. Those have to done by the people of varying skills. Some jobs are cyclic tasks some are not. Even in the case of cyclic tasks, the interval between the 2 constructive operational ranges quite widely from once week to all most twice a year. Also there are a few works which are alternatively overlapping. In some causes execution of certain the task is automatically implies carrying out of certain other tasks also. 

SCHEMATIC DIAGRAM of MAINTENANCE ACTIVITIES DEPENDING on THEIR UNCERTAINITY LEVEL:

There the things are shown below:

Repetitive:  

1. Routine maintenance 
2. Preventive maintenance 
3. Statuary maintenance

Non-repetitive: 

1. Major repairing 
2. Erective maintenance 
3. Re-erective maintenance
4. Overhauling maintenance

Unknown: 

1. Corrective action to be taken on the basis of the preventive maintenance. 
2. Emergency maintenance
3. Re-storative maintenance
4. Change of lay out.

STEPS of MAINTENANCE: 
The steps of maintenance are: 

1. Planning 
2. Scheduling 
3. Controlling

Planning: 
Controllable work is considered as a planning. Since a comprehensive maintenance analysis is needed for the purpose. It is usable to cover a time spam of one year. 

1. Basically the decision to be taken in the 1st 2 stapes of planning are more oh technical in nature then administration. It sufficient to make the following brief remarkable to indicate. The range of decision to be taken at planning stages. 

2. The frequency cleaning needed to be established with reference to degree of dirt & fly accumulation. 

3. lubrication cycle are laid down taking into account bearing design & operating speed, the re-commendation of the different oil companies may be as guide in the content. 

4. The frequencies & kind of routines maintenance operation are fixed with regarding the machinery manufacturing & the recommending rate of the wear precession & accuracy of settings, adjustment, loss in efficiency process faults machinery break down & above the all past experience to related matters. 

5. Details of preventive maintenance program suited for the particular condition the mills are finalized after taking into amount such as no of machines & types of the skilled technician’s available tools & aids are in the disposal, necessary check the lists are also developed for preventive maintenance. 

6. Re-storative maintenance plans like likely to neutralized during the year ahead are also taken note of. Most of the data for the steps have to be gathered from the equipment history records. If such records are not available in the mills they must be 1st made from purchase envious. Manufacturing manual & leaflets are before analysis. Additional data required can be had from production, costing & quality controls departments. 

Factors should be considered & stressed during planning & maintenance: 

1) Timing (on over time or least over timing is considered) 
2) Skill of man power 
3) Relevancy 
4) Costing. 

SCHEDULING: 
Planning has defined as the various maintenance tasks to be carried out on the each machines during the course of year. Scheduling is the process of getting RIGHT man & facilities with RIGHT time & the RIGHT place in scheduling comprises the process of 3R’s. 

Advantages: 
1) Minimize the delays arising from the lacks of the co-ordinates between production & maintenance schedule. 
2) Reduce the loss of useful man hours because of unnecessary walking tines & material handling. 
3) Co-ordinates multi skilled jobs to optimize the skills utilization consistent with minimum m/c down time. 
4) Operative idle time is minimized. 
5) Co ordinates with SQC to ascertain the effectiveness of the maintenance operation & their adequacy.

Scheduling Component: 
1) Work unit 
2) Size of the jobs 
3) Man- hour scheduling in relation with the total man hour available. 
4) Lead time for scheduling. 

CONTROLLING: 
All planning & scheduling without effective control & the means of enforcing then would be unless & waste of time & efforts. The aims of maintenance control are given below: 

1. To provide mgt with the tools, that will disclose deviation from Plane & schedules so that back logs can deal with
2. To provide the feedback information from preventive maintenance. Check the lists & diagnostic report signaling.
3. The need not only for the remedial maintenance but for reviewing the various scheduling established in the annual plans.
4. The information for the QC & costing department will also the supplementary sources & feedback.

RECORDS FOR THE EFFECTIVE MAINTENANCE CONTROLLING: 

1) Maintenance ledger 
2) M/c cards 
3) Job in complete report 
4) Lubricant control chart 
5) Over time requisition form 
6) Weekly work order sheet 
7) Maintenance chart 
8) Mechanical down time 
9) Break-down time 
10) Over time engagement record 
11) Monthly spares & lubricant consumptions. 

ELEMENTS of MAINTENANCE: 

1) Inspection / check up

• (External – sound, noise, vibration,)
• (Internal – spare parts, shafts, motors & other mechanical & electrical installation)

2) Lubrication – Is the application of lubricant in the machinery during operation / break down. Application of lubricant is governed by 4R’s. Such as 

• Right types of lubricants
• Right place
• Right tune
• Right quality

(Note: High moving parts – oil; Low moving parts – grease) 

3) Planning & scheduling – Every preventive maintenance or work is pre-planned. A routine is made for maintenance & by scheduling it is followed strictly. 

4) Training – Training is the essential the works fours of maintenance. It increases the skillness of man power & effect the cost of production by enhancing the productivity, quality & machine legibility. 

5) Recording & analysis – Work done & matter of maintenance should be properly recorded. Recording is the very important for their maintenance guideline & trouble shooting. Remedial measures taken for a particular trouble & its result during machine operation are also great importance for future schedule & activities. Frequency of fault detection corrective measure etc analysis is the criterion for maintenance job. 

STORAGE of SPARE PARTS: 
1) Slow moving items (Available as per scheduling) 
Fast moving items (Always available) 
2) Lubricants should be available as per desired grade & amount. 
3) Tools & equipments should also available in the maintenance department. 

LUBRICANTS & LUBRICATION'S: 
Lubricant is the organic compound higher molecular wt used in the m/c to protect corrosion & possibility of failure. Lubrication is the process of application of lubricants in machinery during operation or maintenance. Follow of 4R’s play vital role in congenial role of machine. 

IMPORTANCE of LUBRICANT: 

1. Reduction of wear & tear Reduces m/c maintenance time & cost.
2. Synchronized m/c operation appropriate rpm of m/c in optimal speed & uniformity of speed.
3. Legibility assurance of m/c & m/c parts.
4. Higher operating efficiency less idle time & stopping.
5. Better quality of products: due to well-running & disturbance are the causes of better quality products. Reduces m/c stoppage frequency, so attainment of the higher quality.
6. Reduces fatigue & boredom of work forces due to well running less stoppage & troubles.
7. Develop ergonomics & improve working environment.
8. Above all maintenance, reduce work load & cost of overall manufacturing.

TYPES of LUBRICANT: 
Lubricant can be classified broadly on their viscosity & sp viscosity 

• Grease – higher viscosity & lower fluidity
• Oil – lower viscosity & higher fluidity

CHARACTERISTIC of LUBRICANT: 

1. Viscosity
2. Sp. gravity
3. Flash point
4. Pour point
5. CST(Centistroke)
6. Volatility
7. Acid no of parts per million (ppm)

SELECTION of LUBRICANT: 
Selection of lubricant is governed by following factors 

1. Types of gear/bearing or point of lubricants
2. Speed of gears/shaft (in case of seal box of gear)
3. Reduction ratio
4. Operating temperature
5. Input horse power
6. Nature of load provided

The lubricant must reduce friction, prevent wear & tear on the corrosion & carry the load needed to keep the m/c operation at higher efficiency level. 

Furthermore the lubricant is required to maintain its physical characteristics & performance characteristics for a long period of time without any degradation. 

Recommendation of m/c manufacturer in the selection of lubricant & the frequency of lubricant are important & to be taken as broad guide line. 

Special consideration for the lubrication of the textile machinery: 

• Maintain low power consumption
• Protection against corrosion
• Avoidance/safety from staining of product (yarn, fabric…etc)

FUNCTIONAL PROPERTIES of LUBRICANT: 
Outcome from the physical properties 

1. Lubricant must be resist oxidation
2. Lubricant must be resist carbon formation
3. Lubricant must be resist rust formation
4. Lubricant must anti-foaming
5. Lubricant must be resist extreme load
6. Lubricant must possess required viscosity
7. Lubricant must act goods cleaning agent (CCl4, petrol, diesel)

GEARS: Gears are toothed disc/pulley used for power transmission. 

Kinds: 

1. Straight gears/plain gears (used for power transfer at 1800 angle)
2. Helical gears (for avoiding slippage)
3. Bevel gears (for transfer at 900 angle)
4. Worm gear/wheel (for reduced power)
5. Sprocket wheel (straight transfer)

PULLEY: Plain disc which transmitted power by belt. 

BEARING: (Anti-friction element) it is an anti-friction element used to safe the rotary equipment from the frictional element. 

Kinds: 
 (On the basis of shape) 

1. Ball bearing (Used in high speed terms)
2. Roller bearing (used large dimension terms)
3. Needle bearing (used in low speed terms)

According to lubrication facilities: 

1. Open bearing (gradual lubricant)
2. Sealed bearing (no requirements of lubrication)

BUSH: Anti-friction arrangement used to safe the rotating shaft at very lower level rpm from corrosion. 

PULLEY & BELT: 

1. Flat pulley + Flat belt
2. Grooved pulley + V-belt
3. Toothed on timing pulley + Toothed belt (short distance & low speed)
4. Flange pulley + Flat belt

MAINTENANCE SCHEDULE: 
Factor must be considered for maintenance schedule: 

1. M/C type (mechanical, electrical, mechatronics basis)
2. Danger level/Risk level
3. Operational tenure (operational period round the clock/ shift basis/weekly/occasional)
4. Nature of the equipment
5. Availability of man power & skilled
6. Expenditure 

Author of This Article:

Shafat Hossain Sajib
B.Sc. in Textile Engineering
Noakhali Textile Engineering College