BY

A.KANTHIMATHINATHANCEO

WINSYS SMC winsyssmc@gmail.com

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