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To ensure that produced yarn quality conforms to international level, CSL is equipped with world's latest testing instruments such as, USTER HVI-900A alongwith BIAS, USTER AFIS-LMN, USTER evenness tester UT-3/B/M+H, USTER TENSORAPID UTR-3 and Auto Sorter-4. With these facilities complete process is controlled to ensure 'TOTAL QUALITY MANAGEMENT' from Raw Material to final product to meet customer requirement.
Research & Development
Sampling Of Raw Cotton and Yarn

Since 100% testing is not possible, random sampling is done

Zoning Technique For Raw -Cotton

As cotton in bulk is not homogenous, a number of sub-samples must be taken at random from different places in the bulk. When we do sampling from cotton bales, the require number of fibers should be taken one by one at random from different parts of bale. Following method is used for sampling of cotton:

Step-1 A sample of 2 OZ (Approx.906.72gms) is made by selecting about eighty large tufts chosen over the bulk.
Step-2 This sample is divided into four quarters.
Step-3 Sixteen small tufts are taken at random from each quarter (Approx.20mg).
Step-4 Each tuft is halved four times, discarded alternately turning the tuft through right angle between successive halving. Sixteen whips are thus produced from each quarter.
Step-5 These whips are combined to from a tuft.
Step-6 Each tuft is mixed by doubling and drawing between fingers.
Step-7 Each tuft is divided into four pieces.
Step-8 A new tuft is obtained by combining a part of each of four tufts.
Step-9 Sample is mixed again by doubling and drawing.
Step-10 A quarter of sample is taken out to form final sample.

The aim of the process control is to ensure ourselves that the manufactured goods are according to the specification of the customers and do not contain many defects. For this, it is imperative that the product should be examined at strategic points, which is designated as receiving inspection. The basic tool used for examination of raw-material, in-process and finished product are called acceptance sampling in which a decision to accept or reject a lot is made on the basis of random sample drawn from it. These plans are basically designed for lot quality protection so that a lot having poor quality has virtually no chance of being accepted. The main objectives of random sampling are:

1. To determine the acceptability of incoming products and outgoing products.
2. Providing a definite assurance against accepting any lot.
3. For taking corrective action on the processes as and when required.
4. To determine the acceptability of the product from one department to another within the unit.
5. To improve quality of the material supplied by vendors.

As yarn is available as a number of independent packages and the problem of sampling is the selection of a small number of such packages from a large number, so to avoid biased sampling we use Cambridge Elementary Statistical Tables for random sampling method.

BIAS Bale inventory analysis system is developed by M/S Zellweger Uster. According to this system, mix is formed in a way that bales taken from stock are having min variation in quality parameters from bale to bale and from day to day.



1. 100% testing of bales All the bales received are tested in HVI. Tested results are exported to BIAS either directly or by floppy disk.
2. Categorization of Bales All bales tested are numbered and divided into categories. Eg. if categorized according to SCI & MIC.
3. Mix Formation Eg. mix for 20 bales
SCI total = DSCI
MIC total = CMIC

FOR SCI- Make 6 categories<80,80-90,90-100,100-110,110-120,>120
FORMIC- Make 6 categories<3.0,3.0-3.3,3.4-3.6,3.7-3.9,4.0-4.2,>4.2

These categories are decided by analyzing at least 1000 bales for particular Season. Since total categories are 6 x 6 = 36, so all the bales tested are stocked in to 36 categories.

In this mix plan ASCI=BSCI=CSCI=DSCI
In other words, total of SCI category MIC category in any direction will be the same. Now bales issued are subtracted from stock.
4. Printout Of Mix Plan Enter bale number of each bale issued. Average of all quality parameters will be printed. Thus, BIAS helps to reduce variation in quality parameters on a day to day basis for particular mixing.

Process Control Methods

In large scale industrial production, it is found that variation in quality are unavoidable. We can prevent large variations by imposing proper checks and controls on the production process. One advantage of ensuring the absence of factors responsible for large variations in the process is that quality follows a regular statistical level. A production is said to be in a "stage of control" if it is under the influence of factors responsible for small variations only. The quality control is an activity which assures that goods conform to specified standards. Thus, it is an assessment of quality in either or all three of the input transformation or output phases of a production process. The control of quality involves measurement, feedback, comparison with standards and corrective action when necessary.


How do we do Preventive maintenance of our machinery

Routine and preventive maintenance generally focus attention on continuous smooth working of the machine over its life time of many years. The system of machinery assessment concentrates on the following:

1. Quality of the material being processed.
2. Production of the material / unit machine time.

Those machine conditions, which influence the quality and production are identified and special attention is given to improve these conditions. It is necessary to have a critical assessment of the machinery condition and other related activities through an in-depth study and to take the appropriate action to keep the machine in 'Best Working Condition'. This will aim at implementation of machinery maintenance management which is essential for any quality conscious manufacturing unit. We are covering following major areas of various activities related with maintenance to achieve this goal:

A. Evaluation of maintenance schedules, its follow-up and upkeep.
B. Assessment of the mechanical conditions of machines and their critical components.
C. Checking of critical settings and gauges for its better accuracy.
D. Identifications of the scope of improvements in general maintenance practices and methods.
E. Assessment of existing resources in terms of skilled man power, maintenance accessory equipment, tools & gadgets etc.
F. Assessment of investment in maintenance activity.
G. 'On the spot' demonstration for achieving the effectiveness in maintenance operations.

Assessment Procedure

1. The machine is taken into maintenance for assessment.
2. The machine-parts, wear-tear, settings and gauges critically examined.
3. The lacuna is pointed out on the spot and corrected immediately.
4. The maintenance practice and methods of the work-force are critically evaluated.
5. The existing maintenance schedules, record keeping is scrutinized and scientific computerized methods adopted for the maintenance scheduling and record keeping.
6. Finally a detailed comprehensive report is prepared for machine wise grading, where suggestions and recommendations are shown in detail.