After manufacturing of yarn, from different departments in the preparatory process and ring
department, it is ready to make a shape into final cone form so that it can be shipped to customer
for use. During winding process of yarn following objectives are met.
- Scanning and faults removing
Electric Scanners (uster) are used for checking and elimination of yarn faults during winding process. This process is called Usterization of yarn. Such faults are called scan-cuts.
- Splicing of broken or cut yarn
Auto splicing is done for broken yarn pieces to eliminate yarn knots and bad piecing.
- Bigger package Conversion of yarn from small ring bobbins to bigger yarn cones of
different international standard or as per requirement of customer.
During achieving above objectives or making of winding cones some faults are created during the process. These faults need to be controlled through monitoring and continuous study. Most of the winding faults are very dangerous for the next subsequent process which can be warping or knitting or doubling. We can face complains from customer of breakage of yarn during unwinding process.
In order to avoid any complaints from customers, faulty winding cones are separated during inspection by inspectors. Following three decisions are taken at this stage.
- Use as it is: When the fault is of some minor category, and there is no risk of next process failure during unwinding. Decision is only taken by some senior person of quality.
- Rewind:
Some faults can be removed after rewinding. But rewinding itself is costly affair and quality of cones also detritus after reprocessing.
- Degraded as B grade:
If fault is of such nature that rewinding can’t remove that fault and there is doubt for customers to complains then such cones are downgraded to lower grade. Degrading cones in to lower grade is again financial loss to the company.