PRODUCT QUALITY IMPROVEMENT ON ROVING MACHINE

2.1 BACKGROUND
Quality means customer satisfaction, now day’s quality requirements is getting stringent as buyers
are becoming more and more demanding hence; it has become necessary to follow systematic
method of sample collection and testing to ensure that only quality goods are produced. MAA
garment and textile Plc. Company Most of time process its product based on the customer
requirements, since the customer needs a quality product we have to focus on the quality.

Improve the quality and productivity of Roving machine which is essential to economic success of
spinning plant international completion and market requirements, if the product is not quality it fails
for export and the export will changes to local market that will reduce the cost of product. This cause
for minimization of productivity. In general roving quality is influenced by different factors. Quality
of roving is estimated from some important roving properties like, count and strength twist sliver
evenness imperfection (thin and thick place, and naps) it’s these properties have influences on the
quality of the products. In order to produce quality product and satisfy the customer this study is
helpful in identify the factors of quality.

2.2 SIGNIFICANCE OF THE STUDY

The study will have significant contribution to the company in order to give feed back to the
responsible person to give a big attention to the quality and increases the knowledge in the field of
study.
MAA garment and textiles factory should give attention to the quality in order to have the following
benefits.
The customer will satisfy due to the quality product
The product which fails from export standard to local standard will no longer happened.
The company will competitive with national and international market due to quality.

2.3OBJECTIVES OF THE STUDY

GENERAL OBJECTIVE
To improve the quality of roving material

SPECIFIC OBJECTIVE
To satisfy customer needs
To know the cause for quality degrading
To minimize count vibration
To minimize yarn breakage
To increase profit of the factory.
T give solution to the cause for quality degrading.

2.4STATEMENT OF PROBLEM
MAA garment spinning section has one big head age. That is quality problem. Roving is one of the
company’s machines which have a series problem. Those problems are caused a series degrading the
quality of the product or the output of the roving machine .This problem takes place due to different
reasons. Those problems are:
Problem of count variation
Problem of improper handling of material
Problem of Breakage
 Problem of roving tension
Problem of maintenance
Carelessness of workers
Generally roving quality is influenced by different factors like, quality raw material (sliver quality),
machine setting and luck of spare part management which influence the quality.

2.5 LITRETER REVIWE

Since speed frame is the final process Control of quality at roving stage is necessary before the actual
yarn production.
 Roving process contributes for about 1520% of the yarn irregularity.
 About 80% of the source of yarn faults can be attributed to the bad condition of roving
bobbin.
 High roving cv% and periodic variation tend to deteriorate the tensile characteristics of yarn
 Short-term variation in roving’s become medium term yarn variation leading to end
breakage.

Roving strength
Roving strength plays an important role for optimizing the roving tm and the ring frame drafting
parameters. Defects in roving quality are caused by work practices also.
 Sliver piecing at creel
 Roving piecing
 Cleanness of drafting zone and flyers
 Poor handling of sliver can
 Mechanical condition of individual spindles

Critical Factors Affecting Roving Strength.

Critical factors affecting roving strength are given below:
 Theamountoftwistandcompactnessoftheroving.
 Linear density and uniformity of the twist.
 CV% of roving.

Quality related.
Creel tension draft
 for carded counts
 0.99 for combed cotton count
Spacer.
Spacer influences the following parameters
 Long thin faults
 U%
Smaller spaces will provide better fiber control
Between bobbin counts cv% is affected by
Variation in drafting pressure
Quality of sliver (1m cv%)
This variation will also lead to high yarn count cv% and weft bar in woven fabric. Within bobbin cv
% possible causes
Uneven tension during bobbin built up
Sliver splitting and stretching at creel zone
Roller lapping
 Defective spindle

The following are the main point regarding to quality in Roving machine.
Buffing should be on time and after 20 days there should be buffing. If buffing is not done on
time then it will create problem in the yarn such as thick and thin places.
Spacer (distances trip) color also affects the quality of yarn. Because the mm of the spacer is
differences by their color. We should change the color according to roving count. But MAA garment
and textiles purchase same color spacers without considering the mm, and they use same color spacer
with different mm. this has negative effect in quality and regularity of the roving.

Bottom and top apron also effect on quality in the form of thick and thin places produce.
Density of roving bobbin should be same as in this case if variation will be there then
count C.V will increases .(p.r.lord,2003)

2.6 METHODOLOGY
Data’s which concern about roving machine that are helpful for my project are collected from
different department of MAA garment and textile plc such as; quality control production and
planning also from technical department study or project both primary and secondary data From
different sources which gathered and analyzed.

Primary data: are collected through orally by asking a communicating with the engineers, by
observation, by measuring and testing of roving was carried out for roving frame input count and
inspection roving output.

Secondary data: are gathered from some measured and recorded documented materials
from the company and some different reference books, from notes that I take in from class in
AKSUM University.

2.6.1 MATERIAL AND EQUIPMENT

Material and apparatus used during testing sliver
o Sample of sliver from drew frame machine
o Testing count
o Cutting material
o Uster for testing unevenness

Material and apparatus used during testing roving

o Count testing Ne
o Weighting balance for weighting sample length of roving
o Calculator use for obtaining actual count

2.6.2 PROCEDURE
I have adopted different procedures during testing and measurement of data.
Steps for testing sliver count
• Step1: to feed the sliver in to testing yarn
• Step2: to rotate the yards with in 10m
• Step3: to put the sample in to the measuring yards
• Step4: to read the result and record the result
By following these steps to take sample of spindle from one roving frame for knowing the
measure causes of roving count variation .the result is put in the form of table.

2.7 DATA PRESENTATION

During my internship period I have collected data’s which are help full to understand the measure
causes of roving count variation. The collected data’s are presented in the form of table. During the
time of my observation time I have observed this problem through testing roving count on the count
tester in quality control laboratory.

Main cause of the roving count variation

Not using uniform

Uneven sliver spacer Not using
uniform apron

Roving count
Lack of proper variation Not treated
maintenance raw material

Unskilled Not using Machine

operator smooth top setting not
roller properly settled

Poor
cleaning
 Table of roving count value

table 2.1 first list of roving count value

Input
No. of spindle Input count Evenness ( um % ) Required count Output count

117 0.1114 4.99 0.8 0.7786

117 0.1121 4.93 0.8 0.7892

117 0.1105 4.90 0.8 0.7871

117 0.1118 4.96 0.8 0.7862

117 0.1108 4.98 0.8 0.7834

Average 4.92 0.8 0.7849

Table 2.2 Second list of roving frame count value

No. of spindle Input count Input evenness Required count Output count
(um%)

119 0,1119 4.93 0.8 0.7804

119 0.1106 4.98 0.8 0.7836

119 0.1121 4.91 0.8 0.7753

119 0.1114 4.99 0.8 0.7881

119 0.1125 4.89 0.8 0.7810

Average 0.8 0.7816

 FIG: 2.1 PROBLEM OF CARELESSNESS

FIG: 2.2 PROBLEM OF NOT SMOOTH FIG: 2.3 PROBLEM OF ROVING BREAKAGE
TOP APRON.

FIG: 2.4 PROBLEM OF WORKING WITH OUT FIG: 2.5 PROBLEM OF DOFFING
TOP APRON.
FIG: 2.6 PROBLEM OF IRREGULAR STORAGE

2.8 DATA ANALYSIS

In MAA garment and textile factory there are four roving frame machines which feed roving hank
for ten ring frame machines. Generally, this project is concentrated in identifying the causes for the
degrading roving quality of the MAA garment and textile plc. The experimental results obtained
from the various experimental analysis tests carried out during the study and observations are
discussed in detail below. The major causes for quality degrade in the company are –
 Count variation
 Improper handling of material
 Breakage
 Roving tension
 Problem of maintenance

2.8.1 COUNT VARIATION

The term count or roving number is commonly used to define fineness of the material. The roving
determines how many fibers can be found in the cross section of the certain roving.
If the actual count and the standard count are not the same or similar we can say there is a problem of
count variation. According to the above information stetted in the data presentation there is count
variation. This count variation can happened due to different reasons.
Causes of count variation are:-
 uneven input material
 Drafting zone problem
 improper handling of material
 Not using different types Spacer according to the sliver count.
 Luck of proper maintenance

MAA garment and textile factory used 0.8 as standard count for roving machine. but when I observe
and collect a data the count of produced output material of roving machine have a variation as I set or
presented in the above table 1 of data presented. All the tasted sample of roving are below the
standard (0.8). when the roving is below the standard it means it is hick so to be in the standard the
material should draft other than it was before. This happened due to the problem of drafting or gear
number setting.
The output roving material is input for the next process which is ring frame, but as I mention before
the roving material have problem of count variation .This input material can cause a problem in
processing specially it changes the output count of ring frame. When I checked the ring frame
machine that process count of 40 I absorb from the result as it changes its count from 40 to 39 due to
the variation of input material (roving),so the problem of count variation affect quality and also the
subsequent process.
 2.8.2 IMPROPER HANDLING OF MATERIAL
Roving material is very sensitive regarding to quality point of view. It is necessary to take care of
material. The material should be handled in such a way that fine dust must not affect the material. It
must be avoided touching because of its sensitivity. This material should not be keep for long time.
If it will be kept for long time then it will create variation. C.V% increases if material is not used. But
in MAA garment and textile plc the roving machine produce a lot of roving materials and the
material are put or store in the ground for long time as it sew in the above picture. So the produced
roving is a material with dust and count variation this leads for degrading the quality of roving.

2.8.3 POOR MAINTENANCE OR LUCK OF SPARE PART MANAGEMENT

The machine maintenance is the chief requirement of machineries and quality production. In MAA
garment and textile factory there are four roving frame machines which feeds roving hank for ten
ring frame machines. The first two are combed and the other two are carded line of roving machine
which process in their own machine and their own setting of drafting and also setting of aprons. But
due to spare part management problem the first one machine which process the combed line is most
of time out of function due to this problem the combed sliver is changed its place and processed in
the carded line by the carded setting so due to this problem there is a count variation which degrade
the quality.
Pressure draft for – carded is 2.83 but For – combed is 2.5
Apron for carded is wide

For combed is narrow

Also the combed line machine is use float condenser because of combed quality matter but
when it works on the carded line machine it process wit out float condenser and it causes-
 Overlap
 Breakage
 Improper shape which degrades the quality.
Also it causes mixing of the carded and combed material since they are processed in the same
machine, the operator mix due to carelessness or due to tired off. If the combed material is mixed
with the carded material it may not have any cause in quality but it has an effect on production
because it is costly material and used for export. And also if the combed is mixed with the carded it
have effect on quality because combed is smooth, even and clean as compared with combed so this
cause effect in the quality.

2.8.4 PROBLEM OF ROVING TENSION

Roving tension is directly related to machine. But if it is more tension roving breakage will
happened.
As I mention before due to spare part management problem the first one of roving machine is most of
timeout of function due to this problem they processing two type of material which are carded and
combed material in one machine, since they are different material they have different property like
the combed material is smooth and softer than carded material, so the tension of the two material
must be different and the tension for the combed sliver should smaller than the carded because it is
smooth and soft. But since they process in the same machine they have the same tension this lead to
the roving breakage.

Tension for carded must be 57

For combed must be 54.
 2.8.5 ROVING BREAKAGE
Causes of roving breakages are:-
 Un even input material
 Improper piecing
 Problem of maintenance
 Improper roving tension
 Un condition ac

Uneven input material-Sometimes roving frame machine feed unevenness sliver which come from
drew frame (input for roving), because of the cam in the drew frame is not properly maintain or
clean.
Improper piecing sometimes- the operators are carless and pieced the break improperly. If piecing
will not be proper then it will cause breakage and also it affects the next process.

Problem of maintenance- unclean the suction zone, when improper maintenance and usage of spare
parts in the roving machine and when the delivery and the bobbin are not properly cleaned. Also
sometimes the apron is loose this cause the problem of breakage as we sew in the above picture.
Unconditioned ac- the air condition system are not working properly When the air conditioning is
not condition it means when the temperate and relative humidity are above the standard, when the
RH is below the standard the breakage will cause breakage.

2.8.6 PROBLEM OF DOFFING

Sometimes the operators handle the material improperly and when breakage is more they out the
float condensers from its place and throw it because they are tiered off piecing the broken material
without permission or telling the supervisors condenser without, And also Sometimes the operators
off or down the overhead cleaner because the fluffs or dust becomes to their face due to this the dust
and fluff are un clean .This leads for degrade the quality of the material.
Some time Ridged clearer roller in a can inside the roving machine which is use full to clean the
drafting area but the operators never use it.

2.9 POSIBL SOLUTION

For the above problem, the quality is degrading due to this problem I will prepare the following
solution.
Preventive action

2.9.1 PREVENTIVE ACTION FOR IMPROPER HANDLING OF MATERIAL

The material should be handled in such away that fine dust must not affect the material. Fresh
material should be used for next process. This material should not be keep for longtime.
 Supervisor must treat its worker in a proper way so that handling of material should be according
to policy of mill.

2.9.2 PREVENTIVE ACTION FOR IMPROPER PIECING IN ROVING

Supervisor should train his workers in a proper way. If end breakage is disturbed then its treatment
should be proper. If piecing will not be proper then it will affect the next process. So proper piecing
is useful.
 2.9.3PREVENTIVEA2.9.3PREVENTIVEACTIONFORROVINGBREAKAGE
To enhance the quality of product, the machine maintenance is the chief requirement. For the
Proper solution of roving breakage, speed of machine, trained operator and proper management
Should be must otherwise it create sever problems in ring section.

2.9.4 PREVENTIVEACTIONFORLUCK OF SPARE PART MANAGEMENT

The company must develop the maintenance store activities for store components that used for
facility such as spare part which use to interchange item which are used to replace the broke down
machine part. If there is good spare part management processing two types of material in one
machine and mixing of those material will avoided.

2.9.5 PREVENTIVE ACTION FOR UNEVEN INPUT MATERIAL

Roving frame machine must feed evenness sliver which come from drew frame (in put for roving).
I have prepared some additional solution s Bellow.
 Education and training: To get the total production of a companywide training program
needs to be conducted by workers and giving advice to them.
 Maintenance: use proper maintenance while roving breakages to enhances the quality of
production. To clean and oiling the machine by making schedule maintenance. Trained operators
and proper managements should be must otherwise it creates severe problems in next
process.

 Air conditioning: use better and job satisfaction air conditioning by removing filaments and
dirty from the production and keep the health of workers in order to increase the production
without any operator’s careless and killing time

 Skill up gradation: The organization needs to arrange a skill up gradation program for the
operator so that they can gather the knowledge on the machine they operate. The operator can
attend their machine in case of minor breakdown without waiting for the maintenance
personnel. This saves considerable amount of time.

2.10 DISCUSION AND MAIN FINDING

As shown in the above discussion, the quality degrading is due to count variation, improper handling
of materials, roving tension and problem of maintenance or luck of spare part management. Those
are huge economic crisis for the company. As I observed and understand know a day the number of
customers of MAA garment and textile plc. Are minimize. It is because of the quality, if quality
product is not produced no one can by it because customer needs a quality product. Quality must the
main aim of all factories, since every company needs a customer and productive quality. Quality is
customer satisfaction.
By the proposed solution the quality and then the customer satisfaction improved. The quality means
simply understood types of work. This proposed leads to achieve better quality than the actual
working condition. It indicates that quality is the most important thing for customer satisfaction.
After I understand the quality of roving is degrade because of improper handling of material due to
the roving machine produce a lot of roving materials and the material are put or store in the ground
for long time then it will create variation.
I will propose that the roving production must fit with the receiving capacity or ability of ring frame
and by reducing the speed of roving machine. Also the Roving material is very sensitive regarding to
quality point of view so I propose that as it is necessary to take care of the material or store the
materials in another way other than in ground as shown in the below.

2.11 GOOD PERFORMANC DURING THE TASK

In my internship program I try to have a better relationship with everybody in the company.
I tried my best to make good communication with everybody in the company.
I try to exercise the theoretical knowledge witch I learned in AKSUM University.
I have attained almost all working days and I observed each problem of the company.
I have developed the practical aspects of textile factory with an excellent self esteem.

2.12 CHALLENGES
 It was very difficult to get information’s like, Company back ground,
 It was also difficult to observe the internal parts of machineries.
 It was very difficult to get machine manual, the factory does not have a library to gate
information. As example ALMEDA textiles factory have its own library which is help
full to gate manual and books.
 When I was collecting the data I had faced many challenges. This challenge makes me to
not do my task on time. Because I does not gate enough data.
 Most of the operators do not want to cooperate with students. And the engineers and
maintenance mechanics where not willing to tell me full information for my question.
 It was difficult to communicate with the department heads.
 They factory was not allowed for us to work in every department.
 MAA garment and textile factory does not have weaving department so I cannot gate
experience of this department.

2.13 MEASURES TO OVERCOME THESE CHALLENGES

I select the best and good ways or direction to perform the main goal of internship program.
I communicate smoothly with all the workers of the section to get information what I need.
Shearing ideas with my class mates and wOLO university textile engineering students to
Improve my knowledge.
Think the problem may face for forward life and how to pass these challenges
successfully.

CONCULUTION
As we know quality is the key customer satisfaction or customer requirement. As I mention in the
above chapters most of time MAA garment and textile Plc Company process its product based on the
customer requirements, since the customer needs a quality product we have to focus on the quality.
In generally from my project I conclude that the major causes that barred the quality of roving
machine are –
 Problem of count variation
 Problem ofimproperhandlingofmaterial
 Problem of Breakage
 Problem ofrovingtension
 Problem ofpoor maintenance
 Operator carelessness
Based on an experimental result presented in the above chapters, this study explains the
current situation of quality management in MAA garment and textile plc.
The study has indicates that the quality related problems are the serious deal to the survival
of textile industries. Low market penetration has been resulted due to poor product quality