Hisham A. Azzam
Lecturer of Textile Engineering,
Textile Technology Department,
Industrial Education College,
Beni-Suef, Egypt,
E-mail: hishamiec@yahoo.com
Sayed T. Mohamed
Production Engineering & Mechanical Design Department,
Faculty of Engineering,
Minia University, Minia, Egypt.

Abstract

The Egyptian government has shown substantial consideration regarding the rehabilitation and restructuring of inefficient companies in the public sector with regard to converting them into profitable companies which will be ready for privatisation. Furthermore, textile manufacturing can be considered as one of the biggest industries in the public sector. So, the idea of showing how textile manufacturers in the public sector can be developed to meet the requirements of marketing and product strategies has been initiated.

This study has been prepared to assist in developing one public-sector textile manufacturer to meet the requirements of a quality management system, which in turn reflects on improving the mill performance. Applying the technical means of quality management in the spinning industry, preparing the spinning industry for quality agreements, requirement profiles for different yarn quality characteristics and types, spinning quality problems and solutions, and optimum yarn quality at optimum costs are the key areas which are covered in a unique manner.

Key words:

quality management, spinning industry, quality characteristics, reference values, requirement profile

Introduction

Quality is one of the key factors for the Egyptian textile industry's success. The image of Egyptian cotton is strongly linked to quality products worldwide. To take full advantage of this image, Egyptian textile manufacturers need to maintain a high standard of quality. Unfortunately, a great decrease in quality level has arisen, which in turns seriously affects the level of production in such a way that threatens the future of the workers in this industry.

El-Minia spinning mill may be considered as one of areas which is most at risk;it lacks management which is appropriate for a public-sector body. The key factors that are lacking in the
management of the mill can be broadly categorised as follows:

. lack of quality systems and quality ethic;

. ineffective maintenance systems, and the lack of the wherewithal to carry out essential or preventive maintenance;

. lack of understanding of the customer's needs, and no determination to meet these needs.

. ineffective process and operational control;

. ineffective investment and replacement policy;

. lack of control of the workforce and workforce deployment.

This paper is aimed at assisting in developing one public-sector textile manufacturer to meet the requirements of the quality management system in the spinning industry.


Bale management

Due to the absence of suitable and quickly-operating fibre testing methods, too little has been known in the past about raw material characteristics, their variations and their influence on the various parameters of the spinning process and yarn quality. As a result, and for safety reasons, a higher quality raw material than necessary was often used in order to guard against complaints. Although these preventive measures seemed to be the best compromise, they cost money. Such high costs can only be avoided if agreements with the raw material supplier (or even with the mill's own purchasing department) can be reached.

In order to improve this situation, a sorting of the bales was undertaken. The new generation of fibre testing instruments such as the HVI, AFIS, QUICKSPIN, etc., make a much more comprehensive and quicker means of testing the raw material possible than has previously been the case [3,4,11,12,13]. Bale management covers:

. measuring of the more important fibre properties per bale or per series of bales;

. separation of these bales into classes;

. arranging those bales in a store which hassimilar fibre properties and a defined variation of the more important fibre characteristics.

This results in a process-oriented bale mix and, accordingly, practically constant running conditions. It also results in yarn quality with little inter- and -intrabobbin variation.

Yarn engineering

Many research works have been focused on yarn engineering [11,12,17,18,21, 22,23,24,25,26,27]. According to the literature, yarn engineering refers to the following:

� obtaining optimum conditions in terms of product quality, with respect to the yarn and the end product;

� optimum selection of the raw material for the required quality;

� increase of the added value by means of a better use of the raw material;

� pre-determination of the yarn properties based on raw material and process data, i.e., the quality data of the yarn and the end product are no longer to be considered as chance conditions;

� ensuring the quality level throughout the complete process;

� keeping constant quality in order to ensure long-term marketing conditions;

� reduction of manufacturing costs by increasing efficiency.

It is not difficult to imagine that, for the tasks referred to above, experienced specialists with an excellent fundamental knowledge of textile spinning would be necessary in order to implement the interfaces already referred to. These specialists must not only be good technologists, but must have knowledge of cost accounting in order to be able to solve problems in their correct sequence and in terms of their cost effectiveness.

Process management

With process management, not only is each individual machine in the spinning mill to be run under optimum conditions, but also each separate processing stage is to be exactly tuned to the other processing stages in order that a reasonable and process-oriented compromise can be arranged with respect to quality and costs [11,21,22,23,24,25,26,27]. For this purpose, the following is necessary:

. testing of the fibre properties before and after each important processing stage;

. correct settings, in order to achieve optimum conditions at all machines, taking into consideration the yarn as the end product;

. determination of the most suitable machine equipment;

. arranging optimum conditions for machine maintenance, so that there is no reduction in quality as a result of long-term running of the machine;

. introduction of early warning systems.