How to Obtain Dimensional Stability in Foil Print

Dimensional Stability in Foil Print

How to Obtain Dimensional Stability in Foil Print While Keeping the Desired Shade Within an Optimal Process for Compact Jersey fabrics.

Obtain Dimensional Stability in Foil Print
Setting Target for Obtain Dimensional Stability in Foil Print
Root Cause Analysis of Instability in Foil Print

Solution Analysis

ProblemsResource R.FeasibilitySignificanceTime-SavingTotalPriority
Fabric Structure1191128th
Chemical characteristics2282146th (2)
Cross-linking agent2282146th (1)
Improper roller passing5572194th
Improper temperature8893281st
Improper padding pressure7893272nd
Relative Humidity2361128th
Absenteeism3541137th (1)
Unskilled worker2263137th (2)
Blower pressure2341109th
Machine tension1152910th
Use of steam4381165th
Speed variation5594243rd (2)
Improper fabric feeding7791243rd (1)
Unconsciousness7131128th (3)

5W-1H Analysis (Reason 1)

QuestionImproper Temperature
Where does it happen?In  Finishing
Why it is a problem?Affects foil shade
What to do?Find out an optimal temperature
Who will do?QCC team
When will do?Within 1 month
How much it will cost?Moderate cost

Developing Solutions for Reason 1: Improper Temperature

S/LSolution suggestedAnalysisRemarks
1a) Dryer + Compacting above 100ºC b) Stenter above 100ºCShade not okNot accepted
2Dryer below 100ºCShade ok, but dimension fails in lengthwise & diameter shortNot accepted
3CompactingShade not okNot accepted
4Stenter below 100ºCa) Shade ok but dimension varies with pressure b) Shade & dimension ok; but, requires 5-6% excess process loss due to GSM problemNeed more analysis
5Tumble DryShade & dimension ok; but, requires 5-6% excess process loss due to GSM problemNeed more analysis

5W-1H Analysis (Reason 2)

QuestionImproper padding pressure
Where is happens?In Stenter machine
Why it is a problem?Affects foil
What to do?Find out an optimal pressure & avoid maximum pressure
Who will do?QCC team
When will do?Within 1 month
How much it will cost?Moderate cost

Developing Solutions for Reason 2: Improper Padding Pressure

Solution suggestedAnalysisRemarks
Stenter below 100ºC with double padderAffects foil for high pressure & causes lengthwise extension resulting dimension failureNot accepted
Stenter below 100ºC with single padder (maintaining low pressure)Shade & dimension okAccepted
QCC Team's Solution for Obtaining Dimensional Stability

Foreseeing Resistance

ResistanceAnalysis & Solution
Dimensional stability is changed after foil print due to DelaminationControl GSM, Shrinkage & Water Absorbency before printing (semi-finished while gumming & cutting)
If finished before printing, absorbency may be reduced at finishingUsed Hydrophilic Softener
This technique is not applicable to loose knitted fabricsWe will work on this in our next project

Result Analysis

Order Number: GISGM1419
Fabrication: 100% Cotton, Interlock, Diameter- 62’’, GSM-180
Order Volume: 3,130 KG
Fabric Delivered: 2912 KG

S/LParameter (after finishing)Tumble-dryNew Process
1Processed quantity1490 kg1422 kg
2Diameter57~59’’60~62’’
3GSM188~192175~182
4Consumption6.8% moreNo excess required

The final result achieved from our project

Dimensional StabilityBuyer requirement
Fabric save0.068
Foil Save0.074
Milestone Chart of Dimensional Stability of Foil Print

Written By
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology
Email: [email protected]
LinkedIn: Sharmin Akther Diba

Nahian Mahmud Shaikat

About Nahian Mahmud Shaikat

Experienced Financial Analyst with a demonstrated history of working in different industries. Skilled in Feasibility Study, Business Planning, Business Modeling , Strong finance professional with a Advanced Certificate Course on Business Administration (ACBA) focused in Business Administration from Bangladesh Institute of Management (BIM) and Masters of Business Administration (MBA) focused in Finance & Banking and Marketing from Institute of Business Administration (IBA-JU).
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