The biggest profit of printing and dyeing factories comes from management. The success or failure of management directly determines the difference in income of printing and dyeing factories. Why do some factories do better and better, while some factories still fail to manage well despite changing management one after another? A printing and dyeing factory with good profits must come from: the one-time success rate of the product.
“First-time success” means that the production of the product comes to an end smoothly throughout the entire production process without any remedial measures such as repairs outside the set process route.
“One-time success” can maximize labor productivity and is also Maximize the utilization of raw materials, energy, water and other resources, so “first time success” is the maximum reasonable and effective savings within the allowable range of the process.
Since it is necessary to ensure the one-time success rate, quality issues are the “blocker” in the one-time success rate. There are all kinds of problems in production. Generally speaking, common quality problems in printing and dyeing processing are repeated again and again. ‘s appearance.
As a qualified manager, planning to on-site control will be an important management stage.
1 Summary of common quality problems in dyeing and finishing production
Dyeing and finishing deep processing of textiles has many front and back links. It involves a wide range of areas, so there are many factors that affect the dyeing and finishing results. Therefore, in actual production operations, quality problems of this kind are encountered almost every day. If we want to achieve “first-time success”, we must eliminate the occurrence of any kind of quality problems.
According to their phenomena and attributes, dyeing and finishing defects can basically be divided into the following categories:
Those related to color quality include: color difference, uneven color (color flowers) , color spots, color stains, color spots, etc.), color fastness, etc.
Related to intrinsic quality are: fiber damage, loss of elasticity, dense roads, substandard finishing, shrinkage, gram weight, door width, etc.
Things related to appearance quality include: finishing agent stains, fluffing and pilling, crepe printing, warp and weft bias, etc.
In addition, there are some specific quality problems of certain types of products, such as cracks in long polyester low-density fabrics, wool yarns sticking together, etc. .
2 Achieve the understanding and related concepts of “first-time success”
Some people still have doubts about whether dyeing and finishing production can achieve all-round success. Consciousness determines attitude, understanding produces cognition, and ideas guide the direction. Ideological understanding and belief are a prerequisite.
First of all, we must see the objectivity and reality of achieving “first-time success” and establish confidence in tackling key problems.
Second, it is necessary to accurately identify the nature of things. In view of the multi-links and multi-faceted effects of dyeing and finishing production, it is a systematic project; some quality problems may even involve spinning, weaving, and dyeing. There are many factors such as materials and equipment; but the scope of dyeing and finishing itself is a relatively independent small system. All-round “first-time success” must ensure that every link and every aspect cannot go wrong.
Third, we must establish the concept of prevention over cure. Prevention is better than cure, which is an effective and important means to prevent the occurrence of dyeing and blemishes.
“Prevention is better than cure” means taking a positive and proactive approach, starting from the source, starting from the foundation, and based on the situation reflected in the historical records of the production archives, in all situations that have ever or may be possible Preventive measures will be taken at all links and places where problems arise. In the whole process and each stage of production, we strive to eliminate the occurrence of various defect factors and start from the perfection of each stage, part and process to achieve the perfection of the results. Therefore, “prevention is better than cure” is the guiding philosophy to achieve first-time success.
Fourth, promptly understand and absorb the technical development of professional technology. With the technological development in optical technology, electronic automatic control, machinery manufacturing and instrumentation industry, chemical industry and other fields, the results have gradually penetrated into the printing and dyeing industry, bringing about rapid changes and development in printing and dyeing technology. Coupled with the development of today’s high-speed information media technology, the transmission of information is rapid, timely and high-speed. The rapid development of information technology has expanded the horizons and ideas of scientific and technological personnel, from which they can absorb rich nutrition.
3 Issues with the technical requirements of “first time success”
Technical issues are undoubtedly the top priority for “first-time success”.
1. The relationship between basic work and technical decision-making. Finding out and understanding the details of the nature, performance, personality and other basic elements of things is an important basic work and is the key to solving and overcoming product quality problems. important prerequisite.
In addition to a large amount of basic work, basic work often also requires a large number of orthogonal experiments to select important factors. During the optimization process, we conduct summary, sorting and analysis to find the best points and parameters of each project, the best combination of process conditions, the best formula, the best process route, etc.
Without these solid foundations,��, and the issue of conscious implementation by front-line employees, of which the latter is particularly important.
Dyeing and chemical materials need to be measured accurately and there should be a supervision and error correction mechanism. Although the weighing and measuring of dyeing materials is simple, it has a direct impact and requires absolute accuracy and no errors are allowed. Therefore, there must be a supervision and error correction mechanism, as well as procedures and systems for review and review. Before weighing the dyeing and chemical materials, the zero calibration of the symmetry tool must be checked, the symmetry tool and related equipment should be cleaned, the dust and chemical powder should be prevented from flying, and the regular maintenance system must be implemented in place. Not only must there be supervision, but there should also be corresponding rewards and punishments. measure.
5 Regarding hardware such as mechanical equipment
Dyeing and finishing machinery and equipment systems (including instruments and meters, etc.) are another important pillar of “first-time success”.
First of all, ensuring the normal operation of the entire system of mechanical equipment is inseparable from daily maintenance and upkeep, and the phenomenon of sick operation must be eliminated.
Second, mechanical equipment also has a running-in period, normal operation period, and service life issues during use; the possibility of failure during operation will increase with the length of use. Some parts (such as bearings, valves, sight glass, transmission chains and belts, tenter needle plates, etc.) are originally vulnerable parts, and there is no fixed use schedule to list. Therefore, the regular inspection, testing, and maintenance system is a necessary mechanism to ensure the good condition of equipment, and it is also the implementation of the concept of “prevention is better than cure” in the equipment system.
Another issue that should be noted is that the design, manufacturing and system configuration of dyeing and finishing machinery and equipment are constantly improving and upgrading. Therefore, when a company upgrades its equipment and systems, front-line lathes who operate machinery and equipment must be able to keep pace with the times in terms of control skills.
6 Issues about improving the overall quality of all employees
Nowadays, the frequent turnover of employees in enterprises is an objective reality, and the employment of unskilled employees is inevitable. This will inevitably affect the quality of the company’s employees, and will therefore weaken the basis for achieving “first-time success.” It is a practical problem that companies need to attach great importance to and urgently solve.
Employees in various departments are the most reliable and effective in consciously executing systems, regulations, process procedures, and operating procedures. This first requires employees to have substantial knowledge and professional skills. At the same time, companies also need to have an excellent corporate culture, provide employees with business learning platforms and opportunities, and form a good learning atmosphere.
On-the-job training is a practical and effective way to improve employees’ professional skills. On-the-job training can be flexible, not limited by time, and does not affect daily production. From another perspective, it can also be seen as a “prevention is better than cure” measure embodied in labor and personnel.
The importance of one-time success rate
“One-time success” can give full play to labor production Efficiency is also the maximization of the utilization of raw materials, energy, water and other resources, so “first time success” is the maximum reasonable and effective savings within the allowable range of the process.
Comprehensive “first-time success” is related to the maximization of enterprise production efficiency and economic benefits; and for the small batches, multiple varieties, and fast delivery required by the modern market, it is also It is also very critical and important, and it is what every enterprise strives to pursue.
It is a systematic project that requires no mistakes in any aspect of enterprise management. It is correspondingly difficult to achieve “first-time success” in an all-round sense, and it needs to rely on technology, management and various positions. Only by working together in an all-round and coordinated manner can we achieve this ideal goal. </p
