Loose Knots in the Middle of Package – Case Study

Customer overview

A Nylon BCF manufacturer, specializing in premium residential and commercial carpets, has incorporated the Instrumar Fiber System into their production process to reduce defects, and enhance operational efficiency and provide staff with real-time production data reporting and analysis.

Event Reported by Instrumar Fiber System

The customer experiences periodic quality issues where filaments are pushed out of, then back into the fiber forming a knot of filaments on the outside of the fiber bundle. Because of the plant's downstream specifications and concerns, IFS is set to alarm on and downgrade packages where such events occur.

Maintenance Team Findings

Due to the strong confidence in the accuracy of IFS alarms, such packages are downgraded to waste, and not even sent to the lab for further analysis. In this plant, IFS highlights such alarms on the dashboard, and operators simply segregate the flagged packages for waste. The operators are then tasked with investigating the yarn path to find any points of obstruction/friction that may be causing such knots.

Cost Avoided/Efficiency Gained

• Due to the very short-term nature of these loose knots (less than a second), it is exceptionally challenging for spot checks to capture such defects. Traditional lab testing involves pulling the last few meters of fiber, leaving knots further back in the package undetected.
• The Real-time monitoring and alarming of the Instrumar Fiber System gives the plant an exceptional degree of confidence that such events are not making it through to customers where it could impact downstream production.

Customer Feedback

“The Instrumar Fiber System has given us a great level of confidence in running our operations. We get to catch defects and gain insights that no other way we could have obtained. The system has allowed us to ensure that every package leaving our facility is of the highest quality. That’s piece of mind both for the business, as well as the production.”

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