Self-correcting Crossover/Filament Migration Events – Case Study

Customer overview

A manufacturer of nylon and polyester fiber for high-value industrial applications (including airbag fiber) partnered with Instrumar to improve quality and reduce their labour pressures for testing. Tenacity is a critical product requirement for their applications, which is compromised when filaments migrate between adjoining threadlines on a position.

Event Reported by Instrumar Fiber System

The Instrumar Fiber System (IFS) detected repeat occurrences of filaments migrating between adjacent threadlines which then fixed themselves after a short time. Instrumar data has shown this can even occur in both directions, where a given fiber bundle both gains and loses filaments beyond the initial filament count. IFS alarmed on the issue and the plant’s control software flagged the package for downgrade.

Maintenance Team Findings

The maintenance team was dispatched to investigate the problematic position, and it was determined that there was build-up on a godet due to inadequate cleaning. The position was flagged for additional cleaning at the next break.

Cost Avoided/Efficiency Gained

• Crossovers/filament migrations typically result in a line break, which simplifies detection but can result in short packages and higher waste. Short-term migrations can be difficult to detect in the lab, as they can occur anywhere in the package. But migrations which correct themselves can be even harder to identify. Even detection by weighing may not capture such events, as a threadline that both gains and drops filaments may not show a measurable net weight change.

• Proper identification of these crossovers by the Instrumar Fiber System helped the plant to avoid safety issues, expensive customer claims and reputation damage.

• Immediate detection and alerting by IFS helped the plant adjust their cleaning schedule, thereby avoiding unplanned downtime and waste, and enhancing production efficiency.

• Due to the customer’s confidence in the Instrumar Fiber System’s ability to reliably detect filament migrations, the plant has been able to slash its previous levels of testing and redeploy several plant personnel to other priority functions, as well as save on inventory holding costs.

Customer Feedback

“With IFS monitoring our production, we can identify critical quality issues that we struggled to catch through testing. Our products are too critical, and our customers are too demanding for us to take chances with quality.”

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