George L. Hodge

Adapting lean manufacturing principles to the textile industry

A research project was conducted to determine which lean principles are appropriate for implementation in the textile industry. Lean manufacturing involves a variety of principles and techniques, all of which have the same ultimate goal: to eliminate waste and non-value-added activities at every production or service process in order to give the most satisfaction to the customer. To stay competitive, many US textile manufacturers have sought to improve their manufacturing processes so that they can more readily compete with overseas manufacturers. This study identifies the different tools and principles of lean. The use of lean manufacturing in the textile industry was examined in this research through interviews, plant tours and case studies. A model for implementing lean tools and principles in a textile environment was developed.

Postponement and supply chain structure: cases from the textile and apparel industry

Purpose – The purpose of this paper is to explore the applications of postponement strategy in the textile and apparel industry, with a particular focus on the supply chain structure, relationships and enabling activities supporting postponement strategy across the supply chain.Design/methodology/approach – For this research, a case study approach, supported by structured interviews, was adopted. The purpose was to explore the application of postponement with the objective of gathering considerable data from an organization or multiple organizations to develop the clearest possible picture of the phenomenon.Findings – The nature of product, downstream demand and the supply chain structure impacts the choice of postponement strategy. Companies operating with manufacturing and logistics postponement share data across their supply chain extensively, while companies adopting purchasing postponement work towards enhancing suppliers’ capabilities and fostering relationships across their supply chains.Research l...

On-line color monitoring in continuous textile dyeing

Abstract This paper describes how on-line color monitoring could be used as part of an ultrasound enhanced continuous textile dyeing system. The current state-of-the-art of color measurement and control in textile manufacturing is reviewed. The use of ultrasound in a closed-loop dyeing system is proposed. The current status of on-line color monitoring which would be required is presented. Some possible solutions to measuring the color of wet fabric have been developed.

Warp Break Detection in Jacquard Weaving Using Micro-Electro-Mechanical Systems: Effect of Yarn Type

This paper reports a study aimed at detecting warp breaks in terms of yarn type using a Micro-Electro-Mechanical Systems (MEMS) accelerometer based detection system, which has been described in earlier publications. The MEMS accelerometers were mounted on harness cords of a Jacquard tie. MEMS output acceleration signals were analyzed. The signals were acquired while warp ends were up and at the moment of intentional break with a pair of sharp scissors simulating missing warp ends. The results indicated that MEMS acceleration signals at intentional breaks for continuous filament from standard and high strength fibers could be detected. The break signals of cotton and cotton/polyester spun yarns were undetectable.

Warp breaks detection in Jacquard weaving using MEMS: System development

Abstract Research related to warp breaks has been limited to monitoring break frequency and the reason associated with breaks in order to improve warp yarn quality. While this approach led to improvement in weaving efficiency, warp breaks still represent a major problem, especially for todays high-speed weaving machines. Researchers have been trying to develop commercial automated systems to repair warp breaks with no success. The goal of this study is to explore inexpensive methods to detect warp breaks using nontraditional technique that would pave the way to automate warp break repair. To achieve the goal, a system that can detect warp breaks using MEMS accelerometers as sensors was developed for Jacquard weaving. The MEMS accelerometers were mounted on harness cords of a Jacquard tie. MEMS output acceleration signals components in the vertical and horizontal directions were analysed using time and frequency domains. The signals were acquired while warp ends are running and at the moment of intentional breaks. The analysis led to a successful detection of warp breaks, especially using the horizontal acceleration component that is mainly due to harness cord vibration.

Optimal data use in staple yarn manufacturing

The contemporary cotton spinning mill is home to modern machinery capable of generating a plethora of data. This data comes in the form of online data, which is real-time data created by the processing machinery, and offline data, which is created via laboratory testing of samples. This paper describes a study which applied statistical techniques to the two data sets. One came from an actual open-end spinning plant. The other was created in a laboratory environment. This analysis served to discover trends within this data sample and to determine the optimal data use for the cotton spinning industry. In addition, the paper presents a perspective into the current state of data management in the cotton spinning industry obtained by visiting an assortment of active spinning mills.

Vendor-managed inventory systems in the apparel industry

Abstract The changing retail scenario creates problems for the retailers as well as the manufacturers in terms of managing over-stocking and under-stocking costs. Since 2005, multiple strategic partnership schemes have been researched and implemented to optimize the supply chains. One such strategy has been vendor-managed inventory (VMI). However, the benefits to the supply chain are determined by the extent of implementation of a VMI model. This chapter reviews the VMI relationship between a garment manufacturer and its downstream customers, and it explores the enablers that help a vendor advance from a basic-level VMI relationship to a higher level. This study also looks at the ways in which a VMI model is beneficial to the supplier company.

Wireless yarn tension measurement, and control in direct cabling process

An online yarn tension sensing and control device has been designed and developed. The system was specifically devised for use in a direct cabling machine, wherein yarn tension in the spindle or pot yarn is highly critical and dictates the uniformity of the cabled yarn. Since a balloon formed by the creel yarn always encompasses the pot yarn in a direct cabling machine, yarn tension measurement using a wired sensor is far-fetched. Accordingly, a wireless yarn tension sensor was developed to address this problem and perform online yarn tension measurement. The wireless sensor can be used as an active monitoring tool for measuring online yarn tension in both component yarns, while the closed loop control system replaces passive yarn brakes used in the current direct cabling machines and executes a control mechanism that can control yarn tension adaptively. The device uses Micro-Electro-Mechanical Systems (MEMS) technology with radio frequency (RF) transmission to effectively carry out dynamic online measurement. The control system in conjunction with the wireless sensor ensures equal tension in the component yarns, resulting in the formation of a uniform cabled yarn with equal lengths of both yarns.

Prevention of warp breaks in Jacquard weaving

We developed a system to monitor and locate warp breaks in Jacquard weaving using MEMS accelerometers that are mounted on harness cords. Brief description of the system is provided and system use to prevent warp breaks through the analyses of MEMS signals is demonstrated.

Textile Enterprise Modeling

Textile companies are striving for an advantage using many different competitive strategies and are often employing more than one strategy at a time. To maximize the potential of incorporating new technologies that include process equipment and information systems, an increased level of understanding of the integrated enterprise is required. This paper reviews the current research efforts relating to enterprise modeling in the textile industry. Discussed are two generic enterprise reference architectures: the Purdue Enterprise Reference Architecture and the Open Systems Architecture for CIM (CIMOSA). Areas for research in enterprise modeling in textiles are presented.