Reduction of fabric shade variation using failure mode and effect analysis in dyeing process.

Abstract

There are many problems of shade variation in the piece dyed fabrics in the textile industry and this is caused by various factors such as man, machines, methods and materials These factors include steam pressure variation; temperature, PH, auxiliary chemicals, liquor ratio. This research project presents a methodology to reduce shade variation defects in the fabrics dyeing process on jet dyeing machines in the Southern Range Nyanza textile industry. Shade variation is the most prevalent defect found in the textile industry which leads to huge reduction of profit of Textile Company. Failure Mode and Effect Analysis (FMEA) and Fishbone diagram are used to analyze root causes and prioritize the causes. The pre-treatment process and the dyeing Laboratory are the early Steps of dyeing process. The improvement in these stages has significant effects on reducing process variation which leads to Colour variation defects.