How to Set Up a System to Measure Waste Loss?
Here’s a step-by-step guide to establish an effective waste monitoring system:
- Track Every Yarn Batch
Record each yarn batch that enters your factory. Compare this with the fabric sold from the same batch to identify discrepancies. - Measure Fluff and Running Loss
- Weigh the yarn before knitting.
- Weigh the yarn after knitting.
- Subtract the fabric weight produced from the initial yarn weight to calculate fluff and running loss.
- Recommendation: Measure at least 1,000 doffs to get a reliable average.
- Minimize Fabric Setting Loss
Record key machine parameters like:- Loop Length
- IRO Tension
- Fabric Tension
- Fine-tuning these settings can reduce time wasted on fabric setting, enhancing production speed.
- Optimize Yarn Purchasing
Over-purchasing yarn adds to waste over time. Regularly review your yarn usage data to improve planning and avoid excess stock. - Track Defective Fabric Loss
Break down defective fabric into:- Discarded or cut fabric.
- Grade B and C fabrics that don’t meet premium standards.
- Measuring defective fabric precisely helps identify areas for improvement.
Simplify Waste Tracking with Technology
If manual tracking feels overwhelming, don’t worry—you’re not alone. Many manufacturers face challenges with pen-and-paper methods. To simplify the process, try our free software designed to measure waste precisely. Our system helps you input, track, and analyze your production data in real time, quickly identifying waste areas for improvement. [Click here to request free software.]
Take Action Today
By setting up a comprehensive waste monitoring system, you’ll not only reduce fabric losses but also improve your overall production efficiency and profitability. In our next post, we’ll dive deeper into fabric setting loss and share more tools to help optimize your operations.