PK Laxmi Mills Quality Surveillance Watch
1. Executive QA Highlights & Critical Risks
Shantex (SR Group) 21/1 L/C 55/45 — Shop floor yarn fails buyer spec sheet
Buyer requesting 2 sample cones before opening Letter of Credit (LC). Buyer Spec: U% 13.5–14.5, IPI ≤4,200, RKM ≥17 cN/tex, CSP 2,500+, count CV ≤2.0. Actual production on Lot JA#913021: U% 16.7–17.7, IPI 4,661–5,820, RKM 14.3–14.8 (-14%), CSP NOT tested, count CV up to 2.51 (M22). Raw material mismatch: Buyer PI specifies BCI cotton while PKLM spec states PIMA. Action: Pull sample ONLY from cleaned frame M27 (IPI 4,661) and test complete Uster + Tensojet + CSP before courier dispatch.
Jamuna Group 10/1 55/45 LLEV — 374.9 Tons (9 PIs pending) Quality Hazard
HF/017 shipment balance due in 5 days. Zero CSP testing for past 16 days (promised CSP 1,800+). New lot L@95610: Promised IPI 4,500–5,500, but actual IPI is 5,748 - 8,482 (Frame M16 outlier at 8,482 with U 20.8). Frame M01 count CV is catastrophic at 6.18% (causes horizontal barré stripes after fabric dyeing). Action: Immediate wrap/CSP on L@95610, inspect M16 drafting rollers, and test M01 cone count before carton sealing.
Mondol / Women'Secret 28/1 85/15 Ecovero/Linen — Fabric Knitting Holes Complaint
Initial sample rejected by brand due to drop stitches and fabric holes (12 holes in 6.6 kg 20G fabric, 9 in 6 kg 24G). Buyer spec demands U 13.94, IPI 3,130, RKM 18.06, CSP 2,400. In-house yarn has 1,900–2,900 weak places. Action: Complete Tensojet weak place tests, autoconer splicer strength retention check, and run knitting trial on 1 cone before handing over.
Unit 1 — Low Elongation & Weak Places Spike in 11s C/L and 21s E/L
11s C/L L@95511: Elongation dropped from 4.78% to 3.92/4.13%; weak places reached 1,032–1,274. Frame M10 running with 16.9 breaks/hr and 17 rogue spindles. 21s E/L L@95421: Weak places surged across all frames (M02: 401, M11: 216). M02/M11 thin places at ~260 due to drafting apron wear. Action: Verify cotton laydown twist and renew M02/M11 drafting aprons.
Unit 2 — Frame Cleaning Delays & Shift 1 End Break Surge
Frames M21/M22 (FC 24) and M29 (FC 22) overdue for cleaning (rule: ≤15-20). M28 and M22 S1 breaks spiked to 21.8 and 20.0 (+31% and +37%). Frame M30 running new 10s siro with FC 26, Count CV 4.17, and weak places up by +224%. Action: Complete full deep-clean on M21, M22, M29, M30 prior to Shantex production.
Frame M31 (26s WLC Siro) — 5 mm Spacer Trial Slashes IPI and Weak Places
Frame M31 apron cradle spacer adjusted to 5 mm: IPI dropped from 18,800 to 15,600 (-17%) and weak places plunged from 420 to 202 (-52%). Confirms spacer control works. Frame M14 count CV recovered from 9.64% to 2.22%.
2. Machine & Count-wise Lab Test Breakdown
Unit 1 (19) + Unit 2 (12)| Frame | Count / Lot | Count CV% | U% (CVm) | Thin (-50) | Thick (+50) | Neps (+200) | Total IPI | RKM (cN/tex) | Elong % | Weak Places | FC Clean | Diagnostics & Action Plan |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| U1 · M01 | 21s LL L@106721 |
1.56% | 6868.0% (4146.0%) | 551 | 0 | 0 | 551 | 17.36 | 5.87% | 700 | FC 13 | Controlled / Normal (FC: 13) |
| U1 · M02 | 21s LL L@106721 |
2.06% | 6783.0% (4131.5%) | 569 | 0 | 0 | 569 | 18.43 | 6.18% | 86 | FC 3 | Controlled / Normal (FC: 3) |
| U1 · M03 | 14 HC L@106314 |
2.62% | 6106.0% (3276.0%) | 403 | 0 | 0 | 403 | 16.91 | 4.9% | 139 | FC 15 | Controlled / Normal (FC: 15) |
| U1 · M04 | 21s EL L@106921 |
1.07% | 3707.5% (1707.5%) | 279 | 0 | 0 | 279 | 27.27 | 8.05% | 20 | FC 11 | Controlled / Normal (FC: 11) |
| U1 · M05 | 21s LC L@106321 |
1.9% | 7484.5% (4775.5%) | 459 | 0 | 0 | 459 | 15.73 | 4.46% | 1 | FC 0 | Low Elongation (4.46%) — optimize traveler weight |
| U1 · M06 | 21s LC L@106321 |
2.24% | 7169.0% (4379.0%) | 384 | 0 | 0 | 384 | 16.4 | 4.94% | 0 | FC 0 | Controlled / Normal (FC: 0) |
| U1 · M08 | 21s LC L@106321 |
8.59% | 6462.5% (3685.5%) | 261 | 0 | 0 | 261 | 15.73 | 4.51% | 3 | FC 0 | High Count CV% (8.59%) — inspect drafting & cone count |
| U1 · M09 | 21s LC L@106721 |
1.0% | 5958.0% (3235.0%) | 200 | 0 | 0 | 200 | 16.11 | 4.61% | 1 | FC 12 | Controlled / Normal (FC: 12) |
| U1 · M10 | 21s LC L@106321 |
1.35% | 7304.5% (4386.5%) | 317 | 0 | 0 | 317 | 15.91 | 4.6% | 1 | FC 9 | Controlled / Normal (FC: 9) |
| U1 · M11 | 21s LC L@107321 |
3.31% | 7337.0% (4550.5%) | 304 | 0 | 0 | 304 | 15.04 | 4.42% | 8 | FC 0 | High Count CV% (3.31%) — inspect drafting & cone count |
| U1 · M12 | 20s BAMBOO L@104920 |
0% | 0% (0%) | 0 | 0 | 0 | 0 | 21.54 | 14.88% | 1 | FC 0 | Controlled / Normal (FC: 0) |
| U1 · M13 | 20s BAMBOO JA#1012713 |
1.74% | 3900.0% (1509.5%) | 166 | 0 | 0 | 166 | 21.59 | 14.79% | 4 | FC 0 | Controlled / Normal (FC: 0) |
| U1 · M15 | 10 LLEV L@105610 |
1.52% | 5755.5% (2908.5%) | 707 | 0 | 0 | 707 | 10.83 | 6.58% | 3 | FC 24 | Low Tenacity (10.83 cN/tex) — check traveler & twist |
| U1 · M16 | 10 LLEV L@105610 |
2.37% | 6221.0% (3316.0%) | 1008 | 0 | 0 | 1,008 | 10.54 | 6.34% | 21 | FC 22 | Low Tenacity (10.54 cN/tex) — check traveler & twist |
| U1 · M17 | 21s EL L@106921 |
1.16% | 4140.5% (2009.0%) | 380 | 0 | 0 | 380 | 27.02 | 7.82% | 73 | FC 2 | Controlled / Normal (FC: 2) |
| U1 · M18 | 14 HC L@106314 |
1.19% | 5863.5% (3219.0%) | 356 | 0 | 0 | 356 | 16.66 | 5.02% | 203 | FC 1 | Controlled / Normal (FC: 1) |
| U1 · M19 | 21s LL L@106721 |
2.85% | 6821.0% (4031.5%) | 821 | 0 | 0 | 821 | 18.35 | 6.74% | 35 | FC 5 | Controlled / Normal (FC: 5) |
| U2 · M20 | 12s VL L@104920 |
2.12% | 147.5% (37.0%) | 263 | 0 | 0 | 263 | 14.11 | 10.54% | 178 | FC 0 | Low Tenacity (14.11 cN/tex) — check traveler & twist |
| U2 · M21 | 13s VL JA#1014012 |
1.26% | 3956.0% (1698.0%) | 473 | 0 | 0 | 473 | 16.4 | 12.13% | 6 | FC 9 | Controlled / Normal (FC: 9) |
| U2 · M22 | 13s CL JA#1013013 |
0.98% | 3403.0% (1188.0%) | 166 | 0 | 0 | 166 | 14.52 | 5.27% | 0 | FC 11 | Low Tenacity (14.52 cN/tex) — check traveler & twist |
| U2 · M23 | 13s CL J#A1013013 |
0% | 0% (0%) | 0 | 0 | 0 | 0 | 14.24 | 5.0% | 4 | FC 0 | Low Tenacity (14.24 cN/tex) — check traveler & twist |
| U2 · M24 | 12s CL JA1013012A |
1.38% | 2473.5% (751.0%) | 401 | 0 | 0 | 401 | 14.49 | 5.75% | 0 | FC 13 | Low Tenacity (14.49 cN/tex) — check traveler & twist |
| U2 · M25 | 12s CL JA1013012A |
2.48% | 3252.5% (1128.0%) | 403 | 0 | 0 | 403 | 14.63 | 5.66% | 3 | FC 24 | Low Tenacity (14.63 cN/tex) — check traveler & twist |
| U2 · M26 | 30.0s JA1014130S |
4.67% | 3670.5% (2830.0%) | 173 | 0 | 0 | 173 | 0 | 0% | 0 | FC 0 | High Count CV% (4.67%) — inspect drafting & cone count |
| U2 · M27 | 16s CL JA#1013016 |
1.5% | 3804.0% (1524.5%) | 141 | 0 | 0 | 141 | 14.76 | 4.87% | 0 | FC 4 | Low Tenacity (14.76 cN/tex) — check traveler & twist |
| U2 · M28 | 16s CL JA#1013016 |
0.64% | 3804.0% (1538.5%) | 163 | 0 | 0 | 163 | 14.53 | 4.84% | 0 | FC 14 | Low Tenacity (14.53 cN/tex) — check traveler & twist |
| U2 · M29 | 16s CL JA#1013016 |
0.9% | 4206.0% (1838.5%) | 126 | 0 | 0 | 126 | 14.18 | 4.5% | 0 | FC 6 | Low Tenacity (14.18 cN/tex) — check traveler & twist |
| U2 · M30 | 16s CL JA#1013016 |
1.8% | 4406.0% (1977.0%) | 235 | 0 | 0 | 235 | 14.26 | 4.62% | 1 | FC 2 | Low Tenacity (14.26 cN/tex) — check traveler & twist |
| U2 · M31 | 26 WLC JA#1013926SI |
1.15% | 7699.0% (4772.5%) | 189 | 0 | 0 | 189 | 16.83 | 4.19% | 97 | FC 5 | Low Elongation (4.19%) — optimize traveler weight |
3. Customer Spec vs Actual Gap Analysis
| Parameter | Customer Agreed Spec | Shop Floor Actual Test | Gap / Difference | Audit Status |
|---|---|---|---|---|
| Yarn Count | Ne 21/1 | Ne 21.0s (CV 0.90–2.51%) | M22 CV 2.51% > 2.0% | ATTENTION ⚠️ |
| Evenness U% (CVm%) | 13.5–14.5% (CVm 17–18%) | 16.66–17.67% (CVm 21.7–23.0%) | +2.9 points (+20% worse) | REJECT RISK ❌ |
| Thin Places (-50%) | 30–60 /km | 99–229 /km (Avg 168) | 2.8x higher than limit | REJECT RISK ❌ |
| Thick Places (+50%) | 1,200–1,600 /km | 2,025–2,452 /km (Avg 2,330) | +46% above limit | REJECT RISK ❌ |
| Neps (+200%) | 1,800–2,400 /km | 2,538–3,197 /km (Avg 2,870) | +20% above limit | REJECT RISK ❌ |
| Total IPI | ≤ 4,200 /km | 4,661–5,820 /km (Avg 5,368) | +28% above limit | REJECT RISK ❌ |
| Lea CSP | 2,500+ | Not Tested (Proxy ~2,194) | -12% shortfall | REJECT RISK ❌ |
| Tenacity (RKM) | ≥ 17.0 cN/tex | 14.33–14.81 cN/tex | -14% below spec | REJECT RISK ❌ |
| Raw Material Fiber | 100% PIMA ELS + Belgium Flax | SR Booking: BCI Cotton | Contract Spec Mismatch | ATTENTION ⚠️ |
4. Customer Complaints & Claim Risks
Mondol Fabrics / Women'Secret
Issue: Fabric drop stitches & holes during knitting (12 holes in 6.6kg 20G). High weak places and weak autoconer splices.
Jamuna Group / Nautica
Issue: Cone-to-cone color shade variation and dyeing barré stripes. Frame-to-frame IPI varies from 5.7k to 8.5k, M01 count CV 6.18%.
Texspin / Ferre Sanz (Spain)
Issue: Knots and weak slub breaks causing 70–96 loom stops on air-jet warp.
5. Root Cause Chain — High Breaks & Maintenance
6. Critical Data Blindspots & Lab Gaps
Shift Attendance & Overtime Logs
6 days of shift attendance data missing (Sept 22–27). Cannot correlate night-shift break surges with operator absenteeism.
Statex Lea CSP Strength Testing
Zero wrap/CSP tests since Sept 22; 16-day testing backlog on 10s Jamuna, and zero tests on Shantex 21s.
M07 End-Break Sensor Failure
Frame M07 reported '0 breaks' across Shifts 2 and 3 — optical sensor is dead and maintenance missed it.
Lab Count Testing Mismatch
Frame M05 switched to 12s on Sept 27, but lab continued running it under 21s test profile.