Yield Control System Information

Automation Partners Inc.

Overfeed Control

Controlling the overfeed of a tenter frame with the Yield Control System results in a significant improvement in fabric density uniformity and, as a result, the means to obtain a substantial increase in production yield. In addition, more uniform fabric results in higher quality fabric, better prediction of shrinkage, and better shade consistency of dyed and napped fabrics.
The Yield Control System automatically adjusts the overfeed speed of a tenter frame to compensate for variations in fabric course count. By measuring the course count before the fabric is fed to the frame, the overfeed can be properly adjusted to yield uniform, on-target fabric density.

By automatically controlling the amount of fabric placed on the tenter frame, the density is uniformly maintained from seam-to-seam. As a result of the significant reduction in density variations, typically 50%, the target density can be reduced thus increasing production yields while remaining within specification. The graph above shows this reduction and allowable shift of target. The cost savings provide a tangible benefit which can result in a quick payback of the investment in the system.
For example, a finisher producing 500,000 yards per month at an average of 50.5 cpi can reduce the average (target) density to 50.0 cpi and obtain a 1% increase in the yardage produced from the same amount of raw material. If the fabric sells for $2.00 per yard, this increase in production yield provides added revenue of $10,000 per month at no additional cost.
There are other benefits which, although perhaps intangible, result in improved operational performance and fabric quality. Consistency among different operators is assured by the use of stored recipe (style) control parameters. Rework (reruns) due to over or under weight fabric is reduced which results in higher capacity utilization of the tenter frame. In addition, the system provides uniformity of shrinkage allowing for better prediction of shrink, a very important parameter for most fabric producers.
Historical data stored by the system can be used to detect off-quality fabric supplied by the knitter. Other data can be used to determine when machine parameters are reaching operational limits which may signify that preventive maintenance is required.

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October 6, 2003

More YCS Information


Overfeed Control
		Controlling the overfeed of a tenter frame with the Yield Control System results in a significant improvement in fabric density uniformity and, as a result, the means to obtain a substantial increase in production yield. In addition, more uniform fabric results in higher quality fabric, better prediction of shrinkage, and better shade consistency of dyed and napped fabrics. The Yield Control System automatically adjusts the overfeed speed of a tenter frame to compensate for variations in fabric course count. By measuring the course count before the fabric is fed to the frame, the overfeed can be properly adjusted to yield uniform, on-target fabric density.


	By automatically controlling the amount of fabric placed on the tenter frame, the density is uniformly maintained from seam-to-seam. As a result of the significant reduction in density variations, typically 50%, the target density can be reduced thus increasing production yields while remaining within specification. The graph above shows this reduction and allowable shift of target. The cost savings provide a tangible benefit which can result in a quick payback of the investment in the system. For example, a finisher producing 500,000 yards per month at an average of 50.5 cpi can reduce the average (target) density to 50.0 cpi and obtain a 1% increase in the yardage produced from the same amount of raw material. If the fabric sells for $2.00 per yard, this increase in production yield provides added revenue of $10,000 per month at no additional cost. There are other benefits which, although perhaps intangible, result in improved operational performance and fabric quality. Consistency among different operators is assured by the use of stored recipe (style) control parameters. Rework (reruns) due to over or under weight fabric is reduced which results in higher capacity utilization of the tenter frame. In addition, the system provides uniformity of shrinkage allowing for better prediction of shrink, a very important parameter for most fabric producers. Historical data stored by the system can be used to detect off-quality fabric supplied by the knitter. Other data can be used to determine when machine parameters are reaching operational limits which may signify that preventive maintenance is required.