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RFT dyeing to meet perfect quality and gain profit

Dyeing is the last and most significant step in textile manufacturing process since it ensures defects control as well as cost reduction. RFT stands for ‘right first time’ in the wet processing sector which refers to dyeing efficiency; if the efficiency exceeds the company’s dyeing capabilities, the company is considered good; otherwise, it is not. Every dyeing process has an RFT % aim to meet. As a result, textile dyeing houses go for RFT dying in order to shorten lead times and increase profitability. So we can say that if the dyeing process is completed properly without any fault and there is no need to put the dyed fabric into the bath to get the proper shade then this dyeing is called RFT dyeing.

RFT-dyeing-textile-wet-processing -quality-profit
Figure: RFT dyeing is when the dyeing process is completed without faults and the dyed fabric does not need to be placed in the bath to acquire the desired shade.

Wrong-first-time (WFT) was the rule rather than the exception in the dyehouses of 50 years ago and for many centuries before that. Right-first-time (RFT) manufacturing could only be achieved by chance under ideal conditions, such as a series of repeat dyeing to the same shade on the same substrate.   The technology of RFT processing in exhaust dyeing became established in the late 1970s and early 1980s.

Basically, RFT dyeing is when the dyeing process is completed without faults and the dyed fabric does not need to be placed in the bath to acquire the desired shade. RFT dyeing allows us to achieve certain goals. They include, among other things, higher productivity, reduced time consumption, increased profit, reduced fabric waste and lower costs. RFT dyeing requires the deployment of some technology. Among the technologies are machinery in the dyeing house, as well as an automatic dosing system and a heat control unit.

In order to achieve RFT dyeing in Bangladesh, a number of challenges must be resolved. Among the challenges highlighted are a lack of automation technology in the dyeing house, conventional machines, a shortage of experienced workers, a financial barrier and low-quality dyes and chemicals. To achieve RFT, it was realized that a successful practical dyer had to meet specific parameters.

The objectives are as follows:

  1. The material must be colour consistent or isomeric in different off and it must match the desired colour.
  2. The colour must be applied evenly, and the treated material must be of acceptable fastness and physical characteristics.
  3. The production cost must be within the budget limitations;
  4. Timely delivery of the materials is required.

When the buyer’s order or booking sheet arrived, RFT was given a specific plan. The RFT sample’s shade was quite similar to the authorized sample of the buyer. Other essential quality parameters like wash fastness, rubbing fastness, and bursting strength were assessed on both the regular and RFT samples. While matching the buyer’s expectations, the RFT sample displayed excellent shade quality.

If any problem occurs, we’ll have to start over with all of the procedures, which will take a long time and cost a lot of money. Fabric re-dyeing mostly raises the manufacturing cost. The extra time spent re-dying has a negative influence on the time it takes to produce the end-lead product. Paying a high price for an out-of-stock goods, on the other hand, results in a large loss for any manufacturer. As a result, textile dying companies should employ RFT dyeing to reduce lead times while also enhancing profitability and competitiveness.

To achieve the Right-First-Time aim in dyeing, the researchers employed the Six Sigma DMAIC (define-measure-analyse-improve-control) methodology to identify critical elements and develop corrective methods. RFT yield increased by 4% as a result of actions taken on key processes, resulting in a monthly cost savings of INR 2.951 million. The Six Sigma DMAIC technique was successfully utilized to standardize the fabric dyeing process in a manufacturing unit, according to a research published in 2013.

    

Phases

 

Tools

 

Define

 

Project charter ( mission, goals, boundaries etc), SIPOC ( High Level Process Mapping ), CTQ ( Identifying Projects Critical to Quality )

 

Measure

 

“As is ” process map, Measurement System Analysis, Data Collection Plan, Base Level Sigma.

 

Analyse

 

Pareto Chart, Cause & Effect diagrams, 5-why analyse, Hypothesis testing.

Improve

 

Counter Measure Matrix
Control Control Plan

So, Six Sigma is a disciplined problem-solving strategy for reducing process variance and manufacturing failures. It offers a powerful option for strengthening textile processes that produce a lot of variation and flaws by their very nature. This approach can be used to any business operation that aims to reduce expenses and enhancing profits. In terms of the value contributed during the operation and the resources employed, right-first-time dyeing processes provide significant economic benefits.

Aside from cost savings, RFT processing has a number of other benefits, including greater quality due to faster processing times, more output with the same equipment and better production planning. The benefits of achieving right-first-time (RFT) manufacturing through blind dyeing include enhanced productivity, just-in-time (JIT) processing, and a quick response (QR) to client requirements.

The RFT concept attempts to increase productivity, process efficiency and profitability while improving quality. A number of factors have to be checked and ensured in order to get the right production with the right quality. By remaining active throughout the manufacturing process, RFT may play a crucial role in ensuring that the appropriate product is supplied at the correct time, saving both money and time. Any reprocessing is very expensive for the company.

Recently Ibrahim Khalil student of Ahsanullah University of Science and Technology has achieved Setting Transformation Blueprint (STB) Black Belt from Textile Today Training through his 4 months’ intensive journey of 128 hours of factory skill development training in 8 different courses and 128 hours of practical project work at Fatullah Dyeing and Calendering Mills Ltd regarding lab to bulk right first time (RFT). Khalil had extensively worked with the lab to bulk dyeing RFT.

According to Khalil, the project outcome is extraordinary. Though it is tough to implement lab to bulk RFT in any factory considering the organization culture, but if we can implement it, factories will be greatly benefitted and it is clearly shown in this project.

If anyone has any feedback or input regarding the published news, please contact: info@textiletoday.com.bd

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