A case study in off-line quality control: characterisation and optimisation of batch dyeing process design

Abstract

A method is provided and demonstrated for robust design of the batch dyeing process. This method is used to identify optimal batch dyeing process parameter settings which produce target color with the least color variation within and among dyed fabric pieces. The robust design problem is defined in terms of the design objectives, control factors and noise factors. Performance measures are presented to evaluate mean and dispersion characteristics of the dyeing output. Design and conduct of experiments are discussed for developing empirical models of the performance measures, and these models are developed for the study case. The robust design problem is formulated and solved as a nonlinear programming problem. Confirmation of results and iterative use of the proposed design method are discussed.

Numerical Analysis of a Periodically Forced Dyeing Process

“…Various models have been proposed to describe the dyeing process and/or relate the operating conditions during a dyeing process to the quality of the resulting dyed product. Some studies have focused on the online control of dyeing processes. – Others have dealt with the physical chemistry of dye adsorption and transport of dye into the threads, providing a comprehensive investigation of the effect of various process parameters on dye distribution and dye uptake. ,,– …”

“…Some studies have focused on the online control of dyeing processes. [8][9][10][11] Others have dealt with the physical chemistry of dye adsorption and transport of dye into the threads, providing a comprehensive investigation of the effect of various process parameters on dye distribution and dye uptake. 6,7,[12][13][14][15][16][17] In the standard dyeing processes, the bobbins of threads are fixed to perforated supports and receive dye from the liquid crossing the bobbins and recirculating to a mixing tank (e.g., see ref 7).…”