

Itru E Learning by Teaching Series 












Application of Knowledge Based SPC for Textile Mills 





Version 1.1 with Itru SPCv software Parts I and II 


























Introduction 





SPC (STATISTICAL PROCESS CONTROL) is still widely used in Textile industry to analyse mainly off standard running processes. Application of SPC starts from raw material selection to ready made garments. In this training course examples were included from actual mill practice of SPC in spinning, weaving and finishing mills.
What's new in Knowledge Based SPC
Knowledge Based SPC system considers most of the statistical systems as a whole and combines them with all process /material factors not only taking ± 3 sigma control charts into consideration . In addition to this there are two new charts 95 % Upper and Lower limits of Coefficient of Variations and 2S bar with whole single values in one line for each group . Intention of SPC is to improve process by minimizing the defects, intention of Knowledge Based SPC integrated to Knowledge Based Quality Management is to minimize cost and optimize quality according to customer requirements.
Therefore, SPC concept in this training course should be considered in relation to Knowledge Based Quality Management. SPC is a useful tool for textile mills to control and improve quality. In this training course most of the terms, definitions and derivation of full formulas that are used in existing textile testing equipment were included so that these systems could be more effectively used.
Trainees are also supported with Itru SPC ver 1.0 PCProgram and Spread Sheet Exercise Examples to make their knowledge enhanced and practical. After a completing the course a trainee could establish and or improve SPC System in their field. Support will be given for those who enroll the course and as well as in actual mill practices.
SPC is also closely related to Quality/Process Control procedures in spinning, weaving and finishing mills as well as a part of Knowledge Based Quality Management System.
SPC ver 1.1 for Textiles is a part of Itru SPCv1 for Textiles Software. This software covers most of the chapters that are explained in this course. SPCv1 makes it simple to adapt SPC systems in textile industry. After completing this course the candidates will make use of Spread Sheet software and Itru SPCv1 more effectively.
Requirements: In order to enroll this course the candidate should have a minimum of BSC in Science. Since course is intended for Textile Mills technicians and engineers. Hence candidates are obliged to send a scanned copy a of diploma Requirements: In order to enroll this course the candidate should have a minimum of BSC in Science or Engineering 





















This training course has main four parts.
Part II covers from Chapters 1 to 4 Part III from Chapters 5 to 6 Part IIII from Chapters 7 to 8 And finally Part II1 from Chapter 10 to 12
Part II Chapter 1 Introduction to Knowledge Based SPCv ver 1.1 1 Introduction 12 Main Items of SPC 13 1 Deriving Number of Tests per group and Total 132 Sample Selection (Simple Random Sampling and Random Numbers Generating ) 133 CV % , Set Error % and Sampling Relations 14 Determination of OffStandard Process with the aid of 95 % Confidence Limits 15 Evaluation of OffStandard Results How
to decide number of tests per unit(samples) and total number of
samples Chapter 2 Process Improvement (Before and After Test) Chapter 3 Control Charts and General Statistical Terms and definitions 31 3 s Control Charts (3 Sigma Control Charts) and Basics of Statistics 3 2 Confidence Range of Mean with ttable calculations (unknown Population sigma ) 33 Confidence range of standard deviation and CV% 3.4 Card Sliver Count Control and Control Charts 35 Process out of Control What
is 3 s Control Charts (3 Sigma Control Charts) and how can be
used ? Chapter 4 Frequency Distribution and Analyses 41 Summary of Terms Used and Derived from Relative and Cumulative Frequency Diagrams Part III covers ;Differences Between Averages and Variances ; and ;Significant Difference between Nominal and Actual Value ; Is
the difference between samples statistically significant?
Although Ring Span yarn as an average exhibits higher strength than compare to rotor span yarn may lead to more end break rate in weaving due to weak places in the yarn. Therefore, Coefficient of variation in other words distribution of yarn strength becomes more significant than average value .
It is the FTest that compares two samples distribution. How to control Nominal Set Value and Actual Measured Value in Process?
Part IIII
Chapter #7 Normal Distribution Curves How can Normal Distribution Curves be used in testing and what are their limits?
Chapter #8 SPC Distributions
Application of Binomial, Poisson;s , Confidence Limits of Mean of Poisson;s Distribution and c² Distribution (ChiSquare) are explained.
Part III SPC Charts, which is the main part of the ELearning Course
The Knowledge Based Management System Structure is to conglomerate mathematical models between raw material, semi product and end product quality parameters. The factors of this model are defined as System Factors.
In order to make use of Knowledge Based SPC we have to take into consideration of Control Factors and Interference Factors in SPC Charts. It is not sufficient to control the process within limits but also minimize the steps in process and reduce the management and manufacturing cost to minimum levels We call this Optimum Quality Minimum Manufacturer Costs with Zero Defects fulfilling customer Requirements.
Which type of SPC charts should be used to control Process? There are mainly 7 control SPCCHART that are used these are: 1X
bar (Normal distribution) 3
2S/CV bar (Normal distribution) 7 ubar (Poisson;s) How can defects be annualized and OffStandard Reports are implemented.

















The aims of this elearning SPCver.1.1 for textiles could be More
effectively using the existing textile testing
equipment
The candidate will be able to control quality level in fibers, yarns and fabrics as well as spinning and weaving and knitting mill performance.This course will help to apply and improve the ISO9000 standard procedures. Itru SPCv1 software could also be used for process improvement in spinning, weaving and knitting and processing mills.
Any candidate who completes and passes the main two exams will be able to take over the tasks of Quality /Process Control management of Spinning, Weaving and Knitting Mills and will have a certification signed and approved by Itru Group Ltd. 
















The main course is written in PDF file format which covers main subject,exercises and examples. The course is divided into 12 chapters .
Each chapter does not exactly follow one another. The content moves forward and backward and then forward up to Chapter 11 Defects Probability Effect Analyses. This procedure intentionally done this way to make the candidate to learn to tackle problems and read further readings to solve the problems more effectively.
The content has been designed to learn basic statistical methods and adapt to practical mill conditions and then move into more advanced topics . The content starts with SPC Control Charts and end up with Control Charts which is the core of SPC systems . Therefore , when candidate completes the course who will be able to apply this system in practice.
Table
of Contents PART II Table
of Contents PART I II
Table of Contents PART IIII 7Normal
Distribution Curves 5 Table
of Contents PART III Time
schedule : Any candidate could start the course any time of the
year. However, total time Course
Content Learning Period Weeks Questions
for Examinations for Part I I 1 Total 38

















The core of the system is Learning Path, which covers a) Reading Chapters b) Understanding examples c) Solving exercises d) Passing the test at the end of the course. e) Submitting assignments to course administrator and further reading related documents from Wiki and prepare Home Works f) Submitting questions and answers to Forum g) Suggestions new subjects to main course to be included or excluded












5 Support 





Training course has selfsupporting system. Each candidate will submit their questions to Forum and will be answered by the forum or course Administrator 











6  Human and Physical Resources 





SPC ver 1.1 Software , Spread Sheet Examples and practical mill samples applications. 
















This course has been intended to give training for Quality Technician and Quality Manager certifications for textile industry. Therefore, there are two main exams one for Quality Technician and two for Quality Management.
Exam I ( Part I ) for Quality Technician Exam II (Part II ) Quality Manager
The evaluation is a total of a)
Exercises solving ( % 20)
This procedure covers from part I to Part II . The candidate who passes Exams of Part I then continues to Part II ( at least 50 % Total ). Those who pass the both exams with 85 % success will be awarded with Itru SPCv1 PCprogram. Any candidate who can not complete the course for a given period of time automatically deleted from the course without any refunding . Any misuse of the system resources may lead to canceling of enrollment without any refunding and notification .
















Requirements : A diploma of minimum of BSC. in Science or Engineering ,Internet connection and familiarity with spread sheet software. Mswindows Operating System XP,Vista or Windows 7 , Open office ver 3.4.0 English version and Adobe Reader Course Fee : For individuals = 440 USD per person For companies = 440 USD per group ( Each group has 1 to maximum 4 members ) Registration : Click here for registration to SPC Validation of Registration : An email will be send to you for validation of your registration including information about payment and a scanned copy of the diploma. Read before enrollment Distribution  License File Limited Warranty And Disclaimer Of Warranty And Terms Of Use
















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