RELIABILITY ENGINEERING AND MANAGEMENT RELIABILITY MANAGEMENT STRATEGY FOR TEXTILE MANUFACTURING PROCESS FOR RELIABLE TEXTILE MATERIALS

BY

YUSUF AJIBOLA SARAFADEEN (201318885) Mini Research paper in partial fulfillment of the requirement for the degree MASTER OF ENGINEERING IN ENGINEERING MANAGEMENT FACULTY OF ENGINEERING

UNIVERSITY OF JOHANNESBURG Supervisor: Mr. Alex Rooney

TABLE OF CONTENTS TITLE PAGE TABLE OF CONTENTS ABSTRACT INTRODUCTION INTRODUCTION RELIABILITY RELIABILITY RELIABILITY MANAGEMENT AND STRATEGY RELIABILITY MANAGEMENT AND STRATEGY TEXTILE MATERIALS AND MANUFACTURING PROCESS TEXTILE MATERIALS AND MANUFACTURING PROCESS TEXTILE MATERIALS AND MANUFACTURING PROCESS TEXTILE MATERIALS AND MANUFACTURING PROCESS DESIGN FOR RELIABILITY DESIGN FOR RELIABILITY 1 2 3 4 5 5 6 6 7 7 8 9 10 11 12

DESING FOR RELIABILITY

13

DESIGN FOR RELIABILITY OF A TEXTILE MANUFACTURING SYSTEM TO PRODUCE RELIABLE TEXTILE MATERIALS 13 -15 CONCLUSION REFERENCES 16 17

ABSTRACT The improvement of manufacturing process during the past years due to technology advancement and data collected from statistical analysis of plant/equipment failures is remarkable. Many companies have developed to the point where breakdown maintenance and preventive maintenance are the predominant maintenance approaches. Despite these improvements in technology and apparent unending stream of new maintenance management strategies plant/equipment performance is in many cases not the most reliable. This paper will explore the improvement of plant/equipment reliability during manufacturing process and will show the use of design for reliability to improve the reliability of textile manufacturing process as improvement tools to improve the quality of textile materials specifically cotton.

Keywords: Reliability, reliability management strategy, design for reliability, textile materials and manufacturing process, manufacturing of reliable textile materials through design for reliability.

INTRODUCTION A reliable product is robust and mistake-free. Reliability is defined as the probability that an item will perform a required function without failure under stated conditions for a specified period of time. Reliability is a motion picture of the day-by-day operation. Customers expect products to not only meet the specified parameters upon delivery but to function throughout what they perceive as a reasonable lifetime. Accurate prediction and control of reliability plays an important role in the profitability of a product. As products become more complex, the reliability requirements of individual components increase. The reliability of a device is typically associated design for reliability (DFR) is the process conducted during the design of a system that is intended to ensure that the system is able to perform to a required level of reliability. Proper spare part stocking and support personnel hiring and training

depend upon good reliability fallout predictions. Reliability management strategy is the systematic approach to achieving reliability of products, components and systems. Reliability Management deals with the different reliability related issues during manufacture and/or operation of products (systems) from the overall business viewpoint. The issues are different for manufacturer and buyer and must be addressed in the context of the product design as well as during operation/usage. The process of making this happen through strategic means is simply one of the major areas of interest. As it is clearly understood, whatever happens here has a long time effect on what the products turn out to be. So, careful attention and utmost importance must be designated to the strategic management area of reliability. Design for Reliability (DFR) is the process conducted during the design of an asset that is intended to ensure that the asset is able to perform to a required level of reliability. The reason there is a separate and distinct focus on DFR is that historically most design processes have tended to ignore the specific activities during system design that would ensure reliability performance at any specific level. Systems require having certain level of reliability to be able to consider for operation, if this is not there, there is every tendency the system will not function. As result of this, careful attention has been given to the area of design for reliability and it has been carefully introduced into the design system so as to further improve system reliability. Textile materials are made from raw cotton going through series of processes starting from cultivation through harvesting, and then finally a textile which is then made into garment. Producing reliable textile materials requires a lot to be done, for this reason the design for reliability was cleverly integrated into the textile manufacturing process using the design for reliability process during the design stages of the system as well as creating a well ran reliability process during the system operations.

All resources brought together results into a successful operation and creation of reliable textile material from cotton using a standard design for reliability and system reliability. RELIABILITY Reliability is the probability that a part or system will perform as required for a desired time during which it is subjected to a given set of conditions under certain environmental conditions. Reliability also can be defined a design engineering discipline which applies scientific knowledge to assure a product will perform its intended function for the required duration within a given environment. This

includes designing in the ability to maintain, test, and support the product throughout its total life cycle. Reliability is best described as product performance over time. This is accomplished concurrently with other design disciplines by contributing to the selection of the system architecture, materials, processes, and components both software and hardware; followed by verifying the selections made by thorough analysis and test. Reliability deals with the longevity and dependability of components, products and systems. More importantly, it is about controlling risk and avoiding unwanted spending in repair or warranty cost. Reliability incorporates a wide variety of analytical techniques designed to help engineers understand the failure modes and patterns of these parts, products and systems. Reliability though might be a little bit complex, expensive, time consuming when applying during production but it minimizes cost, protect manufacturers reputation, build competitive brand and in the end a huge market shares. All of which would not have been possible should the product failed under the required customer’s expectations and conditions of usage. Reliability engineering has both quantitative and qualitative aspects; measurements of reliability are necessary for product reliability to ensure the product satisfied it intended purpose of creation. However, measuring reliability does not make a product reliable; only by designing in reliability can a product achieve its reliability targets. As much as reliability prevents, failure, predict and analyzes it. Reliability also improves performance of products. Creating a detail maintenance routine, specification of environmental conditions which products can function without risk, specifying how product will be operated and under which condition it can be used, are all part of reliability practice which in turns improves the perfect working condition of the products. Hence reliability of the products guaranteed. Reliability is very important in the sense that, it Identifies the needs of the customer (What does the customer want?). Translate customer requirements into performance-based product design requirements. Competitive Market Factors is one other area reliability has enhanced. Identify the required level of reliability for achieving best in class. Use product reliability as a competitive tool in the marketplace. Also Liability Concerns are identified before going into full production. It Eliminate these failures to minimize potential liability.

RELIABILITY MANAGEMENT AND STRATEGY

Like the word ‘management’ to achieve reliability of components, products and systems reliability process has to be managed. Reliability management simply is the systematic approach to achieving reliability of products, components and systems through strategic means by application of reliability engineering processes. Reliability Management monitors unscheduled discrepancies that can significantly affect system dispatch reliability, maintenance workload and costs. Monitors the individual component reliability, helping to transform unscheduled maintenance into scheduled maintenance and triggers engineering changes based on reliability information, e.g., initiating the exchange of components. Reliability Management helps evaluate the effectiveness of an existing maintenance program via system reliability program. Provides monitoring of reliability performance to identify deficiencies and thus enables the optimization of the maintenance program with the goal of balancing system availability and total costs. Monitors key figures such as dispatch reliability, scheduled completion rate, repetitive failure rates, MTBUR (Mean Time Between Unscheduled Removal), MTTUR (Mean Time To Unscheduled Removal), MTBR (Meantime Between Removal), MTBF (Meantime Between Failure, etc., in the Reliability Reporting. Captures key data like utilization, operating reports, and unscheduled component replacements etc. and provides statistical analyses including reliability trends via systems reliability model. Structures and presents the information to effectively analyze the reliability of the system.

TEXTILE MATERIALS AND MANUFACTURING PROCESS Textile materials are made from different raw materials mainly, animal, plant, minerals and synthetic. All the aforementioned raw materials undergo different manufacturing processes to be suitable for the production of clothing, house hold equipment etc. In this paper we will be talking about the production of fabrics from cotton and all the manufacturing process it undergoes from cultivation to clothing materials suitable for garment production. Cotton is the world's most important natural fibre. Cotton is cultivated mainly in Africa, Asia and some part of South and North America. Cotton is grown anywhere with long, hot dry summers with plenty of sunshine and low humidity. Planting is from September to mid-November and the crop is harvested between March and June.

Cotton was originally harvested by hand, until the mid-nineteenth century when the process is mechanized. The cotton bolls were put into heavy sacks which would be emptied into waiting baskets at the end of each row. A good picker could harvest 100-300 lbs of cotton a day, consisting of one-third fibres and two-thirds seeds. Now the cotton bolls are harvested by stripper harvesters and spindle pickers which remove the entire boll from the plant producing high quality cotton. Once the harvest is complete, the cotton is made into bales to be stored until it is ready to be ginned. Bales of cotton of various grades are moved from the warehouse to the bale opening room. Selected bales are opened and placed in position beside the breaking and opening machine. This is actually a line of machines, working as a unit, that tear apart and partially clean matted, compressed, and baled cotton. The result is small loose bunches of cotton. The cotton is then placed into the blending machine. This is a group of devices that are synchronized to proportion definite amounts of various grades of cotton which are to be blended together. At this time, matted cotton and waste yarn salvaged from operations in the mill are placed into the waste machine. This machine beats, pulls apart, and fluffs up waste cotton to prepare it for re-use. Cotton from both the blending machine and the waste machine is fed into the breaker picker. In this unit the raw cotton is partially cleaned by beating and fluffing and then fed into the finisher picker. The finisher picker receives partially cleaned cotton in the form of lap from the breaker picker and completes the cleaning and fluffing process. Lap is a general term used to designate wide sheets of loosely matted cotton. The cotton is next processed by a carding machine, where dirt and short fibers are removed; other fibers are laid parallel and formed into a ropelike strand called a sliver. The sliver is deposited in large cylindrical containers called cans. Subsequent processing depends on whether better grade (combed) yarn, or lower grade (carded) yarn is desired. For the lower grade, processing continues at the drawing frames. For better grade yarn, the sliver is first processed by the sliver lapping machine, which draws and combines several strands of sliver into a sheet of lap and winds it on a spool ready for ribbon or combing. The lap is processed by a ribbon lapping machine which draws and combines several rolls of Lap into one roll of ribbon lap, straightening the fibers slightly and making the lap more uniform in weight and texture, ready for feeding to a combing machine. Ribbon lap is a roll of closely matted cotton fibers, about 10 inches wide. Combing is the process of extracting fibers below a predetermined length and removing any remaining dirt. Output of the combing machine is deposited in cans. The cotton is next processed by the drawing frame. It is a machine in which several strands of sliver are combined into one strand and drawn out so that the combined strands approximate the weight and size of any

one of the original strands. The term drawn out means to stretch a strand of cotton, usually by running the strand between several pairs of rollers, each pair turning faster than the pair before it. The slubbing machine then draws out strands of sliver and twists them together loosely in order to give the strands (now called ROVING) sufficient strength to withstand subsequent operations. The roving is processed by the fly frame. This machine progressively combines two strands of partially processed roving into one, draws out the combined strands until they are of prescribed weight, and twists them loosely in order to give them sufficient strength to withstand subsequent operations. The cotton is now ready for spinning. Spinning is the process of making yarn from cotton fibers by drawing out and twisting the fibers into a thin strand. That is, one or more strands of slightly twisted roving are used to produce one strand of spun yarn. The yarn is wound on bobbins. The next step is to produce either warp or filling. Warp is the set of yarn strands which run lengthwise in a piece of cloth. Filling, also called WOOF and WELT is the yarn which is interlaced through the WARP to produce cloth. A filling may be single-ply or multiple-ply. The doubling machine winds two or more strands of yarn onto one package without twisting them. Package is simply a general term for any wound arrangement of yarn. The yarn is then twisted. The twisting machine twists two or more strands of spun yarn into a heavier, stronger, single strand. This process may be repeated until the desired number of ply’s is produced. The winding machine winds yarn from several bobbins in a continuous length onto a spool. Output is cheeses or cones of yarn to be used for warp. The term cheese refers to a roll of yarn built up on a paper or wooden tube in a form that resembles a bulk cheese. A cone is a tapered cylinder of wood, metal, or cardboard around which yarn is wound. The WARP may, or may not, be dyed. If not, then it is next processed by the warping machine. This machine takes about 500 strands of yarn and winds them side by side onto one large spool called a section beam. The section beam is about three feet in diameter. Processing continues at step 6 below. If the warp is to be dyed, it is processed by the ball warping machine. This machine takes about 500 strands of yarn and gathers them together into a large, loose, rope-like strand, and winds it on a wooden core preparatory to dyeing. The yarn is then dyed in a different location, producing rolls of dyed warp yarn. The dyed yarn is processed by the beamer machine which separates the individual strands of dyed yarn and winds them onto one large spool (BEAM). The slashing machine takes the yarns from several section beams and winds them side by side onto one wider spool called a loom beam. Weaving is the interlacing of warp and filling yarn to form a cloth. The inputs to the weaving process, performed on a loom, are (1) the warp yarn from the loom beam (2) the fill

yarn from a bobbin, and (3) the mechanism that controls the design to be applied to the cloth. If there is no loom beam currently in the loom, the new beam must be drawn-in. Drawing in is the process of threading the warp filaments from the loom beam into the loom in the order indicated by the design to be applied to the cloth. If the current loom beam has been exhausted, the yarn ends from the new beam are twisted or knotted to the ends of the exhausted beam. As the loom runs, the longitudinal strands of warp yarn are positioned so that every other strand is raised. A pointed block of wood called a shuttle pulls the filling yarn through the strands. The position of the warp yarn strands is then reversed and the shuttle pulls the filling yarn in the reverse direction. This process then repeats. As bobbins are emptied, any remaining yarn is removed from them and returned to the waste machine for salvage. The clean bobbins are then returned to the spinning operations. Cloth produced by the loom is wound on a large roll and sent to the stitching machine, where lengths of cloth are stitched together. The shearing machine cuts away knots and loose yarn ends from the surface of the cloth to give it a smooth surface. Finally, the cloth is inspected, graded for quality, and delivered to shipping. And then can be design into different pattern. DESIGN FOR RELIABILITY The demand to achieve desired performance level in an efficient and optimized manner has led to a growing movement towards increasing applications of design for reliability and its spread to industries where it had not been used in the past. Previously design practices tend to focus on mainly on functionality and robustness or product integrity. Design for Reliability (DFR) is a systematic, streamlined, concurrent engineering program in which reliability engineering is woven into the total development cycle in order to meet customer expectations for reliability while maintaining low overall life-cycle costs. From the concept stage through to product obsolescence, DFR describes the overall order of deployment that an organization needs to follow in order to design reliability into its products. There are a variety of activities involved in an effective reliability program and in arriving at reliable products. Achieving the organization’s reliability goals requires strategic vision, proper planning, sufficient organizational resource allocation and the integration and institutionalization of reliability practices into development projects. Design for Reliability could be considered useless and time consuming. What any critics claiming this forget, is the fact that reliability does make a person look at the design through different eyes. Reliability demands an optimal design to avoid failures. To design for

reliability does not mean that the reliability alone should be calculated and increased, but that the whole system should be reviewed for solutions which will keep it functioning as long as possible. Given that the use of reliability in the design process also leads to good maintainability and increased availability and safety, its importance during the product development should be obvious. Most companies commit their resources into design for reliability not because they wanted but because they want to be competitive for as long as they remain in the business. As much as companies want to compete, they want to avoid warranty cost and other situation that may arise as a result on producing unreliable products. The consequences of unreliable products go beyond what one can imagine. The following are the likely problems to be encountered when a companies fail to consider design for reliability; Warranty Costs, field Repair Costs, product service indirect costs, inventory costs for spares, loss of potential customers, liability/legal Costs, root cause investigation costs, engineering support costs, concession costs, impact to reputation, lower margins on new jobs, impact of failures on customers, the list are endless. Design for reliability is an important process in production and manufacturing, an iterative process has been proposed for the perfect application of the design for reliability process. The proposed process can be used as guide to the sequence of deploying the different tools and methods involved in a program to ensure high reliability. This process can be adapted and customized based on different industry, corporate culture and other existing processes within a certain company. Identifying, designing, analyzing, verifying, validating, monitoring and controlling are all the steps involve in making sure the reliability of a product is guaranteed. Though, being as it may be, reliability is still a probability. The goal in the Identify phase is to quantitatively define the reliability requirements for a product as well as the end-user environmental/usage conditions. Review customer expectations and how to translate them into engineering metrics (e.g., survive 15 yrs. life). Develop specific environmental test requirements (e.g. converting the requirement of B5 life at 280K miles for a heavy duty truck into a test flow and test sample size). Then identify technology limitations (e.g., battery, optics, specific components, etc.) and the relevant validation strategies. Some tools used in the Identify phase are, goal setting, develop metrics, benchmarking, gap analysis, reliability program plan writing, quality function deployment (QFD). Reliability Goals & Metrics tie together all stages of the product life cycle. Well-crafted goals provide the target for the business to achieve, they set the direction. Reliability Goals can be derived from: Customer-specified or implied requirements, Internally-specified or self-imposed requirements (usually based on trying to be better than previous products), Benchmarking against competition, Industry standards, Engineering common sense.

Metrics provide, the milestones, the “are we there, yet”, and the feedback that all elements of the organization require to stay on track toward the goals. A Reliability Program and Integration Plan are crucial at the beginning of the product life cycle because in this plan, we define: What are the overall goals of the product and of each assembly that makes up the product? What has been the past performance of the product? What is the size of the gap? What are the constraints? What reliability elements/tools will be used? How will each tool be implemented and integrated to achieve the goals? What is our schedule for meeting these goals? The Design Phase is the stage where specific design activities begin, such as circuit layout, mechanical drawing, component/supplier selection, etc. Therefore, a better design picture begins emerging. In this stage, a clearer picture about what the product is supposed to do starts developing. Also, we can achieve the following, more specific reliability requirements are defined, the more design/application change; the more reliability risks are introduced and a program risk can be assessed. Some tools used in the Design phase are, reliability prediction (compare design alternatives, identify preferred components and suppliers) cost trade-offs, tolerance evaluation, better understanding of customer specifications, failure modes and effects analysis (FMEA), fault tree analysis (FTA). In the analysis phase, estimate the product's reliability, often with a rough first cut estimate, early in the design phase. It is important at this phase to address all the potential sources of product failure. This requires close cooperation between reliability engineer and the design team can be very beneficial at this phase. Some tools used in the analyze phase are, finite element analysis (FEA), physics of failure (PoF), reliability prediction, reliability block diagram (RBD), engineering judgment, expert opinions, existing data, warranty analysis of the existing products, design review by failure mode (DRBFM), stress-strength analysis, and FMEA updated. In the verify phase, prototype hardware are built. Quantify all of the previous work based on test results. By this stage, prototypes should be ready for testing and more detailed analysis. Iterative process where different types of tests are performed, product weaknesses are uncovered, the results are analyzed, design changes are made. Some tools used in the verify phase are, highly accelerated life testing (HALT), accelerated life testing (ALT), test to failure (Life data analysis), degradation analysis, reliability growth process (if enough data is available) and design review based on test results (DRBTR). Validation usually involves functional and environmental testing on a system level with the purpose to become production-ready. Make sure that the product is ready for high volume production. Design modifications might be necessary to improve robustness.

Some tools used in the validation phase are, design validation (Including ALT and Reliability Demonstration) and process validation. Often program schedule leaves no time for test to failure at this stage. Most of it should be done at the previous stages. Therefore, validation phase is more often done via test to success rather than test-to-failure In the Control Phase we need to assure that the process remains unchanged and the variations remain within the tolerances. Some tools used in the Control phase are, control charts and process capability studies (Cpk, Ppk, etc.), human reliability, continuous compliance, field return analysis (warranty) and forecasting ongoing reliability testing (ORT), audits and lessons learned for the next generation of products(important to close the cycle on DfR). DESIGN FOR RELIABILITY OF A TEXTILE MANUFACTURING SYSTEM TO PRODUCE RELIABLE TEXTILE MATERIALS Considering the whole textile manufacturing process, we are talking about a system that is running a process; as a result we will be talking about design for system reliability to improve reliability of textile materials. For textile materials to be reliable, mean they have to be durable and the maintainability has to be considered. The machines (system) design for reliability would have been confirmed during the design stages; hence we are talking about the overall system reliability. A reliable system will only run through a reliable process to produce a reliable product. Haven gone through the whole manufacturing process involved in producing cotton textile, and using our design for reliability knowledge area of Identifying, designing, analyzing, verifying, validating, monitoring and controlling, through the design stages of the system. All we have to consider now is the reliability of the entire systems and human reliability. There are 4 critical areas of reliability we have to look at to get reliable textile materials and they are, machine/equipment, methods, man, and raw materials. Cotton is farmed intensively and uses large amounts of fertilizer and 25% of the world's insecticides. Some varieties of cotton were rainwater fed, but modern hybrids used for the mills need irrigation, which spreads pests. Before mechanization cotton was harvested manually by farmers. Recently some major exporter of cotton uses manual labour during the harvest. Human rights groups claim that health care professionals and children are forced to pick cotton on the farm. Producing better quality raw cotton will enhance the reliability of produced textile materials. Best way to guarantee the production of suitable raw cotton is planting at the right time and under a good weather condition. Also using a genetically modified cotton materials will help the industry produced reliable textile materials. To guarantee the continuity of supply of raw cotton materials mechanized harvesting

methods have to be embraced and the use of forced labour should be totally discouraged and abandoned. With machines or equipment, reliability uncertainty may occur because of inadequate maintenance or servicing. In terms of textile technology a breakdown in reliability process is said to have occurred if, for example, the required washing effect, degree of whiteness or absorbency of one of the fabrics being finished is not achieved. These are defects in the specification of the system because the expectations of the customer are not fulfilled and will have all the unreliability consequences. Since reliability is the ability of a machine/system to perform as it is expected over a period of time and under certain conditions of usage. A reliable textile manufacturing machine/system should be able to meet the reliability expectations. A perfect way to increase the ability of producing parts/components of a textile manufacturing system in an expected period of time is to increase the manufacturing capacity. However, the reliability involves not only a manufacturing system but also product and part design. Textile machine reliability is improved by rearranging the machine tools, station etc. Also, reliability can be assured by maintaining high probability of producing parts without failures and to repair failed machine parts in a specified amount of time. Unavailability/insufficient of parts when required by the system operators surely will make the system/machine very unreliable. By improving the reliability of the machine system, the manufacturing process is guaranteed to not be faltered hence, the reliability of producing a reliable material for garment production. Selecting the right process is one huge decision to be made when production is about to take off. The selected production sequence, formulations, etc. often do not conform to the actual reliability requirements. It is well known that knitwear made from cellulose fibres is still too often bleached and dyed discontinuously in jets or Soft flow machines. During the long hour process the textile undergoes extreme mechanical surface finishing. As a result the surface is roughened and a hairy surface appearance is created, if further processed it results into garment of low quality and mostly unreliable. With methods selection problem, careful selection processes using benchmarking or best practices will be a very good idea to handle the method/process selection method. A good method leads to effective process hence, a reliable process and production of reliable textile materials. For any process to run perfectly and produce positive result, it has to be run by person or group of persons with the technical ability to perfectly run the process. We know for sure human are fallible, and can cause system failure in many ways hence, human reliability must be considered in any design in which human fallibility might affect reliability or safety. Design analyses such as FMECA and FTA should include specific consideration of human factors, such as the possibility of incorrect operation or

maintenance, ability to detect and respond to failure conditions and ergonomic or other related factors that might influence them. Also, where human operation is involved, product design should be made in full consideration of physiological and psychological factors in order to minimize the probability of human error in system operation. Attempts have been made to quantify various human error probabilities, but such data should be treated with caution, as human performance is too variable to be credibly forecast from past records. Human error probabilities can be minimized by training, supervision and motivation, so these must be considered in the analysis. With the design having limited or no control over these factors but the analyses can be used to highlight the need for specific training, independent checks, or operator and maintainer instructions and warnings. With all of these reliability problems identified, designed, analyzed, verified, validated and controlled it is certain the processes involved in the manufacturing of textile materials will go as expected under the given conditions. Haven carefully integrated the reliability processes into the system operation, raw material production, human reliability assurance, method selection it is with no doubt reliable textile materials that will work in different environment and under different condition will be produced and use as expected under the given condition of usage over a period of time. Ones customer’s satisfaction is met as required; reliability of the product is confirmed.

CONCLUSION Reliability reveals itself in daily use and is defined by the user as the situation when the expected and the experienced reliability are as close as possible. The important aspects of reliability policy in textile finishing plan design are, avoid potential sources of risk, built-in freedom from maintenance, monitoring of specified and achieved values, control of exceptional situations. All these measures are intended to increase process reliability. Reliability results in the user gaining trust in the producer and developing loyalty towards him, which benefits them both. The successful implementation of the reliability program requires a reliability team comprising of people from different sections (marketing, accounting, engineering, manufacturing, etc.) working with reliability specialists. I am sure the customer satisfaction will be further strengthened and loyalty will be increased hence, larger market share resulting into high profits if the reliability processes are being followed as expected. Failure to go by all of these rules or practices could lead to serious consequences and eventualities that might not be perfectly solved. First, the producer's reputation would be long gone the moment the textile materials can't meet the required customer's need. Customer's loyalty that has been destroyed will go a long way reducing the market value hence, producer record high warranty costs, repair costs, product service indirect costs, inventory costs for spares, loss of potential customers, liability/legal costs, root cause investigation costs, engineering support costs, concession costs, impact to reputation, lower margins on new jobs, impact of failures on customers, the list are endless. It is evidently visible the price pay on reliability is too high and involves a very complex process. But also, the price of unreliability is very high and much more colossal than that of managing reliability.

REFERENCES [1] O’Connor, P. and Kleyner, A., Practical Reliability Engineering, 5th Ed., UK, West Sussex: John Wiley & Sons, 2012. [2] Dunton, T. and Snider, M., Implementing Reliability improvements: A team approcah, Aspen Park,CO, USA, Universal Technologies, Inc. [3] Keeter B., Using Reliability Engineering Methods as a Tool for Continuous Process Improvement, Presented at IMC-2003 the 18th International Maintenance Conference, ARMS Reliability Engineers. USA, 2003. [4] Stolte, B., Some Strategic Management Aspects of Reliability, 2010 [5] Design for Reliability: Overview of the Process and Applicable Techniques, Volume 8, Issue 2., ReliaSoft Corporation. [6] Nikos I. K., Production planning and control in textile: A case study, German National Research Center, Sankt Augustin, Germany. [7] Waste Generation and Effluent Treatment, Ramesh B. B., Parande A.K., Raghu, S., and Prem Kumar, T., Cotton Textile Processing: Waste Generation and Effluent Treatment, The Journal of Cotton Science, The Cotton Foundation, (2007). [8]

��������������������������������������������������������������������������� ��������������������������������������������������������������������������������� �����������������������������������������������������