I. Overview of the Current Situation

The customer’s setting machine was originally equipped with a four-finger edge stripper. During the elastic fabric edge-stripping process, issues such as non-compliant edge stripping, excessive width variation, excessive fuzz on the finished fabric edges, and cases where certain batches failed to meet the customer’s order requirements after edge stripping have occurred. This problem has resulted in nearly 20% of finished products requiring rework, and the generation of edge and corner waste has increased by 60%. This not only increases production man-hours and material losses but also delays the delivery of some orders.

II. Root Cause Analysis

The existing four-finger edge-stripping equipment is outdated. Edge stripping relies primarily on the rotational guidance of four threaded fingers, which provides unstable control over the elastic contraction of the fabric. The tension of the fabric as it enters the machine is inconsistent, leading to re-rolling of the edge before needle insertion, and this cannot be adjusted or controlled through the equipment itself.

III. Targeted Solutions

Equipment optimization and modification: Replace and upgrade the existing four-finger edge stripper with a single-sided air-blowing edge stripper. This new equipment uses pressurized air blown out through multiple directional air nozzles to strip the rolled edges. By adjusting the air volume, the degree of edge stripping can be precisely controlled, ensuring that the fabric meets edge-stripping requirements prior to needle insertion, thereby reducing issues such as inconsistent widths, incorrect basis weights, and increased edge and corner waste caused by uneven edge stripping.

IV. Implementation and Effectiveness Verification

Following on-site installation and commissioning, edge-width variation has been brought within the required range, the rework rate of finished products has dropped below 5%, and the fabric width fully meets the acceptance criteria specified in the order. Edge and corner waste has been reduced by more than 50%, significantly cutting down on fabric wastage.

Moreover, this equipment allows flexible adjustment of air-volume parameters according to different types of elastic fabrics, accommodating the edge-stripping production needs of various specifications. Production stability has improved markedly, with production man-hours shortened by approximately 20% compared to before the modification, and order-delivery delays completely resolved. Going forward, dedicated personnel will conduct regular follow-up visits to monitor equipment operating conditions, assist customers with equipment maintenance and upkeep, promptly address any issues arising during production, and ensure the long-term stable and compliant operation of this edge-stripping process.