CHALLENGES IN WARP YARN TENSION AND MITIGATION STRATEGIES IN WEAVING

Abstract

Inconsistent or improper warp tension remains a primary source of quality defects and production losses in weaving mills. This paper identifies and categorizes the most prevalent tension-related challenges, including uneven tension across the warp sheet, periodic tension variations, and yarn breakage. We systematically analyze the root causes—spanning mechanical, procedural, and human factors—and present a comprehensive framework for problem diagnosis and resolution. The paper advocates for an integrated approach combining advanced monitoring technologies, Total Productive Maintenance (TPM), and Statistical Process Control (SPC) to proactively manage tension and achieve zero-defect manufacturing goals.