One damaged needle produces a continuous vertical line down every metre of fabric the machine knits. It is not a gradual defect and it does not self-correct — a bent latch or a chipped hook simply prints itself into the roll until someone finds it. With hundreds of needles running at speed, inspection is the only realistic detection method, and lint packed into the needle bed is what causes most of the damage.
The steps ChatterFix schedules for this PM. Every step is a checkable item on the work order — a technician can speak their way through it without touching a keyboard.
One damaged needle produces a continuous vertical line down every metre of fabric the machine knits. It is not a gradual defect and it does not self-correct — a bent latch or a chipped hook simply prints itself into the roll until someone finds it. With hundreds of needles running at speed, inspection is the only realistic detection method, and lint packed into the needle bed is what causes most of the damage.
Whole rolls are downgraded to second quality, and because the fault is continuous the loss is total rather than partial. The damage also propagates: a broken needle can take out its neighbours and score the cylinder, turning a needle change into a machine repair.
Monthly full inspection, with lint clearing far more often — daily on fine gauges. Any needle line found in inspection means stopping the machine at once rather than finishing the roll; every additional metre is scrap.
This procedure — and every other PM for your industry — is already built into ChatterFix. Pick your industry and it lands on the right equipment, on the right interval, in about three minutes.