Solving Processing Problems on Cotton Swab Manufacturing: A Novel Troubleshotting Approach, 1997 Nonwovens Conference Proceedings

Cotton swabs are manufactured from bleached by-product cotton fiber such as comber noils, gin motes, and other mill waste. In the recent past a leading cotton swab manufacturer experienced a 34% production downtime. Causes for downtime such as line jams, bad tips, marked sticks, equipment repairs, coil breaks, and waiting for the materials were scientifically studied. The major parameters affecting downtime were examined. Our team approach to diagnosis and problem solving included data collection, analysis, and open discussions with management, supervisors, and operators to create action items and their implementation. This study led to solutions, (or easing), of the problems and resulted in high machine efficiency. While this scientific technique can be used to solve any problem in nonwoven swab manufacturing, it was presently used to determine the performance of paper sticks prepared in-house versus those purchased from a commercial source. Swab machines were monitored for 105+ hours for downtime using in-house and commercial sticks alternatively. The study showed that in-house sticks were responsible largely for downtime and inferior quality swabs. It was concluded that commercial sticks were more cost effective. The practice of manufacturing in-house paper sticks was subsequently eliminated. Cotton swabs are now exclusively made with commercial sticks with greatly improved machine efficiency.