‘assessment and control of hard waste in spinning mill’
TRANSCRIPT
BY
BAGADI NIKHIL L. 08 TEXT 02BUCHADE SACHIN G. 08 TEXT 05CHAVAN HRISHIKESH V. 08 TEXT 07DAMLE RAVIRAJ V. 08 TEXT 12PATNAWAR SHREYAS M. 08 TEXT 36
UNDER THE GUIDANCE OFProf.A.U.AwasareProf.S.D.Mahajan
D.K.T.E SOCIETY’S
TEXTILE AND ENGINEERING INSTITUTE,ICHALKARANJI
2011 - 2012
Yarn realization Types of waste Economics
Causes of Hard Waste Ring cops Winding Ring Doubling and Two For One Twisters (TFO) Open End Spinning Material Handling & Poor House Keeping Length of yarn taken to piece a break
1) Estimation Of Overall Expected Hard Waste %
= (∑ PW ) / T . P = Production in Each Process. W= expected waste as per norms. T = total production in Kg.
2) Hard Waste Index (HWI) = (actual hard waste %) /
(expected hard waste %) * 100
Maintaining low breakage level at all operations Reducing ring cop defects Correct work practices Maintain cop rejection in winding at low level Backwind should be less Improve house keeping Maintain proper records
Ring cut Improper built Less clearance at top and bottom Stained and oiled bobbin Slough off Defective empty bobbin Soft built
Improper Built
Less clearance at bottom
Defective empty bobbin
Contaminated bobbins
Wild Yarn
Rubbed yarn
Avg. yarn content of improper built
bobbin( gm )
Avg. yarn content of full bobbin
( gm )
% reduction in wt.
37 53 30
40 52 23
39 50 22
38 54 29
Reduction in wt of bobbin due to improper built for LR 6/S
Avg. yarn content of improper built
bobbin( gm )
Avg. yarn content of full bobbin
( gm )
% reduction in wt.
42 53 20
40 50 20
41 50 18
44 54 19
Reduction in wt of bobbin due to improper built for KTTM
Results for defective bobbinsMake and Machine No
KTTM ( No 4 )
LR 6/S (No.17)
LR 6/S (No.15)
KTTM ( No.1)
LR 6/S ( No. 15)
LR 6/S ( No. 19)
Count 32 s Ne 32 s Ne 32 s Ne 32 s Ne 32 s Ne 30 s Ne
No Of Spindles Tested
1104 1104 1104 1104 1104 1104
Defect Type Ring Cut 7 12 2 0 9 2Less Clearance At Top
8 0 0 2 0 0
Less Clearance At Bottom
15 15 9 10 7 9
Slough Off 1 0 0 3 3 0
Soft Built 0 1 1 0 0 0
Improper Build 15 45 59 40 52 28
Stained / Oiled Bobbins
2 2 0 2 0 0
Bobbin Mix Up 5 11 0 0 0 5
Defective Empty Bobbins
11 5 1 11 0 4
Total 64 91 72 68 68 48
DefectAvg.length removed
during winding ( mtr )
Avg Weight of removed yarn
( gm )
Less clearance at top
32.48 0.60
Less clearance at bottom
33.86 0.625
Double gaiting 46.56 0.86
Slough off 26.52 0.49
WASTAGE DUE TO DEFECTIVE BOBBINS
MACHINE NO
1 2 3 4 5 6 7 8 9
MAKE KTTM KTTM KTTM KTTM KTTM KTTM KTTM KTTM KTTM
COUNT (Ne) 34 34 32 34 32 40 40 32 40
1 103 97 125 101 108 104 107 104 103
2 114 106 117 102 112 92 91 108 96
3 111 99 109 108 120 80 103 110 90
4 102 94 114 103 108 101 84 97 82
5 105 107 99 101 119 103 102 112 100
6 111 104 104 104 118 84 100 119 102
7 115 102 108 98 112 102 98 103 104
8 107 92 110 116 116 100 104 101 103
9 105 112 97 101 101 98 96 118 90
10 103 108 112 100 118 104 103 105 118
11 106 102 119 95 105 96 84 107 90
12 100 92 103 107 107 90 102 106 124
13 112 107 98 102 106 85 100 118 95
14 128 99 106 104 119 99 98 112 95
15 92 102 109 110 102 97 99 116 91
avg (cm ) 107.6 101.53 108.67 103.47 111.4 95.66 98.07 109.07 95.19
Grand average ( cm ) 103
M/C NO 10 11 12 13 14 15 16 17 18 19
MAKE LR 6/S LR 6/S LR 6/S LR 6/S LR 6/S LR 6/S LR 6/S LR 6/S LR 6/S LR 6/S
COUNT (Ne)
32 30 32 32 32 30 30 30 32 30
1 81 102 95 99 101 75 96 99 90 87
2 80 93 97 77 101 90 84 98 102 95
3 84 113 84 79 104 72 96 101 84 91
4 84 90 89 92 95 77 84 102 95 90
5 89 96 95 87 98 77 84 93 88 89
6 95 84 91 87 95 78 96 113 81 85
7 91 96 87 81 99 84 84 90 88 106
8 87 84 77 101 80 89 113 96 76 89
9 77 70 81 84 81 87 90 84 82 94
10 81 77 78 95 88 107 96 70 94 99
11 78 78 79 78 81 101 84 77 90 92
12 79 100 97 95 76 101 96 78 64 77
13 82 101 99 99 83 104 84 100 80 87
14 72 93 101 81 79 95 79 101 77 91
15 77 113 92 98 89 79 75 84 78 79
avg (cm) 82.47 92.67 89.47 88.87 82.2 87.73 89.4 88.5 84.6 90.07
Grand average ( cm ) 87
R/F Make (Machine No)
Breaks At
Start
End Pieced
Breaks At End
Total Breaks
No Of Breaks / 100 Spl /
Hour
KTTM (1) 58 145 37 124 12.30
KTTM (3) 49 97 52 100 9.92
KTTM (4) 53 90 63 100 9.92
LR 6 / S (11) 44 88 34 78 7.20
LR 6 / S (16) 85 113 53 81 7.48
LR 6 / S (18) 68 92 49 73 6.61
Content Weight ( kg )
Fan waste 0.251
Bottom waste 0.024
Total waste ( fan + bottom ) 0.275
Total ring yarn weight ( doff wt.- 500 bobbins )
27
Hard waste %( 0.275 / 27 ) * 100
= 1.01 %
Content Weight ( kg )
Fan waste 0.120
Bottom waste 0.118
Total waste ( fan + bottom ) 0.247
Total ring yarn weight ( doff wt – 500 bobbins)
27
Hard waste %( 0.247 / 27 ) * 100
= 0.914 %
Machine No Spindle No ObservedNo Of Bottoms
( Cop Rejected )Total Cuts
1
21 0 1022 0 557 0 1958 0 1635 1 1536 3 17
2
25 1 926 2 946 0 2347 2 2840 0 2041 0 13
3
7 2 148 1 9
23 1 1724 0 179 1 18
10 0 18
4
1 1 102 1 153 1 184 0 17
19 0 1720 1 20
5
49 3 13
50 2 12
1 0 30
2 0 18
32 0 12
33 2 11
6
1 1 19
2 3 22
3 0 23
4 0 35
5 1 17
6 0 19
R/F MAKEEnd breaks / 100 spl hr Defective Bobbin
On 10th day ON 12TH DAY On 10th day ON 12TH DAY
KTTM 9.15 10.65 52 68
LR 6/S 5.98 7.28 36 46
Cuts / 100 KMLoepfe Uster Quantum 2
On 10th day On 12th day On 10th day On 12th day
Total cuts 88 104 44 58
Neps 5 8 7 12
Short thick 40 51 18 25
Long thick 12 15 2 4
Thin 5 5 4 4
Other 20 25 9 17
EFFECT OF MACHINE CLEANING ON WINDING CUTS
R/F MAKE END BREAKS / 100 spl hr DEFECTIVE BOBBIN
On 10th day On 12th day On 10th day On 12th day
KTTM 7.94 9.34 48 70
LR 6/S 6.10 7.25 36 46
EFFECT OF TRAVELER LIFE ON WINDING CUTS
Cuts / 100 KMLoepfe Uster Quantum 2
On 10th day On 12th day On 10th day On 12th day
Total cuts 88 104 44 58
Neps 5 8 9 12
Short thick 44 51 20 25
Long thick 13 15 2 4
Thin 5 5 4 4
Other 20 25 9 17
BOBBINS FALL UNDER THE MACHINE
MIXING OF WASTE WITH GOOD BOBBINS WHICH LEADS TO CONTAMINATED OR SOILED BOBBIN
BABBIN FALL ON GROUND
IMPROPER MATERIAL STORING SYSTEM
BAD WORK PRACTICE - DOING DOUBLE GAITING AT WINDING OF RING BOTTOM WHICH LEADS IN COP REJECTION IN WINDING
MIXING OF DIFFERENT COLOR BOBBINS - NO CODING
BROKEN MATERIAL HANDLING DEVICESBROKEN MATERIAL HANDLING DEVICES
BROKEN MATERIAL HANDLING DEVICES
BOBBIN MIX UP AND LABOUR ABSENTISM
USE OF DIFFERENT TOP ROLLER (ORANGE)
IMPROPER STORAGE OF MATERIALTO BE PROCESSED
IMPROPER STORAGE OF MATERIAL TO BE PROCESSED
POOR HOUSE KEEPING
ENTANGLEMENT
WASTE ENTANGLED WITH OHTC
•Loepfe clearer produces more hard waste than UQ2.•Mill has proper control on winding process.•In ring cops, defects like less clearance at bottom, improper built and defective empty bobbins are to be controlled to reduce hard waste.•In case of backwind length, NF speed of ring rail & the time at which ring rail comes down at the time of doff should be controlled.•Optimized machine cleaning schedule and traveler change schedule should be followed to reduce end breaks at ring frame and winding cuts.•Another major reason of hard waste generation i.e. bad work practices, improper material handling, poor house keeping etc. should be avoided.
•Process control in weaving By Kimothi & Paliwal (ATIRA)•Studies on ring frame to reduce Winding Cuts, Spinning Textiles, June 2010•Yarn waste control in textile mills, by BTRA•‘Impacts of hard waste on profitability of spinning mills’ By G. Kathirvel Pandian, D. Shanmuganandam (T.I.T.J.,MAY1996)•‘Measures to control hard waste in spinning mill’ By G.Kathirvel Pandian, D.Shannmuganandam (A.T.J.,1996)•‘Quality requirements of ring cop in modern cone winding’ - (I.T.J.,MAY2008)•‘Process control in weaving’ By Paliwal •‘How to improve Yarn realization and control wastes?’ By D.Shanmuganandam•Lappage James,End breaks in spinning and weaving of weavable single yarns, textile research journal, June 2005•www.fiber2fashion.com