‘assessment and control of hard waste in spinning mill’

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