BY

BAGADI NIKHIL L. BUCHADE SACHIN G. CHAVAN HRISHIKESH V. DAMLE RAVIRAJ V. PATNAWAR SHREYAS M. 08 TEXT 02 08 TEXT 05 08 TEXT 07 08 TEXT 12 08 TEXT 36

UNDER THE GUIDANCE OF Prof.A.U.Awasare Prof.S.D.Mahajan D.K.T.E SOCIETYS TEXTILE AND ENGINEERING INSTITUTE, ICHALKARANJI 2011 - 2012

INTRODUCTION
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

Assessment Method Of Hard Waste

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

Measures To Reduce Hard Waste

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

Assessment Of Existing Situation

Finding Key Result Areas

Designing Corrective Actions

Implementing Corrective Actions

Reassessment

 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

Reduction in wt of bobbin due to improper built for LR 6/S

Avg. yarn content of improper built bobbin ( gm ) 37 40 Avg. yarn content of full bobbin ( gm ) % reduction in wt.

53 52

30 23

39
38

50
54

22
29

Reduction in wt of bobbin due to improper built for KTTM

Avg. yarn content of improper built bobbin ( gm )
42 40 Avg. yarn content of full bobbin ( gm ) % reduction in wt.

53 50

20 20

41
44

50
54

18
19

Results for defective bobbins

Make and Machine No Count No Of Spindles Tested Defect Type Ring Cut Less Clearance At Top Less Clearance At Bottom Slough Off Soft Built Improper Build Stained / Oiled Bobbins Bobbin Mix Up Defective Empty Bobbins Total 7 8 15 1 0 15 2 5 11 64 12 0 15 0 1 45 2 11 5 91 2 0 9 0 1 59 0 0 1 72 0 2 10 3 0 40 2 0 11 68 9 0 7 3 0 52 0 0 0 68 2 0 9 0 0 28 0 5 4 48 KTTM ( No 4 ) 32 s Ne 1104 LR 6/S (No.17) 32 s Ne 1104 LR 6/S (No.15) 32 s Ne 1104 KTTM ( No.1) 32 s Ne 1104 LR 6/S ( No. 15) 32 s Ne 1104 LR 6/S ( No. 19) 30 s Ne 1104

WASTAGE DUE TO DEFECTIVE BOBBINS

Defect Avg.length removed during winding ( mtr ) 32.48 Avg Weight of removed yarn ( gm ) 0.60

Less clearance at top Less clearance at bottom

33.86

0.625

Double gaiting
Slough off

46.56
26.52

0.86
0.49

MACHINE NO MAKE COUNT (Ne) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 avg (cm )

1 KTTM 34 103 114 111 102 105 111 115 107 105 103 106 100 112 128 92 107.6

2 KTTM 34 97 106 99 94 107 104 102 92 112 108 102 92 107 99 102 101.53

3 KTTM 32 125 117 109 114 99 104 108 110 97 112 119 103 98 106 109 108.67

4 KTTM 34 101 102 108 103 101 104 98 116 101 100 95 107 102 104 110 103.47

5 KTTM 32 108 112 120 108 119 118 112 116 101 118 105 107 106 119 102 111.4

6 KTTM 40 104 92 80 101 103 84 102 100 98 104 96 90 85 99 97 95.66

7 KTTM 40 107 91 103 84 102 100 98 104 96 103 84 102 100 98 99 98.07 103

8 KTTM 32 104 108 110 97 112 119 103 101 118 105 107 106 118 112 116 109.07

9 KTTM 40 103 96 90 82 100 102 104 103 90 118 90 124 95 95 91 95.19

Grand average ( cm )

BACKWIND LENGTH STUDY FOR LR 6 / S

M/C NO MAKE COUNT (Ne) 10 LR 6/S 32 11 LR 6/S 30 12 LR 6/S 32 13 LR 6/S 32 14 LR 6/S 32 15 LR 6/S 30 16 LR 6/S 30 17 LR 6/S 30 18 LR 6/S 32 19 LR 6/S 30

1
2 3 4 5 6 7 8 9 10

81
80 84 84 89 95 91 87 77 81

102
93 113 90 96 84 96 84 70 77

95
97 84 89 95 91 87 77 81 78

99
77 79 92 87 87 81 101 84 95

101
101 104 95 98 95 99 80 81 88

75
90 72 77 77 78 84 89 87 107

96
84 96 84 84 96 84 113 90 96

99
98 101 102 93 113 90 96 84 70

90
102 84 95 88 81 88 76 82 94

87
95 91 90 89 85 106 89 94 99

11
12 13 14 15 avg (cm)

78
79 82 72 77 82.47

78
100 101 93 113 92.67

79
97 99 101 92 89.47

78
95 99 81 98 88.87

81
76 83 79 89 82.2

101
101 104 95 79 87.73

84
96 84 79 75 89.4

77
78 100 101 84 88.5 87

90
64 80 77 78 84.6

92
77 87 91 79 90.07

Grand average ( cm )

END BREAKAGE STUDY AT RING FRAME

No Of Breaks / 100 Spl / Hour 12.30 9.92 9.92 7.20 7.48 6.61

R/F Make (Machine No)

Breaks At Start 58 49 53 44 85 68

End Pieced

Breaks At End

Total Breaks

KTTM (1) KTTM (3) KTTM (4) LR 6 / S (11) LR 6 / S (16) LR 6 / S (18)

145 97 90 88 113 92

37 52 63 34 53 49

124 100 100 78 81 73

Effect Of Type Of Yarn Clearer On Hard Waste COUNT - 32S Ne On LOEPFE clearer
Content Fan waste Bottom waste Total waste ( fan + bottom ) Total ring yarn weight ( doff wt.- 500 bobbins ) Hard waste % Weight ( kg ) 0.251 0.024 0.275 27 ( 0.275 / 27 ) * 100 = 1.01 %

On Uster Quantum 2 clearer

Content Fan waste Bottom waste Total waste ( fan + bottom ) Total ring yarn weight ( doff wt 500 bobbins) Hard waste % Weight ( kg ) 0.120 0.118 0.247 27 ( 0.247 / 27 ) * 100 = 0.914 %

STUDY OF COP REJECTION

Machine No Spindle No Observed 21 22 57 58 35 36 25 26 46 47 40 41 7 8 23 24 9 10 1 2 3 4 19 No Of Bottoms ( Cop Rejected ) 0 0 0 0 1 3 1 2 0 2 0 0 2 1 1 0 1 0 1 1 1 0 0 Total Cuts 10 5 19 16 15 17 9 9 23 28 20 13 14 9 17 17 18 18 10 15 18 17 17

Contd.
49 50 3 2 0 0 0 2 1 3 0 13 12 30 18 12 11 19 22 23

1 2 32 33 1 2

4
5 6

0
1 0

35
17 19

EFFECT OF MACHINE CLEANING ON RING FRAME Idle spindle = 3 % total bobbins tested = 1070
R/F MAKE KTTM LR 6/S End breaks / 100 spl hr On 10th day 9.15 5.98 ON 12TH DAY 10.65 7.28 Defective Bobbin On 10th day 52 36 ON 12TH DAY 68 46

EFFECT OF MACHINE CLEANING ON WINDING CUTS

Loepfe Cuts / 100 KM On 10th day Total cuts Neps Short thick Long thick Thin 88 5 40 12 5 On 12th day 104 8 51 15 5 On 10th day 44 7 18 2 4 On 12th day 58 12 25 4 4 Uster Quantum 2

Other

20

25

17

EFFECT OF TRAVELER LIFE ON RING FRAME Idle spindle = 3 % total bobbins tested = 1070
R/F MAKE END BREAKS / 100 spl hr On 10th day KTTM LR 6/S 7.94 6.10 On 12th day 9.34 7.25 DEFECTIVE BOBBIN On 10th day 48 36 On 12th day 70 46

EFFECT OF TRAVELER LIFE ON WINDING CUTS

Cuts / 100 KM Loepfe On 10th day On 12th day Uster Quantum 2 On 10th day On 12th day

Total cuts
Neps Short thick Long thick Thin Other

88
5 44 13 5 20

104
8 51 15 5 25

44
9 20 2 4 9

58
12 25 4 4 17

BAD WORK PRACTISES AT SITE

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 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