In a 40s warp yarn manufacturing mill
followings are major complaints
v Low production to the existing machines
v Execes labour requirement
v More power bill
v More soft waste generation
BY CLOSE OBSERVATION WE FOUND FOLLOWING
DEFECTS
Ring frame
1.Excess end breaks 13 breaks/100spl hrs
2.More TM (4.5)
3.Lot of idles
Simplex
1.More breaks 12/100 spl hrs
Draw-frame
1.Frequent
lappings
2.Coiler chockings
3.Creel breaks
4.More 0.5mts cv%
Carding
1.Frequent web fallings
2.Incorrect suction systems
3.Card to Card draft difference
CHANGES COMPARITION
RING FRAME (G5/1)
PARAMETERS
|
BEFORE
|
AFTER
|
REDUCTION
IN LABOUR
&
COST/DAY
|
COUNT
|
40
|
40
|
|
SPEED (RPM)
|
13000
|
16500
|
12 Heads
3240 Rs
(RS 270/SHIF)
|
TPI & TM
|
28.46 &
4.5
|
25.93 &
4.1
|
|
EFFICIENCY
(AVE)
|
78%
|
92%
|
|
GPS
|
64
|
106
|
|
INSTALLED
SPLS
|
8064
|
8064
|
|
ACHIEVED
PRODN/DAY
|
1548
|
2564
|
|
NO OF
LABOURS/DAY
|
36
|
24
|
SIMPLEX (LF 1400A)
PARAMETERS
|
BEFORE
|
AFTER
|
REDUCTION
IN LABOUR
&
COST/DAY
|
SPEED (RPM)
|
800
|
1100
|
|
HANK
|
1.10
|
1.3
|
|
TM & TPI
|
1.35 &
1.41
|
1.25 &
1.43
|
4
1080
Rs
|
NO MACHINES
& SPLS
|
2 &288
|
2 &288
|
|
PRODUCTION
EFFI
|
62%
|
83%
|
|
PRODUCTION/SHIFT
|
664Kgs
|
1020Kgs
|
|
HRS RUNNING
|
24
|
20
|
|
NO OF
LABOURS/DAY
|
9
|
4
|
DRAW-FRAME
(RSB)
PARAMETERS
|
BEFORE
|
AFTER
|
In this case
required prodn more so runnig time higher
|
SPEED
|
650 MPM
|
510MPM
|
|
HANK
|
0.120
|
0.130
|
|
EFFICIENCY
|
55%
|
83%
|
|
PRODN/SHIFT
|
846 Kgs
|
925 Kgs
|
|
NO OF SHITS
|
3
|
3
|
Excess
speed and coarser hank in D/F leads to more breaks in simplex & spinning.
Also efficiency drop in D/F
CARDING
PARAMETERS
|
BEFORE
|
AFTER
|
Due to the
finner Hk and more req of prodn working hours more
|
SPEED (Mpm)
|
60
|
100
|
|
HANK
|
0.100
|
0.120
|
|
EFFICIENCY
|
74%
|
93%
|
|
NO OF M/CS
|
5
|
5
|
|
PRODN/SHIFT
|
126
|
175
|
|
NO OF SHIFTS
|
630
|
875
|
|
WORKING HRS
|
20
|
24
|
v Due to frequent web
falling restricts higher speeds
v Coarser hk leads to more
neps and thick place
LABOUR REQUIREMENT
DEPARTMENT
|
BEFORE
|
AFTER
|
MIXING
|
4
=4
|
2=2
|
BLOW
ROOM
|
2×2=4
|
1×2=2
|
CARDING
|
1×3=3
|
1×3=3
|
DRAWING
|
1×3=3
|
1×3=3
|
SIMPLEX
|
3×3=3
|
2×3=3
|
RING
FRAME
|
12×3=36
|
8×3=24
|
CONE
WINDING&PKG
|
60Kgs/head→
26+1
(Pkg)
|
85Kgs/head→
30+1
(Pkg)
|
SWEEPERS
|
2×3=6
|
2×3=6
|
M/C
CLEANING
|
-NIL-
|
6
|
TOTAL
|
86
|
73+6
|
LABOUR/KGS(Rs)
|
86×250÷1548=13.89
|
73×280÷2564=7.98(Excluding
Cleaning
labours)
|
CONCLUTIONS
§ IN THIS MILL ALL PROBLEMS
ARAISED DUE TO POOR MAINTANCE
§ AFTER FINISHING OF ALL
TUNE UPS WE GET GOOD RESULTS
§ LABOUR WAGES/KG REDUCED
FROM Rs13.89 TO Rs7.98
§ ALSO LABOUR SHORTAGE
TOTALLY ELIMINATED DUE TO WORKLOAD IMPLIMENTATION (2M/Cs / TENDER)
§ DAILY PRODUCTION RAISED
FROM 1548Kgs TO 2564Kgs
FOR ASSISTANCE CALL +91-98342-79009
& +91-99941-79009
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