Yarn realisation is one of the Key Performance parameter for achieving profits in a Spinning mills.In these slides WINSYS SMC explains in detail along with its case studies.
2. Learning goalsLearning goals
Role played by Moisture contentRole played by Moisture content
Expectation from Openers/CleanersExpectation from Openers/Cleaners
Expectation in a CardExpectation in a Card
Expectation from CombersExpectation from Combers
Understanding CustomerUnderstanding Customer
requirementsrequirements
3. YARN REALISATIONYARN REALISATION
YARN REALISATIONYARN REALISATION
How best mills has used the resourceHow best mills has used the resource
called `RAW MATERIAL`called `RAW MATERIAL`
Ratio of `output of yarn vs input ofRatio of `output of yarn vs input of
Mixing`Mixing`
4. Deciding factors-YRDeciding factors-YR
Customer SpecificationCustomer Specification
Raw material QualityRaw material Quality
Type of MachineryType of Machinery
5. Customer SpecificationCustomer Specification
Yarn Imperfections in terms ofYarn Imperfections in terms of
Periodical imperfections/ClassimatPeriodical imperfections/Classimat
faultsfaults
Yarn HairinessYarn Hairiness
Yarn unwinding PerformanceYarn unwinding Performance
Yarn Strength in CSP/RkmYarn Strength in CSP/Rkm
Yarn ElongationYarn Elongation
6. Raw Material QualityRaw Material Quality
2.5% Span length/Mean Length2.5% Span length/Mean Length
FinenessFineness
Fiber strengthFiber strength
Fiber MaturityFiber Maturity
Trash ContentTrash Content
SFC(n)-Ignored by majority of the millsSFC(n)-Ignored by majority of the mills
7. Raw material QualityRaw material Quality
SFC(n)SFC(n)
Varies from 16% to 37%Varies from 16% to 37%
Fine counts-16 to 22%Fine counts-16 to 22%
Medium counts-20 to 24Medium counts-20 to 24
Coarser counts- 22 to 28Coarser counts- 22 to 28
8. Raw material QualityRaw material Quality
For other parameters mills know theFor other parameters mills know the
level of the specifications they requirelevel of the specifications they require
to spin their Yarn meeting customerto spin their Yarn meeting customer
requirementsrequirements
9. Raw Material QualityRaw Material Quality
Role of LengthRole of Length
Spinning performance and contributionSpinning performance and contribution
to Yarn strengthto Yarn strength
Role of finenessRole of fineness
Feel of theFeel of the
fabric/Hairiness/Strength/Runningfabric/Hairiness/Strength/Running
performanceperformance
10. Raw material QualityRaw material Quality
Impact of Trash contentImpact of Trash content
When ginning is done properly, MillsWhen ginning is done properly, Mills
will get a `clean cotton ` with Leastwill get a `clean cotton ` with Least
trashtrash
In Imported PIMA we have only 1.2%In Imported PIMA we have only 1.2%
trash contenttrash content
Indian Ginneries fool their VendorsIndian Ginneries fool their Vendors
11. Raw Material QualityRaw Material Quality
Indian Government has taken so manyIndian Government has taken so many
measures to improve Ginneriesmeasures to improve Ginneries
Precleaning/Post cleaning/AutomationPrecleaning/Post cleaning/Automation
etcetc
Ginneries take commercial stand andGinneries take commercial stand and
they don’t use Pre/post cleaners whichthey don’t use Pre/post cleaners which
are established practices across theare established practices across the
worldworld
12. Handling Trash ContentHandling Trash Content
Removal of trash from compressedRemoval of trash from compressed
bales require proper opening(takencbales require proper opening(takenc
are of by first openers likeare of by first openers like
MBO/CLP/AFC/MC/SC/UC/VCMBO/CLP/AFC/MC/SC/UC/VC
Seed trap removes full and BrokenSeed trap removes full and Broken
seedsseeds
Final beaters remove fine trashFinal beaters remove fine trash
particlesparticles
13. Handling Trash ContentHandling Trash Content
Cards take the role of removing fineCards take the role of removing fine
trash embedded with Bunches as welltrash embedded with Bunches as well
as Individual fibersas Individual fibers
Role of each segment in CardsRole of each segment in Cards
14. Role of LickerinRole of Lickerin
To remove leafy/broken seeds/heavyTo remove leafy/broken seeds/heavy
particles if anyparticles if any
Preferentially no damage to the fiberPreferentially no damage to the fiber
To individualize the fiberTo individualize the fiber
15. Role of SFLRole of SFL
Remove fine fragmented seedRemove fine fragmented seed
particles clinging with short fiber asparticles clinging with short fiber as
well as loose trashwell as loose trash
16. Role of Flat topsRole of Flat tops
Preferential Removal of finePreferential Removal of fine
fragmented seeds/Leafy husks/Shortfragmented seeds/Leafy husks/Short
fiber associated with trashy particlesfiber associated with trashy particles
Does the job without damage to fiberDoes the job without damage to fiber
17. Customer RequirementsCustomer Requirements
Yarn ImperfectionsYarn Imperfections
--Waste level at BR/CardsWaste level at BR/Cards
-Type of Machinery/Drafting-Type of Machinery/Drafting
-Type of process-Type of process
-Fineness of cotton-Fineness of cotton
-Mixing neps-Mixing neps
-Noil level-Noil level
-Type of Autoconer-Type of Autoconer
18. Customer RequirementsCustomer Requirements
Yarn StrengthYarn Strength
Twist levelTwist level
Fiber length/Fiber finenessFiber length/Fiber fineness
SFC(n) in Drawing sliverSFC(n) in Drawing sliver
RH in departmentsRH in departments
Drafting QualityDrafting Quality
19. Customer RequirementsCustomer Requirements
Yarn HairinessYarn Hairiness
Type of SpinningType of Spinning
Type of YarnType of Yarn
Type of Traveller/RingType of Traveller/Ring
LiftLift
Lappet diaLappet dia
Fiber FinenessFiber Fineness
21. Mixing PrecautionsMixing Precautions
Incoming bales moisture contentIncoming bales moisture content
should be 7 to 7.5%. If high there willshould be 7 to 7.5%. If high there will
be loss.be loss.
Avoid Storage in outside areas.Avoid Storage in outside areas.
Cotton godown roof spraying duringCotton godown roof spraying during
summer/24 Hours conditioning undersummer/24 Hours conditioning under
fog master in Blow roomfog master in Blow room
Good cotton in yellow pickingGood cotton in yellow picking
22. BLOWROOMBLOWROOM
No. of beating points depends onNo. of beating points depends on
trash %, mic. Etc.trash %, mic. Etc.
White waste in droppings.White waste in droppings.
Beater chocking.Beater chocking.
Bales moisture conditioning in B/RBales moisture conditioning in B/R
department.department.
23. BLOWROOMBLOWROOM
Lint loss in BRD while new mixing,Lint loss in BRD while new mixing,
setting changessetting changes
Proper synchronization of B/R m/cs.Proper synchronization of B/R m/cs.
(ERM luminar duct should not be(ERM luminar duct should not be
empty)empty)
Excessive suction in AWES and cottonExcessive suction in AWES and cotton
goes in suction.goes in suction.
Micro dust exhausts suction too high.Micro dust exhausts suction too high.
24. CARDINGCARDING
Lint in droppings.Lint in droppings.
Chute beater chockingChute beater chocking
Between card, with in card wasteBetween card, with in card waste
variation.variation.
(b/w cards variation + OR – 0.5%)(b/w cards variation + OR – 0.5%)
Excessive suction in AWES and webExcessive suction in AWES and web
goes in suction.goes in suction.
25. CARDINGCARDING
B/R & Carding set the waste % initiallyB/R & Carding set the waste % initially
while new mixing and maintain uptowhile new mixing and maintain upto
exhaust of mixing. (Visual inspection,exhaust of mixing. (Visual inspection,
Periodical waste % checking)Periodical waste % checking)
Chute micro dust exhausts suction tooChute micro dust exhausts suction too
high.high.
Running cards in slow speed (like DKRunning cards in slow speed (like DK
series) cause high wasteseries) cause high waste
26. COMBERCOMBER
Between heads noils % variation.Between heads noils % variation.
Higher noils % than STD.Higher noils % than STD.
SFC based noils %.SFC based noils %.
Possibilities to reduce noils % with outPossibilities to reduce noils % with out
compromising quality.compromising quality.
27. DRAWINGDRAWING
White waste in blower waste.White waste in blower waste.
Excessive positive clearer waste.Excessive positive clearer waste.
29. SPINNINGSPINNING
Double gaiting.Double gaiting.
Use of damaged ring tubes.Use of damaged ring tubes.
Poor work practice by doffersPoor work practice by doffers
(like delayed doffing and cause top(like delayed doffing and cause top
adoss, low clearance in bottom)adoss, low clearance in bottom)
Under winding coils (4-5 coils).Under winding coils (4-5 coils).
Low cop content. (Ring dia. & Lift)Low cop content. (Ring dia. & Lift)
30. WINDING /WINDING /
AUTOCONERAUTOCONER
Excessive hand hard waste.Excessive hand hard waste.
Rogue EYCRogue EYC
Improper clearance curve.Improper clearance curve.
Poor paper cones.Poor paper cones.
Oil stained / removal of yarn fromOil stained / removal of yarn from
heavy weight cones.heavy weight cones.
31. GENERALGENERAL
Daily monitoring of BRD, Card waste &Daily monitoring of BRD, Card waste &
Noils % by quantity extracted VsNoils % by quantity extracted Vs
production out put.production out put.
Maintaining proper R.H% in allMaintaining proper R.H% in all
departments.departments.
(Prep – 55 to 60%, Spg – 50-55%,(Prep – 55 to 60%, Spg – 50-55%,
A/C – 60-65%)A/C – 60-65%)
Variations in Month end closing stock.Variations in Month end closing stock.
32. GENERAL (Contd.)GENERAL (Contd.)
Excess gives away in finished goods.Excess gives away in finished goods.
(Cone, hanks)(Cone, hanks)
Error in weighing scale. (InsufficientError in weighing scale. (Insufficient
calibration)calibration)
Excess in II quality.Excess in II quality.
Installing YCP.Installing YCP.
33. GENERAL (Contd.)GENERAL (Contd.)
Using mixing oil for flies control &Using mixing oil for flies control &
reducing invisible loss.reducing invisible loss.
Allowed invisible loss 0.8 to 1.0% dueAllowed invisible loss 0.8 to 1.0% due
to variation in incoming cotton andto variation in incoming cotton and
despatch yarn.despatch yarn.
Container, Lorry before & after loadingContainer, Lorry before & after loading
weight checking.weight checking.
34. GENERAL (Contd.)GENERAL (Contd.)
Excessive soft waste causeExcessive soft waste cause
reprocessing and further loss in backreprocessing and further loss in back
process.process.
BRD, Card waste % increase andBRD, Card waste % increase and
reduce comber noils.reduce comber noils.
Customer based yarn quality (notCustomer based yarn quality (not
giving big importance forgiving big importance for
imperfections) based on fabric quality.imperfections) based on fabric quality.
UQC settings based on fabric qualityUQC settings based on fabric quality
in terms of contamination & faults.in terms of contamination & faults.
35. GENERAL (Contd.)GENERAL (Contd.)
Trend charts display for Y.R%, DeptTrend charts display for Y.R%, Dept
wise waste %, and Soft waste %.wise waste %, and Soft waste %.
High hard waste, soft waste andHigh hard waste, soft waste and
sweepings due to negligence ofsweepings due to negligence of
workers, rough handling of materials,workers, rough handling of materials,
bad storage and poor workingbad storage and poor working
conditions.conditions.
36. Yarn Realisation-40s C-Yarn Realisation-40s C-
CompComp
YR can beYR can be
increased byincreased by
controls on Wastecontrols on Waste
monitoring frommonitoring from
Blow room itself.Blow room itself.
Each Zone has theEach Zone has the
task of `specifictask of `specific
type of waste`type of waste`
removalremoval
Best In CPQ 72.5
Cotton 100% Bunny
37. Yarn Realisation-60sCYarn Realisation-60sC
Better YR doesn’tBetter YR doesn’t
meanmean
loss in YQ orloss in YQ or
Poor YSPPoor YSP
Best In CPQ 71.2
Cotton Used MCU5
Yarn
imperfections
293
YSP +Rs 3 over
Average
38. Mills Current level-74%Mills Current level-74%
Count pattern -Medium SC and CCount pattern -Medium SC and C
Target planned -3% improvementTarget planned -3% improvement
Improved areasImproved areas
Card waste Zonewise analysis revealed SFDCard waste Zonewise analysis revealed SFD
waste is abnormally high at the level ofwaste is abnormally high at the level of
2%.Reduced to 0.5%2%.Reduced to 0.5%
Case Study by WINSYSCase Study by WINSYS
SMC-Yarn RealisationSMC-Yarn Realisation
39. Hard Waste:Retrained the workforceHard Waste:Retrained the workforce
and reduced the hard waste from 0.9and reduced the hard waste from 0.9
to 0.6%to 0.6%
In Semi combed Variety mills has notIn Semi combed Variety mills has not
done Conditioning. Effectivelydone Conditioning. Effectively
restarted.restarted.
Sweepings found to be 0.8%-Sweepings found to be 0.8%-
Unusually high.On checking it is aUnusually high.On checking it is a
mixture of Usable waste .Reducedmixture of Usable waste .Reduced
the same to 0.5% levelthe same to 0.5% level
Case Study by WINSYSCase Study by WINSYS
SMC-YarnSMC-Yarn RealisationRealisation
40. Finally the mills is able to exceed itsFinally the mills is able to exceed its
expected target of 3 and achievedexpected target of 3 and achieved
3.5%.3.5%.
Final YR -77.5%Final YR -77.5%
Case Study-YR contd..Case Study-YR contd..
41. Monitoring & Maintaining MoistureMonitoring & Maintaining Moisture
content in Mixing and outgoing yarncontent in Mixing and outgoing yarn
Monitoring and Maintaining MoistureMonitoring and Maintaining Moisture
content in Saleable wastecontent in Saleable waste
Strict monitoring and control of AWESStrict monitoring and control of AWES
waste level by visual checks inwaste level by visual checks in
Compactors-weeklyCompactors-weekly
Efforts taken on other YREfforts taken on other YR
studiesstudies
42. Tare weight control in PackingTare weight control in Packing
Weighment of Mixing at the time ofWeighment of Mixing at the time of
LayingLaying
Ensuring 65 to 70 % in PackingEnsuring 65 to 70 % in Packing
departmentdepartment
Efforts taken on other YREfforts taken on other YR
studiesstudies