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Yarn realisation in spinning mills

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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.

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Yarn realisation in spinning mills

  1. 1. YARN REALISATION -A critical analysis by A.Kanthimathinathan, CEO,WINSYS SMC
  2. 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. 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. 4. Deciding factors-YRDeciding factors-YR  Customer SpecificationCustomer Specification  Raw material QualityRaw material Quality  Type of MachineryType of Machinery
  5. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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
  20. 20. Customer RequirementsCustomer Requirements Yarn Classimat FaultsYarn Classimat Faults  Type of SpinningType of Spinning  Fiber opening efficiencyFiber opening efficiency  Sliver trash contentSliver trash content  Exhaust QualityExhaust Quality  OHTC performanceOHTC performance
  21. 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. 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. 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. 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. 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. 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. 27. DRAWINGDRAWING  White waste in blower waste.White waste in blower waste.  Excessive positive clearer waste.Excessive positive clearer waste.
  28. 28. SIMPLEXSIMPLEX  Excessive positive clearer waste.Excessive positive clearer waste.  Excessive roving waste.Excessive roving waste.
  29. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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
  43. 43.  THANK YOUTHANK YOU

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