National Textile University

Final Year Project [2006 2010] Identification and Elimination of Hidden Losses in the Weaving Process Project Conducted By:
Waqar Ahmed (06-NTU-056) Awais Umer (06-NTU-065) Muhammad Ubaid Ullah (06-NTU-084)

Project Supervised By:

Mr. Muhammad Zubair

Department of Fabric Manufacturing

11 KM, Sheikhupura Road, Manawala, 37610 Faisalabad, Pakistan. Ph: +92 41 9230081-83

Permission to Use
In presenting this thesis in partial fulfillment of the requirements for a Bachelor degree from the National Textile University, I agree that the Library of this University may make it freely available for inspection. I further agree that permission for copying of this thesis in any manner, in whole or in part, for scholarly purposes may be granted by the professor who supervised my thesis work or, in her absence, by the Chairman of department or her appointed authority. It is understood that due recognition shall be given to me and to the department in any scholarly use which may be made of any material in my thesis.

Request for permission to copy or to make other use of material in this thesis in whole or in part should be addressed to:

Chairperson Department of Fabric Manufacturing 11 KM, Sheikhupura Road, Manawala 37610 Faisalabad Pakistan Dec. 27, 2007

The Authors

Waqar Ahmed

Awais Umer

Muhammad Ubaid Ullah

O. ALLAH
OPEN OUR EYES TO SEE WHAT IS DUTIFUL OUR MINDS TO KNOW WHAT IS TRUE OUR HEARTS TO LOVE WHAT IS GOOD.

Dedicated
To MY BELOVED, HONORABLE PARENTS AND TEACHERS

ACKNOWLEDGEMENTS
First of all we would like to bow our head before ALMIGHTY ALLAH the Omnipotent, the Omnipresent, the Merciful, the Beneficial who presented us in a Muslim community and also bestowed and blessed us with such a lucid intelligence as we could endeavor our services toward this manuscript. Countless salutations are upon the HOLY PROPHET MUHAMMAD (May Peace Be upon Him), the fountains of knowledge, who has guided his Ummah to seek knowledge from cradle to grave. We have been supported by many people during our final year, which led to this final project. Without their support we couldnt have come this far. This thesis is by far the most significant accomplishment in our life and it would be impossible without people who supported us and believed in us. We would like to express our sincere gratitude and deep appreciation to those who gave us support. We feel much pleasure to intend our sincerest gratitude, inspiring cooperation and appreciation to our supervisor, Mr. Muhammad Zubair for his keen interest, expert guidance and invaluable suggestions during the entire study period and preparation for this manuscript. We feel utmost pride in acknowledging the inspiring guidance, encouraging attitude and valuable comments, which we received from Mr. Waris (DGM, Nishat Mills Ltd.). We also offer our sincerest words of thanks to Mr.Rashid (WM, Nishat Mills Ltd.) for his help and encouragement through the research studies. We thank Mr. Ashfaq (DWM, Nishat Mills Ltd.) and Mr. Hassan Rizwan (AWM, Nishat Mills Ltd.), and Mr. Usman (AWM, Nishat Mills Ltd.) for their guideline and suggestions throughout our research work. As always it is impossible to mention everybody who had an impact to this success. Finally, we would like to thank all those, whose direct and indirect support helped us completing this thesis in time and attaining this position.

Table of Contents
1.1. 1.2. 1.3. 2.1. 2.1.1. 2.1.1.1. 2.1.2. 2.1.3. 2.2. 2.2.1. 2.2.2. 2.2.2.1. 2.2.2.2. 2.2.2.3. 2.2.3. 3.1. 3.2. 3.2.1. 3.3. 3.4. 3.4.1. 3.4.1.1. 3.4.1.2. 3.4.1.3. 3.4.1.4. 3.5. 3.5.1. 3.5.1.1. 3.5.1.2. 3.5.2. 3.5.2.1. 3.5.3. 3.5.4. 3.5.5. Research Objective ..................................................................................................... 5 Concept of Value ........................................................................................................ 5 Weaving Process ........................................................................................................ 8 Six Big Losses .......................................................................................................... 10 Downtime Losses .................................................................................................. 10 Downtime Stoppages ......................................................................................... 10 Speed Losses......................................................................................................... 11 Quality Losses ...................................................................................................... 11 Overall Equipment Effectiveness .............................................................................. 12 OEE Factors.......................................................................................................... 13 The Element of OEE ............................................................................................. 13 Availability ....................................................................................................... 13 Performance ...................................................................................................... 14 Quality .............................................................................................................. 14 World Class OEE .................................................................................................. 14 Warping ................................................................................................................... 16 Sizing ....................................................................................................................... 17 Requirements for Size Materials............................................................................ 17 Drawing-In ............................................................................................................... 19 Loom Shed (Shuttle-less Looms) .............................................................................. 19 Stoppages.............................................................................................................. 19 Knotting Stoppages ........................................................................................... 19 Article Change .................................................................................................. 20 Warp Stoppages................................................................................................. 20 Weft Stoppages ................................................................................................. 20 Types of Maintenance ........................................................................................... 22 Electrical Maintenance ...................................................................................... 22 Mechanical Maintenance ................................................................................... 22 Lubrication ........................................................................................................... 23 Normal Interval for Lubrication ......................................................................... 23 Machine Settings................................................................................................... 24 Light Indication System ........................................................................................ 26 Routine Inspection and Maintenance ..................................................................... 27 1

Literature Review .................................................................................................................. 9

Maintenance ............................................................................................................. 21

3.6. 3.6.1. 3.6.2.

Energy in Shed ......................................................................................................... 31 Sources of Energy Consumption ........................................................................... 32 Lighting ................................................................................................................ 32 Paint Ceilings and Walls in a Light Color .......................................................... 33 Types of Lights ..................................................................................................... 34 Incandescent Lights ........................................................................................... 34 Fluorescent Lights ............................................................................................. 35 High Intensity Discharge (HID) Lamps ............................................................. 36 Compact Fluorescent Lights .............................................................................. 37 LED Lights........................................................................................................ 37 Smart Light ....................................................................................................... 38 Brief Description of Air Jet Looms ....................................................................... 40 Filling feeding system ....................................................................................... 40 Optimization of Compressed Air Consumption ..................................................... 42 Preventing Air Leakages .................................................................................... 42 End Use of Compressed Air .............................................................................. 42 Physical Properties of Yarn ............................................................................... 42 Ultra sonic Cleaning ........................................................................................ 43 Opening & closing timing of nozzle .................................................................. 43 Pressure on the nozzle ....................................................................................... 43 Setting of nozzle ................................................................................................ 43 The Perfect Nozzle for any Air Jet Machine .......................................................... 44 D-Type Relay Nozzle ............................................................................................ 44 Unique Body Design ......................................................................................... 45 New Nozzle Head .............................................................................................. 45 Different Hole Patterns ...................................................................................... 45 Insertion Time ................................................................................................... 46 Higher Performance........................................................................................... 46 DLC Coating ..................................................................................................... 46 Control of Sub Nozzles ...................................................................................... 47 Improvement in Nozzle for Feeding the Filling in Reed ..................................... 47

3.6.2.1. 3.6.3. 3.6.3.1. 3.6.3.2. 3.6.3.3. 3.6.3.4. 3.6.3.5. 3.6.3.6. 3.7. 3.7.1. 3.7.1.1. 3.7.2. 3.7.2.1. 3.7.2.2. 3.7.2.3. 3.7.2.4. 3.7.2.5. 3.7.2.6. 3.7.2.7. 3.7.3. 3.7.4. 3.7.4.1. 3.7.4.2. 3.7.4.3. 3.7.4.4. 3.7.4.5. 3.7.4.6. 3.7.4.7. 3.7.4.8. 4.1. 4.1.1. 4.1.1.1. 4.1.1.2.

Air Requirement ....................................................................................................... 39

EXPERIMENTAL WORK ................................................................................................. 49 Warping ................................................................................................................... 50 Types of Stoppages ............................................................................................... 51 Cleaning Stoppages ........................................................................................... 51 Production Stoppages ........................................................................................ 51 2

4.1.2. 4.2. 4.2.1. 4.3. 4.3.1. 4.3.2. 4.3.3. 4.3.4. 4.4. 6.1. 6.2.

Percentage Downtime for Different Qualities ........................................................ 54 Sizing ....................................................................................................................... 63 Production Stoppages in Sizing Department .......................................................... 63 Weaving Shed .......................................................................................................... 68 Knotting Stoppages ............................................................................................... 68 Article Change Stoppages ..................................................................................... 71 Warp Stoppages .................................................................................................... 72 Weft Stoppages ..................................................................................................... 73 Calculation of down time for different qualities and loom efficiency ........................ 74 Calculations .............................................................................................................. 87 Florescent light vs. LED Light .................................................................................. 88

7.2. Factors Affecting Amount of Air Consumption .......................................................... 101 7.3. Effect of Costing ........................................................................................................ 102 8.1. 8.2. 8.3. 8.4. 9.1. 9.2. 9.3. 9.4. 10.2. 10.3. 10.4. Time Analysis ........................................................................................................ 104 Maintenance ........................................................................................................... 104 Energy Analysis ..................................................................................................... 104 Air Consumption .................................................................................................... 104 OEE of Warping ..................................................................................................... 105 OEE of Sizing ........................................................................................................ 105 OEE of Shed........................................................................................................... 105 Energy and Air Losses ............................................................................................ 106 Suggestion for Sizing .......................................................................................... 108 Suggestion for Shed ............................................................................................ 108 Energy and Air Losses ........................................................................................ 110

10.1. Suggestion for Warping ............................................................................................ 107

CHAPTER 1

INTRODUCTION

In the global marketplace, textile companies find that a growing number of their downstream customers and their competitors are producing high quality products at the lowest possible price. With this increased competition, customers have a growing variety of better products with fewer defects at lower prices to choose from offered at a variety by of sales channels. The affordability of product is the priority of the customer in their daily life and in this respect cost of the product plays its role up to maximum. Customers do not mind how hard a manufacturer works, what technology he uses or what is the over head cost at the back of manufacturers facility; he will evaluate and buy the product only by looking at how well it is going to fulfillment his requirements. In this regard, the cost and quality of the product are the main concern of the customer. The cost and quality of the product depends on the variation and wastes of the manufacturing process. Almost each and every organization wastes up to 95% of their resources and most commonly this value exceeding 70%. Even the best manufacturers waste up to 30% of their resources. So it means that there are some serious wastes and variations that are hidden in any organization which are yet to be discovered. To identify and eliminate these wastes, this project has been performed.

1.1. Research Objective

The objective of this project is to determine and remove the hidden losses in a Weaving mill To reduce the cost of the manufacturing processes through reduction, elimination, modification, substitution or innovation. All cost drivers are taken into account and with thorough analysis the best and least cost path is adopted for each activity. The best method to achieve results are to bench mark operating parameters to world class companies .This drives everyone to match or even surpass these figures. To increase the productivity of the Weaving Mill by eliminating the losses and wastes.

1.2. Concept of Value

What do you see as a waste in your organization? Product with defects, bundle of waste papers, and a light turned on unnecessarily or even a person taking a private call from the office telephone. Yes of course these are wastes. But do they account for the 70% - 95% of 5

the resources wasted in your organization alone. Each and every organization wastes up to 95% of their resources, while most commonly this value exceeding 70%. Even the best manufacturers waste up to 30% of their resources. So it is obvious that there are serious wastes that are hidden or yet to be discovered in your organization. Knowing the scale of the wastes, it is worthy to know exactly about a waste. Wastes or losses are defined as anything which does not add value to the end product. If customer sees the value with the end product, it is very much fair to define a waste in this way. Customers do not mind how much it costs you to repair damage, cost for your huge stocks and stores or other over heads. Of course there are wastes that can be avoided but some are unavoidable to many reasons, for example due to technical concerns. But let me tell you, most of these wastes are avoidable. Even worst is that they are avoidable with very little effort, if you see them as wastes. Therefore think all over again with a refreshed mind. There will be many wastes appearing in your organization. With that you will be finding many and many ways to get rid of them. Keep in mind, every waste shows an opportunity for the improvement. When you identify the wastes and categorize them in to avoidable and unavoidable, you have to think about removing the wastes from the system. Every problem in the system has a cause for it. Sometimes one or more root causes for a problem. One root cause may even contribute for more than one problem. For an example, if you have frequent machine breakdowns, the root cause for this might be low skilled maintenance people. So, how to overcome this problem? Should you dismiss the maintenance people? No, you should not get rid of the people. You have to improve the skills of them with training and teaching. Of course if you cannot improve the skills of a person then you can think about giving him a transfer to another department or changing his job role. When you clearly understand the problems and their causes, then it is the time to find out the solutions. This kind of problem solving requires people who can think differently or creatively. Sometimes simplest innovative thinking can change your world completely. In todays world where you want to be, is only a thought away. When you find the solution to the problem, then it is the time to implement the solution and to make sure that you achieve your objectives. Problems are solved in this way over and over again. This is actually the cyclic concept of improvement. Therefore this cycle of identifying, finding root causes, finding solutions and implementing will go on again and again. This process will continue until there are wastes to 6

be removed. Do not worry, for you this cycle will never end. Therefore you will have increments in your total productivity every day. Remember even the best manufactures wastes 30% of their resources.

Figure 1 Cycles of Finding and Solving Problems

What are the solutions for your problems? How to find them? Are you afraid? No need to. Priority should be given to simple, small, continuous improvement, rather than big innovations. Of course there is enough room to absorb big advancements in the system. But the priority is set for the continuous improvement. These improvements might be very simple as adjusting the height of a seat or changing the position of the tools which you use frequently. Every simple improvement will improve the system as whole. Therefore final objective is one more step closer as an organization. What really does matter is being productive. No waste means you are productive. But there are ways still to increase your productivity further. Being busy is not good enough but you have to be productive. Not productive individually, but being productive collectively as an organization. It doesnt matter how productive you are as an individual or as a department, what counts at the end is how productive you are as an organization. With no work in progress, with really productive work place you must always target to become the ideal factory in the manufacturing industries.

1.3. Weaving Process

Weaving is the process of manufacturing by using two sets of yarns intersecting at right angle to each other. These two sets of yarns intersect one another by a special scheme called weave design. These designs produce special effect on the appearance of fabric. The weaving technology is unique and distinct part of the textile industry. In general textile mills, which manufacture woven fabrics, do not manufacture knitted fabrics. The distinctive features of weaving is that comprises highly specialized and sophisticated machinery and technical skills are required to run these machines. With the increase in customer demands and the competitive market trends which requires high quality products with low cost. The only way to produce such high quality products with low cost is to increase the speed of manufacturing process and the use of most sophisticated machines with more and more automations and to decrease the down time. This project has been done to identify the losses occurring in a weaving mill and some suggestions have been recommended to eliminate these losses.

Literature Review

CHAPTER 2
2.1. Six Big Losses

SIX BIG LOSSES

There are three general categories of losses to consider as described earlier. However these losses are divided into six other losses. One of the major goals of TPM and OEE programs is to reduce and/or eliminate what are called the Six Big Losses the most common causes of efficiency loss in manufacturing. A brief description of these losses is provided below.

2.1.1. Downtime Losses

Time during which machine remains stop and do not give production due to any reason is known as downtime of machine. The duration of depends upon the type of fault that the machine is facing. Downtime loss includes the following losses. 1. Breakdowns Sudden and unexpected equipment failures or breakdowns are an obvious cause of losses, since an equipment failure means that the machine is not producing an output. Eliminating unplanned Down Time is critical to improving OEE. Other OEE Factors cannot be addressed if the process is down. It is not only important to know how much Down Time your process is experiencing (and when) but also to be able to attribute the lost time to the specific source or reason for the loss (tabulated through Reason Codes). With Down Time and Reason Code data tabulated, Root Cause Analysis is applied starting with the most severe loss categories. 2. Setup and Adjustments Setup and Adjustment time is generally measured as the time between the last good parts produced before Setup to the first consistent good parts produced after Setup. This often includes substantial adjustment and/or warm-up time in order to consistently produce parts that meet quality standards. Percentage Downtime In service level agreement, it is common to mention a percentage value (per month or per year) that is calculated by dividing the sum of all downtime spans by the total time of a reference time span (e.g. a month). 0% down time means that the machine server was available all the time. % =

2.1.1.1. Downtime Stoppages

There are three types of stoppages that cause downtime to occur. These are as follows: 10

1. Production Stoppages Production stoppages are those which come during manufacturing of a product. These stoppages may be due to faulty raw material, poor handling of material, unskilled labor, transportation and packing of the raw material. 2. Maintenance Stoppages These stoppages include all types of maintenance activities for which are performed during the production of a product. These stoppages may include breakdown maintenance, planned maintenance stoppages. 3. Cleaning Stoppages These are the type of stoppages in which the machine is stopped for cleaning purposes. Usually in shed the cleaning is done after each shift but it still causes stoppages because of the dust and fluff in the sized yarn. All these stoppages combine effect the production process by increasing the down time of machines. We will note the time of different stoppages and the reasons of these stoppages and their effect on the production and the efficiency of all departments of a weaving mill.

2.1.2. Speed Losses

A speed loss mean that the equipment is running but it is not running at its maximum designed speed. Speed losses include two main types of losses: idling and minor stoppages, and reduced speed operations. Speed losses include the following losses. 1. Small Stops and Reduced Speed When a machine is not running smoothly at a stable speed, it will loss speed and obstruct a stable and smooth flow. The idling and stoppages in this case are not caused by technical failures, but by small problems such as parts that block sensors or get caught in chutes. Although the operator can easily correct such problems when they occur, the frequent halts can dramatically reduce the effectiveness of the equipment. 2. Reduced Speed Operation It refers to the difference between the actual operating speed and the equipments designed speed.

2.1.3. Quality Losses

A quality loss means that the equipment is producing products that do not fully meet the specified quality characteristics. It includes two major types of losses namely start up rejects and production rejects and startup losses.

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1. Startup Rejects and Production Rejects Loss occurs when product do not meet the quality specifications, even if they can be reworked to correct the problem. The goal should be zero defects-to make the product right at first time and every time. 2. Startup losses These are yield losses that occur when production is not immediately stable at equipment startup, so the first product does not meet the customer satisfactions. This is a latent loss often accepted as inevitable, and it can be surprisingly large. The following table lists the Six Big Losses, and shows how they relate to the OEE Loss categories.

Table 2.1: Six Big Losses

2.2. Overall Equipment Effectiveness

Overall Equipment Effectiveness, often shortened to just OEE, is an established method of measuring and then optimizing the efficiency of a machine's performance or that of a whole manufacturing plant. Overall Equipment Effectiveness is a well known concept in maintenance and is a way of measuring the effectiveness of a machine. It is the backbone of many techniques employed in asset management programs.

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There are certain terms that are often used in different ways. Three of them are efficiency, effectiveness and productivity. Therefore it is necessary to start with their definition.

2.2.1. OEE Factors

There are certain factors of the OEE which are described hereunder. 1. Plant Operating Time The amount of time your facility is open and available for equipment operation. 2. Planned Shutdown Time It is the time which includes all events that are excluded from efficiency analysis because there was no intention of running production (e.g. breaks, lunch, scheduled maintenance, or periods where there is nothing to produce). 3. Planned Production Time It is the time which is available after subtracting the planned shut down time from the plant operating time. OEE begins with Planned Production Time and scrutinizes efficiency and productivity losses that occur, with the goal of reducing or eliminating these losses. There are three general categories of loss to consider - Down Time Loss, Speed Loss and Quality Loss.

2.2.2. The Element of OEE

The three main categories of machine related losses i.e. downtime, speed losses and defect or quality losses are also main ingredients for determining the overall machine effectiveness. Overall machine effectiveness is calculated by combining the three factors that reflects these losses; the availability rate, the performance rate and the quality rate.

2.2.2.1. Availability
Availability is the ratio of Operating Time to Planned Production Time (Operating Time is Planned Production Time less Down Time Loss). 100% Availability means the process has been running without any recorded stops. Availability takes into account Down Time Loss, which includes any Events that stop planned production for an appreciable length of time (usually several minutes long enough to log as a track able Event). =

Examples include equipment failures, material shortages, and changeover time. Changeover time is included in OEE analysis, since it is a form of down time. While it may not be

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possible to eliminate changeover time, in most cases it can be reduced. The remaining available time is called Operating Time.

2.2.2.2. Performance
Performance is the ratio of Net Operating Time to Operating Time (Net Operating Time is Operating Time less Speed Loss). 100% Performance means the process has been consistently running at its theoretical maximum speed. Performance takes into account Speed Loss, which includes any factors that cause the process to operate at less than the maximum possible speed, when running. =

Examples include machine wear, substandard materials, miss feeds, and operator inefficiency. The remaining available time is called Net Operating Time.

2.2.2.3. Quality
Quality is the ratio of Fully Productive Time to Net Operating Time (Fully Productive Time is Net Operating Time minus Quality Loss). It is calculated as the ratio of Good Pieces to Total Pieces. 100% Quality means there have been no reject or rework pieces. Quality takes into account Quality Loss, which accounts for produced pieces that do not meet quality standards, including pieces that require rework. =

2.2.3. World Class OEE

OEE is essentially the ratio of Fully Productive Time to Planned Production Time (refer to the OEE Factors section for a graphic representation). In practice, however, OEE is calculated as the product of its three contributing factors: OEE = Availability x Performance x Quality This type of calculation makes OEE a severe test. For example, if all three contributing factors are 90.0%, the OEE would be 72.9%. In practice, the generally accepted World-Class goals for each factor are quite different from each other, as is shown in the table below.

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Table 2.2: OEE Factors and Their World Class Values Of course, every manufacturing plant is different. For example, if your plant has an active Six Sigma quality program, you may not be satisfied with a first-run quality rate of 99.9%. Worldwide studies indicate that the average OEE rate in manufacturing plants is 60%. As you can see from the above table, a World Class OEE is considered to be 85% or better. Clearly, there is room for improvement in most manufacturing plants.

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CHAPTER 3 WEAVING PLANT MANAGEMENT

3.1. Warping
Warping is the process of winding together on a beam a specified number of warp ends from Creel. The creel is a convenient rack for holding spools, cones or cheeses while the yarn is withdrawn to the warp beam. The following are the process control parameters in a warping department: 1. Minimizing End breaks 2. Quality of warping beams 3. Control of productivity 1. Importance of Minimizing End Breaks T he stoppage of the machine due to an end break is likely to deteriorate the quality of the beam due to three reasons: i. ii. The rubbing of the beam by the drum which stops abruptly Owing to the difficulty in finding the broken end, there is a possibility of incorrect mending. It may lead to lappers during sizing iii. There is some loss in the extensibility of broken end when the machine is stopped; it increases the probability of breakage in weaving and sizing. Machine Types Super High Speed Warping Machine Warping stops/400 ends/1000 meters Good 0.2 Average 0.5 Poor 0.7

Table 3.1: Warping Stoppages 2. Improving Quality of Warp Beams The quality of the warp beam can be improved by taking following steps. i. Condition of Beam Flanges If the beam flanges are damaged, the unwinding of yarn near the flanges will not be satisfactory. This will cause difficulties in sizing and weaving. ii. Stop Motions and Breaks Proper stopping of the warping machine after an end break ensures that the broken end on the beam can be traced easily.

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iii.

Condition of the Driving Drum On most warping machines the beam is driven by frictional contact with the driving drum. In order to get a package of the correct density, the pressure between the drum and the warp beam has to be kept at fairly high level. Barrel Diameter of the Beam Beams of small barrel diameter give rise to high unwinding tension at sizing, particularly when the beam is about to become empty. Cuts in Accessories in the Path of Yarn Drop pins of stop motion, guide rollers, reed denting etc. should both have any grooves. Creel Fans Fluff accumulated on the machine, particularly at thread guides, causes tension variations in the yarn. This fluff can pass on to the beam. Length Measuring Motion The length measuring motion should be accurate, otherwise estimation of beam count would be wrong and subsequently will give incorrect values of size percent which is commonly determined from the weights of yarns on the warp and the size beams. Density of the Beam The beam should be firm, inadequate pressure between the beam and the drum causes soft beam. Adequate pressure should be maintained by making suitable mechanical adjustments.

iv.

v.

vi.

vii.

viii.

3. Control of Productivity The productivity at warping depends upon the machine efficiency and machine speeds. The speed is governed by the mechanical condition of the machine and its design. Machine efficiency depends on several factors, such as the breakage rate, the time taken to mend the machine stop, set length, length of yarn on supply package etc.

3.2. Sizing 3.2.1. Requirements for Size Materials

i. Adequate Viscosity Penetration or the soaking property of the size material indirectly related to its viscosity. Viscosity must be adequate otherwise: a. Less Viscosity will cause too much penetration and no film will be formed on the surface of the yarn. b. More viscosity will cause more film and less penetration. The size material to be used must have the property to maintain its viscosity during the storage period. 17

ii.

Penetration There should be proper penetration of the size material in the yarn otherwise yarn will be like a stiff rod, and there will be no cohesion in between the fibers, so no strength will be gained. Hygroscopic Nature In sizing, the yarn surface is coated with the sizing film so the yarn itself is unable to absorb moisture from atmosphere. Therefore ingredients to be used in sizing should have the property to retain moisture. This will help the weave room to be operated at a relatively low humidity. Uniformity Most of the troubles in weaving are faced due to non uniformity in loading of size mix on warp yarn, because the loom settings and humidity conditions are always adjusted according to the qualities and specifications of materials applied in the previous process. Easy De-sizing Before further processing the size from the fabric is removed in wet processing in order for proper and smooth effect of dyeing and finishing on fabric. So ingredients used in sizing should be easily removable without involving extra cost and time. Reasonable Cost Cost of the sizing material should be reasonable as it directly affects the cost per meter of the fabric. But the compromise should not be on the quality and efficiency of department. Antiseptic Properties During storage of loom state fabrics or sized yarn for a long time, mildew or fungus could spoil the fabrics by reducing strength, strains and tendering etc. so the size solution must have the antiseptic property Antistatic Properties When the yarns of hydrophobic materials rub each other or with metallic parts of the loom, static charge is produced leading to breakages. So some materials which have the antistatic property must be used to nullify the charge.

iii.

iv.

v.

vi.

vii.

viii.

ix.

General Requirements a. There should be no foaming in the size solution. The foaming prevents the proper penetration of the size in the yarn. For this purpose anti foaming agents are also used. b. The material should not be toxic, or injurious to health. c. Sizing materials should be soluble in water and should mix with other constituents. d. Size materials should be stable in the mills normal conditions, its viscosity and other parameters must be uniform and stable.

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3.3. Drawing-In
Drawing in department is one of the neglected areas of a weaving mill. The main function to weave a fabric is done in drawing department. Where the warps threads passed through droppers, healed wires and reed according to the given plan and weave. It takes a lot of time which depends upon the number of ends of the quality to be produced. Downtime in drawing-in department depends upon the following factors. Skilled workers Use of modern technologies Different types are stands are used in drawing-in department for droppers, heald wires, heald frames and reed. A proper management system is required which manage all the quality for drawing-in one by one without any extra time.

3.4. Loom Shed (Shuttle-less Looms) 3.4.1. Stoppages

The main type of stoppages that occurs in the weaving shed is as follows. 1. Knotting 2. Article change 3. Warp stops 4. Weft stops 5. Maintenance problems

3.4.1.1. Knotting Stoppages

It is the process in which new warp sheet is knotted with the previous finished warp sheet on loom provided the quality is same. In knotting following steps are done 1. Finished warp beam unloading from loom 2. New beam loading on loom 3. Brushing of the older warp sheet 4. Adjustment of the knotting stand 5. New warp sheet brushing 6. Warp sheet knotting 7. Removal of temple 8. Slow speed running of machine

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9. Adjustment of temple 10. Knotting of broken ends

3.4.1.2. Article Change

It is done when quality of the fabric to be produced is changed. Article Change Setting Cam settings Heald frame settings Back rest assembly Easing motion setting Dropper box setting Nozzle settings Selvedge setting Machine speed setting Panel setting

3.4.1.3. Warp Stoppages

When warp breakage occurs on the machine, it is indicated by a red light alert on the loom. The time required to mend a warp stop depends upon Length of faulty yarn Labor skill Number of broken ends Distance covered by the worker to reach the stop Interference time

3.4.1.4. Weft Stoppages

These are the stoppages on the loom due to weft yarn breakage also called filling stoppages. Weft stops are indicated by green light on the loom. The time required to mend a weft stop depends on Skill of the labor Position of the worker at the time of weft stop Interference time Count of Yarn

Loom Speed

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Up to 40s

Weft insertion rate (meters per minutes) should be 10 15 % less than that of recommended by loom manufacturers for that loom model. Weft insertion rate (meters per minutes) should be 5 10 % less than speed

Above 40s For colored yarn

maintained for up to 40s yarn Weft insertion rate (meters per minutes) should be 5 10 % less than that of corresponding grey yarn. Table 3.2: Loom Speed vs. Count of Yarn Up to 40s Ne Above 40s Ne Warp Stops/hour 2.0 1.0 1.8 3.1 Weft Stops/hour 1.6 1.4 1.4 1.4

Loom type

Sorts

Warp Stops/hour

Weft Stops/hour 1.5 1.3 1.3 1.3

Twill Air Jet Denim Plain Poplin

1.6 0.8 1.4 2.5

Table 3.3: Warp and Weft Stops per Hour Faults Attending warp stop Attending weft stop Time in Minute 1.00 0.18

Table 3.4: Timing for Weaver Attending Faults Loom Width 190 cm 220 cm Air Consumption in Cubic feet/8 hours* 12000 15000

Table 3.5: Air Consumption on Air Jet Machine

3.5. Maintenance
Maintenance is of prime importance in smooth and efficient running of any m/c. to make most of capabilities and keep the quality of the woven products high, the following maintenance work should be performed properly according to the machine models Daily inspection Inspection during article change 21

 Weekly inspection Monthly inspection Six month inspection Yearly inspection In addition to above periodical maintenance work for the weaving machine, maintenance for peripherals including the gauges, tools measuring devices, air conditioning facilities and dust collectors should also be performed. It is recommended that maintenance records must be retained on the inspection / replacement notebook for future convenience management.

3.5.1. Types of Maintenance

There are two types of maintenance namely: 1. Electrical Maintenance 2. Mechanical Maintenance

3.5.1.1. Electrical Maintenance

It refers to the continuous checking of electrical parts of the m/c and repairing as per requirement. Electrical maintenance is of different types in weaving i.e. Filling detector problem Filling cutter problem Sensor problem Software problem Card problem Panel problem Pre winder problem Batcher Dropper rods assembly Any other electric faults

3.5.1.2. Mechanical Maintenance

Mechanical maintenance in the weaving shed is of two types as described here briefly: 1. Breakdown Maintenance This is an unplanned maintenance attention is given to the machine only when its break down. 2. Scheduled Maintenance It is a planned and coordinated inspection, adjustments, repairs and replacement in maintenance an equipment .This is planned maintenance 22

including the activities required to keep the m/c in working conditions such as periodic cleaning and lubrication. It is also of two types. i. Operative Maintenance It includes the activities such as replacement and tightening of damages, missing or loose parts. ii. Preventive Maintenance It is that where precautionary measurements are taken before a breakdown occurs.

3.5.2. Lubrication
Lubrication concerns with modifying the frictional characteristics and reducing damages and wears at the surface of two solids which one is moved relative to the other. A lubricant is introduced between two moving surfaces to reduce the friction and the wear and tear between them. Lubricants perform the following key functions: Keep moving parts apart. Reduce friction Transfer heat Carry away contaminants Transmit power Protect against wear Prevent corrosion

3.5.2.1. Normal Interval for Lubrication

Normal intervals of lubrication are given below 120 hours lubrication(once every weekly) 240 hours lubrication(two weekly) 480 hours lubrication(monthly) 960 hours lubrication(two monthly) 1440 hours lubrication(three monthly) 3000 hours lubrication(six monthly) during knotting and article change For new machine it is advised to double the frequency for the first 500 working hours.

23

3.5.3. Machine Settings

Machine setting are always kept on changing due to different quality used . no such has been yet invented which has same general setting for every quality of fabric . Normally machine setting include following parameters. Shed height Shed depth Shed timing Backrest setting Guide tube setting machine speed setting machine width setting Leno/ tuck in setting cam setting air nozzle setting etc. All of these settings are carried out during article change. There is no such booklet that exactly the settings for some specific quality. Just a general range of settings might be given. But settings depends upon type of yarn used, atmospheric condition of that mill, type of m/c used, quality of fabric desired etc. so how could one guess the exact machine setting for a certain quality? Mainly it is a matter of experience but there are some rules, which assist us for proper m/c settings. Pick density can be increased by keeping large shed angle and advanced shed timing. More the shed timing better will be appearance of fabric. Much warp breakages might occur if shedding amount is too large at time of beating Increasing shed amount results in clear shedding without fluff problem Decreasing the shedding amount decrease warp breakages in heald section For denser quality increase the shed height Due to more shed height, shed will separate better and is suitable where many heald frames are used Higher the cloth support , lesser will be the vibration of cloth and less bumping effect but more changes of repping mark If there is too much vibration of droppers then increase the height of guide tube so it touches the warp threads If a slubby yarn is used which is too denser, hairy & coarser then early shedding will facilitate weaving Smaller the rear shed, more pick/ inch but more vibration of droppers 24

ITEMS Shedding Amount Shed Closing time Heald Frame (1st) Heald Frame (2nd) Heald Frame (3rd) Heald Frame (4th) Heald Frame (5 ) Tension metal support height
th

PLAIN 150 ~ 230cm 290/300 113 111 109 107

2/2 TWILL 250cm 300 113 111 109 107

1/2 , 1/3 TWILL 150 ~ 230 cm 300 113 111 109 107

2/1,3/1 TWILL 150 ~ 230cm 290 109 107 105 103

1/4 SATIN 150 ~ 230cm 300 111 109 107 105 103

80 ~ 90

80 ~ 90

50

100

40

Table 3.6: Standard Settings of Tsudakoma Air Jet Loom

For spun yarn, standard setting of total warp tension can be calculated by the following formula: T (N) = Total Ends x A x 10 / British Count (Ne) Where A is co-efficient and depends upon weave of a fabric. Fabric Plain(1/1), twill(2/2) Twill(2/1,3/1) and when the warp is thicker than 12s/1 Twill(2/1,3/1) and when the warp is thinner than 12s/1 Twill(1/2,1/3), Stain (1/4) Coefficient A 0.8 ~ 1.1 0.5 ~ 0.7

0.8 ~ 1.0 1 ~ 1.2

Table 3.7: Fabric Coefficient for Spun Yarn But for filament yarn these tension calculations are little different and can be calculated as: T (N) = Total ENDS x Warp Denier x B x 10 /1000 Where B is coefficient whose values are: Pulley Number 77 mm RPM 509 rpm 25

79 mm 117 mm 119 mm

522 rpm 774 rpm 787 rpm

Table 3.8: Fabric Coefficient for Filament Yarn But in the due course, we should have proper adjustment of main motor v-belt tension. If V-belt tension is too high then: The motor shaft bearing will be damaged The V-belt itself may be damaged If V-belt tension is too low: The V-belt may slip when the loom starts Start mark may occur because the loom stop positions shifts The running speed easily changed and the pick density will be will uneven The V-belt will wear out quickly So if all above factors will be kept in mind, it will be quite easy to have a proper m/c setting for a particular fabric quality.

3.5.4. Light Indication System

Four lights of different colors are used to display different situations on the loom through an indication light system. RED (blinks) = Shows warp stop RED (continuous) = Warp stop is off Yellow (blinks) = Weft Stop Yellow (continuous) = Filling motion is off White Light (continuous) = Mechanical Fault White Light (blinks) = Air Pressure drop on loom Green Light = Hand stop Green + Yellow = Yarn Breakage before pre winder

26

Figure 2 Light Indication System

Figure 3.1: Light Indication System

3.5.5. Routine Inspection and Maintenance

Routine inspection is very important as a small negligence can cause a bigger unrecoverable fault. So why to take such risks, just follow the inspection routine to avoid such mishaps:

Inspection position

Check points Check for abnormal high temperature

Maintenance Locate fault

Brake

Check that the clearance b/t the brake oil & armature is 0.4 mm. Check that filling is cut well Check that timing is Adjust Adjust

Cutter

appropriate Check that edges are not damaged

Replace

Catch cord

Check that the tuft is not wound on the take-up roll Check that the grease is applied to the ends Check that the lint has not accumulated on the cover

Remove the tuft & clean it

Centralization lubrication

Apply grease

Driving motor fan

Remove the tuft & clean it

27

Electrical grease pump

Check that the alarm lamp is not ON Check for the dirt on the lens Check that the backlash of

Apply proper amount of grease Cleans the lens

Feeler head

Selvedge

the selvedge gear and slide gear is not too large Check that the selvedge

Adjust to 0.2 mm

Selvedge formation

yarn is intertwined correctly Check that the tension of the selvedge yarn is proper Check that the temple mark

Correct

Adjust

Temple

do not appear Check that needle do not have any trouble Replace

Top lever shaft

Check for the damage of bearing of the top lever

Replace the top lever

Inspection and Maintenance after Weaving Inspection position Air filter Air piping tube Check Points Check if the drain filling up Check air leakage Check that the lint has not Brake accumulated between the brake and armature Check that the tube is not Cutter for APR damaged Check for oil Check that the clearance FDP between the hook pin and the main drum is 0.5 mm Heald frame Check that the heald frame 28 Re-adjust the clearance Re-pipe Remove lint Maintenance Drain Re-pipe

Supply both blades and spring with oil

height difference is 2 mm or less compared with the specific value Check that the fixing bolts for the side stay are not loosened Let-off Check that yarn has not adhered to the easing shaft Grease nipples Teeth of open gears Lubrication Chain Check that the healed frame and guide A are not worn out Control box Centralized lubrication tube Micro mist filter Check that lint has not accumulated in the box Check for grease leakage Check if the drain is filled up Check that the temple rings Temples rotate easily Check that the temple rings are not worn out Six Month Inspection and Maintenance Inspection Position Check that the filter element is not clogged

Adjust with under wire

Adjust with tightening torque Remove waste yarn Apply grease with brush

Apply grease to healed frame guide A Turn off the loom main switch and remove lint Re-pipe

Drain Replace lint and dirt

Replace

Clean Replace the air filter element Lubrication removable and stationary edges and the spring 29

Air filter

APR cutter

Check that the cutter is not run short of oil

Belts Main drum Hook pin assembly of FDP Main nozzle

Check the tension Check for yarn marks or flaws on the drum Check inside for dirt Check that the pipe is not bent Check that the filter element is not broken Check for yarn marks or flaws on the drum Check for adhesive

Adjust the tension If flaw is small polish it with sand paper # 1000 Clean Replace Replace the air filter element If flaw is small polish it with sand paper # 1000 Clean

Micro mist filter

Pin drum

Reed

monomer Check for abrasion and flaws Replace Replace Replace Replace Clean

sensors

Check that they function manually Check for flaws on tips Check for bent nozzles Check for dirt

Sub-nozzles Thread guide

Yearly Inspection and Maintenance Inspection Position Cloth roll metal bush Check Points Check that the bush abrasion is 0.8 mm or less Check the edge for sharpness Check for the abrasion of the rubber strip Check for abrasion Check the hook pin hole for abrasion Check for abrasion Check for the abrasion of Maintenance Replace

Cutter on the LH

Grind or replace

Friction roll Damper guide pin Hook pin assembly Nylon bush Press roll

Wind new rubber Replace Remove burr Replace Replace Wind new rubber 30

the rubber strip Shock absorber Check for function Check that the abrasion of Warp beam journal section is 0.3 mm or less Warp beam metal bush Three Yearly Inspections Inspection position Check point Check that the roll rotates Cloth roll smoothly and cloth is wound Solenoid valve Sub-nozzle Check that the grease is sufficient Check for dirt Disassemble and apply grease Clean Replace the brake lining Maintenance Check brush for abrasion Replace Replace Replace

Seven Yearly Inspections

Inspection points

Check points Loom, bearings, oil seal, cam, bush, hook pins, main

Maintenance

Overhaul

motor, shedding section, let-off section, take-up section, measuring and storage (FDP) section.

Deal according to the faults

3.6. Energy in Shed

Energy plays a very important role in industry; Industries could be classified into like heavy energy consumer, medium energy consumer and low energy consumer. Organization have started doing energy audits in their plants, offices etc .Such studies has highlighted waste of energy and requirement of energy efficient technology The know-how on modern energy-saving and conservation technologies should be disseminated to industrial managers, as well as to engineers and operators at the plant level in 31

developing countries. In energy intensive industries such as textile industry, steel industry, glass industry, etc, savings up to 20% generally could be achieved through investment or implementation of energy efficient systems. No. of Obs. 1 2 3 4 5 6 7 8 Total Machine Warping Sizing Pirn winding Weaving Humidification Compressor Lighting Boiler Power kW 34 14 21 424 70 36 30 15 644 % Total 5 2 3 66 11 6 5 2 100

*For 30, 00 meters of fabric per day. Table 3.9: The power consumption in different sections of Weaving Mill

3.6.1. Sources of Energy Consumption

The major sources of energy consumption in a Weaving Mill are: Lightning Compressor Air conditioning Boiler In shed Motors Type of nozzles Electric wiring Folding and packing section Sizing section

3.6.2. Lighting
The quality of lighting in a workplace can have a significant effect on productivity. With adequate lighting workers can produce more products with fewer mistakes, which can lead to a 10-50 % increase in productivity. Good lighting can decrease errors by 30-60 % as well as 32

decrease eye-strain and the headaches, nausea, and neck pain which often accompany eyestrain. Adequate lighting allows workers to concentrate better on their work which increases productivity. The level of lighting that workers need varies depending on the nature of the task, the sharpness of the workers eyesight, and the environment in which the work is done. For example, detailed work, such as inspection, assembling of small parts or technical drawing, needs a great deal of light. Coarse work, on the other hand, such as loading or unloading materials, handling of materials or packaging, requires less light. Good lighting in the workplace promotes: a reduced risk of occupational accidents and health problems; better concentration and accuracy in work; a brighter, cleaner workplace resulting in a more active, cheerful environment; improved work performance; Better visibility, improved accuracy and increased work speed enhancing production. In can be easy to improve lighting without increasing the number of light bulbs, light fixtures or the electric bill. Improved lighting can be achieved by using more daylight, by changing the position of light sources or workstation layouts and by effectively using reflected light. Consider the following guidelines when planning to improve the lighting conditions in the unit.

3.6.2.1. Paint Ceilings and Walls in a Light Color

Light colors create more reflection than dark colors. Light colors make it easier to keep ceilings and walls clean. Glossy white painted surfaces reflect 100% of the light whereas black surfaces reflect no light at all. To achieve improved illumination, follow these recommendations: Use white or a very light color on ceilings; Paint walls white; Use light or half-tone colors on tables and machines. The background at the workstation is important, especially for visual tasks that demand close, continuous attention. A simple background will allow for more accuracy and an increase in production whereas a complex background may disturb the work and increase the workload. To obtain an optimum visual task background:

33

 Eliminate potential sources of distraction, such as posted papers, forms or schedules on walls; Use light-colored partitions and screens to eliminate or screen sources of distraction; Select an appropriate color for the work background. The following table provides some guidance for making the selection steel, cast iron bronze, copper aluminum, tin dark wood ground castings light-colored wood cream colored grey-blue cream colored grey-blue Light Dark

Table 3.10: Material Appropriate background color

3.6.3. Types of Lights

There are different types of lights that are available in the market having different capacities and characteristics.

3.6.3.1. Incandescent Lights

The most common lights are the incandescent lights usually called Light Bulb. The incandescent and quartz-halogen lights develop their light by passing current through a thin high resistance tungsten wire which gets hot and radiates light. Along with the visible light comes a great deal of heat, so the lights are lowest in efficiency. Only 5% of the input energy is converted to visible light. The tungsten filament gradually evaporates and weakens, and the metal that evaporates gradually coats the inside of the bulb, reducing brightness. Incandescent lights are available in a wide range from 5, 25, 40, 60, 100, 200, 250 Watts and higher capacity and are also available for 12 volt DC operation. This is the cheapest and most commonly used bulb in this country.

34

Figure 3.2: Incandescent Light

3.6.3.2. Fluorescent Lights

In Fluorescent lamps, mercury vapor is excited inside a tube by alternating current, and light is emitted by the gas. The light strikes the inner coating of the tube which is some type of fluorescent material, producing a soft glow. The light produced falls well within the visible range, so the efficiency is good. Traditionally fluorescent bulbs have long cylinders ranging from a few watts to 40 watts. New parallel lengths or PL lamps are now available that are much more compact. The PL lamps fold back the long cylinder to make a compact H shape, double H or quard PL lamps are also available. PL type lamps are available 5,7,9,13,18 or 24 and 36 watts. To operate from DC power, ballast is needed to produce high frequency AC current.

Fluorescent lamps are extensively used in industries, especially garment industries. Thousands of FL is used in these factories. There are two types of FL are available in the market 40 W and 36 W with the same lumen output. There is a saving of 4 W per tube. Moreover, good quality electronic ballast with 36 W lamps can save power. Figure 3.3: Fluorescent Lights

35

Type

Lumen per watt

Life x 1000 hours .7512 7.524

Relative efficiency based HPS 19% on

Start-up time minutes

Lumen

Color

Operation

maintenance rendition cost

Incandescent

15-25

immediate

Fair excellent Fair excellent

to

excellent

High

florescent Compact florescent light

55-85

65%

immediate

to Good to excellent

Average

45-60

10

46%

Immediate Good

Good

Low

LED lights Mercury vapor Metal halide High pressure sodium HPS

70-120

50100 16-24 1.515

92%

immediate

Very good

Good Poor to

Very low

50-60

46%

2-7

Very good

excellent Very good

Average Below average

80-100

77%

2-5

Good

75-130

20-24

100%

3-4

Excellent

Good

Low

Table 3.11: Comparison between different lights

3.6.3.3. High Intensity Discharge (HID) Lamps

The HID lights are Mercury vapor, metal halide, low pressure and high pressure sodium lights. These lamps are ideal for outdoor applications like security lighting where lamps will be operated for extended periods of time. The mercury vapor lamp produces a harsh bluishwhite light and is the least efficient of HID lamps. They have a low initial cost, but higher operating costs than other HID choices. Metal halide lamps have good color rendering capabilities and are widely used for sporting event lighting. The low 36

pressure sodium lamps produce a harsh yellow-gold color and are suitable only for general outdoor lighting. They are most efficient of light sources, but the harshness of light makes their applications limited. High pressure sodium lamps are the most efficient of the white light sources. They produce a soft amber color and are used for street lighting and other exterior lighting applications. Figure 3.4: High Intensity Discharge Bulb

3.6.3.4. Compact Fluorescent Lights

Compact Fluorescent Light (CFL) is an energy efficient light. The main benefits of CFLs are 80% savings in electricity costs compared with incandescent lamps of same brightness. And up to 13 times the life of incandescent lamps. But the main problem is price. It is about 15 times costlier than incandescent lamp in local market. The price can be reduced if government duty is reduced. Renowned light manufacturers like Philips, GEC, and OSRAM have developed energy efficient starters like Conventional Control Gear (CCG) and Electronic Control Gear (ECG), which not only save energy but also bring longer lamp life. Figure 3.5: Compact Fluorescent Light

3.6.3.5. LED Lights

Recent development of Light Emitting Diode (LED) lights may revolutionize the lighting industries. These lights can be used until now to some specialized use. A light-emitting-diode (LED) is a semiconductor diode that emits light when an electric current is applied in the forward direction of the device, as in the simple LED circuit. The effect is a form of electroluminescence where incoherent and narrow spectrum light is emitted from the p-n junction. LED lights operate on DC voltage. AC LED lights are still in experimental stage. There are two ways of producing high intensity white-light using LEDs. One is to use individual LEDs that emit three primary colors red, green, and blue, and then mix all the colors to produce white light. The other is to use a phosphor material to convert monochromatic light from a blue or UV LED to broad-spectrum white light, much in the same way a fluorescent light bulb works. Wal-Mart, a retailer giant supermarket chain with 5,200 stores worldwide has come up with new idea of energy saving in lighting. One of the biggest items on its energy bill is lighting. 37

Instead of going with the cheapest bulbs, the company is experimenting with costlier LED strips for refrigeration units that last longer and use less energy. In future it might replace the GLS lamps.

Figure 3.6: LED Lights

3.6.3.6. Smart Light

By using occupancy sensor lights can be switched on and off. These smart lights are usually used in spaces, which are not all the time used/occupied, like corridor, elevators, etc

38

As by the comparison we see that the LED lights have high watt to lumens ratio and its operating cost is also very low as compared to other types. The only disadvantage of these lights is that these are very expensive in Pakistan. But these would be cheaper in future as the time pass. Figure 3.7: Smart Light

3.7. Air Requirement

For the weft insertion mechanisms of air jet looms, the profile reeds with sub-nozzle systems are the most advantageous in terms of improving high speed weaving and wider cloth width. Not only the airflow from the main nozzle and sub-nozzles but also the airflow in the weft passage is closely related to the flying state of the yarn at the time of weft insertion in this system. In order to manufacture high quality textiles with air jet looms, it is necessary to establish optimum weaving conditions. These conditions include the supply air pressure and air injection timing for the main nozzle and sub-nozzles according to the kind of yarn. Energy saving is the most important of the technical subjects related to air jet looms today. Research about the improvement in performance of main nozzles and sub-nozzles, which plays an important role for weft insertion, has been performed by various researchers. Although some effort has been made to improve the efficiency of compressed air usage, the effort has not been uniform. There is still a critical need to understand the energy loss or consumption in filtration, distribution and machine usage in the textile industry. Due to technical barriers, reducing energy consumption by compressed air systems has been viewed as a complicated task.

Figure 3.8: A Modern AIR JET weaving machine.

39

3.7.1. Brief Description of Air Jet Looms 3.7.1.1. Filling feeding system
The air jet loom feeds the filling as in Figure 3.9 and 3.10. The filling length is measured according to the width of the fabric by 1 rotation of the loom. It is accelerated by the main nozzle at a specific timing, and is inserted into the air guide of the reed. Groups of subnozzles are located across the whole width. Each group jets compressed air in a specific order to feed the filling tip to the right end of the fabric. The compressed air is supplied from the compressor, its pressure is adjusted by the regulators for the main nozzle and the sub-nozzles, and it is stored in the proper tank. The control system of the loom opens and closes the electro-magnetic valve, and sends the compressed air to the nozzles.

Figure 3.9: Modern Feeding System

Figure 3.10: Schematic of Air-Jet Weaving Machine and Process Figure 3.10 shows a schematic of a typical air-jet weaving machine with the primary machine components labeled. The filling yarn is supplied to the pre winder, which wraps the yarn until

40

the correct pick length has been detected. The pick is then supplied to the Programmable Filling Tensioner (PFT) which stretches the pick so that there is enough tension for the pick to travel through the air nozzles. A fixed air nozzle at the end of the PFT uses compressed air at high pressures to move the pick to the movable main nozzle, which then sends the pick in air across the reed. The filling detector at the end of the machine senses the arrival of the pick, which is cut by two electric cutters at opposite ends of the woven fabric, and the process is repeated. The movable main nozzle provides the major force on the yarn during the pick insertion process. To assist in moving the pick through the shed, a set of relay nozzles are incorporated across the shed and are sequentially activated to prevent pick buckling and maintain velocity. The overall forces that the pick experiences during insertion is the sum of the forces applied from the fixed, moving, and relay nozzles minus friction forces from the reed insertion channel and pre winder. In order to successfully weave fabric via air-jet weaving, some of the components of the airjet weaving machine must constantly rotate at high rotational velocities. Beginning with the movable main nozzle, the entire shed rotates at rotational velocities of up to 1000 RPM. Filling insertion usually begins somewhere between 70 and 90 degrees of rotation, and the pick arrives at the filling detector anywhere between 200 and 300 degrees, depending on the user-programmed specifications. The amount of time it takes the pick to travel from the pre winder to the filling detector is defined as the arrival time and is also specified in degrees of rotation. However, if the rotational velocity (often expressed in RPM) the machine is operating at is known, the arrival time can be easily converted to a time unit, usually milliseconds. Typical air-jet weaving machines have two filling insertion channels that alternate consecutively as to which channel is providing the pick to be woven. The arrival time, and therefore the speed at which the pick travels through the shed, is primarily governed by the air efficiency of the filling yarn. Therefore, the arrival time is used by weavers as a means of indicating how well the yarn is matched up to the amount of air being applied to send the pick through the shed. However, pick insertion is a process in which many errors can occur. A filling stop is a temporary weaving machine shut down that occurs when there is an error in the process of the pick traveling from end to end in the shed during weaving. There are many causes of filling stops in air jet weaving, and the microprocessor of the weaving machine detects and records filling errors, temporarily shutting down the

41

machine until a weaver corrects the mishap and restarts the machine. Filling stops result in monetary losses for the weaver and affect the efficiency of the fabric manufacturing process.

3.7.2. Optimization of Compressed Air Consumption

Compressed air consumption can be minimized broadly in two ways. One is by minimizing wasteful consumption of compressed air i.e. by preventing compressed air leakages and secondly by improving the efficiency of compressors. Ways and means for both these aspects are discussed.

3.7.2.1. Preventing Air Leakages

Leakages usually occur in small openings; but the cumulative effect is great. Some tips for preventing the air leakage are given herewith. Standardize on good hose clamps; Replace/repair leaky shut-off valves. Install condensate separators with automatic traps to eliminate the need for operators, opening the manual valve to clear water, thereby wasting air. Use good quality air hoses to avoid breaks and leaks.

3.7.2.2. End Use of Compressed Air

Compressed air savings at the end use leads to a direct reduction in the amount of compressed air needed for operation. A general rule of thumb is that 1 SCFM of air costs approximately $65 per year in a large manufacturing plant. Savings at end usage can be achieved by either reducing the airflow through the equipment, or by lowering the pressure at the point of use. Lowering the pressure at end use will also have a natural flow reduction effect. The flow and pressure reduction must occur without impacting performance. Manufacturing plants should continually monitor production equipment to make sure the minimum pressure and airflow are being used.

3.7.2.3. Physical Properties of Yarn

Several physical properties and characteristics of yarn are thought to have an effect on yarn velocity in air jet weaving applications. The yarn characteristic thought to have the most effect on yarn velocity (and therefore, Air Index value) is the yarn hairiness, which is a quantitative means of describing the surface roughness of a cotton-based spun yarn. It is hypothesized that yarns with higher hairiness values will result in higher Air Index values, due to an increase in surface area of the yarn for the air to push on; i.e., an increased aerodynamic drag. 42

Other physical characteristics of yarn will be investigated in this project to determine whether or not they have an influence on Air Index value, especially yarn count. The higher the yarn count, the smaller the diameter and density of the yarn is, so it is thought that higher yarn counts will result in higher Air Index values. This is due to the increased surface area-to-mass ratio as yarn count is increased.

3.7.2.4. Ultra sonic Cleaning

Cleaning of main nozzle, relay nozzle, air filter, hose pipes etc. ultra sonic cleaning is important to maintaining the efficiency of weaving. It should avoid the damaged or error portion of the surface so such condition of deposition is micro fiber can drop the pressure of air blowing through it so these can be avoided due to these cleaning.

3.7.2.5. Opening & closing timing of nozzle

Correction made delayed opening loss pressure through valve enhance the efficiency of machine. Early opening will reduce the air consumption. Improper opening & closing timing of valves lead to undue stress on yarn thereby leading to break. After proper adjustment the no. of end breaks can be reduced. The air consumption can be reduced up to 5 to 6%.

3.7.2.6. Pressure on the nozzle

Pressure on nozzle has more impact on the m/c performance. Improper pressure adjustment will causes the weft stop during working so quality & productivity can be minimized. To avoid the problem, proper setting of pressure can be required. These can be adjusted according to count, rpm, width of m/c. Proper combination between main & relay nozzle will reduce the air consumption.

3.7.2.7. Setting of nozzle

1- Distance between two nozzles Improper setting between to relay nozzle will cause to variation in air pressure and will cause m/c performance to be in decreasing the air consumption will be unnecessary increases. 2- Nozzle height Proper height setting of relay nozzle will causes reduction in air pressure during weft insertion & air consumption can be reduced. Proper setting of the nozzle height will provide the uniform displacement of yarn during insertion. 3- Nozzle angle For uniform weft insertion of yarn during insertion proper nozzle angle will reduce air consumption. Pressure required for insertion can be reduced. Multi hole versus single hole The multi hole relay nozzles guarantee a very stable blowing angle at different pressure levels. This is recommended for style changes that require 43

different relay nozzle pressure settings. The single-hole nozzles need to be adjusted by hand whereas multi-hole nozzles keep their blowing angle stable and do not need any adjustment or fine tuning. Due to the pre-given horizontal and vertical jetting angles, the multi-hole nozzle requires less space between the warp yarns, which prevents nozzle marks in your fabric.

Figure 3.11: Multi Hole and Single Hole Relay Nozzle The multi hole pattern allows also a more efficient air stream, thus delivering a better performance over single hole nozzles, giving up to 15% higher yarn speed for the same air consumption. Single-hole nozzles are recommended in case of a dusty environment or low air quality.

3.7.3. The Perfect Nozzle for any Air Jet Machine

Over 40 years ago, Te Strake Textile has revolutionized the weaving with the introduction of its unique air jet weaving system. To Te Strake Textile is worldwide recognized as trendsetter and innovator in the air insertion system. With their complete range of relay nozzles, Te Strake Textiles delivers the perfect relay nozzle for your need, no matter which loom type you are using.

3.7.4. D-Type Relay Nozzle

Based on their extensive experience on air insertion technology, Te Strake Textiles take another step in weaving technology with its innovative D type nozzle. This D-type nozzle incorporates unique characteristics to outperform any other model in terms of: Reduced weft stops Improved machine performance 44

 Extra stability of nozzle body Prevention of nozzle marks Reduction of air consumption Increased lifetime

3.7.4.1. Unique Body Design

The new body design makes the D type nozzle the most robust and stable nozzle currently available with up to 45% higher resistance to deformation. This stronger nozzle requires an absolute minimum of adjustment for higher productivity.

3.7.4.2. New Nozzle Head

With the successful experience of a round or convex nozzle head, the D type nozzle head has been further optimized for better fabric quality. Filamentation, nozzle marks or having your warp staying on top of the nozzle, belong now to the past.

Figure 3.12: S-Type and D-Type Nozzle

3.7.4.3. Different Hole Patterns

The D type nozzle is available for different hole patterns i.e. 1-7-16-19 holes depending upon your requirement. The highest performance is given by 16 hole nozzle offering specific benefits.

45

Figure 3.13: Different Types of Nozzles

3.7.4.4. Insertion Time

With the revolutionary 16 hole pattern, the air stream is now perfectly parallel to the warp yarns, thus making maximum use of insertion time. As a result, higher weaving speed for increased productivity or a gentler yarn passage for better fabric quality is guaranteed.

3.7.4.5. Higher Performance

The D type 16 hole nozzle can offer you significant cost saving. This nozzle can generate the same yarn speed for reduce air consumption in some cases 15 20% depending upon the weaving

condition. Either with the same air consumption you can increase the yarn speed. Figure 3.14: Air Consumption vs. Yarn Speed

3.7.4.6. DLC Coating

The D type nozzles are exclusively coated with diamond like carbon coating which is superior to any other coating. It increases its life up to 5 times and avoids wears and yarn cuts. DLC is specially recommended for abrasive warp yarns.

46

3.7.4.7. Control of Sub Nozzles

Control of sub nozzle by increased group conventionally, as in figure, sub nozzles are arranged in groups of 4 nozzles. An electromagnetic valve is attached in each group and the sub nozzle of same group jet simultaneously. Tsudakomas new arrangement as in figure has an electromagnetic valve with smaller inner volume so that it matches to 2 sub nozzles. The control of valve is improved and extra jetting time is reduced.

(a)

(b) Figure 3.15: (a) 4 Sub Nozzles / Valve, (b) 2 Sub Nozzles / Valve

3.7.4.8. Improvement in Nozzle for Feeding the Filling in Reed

The main nozzle pulls the filling with the compressed air and feed it to the reed. A Lavel-type nozzle; the interior is wider at one end than the other end. The nozzles pulling time is increased by 30% and air consumption by main nozzle is reduced by 10% (compared with cylindrical nozzle). In addition, the sub nozzles consume almost all of the air consumption in the air jet loom because of their number. Tsudakoma invented a new sub nozzle. The part around the jetting outlet of the nozzle is hollowed and the flow speed is increased by 10%.beacuse the filling does not touch the end of the jetting outlet, damage to filling is 47

reduced. For the reed, the air guide of reed is narrowed for feeding the filling and air flow speed is increased.

(a)

(b) Figure 3.16: (a) Main Nozzle, (b) Sub Nozzle

48

EXPERIMENTAL WORK

49

CHAPTER 4
include: Warping Department Sizing Department Weaving Shed

TIME ANALYSIS

Time analysis was done in term of downtime of different departments. These departments

This analysis is done in the following sequences. In this analysis different qualities were taken and studied with respect to time. Here below is mentioned the detailed study of times in different departments.

4.1. Warping
Warping is aimed at preparing the weavers beam to be set up on the weaving machine. Warping carries out the following operations. Creation of a limited number of warp threads (creel load) of warp composed of any number of threads with the desired length. Arrangement of the above mentioned threads according to the desired sequence. Manufacturing of a warp beam with desired characteristics. The industrial warping process can be carried out according to two different categories. Sectional warping (conical drum or dresser warping) Direct warping or beam warping Warping Machine Specification Company Model Year Maximum Creel Capacity Maximum Speed Beam Length Barrel Diameter Benninger Ben-direct 2002 960 1200 meter/min 2400 mm 308 mm

50

4.1.1. Types of Stoppages

There are three types of stoppages which can occur on warping machine. Cleaning stoppages Production stoppages Breakdown stoppages

4.1.1.1. Cleaning Stoppages

These include cleaning of AC duct line and cleaning of warp stop sensor. The time analysis is shown here below. i. Cleaning of A.C Duct Line Warping machine is stopped for cleaning the A.C duct line above the creel because when coarser count is run on warping machine, more fluff blows in the warping shed. Some of this fluff get stuck with the inner and outer part of the duct and finally falls down on the yarn and causes problems in the subsequent processes. Average time taken for cleaning the outer duct line of A.C. is 30 minutes ii. Cleaning of Warp Stop Sensors Cleaning of the warp stop sensors is also important because if the fluff is trapped in the sensor, it would cause the sensor to work improperly. In case of breakage the sensor wont detect it and a warp end short would be produced in the beam. Time taken to clean the warp stop sensors: 1. 2. 3. 15 min 16 min 20 min

The average time to clean the warp stop sensor is 17 minutes. Total cleaning time for cleaning is 47 minutes.

4.1.1.2. Production Stoppages

These stoppages are of two types 1. Fixed stoppages 2. Variable stoppages 1. Fixed Stoppages These are the type of stoppages which are independent of the type of material, yarn quality and yarn count. The fixed stoppages that can occur on the warping machine are i. Warp Ends Cutting Time 51

ii. iii. iv. i.

Panel Setting Time Doffing Time Creel Move Time

Warp Ends Cutting Time It is the time that is required to cut the warp ends at the both sides of the creel when one creel is finished. The number of warp ends has a little effect on this time. Average time for the warp ends cutting is 0.60 minutes (36 sec). Panel Setting Time It is the time that is required to feed the data of the running quality on the computer panel of the warping machine. Average time for feeding data is 1.5 minutes. Doffing Time It is time required to replace the finished beam with new empty beam on the warping machine. It depends upon the distance of the empty beam and the finished beam moved from the headstock of the warping machine. But usually the empty beam is placed near the machine when required. Average time = 1 minute, 30 sec Creel Move Time Creel change move time is the time when one creel is finished and the loaded cone rods are moved towards the headstock. Since the rods cover equal distance, it is referred as fixed time. Creel move time = 4 min

ii.

iii.

iv.

2. Variable Stoppages These are the type of stoppages that changes with the change of material and yarn specifications. The variable stoppages that can occur on warping machine are as follows: i. ii. iii. i. Sensor filling time Comb filling time Warp break repairing time

Sensor Filling Time It is the stoppage occurred when one creel is finished and the new cones yarn is passed through sensors against the respective cone. The time of filling sensors depends upon the number of cones, greater the no. of cones larger will be the time. No. of Observations 1. 2. Number of Ends 845 906 Time for Sensor Filling Minutes 06 08 Seconds 22 05 52

3. 4. 5.

870 878 822

06 07 06

50 40 00

Table 4.1: Sensor Filling Time ii. Comb Filling Time It is the time required to fill the comb of warping machine. It also depends on the number of ends to be filled. No. of Observations 1. 2. 3. 4. 5. Number of Ends 845 906 870 878 822 Time for Comb Filling Minutes 08 09 08 08 08 Seconds 22 04 55 41 26

Table 4.2: Comb Filling Time iii. Warp Breakage Repairing Time The time required to repair the warp breakage on warping machine is called warp breakage repairing time. Factors affecting the warp yarn breakage repairing are as follows: The distance of the breakage point from the headstock Number of workers Worker efficiency Type of yarn fault Number of workers No. of obs. 1 2 3 4 5 6 Time to mend the breakage Minutes 1 1 1 0 1 0 Seconds 06 20 05 55 20 45

53

7 8

1 1

00 02

Table 4.3: Time to Mend Breakage

Percentage Downtime in Warping The %age downtime of a warping department is defined as the %age of time for which the warping machine remains unproductive. = 100

4.1.2. Percentage Downtime for Different Qualities

Product Specifications Quality Cone Weight No. of creels Length/beam Starting Time 40 16 63" 128 64 4.16 lb 3 20875 m 11:57 am

Beam No. 1 Machine Causes Downtime 54

Stops 1 2 3 4 5 6 7 8 9 Yarn entanglement and breakage Yarn breakage Yarn breakage Yarn breakage Yarn breakage Yarn breakage Yarn breakage Yarn break Machine unnecessary stop

Min 0 1 1 1 0 0 0 0 2

Sec 35 59 10 36 44 46 32 38 10

Beam finished Total time for completion of beam Downtime due to breakdown Beam No. 2 Downtime to change the beam Starting time Machine stops 1 2 3 4 5 6 7 8 Beam finished Total time for completion of beam Downtime due to breakdown Time at which beam has to be completed Beam No. 3

= 12:31 pm = 34 min = 8.16 min

= 4 min = 12:35 pm Causes Downtime Min Yarn breakage Yarn breakage (cut cone) Yarn breakage (cut cone) Yarn breakage (cut cone) Yarn breakage (weak yarn) Yarn breakage Yarn breakage Yarn breakage = 01:07 pm = 32 min = 6.2 min = 25.8 min 0 1 0 0 0 1 0 1 Sec 09 07 56 36 17 11 49 07

55

Downtime to change the beam Starting time Machine stops 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

= 1 min = 01: 08 pm Causes Downtime Min Weak Yarn Lappet Lappet Cone short Lappet Weak yarn Weak yarn Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Weak yarn Lappet 0 1 0 2 1 1 0 1 0 1 2 1 1 2 1 0 1 1 0 0 0 1 2 1 1 0 0 1 Sec 57 17 59 04 02 31 39 45 49 04 01 37 50 10 00 58 34 45 59 37 46 32 01 43 04 52 31 09

56

29 30 31 32 33 34 35 36 37 38 39 40 Beam finished Time Duration in which beam completed Downtime due to breakdown Beam No. 4 Downtime to change the creel Starting time Machine stops 1 2 3 4 5 6 7 8 Beam finished Beam Completion Time Downtime due to breakdown

Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet = 02: 40 pm = 1: 32 min = 52.5 min

0 2 0 0 1 2 1 1 1 0 0 1

58 10 35 49 04 01 37 50 10 54 37 34

= 55 min = 3:35 pm Causes Downtime Min Yarn break Yarn break Yarn break Yarn break Yarn break Yarn break Yarn break Yarn break = 04:05 pm = 30 min = 8.01 min 57 0 1 1 1 0 1 0 0 Sec 30 23 32 09 56 10 45 36

Time in which beam has to completed Beam No. 5 Downtime to change the beam Starting time

= 12 min

= 2 min = 04:07 pm

Machine stops 1 2 3 4 5 6 7 8 Beam finished Beam Completion Time Downtime due to breakdown

Causes

Downtime Min Sec 12 19 56 05 30 45 02 56

Lappet Yarn Break Yarn Break Yarn Break Lappet Lappet Yarn break Lappet = 04:34 pm = 27 min = 8.75 min

1 1 0 1 1 0 1 0

Beam No. 6 Downtime to change the beam Starting time Machine stops 1 2 3 4 5 6 7 8 Yarn entanglement at cone Yarn breakage Yarn entanglement Yarn breakage Yarn breakage Cone change Yarn breakage Yarn breakage 0 1 1 0 1 = 1 min = 04:35 pm Causes Downtime Min 02 1 Sec 21 12 52 49 16 20 50 05 58

9 10 11 12 13 14 15 16 17 18 19 20 21 22 Beam finished Beam Completion Time Downtime due to breakdown Beam No. 7 Down time of creel change Down time of sensor filling Down time of comb filling Cleaning is done during creel change Total down time Starting time Machine stoops 1 2 3 4 5 6

Cone change Yarn breakage Yarn breakage Yarn breakage Yarn breakage Yarn breakage Cone cut Yarn breakage Yarn breakage Cone change (short cone) Yarn breakage Yarn breakage Lappet Yarn breakage = 05: 31 pm = 56 min = 25.25 min

1 0 0 0 1 1 0 1 1 1 0 0 1 1

10 40 38 35 15 35 57 13 23 45 45 57 34 13

= 13 min = 10 min = 11 min

= 34 min = 06: 04 pm Causes Downtime Min Yarn entanglement (lappet) Yarn breakage (weak yarn) Yarn breakage (weak yarn) Yarn breakage(weak yarn) Yarn breakage (cut cone) Yarn breakage (cut cone) 03 1 1 0 0 1 Sec 12 13 20 56 40 32

59

7 8 Beam finished Beam Completion Time Downtime due to breakdown Beam No.8 Down time to change the beam Starting time Machine stops 1 2 3 Beam finished Beam Completion Time Down time Beam No. 9 Downtime to change the beam Starting time Machine stops 1 2 3 4 5 6 7 8 9 10 11

Lappet Yarn breakage (cut cone) = 06: 34 pm = 30 min = 11.6 min

1 0

45 57

= 2 min = 06: 36 pm Causes Downtime Min Yarn break Yarn break Yarn break = 07: 04 pm = 30 min = 3.6 min 1 1 1 Sec 20 06 10

= 1 min = 07:05 pm Causes Downtime Min Yarn break Yarn break Yarn break Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet 1 0 1 2 1 1 2 1 0 1 1 Sec 05 55 24 01 37 50 10 00 58 34 45 60

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Beam finished Beam Completion Time Down time Calculation of Percentage Downtime Number of beams (n) Total number of stoppages (s) Number of creels used Time of creel change Total Operating Time

Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Weak yarn Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet Lappet = 08:07 pm = 62 min = 42.4 min

0 0 0 1 2 1 1 0 0 1 0 2 0 0 1 2 1 1 1 0 0 1 0

59 37 46 32 01 43 04 52 31 09 58 10 35 49 04 01 37 50 10 54 37 34 39

=9 = 140 =3 = 4 min = 490 min 61

Total Downtime due to Creel Change Total Downtime due to Breakages Total Downtime Total productive time

= 100 min = 167 min = 267 min (100+167) = Total Operating Time Total downtime = 490 267 = 223 min 100 267 100 490

= . % The OEE of the Warping Department As OEE = Availability Performance Quality Now, = 100 223 = 100 490 = . % Now, = 100 850 = 100 900 = . % Now, = 100 9 = 100 9 = % Now, the OEE of the Warping Machine OEE = Availability Performance Quality OEE = 45.5 94.4 100 OEE = 42.9%

62

4.2. Sizing
It is the process in which size is applied to the warp sheet in order to increase the strength of the yarn. Sizing Machine Specification: Manufacturer Year Creel capacity Maximum speed Drying cylinders Size boxes Benninger (Germany) 2002 16 120 m/min 12 2

4.2.1. Production Stoppages in Sizing Department

Following are the production stoppages in sizing department. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Beam loading and unloading Warp sheet cutting from size box Warp sheet knotting Cleaning and washing of the size box Size box filling Sheet transfer time Leasing time Cleaning of comb Combing time Slow speed running of machine

Downtime in Sizing Department Product specification Quality Count Total ends Machine speed Length of weaver beam Beams / set 3030 / 13072 63 30/1 8190 70 m/min 1800 m 5

Downtime in a set of five beams is given as under

Operation

Time consumed 63

Minutes Warp sheet cutting from size box Cleaning & Washing of size box Washing Sheet knotting Size box filling Sheet transfer Leasing time Combing time Cleaning of comb Crawl speed

Seconds

00

25 10 09 08 38 06 04 2 02

00 45 55 02 00 32 12 00 46

Total time Beam no. 1 Starting Time = 09:45 am Machine stops 1 2 3

= 112.2 min

Causes Yarn breakage Yarn breakage Yarn breakage

Downtime Minutes 2 0 1 Seconds 45 10 10

Beam finished = 10:05 am Total time consumed = 40 min Down time = 4.08 min Beam no. 2 Downtime for beam change = 2 min Starting time = 10:07 Machine stops Causes Downtime Minutes Seconds 64

1 2 3

Yarn breakage Yarn breakage Yarn breakage

0 1 0

28 10 30

Beam finished Total time consumed Down time Beam no. 3 Downtime for beam change Starting time Machine stops 1 Beam finished Total time consumed Down time Beam no. 4 Downtime for beam change Starting time Speed of the machine Beam finished Beam no. 5 Downtime for beam change Starting time Speed of the machine Length of beam Beam finished New Set Count of yarn Quality Beam length No. of ends per beam Machine speed

= 10:42 a.m = 35 min = 2.13 min

= 2 min = 10:44 Causes Yarn breakage = 11:08 am = 24 min = 1.81 min Downtime Minutes 1 Seconds 49

= 3 min = 11:11 = 80 m/min = 11:35

= 2.83 min = 11:38 = 80 m/min = 2400 mm = 12:08

= 21/1 =21 16 / 122 60 ~ 63 = 1850 mm = 7686 = 80 m/min 65

Set length No. of weavers beams New Creel Loading: Operation

= 11000 m =4

Time consumed Minutes Seconds 00 00 45 09 02 00 35 55 00 46

Warp sheet cutting from size box Cleaning & Washing of size box Washing Sheet knotting Size box filling Sheet transfer Leasing time Combing time Cleaning of comb Crawl speed Total time Beam no. 1 Starting time Finishing time No breakage Beam no. 2 Time for beam change Starting time Down time due to breakages End time Beam no. 3 Time for beam change Starting time End time Beam no. 4 Time for beam change Starting time = 2 min = 04:37 = 3 min = 04:00 = 04:35 = 2 min = 03:24 = 7 min = 03:57 = 02:48 = 03:22

5 25 10 10 08 38 06 04 2 02 = 114.18 min

66

Down time due to breakages End time Downtime for 8 Hours Total production time span Total down time for set change

= 4 min = 05:17

= 452 min = 2+2+3+2:50+2+3+2 = 16.83 min

Total down time due to breakages Total down time for creel change Total down time in 8 hours Total Productive Time

= 19.23 min = 114.18 min = Approx. 150 min = 452 150 = 302 min 100 150 100 452

= . % The OEE of the Sizing Department As OEE = Availability Performance Quality Now, = 100 302 = 100 452 = . % Now, = 100 75 = 100 95 = . % Now, = 100 9 = 100 9 = % 67

Now, the OEE of the Warping Machine OEE = Availability Performance Quality OEE = 66.8 79.1 100 OEE = 52.8%

4.3. Weaving Shed

The major types of stoppages that occur in the weaving shed are as follows: 1. Knotting 2. Article change 3. Warp stops 4. Weft stops 5. Maintenance problems

4.3.1. Knotting Stoppages

It is the process in which new warp sheet is knotted with the previous finished warp sheet on loom provided the quality is same. In knotting following steps are done: 1. Finished warp beam unloading from loom 2. New beam loading on loom 3. Brushing of the older warp sheet 4. Adjustment of the knotting stand 5. New warp sheet brushing 6. Warp sheet knotting 7. Removal of temple 8. Slow speed running of machine 9. Adjustment of temple 10. Knotting of broken ends

Knotting Stoppages Beam loading and unloading time No. of Beams Loom width (cm) Beam loading and unloading Minutes Seconds 68

1 2 3

170 170 170 Average Time

2 3 3 3.2 min

36 27 25

Brushing of the older warp sheet No. of Obs. 1 2 3 Quality 16 12 63" 108 50 16 12 63" 110 50 16 12 63" 108 60 Total ends 6804 6930 6840 Loom width 170 170 170 Time taken to brush Minutes 2 3 2 2.9 min Seconds 17 52 37

Average Time Adjustment of the knotting stand No. of beams 1 2 3 Loom width (cm) 170 170 170 Average Time New warp sheet brushing No. of Obs. 1 2 3 Quality 16 12 63" 108 50 16 12 63" 110 54 16 12 63" 108 60 Total ends 6804 6930 6804 Loom width 170 170 170 Minutes 2 2 3

Time consumed Seconds 40 51 26 3.0 min

Time taken to brush Minutes 03 8 07 6.3 min Seconds 01 48 43

Average Time Warp sheet knotting time No. of Quality Total Loom

Time taken to brush 69

Obs. 1 2 3 16 12 63" 108 50 16 12 63" 110 54 16 12 63" 108 60

ends 6804 6930 6804

width 170 170 170

Minutes 22 31 30 28.1 min

Seconds 18 38 24

Average Time Removal of temple No. of beams 1 2 3 Loom width (cm) 170 170 170 Average Time Adjustment of temple No. of beams 1 2 3 Loom width (cm) 170 170 170 Average Time Minutes 1 1 1 Minutes 0 1 1

Time consumed Seconds 58 12 08 1.1 min

Time consumed Seconds 10 03 17 1.2 min

Knotting of broken ends No. of Obs. 1 2 3 Quality 16 12 63" 108 50 16 12 63" 110 54 16 12 63" 108 60 Average Time Total ends 6804 6930 6804 Loom width 170 170 170 Minutes 5 6 7 6.3 min 70 Time Seconds 22 32 02

The average time taken to knot 6804 6930 ends is 52.1 min.

4.3.2. Article Change Stoppages

It is done when quality of the fabric to be produced is changed. Article change setting Cam settings Heald frame settings Back rest assembly Easing motion setting Dropper box setting Nozzle settings Selvedge setting Machine speed setting Panel setting Time consumed during article change setting Job done Warp sheet cutting Removal of warp sheet Heald wires and droppers Removal of old beam Dismounting of droppers Dismounting of frames Dismounting of front support Dismounting of reed Dismounting of temple Cam dismounting Cam settings Cam mounting Width adjustment Mounting of reed Nozzle setting Temple Time consumed 30 sec 8 sec 2 min 3 min 2 min 2 min 1 min 5 min 1 min 7 min 8 min 6 min 15 min 5 min 5 min 2 min

71

Guide bar Mounting of frames Droppers Frame height adjustment Shed angle adjustment Back rest setting Dropper box setting Leno adjustment Motor pulley change Cleaning Front support setting Panel setting Mending warp yarn Fine adjustment The
16 12 110 54

3 min 2 min 2 min 2 min 2 min 10 min 4 min 2 min 10 min 4 min 1 min 2 min According to quality 10 min change the article of construction

time

taken

to

63" is 120.6 min (2 hr 38 sec).

4.3.3. Warp Stoppages

When warp breakage occurs on the machine, it is indicated by a red light alert on the loom. The time required to mend a warp stop depends upon Length of faulty yarn Labor skill Number of broken ends Distance covered by the worker to reach the stop Interference time Time taken to repair warp breakage No. of observations 1 2 Time consumed Minutes 1 1 Seconds 20 28

72

3 4 5 6 7 8 9 10

1 1 1 1 2 1 0 0

00 48 30 42 08 35 55 58

Average time to repair warp = 1.4 min

4.3.4. Weft Stoppages

These are the stoppages on the loom due to weft yarn breakage also called filling stoppages. Weft stops are indicated by green light on the loom. The time required to mend a weft stop depends on Skill of the labor Position of the worker at the time of weft stop Interference time Time consumed to repair the weft stop No. of observations 1 2 3 4 5 6 Time consumed Minutes 0 0 1 0 0 1 Seconds 47 45 00 55 24 06

73

7 8 9 10

0 0 0 0

12 30 37 41

Average time consumed = 42 seconds

4.4. Calculation of down time for different qualities and loom efficiency
Machine specification Looms Model Manufacturing TSUDAKOMA ZAX- E 2003

All the work has been done on the machines and quality specifications. All the data entered in this table is for 24 hours of production. Quality Weave
3010 146 70

63

3/1 S Twill

1) Loom No. 27 Loom Speed = 912 rpm Type of stoppage Filling stops Warp stops Total Down time Total time Productive Time 2) Loom No. 57 Loom speed = 850 rpm Type of stoppage Filling stops No. of stops 75 Downtime (min) 52.5 No. of stops 47 29 76 = 73.5 min = 1440 min = 1366.5 min Downtime (min) 32.9 40.6 73.5

74

Warp stops Total Down time Total time Productive Time 3) Loom No. 61 Loom speed = 890 rpm Type of stoppage Filling stops Warp stops Total Down time Total time Productive Time 4) Loom No. 81 Loom Speed = 910 rpm

19 94 = 79.15 min = 1440 min = 1360 min

26.6 79.15

No. of stops 82 60 142 = 141.4 min = 1440 min = 1298.6 min

Downtime (min) 57.4 84 141.4

Type of stoppage Filling stops Warp stops Other stops (knotting) Total Down time Total time Productive Time 5) Loom No. 82 Loom Speed = 910 rpm Type of stoppage Filling stops Warp stops Other stops Total Down time Total time

No. of stops 38 43 1 82 = 139 min = 1440 min = 1301 min

Downtime (min) 26.6 60.2 52.2 139

No. of stops 29 22 1 52 = 96 min = 1440 min

Downtime (min) 20.2 30.8 45 96

75

Productive Time 6) Loom No. 83 Loom Speed = 880 rpm Type of stoppage Filling stops Warp stops Other stops Total Down time Total time Productive Time 7) Loom No. 84 Loom Speed = 900 rpm Type of stoppage Filling stops Warp stops Total Down time Total time Productive Time Now,

= 1344 min

No. of stops 42 45 1 88 = 133.4 min = 1440 min = 1306.6 min

Downtime (min) 29.4 63 41 133.4

No. of stops 48 12 60 = 54.4 min = 1440 min = 1385.6 min

Downtime (min) 33.6 16.8 54.4

Total Downtime for all These 7 Looms = 716.85 min Average Downtime per Loom Total Operating Time per Loom = 102.4 min = 1440 min

100 102.4 = 100 1440

= . % Now, the OEE of These Looms As OEE = Availability Performance Quality Now, = 100

76

1337.6 100 1440

= . % Now, = 100 893.14 = 100 912 = . % Now, = () 100 () 2957 100 3029

= . % Now, the OEE of the Warping Machine OEE = Availability Performance Quality OEE = 92.8 97.93 97.6 OEE = 88.6% No. of weft stoppages/loom/hour = 1.95 No. of warp stoppages/loom/hour = 1.20

77

CHAPTER 5

MAINTENANCE

As for the Tsudakoma air jet loom, all the details of the periodical maintenance work done in this project are described here below. Defective Part Main Nozzle Bolt Pipe Grease Pipe Bearing Loose Type of Defect Loosing Damage Leakage Damage Loosing Damaged 5mm LKT bolt 3Vx360 Belt Take up Belt Gear Bearing Air Switch 4 way Air Pipe Emery Spring Grease Nipple Easing Shaft Bolt Head Slip Joint cut Damage teeth Teeth Slip Play Leakage Pipe Leakage Slip Long tension Nipple Block Play

Serial No.

Area/Location Analyze main nozzle Easing arm bolt Tuck in Air Pipe Load Cell holder Spherical Bearing Emery Roller Take up Gear Box Main Motor Belt Take up Leno R/S Leno L/S Air Switch Sub Nozzle Friction Roller Press Roller Harness Lever Back Rest

Action done Adjustment of main nozzle Changing of Bolt Changing of Pipe Changing of Pipe Adjustment of Bearing Changing of emery Roll Changing of Bolt Changing of belt Belt life completed Gear Change Bearing changed Change Pipe Changed Emery roll changed Spring Changed Nipple changed Change Shaft

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Some pictures of the maintenance work are given here under:

78

79

80

81

82

83

84

85

86

CHAPTER 6
6.1. Calculations

ENERGY ANALYSIS

Here is detailed description of total connected load of the weaving shed. Serial No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Description Main Motor Main Motor Accumulator 200/AC Leveling Motor Lubrication motor 24 V.D.C. WBS Motor 5.4 VDC ELO Motor Take Up Motor Batcher Motor Kilowatt 3.7 7.5 0.15 0.988 10 W 8.1 W 0.41 0.41 0.746 Quantity 110 20 342 106 106 210 130 28 20 Total Kilowatt 407 150 51.3 104.72 1.06 1.7 53.3 11.48 14.92

Total Motive Load = 795 KW Lighting Load = 53 KW Total Connected Load = 848 KW In the weaving shed the tube lights are installed at a height of 4 meters from the roof. This height is not useful for anyone. If we use 2 tube lights per loom and 130 looms per shed for lamination then we can save 50% of our electricity in lighting section without decreasing our efficiency and production. Total number of tube lights in shed = 1060 Power Consumed/tube light = 50 (40+10) watt Total Power Consumed by Lights = 53 KW/Hour Units consumed in one month = 53 x 24 x 30 = 38160 KWH If we use 2 tubes light per loom then: Lights per loom = 2 Total lights on loom = 130 x 2 = 260 Extra Lights = 200 Total lights = 460 Power used= 460 x (40 + 10) 87

= 23000 watts = 23 KW Units consumed in one month = 203 x 24 x 30 = 16560 KWH Power saved = 38160 16560 = 21600 KWH Per unit cost = Rs. 7.48 / KWH Cost saved = 21600 x 7.48 = Rs. 161,568 / Month = Rs. 1,938,816 / Year

6.2. Florescent light vs. LED Light

Now we can see by the comparison that LED lights are best suitable for the energy saving. They have a high initial cost but very low operating cost. Electronic ballasts can also be used instead of classical ballasts. Lets compare these two Florescent Light Power consumed per unit = 40 + 10 = 50 watts Total power consumed = 1060 x 50 = 53000 watts = 53 KW = 38160 KWH (per month) Energy Saver Light Power consumed per unit = 34 watts Total power consumed = 34 x 1060 = 36040 watts = 36.04 KW = 25948 KWH (per month) Power saved = 38160 25948 = 12211.2 KWH Per unit cost Cost saved = Rs. 7.48 = 12211.2 x 7.48 = Rs. 91339 (per month) = Rs. 1,096,077 (per year) 88

CHAPTER 7 AIR CONSUMPTION ANALYSIS

Firstly, we have studied about two looms i.e. A & B having same sorts but running with different settings.

Loom A
Model: Tsudakoma ZAX9100 Professional Loom Speed: 960 RPM Sort Particular:
1414 8048

67" (2/1 S-Twill)

Insertion Start Timing: 90o Arrival Set: 250o ON Pin Main Aux. Main Cutting Relay Nozzle Timing (O) Loom A Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. ON 80 84 96 100 106 112 120 126 132 138 146 152 158 164 OFF 156 162 168 176 180 186 194 200 206 212 220 223 232 240 Difference 76 76 74 74 74 74 70 74 74 74 74 71 74 76 89 68o 78o 78o 350o OFF 260o 190o 180o 34o

15.

172

246

74

Air Consumption = 41.5 44 CFM Loom B Model: Tsudakoma ZAX9100 Professional Loom Speed: 720 RPM Sort Particular:
1414 8048

67" (2/1 S-Twill)

Insertion Start Timing: 88o Arrival Set: 250o ON Pin Main Aux. Main Cutting Relay Nozzle Timing (O) Loom B Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. ON 82 88 94 100 106 112 120 126 132 138 146 152 158 164 172 OFF 152 158 164 170 176 182 190 196 202 208 216 222 228 234 242 Difference 70 70 70 70 70 70 70 70 70 70 70 70 70 70 70 72o 82o 82o 350o OFF 260o 192o 182o 34o

90

Air Consumption = 40 43 CFM Though the qualities on the looms are same, due to different settings, the requirement of compressed air on these looms showed difference. Now we observed C and D. the particulars are: 10 10 + 70 67" (3/1 ) 68 42 Loom Speed: 950 RPM Loom C Insertion Timing Arrival Set 86 240 Loom D 88 238

Loom C ON Pin Main Aux. Main Cutting 72 82 82 350 OFF 260 192 182 34 ON 72 82 82 350

Loom D OFF 260 190 180 34

On loom C we changed the opening timing of relay nozzle and following observation were made: When relay nozzle opens at 82o and closes at 282o, the air consumption is 52.5 54 CFM. When relay nozzle opens at 86o and closes at 282o, the air consumption is 49 49.5 CFM. On loom D, we changed insertion and arrival timings and following observations were made: Serial No. 1. 2. 3. Insertion 78 98 88 Arrival 226 225 238 CFM 47.5 49 52 54 48 49.5

We changed the opening timings for relay nozzles and following observations were made:

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Serial No. 1. 2.

Opening 84 86

Closing 278 276

CFM 50 51.5 49.5 50.5

Nozzle angle for first 7 relay nozzles by relay nozzle angle gauge and following observations were made: Firstly angle was made to 7o Nozzle angle Arrival Set Pressure (Kg/cm2 or bar) C2 253 248 264 2.2 2.2 3.4 49.5 51 M1 M2 S

Pick Arrival Time C1 Average 251 248 260

CFM

7o

238o

Earlier Later

More filling stops were observed here. Now the nozzle angle was changed to 0o. Nozzle angle Arrival Set Pressure (Kg/cm2 or bar) C2 237 236 240 1.8 1.8 2.8 48 49.5 M1 M2 S

Pick Arrival Time C1 Average 238 234 242

CFM

0o

238o

Earlier Later

Excessive filling stops were observed here. Then with some increase in pressure, Nozzle angle Arrival Set Pressure (Kg/cm2 or bar) C2 244 240 248 1.9 2.1 3.2 51.5 53.5 M1 M2 S

Pick Arrival Time C1 Average 244 240 248

CFM

238

Earlier Later

Here also filling stops were more.

92

c) Now the angle was changed to 2o which was at start of changing the nozzle angle. Nozzle angle Arrival Set Pressure (Kg/cm2 or bar) C2 242 240 246 2.0 2.1 3.2 51.5 53 M1 M2 S

Pick Arrival Time C1 Average 241 240 244

CFM

2o

238o

Earlier Later

At relay nozzle angle of 7o, though pressure was less but it gave the moderate filling stops. At relay nozzle angle of 0o, compared to above the pressure required was less but it gave excessive filling stops. Even by increasing pressure the filling stops were unavoidable. At relay nozzle angle of 2 o, though more pressure was required but the loom performance was good. The opening and closing timing of each individual relay was changed. Relay nozzle timing (o) Loom D Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. ON 86 92 98 104 112 118 124 130 136 142 148 156 162 168 OFF 144 146 154 160 168 174 180 186 192 198 204 212 218 224 Difference 58 54 56 56 56 56 56 56 56 56 56 56 56 56 93

15.

174

230

56

By these relay nozzle valve settings we have succeeded in reducing the air consumption up to 44.5 46.5 CFM with a good running of machine.

Loom E
Quality Particulars 50. 36 + 40 . 70" 196 120 Loom Speed = 928 RPM Insertion Start Timing = 84o Arrival Set = 234o ON Pin Main Aux. Main Cutting 70
o

OFF 260o 188o 178o 34o

78o 78o 350o

Now this time the setting of relay nozzle of loom E were changed and following observations were made. Relay Nozzle Timing on Loom E (o) Mill Setting Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. ON 72 78 84 90 96 102 108 114 120 126 132 138 OFF 146 150 156 164 168 174 180 186 192 198 204 210 Difference 72 72 72 74 72 72 72 72 72 72 72 72

94

13. 14. 15. 16.

144 152 158 164

216 224 230 236

72 72 72 72

By these timings, pick arrival time was found. Pick Arrival Timings Average C1 C2 233 233 Earlier 230 232 Latest 236 238

Here air consumption was 64.6 66 CFM. There was some leakage in the pre-winder knob. After removing that leakage i.e. by replacing it, the air consumption was reduced to 63 64.5 CFM. Then the relay nozzles setting were changed. Our Setting Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. ON 80 84 90 96 102 108 114 120 126 132 138 144 150 158 164 OFF 144 148 154 160 166 172 178 184 190 196 202 208 214 222 228 Difference 64 64 64 64 64 64 64 64 64 64 64 64 64 64 64

95

16.

170

234

64

By our setting following was the observation. Pick Arrival Timings Average C1 C2 233 233 Earlier 230 232 Latest 236 238 Pressure (Kg/cm2 or bar) M1 2.8 M2 2.8 S 3.8

Air Consumption = 57 58.5 CFM Running of Loom E with Mill and Our Settings Mill Setting (Shift 1) Efficiency Time Loom Speed Fillings Breaks Downtime Total Break Downtime Stop Analysis H1 H2 Droppers Other C1 17 2 23 86.1% 7hr 55min 928 RPM 24 19.4 min 49 65.8 min C2 5 C1 10 1 17 3 Our Setting (Shift 2) 92.4% 8 hrs 924 RPM 20 14.1 43 41 min C2 7 2

Loom F
Quality Particulars 50. 36 + 40 . 70" 196 120 Loom Speed = 917 RPM Insertion Start Timing = 86o Arrival Set = 240o ON Pin Main 72o 82o OFF 260o 188o

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Aux. Main Cutting Relay Nozzle Timing on Loom E (o)

82o 350o

178o 34o

Mill Setting Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. ON 80 80 86 92 98 104 110 116 122 128 134 140 146 152 158 164 OFF 144 150 156 162 168 174 180 186 192 198 204 210 216 222 228 234 Difference 64 70 70 70 70 70 70 70 70 70 70 70 70 70 70 70 Pressure (Kg/cm2 or bar) Latest 244 244 M1 3.4 M2 3.0 S 4.8

Pick Arrival Timings Average C1 C2 242 239 Earlier 238 236

Air Consumption = 75.5 77.5 CFM Now some pressure was reduced, Pick Arrival Timings Average C1 244 Earlier 240 Latest 248 Pressure (Kg/cm2 or bar) M1 2.9 M2 2.8 S 4.0 97

C2

245

240

248

Air Consumption = 72 73.5 CFM Now relay nozzle valve timings are changed. Our Setting Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. ON 88 88 94 100 106 112 118 124 130 136 142 148 154 160 166 172 OFF 138 144 150 156 162 168 174 180 186 192 198 204 210 216 222 228 Difference 50 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 Pressure (Kg/cm2 or bar) Latest 248 240 M1 2.7 M2 2.7 S 4.1

Pick Arrival Timings Average C1 C2 244 245 Earlier 240 240

Air Consumption = 65.5 67.5 CFM

Loom G
Quality Particulars 40 40 90" 130 68 98

Loom Speed = 711 RPM Insertion Start Timing = 84o Arrival Set = 240o ON Pin Main Aux. Main Cutting Relay nozzle timings by mill, Mill Setting Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. ON 78 78 84 92 98 104 112 118 124 130 138 144 150 158 164 170 176 184 190 196 204 OFF 146 150 156 164 168 174 180 186 192 198 204 210 216 224 230 236 242 248 254 260 264 Difference 68 72 72 72 70 70 68 68 68 68 60 60 60 60 60 60 60 64 64 64 60 99 66o 78o 78o 350o OFF 260o 188o 178o 34o

22. On these settings,

210

268

58

Pick Arrival Timings Average C1 C2 246 246 Earlier 244 242 Latest 252 252

Pressure (Kg/cm2 or bar) M1 2.4 M2 2.4 S 3.6

Air consumption = 60.5 62.5 CFM Following are the settings changed by us, Insertion Start = 76o Arrival Set = 236o ON Pin Main Aux. Main Cutting Relay nozzle timing Our Setting Valve No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. ON 74 76 80 86 92 100 106 112 120 126 132 140 146 OFF 132 132 136 142 148 156 162 168 176 182 188 196 202 Difference 58 56 56 56 56 56 56 56 56 56 56 56 56 58o 70o 70o 350o OFF 260o 160o 170o 34o

100

14. 15. 16. 17. 18. 19. 20. 21. 22. On these settings,

152 160 166 172 180 186 192 198 206

208 216 222 228 236 244 252 258 266

56 56 56 56 56 58 60 60 60 Pressure (Kg/cm2 or bar)

Pick Arrival Timings Average C1 C2 240 241 Earlier 234 238 Latest 244 246

M1 2.3

M2 2.3

S 2.9

Air Consumption = 50 51 CFM Running of Loom with Mill and Our Setting Mill Setting (Shift 1) Efficiency Time Loom Speed Fillings Breaks Warp Breaks Total Break Stop Analysis H1 H2 C1 16 92.6% 8hrs 711 RPM 27 7 40 C2 9 2 C1 10 Our Setting (Shift 2) 93.2% 8 hrs 711 RPM 22 5 30 C2 7 3

Firstly, we changed the settings like relay nozzle timings, angle, opening and closing of different valves, insertion and arrival etc. and got some reduction in the consumption of compressed air. Then we decided to do all the settings on single loom and observed that, there is a significant reduction in the consumption of air.

7.2. Factors Affecting Amount of Air Consumption

Opening time of relay and main nozzles Air pressure at relay and main nozzles 101

 Power fluctuation Coils on pre-winder Nozzle height and angle Waste present of reed support Filter cleaning

7.3. Effect of Costing

Compressed air required for the air jet weaving machine is the major cost element in the fabric costing i.e. about 40%. And by this compressed air we can profits of our company by saving units of electricity. Because of this fabric conversion cost is also reduced. We have saved about 11CFM of air in air losses study. So, its cost calculation is as: Saving = 11 CFM = 18.6 m3/hr Power Consumption = .0975KWH/m3/h 1 KWH = Rs. 7.48 Therefore, power consumption per 18.6 m3/hr = 1.81 KWH Cost of 1.81 KWH = Rs. 13.53 Savings = Rs. 13.53/hr/Loom = Rs. 324.72/day/loom = Rs. 9741.6/month/loom = Rs. 116899.2/year/loom = Rs. 1,402,790.4/year/120 looms Earning of about 1.4 million per year for a shed of 120 looms by saving just 11 CFM is possible. This gives an additional turnover of about 1.4 million to a company without investing any money. This was big hidden loss in our project. In addition to these observations, there are other ways to reduce the consumption of compressed air. One source of air consumption other than loom is the cleaning pipe. The normal cleaning pipe has nozzle opening of 9 mm dia. The air consumption through a hole of greater size is more as compared to the small hole. So if we reduce the diameter of the nozzle to 3 mm, the consumption of air will definitely be reduced. Although, the amount of air consumption will be reduced but the time of cleaning will also increase. But this increase in time will be negligible. The speed of the air passing through the hole will be increased as the diameter of the hole of the nozzle decrease.

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Moreover, the air consumption can also be reduced by fixing a control valve on the nozzle opening of the pipe. As without valve the worker does not bother that how much air is being consumed during cleaning. As the nozzle opening is always open a considerable amount of the air is wasted during cleaning when the pipe is not in use such as worker taking the pipe away from the source of air to the cleaning point. The wastage of the air will be increased as the distance between the air source and the cleaning point is increased. Sometimes, worker bends the pipe to block the air passage through the pipe. But this action can damage the pipe thus creating the cost of the new pipe. So if careful practice is done this source of air wastage can be reduced by just fixing the spring loaded air control valve to the nozzle opening and a lot of money can be saved in this way.

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CHAPTER 8
8.1. Time Analysis

RESULTS

The percentage downtime of warping = 54.55% Availability = 45.5% Performance = 94.4% Quality = 100% The OEE of Warping = 42.9% The percentage downtime of Sizing = 33.2% Availability = 66.8% Performance = 79.1% Quality = 100% The OEE of Warping = 52.8% The percentage downtime of Looms = 7.1% The OEE of Looms = 88.6%

8.2. Maintenance
Different parts of looms were inspected when identifying the losses. There were several parts that were damaged and could be the cause of big problem further.

8.3. Energy Analysis

During the energy analysis, the focus was on lighting in the shed. By replacing the shed lights with the more energy efficient lights Rs. 1,096,077 per year. And by reducing the shed lights as recommended in the experimental work the cost can be saved as Rs. 1,938,816 per year.

8.4. Air Consumption

During the study of air consumption, we calculated that total cost can be saved as up to Rs. 1,402,790.4 per year by saving just 11CFM of air per loom. Overall cost that can be saved by implementing good practices is Rs. 2,498,867 per year.

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CHAPTER 9
9.1. OEE of Warping

CONCLUSION

As the percentage downtime in the warping department is 54.5%, it is very big value. When OEE of the warping machine is compared with the world class OEE, we come to know the availability of the warping machine which is 45.5% where as world class availability value is 90%. The reason for this lower value may be due to breakdown, due to change over time, warm up adjustments, unplanned maintenance. So, to avoid this lower value of availability some good practices are required to cope with this availability value. For this, we will have to consider upon the downtime losses such as breakdown, quality of the raw materials that causes the machine to stop again and again.

9.2. OEE of Sizing

As the percentage downtime in the sizing department is 33.2% it is also a big value. However it is less than 50% of the total time consumed. When OEE of the sizing machine is compared with the world class OEE, we come to know the availability of the warping machine which is 66.8% where as world class availability value is 90% and performance is compared with the world class performance that is 95%, the value for availability and performance are very low. By comparing the values of availability and performance, we come to know that these lower values may be due to breakdown, setup and adjustment losses, warm up adjustments, reduced speed operation and small stoppages. So, to avoid this lower value of availability and performance some good practices are required to cope with this. For this, we will have to consider upon the downtime losses such as breakdown, quality of the raw materials that causes the machine to stop again and again and causing it to run on reduced speed.

9.3. OEE of Shed

As the percentage downtime in the shed is only 7.1%. It is means that this process is going well. Although the OEE of the shed is 88.6%, but the quality rate, 97.5% in the shed is less than the world class OEE which is 99.9%. This has a smaller difference and can be improved by just decreasing the startup rejects and production reject rejects which may cause scrap and rework problems. If we take the average of the these OEEs of differ department the overall OEE of the mill will be 61.4%, which is less than the world class OEE and considered as average. However, we can improve this overall OEE, by taking careful and good step to improve OEE of the warping and sizing machine. 105

9.4. Energy and Air Losses

During the study of air consumption, total cost can be saved as up to Rs. 1,402,790.4 per year. Overall cost that can be saved by implementing good practices is Rs. 2,498,867 per year.

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CHAPTER 10

SUGGESTION

10.1. Suggestion for Warping

In warping the main causes of downtime are 1. Yarn breakages 2. Yarn entanglement 3. Operator efficiency 4. Maintenance problems 5. Operator efficiency Yarn Breakages In warping the main reason of down time is yarn breakages. If the yarn breakages are low then the warping efficiency will be higher. In order to reduce the yarn breakages, yarn of greater strength and less number of faults should be used. The environmental conditions also have a great influence on the yarn breakages. The humidity in the atmosphere also affects the strength of the yarn and depends upon the type of the fibers from which the yarn is made. To reduce the yarn breakages appropriate tension should be given to the yarn in warping, as tension is directly proportional to the yarn breakages. So the tension in the creel section should be appropriate. Yarn Entanglement Yarn entanglement occurs because of the improper sensor filling, improper comb filling, faulty cones or machine running at higher speed. Also the loosely yarn wound on cones causes yarn entanglement. When such cone is unwound by high speed unwinding, many circles of yarn come out thus causing entanglement with the neighboring yarn and many yarn are broken. So to reduce these factors the cones should be handled by an experienced worker and cone winding should be proper. Operator Efficiency The time taken to mend a stop depends on the operator efficiency. An active operator will mend the breakage in short time and vice versa. So to reduce the down time an experienced, active and skilled worker is preferred. Maintenance Sudden breakdown of any machine component is an undesired one and causes an increase in the down time percentage, which can be eliminated by proper preventive maintenance. Machine Speed The greater the speed of the machine the greater will be production and lesser will be down time and vice versa. Also the higher machine speed causes more breakages so the machine should be run at optimum speed. 107

10.2. Suggestion for Sizing

The main factors on which the OEE depends in sizing depends are 1. 2. 3. 4. 5. Yarn strength Cleaning and maintenance Sticky yarn Viscosity of the size solution Worker skill

Yarn Strength The strength of the yarn should be higher so as to bear the tension to which it is subjected in sizing. Moreover high tension is given to the yarn in warping section so that the thin and weak places may reduce to reduce the downtime in sizing. Cleaning and Maintenance The cleaning and maintenance of the sizing machine should be proper and scheduled. The hood of the cylinders should be kept clean because the rust and fluff may fall on the warp sheet which may cause the yarn breakage on the machine. Preventive maintenance should be conducted to reduce unexpected breakdown of machine malfunctions because much time is wasted if machine failure occur. Sticky Yarns Leasing should be proper so that the ends separate from each other or they may cause stoppages in the subsequent process. Workers Efficiency and Skills The worker should be skilled and efficient to deal the breakages. Worker should not be authorized to the duty beyond the shift because it is natural that worker tires after the respective shift time which badly affects the worker efficiency and hence the machine efficiency. Viscosity of the Size Solution Viscosity of the size solution also influences the downtime. The less viscous will be the size solution more will be the warp sheet dipping time to achieve the desired size pick up and size absorption and hence less will be the machine speed and vice versa.

10.3. Suggestion for Shed

OEE in the shed can be affected by: 1. High tension warping 2. Reduction of downtime in knotting 3. Reduction of downtime in article change 4. Reduction of warp breakages 108

5. Reduction of weft stops 6. Proper machine maintenance and cleaning 7. Labor skill and machine interference High tension in warp sheet Warp sheet should be done with increased necessary tension so that maximum defects in warp should be removed because greater the tension will be greater will be the yarn breakages. This is beneficial to the subsequent processes especially for fabric manufacturing on the loom yet it will also decrease the warping efficiency. The shed efficiency has a greater effect on the overall process efficiency as compared to warping and sizing. In other words greater the breakages will be in the warping lesser will be the breakages on the loom. Reduction of downtime in knotting The knotting time can be reduced by using automatic knotting devices like automatic knotters and splicers. These knotters have speed of 450 knots / min with an efficiency of 99.8 % as compared to manual knotting which has less efficiency. Also the brushing of the warp sheet should be proper to reduce breakages on the start attempt of the loom. Reduction of downtime in article change The downtime due to article change is about two and a half hour. The downtime in warping is reduced to 25 minutes by picanol omni plus in which the loom is divided into two halves and on the article change the whole back part containing weaver beam, back rest assembly, droppers and healed frame etc is replaced by the new one. The downtime can also be reduced by introducing another tool box on the cam box side because in cam box setting the worker has to move to the picking side of the loom and then bring the tools to the cam box side for cam settings. The distance covered by the worker depends upon the loom width, greater the width will be greater will be the distance and more will be the downtime. Reduction of warp breakages The warp breakages should be reduced in order to improve the loom efficiency. It can be reduced by proper warping and sizing, proper settings of warp tension assembly, proper cleaning and maintenance. Reduction of weft stops The weft stops can be reduced by using strong yarn, proper tension arrangement and accumulator, proper pressure of main nozzle and sub nozzles and removal of dust and fluff on weft sensors, proper setting of weft cutters and weft brake system and proper cleaning and maintenance. Proper machine maintenance and cleaning The cleaning and maintenance of the looms should be proper and scheduled. The oiling and greasing of the parts should be done properly 109

and the cam box oil filter and oil change system should be properly planned to reduce breakdowns. Also the air blow system should work properly because the fluff and dust fall on the sensors, reed dents, heald wire eye and the warp sheet etc thus causing breakages. Preventive maintenance should be conducted to reduce unexpected breakdown of machine malfunctions because much time is wasted if machine failure occur. Labor skill and interference time The labor should be skilled and active so as to deal the stop as quickly as possible. Interference refers to the time for which the machine or loom is waiting for the operators attention when he is busy in attending another machine. Greater the interference time will be greater will be the downtime. In case, a warp stop occurs on one loom and at the same time a weft stop comes on the nearby loom, the operator is supposed to deal the weft stop first and then the warp stop. Because the warp stop consumes more time (1min and 20sec) to mend it as compared to the weft which takes about 45 seconds to mend it. Moreover the worker should attend the machine from the picking side in case of weft stop so as to see whether the filling stop is due to accumulator and tension guide or not and then proceeds further.

10.4. Energy and Air Losses

There was much energy wasted in the shed due to lighting, this energy can be saved by replacing the tube lights with the electronic chock energy savers. Similarly, air consumption can be optimized by doing good practices, up to 18%, by making the shortest possible blowing time of the nozzles and optimizing these settings by trial and error method without affecting the performance of loom and quality of fabric.

110