Manufacturing Excellence in Spinning Mills 1st Edition by A Kanthimathinathan ISBN 9781032191003 1032191007

1 Quality and Process Management in a Spinning Mill

Learning Goals

Introduction

1.1 Spinning Mills-Flow Chart of Operations

1.2 Quality of Incoming Raw Material (Cotton)

Moisture Content

Trash Content

Length, Fineness, and Strength Characteristics

ICC Mode of Evaluation

1.3 Mixing Quality

FQI &CSP Prediction (as per SITRA)

Prediction of CSP for Carded Counts:

Prediction of CSP for Combed Counts:

1.4 In-Process Quality

1.4.1 Blow Room

Cleaning Efficiency with Trash Separator

Control of Neps in Blow Room

1.4.2 Cards

1.4.3 Pre-Comber Draw Frames and Lap Formers

1.4.4 Combers

1.4.5 Finisher Draw Frames

1.4.6 Speed Frames

1.4.7 Ring Frames

Count and Count CV of Yarn

Twist in Single Yarn and its CV

Yarn Unevenness and Imperfections

Single Yarn Strength/Elongation/Weak Places

Snarling Tendency

1.4.8 Ring Frames With Compact System

1.4.9 Autoconers

1.4.9.1 Electronic Yarn Clearers (EYC) in Autoconers

1.4.10 Yarn Conditioning

1.4.11 Packing

1.4.12 Assembly Winding and Two for One Twister

1.5 Classimat Faults

1.6 Package Defects –end Use Performance

1.7 Process and Quality Audits

1.8 Application of Statistical Techniques in Spinning Mills

Range

Standard Deviation and Variance

Coefficient of Variation

Critical Difference

Example: Fiber Rupture in Blow Room Line

Control Charts

Special/Advanced Statistical Techniques

F Test

Process Capability Estimate Cp

1.9 Quality Control Equipments in a Spinning Mill

1.9.1 Fiber Testing Equipments

Trash Analyser

HVI-High Volume Instrument

1.9.2 In-Process Materials Testing Equipments

AFIS-Advance Fiber Instrument System

Sliver/Yarn Evenness Testers

Yarn Strength Testers

Lea Strength Testers

Single Yarn Strength Testers

1.9.3 Final Yarn Testing Equipments

1.10 Final Lot Inspection of Products

1.11 Key Performance Parameters (Quality) in each department

CS1 Case study on “Higher level of End breaks in 40s Combed Compact Warp yarn”

CS2 Case study on “Higher Unevenness in Finisher Draw frame sliver”

CS3 Case study on “Increase of Clearer cuts in Autoconer in 60s Combed Compact weaving yarn”

CS4 Case study on “Increase in foreign fiber(FD) cuts in Autoconers”

CS5 Case study on “Increase of Yarn Count CV in 40s Combed Hosiery yarn during final lot inspection.”

Annexure I Quality Control Department Organogram for a Spinning Mill with 50000 Spindles

Annexure II Model Quality Control Schedule for Mills Striving for Excellence in Manufacturing

Annexure III Estimation of Contamination Index in Raw Material

Annexure IVA Evolution of Clearers

Annexure IVB Classimat Faults

Annexure V Package Defects

Annexure VI Process Audit format

Annexure VII Quality Audit format

Annexure VIII Final Inspection Lot Report Model Format

2 Maintenance Management in Spinning mills

Learning Goals

Introduction

2.1 Types of Maintenance

2.2 Breakdown Maintenance-First Generation Maintenance

2.3 Planned Maintenance-Second Generation Maintenance

2.3.1 Routine Maintenance

2.3.2 Lubrication

2.3.3 Replacement programme

2.4 Preventive Maintenance

2.5 Systems to enhance Maintenance of Assets/Machinery in Spinning mills

2.5.1 5S System for shop-floor excellence

5S -Explanation

2.5.2 FMEA-Failure Mode Effect Analysis

FMEA process

2.5.3 TPM-Total Productive Maintenance

2.5.3.1 Origin of TPM

2.5.3.2 TPM implementation

2.5.3.3 ZDQC-Zero Defect Quality Control

2.5.3.4 Jidoka

2.6 Predictive Maintenance-Third Generation Maintenance

2.6.1 Smart Predictive Maintenance –SPDM (Third Generation Maintenance Extension)

SPDM Tools in practice in Smart Spinning mills

2.7 Smart Prescriptive Maintenance Framework-SPMF(Fourth generation maintenance)

Key inputs into the system by Muratec in VMS:

Prescriptions:

Case studies on Maintenance Management

CS6 Case study on “Impact of Buffing accuracy on Yarn quality”

CS7 Case study on “Impact of Air leakage on Mis-splicing% in Autoconers“

CS8 Case study on “Process FMEA on Weak places in 80s Combed Compact Warp Yarn“

CS9 Case study on “Impact of 5 S Implementation in a Spinning mill”

CS10 Case study on “Design FMEA in a Spinning mill“

CS11 Case study on “QAD-Maintenance interface“

CS12 Case study on “MTTR-Mean Time To Repair(TPM)”

Annexure IXA Model Check list for effective Machinery Maintenance Audit-Online

Annexure IXB Model Check list for effective Machinery Maintenance Audit- Offline

Annexure X TPM Organogram

Annexure XI TPM Gap Analysis Audit format

3 Production Management in Spinning Mills

Learning Goals

Introduction

3.1 Utilization Efficiency

Factors that should be focused for improving the Utilization of Ring frames are as below:

Controllable factors:

Uncontrollable factors:

Achievable Levels of Utilization in Spinning Mills

3.2 Production Efficiency

3.3 Benchmarking

Example 1

Example 2

Practices to be followed to achieve higher production per spindle:

3.4 Yarn Realization

Breakup of Yarn Realization

3.4.1 Invisible loss

3.4.2 Best Practices To Achieve Higher And Consistent Yarn Realization & Control On Saleable Waste

Settings in Blow Room and Cards

3.4.3 Measures to Achieve Standard Yarn Realization

3.5 Manufacturing of Sustainable Products

3.6 Manufacturing of Value-Added Yarns

3.7 Automation in Spinning Mills

3.7.1 Automation towards Yarn Quality Improvements

3.7.2 Automation toward Production Improvement

3.7.3 Automation toward Improving Labor Productivity

Case Studies on Production Management

CS13 Case study on “Spindle point production improvement in 80s Combed Compact weaving”

CS14 Case study on “Impact of Short stretch in Compact Spinning Ring Frame”

CS15 Case study on “Improvement of Spindle point production with Slim tubes”

CS16 Case study on “Utilization efficiency improvement”

CS17 Case study on “Yarn realization improvement”

Annexure XIIA Model Spin Plan

Annexure XII B Production Formulae Used in Spin Plan

Annexure XIII Model Mill Standard Document for Spindle Point Production in Grams /Spindle/8 Hours

Annexure XIV Model Chart for Estimation of Yarn Realization

Annexure XV Model Chart for Zone-Wise Waste Analysis for Cards

4 Training and Development

Learning Goals

Introduction

4.1 Definition of Training

4.2 Chronology of the Development of T&D

4.3 Scope of Training and Development

4.3.1 Development of Employees by Human Resource Department

4.3.2 Mechanisms for Successful Training and Development System

4.4 Management Development Programme

4.4.1 Objectives of the Management Development Programme

Role of Learning in Management Development

Training Deliverables

Training Techniques

Assessment of Training Needs

4.5 HPT-Human Performance Technology

Five Habits of the Mind to become an Effective Manager

CS18 Case study on “Improvement in Work Assignment in Ring Frame through Re-training”

CS19 Case Study on “Improvement in Work Assignment in Autoconer Department through Retraining”

Annexure XVI Standards for Training Period and Evaluation Measures

5 Energy Management

Learning Goals

Introduction

5.1 Power Consumption in a Spinning Mill

5.2 Power Consumption–Industry Norms for Spinning Mills

5.3 Innovative Projects for Energy Conservation

5.4 Measures to Reduce Energy Consumption in Compressors

5.5 Power Quality-Harmonics

5.5.1 Sources of Harmonics

5.5.2 Effects of Harmonics

5.5.3 Selection of Harmonic Filters

5.6 Energy Audit

5.7 Rewinding of Motors

5.8 Energy Efficient Motors

5.9 Renewable Energy

CS20 Case study on “Incorporation of MD controller”

CS21 Case study on “Energy Savings in AWES-Automatic Waste Evacuation System”

CS22 Case study on “Inverter control for Pneumafil in Ring frame”

Annexure XVII Model chart for Standard power consumption in a Spinning mill with 50400 spindles.

Annexure XVIII Test Procedure for Assessment of Rewound Motors

6 Customer Focus

Learning Goals

Introduction

6.1 Types of Customers of Spinning Mills

6.1.1 Knitters

End-Use Requirements of Grey-Knit Fabricators

End-Use Requirements of Yarn-Dyed Knit Fabricators

6.1.2 Weavers

End-Use Requirements for Grey Fabric Weavers

End-Use Requirements for an Yarn-Dyed Fabric Weaver

6.1.3 Value Addition Customers like Double Yarn/Plied Yarn/Gassed Yarn Manufacturers

6.1.4 Industrial Thread Manufacturers Like Cotton Sewing Threads/Tyre Cord Fabric Manufacturers

6.2 Customer Satisfaction

6.3 Co-Creation

6.4 Taylor-Made Products

CS23 Case studies on: “Customer Service Environment-Take the initiative”

CS24 Case studies on “Customer Service Environment-Customer Service Horror story”

CS25 Case studies on “Customer Service Environment-`Do more than the Competition`”

Warping Breakage Study

Annexure XIX Model Format for Customer Satisfaction Audit

Annexure XX Estimation of Customer Satisfaction Index (CSI)

7 Industry 4.0

Learning Goals

Introduction

7.1 Industry 4.0-What Does It Bring To Us?

7.2 Evolution of the Industry 4.0

7.3 Goals of the Industry 4.0

IoT-Internet of Things

IIoT-Industrial IoT

Additive Manufacturing

IIoT-Technology of Connectivity

Cyber Physical Systems

Application of CPS

Cloud Computing

CharacteristiCSof Cloud Computing

Benefits of Cloud Computing

Big Data

Big Data Analysis Involves:

Big Data-Core Deliverables:

7.4 Smart Manufacturing Spinners

Conclusion

Annexure XXI Smart Manufacturing Spinners (Industry 4.0)—Configuration

Annexure XXII Payback Estimation—Factors To Be Considered for Installation of Individual Spindle Monitoring System

List of Tables

List of Case Studies

List of Annexures

References

Index