Spinning management Textiles Limited.pptx

It is compersion among three big cotton unit 1. Vardhman Textiles ltd, 2 sagar manufactures pvt ltd , Trident ltd

1. Cost management Raw material management Process management Energy management Man power management Quality management Inventory management

2. Raw Materials management Basic steps for Raw material management Cotton arrival Cotton testing Cotton stacking in raw materials godown Cotton selection for mixing laydown Preparation of laydown matrix

3. Raw materials management Cotton arrival :- as Cotton bales are arrived in mills. Mill gives lot no- in Arisht spinning mill- 101sirs20075 1 – godown no 01 – mixing types Sirs – station 20 – year 075- lot no In sagar manufactures pvt ltd M19- 146 M- mixing type 19 – year 146 – lot no

4. Raw materials management Cotton testing  Indian cotton   10% bale are selected randomly for sampling 50 gm samples are taken on all sides of the bale. Samples are kept in lab for 24 hour for conditioning  Two readings per bales are taken in HIV testing  Avg results are to be considered  Import Cotton  100% bale are tested  Grades are also given  Godown management is very very important

5. Raw materials management Cotton bales stacking   Cotton bales stacking should be such types to utilize maximum capacity of godown.  Same station and quality bale should be kept in the same godown.

6. Raw materials management Single Blends Import Cotton Mic Range 0.8 0.6 0.8 Rd 6.0 6.0 6.0 +b 1.0 1.0 0.5 Cotton selection for mixing laydown   Selection HIV Parameter  For Knitting yarn  in Arisht spinning mill For weaving  Length, strength and elongation  For Perfecto yarn in 40CWC principle  = length + strength >61

7. Raw materials management Parameter A+ A A- B+ Mic 3.8-4.5 4.20-4.50 4.5-4.7 +4.7/-3.7 UHML 30.5 29.5-30.5 29-29.5 Less 29 SFI 5.0-5.50 5.50-6.0 6.0-6.5 Above 7.0 STR 32.0 31-32 30-31 Below 30.0 RD 77-78 78-78.5 78.5-79 above 79 +B 8.0-9.0 9.0-9.30 9.3-9.50 Above 9.50 Sagar cotton grading Principle  of mixing in sagar manufacturers pvt ltd Mic cv% Rd cv% +b Knitting/ weaving Less than 5% Less than 5% +/-0.5

8. Raw Materials management Preparation  of laydown  matrix  Size of laydown should not be less than 42 bales.  No of lots in laydown should be allowed more than 50 -70. No of station/ laydown should be minimum 20 lot .( larger will always better) Station change should be replaced with the same station as far as possible.  Station change should not be more than one per week.  Lot change should not be more than 4% on a single day.  Lot change should try to put nearest lots.  Mixing of 3 rd picking and 2 nd picking must be changed gradually.  Mic change from  one laydown to another laydown should be nearly zero.  Range of avg mic in 4 bales in the traverse direction should be less than 0.2. Change in mic from one container to another container should be less than 0.02  Position  of bales will  remain  unchanged  throughout the lots.  Bale conditioning at the blow room must be done for 48 hr.

9. Process management Productivity Utilisation Yarn realization Hard waste B-grade Ukg Soft waste

10. Productivity

11. Productivity Count Arisht( gpss) Sagar ( gpss) Trident ( gpss) 20 CH 352 330 300 24 CH 270 250 240 30 CH 210 198 180 30 CWC 220 225 300 40 CWC 145 150 148 In Arisht, productivity is higher because of we add b grade kg, weight gain by pre & post conditioning and – 0.5 % reconciliation. While in sagar and Trident do not add them. 2. In Sagar and Trident, production are noted in winding deptt while In Arisht, production is noted in ring frame ( due to this productivity may be slightly varied from actual). 3. In sagar , Actual count considers in productivity . R&D deppt checks wrapping iin running count and avg Count is calculated in productivity. 4. In Arisht Compact section productivity are down due to producing perfecto quality yarn.

12. Productivity Parameter Arisht ( ultimo) Sagar (R&D) Trident (R&D) Breakages/100sp/hr 3.0-3.5% 2.5-3.0% 5.0-8.0% Start up bkg/100Sp/doff 1.5-2.5% 1.0-2.0% 4-4.5% Idle % 0.3% Less than 0.05% 1.0 (appox.) Pneumfil % 1.2% 0.8% 3.5% Doff/min 3.0 2.5 5.0 EMT 7 min Not considered Not considered In Arisht, ring data system ( ultimo) are running and In sagar, ring data system is available, but reports are not generated, In Trident, all reports are generated by R&D. In Arisht one person from maintenance department is engaged for ultimo data. He attends idle, sick spindle, slip spindle etc quickly In sagar, one person from maintenance department is engaged to attend red light spindle of ring data system and other person for doffer problems.

13. Utilisation Causes ( major) Arisht Compact std Sagar Compact Std Trident rocos std Count /Lot change 0.30 0.030 0.40 R/tr change 0.20 0.003 0.20 Maint cleaning 0.52 0.021 0.37 Cot change 0.00 0.000 0.13 Service O.20 0.100 0.20 Total 1.22 0.154 1.49 U% 98.78 99.846 98.7

14. Utilisation Count change:- In sag , ar, Count change is very less because range Count are divided in three different unit. Ppc department- try to reduce Count change detention Lot change becomes always done in shift change sothat both shift operators are involveD and saved detention R/tr change- in sagar, ring travellers change activity is done 30 day, it change during maintenance cleaning. Ring travellers are changed by maintenance team. Cot change – cot changes done in maintenance cleaning Maintenance cleaning Count range Unit 20-30s NE Unit -2 30-40s NE Unit-3 24-40 Ne Unit-4 Maint. cleaning Arisht Sagar Trident Schedule 21 day 45 day 30 day Time 2.5 hour 2.0 hour 3 hour

15. Yarn realization Waste type Arisht( s6100%) Sagar std mech100% Trident mech100% Blow room droppings 2.25 1.60 2.20 Card droppings 4.30 3.40 4.35 Flat waste 2.00 1.85 2.20 Contamination Not considered 0.05 Not considered Cotton seed Not considered 0.05 Not considered Micro dust 1.40 1.20 1.30 Comber noil(RM) 17.25 17.25 18.0 Hard waste (RM) 0.45 0.25 1.05 Daffu waste Not considered 0.02 Not considered H plant waste Not considered 0.15 Not considered Ohb waste 0.25 0.23 0.25 Sweeping 0.30 0.05 0.30 Prep.fan waste Not considered 0.25 O.25 Invisible loss 1.00 1.00 1.0 Total 29.6 27.1 31.3

16. How to improve yarn realization Bales should be kept 24 hour in the blow room for conditioning.  Bale cloth and 2or 3 stripes are opened in the blow room. ( Arisht & sagar). Trenches are cleaned in a week & separate sliver and roving waste & reuse in laydown ( only (only Sagar). Maximum Cotton seeds are removed in the blow room by seed trapping machine and Gravity box etc. Cotton seeds are collected separately from droppings waste  and sold in the domestic market. OHB waste is separated into a good sliver & roving & reused in the laydown. Prep. Fan waste to be mixed in noil waste. After Contamination sorting cotton is used in sliver preparatory  in the Arisht In order to less reject lots due to Contamination.  Optimize beater speed and gauge of waste. Optimize noil% as per customer quality requirements 

17. Hard waste Arisht Sagar Trident O.55 0.38 1.05 Reduce winding cut Reduce textile alarm Reduce start up breakages Improve ring frame bobbin quality ( no sick bobbin, no bottom spoil Etc) Optimize loop gate setting in link coner Reducing rewinding and package defects Increasing bobbin content . Reducing repeated cycles Increasing full bobbin rejection efficiency.

18. Hard waste Reducing CBF hard waste, a new cbf program 9cf- p600- 6*v1.132 in murRata 30 cwc Old program New program Gain% Production 70 kg 69 kg CBf HW 0.105 kg 0.036 kg CBF HW% 0.150% 0.052 % 65.33% UNIT HW 0.229 kg 0.226 kg Unit HW% 0.323% 0.327% Total HW% 0.473% 0.379% 8.0%

19. B grade Arisht Sagar Trident 0.07 0.04 0.12 No off count in ring frame No smoking doff In ring frame No materials mix up throughout process Reduce textile alarm Check textile alarm ring frame wise ,speed frame wise and rsb wise Best method, one finished draw frame to be run one speed frame and one speed frame to be run 3 /3.5 ring frame and observe machine wise breakages and alarm. Focus machine cleaning in every stage Strength Prep. Process Parameter by trail. Alarm ring frame bobbin to be cleaned one time and remark line on bobbin by pencil. Second bobbin is remarked double line and sent to b- grade with writing on which type of b- grade ( b5 ,b6,b3,bd,ba etc.) Buffing are done together all finisher draw frame in any one day. Alarm can of Finisher draw frame ( A%,CV%) are run again creel side. In sagar , b grade material run count wise and sell to market (zero compensation)

20. Soft waste Stage Std waste %( sagar) Carding 0.05 Pre draw frame+ lap former 0.60 Comber 0.45 Post draw frame 0.15 Speed frame sliver waste 1.54 Speed frame roving waste 0.02 Roving waste 1.54 Pneumfil waste Less 1 Total 5.35 Soft waste monitoring must be daily basis. It can be reduced by increasing can content and bobbin contents. It can be reduced by card stopping time, length measuring sensor setting. It can be reduced by increasing skill operator. It can be reduced to adjust batch and doff length. In sagar actual soft waste % is added in laydown.

21. Manpower management Stage Arisht Sagar Trident B/R Reiter Truzschler LMW Card C50 TC10 LC363 Pre draw frame Sbd22, SB-2 SBD22 LD2 Lap former E 5/7 E 35 Lap former LMW Comber E 60 E 86 LK54 Post draw frame RSB-1 D 50 LD1 Speed frame LF1400 Electro jet LF1600 Ring frame LR60AXL K47 LR60AXL Winding X 5 Murrata Murrata Auto Packing Techno pack Signode Seiger Machine details in organization wise

22. Manpower management Stage Arisht Sagar Trident B/R 2 2 2 Card 20 30 30 Pre draw frame 4 5 6 Lap former 3 3 4 Comber 18 16 24 Post draw frame 10 8 11 Speed frame 9 of 1200 spdle 8 of 192 spdl6 12 of 132 spdl Ring frame 26 of 960 spdl 21 of 1200 spdle 43 of 1200 spdle Total 102 85 132 No of Machine details in organization wise

23. Manpower management Stage Arisht ( per day) Sagar(per day) Trident ( per day) B/R 3 6 3 Sorting 2 4 2 Card + card cleanet 3+1 3 3 Pre draw frame Lap former 9 9 12 Comber+cleaner 6+3 6+3 6+3 Post draw frame 6 6 6 Speed frame( without RTS) 21 21 Speed frame with RTS 15 Total 54 52 56 Manpower details in organization wise

24. Manpower management Stage Arisht ( per day) Sagar(per day) Trident (per day) Ring frame Sider 39 33 39 Gaitor 12 12 21 Batch 12 12 15 Daffu cleaner 2 ( machine) 2 (machine) Lappeta cleaner 3 (machine) 3 (RTS) 3 ( without machine) Jobber 3 3 3 Floor cleaner 3 3 3 Cleaner 7 2 3 R/tr change 4 0( maint. Deptt) 4 Total ring frame 85 70 91 Manpower details in organization wise

25. Manpower management Stage Arisht ( per day) Sagar(per day) Trident Winding Sider 9 12 12 Checker 12 9 9 Cone tip 2 2 1 Cleaner 1 B grade management 2 Jobber 3 3 Floor cleaner Packing 12 15 12 Total ring frame 38 41 37 Manpower details in organization wise

26. Manpower management Stage Arisht ( per day) Sagar(per day) Trident Total 177 163 184 Total spindles 24960 25200 51600 Production/day 18500 kg 24000 kg 20000 kg Man/ 1000 spindles 7.09 6.62 3.35 Man/ 100 kg 0.96 0.67 0.92 Avg count 24s Ne 22 Ne 34 Ne Manpower details in organization wise 6 man power are engaged Mixing laydown in Arisht and contactor persons are engaged Mixing laydown in sagar & Trident In Trident no of machine is higher so load of worker increased itself.

27. Manpower management Stage Arisht Sagar Trident B/R 2 line/ P line/ P 2 line/P Card 25 card( 44kg/hr)/P 30 card( 50 kg/ hr)/P 30 Card ( 45 kg/hr)/P Pre draw frame 4 delivers (600mt/min)/0.5 P 4 delivers (800 mt/min)/0.5P 4 delivers ( 600mt/min )/ 0.5P Lap former machine ( 100m/m)/0.5P Machine ( 200m/m)/0.5P machine (100 m/m)/0.5P Comber 8 comber (350 nip /min)/P 8 comber (550 nip/min)/P 9 comber ( 400nip/min)/P Post draw frame 5 mc (350m/m)/P 5mc (550m/m)/P 6mc ( 350 m/m)/P Speed frame Sider 360 spdle /P 400 spdle /P 500 spdle /P Doffer 1000bb/ doffer RTS 1200 bb/doffer Batch 500 can/person 400 can / person 600 can / person Work load details in organization wise

28. Manpower management Stage Arisht ( per shift) Sagar(per shift) Trident per shift Ring frame Sider 2000 spdle/ sider – 20s Ne 1800 spdle- 20sNe 2400 spdle- 20s ne 3000 spdle/ sider- 30s Ne 3000 spdle-30 s Ne 3600 spdle- 30s ne 4200 spdle/ sider- 40s Ne 4200 spdle-40 s Ne 4200 spdle- 40s ne Gaitor 2500 gaiting/person 2000 gaiting/person 2500 gaiting/ person Batch 750 bobbin/ person 550 bobbin/person 800 bobbin/person Batch with RTS 750 bobbin/person Lappeta cleaner 3600 bobbin/person 3600 bobbin/person 5000 bobbin/person Cleaner 6000 spdle/person Maint team 15000 spdle/person R/tr change 2000 spdle/person 0( maint. Deptt) 2000 spdle/ person Wing sider 9 machine/person 6 machine/person 14 machine/person Checker 850 cone /person 550 cone /person 1200 cone/ person Manpower details in organization wise

29. Energy management Ukg Compressor air consumption Water consumption -125 liter /person /day- save water & save life STP water need to be cleaned and used in gardening

30. Ukg Arisht Sagar Trident Avg count 24s ne 36s ne 34s ne Ukg 3.5 5.0 (approx) 5.1 Optimization of suppliers fan and return fan frequency in time to time According to department condition. Optimization speed of all machines using inverter. Optimization Hplant fan blades angle All motor are checked efficiency and power consumption. Less efficiency motor is changed new motor According to pay back basis. Compare machine wise power consumption at same Parameter and remedy high power consumption machines. Prep. Machine cleaning like as – card and blow room are done in peak time at 6.00 pm to 10 pm Check ukg at top position, if ukg may be high than avg ukg then reduce speed. Replacement of existing transformer with energy efficient transformer

31. Ukg Power % Machine 69 Hplant 23 Compressor 5 Light 3 VFD installation  at different locations of the  h plant. Cooling tower of Compressor by VFD installation Ecorise tube installation in ring frame. Replacement of 150 watt HP SV street lights  with LED street  lights 

32. Air consumption Arisht No of spindles 87652 Units of power 198200 Power consumption to Compressor 8313.2 % Compressor to total power 4.2 Total consumption CFM 2022 Std CFM 1933 Excess CFM 4.6 Power consumption/CFM 0.163 Suction  optimization at winding machines . Air consumption to be optimized by arresting leakage. Incorporation of high pressure nozzles in air washers of humidification plants Optimization Compressor line losses. Check CFM of all machines in every month & challenge OEM std of air consumption Check unit wise Compressor air consumption in daily basis Optimization cleaning points & schedules Divide higher pressure point & lower pressure point

33. Air consumption Machine No of m/cs Kg/sqcm CFM Total CFM Actual CFM Blow room line 2 6 0.61 1.22 Magic Eye 2 6.5 17 34 C50 20 6.5 0.61 12.2 Sb2 4 6 0.06 0.24 Omegalap 3 6 9.71 29.13 Comber 18 6 0.24 4.32 LR60AXL 26 7 0.95 24.7 Link coner 30 drum 26 7 14 364 Xoralla 1 6.5 2.0 2 R&D instruments 6 65 65 Pneumfil shut off damper 26 6 0.6 15.6 Buffing room 6 20 20 Bale press 1 6 5 5 Cleaning point 19 4.5 50 50 Total 627.41 667.0

34. Quality management STT STT STT LTK/LTT LTK/LTT LTK/LTT Evenness 4.0 -4.5 +4.5 4.0 -4.5 +4.5 16s -23s <=11.5 >11.5-11.7< >11.7 <=20 >20-24< >24 24s-40s <=11.7 >11.7-12< >12.0 <=20 >20-24< >24 Fabric evenness Bleach fabric For short thick and thin places( STT),long thick( LTK),long thin(LTN) in combed yarn

35. Quality management STT STT STT LTK/LTT LTK/LTT LTK/LTT Evenness 4.0 -4.5 +4.5 4.0 -4.5 +4.5 16s -23s <=12.3 >12.3-12.7< >12.7 <=24 >24-28< >28 24s-40s <=13.3 >13.3-13.7< >13.7 <=24 >24-28< >28 Fabric evenness Bleach fabric For short thick and thin places( STT),long thick( LTK),long thin(LTN) in karded & blend yarn Slub/3yard Survivable cont/3 yds Total cont/3yds PP cont/3yds Indian cotton 3 8 16 2 Import Cotton 3 3 6

36. Quality management Parameter A level customer B level customer C level customer Evenness grade 4.0 /-4.5 -4.5 +4.5 Slub/3yard =<2 =<3 =<4 Barre No barre/slightly barre Slightly barre Slightly barre White specs grade 3.5/4.0 4.5 4.5 Cont/3 yds =<5 =<12 =<24 PP/3yds =<1 =<2 =<2 White and light shade Parameter A level customer B level customer C level customer Evenness grade 4.0 /-4.5 -4.5 +4.5 Slub/3yard =<2 =<3 =<5 Barre No barre/slightly barre Slightly barre barre White specs grade 3.5/4.0 4.0 4.5 Cont/3 yds =<16 =<20 =<40 PP/3yds =<1 =<2 =<4 Dark and medium shade

37. Quality management Major quality complaints Barre Count variation:- it relates ccp and ccm settings Weak yarn - low tpi High Contamination – it is directly related to magic eye setting and QuantumFd setting. Weight shortage-it related to conditioning Parameter Cause Contribution % Fiber 70 Count variation 10 Twist variation 10 HAIRINESS /periodical 10

38. Quality management Major issues in cotton products Barre Raw materials SOP followed Randomization in preparatory section. FiFo system need to be followed Avoid accumulation of materials at the all stages Plan to complete one lot within 7 days Randomization of cones from all link coners in each Carton. UPS installed in xorella, it is ensured that all the heaters operates xorella should always be fully loaded. In case of power failure or any other breakdown, the materials is segregated & packed separately Whites specs In comber, IFC% should be <4.5% L-in speed, wing setting need to be optimized Flat speed need to be increased to extract more immature fiber

39. Quality management Thick,thin places Focus on material handling in preparatory section Replace of defective cans Ensures removal piecing material RSB calibration schedule 3 months off 6 months Stretch control in speed frame Last layer of roving should be removed Spindle to Spindle monitoring for abnormalities ( I.e. defective cot ,apron ,tape, missing spacer Alarm settings and control of alarm rejection bobbin Colour Contamination Optimization Magic Eye setting Optimization FD settings

40. Inventory management Inventory Min requirements Max requirements Card can 1000×1200 6 PC/card 10 pc/ card Pre drew frame 1000 ×1200 48 can/ lap former ( 24 doubling) 54 can / lap former Spool 12 PC/ comber 2.0 PC/ comber Comber 600×1200 8 PC/ comber 12pc / combet Post draw frame 500×1200 1.25 × speed frame spdle 1.50 × speed frame spdl Speed bobbin 2.25× ring spindle 2.50 × ring spindles Ring Frame bobbin 2.3× spindles with link coner 2.5× spindles with link coner Proper maintaining spinning accessories & take long life Reducing packing cost by proper utilize inventory like wax ,HM bag, cone sticker, Carton, separator, label, nylon stripes, . Write down scrap cone and Carton % in daily basis In Trident, there are no use stationary in any department. Every communication are done by what’s up. All data entry must be done in SAP program. Trident group saved Rs 25 – 30 lac / annual Zero paper work In Trident. Ring travellers cost is major. So zero wastage of r/tr are saved inventory cost, In Arisht ring travellers are given in polythene punch. And sagar , this activity are hand over maintenance deptt.

41. Inventory management Scrap ring travellers are collected and sell in scrap materials as iron substance In Arisht, unit -3 is flexible, it can convert cotton % to polyester/ Cotton blends when cotton bale may be shortages. In Arisht, manpower rationalization project from 2011 to 2018, reduce Manpower from 1000 to 600 in every deptt . Spear one colony of worker and converted into saff colony and earn approximately Rs 2.0 lac as rent. Create a sliver preparatory for melange unit when Space are saved during modification of Unit 1,2 in Arisht In sagar, there are four unit and all unit have same machine, if any unit Manpower will be short, excess Manpower of other unit can be utilized. Such type culture are created. In Trident, Gear changes and maint related breakdown are attended by ring frame & Prep Jobber in evening shift and night shift for reducing overtime work.

42. THANKS