Reedisha Spinning Ltd_industrial Report

A Practical Methodology throughout Factory Evaluation

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CHAPTER ONECHAPTER ONECHAPTER ONECHAPTER ONE

Project DescriptionProject DescriptionProject DescriptionProject Description


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CHAPTER – 01

PROJECT DESCRIPTION

Name of the Mill : Reedisha Spinning Ltd.

Type : 100% Export Oriented Spinning Mills

Year of Establishment : September, 2006

Head office of the Mill : 36, Shahid Tajuddin Ahmed Sharani

Tajgaon Industrial Area,

Dhaka – 1208, Bangladesh

Phone : +880-2-8823227, 9897817-20

Fax : +880-2-8826086

e-mail : [email protected]

Factory of the Mill : Zamirdia(Square Masterbari),

Valuka,

Mymensingh

Phone : 02-8891498, 01713163897, 01713129260

Fax : 02-8891523, 01713050446

e-mail : [email protected]

Sponsor of the Mill : Islami Bank Bangladesh Ltd.

Kawran Bazar Branch,

Dhaka

Project Cost : Investment USD 24 Million

Area of the Mill : 20 Acres of Land

Raw Materials : CIS Cotton (Origin)

COTTONEX (Brand Name)

28~32mm (Staple Length)

3.3~4.9 (MIC Value)

Product Mix : Ring Yarn (Carded & Combed)

Slub Yarn

Mill Capacity : 36,000

Total No. of Spindles : (1008*36) 36,288 Spindles

Production Capacity : 22,000 Kg per day

Production (Produced) : Average 20,000 Kg per day

Production Achievement : 85%

Yarn Count Range : 16~60 Ne

Power Generation : 5.15 MW


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Historical Development of the Project :

Reedisha Spinning Ltd. is a sister concern & profitable project of KOHINOOR

Chamical Company (BD), Ltd. The factory is located at Zamirdia, Valuka,

Mymensingh, near to the Valuka and besides the Dhaka-Mymensingh Highway on

about 20 acres of Land. It is covered the Floor Space of total about 1,50,000 SFT

(Factory, Raw Cotton & Finished Godown). The main factory has divided into three

commercial buildings. One is Production building, Second is Utility building & the

Las one is Office building. Reedisha Spinning Ltd. is the new bright baby of the

Textile Sectors of Bangladesh.

Back Ground of RKL Group :

RKL group is a family business which was established in the year of 2006 in

September by Mr. Rezaul Karim. This business is initially started as Garments

Manufacturing Unit on its own premises which is also currently the Corporate

Office. The vision of the Management gradually turned into a Reality with the

formation of the Member Units Marketing a growth pattern of the Group.

Project Name Date of Establishment

Reedisha Knitex Ltd. September, 2004

Reedisha Spinning Ltd. September, 2006

To uphold Social commitment at Highest Level and for achieving expected Quality

production of Exported Garments, the board of Director has decided to establish a

100% Export Oriented Cotton Spinning Mills to turn the Group as Composite Knit

Project in true sense.

Keeping the above in view this good management has started Reedisha Spinning Ltd.

with 36000 spindles to get average 20ton production per day. The total investment of

the Project is about USD 24 Million. The produced yarn will be consumed by Sister

Concern.

Different Departments of the Factory :

1. Administrative Department

2. Security Department

3. Production Department

4. Quality Control and Assurance Department

5. Maintenance Department

6. Utility Department

7. Electrical Engineering Department

8. Civil Engineering Department

9. Store (Local & Foreign) Department

10. Medical Department


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Physical Infrastructure :

Reedisha Spinning Ltd. is organized into three major parts,

1. Factory Department

2. Sales & Production Department

3. Finance & Accounts Department

But the factory is consist of mainly Five Control Department,

1. Production Department

2. Quality Control & Assurance Department

3. Maintenance Department

4. Administrative Department

5. Information Department

Again, the factory has various buildings, such as,

- Generator building

- Store building

- Security building

- Raw Cotton Godown

- Wastage Godown

- Family Quarter

- Bachelor Quarter

- Workers(Male) Dormitory

- Workers(Female) Dormitory

- Office building (MD, VP, GM etc.)

Remarks :

Reedisha Spinning Ltd. is a profitable project & sister concern of KOHINOOR

Chemical Company(BD), Ltd. Reedisha Spinning Ltd. earns a lot of Foreign

Currency and contributes the economy of the Country.


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CHAPTER CHAPTER CHAPTER CHAPTER TWOTWOTWOTWO

Man Power ManagementMan Power ManagementMan Power ManagementMan Power Management


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CHAPTER – 02

MAN-POWER MANAGEMENT

MANPOWER :

Reedisha Spinning Ltd. is a well organized company and it is certified by the

OKO Tex and Its management system & manpower management is completely

different from other company.

Man-Power Management for Quality Department :

Serial Designation Shift Schedule No. of

Post

01 Manager/QIC General Shift 01

02 Asst. Manager/Sr. Quality Assurance

Officer

General Shift 01

03 Quality Assurance Officer Shift – A / B / C 03

04 Supervisor Shift – A / B / C 03

05 Lab Assistant Shift – A / B / C 06

06 Lab Helper Shift – A / B /C 03

07 Staff General Shift 02

08 Staff (Blow Room) Shift – A / B / C 03

09 Worker (Mixing Man) Shift – A / B / C 18

10 Worker (Contamination) Shift – A / B / C 15

Total 55

Man-Power Management for Maintenance Department :


Post

01 Maintenance Manager General Shift 01

02 Maintenance Officer General Shift 02

03 Senior Foreman General Shift 01

04 Foreman General Shift 03

05 Head Feeder Shift – A / B / C 02

06 Senior Feeder Shift – A / B / C 04

07 Feeder Shift – A / B / C 12

08 Assistant Feeder Shift – A / B / C 14

09 Helper Shift – A / B / C 17

10 Learner Shift – A / B / C 24

Total 80


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Man-Power Management for Utility Department :


Post

01 Assistant General Manager General Shift 01

02 Assistant Manager General Shift 02

03 Engineer General Shift 01

04 Sr. Assistant Engineer Shift – A / B / C 01

05 Assistant Engineer Shift – A / B / C 03

06 Foreman Shift – A / B / C 03

07 Head Feeder Shift – A / B / C 02

08 Feeder Shift – A / B / C 04

09 Assistant Feeder Shift – A / B / C 06


11 Learner Shift – A / B / C 05

Total 38

Man-Power Management for Store Department :


Post

01 Store In-charge General Shift 01

02 Store Officer General Shift 01

03 Assistant Store Officer General Shift 02

04 Store Keeper Shift – A / B / C 02

05 Staff Shift – A / B / C 04


Total 12

Man-Power Management for Administrative Department :


Post

01 Sr. Administrative Officer (In-Charge) General Shift 01

02 Junior Administrative Officer General Shift 02

03

Sta

ff

Time Keeper 02

04 Photocopier-Fax Operator 01

05 Peon 01

06 Driver 04

07 Driver-Helper 03

08 Hostel Super 01

09 Carpenter 01


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10 Gardener 02

11 Swifter 07

12 Imam 01

13 Cowboy 01

14 Cooker 07

15 Cooker-Helper 03

Total 37

Man-Power Management for Security Department :


Post

01 Senior Officer General Shift 01

02 Habilder 03

03 Ladies Checker 01

04 Security Guard 17

Total 22

Shift Change Schedule :

General Shift : 09.00 AM to 05.00 PM

Shift – A : 06.00 AM to 02.00 PM

Shift – B : 02.00 PM to 10.00 PM

Shift – C : 10.00 PM to 06.00 AM


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RESPONSIBILITIES :

Responsibilities of Quality Control In Charge :

- Maintain proper Quality Control daily and monthly records

- Ensure that the studies allotted in various departments are carried out as per

plan

- Prepare necessary Standards for the product manufactured in the mill

- Fix up the mode of Sampling for the various studies

- Work out the tolerance limits for the data collected by the Investigator

- Monitor the salient studies like Pinion changes in different spinning machine,

average sliver, lap weight over a period of time etc. in a graphical

representation

- Keep himself aware of the technical features of the testing machinery under

his control

- Keep in touch with the modern developments in the field of textile testing and

arrange where ever possible, for the incorporation of advanced features to the

existing testing instruments

- Co-ordinate with the factory manager and spinning master to rectify the

defects found out by the quality control studies. Decide the feasibility of

reducing the repeated studies

- Check the mode of conducting the studies in the shop floor by the

investigators

- Conduct a periodic review of the stores and stationeries like printing paper,

graph sheets, calibration cotton, etc. required by the quality control

department

- Find out rogue machines/parts from the quality control study and plan for

crash programmes to set right those machines in consultation with

Maintenance In-charge

- Co-ordinate with production personnel by giving a patient hearing to the

problems connected with the performance of the machines

- Liaise with Maintenance department for evaluating the performance of the

Machinery in all the department and to take corrective actions

- Inculcate the capacity to guide, motivate and handle the Quality control crew

- Should maintain close contacts with the top management to discuss about his

achievements as well as constraints


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Responsibilities of Quality Control Officer :

- Distribute the planned Quality control operations to the quality control crew

(Investigators, Testers & Wrapping boy)

- Inform the Product changes that have taken place to the Quality Control In-

charge for which he should liaise regularity with production officers

- Ascertain whether the action plan decided to rectify some of the deficiencies

found from the quality control studies are implemented in the shop floor

- Should maintain close contact with the investigators wrapping boy and testing

operatives to avoid flaws, if any, in the various studies conducted by them

- Co-ordinate with Production officers and Quality Control In-charge in

implementing the action plan decided to rectify deficiencies, if any in the

process

- Test the accuracy of the testing machines using the calibration tools suggested

by the instrument manufactures

- Inform the instrument service contact personnel about the defects, if found

- Maintain proper records for the servicing operations undertaken for the

testing instruments

- Prepare neat graphical representation of the salient studies like average full

sliver, lap weight; Pinion changes in different spinning machines, End breaks

in Ring frame etc.

- Tabulate monthly average of the Lea CSP, Count CV, Strength CV, Yarn IPI

etc. to have quick glance of the salient quality data of different counts

- Help the Quality Control In-charge in preparing the monthly report by feeding

him the consolidated figures properly

- Check the standards and tolerance limits fixed for the various quality

attributes, before informing for corrective actions

- Plan for periodic spot check in the shop floor to examine the accuracy of the

studies conducted by the investigators

- Check the calculations and interpretations made by the investigators before

submitting the report to the Quality Control In-charge

- Inform the Quality Control In-charge about the reasons for any abnormalities

in the study results for proper interpretation

- Note down the wet bulb and dry bulb temperature before and after completion

of the study

- Inform the shop floor Supervisor after the completion of the study


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Responsibilities of Production Officer :

- To check the rules and regulation inside the factory

- To ensure the target production of each machine with appropriate quality

- To arrange necessary punishment for the worker if they violate discipline

- To collect necessary information and instruction from the previous Shift

Officer

- To run his Shift smoothly and accurately

- To supervise Junior officer and worker

- To make decision how to operate whole production process

- To check the worker setting for the spinning process

- To control the production processes and quality parameters

- To control the workers so that they can operate the machine as per

instruction

- To train up the learners & ensure cleanliness of all machine

- In case of any machine breakdown, has to be started as early as possible

- To minimize machine down time & take necessary steps to reduce wastage

- To check of machine settings, gauging, drafting, etc.

- To check the proper use of waste sliver and pneumafil in the Blowroom

- To check the production report, Sticker, Detective cone & Package weight in

finishing avoiding mixing

- To hand over the Shift with all information to the coming Shift officer


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Job Description of Production Officer :

- To monitor of Blowroom to Finished good to achieve target production

- To check Humidity of the different section

- To supervise performance evaluation

- To check count wise & lot wise process parameter from Blowroom to Finished

good

- To take the charge from the outgoing shift & hand over the charge to

incoming shift

- To control unusable wastage in every stage from Blowroom to Finished good

- To allow leave of Workers & Subordinate supervising staffs in systematic way

- To check the Attendance

- To control Count mixing, Lot mixing of sliver, Roving yarn and Mixing / Bale

management of Raw cotton

- To charge Ring traveler as per schedule

- To change count wise & lot wise process parameter from Blowroom to

Finished good against standard value

- To attend duties self and subordinate supervising staff and workers by

minimum 15 minutes earlier

- To maintain Doff ticket and control of doffing time in Ring section

Job Description of Quality Assurance Officer :

- To check the Quality parameters of the product

- To direct for changing the Quality settings point according to customer

requirement

- To maintain close contact with Investigator wrapping boys & testing boys

- To test the accuracy of the testing machine in the testing laboratory

- To verify the Quality test result of previous quality test result

- To maintain the proper records of Quality servicing list parameters

- To prepare the Neat graphical representation of every Quality changing

module

- To tabulate the monthly average test result of CV value, Strength value,

Count value, CSP value, IPI value, Graphical Neat sketch etc.

- To decrease the fault appearance of any machine parameters

- To give the direction of worker for improving Quality parameters

- To check the Quality calculation done by Investigator & testing boy for better

sincere of the Calculated result

- To inform the Senior Officer or Quality Control In-charge for any

machine/quality/ product faults

- To maintain the quality control management


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CHAPTER CHAPTER CHAPTER CHAPTER THREETHREETHREETHREE

Machine DescriptionMachine DescriptionMachine DescriptionMachine Description


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CHAPTER – 03

MACHINE DESCRIPTION

Layout plan for Blowroom :

Laydown-1

Laydown-2

Uni

M

ixin

g o

f sl

iver

& p

neu

mofi

l

Main

tan

an

ce M

an

ager’

s B

low

room

& C

ard

ing

Condenser

Jossi

Uni Flex

Uni Mix

Uni Clean

Identification:


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Layout plan for Back Process :

Carding m/c=16

Breaker D/F=7

Finisher D/F=7

Lap Former=1

Simplex=9

Comber=5

To

ile

t Q

ua

lity

Co

ntr

ol

roo

m

D C

S M

ain

ten

an

ce r

oo

m


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Layout plan fro Ring to Finishing :

Sto

re

Win

din

g

Rin

g

Me

dic

al

To

ile

t

Packing Area

Heat Setting

Co

mp

ress

or

To

ile

t A

C

DG

M

WC

A

C

AC

Ring Frame=36 Winding m/c=12

Identification:


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Origin of Machineries & Equipment :

India, Switzerland, China, Japan, Germany, USA

List of Material Processing Machineries :

(A) Blowroom Department : Unifloc(1), Uniclean(1), Unimix(2), Uniflex(2),

Condenser(2)

(B) Carding Department : Carding(16)

(C) Drawframe Department : Breaker Drawframe(7), Finisher Drawframe(7)

(D) Lap Former Department : Lap Former(1)

(E) Comber Department : Comber(5)

(F) Simplex Department : Toyota Simplex(6), China Simplex(3)

(G) Ringframe Department : Ringframe(36)

(H) Autocone Department : SAVIO Autocone(4), SCHLAFHORST Autocone(8)

(I) Quality Department : HVI(1), AFIS(1), USTER Auto Sorter 5(1), Electro

Magnetic Strength Tester(1), Electronic Twist

Tester(1), WIRA Yarn Count Tester(1), Finisher

Wrapping Tester(1), Sliver Roving Reel(1),

Electronic Weight Balance(1), Electro Yarn Reel(1),

Hand Held Moisture Meter(1), MAG Yarn

Appearance Board Winder(1)

Specification of Machineries :

Blow Room Machineries :

(A) Unifloc : Model : Unifloc A11

Origin : Rieter (Switzerland)

Year : 2006

Serial : 40002940-00051

Electrical : 3*400V, 50Hz, 21Amp

No. of M/C : One

Function : To pluck & passes Raw material


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(B) Heavy Metal Detector : Origin : Jossi Metal Detector (Switzerland)

No. of M/C : One

Function : To detect the Metal

(C) Uniclean : Model : Uniclean B11


Year : 2006

Serial : 40004050-00061

Electrical : 3*400V, 50Hz, 25Amp

No. of M/C : One

Function : To remove dust & trash particle

(D) Unimix : Model : Unimix B70


Year : 2006

Serial : 40004000-00081

Electrical : 3*400V, 50Hz, 14Amp, 6Bar

No. of M/C : Two

Function : To mix & store the plucked fibre

(E) Uniflex : Model : Uniflex B60


Year : 2006

Serial : 40008240-00075


No. of M/C : Two

Function : For fine mixing & cleaning

(F) Jossi Vision Shield : Model : ED-35.1-1200T

Origin : Jossi (Swiss Made)

Year : 09-02-2006

Serial : 3102381

No. of M/C : Two

Function : To detect the foreign fibre particles

(G) Condenser : Model : Condenser A21

Origin : Riter (Switzerland)

Year : 2006

Serial : 4009560-00027


Function : To condensed the plucked fibre


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Carding Machineries :

Model : Carding C60


Year : 2006

Electrical : 3*400V, 50Hz, 6Bar

No. of Machine : 16

Function : Drafting & attenuating of the fibre.

Breaker Drawframe Machineries :

Model : Breaker Drawframe SB-D 40


Year : 2006


No. of Machine : 7

Function : Drafting & Parallelization

Finisher Drawframe Machineries :

Model : Finisher Drawframe RSB-D 40


Year : 2006


No. of Machine : 7

Function : Drafting & Parallelization

Lap Former Machineries :

Model : Lap Former E-32


Year : 2006

Electrical : 3*400V. 50Hz, 6Bar

No. of Machine : 1

Function : To form the lap

Comber Machineries :

Model : Comber E-65


Year : 2006


No. of Machine : 5

Function : Combing, Removing various impurities.


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Simplex Machineries :

Model : Simplex FL100 & Simplex HY492C

Origin : Toyota(Japan) & Hong Yuan (China)

Year : 2006


No. of Machine : 9

Function : To form roving imparting necessary amount of twist

Ringframe Machineries :

Model : Ringframe LR 6/A

Origin : Laxmi (India)

Year : 2006


No. of Machine : 36

Function : To form yarn with the desired strength of twist

Autoconer Machineries :

Model : Autoconer 338 & Autoconer Orion M

Origin : Schlafhorst/Saurer (Japan) & Savio

Sensors : Uster Quantum 2 & Loepee

Year : 2006

Electrical : 3*400V, 50Hz, 6bar

No. of Machine : 12

Function : Cone winding

Heat Seating Machineries :

Model : XORELLA AG

Specification : LT-0/2000*4000

Year : 2006

Electrical : 40-450C, 55min,

Relative Humidity : 65%

No. of Machine : 1

Function : Conditioning & Weighting


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CHAPTER FOURCHAPTER FOURCHAPTER FOURCHAPTER FOUR

Raw MaterialsRaw MaterialsRaw MaterialsRaw Materials


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CHAPTER – 04

RAW MATERIALS

Raw Cotton Parameters :

Model : CIS Cotton (Uzbekistan)

Brand Name : COTTONEX

Staple Length : 28~32mm

MIC Value : 3.3~4.9

Source of Raw Materials :

Required of Raw Materials are purchased by L/C

Price : 92 cents/lb

Raw Materials related Parameters :

� Binding material used for bales : Steel wire

� No of binder : 10

� Bale size:

Height: 59 cm

Length: 95 cm

Width: 80 cm

� Bale weight : 220 kg

� Tare weight : 2.6 kg

� Bale loading & unloading system : It is done by FORKLIFT.

� Capacity of raw cotton godown : 12000 bales

� Maximum maintain of raw cotton godown : 8,000

� Bales used in per laydown : 75 bales

� Bales consumption/day : 150 bales/day


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Contamination of Raw Materials :

� Black cotton

� Piece of cotton cloth

� Color thread

� Piece of polythene

� Piece of white cloth

� Piece of plastic

� White thread

� Polypropylene

� Feather

� Wooden piece

� Bale covering cloth

� Color cotton

� Jute

� Hair & Wool

� Others

Processing of Cotton before Bale form :

Cotton fibre originated from seed, which is called seed cotton. In cotton plant several cotton

pot or ball produced. Cotton growing origins are USA, CIS countries, Egypt, Africa,

Australia, China and also India and Pakistan. In our country cotton is mainly imported from

huge cotton grower USA, CIS, Australia, Africa, Egypt etc. because cotton of India and

Pakistan fails to meet our demand from view of quality and quantity. During harvesting seed

cotton pots are collected from the plant which is known as picking of cotton. Picking can be

done manually and mechanically. Manual picking can ensure cotton pot selection,

segregation and collection separately. So manual picked cotton is less trashy but

collection/production is very low. Again in mechanical picking, production rate is very high

but have no choice. Big cotton growing countries like USA use mechanical picking which in

the other hand reduce cost of cotton. After picking seed cottons, fibers are separated from

seed by ginning machine for subsequent processing. Seedless cotton fibres are then

compressed to bales of around 500 lbs for easy shipment to users. Seed cotton process flow

and a typical bale size (95cm*59 cm*80 cm)is shown as below.In REEDISHA SPINNING

LTD. CIS(Uzbekistan) cotton is used.


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Spinning mill purchase those cotton bales under contract of some fibre property like fibre

length, fineness, strength, trash content etc. But modern spinning mills test all fibre

properties for each and every bale under Id. no. prior use taking representative samples of

about 4 ounces from both side of each bale. For this, thousands of bales need to be tested

within very short time where HVI has no alternatives. HVI i.e. High Volume Instrument

offers all possible fibre property tests at a very high speed.

95cm

80 cm

59 cm


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CHAPTER FIVECHAPTER FIVECHAPTER FIVECHAPTER FIVE

Production Planning Sequences & OperationsProduction Planning Sequences & OperationsProduction Planning Sequences & OperationsProduction Planning Sequences & Operations


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CHAPTER – 05

PRODUCTION PLANNING SEQUENCES & OPERATIONS

Production parameters & Description of production process :

1. Blow Room section :

Wastage percentage(max) : 4.0%

Production rate : 800kg/hr/line

Machine efficiency : 85%

Total production : 16,320 kg/machine/day

2. Carding section :


Production rate : 60 kg/hr

Production speed : 176m/min


Total production : 1368 kg/machin/day

3. Drawframe section :

Breaker Drawframe :





Total production : 4455 kg/machine/day

Finisher Drawframe :






4. Lap former section :



Production speed : 125 m/min




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5. Comber section :

Wastage percentage(max) : 13.5 %


Production speed : 430 nip/min


6. Simplex section :


Spindle speed : 950 rpm

TPI : 1.03



7. Ringframe section :


Spindle speed : 17000 rpm

TPI : 19.58



8. Autoconer section :


Winding speed : 1500 m/min


Description of production process :

1. 100% combed cotton (knit)

2. 100% carded cotton (knit)


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Flow chart for 100% combed cotton production process :

Flow chart for 100% carded cotton production process :

Blow Room

Carding

Breaker Drawing

Lap Former

Comber

Finisher Drawing

Simplex

Ringframe

Autocone

Blow Room

Carding

Breaker Drawing

Finisher Drawing

Simplex

Ringframe

Autocone


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Spinning plan for 20 ton per day production(30KH Ring yarn)

Spinning

process

Wastage

rate(%)

Required

Production

(Kg)

TPI Count

(Ne)

Speed No. of

Head /

Spindles

Machine

efficiency

Production

(kg/m/c/day)

No. of

machine

required

Actual

machine

required

Autocone

winding

0.6% 20,000 - 30 1550m/min 60 70% 1846 10.83 11

Ringframe

machine

2.0% 20,120 19.58 30 17,000rpm 1008 95% 599 33.59 34

Simplex

machine

0.6% 20,530 1.03 0.80 950rpm 120 80% 2391 8.59 9

Finisher

drawframe

0.5% 20,654 - 0.11 500m/min 1 96% 3712 5.56 6

Breaker

drawframe

0.5% 20,757 - 0.11 600m/min 1 96% 4455 4.66 5

Carding

machine

6.0% 22,862 - 0.104 176m/min

60kg/hr

1 95% 1368 15.25 16

Blowroom 4.0% 22,193 - - 800kg/hr/line 2 line 85% 16,320 1.36 2 line

Bale

management

--- 23,118 - - Per bale weight 220 kg 105.08 105

Production = �� ×�×� . � ��×��×��

��×�×��×�.��×� �� or

�� ×�×�.��×��×��

��×�.��×� �� or

�� ×�×� . � ��×��×��×�.��

��×�.��×� �� or !""# × 24 × "&&.


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CHAPTER SIXCHAPTER SIXCHAPTER SIXCHAPTER SIX

Quality Assurance Quality Assurance Quality Assurance Quality Assurance SystemSystemSystemSystem


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CHAPTER – 06

QUALITY ASSURANCE SYSTEM

Quality Control & Assurance System :

Bale Management :

The efficiency of production and the quality of the end product is determined by the

suitability and quality of the fibre input. It is the process of inventory control and

selection of fibre according to its properties and also to mix fibre homogeneously to

get consistent production and quality of yarn.

Basic Principle Bale Management :

Bale management refers to a choice of cotton bales according to the fibre

characteristics in order to achieve acceptable and economical processing conditions

and a constant yarn quality. The quality of yarn is primarily determined by the worst

bales. In this respect, the specific remarks should be maintained,

- Each individual bale contributes to the fibre blend and to a large extent, the

yarn properties. Therefore, the fibre characteristics of each individual bale have

to be checked.

- The final mix is only completed at the last passage of drawing. The best place,

therefore, to check the resulting fibre properties of a mix is at the finisher

sliver.

- The influence of the individual fibre properties of a mix on the yarn properties

is not fully known because there are many contributing factors.

- With bale management the random uncontrolled variation of the bale mix can

be improved for this reason the variation of each fibre characteristic in every

bale mix and in the blen material as well as the variation in the yarn properties

are to be carefully monitored.


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Quality Assurance Department : (Reserved & New Lot Cotton Calculation, CIS DAWEOO)

MIC

No

of

Ba

le

Use

ab

l

e

Use

ab

l

e

To

tal

Use

ab

l

e

Use

d

Ba

le

Sto

ck

Ba

le

Actu

al

Ba

le/

La

y

Prese

n

t B

ale

/

La

y

Gra

de

+B

Av

g.

+b

No

. o

f

Ba

le

Use

ab

l

e

Use

ab

l

e

To

tal

Use

ab

l

e

Use

d

Ba

le

Sto

ck

Ba

le

Actu

al

Ba

le/

La

y

Prese

n

t B

ale

/

La

y

Lot 50/10 59/10 60/10 59/10 60/10 50/10 59/10 60/10 59/10 60/10

3.2 Residue Residue

3.3 Z 7.0-7.4 7.2

3.4 A 7.5-7.8 7.65

3.5 B 7.9-8.2 8.05 3 19 1 23 22 1 0.06

3.6 C 8.3-8.6 8.45 2 69 12 83 50 33 2.10 2

3.7 D 8.7-9.0 8.85 22 200 32 254 180 74 4.70 5

3.8 64 172 12 248 144 104 6.60 4 E 9.1-9.4 9.25 13 428 82 523 360 163 10.35 10

3.9 31 119 18 168 108 60 3.81 3 F 9.5-9.8 9.65 24 548 180 752 504 248 15.75 15

4.0 11 126 16 153 108 45 2.86 3 G 9.9-10.2 10.05 48 372 340 760 540 220 13.97 15

4.1 16 145 22 183 144 39 2.48 4 H 10.3-10.6 10.45 48 157 481 686 504 182 11.59 13

4.2 4 250 40 294 230 64 4.06 7 I 10.7-11.0 10.85 34 30 414 478 324 154 9.78 9

4.3 5 358 46 409 324 85 5.40 9 J 11.1-11.4 11.25 13 4 232 249 180 69 4.38 4

4.4 1 342 74 417 324 93 5.91 9 K 11.5-11.8 11.65 6 6 61 73 36 37 2.35 2

4.5 1 185 194 380 310 70 4.45 8 L 11.9-12.2 12.05

4.6 18 75 334 427 346 81 5.14 9 M 12.3-12.6 12.45

4.7 18 27 346 391 302 89 5.65 9 N 12.7-13.0 12.85

4.8 30 15 347 392 288 104 6.60 8 O 13.1-13.4 13.25

4.9 14 19 386 419 72 347 22.04 2 P 13.5-13.8 13.65

5.0 Q 13.9-14.2 14.05

5.1 R 14.3-14.6 14.45

5.2 S 14.7-15.0 14.85

5.3 T 15.1-15.4 15.25

Total 213 1833 1835 3881 2700 1181 75.0 75.0 213 1833 1835 3881 2700 1181 75.0 75.0

Average MIC 4.503 4.412 Average +b 10.02 10.01

CV% 6.42 CV% 7.04

Lot T_Bale Bale Par% T_Laydown B.N. Out

59/10 1833 39.01 52.01

46.99

4.9 300

60/10 1478 31.46 41.94

Before 213 4.53 6.04

TOTAL 3524 75.00 100%


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BALE MANAGEMENT PROCEDURE :

Reedisha Spinning Limited Valuka, Mymensingh

Quality Assurance Department

Date : 01-08-2010 Cotton Lot : (59/10+60/10) CIS Daewoo

After Lay Down = 36 Yarn Lot : Comb – 119/10

Lot Normal Card – 228/10

Lot Semi Comb – 230/10

S.

N.

Grade of +b +B Grade of +b +B Grade of +b +B Avg.

+B

Remarks

01 E 9.25 G 10.05 I 10.85 10.05

02 G 10.05 F 9.65 H 10.45 10.05 Lot Bale

03 D 8.85 I 10.85 G 10.05 9.92 59/10 38

04 I 10.85 Pneu.+Sliver 10.013 E 9.25 10.04 60/10 33

05 F 9.65 G 10.05 H 10.45 10.05 56/10 4

06 G 10.05 J 11.25 D 8.85 10.05 57/10

07 I 10.85 E 10.25 F 9.65 9.92 Total 75.00

08 E 9.25 Pneu.+Sliver 10.013 I 10.85 10.04

09 H 10.45 F 9.65 G 10.05 10.05

10 K 11.65 C 8.45 F 9.65 9.92 Grade of +b

Distribution 11 G 10.05 H 10.45 E 9.25 9.92

12 F 9.65 Pneu.+Sliver 10.013 H 10.45 10.04 A

13 E 9.25 J 11.25 F 9.65 10.05 MIC

Distribution

B 0

14 H 10.45 G 10.05 E 9.25 9.92 C 2

15 F 9.65 H 10.45 G 10.05 10.05 3.8 4 D 5

16 H 10.45 Pneu.+Sliver 10.013 F 9.65 10.04 3.9 3 E 10

17 E 9.25 G 10.05 I 10.85 10.05 4.0 3 F 15

18 C 8.45 J 11.25 H 10.45 10.05 4.1 4 G 15

19 G 10.05 D 8.85 I 10.85 9.92 4.2 7 H 13

20 F 9.65 Pneu.+Sliver 10.013 H 10.45 10.04 4.3 9 I 9

21 G 10.05 H 10.45 F 9.65 10.05 4.4 9 J 4

22 D 8.85 F 9.65 K 11.65 10.05 4.5 8 K 2

23 I 10.85 G 10.05 E 9.25 10.05 4.6 9 L

24 H 10.45 Pneu.+Sliver 10.013 F 9.65 10.04 4.7 9 M

25 J 11.25 D 9.85 G 10.05 10.05 4.8 8 N

26 I 10.85 F 9.65 E 9.25 9.92 4.9 2 O

27 G 10.05 H 10.45 F 9.65 10.05 5.0 P

Average MIC 10.006 10.027 10.006 10.013 Total 75 75

Standard Deviation 0.7792 0.6882 0.6687 0.0581 Avg. MIC 4.412

CV% 7.79 6.86 6.68 0.58 CV% = 7.04

CV% = 7.04%

___________ __________ ________________

Prepared by (Q.C.O.) Manager (Q.C.D.)


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Raw Cotton Colour Grading in HVT :

S/

N

Colour Grade (Rd)

Sy

mb

ol

Lea

f

Colour Code (+b)

Wh

ite

C. C

.

Lig

ht

Sp

ott

ed

C. C

.

Sp

ott

ed

C. C

.

Tin

ged

C. C

.

Yell

ow

Sta

ined

C. C

.

01 Good Middling GM 1 11 12 13 -- --

02 Strict Middling SM 2 21 22 23 24 25

03 Middling M 3 31 32 33 34 35

04 Strict Low Middling SLM 4 41 42 43 44 --

05 Low Middling LM 5 51 52 53 54 --

06 Strict Good Ordinary SGO 6 61 62 63 -- --

07 Good Ordinary GO 7 71 72 -- -- --

08 Blow Colour Grade 8 81 82 83 84 85

Raw Cotton Colour Grade Value :

Serial Range of colour grade value Colour grade 01 < 7.4 Z

02 7.5 – 7.8 A

03 7.9 – 8.2 B

04 8.3 – 8.6 C

05 8.7 – 9.0 D

06 9.1 – 9.4 E

07 9.5 – 9.8 F

08 9.9 – 10.2 G

09 10.3 – 10.6 H

10 10.7 – 11.0 I

11 11.1 – 11.4 J

12 11.5 – 11.8 K

13 11.9 – 12.2 L

14 12.3 – 12.6 M

15 12.7 – 13.0 N

16 13.1 – 13.4 O

17 13.5 – 13.8 P

18 13.9 – 14.2 Q

19 14.3 – 14.6 R

20 14.7 – 15.0 S

21 15.1 – 15.4 T


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List of Testing & Quality Control Equipments :

S/N Machines Name Model No. Manufacturer

01 High Volume Instrument (HVI) HVI Spectrum Switzerland

02 Advance Fibre Information System (AFIS) AFIS Pro Switzerland

03 Uster Auto Sorter 5 Switzerland

04 Electro Magnetic Strength Tester MAG-Y0251 India

05 Electronic Twist Tester Germany

06 WIRA Yarn Count Tester 075306 Italy

07 Finisher Wrapping Tester MAG-F0701 India

08 Sliver Roving Reel England

09 Electro Yarn Reel England

10 Hand Held Moisture Meter England

11 MAG Yarn Appearance Board Winder MAG-Y0801 India

12 Electronic Weight Balance (For Package Weight) KERN TB England

13 Electronic Weight Balance (For Sliver Weight) ALT310-4 England

14 Heat Setting machine XORALLA AG

USTER HVI Spectrum(Quality Assurance Machine):

1. Name of the equipment : USTER High Volume Instrument (Version :

Spectrum)

2. Objectives: To measure MIC, Maturity, SCI, Length, Amt, Uniformity,

Strength, Short Fibre Index, Elongation, Moisture, Rd, +b, Color grade, Trash

Content, Trash Area, Trash Grade, UV.

3. Testing type:

(i) System testing : Length, Moisture, maturity, SCI, Rd, +b, length

uniformity, SFI, strength, elongation, micronaire, trash and color

determined together

(ii) Module testing :

�� Length & Strength module

�� Micronaire module

�� Color & Trash module

4. Test parameters:

(A) Main menu :

�� System testing

�� Module testing

�� Calibration

�� Data manager

�� Status

�� Man-made fibre test

�� Diagnostics


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(B) Quality parameter :

�� ICC (International Cotton Calibration) mode

� Fibre length (2.5% span length, 50% span length in

mm or inch)

� Length uniformity (Uniformity Ratio)& SFI

� Strength & Elongation

�� HVI (High Volume Instrument) mode

� Fibre length (Upper Half Mean Length, Mean

length in mm or inch)

� Length uniformity (Uniformity Ratio)& SFI

� Strength & Elongation

5. Operating procedure:

�� Switch on the power of the machine.

�� Calibrate the color, MIC, length and trash.

�� At first mic of the fibre sample is carried out followed by the

color and length-strength test.

�� The print-out of test results can be obtained.

6. Report type:

�� HVI Quality Report

�� Results of each tested sample

�� Summary of the results with statistics

�� Graphical presentation of each and every parameter

7. Inspection procedure method:

�� Visual inspection of the printed individual and summary test

results.

�� Segregation of the raw cotton bales and reject the below standard

bales.

�� Bale management is carried out with BIAS from these results.

8. Details about three modules:

(A) Micronaire (MIC) module:

�� Working Principle→ Air flow method

Fibre thickness↑, Inter space↑, Air pass↓, MIC↑, Fineness↓

�� Sample weight→ 8.5—11.5 gm

�� Application range of MIC→ 2.0—7.0

�� Micronaire: Micronaire is the measure of fibre fineness and

maturity. An airflow instrument is used to measure the air

permeability of a constant mass of cotton fibres compressed to a

fixed volume. The rate of airflow represents fibre fineness as per


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previous calibration and expressed in terms of Micronaire i.e. per

inch fibre weight in microgram [1µg=10-6gm].

�� Fibre maturity: The fibre indeed a hollow pipe like material where

the degree of the cell wall thickness is expressed in terms of fibre

maturity.

�� The table below can be used as a guidance in interpreting

micronaire and maturity measurement :

+Fibre fineness (µg //// ′′ ) Fibre Maturity (Maturity

Ratio)

below 3.3 Very fine below 0.7 Uncommon

3.4-4.3 Fine 0.7-0.8 Immature

4.4-5.0 Average 0.8-1.0 Mature

5.1-5.8 Coarse above 1 Very mature

(B) Color & Trash module:

�� Working principle→ Electro-optical method

�� Color grade is determined by the combination of Rd and +b.

�� Rd→

• Expresses degree of brightness

• Rd↑, Brightness↓

• Application range of Rd→ 35%—90%

�� +b→

• Expresses degree of yellowness or degree of pigmentation

• +b↓, more white cotton

• Application range of +b→ 4.0—18.0

�� Leaf grade→

• Trash is expressed by Leaf grade or Trash code

• Application range of leaf grade→ 1.0—7.0

�� Measure of color →This module offers some light source to expose

over the cotton sample that placed on the color tray/window. What

happened is the exposed light partially absorbed by the cottons and

the rest subjected to reflection. Light absorption results the degree

of pigments in cotton sample i.e. yellowness (+b) and reflectance

(Rd) measured from the light reflection from cotton sample which

sensed by a video camera. The HVI Rd reading indicates how bright

or dull a sample is and the +b indicates the degree of color

pigmentation. A three digit color code is thus determined by plotting

the values on the Nickerson-Hunter cotton colorimeter diagram and

locating the point at which the Rd and +b values intersect. Each

grade area in the diagram aside is subdivided into quadrants to

denote small color differences.


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�� The color of cotton fibres can be affected by rainfall, freezes, insects

and fungi, and by staining through contact with soil, grass or the

cotton plants leaf. Excessive Moisture and temperature levels can

also affect color deterioration while cotton is being stored.

(C) Length & Strength module:

�� Working Principle→

• For length→ Photo-electric cell or Electro-optical

method

• For strength→Pneumatic or Mechanical break

�� Fibro-comb and Fibro-sampler are used to prepare sample. A test

sample is prepared with Fibro-comb by Fibro-sampler.

�� Length measurement → Fibre length and length distribution

(Uniformity) measured through light scanning prior strength

measurement. HVI tests fibre length in terms of span length by

geometrical analysis of fibre array (orderly arrangement). Here 2.5%

Span Length (S2.5%) is very close to classer’s staple length. It also

tests 50% Span Length (S50%) and Uniformity Ratio (UR) to evaluate

length distribution of fibre in ICC mode. In HVI mode respective

terms are Upper Half Mean Length (UHML), Mean Length (ML)

and Uniformity Index (UI).

UR = 100

100

100

100

Length

Length

Length

Length

Span

Span

Span

Span

2.5%

2.5%

2.5%

2.5%

Length

Length

Length

Length

Span

Span

Span

Span

50%

50%

50%

50%

×

UI = 100

100

100

100

UHML

UHML

UHML

UHML

MLMLMLML ×

�� Fibre length and uniformity affects yarn strength, evenness and the

efficiency of the spinning process. Some USDA (United States

Department of Agriculture)cotton grades are given as under :

Upper Half Mean Length Uniformity Index

Below 0.99 Short below 77 Very low

0.99 ~ 1.10 Medium 77 ~ 79 Low

1.11 ~ 1.26 Long 80 ~ 82 Average

above 1.26 Extra long 83 ~ 85 High

above 85 Very high

Fibre length and uniformity is also related to short fibre (<½′′ )

content. Cotton with a low uniformity index is likely to have a high

percentage of


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�� short fibres. It is in HVI expressed as Short Fibre Index (SFI) and

can be defined as follows:

SFI = 122.56 – (12.55 � UHML) – (1.22 � UI)

�� Strength measurement → Strength module is offered the very same

test sample beard gripped with Fibro-comb by one end. A moveable

clamp grips the sample fibre beard at ⅛″ distant opposite end and

moves until break just after length test. Measurement of fibre

strength is reported in terms of gm/tex. A tex is equal to the weight

in grams of 1000 meters of fibre. Therefore the strength reported is

the force in grams required to break a bundle of fibres of one tex

unit in size. The bundle fibre of course elongates to some extent

prior breakage. An elongation percentage also measured from initial

clamp distance (L1) i.e. over final clamp distance (L2) prior fibre

breakage during strength measurement.

Elongation% = 100

100

100

100

L1L1L1L1

L1L1L1L1 ---- L

2L2L2L2 ×

�� The following tabulation can be used as guideline in inter fibre

strength & elongation measurement

Fibre strength

(⅛″ gauge strength in gm/tex)

Fibre elongation

(%)

17 & below Very weak Below 5.0 Very low

18 ~ 21 Weak 5.0 ~ 5.8 Low

22 ~ 25 Average 5.9 ~ 6.7 Average

26 ~ 29 Strong 6.7 ~ 7.6 High

30 & above Very strong Above 7.6 Very high

�� In ICC mode fibre strength is accurate, on the other hand in HVI

mode strength is 25% more than the actual.


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USTER AFIS PRO(Quality Assurance Machine):

Objectives: To measure following fibre properties-

�� Nep (Cnt/gm)

�� Nep (µm)

�� SCN (Cnt/gm)

�� SCN (µm)

�� L(w) (mm)

�� L(w) (%cv)

�� SFC(w) (mm)

�� SFC(w) (%<12.7)

�� UQL(w) (mm)

�� L(n) (mm)

�� L(n) (%cv)

�� SFC(n) (%<12.7)

�� IFC (%)

�� Maturity Ratio

Technical data:

Its Application ranges are as below,

�� Number of fibres : maximum-10000 & default- 3000

�� Sample weight : 0.5 gm

�� Sample length : 30

Modules Testing :

�� Multidata testing module : UQL, SFC, Fineness, IFC, M.R.,

Neps, SCN, Dust, Trash, VFM

�� Neps module : Neps, SCN

�� Length & Dia module : UQL, SFC, IFC,M.R., Fineness

�� Trash module : Dust, Trash, VFM

Operating procedure :

�� Switch on the power of the m/c.

�� Select measurement from the main menu.

�� Select module

�� Select identifier

�� Select sample type

�� Input filename

�� Press start button.

�� Feed the prepared samples in the feed nozzle

�� The print out of the tested results could be obtained after the

test.


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Report type :

�� AFIS quality report

�� Results of each tested sample

�� Summary of the results with statistics

�� Graphical representation of each and every parameters e.g.

histogram etc.

Inspection :

�� Visual inspection of the printed individual and summary test

results.

�� Raw cotton selection is done from the measured neps, SFC,

Maturity Ratio etc.

�� Test results help to select proper process parameter.

USTER TESTER-5(Quality Assurance Machine):

�� Name of the Equipment : Uster tester-5 (UT-5)

�� Objectives : To test below the parameters,

�� Thin -50% /km

�� Thick +50% /km

�� Neps +200% /km

�� U%

�� CVm

�� CVm 3m

�� CVm 10m

�� Hairiness

�� Number of Slots : For Slivers :1 Slot

For Roving : 1 Slot

For Yarn : 2 Slot

�� Measuring principle :

�� Electronic Capacitance Method.

�� Testing speed:

�� For yarn – 400 m/min

�� For roving – 50 m/min

�� For sliver – 50 m/min


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�� Testing results :

�� Mass variation (U%, CV%)

�� Imperfections (Thin/km, Thick/km, Neps/km)

�� Hairiness

�� Periodic faults of machine parts

�� Fabric Construction.

�� Quality parameters :

(i) Unevenness (Um %, CVm % at different cut length)

Cut length – For sliver: 20mm

For roving: 12mm

For yarn: 8mm

(ii) Imperfections

Thin place/km : at -30%,-40%,-50%&-60% sensitivity

Thick place /km : at +35%,+50%,+70%&+100% sensitivity

Neps/km : at +140%,+200%,+280%&+400% sensitivity

(iii) Hairiness (at different cut length and CV% of hairiness)

(iv) Periodic faults (mechanical)

�� Operating System :

�� Switch on the power of the machine.

�� Select “Test Program” and then press recall button.

�� Write the changeable parameter through keyboard and start

the test with start button.

�� Feed the test sample manually through the proper guide. No

interruption is valid during test period.

�� The printer automatically prints a report along with diagrams

just after a test is being completed.

�� Report type :

�� Single / Overall values

�� Diagram (mass)

�� Diagram (hairiness)

�� Spectrogram (mass)

�� Spectrogram (hairiness)

�� Histogram

�� Variance-Length curve


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ELECTRONIC TWIST TESTER:

�� Machine specification :

�� Sample clamp

�� Load adjusting cursor

�� Scale

�� Level adjusting screw

�� Plum bob

�� Change lever of untwisting direction both ‘S’ and ‘Z’ twist.

�� Sample elongates and shrinks scale

�� Handle for move the revolve chuck.

�� Operating procedure :

�� Set the reference length (e.g. 10 cm) in the twist tester.

�� Adjust deflecting needle deflection ‘0’ degree as weight free.

�� Select proper weight from weight table.

�� Adjust deflecting needle again to the centre of the graduated

scale (i.e. deflection ‘0’ degree) while attaching the sample

yarn with rear end by fixed and rotating jaw.

�� Rotate the wheel against the twist in the yarn allowing the

deflection needle to move not or more than three graduations.

�� Rotate the wheel until deflection angle becomes ‘0’ degree

again.

�� Report type : Calculation of twist per inch or cm from display counter

�� Inspection : Check the twist variation and take necessary action.


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Waste percentage calculation in Blowroom & Carding :

m/c

no

Initial

Reading(Kg)

Final

Reading(Kg)

Actual

Production

1 334 439 105

2 333 438 105

3 329 434 105

4 315 420 105

5 306 411 105

6 298 404 106

7 297 403 106

8 329 428 99

9 330 429 99

10 327 426 99

11 330 429 99

12 284 370 86

13 151 183 32

14 285 378 93

15 281 374 93

16 282 375 93

17 281 371 93

18 309 414 90

Total 1725

Wastage Produce in Blow Room =45.85 Kg

Wastage Produce in Carding =130.60Kg

Total =176.45Kg

Total Raw Cotton Production=1725+176.45

=1901.45 Kg

Percentage of wastage in Blowroom = �'.�'×��

��.�' = 2.41%

Percentage of wastage in Carding = ��.×��

��.�' = 6.87%


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End Breakage Study :

� Start time 12.24pm

� Ring frame no 21

� Stop time 2:50 pm

� Lot no 06/07(A)

� Total time observed(min) 146

� Bobbin wt 43 gm

� TPI 23.39

� Traveller no 5/0

� Avg spindle speed(rpm) 18500

� Temperature 29° C

Patern

position

Length(

%)

Spee

d

patte

rn

speed

(rpm)

Avg

speed

No of end

breaks/posi

tion

Total no

oftends

breaks/posit

ion

Tota

l end

brea

ks

Ends

break

1000

spi/h

0 0-10% 18000 20

1 10-20% 18000 7

2 20-30% 18500 3

3 30-40% 19000 3

4 40-50% 19000 4 55 19

5 50-60% 19000 18500 3

6 60-70% 19000 4

7 70-80% 19000 2

8 80-90% 19000 6

9 90-100% 18100 3


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Weight increase in percentage after conditioning :

� Yarn count : 26/1 KH

� Yarn Lot : 09/09

� Steaming Temp : 700C

� Steaming Time : 45 min

Cone no. Weight

W1(kg)

Weight

w2(kg)

Weight diff

Wx(kg)

Weight

increase in

%

1 2.11 2.15 0.04 1.89%

2 2.10 2.14 0.04 1.9%

3 2.10 2.14 0.04 1.9%

4 2.11 2.14 0.03 1.4%

5 2.12 2.16 0.04 1.8%

6 2.11 2.14 0.03 1.4%

7 2.10 2.14 0.04 1.9%

8 2.11 2.14 0.03 1.4%

9 2.10 2.14 0.04 1.9%

10 2.11 2.15 0.04 1.8%

11 2.10 2.14 0.04 1.9%

12 2.11 2.15 0.04 1.8%

13 2.12 2.16 0.04 1.8%

14 2.09 2.13 0.04 1.9%

15 2.09 2.13 0.04 1.9%

16 2.10 2.14 0.04 1.9%

17 2.09 2.12 0.03 1.4%

18 2.10 2.14 0.04 1.9%

19 2.10 2.13 0.03 1.42%

20 2.11 2.14 0.03 1.45

# Yarn Weight W1= mlt before conditioning

# Yarn Weight W2= mlt after conditioning

# Yarn Weight Increase Wx = W2-W1(MR)


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Snap Study in a Particular day :

� Monitoring Date : 14-08-2010

� Monitoring Time Start : 10.30 am

Machine type No. of m/c Stoppage time Causes

Carding 5 10:40 Maintenance

Carding 11 10:40 Maintenance

Carding 16 10:40 Cleaning

Breaker D/F 2 10:45 Maintenance

Lap former 3 10:45 Lap change

Comber 1 10:50 Operator short

Comber 8 10:52 Can change

Finisher D/F 4 10:58 Maintenance

Simplex 9 11:00 Maintenance

Simplex 8 11:00 Back side cleaning

Simplex 6 11:00 Roving break

Simplex 2 11:00 Sliver short

Finisher D/F 4 11:02 Opening & cleaning

Ring 14 11:02 Maintenance



Autocone 5 11:06 Maintenance

Autocone 2 11:07 Uster Quantum Jam

Autocone 8(Drum-12) 11:08 Uster Quantum Jam


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Material Flow Processes Machineries Quality Parameters :

1. Blowroom Quality Control & Assurance :

Blowroom machine parameters :

Blowroom line : 2

Bale lay down : Double sided

Actual bale lay per lay down : 75

Total spaces per lay down : 81

Total lay down time : 16-17 hours

Bale management procedure : According to MIC value & +b

Blowroom wastage name : Dropping-2

Blowroom wastage percentage : 3-6%

Wastage by metal detector : 200-500gm per detection

Blowroom machine efficiency : 85%

Blowroom various settings points :

(A) Uniclean :

�� Cleaning intensity (C.I.) = 0.3-0.4

�� Relative Wastage Ratio (R.W.) = 0.6-0.8

(B) Unimix :

�� Production level = 85=86

�� Degree of opening = 0.3

(C) Uniflex :

�� Cleaning intensity (C.I.) = 0.2

�� Relative Wastage Ratio (R.W.) = 0.4-0.6

(D) Cotton Staple Length : 11/8 inch

(E) Jossi Settings(Foreign Fibre Detection) :

�� Particle size = 140-150

�� Colour grade = 0-4


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2. Carding Quality Control & Assurance :

Carding Machine Parts Parameters :

Sliver Weight : 80.0 grains/yards

Production (in weight) : 60 kg/hr

Production (in length)/ Delivery : 176 m/min

Sliver Count : 0.104 Ne

Total Draft (Actual) : 100-150

Carding Wastage Percentage : Flat Stripping/Dropping-1 = 1.5-5.5%

Neps Removal Efficiency : 60-70%

Machine Efficiency : 95%

Input : Mat (Chute feeding)

Output : Carded Sliver

Delivery Can Size : 1200 × 1000 mm

Delivery Can Capacity : 7500 meter

Delivery Can Weight : 42.5 kg

Opening Roll Speed (Chute) : 838 rpm

Feed Roller Speed : 17-30 rpm

Cylinder Speed : 855 rpm

Flats Speed : 0.37 m/min (Depends on Cylinder)

Licker in Speed : 1452 rpm

Creep Speed : 15 m/min

Deliver Roller Speed : 17-30 rpm

Doffer Speed : Depends on Delivery

Stripping Roller Speed : Depends on Delivery

Squeezing Roller Speed : Depends on Delivery

Cleaning Roller Speed : Depends on Delivery

Disc Roller Speed : Depends on Delivery

Diameter of Cylinder : 840 mm

Diameter of Doffer : 680 mm

Diameter of Licker in : 260 mm

Diameter of Opening Roller : 292 mm

Diameter of Feed Roller : 172 mm

Diameter of Stripping Roller : 118 mm

Diameter of Delivery Roller : 156 mm

Diameter of Squeezing Roller : 80 mm

Diameter of Cleaning Roller : 100 mm

Diameter of Disc Roller : 72 mm

No. of Stationery : 3 (One Stationery placed two flat)

No. of Flat in Whole circumference : 79

No. of Motes Knife : 4

No. of Waste Plate : 3


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Gauge Settings of Carding :

S/N Machine Points Distance

01 Feed Roller to Feed Plate 0.1mm

02 Feed Roller to Licker In 0.9mm

03 Licker In to Cylinder 0.25mm

04 Cylinder to Bottom Plate 1.00mm, 1.20mm

05 Cylinder to Bottom Stationery 0.45mm

06 Cylinder to Bottom Waste Plate 1.50mm

07 Cylinder to Bottom Motes Knife 0.40mm

08 Cylinder to Top Stationery 0.40mm

09 Cylinder to Top Waste Plate 1.50mm

10 Cylinder to Top Motes Knife 0.40mm

11 Cylinder to Top Plate 1.10mm

12 Cylinder to Flat (Back, Middle, Front) 0.225mm, 0.2mm, 0.125mm

13 Cylinder to Top Plate 1.00mm

14 Cylinder to Motes Knife 0.9mm

15 Cylinder to Waste Plate 1.40mm

16 Cylinder to Motes Knife 0.35mm

17 Cylinder to Stationery 0.35mm

18 Cylinder to Bottom Plate 1.00mm

19 Cylinder to Doffer 0.2mm

20 Doffer to Stripping 0.15mm

21 Stripping to Cross Roller 0.15mm

22 Cross Roller to Cross Roller 0.15mm


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3. Drawframe Quality Control & Assurance :

Breaker Drawframe Machine Parts Parameters :



Production (in length)/ Delivery : 615 m/min


Total Draft : 1-1.5

Doubling : 6:1 (Card) & 5:1 (Comb)

Drafting System : Pneumatic 4 Over 3

B/D Wastage Percentage : Sliver 0.5%


Input : Carded Sliver

Output : Drawn Sliver

Delivery Can Size : 1200 × 600mm

Delivery Can Capacity : 4500 meter

Delivery Can Weight : 28.0-29.0 Kg

Diameter of Top Front Roller : 38mm

Diameter of Top 2nd & 3rd Roller : 38mm & 38mm

Diameter of Top Back Roller : 38mm

Diameter of Bottom Front Roller : 40mm

Diameter of Bottom Middle Roller : 35mm

Diameter of Bottom Back Roller : 35mm

Diameter of Creel Roller : 100mm

Diameter of Condenser(Inside) : 4.6mm

Gauge Settings – Front to Middle : 40mm

Gauge Settings – Middle to Back : 44mm

Quartz Length : 157mm

Sensors Present : Delivery Sensor, Can Change Sensor

Pneumatic Pressure : 140 bar (Card Process) &

120 bar (Combed Process)

Cot Roller Hardness : 700 Shore (comb) & 800 Shore (card)


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Finisher Drawframe Machine Parts Parameters :



Production (in length) / Delivery : 500 m/min


Total Draft : 1-1.5

Doubling : 8:1 (Card & Combed Process)

Drafting System : Pneumatic 4 over 3

Auto Leveling System : G&G Autoleveler

F/D Wastage Percentage : Sliver 0.25%


Input : Sliver (Carded & Combed)

Output : Drawn Sliver

Delivery Can Size : 1100 × 500mm

Delivery Can Capacity : 3300mm

Delivery Can Weight : 21.0-21.5 Kg

Diameter of Top Front Roller : 38mm

Diameter of Top 2nd & 3rd Roller : 38mm

Diameter of Top Back Roller : 38mm

Diameter of Bottom Front Roller : 40mm

Diameter of Bottom Middle & Back : 35mm

Diameter of Condenser (inside) : 4.6mm

Diameter of Creel Roller : 101mm

Gauge Settings – Front to Middle r/r : 39mm

Gauge Settings –Middle to Back r/r : 44mm

Quartz Length : 157mm

Sensors Present : Delivery Sensor, Can Changer Sensor

Pneumatic Pressure : 140 bar (card process)

120 bar (comb process)

Cot Roller Hardness : 700 shore (comb) & 800 shore (card)


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4. Lap Former Quality Control & Assurance :

Lap former machine parameters :

Lap Weight : 20 kg or 80gm/meter

Lap Width : 300mm


Production (in length) / Delivery : 125 m/min

Lap Count : 0.0074 Ne

Doubling : 26:1

Doubling Capacity : 28:1

Drafting System : 3 over 3


Input : B/D Sliver

Output : Lap

Diameter of Front Roller : 39mm

Diameter of Back Roller : 32mm

Maximum Diameter of Lap : 650mm

5. Comber Quality Control & Assurance :

Comber machine parameters :



Delivery Speed : 430 nip/min

Feed/nip : 4.7mm

Total Draft : 9.12 - 25.12

Doubling : 8:1

Drafting System : 3 over 3

Batt Feed Tension : 9.1%

Comber Wastage Percentage : Noil 8.5-13.5%


Input : Lap

Output : Combed Sliver

Delivery Can size : 1200mm × 600mm

Delivery can capacity : 4500 m

Diameter of Top Front detaching : 24.5mm

Diameter of Top Back detaching : 24.5mm

Dia of Bottom Front detaching : 25mm

Dia of Bottom Back detaching : 25mm


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Dia of Front draw box roller : 35mm

Dia of Middle draw box roller : 27mm

Dia of Back draw box roller : 27mm

Roller gauge of Front to Middle : 42mm

Roller gauge of Middle to Back : 50mm

Roller Hardness : Front 76 degree shore

Middle 80 degree shore

Back 80 degree shore

6. Simplex Quality Control & Assurance :

Simplex machine parameters :

Count range : 0.8~1.01 Ne

TPI range : 1.02-1.08

Twist multiplier : 0.9-1.2

Spindle speed : 850-900rpm

No. of spindle/machine : 120

Drafting system : Pneumafil 4 over 4

Wastage name : Sliver

Wastage percentage : 1%


Input of Simplex : Sliver

Output of Simplex : Roving

Length of Bobbin : 2000 meter

Weight of Bobbin : 2.5 lb

Colour of bobbin : blue, orange black, white, red, brown, yellow

Stop Motion : Auto stop motion, Problem indicating lamp

Sensor used : Cover open, Roving breakage, Roving breakage

in bobbin, Sliver breakage

Diameter of Front top roller : 28mm

Diameter of 2nd & 3rd top roller : 28mm, 25mm

Diameter of Back top roller : 28mm

Diameter of Front bottom roller : 28.5mm

Diameter of 2nd & 3rd bottom roller : 28.5mm

Diameter of Back bottom roller : 28.5mm

Roller settings of Front to 2nd roller : 37.5mm

Roller settings of 2nd to 3rd roller : 48.5mm

Roller settings of 3rd to back roller : 48.5mm

Creadel type : OH 514

Dimension of Spacer : Black(4.5mm), Baise(5.4mm), Gray(6.5mm)


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7. Ringframe Quality Control & Assurance :

Ringframe machine parameters :

Count range : 16-60 Ne

TPI range : 144-27.72

Twist multiplier : 3.6(+-0.1)

Spindle speed : 13,000-17,000 rpm

No. of spindle/machine : 1008

Drafting system : Pneumafil 3 over 3

Wastage name : Bonda, Pneumafil

Wastage percentage : 2%


Input of Ringframe : Roving

Output of Ringframe : Yarn

Weight of cop : Average 40gm

Colour of bobbin : Brown, yellow, red, blue, black, baise, green,

orange, violet, white, ash

Auto Motion : Auto stop motion, Auto doffing

Diameter of Front top roller : 30mm

Diameter of Middle top roller : 25mm

Diameter of Back top roller : 30mm

Diameter of Front bottom roller : 27mm

Diameter of Middle bottom roller : 27mm

Diameter of Back bottom roller : 27mm

Roller settings of Front to Middle : 42.5mm

Roller settings of Middle to Back : 60mm

Creadel type : OH 2024

Specification of Apron : Top = (38.1*30*1.05)mm

Bottom = (80.5*32*1.05)mm

Roller Pressure :

Color Front Middle Back Green 14 kg 10 kg 12 kg

Red 18 kg 14 kg 16 kg

Black 10 kg 10 kg 10 kg

Traveller No :

Color Front Middle Back Green 14 kg 10 kg 12 kg

Red 18 kg 14 kg 16 kg

Black 10 kg 10 kg 10 kg


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8. Autocone Quality Control & Assurance :

Autocone Machine parameters :

Count range : 16-60 Ne

No of drum/machine : 60

Wastage name : Hard waste

Wastage percentage : 0.6%


Sensor Used : Uster Quantum-2 & LOEPEE

No of machines : Schlafhorst Autoconer 338 (8 m/c)

Savio TIPO Autoconer (4 m/c)

Important parameters :

PARAMETERS DIMENSION/VALUES Winding Position 60

Drum Dia 100 mm

Tensioning Device Tensioner

Yarn Speed 1350 m/min

Splicing System Auto

Finished Package Wt. 2070 gm

Yarn Length 126503 m

Electronic Clearer Uster Quantum 2

Yarn Strength 250 CN

Package Hardness Std.

Vegetable filter Without cotton, any type of fibre

Splicing zoned Under measuring system

Magazine 9 bobbin feed

Measuring head Ray type

Cutter Ceramic

Traverse length 6 inch

Drum type 2-2.5 turns

Uster Quantum Data-2 :

For N/S/L


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% Cm

N 340

S 160 1.6

L 32 22

H1 140 3.0

H2 125 3.5

H3 100 4

H4 60 8

H5 30 32

H6 28 40

C/CC Yarn count Deviation

CP +12% CCp+14%

Cm -12% CCm-14%

C 2.m CC-5m

For Thin

% Cm

T 30 16

H1 40 3

H2 36 5

H3 34 7

H4 30 12

H5 26 40

H6 0 0

For FD

% Cm

FD 6 0.5cm

H1 15 0.1

H2 5 1.4

H3 0 0

H4 0 0

H5 0 0

H6 0 0


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Classimat System & EYC :

Classimat defect classification:

Fault Cross-sectional size

+400

+250

+150

+100

+45%

-30%

-45%

-75%

0.1 1 2 4 8 32 CM

A4 B4 C4 D4

A3 B3 C3 D3

A2 B2 C2 D2

A1 B1 C1 D1

F G

H1 I1

H2 I2


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Packing Section

Length of packing bag : 37 inch

Height of packing bag : 48 inch

TR weight : 1 kg 300 gm(Cone + poly bag)

Total packing bag weight : 51.3 kgs

Yarn weight : 50 kgs

Contains in label :

�� Count

�� Lot no.

�� Quantity

�� Net wt.

�� Serial no.

�� Packing date

Yarn length/package :

Yarn count Length(m)

36/1 CH 125276

30/1 CH 104397

32/1 KH 111354

30/1 KH 104395

26/1 KH 90475

18/1 KH 62637

20/1 KH 69596

No. of cone/packing bag : 24(Generally)

RH% of packing section : 62


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Quality testing results of different section :


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CHAPTER SEVENCHAPTER SEVENCHAPTER SEVENCHAPTER SEVEN

MaintenanceMaintenanceMaintenanceMaintenance DepartmentDepartmentDepartmentDepartment


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CHAPTER – 07

MAINTENANCE

Maintenance of Different machineries :

At the beginning of the Maintenance operation, all the covers of the machines are

opened and the machines is cleaned with a cloth internally, which is called General

Cleaning.

Inside the machine the conveyor belt tension is checked and wooden lattice is also

cleaned and conveyor belt is cleaned if needed.

Jam in the two sides of spiked lattice is opened and under cover of spiked lattice is

opened and cleaned. Jam in the sides of the bearing house of evener roller, cleaner

roller with oils or lubricants as instructed by the manufacturer.

Chain box is checked and jam is cleaned if necessary.

Machine parts are checked conveniently or changed if necessary.

Maintenance Tools/Equipments and their functions

(A) Section Wise :

1. Blowroom & Carding : Mounting machine, Grinding Machine

2. Drawframe & Simplex : Long card mounting machine, Flyer

washing machine, Grinding machine,

Barcolizing machine, Brush cleaning m/c.

3. Ringframe : Cot grinding m/c, Barcolizing m/c, Spindle oil change

m/c, Cot mounting machine.

(B) Various Tools :

1. Hard Hammer : For opening & cleaning, tied & united the differential

parts.

2. Soft hammer : In where soft material are used.

3. Adjustable Range : For tied & untied nut, bolts etc.

4. Ring range : For tied & untied nut.

5. Socket range : In where normal range is not use.

6. Flat screw driver : To tied & untied the flat type nut.

7. Star screw driver : For tied & untied the screw type nut.

8. Cutting pliers : For cutting something .


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9. Nose pliers : For some sensitive cutting.

10. Combination pliers : For cutting both performance.

11. Spinner : For ring opening.

12. Inner scarlet pliers : To put/set bearing in the inner side of

bush/shaft/house.

13. Outer scarlet pliers : To put/set bearing in the outside of bush/shaft/house.

14. L-Key : For opening L-cord key.

15. Flat pile : For sharpening.

16. Scissor : For cutting something.

17. Hack saw frame & blade : For holding & cutting anything rod.

18. Belt lacing : For belt arranging.

19. Inside calipers : To measuring the inside diameter of the roller.

20. Outside calipers : To measure the outside diameter of rollers.

21. Variable calipers : To measure both side diameter.

22. Measuring tape : To measure length of different parts.

23. Puller : To open the gears.

24. Roller setting gauge : To adjust roller to roller distance.

25. Leaf/file gauge : To adjust different setting of carding machine.

26. Spindle gauge : To set the spindle vertically in ringframe.

27. Hook : For tied & untied the bush.

28. Roller hardness tester : To measure the hardness of different types of

roller.

29. Oil cane : For oiling inside the machine.

30. Spindle oil machine : To change oil in the machine.


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Maintenance of Machinery, Procedure & maintenance schedule/routine :

1. Maintenance Schedule for Blowroom Machine

(A) Rieter Unifloc A11 (Origin = Switzerland)

Intervals Maintenance Points

Daily - Normal Cleaning

- Cleaning of Dust & collected fly from the m/c

15 Days - Checking Chain & Sprocket

- Cleaning & Greasing Chain & Sprocket

- Take-off unit correct balance checking

4 Years - Changing Chain & Sprocket

- Changing Roller change

5-6 Years - Opening roller teeth change

(B) Rieter Uniclean B11 (Origin = Switzerland)



15 Days - Checking Grid bars & Polishing

(C) Rieter Unimix B70 (Origin = Switzerland)



1-5 Months - Checking Conveyor belt & Balancing

- Remove dust & fly from conveyor belt drive roller

- Checking Spike lattice(Pin change of Not & roller check)

4-6 Years - Changing Conveyor belt

6-7 Years - Changing Spiked lattice

(D) Rieter Uniflex B60 (Origin = Switzerland)



15 Days - Perforated drum cleaning

- Feed roller cleaning

- Grid bar checking & polishing

- Opening roller cleaning

After 12000 - Opening roller wire change

Ton production


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2. Maintenance Schedule for Carding Machine

- Daily Routine Cleaning

- Checking all gauge settings

- Autoleveller : Short term autoleveller & Long term autoleveller

- Stripping roller wire change 2200-2400 ton production

- Cylinder, Doffer & Flat drops wire change 800-900 ton production

- Licker-in wire change 400-500 ton production

- Back Stationery & Front Stationery 300-400 ton production

- Grinding : Cylinder grinding (400 ton)

Doffer grinding (250 ton)

Flat grinding (300 ton)

Licker-in grinding (250 ton)

- Internal Grinding System : Integrated Grinding System(IGS), grinding is

done periodically after a fixed time in the Cylinder.

3. Maintenance Schedule for Drawframe Machine

Normally it is expressed,

- Cleaning : Drafting zone – Every two hours

Suction filter spring – Every 2-3 hours

Every belt – 10days

- Greasing : Top roller end bush – 2 times in Weekly (Special A = LDS 18)

All greasing points – 2 months (Special A = LDS 18)

- Hardness : Cot Hardness (Karded Process) = 80 & 83 degree

Cot Hardness (Combed Process) = 74 & 75 degree

- Changing : Top roller & brush gearing = Every weeks two times

Cot grinding = After one month

Flat belt = After 8-12 months (435-5m-15) & After 1-1.5 years

- (others) :

Top roller cot change = After one year

Top & Bottom clearer leaf = After 3-4 years

Gas pressure spring = After 3-4 years

Different types V-ripped belt = After 3 years

Top roller & End bush = After 6-7 years


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Intervals Maintenance Points Operation / Task

Interval the

Cleaning &

Controlling,

Depending

on the

Waste &

Short fibres

Count in the

Material

Cleaning of Power Crel - Clean all contact rollers

- Clean all feeding rollers

- The sliver rake for the sliver feed

located on the back of the machine

Clean creel - Clean all sliver guides

- Clean the light barriers BIO with rod

- Clean the all cross bar

- The sliver rake for the sliver feed

located on the back of the machine

Clean entry plate - Fibre accumulation on the entry

plate should be removed periodically

Clean scanning rollers - Fibre accumulation around the

scanning rollers 1 & 2 should be

removed periodically

Clean the filter screen on

the main motor and check

on the main motor fan

- The Main motor sucks its cool air

from the outside, on the back side of

the machine, with a spiral enforce

hose

- The filter sieve on the rear side of

the machine clean the sucked in

cooling air

- The exhaust air is divided up into

several areas

- The fan hood for the main motor and

the connection for the spiral hose are

accessible from the front side of the

machine

- Vacuum or Wipe-off the filter screen

at regular intervals

- The cover sheet with the filter sieve

can be removed if required

Check the gas pressure

springs of the weighting

arms in the drafting

system

- The gas pressure springs are wear &

tear parts and have to be replaced

within the order time frames

- In addition, with all task of loading

arm need to be paid attention, that

the two gas pressure are in perfect

working condition

- With the slightest deviation, the gas

pressure spring should be replace

immediately for safety reason


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Clean pressure bar - Clean pressure bar periodically

- The pressure bar can wear out. The

wear and tear is dependent on the

material & its friction behavior as

well as the delivery speed

- In this case, the pressure bar can be

removed or turned over

Clean guide rails - Clean the guiding tracks periodically

Clean the timing belt for

the setting device

- Periodically clean the timing belt

Clean the setting spindle

for the adjustment of the

draft zone distance

- Clean the two setting spindles from

the left & on the right

Clean the clearer lip for

the draft system cylinder

- All of the clearer lip must be cleaned

periodically

Clean and control clearer

for the top roller

- Clean the clearer lip on the suction

head and intervals

- Check the clearer lips for the sign of

wear and tear

Cleaning of top rollers - Clean all top rollers periodically

Clean insert for web

funnel

- Clean the inside of insert from the

web funnel

Clean sliver duct - Thoroughly, clean the sliver funnel,

especially the two small injector

holes

- Additionally, clean the hole of the

compressed air in the swivel plate

Clean optical sliver jam

monitor

- During the periodic clean of the

machine, the area around the optical

sliver jam monitor should be cleaned

as well as

Clean sliver duct (Coiler) - The sliver duct must be periodically

with the provided cleaning tool

Clean the SERVO

controller G90 and the

Fan M92

- The cleaning is done with short

compressed air blows in the

direction, top to bottom, on the

SERVO controller G90 and by

vacuuming the electrical panel area

- The fan on the fan motor must be

cleaned periodically

Clean the ventilator - Clean the ventilator blades of the


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blades of the suction fan suction fan in periodic intervals,

from coarse fibres waste

accumulation and vacuum

thoroughly

Clean the filter screen - Vacuum the filter screen in front of

the suction fan with the aid of

vacuum clearer

Clean the sliver deposit

can changer

- Clean the entire area of the can

changer periodic

Interval 300

Operating

Hours

Lubricate the lubricating

nipple on the central

lubrication : Variant with

lubricating nipple

- Grease used Medium S22

- Location Z(1)

- Place “Central lubrication : Variant

with lubricating nipple”

- The lubricating system “Central

Lubrication” must be adjusted and

welly operated

Interval 500

Operating

Hours

Lubricate lubricating

point 10 (Top Roller

Bearings)

- Clean the top roller bearings and

studs prior to the re-lubrication with

a suitable cleaning agent

- Lubricate the top roller bearings of

all top rollers one after the another


- Location 10

- Place “Top Roller Bearings”

Buff top rollers cot - Prior to buffing, establish the actual

diameter of the cot as long as they

are cooled

- Nominal diameter of the Top roller

cot is 38mm

- During the buffing cycle, the buffing

depth is approximately 0.2mm

- The buffing tolerance for the entire

concentric running of the top roller

cot, between the two studs must be

<.03mm

- The buffing tolerance at parallel

settings of the cots must be

<0.08mm

- Grinding disc diameter 200-500mm

- Grinding disc width 25-45mm

- Circumference speed of the grinding


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disc is 1800-2000m/min

Replace top rollers cot - Remove the cots from arbor

- Replace the top roller cots

Interval

1500

Operating

Hours

Lubrication on version

with lubrication bar

- Distribute the required amount of

lubricant to all grease nipples on

lubrication bar


point 1.1 on the

lubricating strip (Loose

calendar roll bearing, left)


- Location 1.1

- Place “Loose calendar roll bearing,

Left”


point 1.2 on the

lubricating strip

(Stationery calendar roll

bearings, left)


- Location 1.2

- Place “Firm calendar roll bearing,

Left”


point 1.3 on the

lubricating strip (Cylinder

bearings of the front

roller, left)


- Location 1.3

- Place “Cylinder bearings of the

Delivery roller, Left”


point 1.4 on the


bearings of the middle

roller, left)


- Location 1.4


Delivery roller, Left”


point 1.5 on the


bearings of the feed

cylinder, left)


- Location 1.5


Entry cylinder, Left”


point 1 on the lubricating

strip (Main shaft, left)


- Location 1

- Place “Main shaft, Left”



strip (Main shaft, middle)


- Location 2

- Place “Main shaft, Center”


point 2.1 on the

lubricating strip (loose

calendar roll bearings,

right)


- Location 2.1

- Place “Loose calendar roll bearings,

Right”


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point 2.2 on the

lubricating strip

(Stationery calendar roll

bearings, right)


- Location 2.2

- Place “Firm calendar roll bearings,

Right”


point 2.3 on the


bearings of the front

roller, right)


- Location 2.3


Delivery roller, Right”


point 2.4 on the


bearings of the middle

roller, right)


- Location 2.4


Middle cylinder, Right”


point 2.5 on the


bearings of the feed

cylinder, right)


- Location 2.5

- Place “Cylinder bearings of the Feed

cylinder, Right”



strip (Main Shaft, right)


- Location 3

- Place “Main shaft, Right”


point 5 (Universal of Can

table drive)

- Apply lubricant on the two upper &

lower grease nipples of the universal

shaft

- Grease used Medium K3

- Location 5

- Place “Universal of can table drive”


point 6 (Can table, only

with spinning can

diameters 800-1000mm)


- Location 6

- Place “Can table, only with spinning

can diameters 800-1000mm”


point 11 (Calendar roller

bearing-swiveling axis)


- Location 11

- Place “Calendar roller bearing

swiveling axis”


point 12 (Calendar roller

bearing-Connecting rod)


- Location 12

- Place “Calendar roller bearing-

connecting rod”


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Interval

5000

Operating

Hours


point 7 (Can table-Cog

wheels)


- Location 7

- Place “Can table-Cog wheels”


point 8 (Can table-Cog

wheels)


- Location 8

- Place “Can table-Cog wheels”

Interval,

Depending

on the filling

capacity of

the

Lubricant

Container

(Cyclic,

repeatedly)

Lubrication on Central

Lubrication : Variant with

electrical lubricating

pump


- Location Z(6)

- Place “Central lubrication : Variant

with electrical lubricating pump”

- The pump should be refilled in the

sufficient time with clean lubricant

Interval

10000

Operating

Hours

Replace the Oil on the

Lubrication Point 9

(Differential)

- Grease used Medium CC220

- Location 9

- Place “Differential”

4. Maintenance Schedule for Lap Former Machine

- General cleaning of the machine & machine parts by compressed air

- Cleaning the different gear and belt

- Cleaning the top roller, feed roller, calendar roller, conveyor belt etc.

- Cleaning all cot rollers and coil spring

- Cleaning all cotton & others parts of the machine

- Gauge setting or resetting

- Over hauling of pneumatic unit

- Cleaning & polishing of sliver table, calendar rolls etc.

- Cleaning of top roller bushes by spindle oil

- Greasing the ball/needle bearings shell roller bearings open gear

- Checking & tightening of nuts, bolts etc.

- Top roller cot grinding, buffering & pressure setting

- Greasing with EP2 in all greasing points


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5. Maintenance Schedule for Comber Machine

Intervals Maintenance Points Operation / Task

Interval 4-8

Operating

Hours

Cleaning Bearings on

Combing Position

- Clean bearings on bottom roller

and Circular comb shaft with

roller picker

Clean area around spring

assemblies, nipper, top-

detaching roller pressure

unit from fibre and trash

accumulation

- Dry clean the whole area

assemble at the combing position

Remove fibre and dust from

the top comb

- Push accumulate trash in the top

comb from the front by

repeatedly pushing it downwards

Removing accumulated

fibres from the clearer roller

- Take the clearer roller off the

machine

- Clean with the aid of cleaning

truck

Interval 24-165

Operating

Hours

Cleaning technological parts - Remove cotton completely from

the combing position

- Wash all listed parts

- Rub all cleaned parts dry with a

clean rag

- Polish the parts with a Chalk

powder

Remove fly and fibres in the

of Drafting system

- Remove the accumulated fibres

behind the bottom draft rolls

- Remove fibre and trash deposits

from around the top and bottom

draft rolls

Washing draft system - Wash the strippers with water

- Wash the bottom drafting rolls

- Wash top rollers & Web

collecting

- Remove honeydew and grease

deposits on the metal plate

Interval 165

Operating

Hours

Clean area around the

Nipper shaft, Nipper crank,

Fly duct outside from

accumulated fibres

- Dry clean the whole area

accessible at the combing

position

Clean area around the - Open the flap cover


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Conveyor belt, Delivery rolls - Dry clean the whole area of

accessible parts

Interval 660

Operating

Hours

Wash technological parts - Clear away cotton completely

from the delivery zone

- Wash all parts that come into

contact with the material

Lubricate the bearing bushes

of the top detaching roller

- Clean top detaching rolls

- Remove the bearing bushes

- Push the bearing bushes back

onto the Journal pin

- Clean access grease from the

outside of the bearing bushes

- Grease used Medium EP2

- Location 308

- Place “Top detaching roller”

Lubricate the bearing bushes

of top roller bearing

- Take the bearing bushes off the

Top roll

- Insert the lubrication tools on

the bearing bushes


- Location 44

- Place “Draft system top rolls,

bearing bushes”

Interval 1320

Operating

Hours

Wash stripper & fly duct - Remove the fleece bowl

- Wash the strippers of the bottom

roller

- Wash inside the fly duct

Clean out Circular comb - Scrape out the accessible rear

half of the circular comb

- Set the machine exactly to Index

35

- Scrape out the accessible front

half of the circular comb

Oil level check - Check oil level at the inspected

glass and top up if necessary

- Oil used Medium S14

- Location 1 & Place “Gear Box”

Lubricating points on Front

lengthways shaft


- Location 21, 22 & 23

- Place “Bottom delivery roller”,

“Table calendar roll” &


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“Eccentric shaft”

Lubricating points on Rear

lengthways shaft


- Location 11, 12, 13, 14, 15 & 16

- Place “Circular comb shaft”,

“Rear detaching roll”, “Front

detaching roll”, “Drive shaft

delivery”, “Nipper shaft” &

“Brush shaft”

Lubricating points on the

Nipper


- Location 301, 302, 303, 304, 305

& 306

- Place “Top spring assembly”,

“Nipper-top nipper”, “Crank

nipper”, “Front support at top”,

“Front support at bottom” &

“Eccentric top nipper”

Lubricating the bearing bush

of the feed roll

- Clean the bearing bushes of the

journal pin and the bearing

guide of dirt and lubricant

residue

- Lubricate the bearing bushes


- Location 307

- Place “Nipper-Feed cylinder”

- Remove excess grease from the

outside area

Lubricating the bottom

drafting rolls

- Clean the lubricating nipples


- Location 41

- Place “Draft system bottom roll”

- Wipe of grease that has come out

of the side bearings

Lubricating can turntable

bearings

- Clean the side supports and the

slide platform


- Location 42

- Place “Can turntable bearings”

Lubricating can turntable

chain drive

- Clean &lubricate drive chain


- Location 43

- Place “Can turntable chain

drive”


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Clean the lubricating nipples - Clean the lubricating nipples

with a dry cotton cloth before

and after lubricating

Interval 4000

Operating

Hours

Oil change - Drain of Old oil & Refill new Oil


- Location 1 & Place “Gear box”

Lubricating journal pin of

top draw-off roller

- Clean dirt and lubricant residue

of Journal pin and bearing bush

- Grease used Medium CC150

- Location 310

- Place “Top draw-off roll”

Clean Housing & Filters - Clean accessible parts from dust

and accumulated fibres

Wash fibre separator - Remove filter cloth and wash

- Wash metal parts and clean off

any honeydew residue

Interval 8000

Operating

Hours

Cleaning the Motor - Dry clean the impeller and fan

cowl

Wash Fan - Dismantle the Motor with fan

wheel

- Dismantle duct elbow

- Wash fan wheel & fan housing

Interval 32000

Operating

Hours

Lubricate spur gear drive for

can turntable drive

- Dismantle the spur gear

- Drain the old oil and Refilled

with new oil


- Location 45

- Place “Spur gear drive for Can

turntable drive”


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Standard Lubricant :

Code Designation Viscosity DIN ISO Description

EP2 Grease Viscosity

of the

Basic Oil

100-250

KP2G-20

(51825)

EP-lubricant, Iithium base or

equivalent penetration ; 260-

310, NLGI-Class 2. High load

additives phosphor-sulphur-

based or equivalent EP

additives. Aging and corrosion

protection, No aggression

toward bronze

CC

150

EP Oil Viscosity

according

to ISO

mm2/s

400C 150

CLP 150

(51517/3)

CC 150 Oil on paraffin base, VI>90. No

or no significant swelling of O-

rings or any other synthetic

seals, No aggression toward

bronze, Good load bearing

ability; FZG-Test load class 12.

High load additives phosphor-

sulphur-based or equivalent EP

additives

Special Lubricant :

Code Designation Viscosity Description

S 14 SHC-Oil Heavy 150 Oil for high temperature, based on synthetic

carbonic hydrogen(SHC) or Polyalphaolefine, wear

resistant additives, Not aggressive to bronze

S 21 Chain Spray Optimol Viscogen KL 23 von Optimol-Werke

GmbH, Friedenstrasse 7, Munchen, Deutschland

S 13 SHC-Oil Light 68 Oil for high temperature, based on synthetic

carbonic hydrogen (SHC) or Polyalphaolefine.

Wear resistant additives


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6. Maintenance Schedule for Simplex Machine

Interval Maintenance Points Operation/Task

Daily

Cleaning

Flyer Rail & Roller Beam - Clear fly or fleece

Fly Spindle & Bobbin Rail - Wipe them with a clothed dampened

with a silicone oil

Top Clearer - Clear Accumulated fibres

Bobbin Rail - Clear fly or fleece

Floor - Clear the floor in front of & at rear of

FL100 & HY492C

CWC belt, Pulleys & their

surroundings

- Remove fly or fleece

Fan cover mesh on the GE

Head

- At the rear of FL100 & HY492C

- Clear fly or fleece

Every 2

Weeks

Back of the FL100 &

HY492C

- Remove fly or fleece from the Lifter

racks & pinions

- Remove fly or fleece from the Balance

springs & Chains

- Remove fly or fleece from the Lifter

slides & Spring pieces

- Clean the creel & its surroundings

- Clean the floor

Every 6

Weeks

Roller Part - Remove fibres and entangled the

bottom roller neck

- Remove fly or fleece accumulated on

the top & bottom faces on the top &

bottom clearers

- Remove fly or fleece accumulated on

the Clearer drive shaft

Flyer Rail - Clean the bottom of the flyer rail

- Clean the roving path in the flyer rail

- Always in contact with the passing

roving

Bobbin Rail - Clean the bobbin rail and its

surroundings

Main Gearing - Open the GD door and Clear fly or

fleece

Inside the GE Head - Clean fly or fleece from Inside of GE

Head


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- Clean fly or fleece from the Motor fan

cover & clothy from mesh

- Clean the inside of the Control box

- Clean fly or fleece accumulated on

Cooling fan

OE (Open End) - Open the OE door and Clear fly or

fleece

Every 6

Weeks

(Checking)

Roller Part - Check the sliver guides, condenser and

collector from damage

- Check the top & bottom aprons to make

sure that they are not damaged or missed

- Check the top & bottom clearers

- Check the pressurized state of the

weighting arms by using a height gauge

Main Gearing - Check the engagement of the gears

- Check the tension of the Timing belts

Draft Gearing - Check the engagement of the gear

Tension Roller Settings - To keep the tension sensors optimum

setting condition, Check the Tension

sensors

Every 24

Weeks

(Semiyearly)

Grease Tank Refilling filters

of the Centralized

Lubrication System

- Check & Clean refilling filters which may

become clogged with fly or fleece or other

foreign materials

Every 48

Weeks

(Yearly)

Simplex FL100 & HY492C - Check the machine according to the Check

sheet and adjust or replace the faulty

sections if any

Triennially Simplex FL100 & HY492C - Check the Levelness of the machine

between the left and right sides as well as

between the front and back on top of the

roller beam triennially


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7. Maintenance Schedule for Ringframe Machine :

(A) Interval 15 Days :

- Routing Cleaning

(B) Interval 2 Months :

- Bottom Roller Greasing

(C) Interval 4 Months :

- Spindle Gauging

- Lapped Hook Gauging

- Top Arm Settings (Seddle Gauge)

(D) Interval 6 Months :

- Bottom Roller Settings

- Spindle Oil Change

- Jocky Pulley Greasing

(E) Interval 1 Years :

- Bottom Roller eccentrically checking

(F) Interval (1.5-2.5) Years :

- Bottom roller top apron change

- Cot Changing

- Spindle tape changing

(G) Interval (2.5-3) Years :

- Cot roller greasing

- Cradle roller greasing

- Over hauling

(H) Interval (3-5) Years :

- Snarl wire/Lapped hook Changing

- Wooden clearer roller/Top clearer roller changing

(I) Interval (2-7) Years :

- Ring Cup Changing (Demands on Quality)

(J) Interval (4-7) Years :

- Bobbin Holder Change

(K) Interval 6-8) Years :

- ABC ring change

(L) Interval (4-10) Years :

- Spindle Change (Demands on Quality)


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8. Autoconer Maintenance :

- General cleaning of magazine peg

- Checking & removal of blow cleaner waste

- General cleaning of blower motor, filter cam shaft, motor filter control box,

chipper filter.

- Measuring head, blow cleaning, motor amp checking

- Gauge settings/re-settings

- Drum checking

- Lubricant & wax checking

- Replacement of damage parts/over life time

- Checking cone sensors


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Maintenance Schedule for the Month of August 2010 :

Date & Time Blowroom & Carding D/F, S/F & Comber Ringframe Autocone

Date Day Time Schedule Maintenance Cleaning S. Maintenance Cleaning S. Maintenance Cleaning S.Maintenance Cleaning

01 Sunday C-8, C-13 Daily B-5, F-7, S-1, C-4 Daily R-14, R-35, R-36 Daily A-1, A-10 Daily

02 Monday C-2, C-10 Daily B-4, F-3, S-7, C-2 Daily R-18, R-21, R-24 Daily A-11, A-12 Daily

03 Tuesday C-1, C-3, B/R Daily B-1, F-6, S-3, C-1 Daily R-1, R-7, R-13 Daily A-3, A-6 Daily

04 Wednesday C-7, C-9 Daily B-3, F-4, S-9, C-3 Daily R-5, R-30, R-33 Daily A-7, A-9 Daily

05 Thursday C-6, C-11 Daily B-2, F-5, S-4, C-5 Daily R-2, R-15, R-28 Daily A-4, A-8 Daily

06 Friday C-4 Daily B-7, S-2 Daily R-12 Daily A-2, A-5 Daily

07 Saturday C-5, C-12, B/R Daily B-6, F-2, S-5 Daily R-17, R-19, R-34 Daily A-10 Daily

08 Sunday C-14, C-16 Daily F-1, S-8, C-2 Daily R-4, R-10, R-29 Daily A-12 Daily

09 Monday C-15 Daily B-4, S-6, C-4 Daily R-22, R-26, R-27 Daily A-1, A-11 Daily

10 Tuesday C-2, C-13, B/R Daily B-5, F-3, C-1 Daily R-3, R-8, R-9 Daily A-6 Daily

11 Wednesday C-8, C-10 Daily F-6, S-7, C-3 Daily R-23, R-25, R-32 Daily A-3, A-7 Daily

12 Thursday C-3, C-9 Daily B-3, S-1, C-5 Daily R-6, R-11, R-20 Daily A-9, A-4 Daily

13 Friday C-1 Daily F-2, S-3 Daily R-16 Daily A-8 Daily

14 Saturday C-5, C-11, B/R Daily B-2, F-4, S-9 Daily R-14, R-24, R-31 Daily A-5 Daily

15 Sunday C-4, C-6 Daily B-1, F-5, S-2, C-4 Daily R-7, R-15, R-30 Daily A-2 Daily

16 Monday C-14, B/R Daily B-7, F-7, S-4, C-3 Daily R-1, R-5, R-33 Daily A-10, A-12 Daily

17 Tuesday C-12, C-16 Daily B-6, F-1, S-5, C-2 Daily R-18, R-21, R-27 Daily A-1, A-6 Daily

18 Wednesday C-7, C-15 Daily B-4, F-3, S-6, C-5 Daily R-2, R-16, R-28 Daily A-11 Daily

19 Thursday C-2, C-8, B/R Daily B-5, F-6, S-8, C-1 Daily R-12, R-9, R-3 Daily A-7 Daily

20 Friday C-9 Daily F-2, S-7 Daily R-35, R-36 Daily A-3 Daily

21 Saturday C-1, C-13 Daily B-3, F-4, S-1 Daily R-8, R-10, R-34 Daily A-8, A-9 Daily

22 Sunday C-3, C-10, B/R Daily B-2, F-5, S-3, C-1 Daily R-17, R-19, R-22 Daily A-4 Daily

23 Monday C-6, C-11 Daily B-1, F-7, S-9, C-3 Daily R-4, R-27, R-29 Daily A-2, A-5 Daily

24 Tuesday C-4, C-5 Daily B-7, F-1, S-2, C-5 Daily R-16, R-32, R-34 Daily A-12 Daily

25 Wednesday C-12, B/R Daily B-6, F-3, S-4, C-2 Daily R-11, R-20, R-25 Daily A-1 Daily

26 Thursday C-14, C-16 Daily B-4, F-6, S-5, C-4 Daily R-6, R-23 Daily A-10, A-6 Daily

27 Friday C-15 Daily B-5, S-8 Daily R-14, R-24 Daily A-7, A-11 Daily

28 Saturday C-2, C-7 Daily B-3, F-2, S-7, C-3 Daily R-1, R-7, R-31 Daily A-3, A-8 Daily

29 Sunday C-8, C-9, B/R Daily B-2, F-4, S-1, C-4 Daily R-13, R-18, R-33 Daily A-9 Daily

30 Monday C-10, C-13 Daily B-1, F-5, S-3, C-1 Daily R-5, R-28, R-30 Daily A-2 Daily

31 Tuesday C-1, C-3 Daily B-7, F-7, S-9, C-2 Daily R-2, R-27 Daily A-4, A-5 Daily


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Maintenance schedule for the Month of September 2010 :

Date & Time Blowroom & Carding D/F, S/F & Comber Ringframe Autocone

Date Day Time Schedule Maintenance Cleaning S. Maintenance Cleaning S. Maintenance Cleaning S.Maintenance Cleaning

01 Wednesday C-1, C-13 Daily B-3, F-4, S-1 Daily R-8, R-10, R-34 Daily A-8, A-9 Daily


03 Friday C-6, C-11 Daily B-1, F-7, S-9, C-3 Daily R-4, R-27, R-29 Daily A-2, A-5 Daily

04 Saturday C-4, C-5 Daily B-7, F-1, S-2, C-5 Daily R-16, R-32, R-34 Daily A-12 Daily

05 Sunday C-12, B/R Daily B-6, F-3, S-4, C-2 Daily R-11, R-20, R-25 Daily A-1 Daily

06 Monday C-14, C-16 Daily B-4, F-6, S-5, C-4 Daily R-6, R-23 Daily A-10, A-6 Daily

07 Tuesday C-15 Daily B-5, S-8 Daily R-14, R-24 Daily A-7, A-11 Daily



10 Friday C-10, C-13 Daily B-1, F-5, S-3, C-1 Daily R-5, R-28, R-30 Daily A-2 Daily

11 Saturday C-1, C-3 Daily B-7, F-7, S-9, C-2 Daily R-2, R-27 Daily A-4, A-5 Daily

12 Sunday C-8, C-10 Daily F-6, S-7, C-3 Daily R-23, R-25, R-32 Daily A-3, A-7 Daily

13 Monday C-3, C-9 Daily B-3, S-1, C-5 Daily R-6, R-11, R-20 Daily A-9, A-4 Daily

14 Tuesday C-1 Daily F-2, S-3 Daily R-16 Daily A-8 Daily

15 Wednesday C-5, C-11, B/R Daily B-2, F-4, S-9 Daily R-14, R-24, R-31 Daily A-5 Daily

16 Thursday C-4, C-6 Daily B-1, F-5, S-2, C-4 Daily R-7, R-15, R-30 Daily A-2 Daily

17 Friday C-14, B/R Daily B-7, F-7, S-4, C-3 Daily R-1, R-5, R-33 Daily A-10, A-12 Daily


19 Sunday C-7, C-15 Daily B-4, F-3, S-6, C-5 Daily R-2, R-16, R-28 Daily A-11 Daily

20 Monday C-2, C-8, B/R Daily B-5, F-6, S-8, C-1 Daily R-12, R-9, R-3 Daily A-7 Daily

21 Tuesday C-9 Daily F-2, S-7 Daily R-35, R-36 Daily A-3 Daily


23 Thursday C-2, C-10 Daily B-4, F-3, S-7, C-2 Daily R-18, R-21, R-24 Daily A-11, A-12 Daily

24 Friday C-1, C-3, B/R Daily B-1, F-6, S-3, C-1 Daily R-1, R-7, R-13 Daily A-3, A-6 Daily


26 Sunday C-6, C-11 Daily B-2, F-5, S-4, C-5 Daily R-2, R-15, R-28 Daily A-4, A-8 Daily

27 Monday C-4 Daily B-7, S-2 Daily R-12 Daily A-2, A-5 Daily

28 Tuesday C-5, C-12, B/R Daily B-6, F-2, S-5 Daily R-17, R-19, R-34 Daily A-10 Daily

29 Wednesday C-14, C-16 Daily F-1, S-8, C-2 Daily R-4, R-10, R-29 Daily A-12 Daily

30 Thursday C-15 Daily B-4, S-6, C-4 Daily R-22, R-26, R-27 Daily A-1, A-11 Daily


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CHAPTER EIGHTCHAPTER EIGHTCHAPTER EIGHTCHAPTER EIGHT

Utility ServicesUtility ServicesUtility ServicesUtility Services


of 112

CHAPTER – 08

UTILITY SERVICES

Utility Department is one of the most valuable department in a factory or mill.

In REEDISHA SPINNING LTD. Utility department facilitates various Utility

Facilities, Which are available below,

(A) A/C Plant

(B) Chiller

(C) Boiler

(D) Generator

(E) Compressor

(F) Water treatment Cooling Tower

A/C Plant :

There are various types of A/C Plant. Such as :

- LTG A/C Plant (Germany, France)

- BEST AIR A/C Plant (Germany)

- LOWA A/C Plant (Germany)

- BATLY BOIL A/C Plant (China)

In REEDISHA SPINNING LTD. the categories of A/C plant is LTG A/C Plant. The

capacity & design of A/C plant is goes according to the different companies. Again,

This LTG A/C Plant mainly three of types,

1. Spilyte Type A/C :

This Spilyte type A/C has two of machine parts. One is Condenser which

condensed the air and Another is Evaporator which evaporates the

Compressed air. Its production capacity varies 1 ton, 2 ton, 5 ton etc. USRT

value.

2. Window Type A/C :

This Window type A/C also has two of machine parts same as Spilyte Type

A/C.

3. Centralizes Type A/C :

This Centralizes Type A/C is centralized settings up for the air flow. It has no

such several parts of the machine. Its production capacity ranges higher varies

from 1000-more required amount of USRT value.


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Generator :

Every generator is completely setup of three parts, such as

1. Engine

2. Generator/Alternator

3. Control system

In on alternator/generator it has mainly three parts, such as

1. Rotor

2. Armature

3. Exciter

Electrical :

In the flow of electrical transferred there is several properties such as,

� From the “BBT” by the taking off box with circuit breaker the electrical line is

placed

� By isolator or circuit breaker the electrical line is given to the different

machine.

In the REEDISHA SPINNING LTD. there is three BBT on capacity, such as

A. Back-side “BBT” : 4000 amp power

B. Ring frame “BBT” : 4000 amp power

C. Autoconer “BBT” : 2000 amp power


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Features of Utility machineries :

Features of Chiller :

A. Steam Fire Chiller :

Model : LSH-SO635

Cooling Capacity : 560 USRT

Chilled Water Flow Rate : 338.7 m3/h

Chilled Water Temperature : 13 – 90C

Cooling Water Flow Rate : 630.2 m3/h

Cooling Water Temperature : 32-370C

Heating Source Type : Steam

Heating Source Consumption : 2490 kg/h

Steam Pressure : 3 kg/cm3

Electric Power : ~3 ∅ 420V 50Hz

Serial Number : 054301098900201C

Manufacture Date : 2005/12

B. Hot Water Chiller :

Model : LWM-W048



Chilled Water Temperature : 13 – 80 C

Cooling Water Flow Rate : 587.3 m3/h

Cooling Water Temperature : 32 – 370 C

Heating Source Type : Hot Water

Heating Source Consumption : 115.100 kg/hr

Heating Source Temperature : 95 – 800 C


Serial Number : 051201098900101C

Manufactured Date : 2005/12

C. Direct Fire Chiller :

Model : LDF-S056S


Heating Capacity : 1.118.000 Kcal/h


Chilled Water Temperature : 13 – 80 C

Cooling Water Flow Rate : 484 m3/h

Cooling Water Temperature : 32 – 370 C

Hot Water Flow Rate : 266.1 m3/h

Hot Water Temperature : 55.8 – 600 C


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Fuel Type : LNG

Total Calorific Value : 9.200 Kcal/Nm3 kg

Gas Pressure : 4.000

Fuel Consumption (cooling) : 1,295,000 Kcal/h

Fuel Consumption (heating) : 1,295,00 Kcal/h


Serial Number : 051201098900401 H

Manufactured Date : 2005/12

Features of Boiler :

Model : WHR-4115/10

Standard : TRD

Standard Capacity : 4.11 ton/h

Max, Allowable Working Pressure : 10 barg

Total Pressure : 18.1 barg

Serial No. : 0396

Manufactured Date : 2006

Features of Generator :

Model : G3516

Generator Serial : 8GW01402

Manufactured In : LAFAYETTE, IN

Manufacturer : Caterpiller (USA)

Manufactured Date : 2006

Rated Power (Capacity) : 1287 KVA (1030 KW)

Phase Rotation : Counter Clockwise

Rated Ampere : 1857 Ampere (P = VICos))

Electric Power : ~ 3Ø, 400V, 50Hz

Ambient : 400 C

Maximum Temperature Rise : 1050 C

Bore : 1070 mm

Stroke : 190 mm

Pole : 4

Features of Compressor :

Model : S 60-2

Type : BOGE SCREW TYPE

Manufacturer : Germany

Serial Number : 5016872

Year of Construction : 2007


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Rate of Flow : 6.34 m3/min

Maximum Service Pressure : 10 bar

Motor Speed : 3,000 rpm

Motor Power : 45+1, 10 KW

Continue Heat upto : 1100 C

Features of Dryer :

Model : BOGE TYPE DB 130

Type No. : 753A

Serial Number : 061/18318/07

Electric Power : 220-230V, 1N~/50Hz

Compressed Air : PS 16bar, TS2 20 C, TSH 600 C

Refrigerant : R 134a/1.60kg, PSL 16bar, PSH 20bar

TSL -100 C, TSL 1200 C

Features of Water Treatment Cooling Tower :

Model : STA 600 SUN

Suction Pipe Dimension : 25 cm

Capacity : 468 m3H

Water in : 370 C

Water out : 320 C

Fan Motor : 7.5×Q H.P.

Poler Volts : 10+ 400V

Air Capacity : 132400 m3/min

Manufactured Date : 2006/03/07


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Log Sheet for Temperature & RH% Control : (Date = 20-09-2010)

(a) Blow Room A/C Plant-1 Log Sheet :

Time Section A/C Plant No. – 1 Outside Air

Standard

R.H.%

Existing

R.H.%

Existing

Temp. 0C

Existing

R.H.%

Existing

Temp. 0C

08.00am

Blo

w R

oo

m D

ep

art

men

t

49 49.0 32.9 92.5 27.2

09.00am 49 49.1 33.2 82.6 28.6

10.00am 49 48.9 33.7 79.1 29.0

11.00am 49 49.0 33.9 75.3 30.1

12.00pm 49 48.8 34.2 78.4 30.4

01.00pm 49 49.1 34.2 75.5 30.3

02.00pm 49 49.1 34.3 61.1 30.9

03.00pm 49 49.0 34.2 70.8 31.0

04.00pm 49 49.0 34.3 61.6 32.8

05.00pm 49 49.2 34.8 62.5 32.9

06.00pm 49 49.1 34.9 60.0 33.0

(b) C/D, D/F, Comber & S/F A/C Plant-2 Log Sheet :

Time

Section

A/C Plant No. – 2 Outside Air

Standard

R.H.%

Existing

R.H.%

Existing

Temp. 0C

Existing

R.H.%

Existing

Temp.0C

09.00am

Carding

Department

50 50.0 33.8 82.6 28.6

10.00am 50 48.8 33.9 79.1 29.0

11.00am 50 50.1 33.8 75.3 30.1

12.00pm 50 50.0 34.1 78.4 30.4

01.00pm 50 49.9 34.0 75.5 30.3

02.00pm 50 50.2 34.5 61.1 30.9

03.00pm 50 50.1 34.2 70.8 31.0

04.00pm 50 49.0 34.6 61.6 32.8

05.00pm 50 50.6 35.0 62.5 32.9

09.00am

Draweframe,

Lap Former &

Comber

Department

48 47.9 33.9 82.6 28.6

10.00am 48 48.0 33.0 79.1 29.0

11.00am 48 48.6 33.4 75.3 30.1

12.00pm 48 47.3 34.6 78.4 30.4

01.00pm 48 46.8 35.0 75.5 30.3

02.00pm 48 49.0 35.1 61.1 30.9

03.00pm 48 50.0 34.8 70.8 31.0

04.00pm 48 50.0 34.1 61.6 32.8

05.00pm 48 48.9 34.0 62.5 32.9


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09.00am

Simplex

Department

46 47.0 34.8 82.6 28.6

10.00am 46 46.9 34.2 79.1 29.0

11.00am 46 45.8 34.0 75.3 30.1

12.00pm 46 46.7 34.6 78.4 30.4

01.00pm 46 47.1 34.9 75.5 30.3

02.00pm 46 46.1 35.1 61.1 30.9

03.00pm 46 46.0 35.4 70.8 31.0

04.00pm 46 46.2 34.0 61.6 32.8

05.00pm 46 46.0 33.9 62.5 32.9

(c) Ring Spinning A/C Plant-3 Log Sheet :

Time

Section


Ring Spinning Frame

Existing

R.H.%

Existing

Temp.0C

Standard

R.H.%

Existing

R.H.%

Existing

Temp. 0C

09.00am

East-01

Side

52 51.8 33.0 82.6 28.6

10.00am 52 52.0 33.0 79.1 29.0

11.00am 52 51.9 33.9 75.3 30.1

12.00pm 52 51.8 33.0 78.4 30.4

01.00pm 52 51.9 33.9 75.5 30.3

02.00pm 52 52.1 34.0 61.1 30.9

03.00pm 52 52.0 341 70.8 31.0

04.00pm 52 52.0 34.6 61.6 32.8

05.00pm 52 52.1 34.7 62.5 32.9

09.00am

East-02

Side

52 51.9 32.1 82.6 28.6

10.00am 52 51.6 32.8 79.1 29.0

11.00am 52 51.9 33.0 75.3 30.1

12.00pm 52 52.5 33.6 78.4 30.4

01.00pm 52 52.9 34.8 75.5 30.3

02.00pm 52 53.0 34.2 61.1 30.9

03.00pm 52 52.9 34.0 70.8 31.0

04.00pm 52 53.0 33.5 61.6 32.8

05.00pm 52 52.4 34.0 62.5 32.9

09.00am

West-01

Side

52 52.9 32.9 82.6 28.6

10.00am 52 52.4 32.8 79.1 29.0

11.00am 52 51.5 32.9 75.3 30.1

12.00pm 52 51.4 33.1 78.4 30.4

01.00pm 52 52.8 33.0 75.5 30.3

02.00pm 52 51.7 33.2 61.1 30.9

03.00pm 52 51.6 33.6 70.8 31.0

04.00pm 52 52.0 32.9 61.6 32.8

05.00pm 52 52.1 33.1 62.5 32.9


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09.00am

West-02

Side

52 52.3 33.7 82.6 28.6

10.00am 52 52.8 33.9 79.1 29.0

11.00am 52 52.0 34.1 75.3 30.1

12.00pm 52 51.9 34.0 78.4 30.4

01.00pm 52 52.2 33.8 75.5 30.3

02.00pm 52 52.9 34.9 61.1 30.9

03.00pm 52 53.0 35.0 70.8 31.0

04.00pm 52 52.8 35.1 61.6 32.8

05.00pm 52 42.9 34.9 62.5 32.9

(d) Ring Spinning A/C Plant-4 Log Sheet :

Time

Section


Ring Spinning Frame

Existing

R.H.%

Existing

Temp.0C

Standard

R.H.%

Existing

R.H.%

Existing

Temp. 0C

09.00am

East Side

52 51.9 32.1 82.6 28.6

10.00am 52 52.1 33.9 79.1 29.0

11.00am 52 52.0 32.8 75.3 30.1

12.00pm 52 51.8 33.0 78.4 30.4

01.00pm 52 51.7 32.8 75.5 30.3

02.00pm 52 52.8 34.0 61.1 30.9

03.00pm 52 52.6 34.1 70.8 31.0

04.00pm 52 52.0 34.2 61.6 32.8

05.00pm 52 52.7 33.7 62.5 32.9

09.00am

West Side

52 52.1 31.8 82.6 28.6

10.00am 52 52.0 32.0 79.1 29.0

11.00am 52 52.3 32.3 75.3 30.1

12.00pm 52 52.8 31.8 78.4 30.4

01.00pm 52 51.7 31.9 75.5 30.3

02.00pm 52 51.4 32.0 61.1 30.9

03.00pm 52 52.9 33.0 70.8 31.0

04.00pm 52 53.0 32.8 61.6 32.8

05.00pm 52 52.8 32.6 62.5 32.9


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(e) Autoconer A/C Plant-5 Log Sheet :

Time Section A/C Plant No. – 5 Outside Air

Standard

R.H.%

Existing

R.H.%

Existing

Temp. 0C

Existing

R.H.%

Existing

Temp. 0C

08.00am

Au

toco

ne D

ep

art

men

t 66 66.1 29.9 92.5 27.2

09.00am 66 66.8 29.8 82.6 28.6

10.00am 66 67.0 30.0 79.1 29.0

11.00am 66 66.7 30.1 75.3 30.1

12.00pm 66 66.2 31.2 78.4 30.4

01.00pm 66 66.0 30.9 75.5 30.3

02.00pm 66 66.0 31.6 61.1 30.9

03.00pm 66 66.8 32.8 70.8 31.0

04.00pm 66 65.9 32.9 61.6 32.8

05.00pm 66 66.0 32.0 62.5 32.9

06.00pm 66 66.1 31.8 60.0 33.0

Air Exchange Rate :

S/N Department Air Exchange Rate

01 Blowroom Department 12.8/hr

02 Carding Department 44.1/hr

03 D/F, Lap Former & Comber Department 9.8/hr

04 Simplex Department 11.2/hr

05 Ringframe Department 47/hr

06 Finishing Department 33.4/hr

Process flow in Air Compressor :

Microfilter – Air filter cartridge – Compressed screw – Air separator – Oil cooler –

Receiver – Dryer – Spinning Machineris.

Compressed air used in different section for different purposes :

A. Blowroom Section :

�� Damper on and off

�� Material distribution

�� Air valve open(in jossi)

B. Carding Section :

�� Coiler tray up and down

�� Sliver cutting


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�� Dust removal from suction hood by air flow

�� Grinding

C. Breaker Drawframe :

�� In drafting system

�� In weighting arm gripping

D. Finisher Drawframe :

�� Scanning roller pressure

�� Weighting arm lock

E. Comber :

�� Detaching roller pressure

�� Draw box

�� Blowing

�� For cylinder

F. Lap Former :

�� In drafting zone

G. Ringframe :

�� SCD (Stationary cop doffing)

�� Tray moving

�� Cop gripping

�� Doffing bar in and out

H. Winding :

�� Cradle lifting

�� Suction mouth lifting

�� Retie pipe lifting

�� Tension device

�� Balcon

Maintenance of Compressor :

�� Air filter change (after 2000 hours)

�� Oil filter change (after 2000 hours)

�� Oil change

�� Oil separator change (after 4000 hours)

�� Motor greasing (after 4000 hours)


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CHAPTER NINECHAPTER NINECHAPTER NINECHAPTER NINE

Power ConsumptionPower ConsumptionPower ConsumptionPower Consumption


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CHAPTER – 09

POWER CONSUMPTION

Power Consumption of Reedisha Spinning Ltd. (Existing Machineries)

S/N Name of

Section

Ampere Load

Avg.

Volt/m/c

(KW)

Avg.

Load/m/c

(KW)

Exist.

M/C No.

Total

Load

(KW) L1 L2 L3

01 Blowroom +

FDP Unit

264 266 268 390 89.08 Complete

Unit

89.08

02 Carding C-60 13 13 13 390 8.52 16 136.32

03 B/D SB D-40 7 7 7 390 4.58 7 32.06

04 F/D RSB D-40 7.5 7.4 7.3 390 4.85 7 33.95

05 Lap Former

E-32

14.4 14.0 14.5 392 9.41 1 9.41

06 Comber E-65 5.5 5.4 5.01 390 3.47 5 17.35

07 S/F FL100 &

HY492C

14.2 14.45 14.0 390 9.33 9 86.97

08 Ringframe

LR 6/A

44.5 44.0 45 395 29.53 36 1063.08

09 Autocone 26 25.5 25 395 16.92 12 203.04

10 Yarn

Conditioning /

Heat Setting

228 227 227 393 149.87 - 149.87

11 A/C Plant-01 150 152 151 391 99.19 - 99.19

12 A/C Plant-02 650 645 648 391 425.66 - 425.66

13 A/C Plant-03 548 547 550 394 363.40 - 363.40

14 A/C Plant-04 254 255 256 392 167.93 - 167.93

15 A/C Plant-05 200 200 200 394 132.38 - 132.38

16 Compressor 88 89.1 89 392 58.61 4 234.44

17 Dryer 9.3 230 2.07 4 8.28

18 Q.C. & Shop

office Lighting

14.5 8.8 11.5 393 7.65 - 7.65

19 B/R to S/F

Lighting

70 92 65 391 49.70 - 49.70

20 Ring to A/C

Lighting

108 91 90 394 63.76 - 63.76

21 Family

Quarter

15.15 31.73 22.27 394 15.25 - 15.25

22 Female

Quarter

23.19 15.97 2.97 391 9.22 - 9.22

23 Office (Admin) 1.80 4.14 19.98 394 5.73 - 5.73

Total Load 3403.72KW


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Power Consumption in Utility Building (Existing machineries) :

S/N Name of

Section

Ampere Load

Avg.

Volt/m/c

(KW)

Avg.

Load/m/c

(KW)

Exist.

M/C No.

Total

Load

(KW) L1 L2 L3

01 Chiller-01

(Steam)

10.84 11.37 10.76 391 7.22 1 7.22

02 Chiller-02

(Hot Water)

9.4 9.8 9.7 392 6.32 1 6.32

03 Chiller-03

(Direct Fire)

9.2 9.5 9.8 391 5.89 1 5.89

04 Boiler 6.2 6.36 3.65 390 3.54 1 3.54

05 Deep Tube

Well

36 37 36 394 28.82 1 28.82

06 45KW Chiller

Pump

58 56 57 393 37.63 7 263.41

07 37KW Chiller

Pump

50 49 50 393 33.01 6 198.06

08 30KW Genera.

Pump

28 27 28 394 18.53 4 74.12

09 11KW Genera.

Pump

18 17.8 17.8 394 11.72 6 70.32

10 Chiller

Cooling Tower

14 15 14 394 9.26 10 92.6

11 Generator

Cooling Tower

8 8 8 394 5.29 4 21.16

12 Make up

Water Pump

10 11 10.5 394 6.95 1 6.95

13 Generator

Exhaust Fan

17.46 25.98 49.6 391 22.56 Complete 22.56

Total Load = 795.08KW

Total Power Consumption : (3403.72 + 795.08)KW = 4198.8KW

Therefore, in Reedisha Spinning Ltd. the existing Power Consumption is 4.2MW.


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CHAPTER TENCHAPTER TENCHAPTER TENCHAPTER TEN

Store & Inventory ControlStore & Inventory ControlStore & Inventory ControlStore & Inventory Control


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CHAPTER – 10

STORE & INVENTORY CONTROL

Inventory system for raw material :

In REEDISHA SPINNING LTD. there different inventory system for different raw

material.

Raw Cotton Store :

All the raw cotton are stored in godown, near the blow room section.

Spears :

In this mills required amount of spears of different machine are stored in mechanical

store room. All the spears are listed in a sheet which is controlled mechanical and

maintenance personal. Spears are arranged in store room according their size,

quantity and requirements. There are selves in store room to keep small spear parts.

Finished Goods :

MSML supplies its finished yarn to different fabric manufacturing industry. So,

package yarn are stored for short time in the finishing section. All the delivered yarn

are noted on tally khata according to lot no, count, quantity, buyer’s name and other

technical parameter.

Inventory system :

From the Head office any one of the Audit officer is done 01st date of every month.

Store’s Various Document :

1. Delivery order

2. Quality certificate

3. Store purchase requisition

4. Store requisition book

5. Packing list

6. Transfer advice of finisher yarn

7. Accounts voucher

8. Scrap return memo

9. Waste cotton transfer advice

10. Money receipt

11. Store return memo (for credit)

12. Gate pass (returnable)


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CHAPTER ELEVENCHAPTER ELEVENCHAPTER ELEVENCHAPTER ELEVEN

Cost AnalysisCost AnalysisCost AnalysisCost Analysis


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CHAPTER – 11

COST ANALYSIS

In REEDISHA SPINNING LTD. The main raw material is cotton. The conversion of

fibre into yarn is made in spinning department of a textile mill.

Since the cost center wise computation of the cost of productions the lengthy and

consuming process, presentation of such an exercise is not possible in a short

training course. The board of categories of cost of spinning process is mention bellow,

�� Raw materials

�� Packing materials

�� Power and gas

�� Store and gas

�� Salary and wages

�� Depreciation

�� Other manufacturing overhead

Raw Material Cost :

Cotton is raw materials used in spinning mill for the production of yarns. Raw

material costs constitute about 55% to 65% of total yarn costs.

A typical example of the computation of raw material cost is given below,

Name of the fibre Fibre Lot Price($) Price(Tk)

CIS-Uzbek-Cottonex 01/05(I,II) 0.72 50.40

CIS-Uzbek- Cottonex 01/05(III,IV) 0.72 50.40

CIS-Uzbek-OLAM 02/05(I) 0.64 44.80

CIS-Uzbek- OLAM 04/05(II) 0.64 44.80

CIS-Uzbek-Cargil 13/05(II) 0.65 45.50

CIS-Uzbek-Cargil 18/05 0.65 45.50


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Rate of count wise yarn Price/Kg :

Yarn count Rate/kg US $ Rate/kg Taka Rate/Lbs Taka

Knitting

20/1k 2.40 168.0 75.6

22/1k 2.45 171.5 77.6

24/1k 2.50 175.0 79.2

26/1k 2.58 180.6 81.8

28/1k 2.70 189.0 85.6

30/1k 2.70 189.0 85.6

32/1k 2.80 196.0 80.7

34/1k 2.90 203.0 91.9

20/1c 2.95 206.5 93.5

22/1c 2.85 199.5 90.3

24/1c 2.85 199.5 90.3

26/1c 2.90 203.0 91.9

28/1c 3.05 213.5 96.7

30/1c 3.05 213.5 96.7

32/1c 3.05 213.5 96.7


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CHAPTER TWELEVECHAPTER TWELEVECHAPTER TWELEVECHAPTER TWELEVE

Marketing ActivitiesMarketing ActivitiesMarketing ActivitiesMarketing Activities


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CHAPTER – 12

MARKETING ACTIVITIES

Exported Consumer of the Product :

Reedisha Spinning Mills is a 100% export oriented company. The main buyers of this

factory are given below,

�� Reedisha Knitex Ltd.

�� P.A. Knit Composite Ltd.

�� Apex Knitwear

�� Greenland Garments Ltd.

�� Unlima Knitting Mills Ltd.

�� HR Textiles Ltd.

�� Fokruddin Textile Ltd.

�� Jointex Knitwear Ltd.

�� KAC Fashion Ltd.

�� Girds Group Ltd.

�� Nigra Textile

�� Meghna Knit Composite Ltd.

�� GMS Group

�� Gross Line Garments

�� Flamigo Fashion Ltd.

�� Jinnat Fashion Ltd.

�� B.Brothers Ltd.

�� Epilion Knitwear Ltd.

�� Harun Twisting Ltd.

�� Kushiara Composite Ltd.

�� Padma Poly Cotton

�� Etc.

Local Consumer of the Product :

Reedisha Spinning Mills produce only Export Quality Yarn. This company does not

sell yarn in local market.

Importing Country :

Raw cotton is imported mainly from Uzbekistan only.


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Exporting Country :

Reedisha Spinning Ltd. Does not export yarn directly? They sell yarn to the various

factory of Kohinoor Group and other export oriented factory. They make Knitted

garments & Dyed fabric, then export final product.

Package Level :

Package level contain following information as shown below,

�� Yarn count

�� Types of yarn

�� Code no

�� Lot no

�� Factory name

�� Date of making yarn

�� Weight in Kg

Measurement of Packaging Bag :

The following measure for the delivery packages as shown below,

�� Length of Packaging bag = 37 inch

�� Height of Packaging bag = 48 inch

�� Weight of Packaging bag = 51.3 Kg

�� In a bag contains 24 cones of the output product

�� Each cone contains 2.04 Kg yarn

Marketing Strategy :

The marketing men at first analysis value of raw cotton present time & future time.

If they see that it will be better to buy cotton at present time, they will contract with

foreign company by L.C. immediately otherwise they will buy cotton in future time.

Bellow the result of topic,

�� Analysis the market

�� Price strategy

�� How will act the market

�� 100% export oriented

�� To take part on the economic condition of Bangladesh

�� To earn foreign currency


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Responsibilities & Duties of Sales man :

The main duty and responsibilities of a sales men are as below,

�� Introductory call script

�� Standard call script

�� Create new customer by giving then concession

�� To introduce into new product

�� To increase use procedure

�� To protect competition

�� To express the quality product for the customer

�� To analysis the test of customer

�� To bring stability of sales by following different techniques

Responsibilities & Duties of Marketing officer :

Marketing officer is a very important person of a company and his duty and

responsibilities are as below,

�� Buying, selling & transportation

�� Financing and packaging

�� Publicity and advertising

�� Collection of marketing information

�� Development of strategy for attacking & penetration customer master list

�� The analysis total consumption of yarn all over the year

�� They produce a cost sheet of yarn

�� They visit different textile mills to realize total yarn required

�� They always look after to world market


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CHAPTER THIRTEENCHAPTER THIRTEENCHAPTER THIRTEENCHAPTER THIRTEEN

ConclusionConclusionConclusionConclusion


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CHAPTER – 13

CONCLUSION

Technical education and its adoption in practical field we involved inextricably,

without the implementation of the knowledge gathered in technical education its

success is bound to suffer. Therefore, this two month industrial attachment as a

partial fulfillment of our B.Sc. in Textile technology course helped us to

accomplish the gap between theoretical and practical knowledge by providing an

elementary idea about industrial environment processing machines, tools and

equipments, production system and maintenance, administration and management

system.


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