SPINNING
Prof. R. Chattopadhyay IIT, Delhi
Quality of incoming raw material to the Khadi Institution Process Monitoring and Control
MATERIAL FLOW
Transportation of Sliver / roving Khadi Institution 1 Internal transportation Khadi Institution2 Khadi Institution3
Institutional spinning
Village 1
Village 2
Village 3
Village n
Charkha
1 2 3 4 10
PROCESS CONTROL
Input PROCESS Output
Corrective action
Monitor
Monitor Process parameters /Intermediate product characteristics/Machine conditions/Work practice / process waste Compare against norm
Monitor
Corrective action
loading on trucks
- Transfer sliver into polythene bags - Put roving bobbins into polythene bags - Transport sliver cans, polythene bags
- Run at a slow speed in the beginning and then raise speed and maintain speed at a convenient level. - Cover the charkha once spinning is over. - The broken end should be pieced (joined) properly. A knot is to be avoided as it becomes too large with respect to the yarn diameter, which deteriorates fabric appearance
II. Lea Making -All the sections of the lea should be made from same yarn count. -The end of the yarn should be inserted in to the inner portion of the lea. -Leas should be properly stored in plastic bags or fabric bags with count wise segregation by colour mark. -If possible, lea bundles should be segregated while storing according to the type of fibres used or count to avoid accidental mixing.
b) Maintenance related -Follow a specified maintenance schedule in terms of cleaning and oiling.
Roving
-Roving cleanliness
Process Performance -Waste level -End breaks in charkha - Productivity
Nominal Count
Average weight of lea Count CV %
= 20 Nm
= 50 gm = 10
S.D. of count
= 60 gm and = 65gm and 40 gm 35gm
= 5gm
50 g 40 g 35 g
Lower Warning Limit (LWL) Lower Action Limit (LAL)
Operator ID
65 g
Lea weight ( gm) 60 g
50 g 40 g
35 g Operator ID
Lower Warning Limit (LWL) Lower Action Limit (LAL)
50 g 40 g 35 g Operator ID
Lower Warning Limit (LWL) Lower Action Limit (LAL)
WHAT ACTION IS TO BE TAKEN For case I -Wrong Draft Change Pinion ( DCP) -Inadvertent change in draft constant -Wrong count of sliver or roving For case II -Count of sliver / roving supplied is to be verified -Too coarse and too fine sliver / roving are to be withdrawn -Draft on charkhas are to be adjusted
1 2 3 4 5 6 7 8 9 10
REASONS FOR HIGH BETWEEN OPERATOR COUNT VARIABILITY (CVBO) Difference in average hank of sliver/ roving used. Difference in the total drafts in the charkhas Difference in effective drafts between spindles of charkhas due to cot slippage. Roving stretch
REASONS FOR DIFFERENCE IN AVERAGE SLIVER HANK Difference in waste level and mechanical draft in card breaker or finisher draw frame. DIFFERENCE IN AVERAGE ROVING HANK Difference in sliver hank. Draft difference in speed frames. Differences in waste level in card.
DIFFERENCE IN AVERAGE DRAFT IN CHARKHAS Wrong draft constant in charkha or wrong change pinions Difference in effective draft within a charkha -Slippage of top rollers, inadequate roller pressure. ROVING STRETCHING Inadequate roving twist, low inter fibre cohesion (specially when fibres are short),defective bobbin holder
be practicable.
2. Only when yarn samples for any new lot arrives , the
YARN APPEARANCE
Subjective assessment based on visual check of yarn boards on yarns received from operators when fresh yarn lots are received from them for a new mixing . Maintain a record according to operator ID REASON FOR POOR APPEARANCE High yarn unevenness Many excessively severe thick, thin places and neps in the yarn Presence of too many impurities like seed coat, leaves, stalks etc in the yarn
1240
LWL LAL
Action to be taken Case I: Points fall below the lower Action Limit or continues to fall in between Warning and Action Limit for many operators.
-Inadequate twist in the yarn. -Finer yarn count. -Weak fibres in mixing.
Twist and count testing of the same are to be performed to find out whether the twist is really low or the count is fine. The lower twist could be attributed to: Lower spindle speed due to slippage, which can be due to Loose driving cord of spindles. Accumulation of oil/grease on cord driving the spindles (mall).
Reasons for finer yarn -Higher total draft. -The finer sliver/roving supplied.
If count and twist are as per nominal value but CSP is still found to be less, inadvertently a sliver/ roving may have been supplied from a mixing in which the fibres are intrinsically weak. Reasons for high strength variation Intermittent slippage of top roller in the charkhas. Variability in between yarn count produced on different charkhas.