Process control in warping-2

Efficiency of Warping Department The following will calculate the efficiency of a warping machine: Let Speed in m/min= 300 Set length (m) = 18000 Yarn length on cone/cheese (m)= 54000 Number of Ends/beam= 500 end breaks/400 ends/ 1000 m = 3 Time to mend a warp break (seconds) = 35 Time to change a beam (seconds) = 500 Time to change a creel (seconds) = 3000 Time loss due to miscellaneous causes/1000 m (seconds)= 25 Calculation Running time R (s) = 1000x60/300 = 200 R is the uninterrupted running time in meters Breaks/running ends in beam/1000 m = 3x500/400 = 3.75 Stoppage time /1000 m (a) to mend breaks (s)= 3.75x35 =131 s (b) to change a beam (seconds) = 500x1000/18000 = 28 s (c) to change a creel = 3000x1000/54000 = 56 sec (d) Miscellaneous time = 25 seconds Therefore, S, the total stoppage time per 1000 meters (s)= 131+28+56+25 = 240 s Therefore total efficiency = Rx100/(R+S)= 200x100(200+240) = 45.5 % Expected Production per shift of 8 hours (m) = (300x60x8x45.5)/100 = 65,500 m Causes of Low efficiency or Low productivity 1. Increase in End breakage rate The machine efficiency at warping is highly sensitive to the end breakage rate 2. Improper utilisation of magazine creel If the creel boy does not keep the magazine creel ready to be used by the time the package in the running creel are over, the efficiency will fall. 3. Reduction in Average Set-length

Lower set lengths reduce the machine efficeincy at warping 4. Number of Tenters per Machine The number of tenters per machine determine the time to mend an end break. This is because by the time the warper finds a broken end on the beam, the creel boy brings the other end of the broken yarn from the creel 5. Stops due to Machine Breakdown, shortage of cones etc. If the stops due to machine breakdown, shortage of empty beams or cones/cheeses etc. are high, the actual efficiency of the machine will be lower than calculated.

Efficiency of Sizing
Efficiency of Sizing Department The major causes of loss of machine efficiency are: 1. Creeling, which includes removing the exhausted beams, mounting new beams, denting, leasing etc. 2. Replacement of weaver's beam on consumption Efficiency in sizing Let yarn count= 34 Set length on warper's beam= 18000 m length of yarn on weavers beam= 1500m Total number of ends= 4000 Full running speed= 50 m/min No of lappers per 3000 ends per 1000 m = 3 Time to cut a lapper = 90 sec Time to doff a beam and put new lease rods = 600 seconds time to change a set = 6300 sec Time loss/1000 m due to miscellaneous causes= 60 sec Calculations Sizing time of one beam with no stops : R = (1500x60)/50 = 1800 seconds Lappers per beam of 1500 m per 4000 ends = 6 time lost in cuttin glappers per beam = 540 seconds Number of weavers beam per set= 12 time lost per beam in a set change = 6300/12=525 seconds time loss in beam doffing and leasing per beam = 600 seconds Miscellaneous losses per beam of 1500 m = 90 sec total time to size one beam = 3555 seconds Machine efficiency = (1800 x 100)/3555 = 50.6%