VISIT REPORT

Page 1 of 26
VISIT REPORT
Customer name: Sepa Mensucat Date: 01.12.2021
Contact: Özcan Bey Created by: Oğuzcan
YAZAR&Akın
ÖZDEMİR
Time of visit: 04.11.2021 Report to: MR.Klaus WOLF
   Mr. C. WEBER

Project no: 108272 

Commission No.: 190544-190548
Machine set-up:  
Yarn process: Regenerated OE yarn

Content of report: 1. Reason for visit

2. Description of situation, problems
3. Measures and results
4. Administration comments
Appendices to the report:   

1. Reason for visit

Customer complained that there is too much broken needle at the revolving flats needles.

2. Description of situation, problem

The customer mix regenerated and Pes fibers as raw material, the content changed every time according to order.
The Customer generally produce between 20 Ne and 30 Ne Open End yarn. The customer has 16 TC 19, the
carding machine MTT design is 3.2, Some of the machine’s revolving flats needles are damaged and broken. I
examine all machine one by one.

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Page 3 of 26
Page 4 of 26
 Card Setting of Machine
Feed roller-1.
40
licker-in
3. licker-in-
10
Cylinder
A 1 2 3 4 5 6 7 8 B/C
Licker-in side Cove Clea MT MT
MTT MTT MTT Clean MTT Clean
MTT 3.2 r n T T
50-
40 28 20 19 18 50-22 16 16 22
22
Revolving
13
Flats
C/B 1 2 3 4 5 6 7 8 A
Doffer side MT MT
MTT 3.2 Clean MTT MTT MTT MTT Cover MTT cover
T T
40-20 14 14 35-18 14 14 - 14 15 40
Cylinder
9
-Doffer
Stripping
7
roller- doffer

Grinding Table
Wire Types Revolving Flats
how many Last done
Machine no Date
times tonnes
1 1 160 26.10.2021
2 1 168 26.10.2021
3 1 169 26.10.2021
4 1 172 26.10.2021
5 1 0
6 1 174 26.10.2021
7 1 175 26.10.2021
8 1 172 26.10.2021
9 1 172 25.10.2021
10 1 174 25.10.2021
11 1 167 25.10.2021
12 1 176 25.10.2021
13 1 159 25.10.2021
14 1 168 25.10.2021
15 1 174 25.10.2021
16 1 177 25.10.2021

Page 5 of 26
3. Measures and results

Page 6 of 26
(ALL THE INFORMATION AND THE DETAILED INFORMATION ABOUT CHANGED
MAGNOTOP ARE ADDED TO EXCEL FILE)

When I examining that problem, I do task list like as:

 Check the machine layout
 Check raw material situation (fiber or fabric for regenerated)
 Check MTT design and status
 Check the all wires status with digital microscope
 Check the Revolving flats one by one
 Examine where the damage according to magnotop (side, middle)
 Give them marks according to damage
 Check at least one machine setting
 Show the place of the machine in the machine layout
 Make an overview of the all machine with adding material feeding direction

Machine Layout

Overview of the Problem

 AFRA TEKSTİL Magnotop Breakage Problem

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 0 - 170 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

Magnotop Damages
Notes Pictures

Very low damage

Medium damage The damaged places are

generally of placed at the middle
of the sides. But sometimes the
damaged place seperated at the
High damage whole magnotop

Very High damage

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320 All cards have same
1 2 3 4 5 6 7 8 MTT
Doffer Side
550 550 Clean 550 550 Cover 550 550
Notes About Machine

The general settings of the machine are normal, but the machine has a serious cleaning problem. machines weigh approximately 180 tons. Revolving flat
wires are sharpened once.
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 1

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054408 1 173 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 32 39 12 1 -
Notes No damage Very Low damage Medium damage High damage Very high damage

Very high
MAGNOTOPNoDAMAGES
damage 32
damage
Very Low High damage
39 0%
Medium damage 1%
damage Medium
14% damage 12
High damage 1 No damage
Very high 38%
0
damage

Very Low
damage
47%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 2

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054407 2 180 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 0 7 10 26 41
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoDAMAGES
damage 0 Very Low
Very Low No damagedamage
7 0%
damage 8% Medium
Medium damage
10
damage 12%
High damage 26
Very high
Very high 41
damagedamage
49%

High damage
31%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 3

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054406 3 182 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 14 32 28 9 1
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoDAMAGES
damage 14Very high
Very Low damage
High damage 32 1% No damage
damage
11% 17%
Medium
28
damage
High damage 9
Very high
1
damage
Medium
damage
33%
Very Low
damage
38%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 4

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054405 4 185 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 27 52 3 1 1
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoDAMAGES
Medium 27 Very high
damage
Very Lowdamage damage
High damage 52 1%
damage 4%
1%
Medium
3 No damage
damage 32%
High damage 1
Very high
1
damage

Very Low
damage
62%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 5

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054404 5 185 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 50 33 1 0 0
Notes No damage Very Low damage Medium damage High damage Very high damage

No damage 50
MAGNOTOPVery
DAMAGES
Low
33
Medium
damage Very high
damage
High damage 1% damage
0%Medium 0%
1
damage
High damage 0
Very Low
Very high
damage 0
39% damage

No damage
60%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 6

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054403 6 188 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 47 7 7 8 15
Notes No damage Very Low damage Medium damage High damage Very high damage

No damage 47
MAGNOTOPVery
DAMAGES
Low
7
damage
Very high
damageMedium
7
18%damage
High damage 8
Very high
15
damage
High damage
10% No damage
Medium 56%
damage
8%
Very Low
damage
8%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 7

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054402 7 189 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 21 30 10 8 15
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoVery
damage
DAMAGES
Low
21
30
damage
Very high
Medium No damage
damage
10 25%
18%damage
High damage 8
Very high
15
High damage damage
9%

Medium
damage
12% Very Low
damage
36%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 8

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054401 8 185 60 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 37 32 11 3 1
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoVeryDAMAGES
damage
Low
37
High damage
Medium 32 4% Very high
damage damage damage
13% Medium 11 1%
damage
High damage 3
Very high No damage
1
damage 44%

Very Low
damage
38%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 9

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054808 9 181 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 56 16 3 9 0
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoDAMAGES
damage 56
High damage
Very Low
Medium 1611% Very high
damage damage
damage
Medium 0%
3% 3
damage
High damage 9
Very high
Very Low 0
damagedamage
19%

No damage
67%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 10

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054806 10 184 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 24 23 10 14 13
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoDAMAGES
damage 24
Very Low
23
Very high
damage
damage
Medium
10 No damage
15%
damage 29%
High damage
High damage 14
17%
Very high
13
damage

Medium Very Low

damage damage
12% 27%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 11

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054807 11 177 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 42 38 3 1 0
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoDAMAGES
damage 42 Very high
damage
Very Low
38 0%
Medium damage High damage
damage Medium 1%
3
4% damage
High damage 1
Very high
0
damage No damage
Very Low 50%
damage
45%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 12

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054805 12 186 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 28 41 12 3 0
Notes No damage Very Low damage Medium damage High damage Very high damage

No damage 28 Very high

MAGNOTOPVery
DAMAGES
Low damage
41
damage 0% High damage
Medium 4%
Medium 12
damage No damage
damage
14% High damage 3 33%
Very high
0
damage

Very Low
damage
49%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 13

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054804 13 169 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 0 16 17 18 33
Notes No damage Very Low damage Medium damage High damage Very high damage

No damage 0
MAGNOTOPVery
DAMAGES
Low No16damage Very Low
damage 0% damage
Medium 19%
17
damage
Very high
damage
High damage 18
39% Very high
33
damage

Medium
damage
20% High damage
22%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 14

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054802 14 170 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 22 20 10 30 2
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoVery
damage
DAMAGES
Low
22
High damage
20 36%
damage
Very highMedium No damage
damage 10 26%
damage
2%
High damage 30
Very high
2
damage

Very Low
Medium damage
damage 24%
12%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 15

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054803 15 184 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 6 42 28 8 0
Notes No damage Very Low damage Medium damage High damage Very high damage

No damage 6 High damage

MAGNOTOPVery
DAMAGES
Low
10%
42 No damage
damage 7%
Very high
Medium
damage 28
damage
0%
High damage 8
Very high
Medium 0
damage
damage
33% Very Low
damage
50%
 AFRA TEKSTİL Magnotop Breakage Problem - Machine No 16

Machine Spefication
Commission Machine Total Production cylinder Licker -in
Machine Type Flat Speed Magnotop no: Flat Bar no:
no: No: Production Speed Speed Speed
250
TC 19 19054801 16 185 66 kg/h 515 rpm 1000 rpm 997170600001 4120461148
mm/min
Position of The Machine

Line 1 1 2 3 4 5 6 7 8

Direction of feeding Direction of the feeding

Line 2 9 10 11 12 13 14 15 16

MTT Design

Material Flow
1 2 3 4 5 6 7 8
MTT 3.2. Licker-in Side
89 Clean 140 140 240 Clean 240 320
1 2 3 4 5 6 7 8
Doffer Side
550 550 Clean 550 550 Cover 550 550
Magnotop Damages
How many flats 37 32 11 3 1
Notes No damage Very Low damage Medium damage High damage Very high damage

MAGNOTOPNoDAMAGES
damage 37
Very Low
Medium damage 32 High damage
damage 4%
Medium
13% 11
damage
Very high High damage 3
damage Very high No damage
1% 1 44%
damage

Very Low
damage
38%
4. Administration comments