Project On Loom Stoppage in Weaving Process

Faculty of Engineering
Department of Textile Engineering
Study on Loom Stoppage in

n Weaving: A Case Study on
Mahmud Denim Ltd.
Course code: TE-417 Course title: Project (Thesis)

(Thesis
Submitted by
Gazi Md Abul Hashem ID: 141-23-3838
3838
Md. Shamim Hossain ID: 141-23-3831
3831
Supervised by
Prof. Dr. Md. Mahbubul Haque
Professor &Head
Head, Department of Textile Engineering
ngineering
Co-supervised by
Subrata Majumder
Lecturer, Department of Textile Engineering
A thesis submitted in partial fulfillment of the requirements for thedegree

the of
Bachelor of Science in Textile Engineering
Advance in Fabric Manufacturing Technology
Fall, 2017
©Daffodil International University 1
Declaration
We hereby declare that the work which is being presented in this thesis entitled, “Study on
Loom Stoppage in Weaving: A case study on Mahmud Denim Ltd.” under the supervision of
Prof. Dr. Md. Mahbubul Haque, Professor & Head, Department of Textile Engineer
Engineering,
Daffodil International University, is an original work of our own, has not been presented for a
degree of any other university and all the resource and materials used for this thesis have
been duly acknowledged.
Gazi Md Abul Hashem Md Shamim Hossain

ID: 141-23-3838
3838 ID: 141
141-23-3831
3831
This is to certify that the above declar

declaration
ation made by the candidate is correct to the best of my
knowledge.
……………………………
……………………………………..
Prof. Dr. Md. Mahbubul Haque,
Professor& Head
Department of textile engineering
Daffodil International University
©Daffodil International University I

Acknowledgement
Above all, we praise the almighty Allah who gave us His enabling grace to successfully
complete this research work. With sincerity, we extend our warm and deep appreciation and
gratitude to our supervisor, Prof. Dr. Md. Mahbubul Haque, Head, Dept. of Textile
Engineering, Daffodil International University and Co-supervisor Subrata Majumder,
Lecturer, Dept. of Textile Engineering, Daffodil International University, Dhaka and for their
guidance and support to come up with this research work. Being working with him, we have
not only earned valuable knowledge but was also inspired by his innovativeness which
helped to enrich our experience to a greater extent. His ideas and way of working was truly
remarkable. We believe that this research could not be finished if he would not help us
continuously.
We would also like to express our sincere gratuity to Gautam Saha, GM, Woven Dyeing,
Mahmud Denim Ltd. Located at Safipur, Kaliakoir, Gazipurfor allowing us to complete our
project in these factories and also for their useful guidance throughout the course.
We would also like to thank all who responded to our questionnaires and interviews, which
helped us to come up with this research outcomes.
We are grateful to all our classmates and friends who played vital roles in fulfilling the
research findings and for their encouragement for this research work. Finally, we express our
sincere gratitude to my father, mother, brother, sister and sister-in-law for their continuous
support, ideas and love during my studies.
Thankfully
Gazi Md. Abul Hashem

&
Md. Shamim Hossain
©Daffodil International University II

Abstract
This project is on “Study on Loom Stoppage in Weaving Process”. In woven readymade

garment manufacturing process weaving plays the vital role and in weaving there are several
reasons to study to focus on the lead time, i.e., for machine stoppage in weaving many defect
are produced and a great extent of time is wasted. To maintain buyer driven lead time and
quality it is very important to detect, to identify and to prevent these causes from reoccurring.
There are many kinds of weaving loom stoppage causes found in textile industries and the
aim of this work is to investigate on those areas in weaving. The study was carried out to find
out the effects of various parameters which are responsible for loom stoppage in rapier and
air jet weaving project. Firstly, different looks like rapier or air jet from the weaving floor
were selected randomly and collect different data like warp stop, weft stop, bobbin stop,
manually stop etc. to complete our project work. Each loom was observed for a particular day
of three (03) equal shifts. The data was collected for four (04) different constructions or
fabric qualities. The time taken for repairing and the time during the stoppage of the loom is
also noted. The noted time is classified into warp, weft, bobbin and other breakage. The study
reveals several important results regarding weaving performance and efficiency and it’s
relation with warn breakage. For instance, it can be stated that our study reveals that biggest
portion of stoppage time take place due to warp stoppage (on an average 2.5 mins per
breakage). Then we tried to analyze their causes very effectively to find out the actual reason
and tried to recommend to solve those problems.
©Daffodil International University III

Table of Contents
Declaration..............................................................................................................................................I
Acknowledgement ................................................................................................................................ II
Abstract................................................................................................................................................ III
1. Introduction ................................................................................................................................... 1
1.1 Background of the study .............................................................................................................. 1
1.2. Rational of the study ................................................................................................................... 2
1.3. Scope of the study ....................................................................................................................... 2
1.4. Limitations of the study .............................................................................................................. 3
2. Literature Review ......................................................................................................................... 4
3. Methodology ................................................................................................................................ 11
3.1. Overview .................................................................................................................................. 11
3.2. Data collection ......................................................................................................................... 11
4. Experimental Work .................................................................................................................... 13
4.1. Data Collection of Warping ..................................................................................................... 13
4.1.1.Details about Warping Machine Studied ................................................................................ 13
4.1.2. Data collection Procedure of Warping ................................................................................. 13
4.2. Data Collection of Sizing ......................................................................................................... 14
4.2.1. Details about Sizing Machine Studied ................................................................................... 14
4.3. Details of Loom Stoppage in Weaving Process ....................................................................... 17
4.3.1. Details of Loom Studied ....................................................................................................... 17
4.3.2. Data collection Procedure of Weaving ................................................................................. 17
4.3.3. Data Collection of Warp Stoppage ....................................................................................... 17
4.3.4. Data Collection of Weft Stoppage ........................................................................................ 22
4.3.5. Data Collection of Bobbin Stoppage .................................................................................... 28
4.3.6. Data Collection of Others Stoppage ..................................................................................... 32
©Daffodil International University IV

5. Result and Discussion ................................................................................................................. 38
5.1. Analysis of stoppage in Warping ............................................................................................. 38
5.2. Analysis of Stoppage in Weaving ............................................................................................ 38
5.2.1. Analysis of Warp Stoppage .................................................................................................. 38
5.2.2. Analysis of Weft Stoppage ................................................................................................... 40
5.2.3. Analysis of Bobbin Stoppage ............................................................................................... 41
5.2.4. Analysis of Others Stoppage ................................................................................................ 42
5.2.5. Comparative study of warp and weft breakage .................................................................... 42
6. Conclusion ................................................................................................................................... 43
7. References .................................................................................................................................... 44
©Daffodil International University V

1. Introduction
1.1 Background of the study
The readymade garments (RMG) industry of Bangladesh is the most important export
oriented industry of the country. In 2004, the sector’s contribution to GDP was 9.11% alone
while the share of the total export of the country was 12.18% only. The export of RMG has
been the driver of the enhanced contribution of the export to the GDP over the last two
decades.
In the year 2016 Bangladesh textile & clothing industry has faced many challenges, including
worker unrest, gas crisis etc. and of course positives were many as it could continue to
contribute to the country economy and global trade very significant. The purpose of the
report is to give a brief view to the readers about 2016’s overall scenario of Bangladesh RMG
industry. According to the IMF, Bangladesh’s economy is the second fastest growing major
economy of 2016 (Dec), with 7.11 percent Gross Domestic Product (GDP) growth rate where
the growth rate was 6.12 percent in 2015. Contribution of industry to the GDP was 28.1%,
where RMG sector donate the biggest part. Since 2004, Bangladesh averaged a GDP growth
of 6.5%, which has been importantly driven by its exports of readymade garments.
A close look at the composition of RMG export of Bangladesh over the last two decades
reveals that the woven garments sub-sector constituted the lion’s share. In fact, the beginning
of the development of RMG sector started with woven garments in 1985. In the first half the
90s, the share of woven garments was above 80%. However, the share gradually started to
decline to about 70% in five years late and to 62% in 2004 and to 38.80% in 2005-2006. In
addition, compared to its double-digit growth in the 90s, the woven garments export grew
only about 8% in 2000. Such a declining growth rate and a steep decline of the share of
woven garments export in the total RMG export makes it urgent to re-evaluate the status of
the sector of Bangladesh vis-à-vis with that of the competing countries.
We the men of Bangladesh are inborn weavers. If we turn back near future we can see that
the local woven sector was very rich in product mix. But in recent times with the gradual
development in knit sector, woven sector is day-by-day lagging behind. A matter of great
sorrow that we only produce 30% of export oriented woven fabrics fabric while we import
around 70%woven fabrics form abroad.
There are many reason are responsible for low production of woven products and production
efficiency. The causes for efficiency losses in looms can be divided into two broad categories
as frequency dependent and miscellaneous. Warp and weft breaks, beam gaiting belongs to
first category, whereas healds broken, doffing, loom repairs, weave away, etc. are termed as
miscellaneous causes. Interference is, yet, another cause of stoppage. Its extent depends upon
the number of looms assigned to a weaver and frequency of warp and weft breaks.
Miscellaneous causes are those occurring at random. Further, such causes cannot be ascribed
any definite frequency. Whenever an operator is in charge of more than one machine, there is
loss due to interference. On looms, this loss is observed to be essentially a function of such

stoppages as warp breaks, weft breaks and hence for all practical purposes, it may be
expressed as a percentage of the total loss on account of these causes.
The efficiency losses arising from loom stoppages in looms are generally of two types such
as those requiring the weaver’s attention and those not requiring weavers attention. The
former category includes causes like warp breaks, weft breaks and interference. Losses due to
warp and weft breaks are in proportion to the frequencies. The interference loss is depend
upon the loom assignment to weavers, frequency of warp and weft breaks, average distance
required to be walked per stoppage and other miscellaneous jobs performed by a weaver.
Losses due to stoppages not requiring weaver’s attention arise from loom repairs, cleaning
and oiling, beam gaiting and others. Efficiency loss on account of beam change varies
according to its frequency, while other losses depend upon the organizational setup,
frequency of breakdowns, types of looms, sorts woven and level of maintenance.
As stated earlier, efficiency losses due to warp and weft breaks and beam gaiting of
frequency dependent and hence they vary from mill to mill and also sort to sort within the
same mill. On the other hand, efficiency losses, ascribable to loom repairs, cleaning and
oiling, doffing and other stoppages are observed to be of more or less the same order between
mills. For all practical purposes, it would be quite in order to provide an overall allowance for
the losses arising from these causes. [1] [2]
1.2. Rational of the study

The main objective of this study is to examine and identify the causes of loom stoppage in
weaving section and analysis the effective steps to minimize these problems. Beside this, the
research targeted to achieve the following specific objectives:
To identify the exact causes of loom stoppage in weaving process.
To know the effect of loom stoppage in weaving efficiency
To know the Effect of yarn breakages on weaving efficiency
To know the different factors which are responsible for loom stoppage?
To take effective steps to minimize these problem.
1.3. Scope of the study

The main scope of the study is to identify the causes of loom stoppage and to prevent this
problem improving the weaving production efficiency. Different types of loom like rapier, air
jet and projectile loom are used to produce woven fabric. During weaving production,
sometimes loom are stopped due to different problem like warp breakage, weft breakage or
overloaded weavers. By this study, we come to know that now-a-days the usual practice to
provide looms with a warp stop mechanism and a weft stop mechanism to bring the loom to
rest whenever a warp thread or a weft thread breaks or becomes otherwise unsuitable for
weaving purposes, and one of the objects of the resent invention is to provide a train of
mechanism of simple and effective character for stopping the loom on the occurrence of
either a warp or weft fault.

1.4. Limitations of the study
Loom stoppage in weaving process is a great problem. Due to loom stoppage the production
efficiency may be low. So during survey the surveyed personnel do not provide us with any
written information about their opinion or any strategy about their activities. So there may be
some short comings. Above all, this study is weak in some points. The notable ones are as
follows:
The survey was conducted in a very short time so it is not able to collect more
information.
Only the big and the reputed factories, suppliers are consider here as sample.
Huge numbers of factories are engaged to produce woven fabric and different types of
loom are used. So it was not possible to visit different industries, so there are some
limitations in this report.
They didn’t want to disclose their business policy. This was unavoidable scenario in
maximum case.
Another limitation of this study is the person’s private information were not
disclosing here, which could be very much useful.
Lack of experience in this field.
Lack of proper personnel to conduct this interview program.
Lack of appropriate sufficient data regarding export oriented woven fabric in internet.

2. Literature Review
In order to work to the loom stoppage in the weaving process, at first we need to analysis
some previous literature or thesis paper which is related to this. So now we analysis some
previous experimental work about loom stoppage, warp breaks, weft breaks and other related
works.
2.1. Reduction of warp breaks on loom by modification of the mode of beat-up
M. JWERAN said that Continuity of weaving is repeatedly interrupted by yarn breaks, warp
breaks being of highest importance, particularly so in the case of broad (multiple-width)
fabrics, partly because the average standstill time is high (1-3min) and also because the
frequency of standstills caused by warp breaks is very high even at apparently low specific
values.
A novel device is described which loosens the fabric in the moment of beating up the weft
and thereby reducing warp tension. Its utilization lowers the number of warp breaks, i.e. the
value basically controlling loom efficiency and the number of looms assignable to one
weaver. Tension peaks in the warp decrease by 30-66% allowing to raise the number of
looms per weaver at a time utilization factor of 70% of the weaver - by 50-100% with a
simultaneous rise by 5-7%in loom efficiency. Another advantage is that fabrics with high
densities can be woven in cases when - owing to insufficient tensile strength of the warp yarn
it would be impossible without the device. [3]
The advantages of the tension-reducing device are:
Decrease of the warp tension peak at beat-up.
Significant decrease in the number of warp breaks.
Higher weft density being achieved.
2.2. Efficiency Analysis in Rapier Loom
According to A. N. M. Masudur Rahman & Md. Ruhul Amin, the study was carried out to
find out the effects of various parameters on efficiency in rapier looms. The main objective of
this study is to increase the efficiency and through that increase the productivity and
profitability.
Surveys shown that the cost of actual weaving operation in mills with modern preparatory
machines and automatic looms about 60%- 65% of the total cost for conversion of yarn into
fabric. This means that a small increase in loom shed efficiency via productivity will result in
considerable reduction of manufacturing cost.
In this project they worked in the different construction of fabric, different design of fabric
and different loom speed in the weaving process. After completing this surveys both of them
saw that productivity decrease due to different stoppage like-

Stops due to warp breaks and warp faults
Stops due to weft breaks
Stops due to mechanical failures
Miscelleneous stops.
Finally they found many faults and problem and suggested many solution like-
Proper lubrication and cleaning should be done frequently. The preventive
maintenance is advised for better performance of the loom.
A supervisor should be present for all eight hours of the shift. It will considerably
increase the efficiency.
When there is poor raw material, then the efficiency of the loom as well as the quality
of the fabric decreases.
Sizing plays a vital role on efficiency. So appropriate size take up should be
maintained strictly.
Skilled weavers can repair broken yarns very quickly compared to unskilled weavers.
Also the work load of the weaver has a very important effect on the weaving
efficiency, since it affects the time a loom is stopped awaiting attendance. The weaver
should be trained so that he takes the minimum possible time for clearing a stop.
Loom allocation should be optimum.
Motivation is another major thing to be considered. If a weaver is able to produce
higher efficiency he should be encouraged by higher percentage of wages or in some
other way. At the same time if a weaver produces lower efficiency he should be
punished by reducing the percentage of wage or by some other way. [4]
2.3. Control of weft breakages for cotton & polyester weft yarn
Tushar Patil said that the project mainly focuses on the control of weft yarn breakages to
improve the loom efficiency. The main advantages of the modern air jet weaving machine is
high weft insertion rate up to 2000 meters per minute.
This study is conducted to reduce the loom stops due weft breakages by changing variables in
terms of air pressure setting and heald frame setting on air jet loom. Trials were conducted
for weft yarn of cotton yarns of 40 Ne, 80 Ne, 100 Ne and polyester filament yarn of 30
Denier.
In this project he worked different count of cotton yarn and polyester filament, different
design of fabricin the weaving process. After completing this surveys he saw that weft yarn
breaks due to different count of cotton yarn and polyester filaments and suggested some of
the solution like-
Weft Breakage study for Cotton yarn
In case of 40Ne cotton yarn, by reducing air pressure of main nozzle gives the 40 %
reduction in filling, this is followed by synchronizing the air pressure of main and
relay nozzles.

As coarser yarn is having more hairiness, as compare to finer yarns it requires low air
pressure value for propulsion during weft insertion.
Also in case of finer yarns (80Ne and 100 Ne) as weft, by changing the timing of shed
crossing timing gives the slight reduction in filling value. This is because closing the
shed earlier will leads to arresting of weft yarn in the warp yarn in the upper layer of
shed.
For cotton weft yarn, 5% increase in loom efficiency is noted after conducting trails
as per the above parameters.
Weft Breakage study for Filament yarn
In Case of filament yarn Co-efficient of friction is less as compare to cotton yarns,
because of having smoother outer surface. Hence it requires higher air pressure value
than it is in cotton yarn. Results from above study shows that by increasing the air
pressure of main as well as sub-nozzles gives the 30 % reduction in weft.
For filament weft yarn, 3.5 % increase in loom efficiency is noted after conducting
trails as per the above parameters
From the above study it has been concluded that by optimising the air pressure value of main
and sub nozzles as well as shed crossing timings gives the 40 % and 30 % reduction in filling
for cotton and filament weft yarns respectively. This will give an increase in loom efficiency
by 5% for cotton yarns and 3 % in case of filament yarns. [5]
2.4. Productivity Improvement of Loom Shed by Optimizing Relative Humidity

According to Vicky Ashok Patil, Sujit Shrikrushnarao, GulhaneRanjit N Turukmane
&Rajendra Patil,this study was conducted toanalyze the effect of relative humidity to warp
breakages in weaving and to optimize relative humidity with minimum warp breakage rate.
The productivity of the loom is govern by the speed, efficiency and quality of the fabric
produced. Loom stoppages during the weaving process not only reduces the productivity but
also affect the fabric quality as startup marks and differential dye take up are appeared on the
fabric as defects. In the woven fabric manufacturing, warps ends are generally sized so that
they can withstand various stresses encountered in weaving process.
The breakage rate of cotton sized warp yarn is highly sensitive to the relative humidity and
shows large difference with change in relative humidity. In weaving industry it is a
challenging task to find out optimum level of relative humidity to get minimum warp
breakage rate.
In this project they worked different count of cotton yarn and different loom in the weaving
process. This study was conducted for one month and collected data was studied for effect of
relative humidity of warp stoppages and loom efficiency.
After completing this survey they saw that the efficiency of the loom ranges from 55% to 91
%. The efficiency of the loom is highest at 85% RH. The efficiency of the loom lies in the
range of 79% to 91% for the 84- 85 % RH.

The efficiency of the loom is on lower side in the range RH 80%-83% this is due to cracking
of size film at low RH and causing to warp breakages whereas above 85% RH drastic
increase in wap breakages results in reduction in efficiency highly, this is due to higher
humidity makes the size coating soft and scrubbed off from the yarn while rubbing with
several parts of the loom such as heald reed etc. This bare yarn does not withstand wear
during weaving and breaks. The results indicate that, given fabric with sort no.- S10700 it
better to weave at a RH of 84% -85% for minimum warp breakages and highest efficiency of
the loom.
The effectiveness control on the loom shed efficiency leads to control on warp breakage rate.
This innovative methodology reduces the ideal time of the loom while improving the
productivity and fabric quality. The present methodology of research, its findings have strong
industrial application. [6]
2.5. Loom Speed and Tension to Reduce Warp and Weft Breaks in Air Jet Weaving
Nkiwane, L and Marashe S said that the study sought to identify correct values of loom speed
and warp tension suitable for weaving 100% cotton yarn on Dornier double beam Air Jet
Looms, AWSE2/E type. The causes of warp breaks are, poor quality yarn, uncontrolled
temperature and humidity, uncontrolled weaving tension and loom speed. The experiments
were conducted to determine warp and weft breaks at i) varying warp tension (50cN to 85cN)
and constant speed (560 rpm,), ii) at constant warp tension(80cN) and different loom speed
(520 to 560 rpm). In these experiment, temperature and relative humidity and were kept
constant at 27℃and 75% respectively. The yarn quality was good (11cN/tex), according to
the Ulster Statistics standard levels which was the exact tenacity of the 30 tex yarn used. The
results showed that warp and weft breaks occur even if the maximum warp tension during
weaving is lower than the breaking strength of the yarn. A combination of high loom speed
(560 rpm) and high tension (80cN) lead to increased breaks, but breaks become reduced with
the reduction in tension to 70cNeven if the machine speed was maintained at 560 rpm.
Above that tension, warp breaks start to increase. The number of warp breaks was also found
to increase with the loom speed. Weft breaks also occurred due to entanglement at low warp
tension (50cN). Adjustment of warp tension and loom speed can help to determine the
optimum values of warp tension and loom speed to be used in order to reduce the number of
warp breaks for individual Air Jet Looms
In weaving, unwanted loom, stoppages always occur leading to low production rates. Loom
stoppages during the weaving process usually occur as a result of warp breaks, weft breaks,
mechanical breakdown, electrical faults, beam gaiting, shortage of spare parts, power cuts,
beam changing, cleaning, oiling and lubricating. Amongst these warp and weft breaks, and
beam gaiting occur more frequently than there it.
In Air Jet Looms, warp and weft breaks causing loom stoppages during weaving, are more
frequent when using 100% cotton yarn.

Wrongly adjusted machine parameters and weaving conditions lead to yarn breaks during
weaving. For instance, warp breaks can be a result of uncontrolled room temperature and
relative humidity, poor quality yarn, excessive loom speed, uncontrolled warp tension. Other
causes can be due to knots on warp yarn, poor size pick-up, loose ends, fly stuck onto threads
and abrasive effect of the drop wires and the heddles. Warp breaks cause longer stoppages as
compared to weft breaks since they require more time for repair particularly when using
100% cotton yarn
The results were analysed so as to find the most appropriate warp tension and loom speed
values that could be used for initial machine settings, and contribute to minimising breaks in
Air Jet Looms. These results can be used as a guide for weavers working under similar
working environments:
Effect of variation of warp tension and constant loom speed on warp breaks
Effect of variation of loom speed at constant warp tension on warp breaks
Time taken to repair a warp break and time taken to repair a weft break
In order to reduce the number of warp breaks, warp tension required when producing plain
weaves on AWSE 2/E Dornier Air Jet Loom should be between 65 and 75cN/thread for a
loom running at a speed of 560 rpm .The modelled equation that defines the behaviour of
warp breaks on varying warp tension can help the weaving companies to predict the number
of warp breaks which can occur at any given warp tension. This can help to determine the
most appropriate tension for initial warp tension setting. Adjustment of warp tension and
loom speed can help to determine the optimum values of warp tension and loom speed to be
used in order to reduce the number of warp breaks in Air Jet Looms.[7]
2.6. Critical efficiency analysis in projectile looms

P. Ganesan & S. Hariharan said thatunlike in winding, warping and sizing where the
emphasis is on the quality of preparation, in the loomshed, control of fabric quality as well as
of productivity assume significant importance. The weaving operation contributes by far the
largest proportion to the cost of conversion of yarn into fabric. Surveys shown that the cost of
actual weaving operation in mills with modern preparatory machines and automatic looms
about 65% of the total cost for conversion of yarn into fabric.
This means that a small increase in loomshed efficiency via productivity will result in
considerable reduction of manufacturing cost. More importantly an increase in efficiency will
bring in additional realization on the extra fabric available.
The object of this project is to increase the efficiency and through that increase the
productivity and profitability. To do so the efficiency is analyzed by various parameters such
as weaver efficiency, RPM, RH%, allocation of machine, etc
By considering various factors the design has been produced. The design is shown below and
the factors considered will help in getting very high degree of excellence in results.
Analysis of Efficiency by Weavers
Analysis of Efficiency by Different Sorts

Analysis of Efficiency by Loom Allocation
Analysis of Improved Efficiency
Analysis of Efficiency by Relative Humidity [8]
2.7. Study on Improving the Production Rate by Rapier Looms in Textile Industry
According to Aby Chummar, Soni Kuriakose and George Mathew, In India the textile
industry is growing very fast. Most of the earlier established textile industries are using
conventional shuttle looms for the production of the cloth. But the advancement in the
technology made the textile industry more competitive. The effective usage of the new
methods of the weaving technology, which is more energy efficient, makes the production
more economical. It is found out that the usage of the conventional looms badly affects the
cloth production. This study focuses on identifying the problems associated with the low
production by the shuttle loom and suggesting suitable methods by which these problems can
be reduced. [9]
2.8. Correctly identifying and avoiding weft stoppages

Mike Kos says that the objectives of this article are the analysis of potential causes of weft
stoppages and measures to eliminate them. Most warp stoppages are not due to the system.
However, depending on the weft insertion system projectile, rapier or air-jet, many weft
stoppages are system-related. In weaving mills operating with different weaving systems, a
thorough knowledge of the systems in question is a precondition of accurate stoppage
analyses. Different, appropriately designed report forms are available for each weft insertion
system.
After completing survey, he found lots of causes which are responsible for loom stoppages.
These are:
Weft loop close to the left selvedge
Weft loop in the shed mid-way along the weaving width
Weft loop on the right in the temple region
snarls in the shed
snarls in the drawing-in area on the right
snarls at the pick tip, mainly on the right
Low weft yarn quality not only impacts on weaving machine efficiency. Depending on how
the machine is equipped it may also severely impair fabric quality. Also, yarn breaks may
occur that do not necessarily cause stoppages. Examples include stop picks on air-jet weaving
machines and very late yarn breaks in the weft tensioning phase on projectile weaving
machines. [10]
2.9. Reduction of warp breakage by effective control of strain on warp yarn

S .Mukherjee & K N Chatterjee says thata study was made for the effective control in warp
breakages on a weaving machine. It is found that the warp breakage rate can be minimized by

effective control of strain on warp yarn within a loom cycle during weaving by means of spring
loaded, self-rotating and reciprocating backrest.
From the experimental results it can be concluded that the strain on the warp yarn during a pick
cycle, which is maximum during full shed open condition and at beat up, can be minimized by
incorporation of a spring loaded, self-rotating reciprocating backrest and by increasing the
free warp length. On incorporating the mechanical attachment on the loom the warp breakage
rate is substantially reduced. The reduction of the breakage rate helps in minimizing the
efficiency loss during weaving. [11]
According to Marks &Robinson, the tension peak at beat up is proportional to the maximum
fell displacement and is independent to basic warp tension. The warp breakage rate can be
minimized by controlling the strain on the yarn during a loom cycle. [12]
Green wood stated that the height of tension peak during shedding may be controlled either by
controlling the size of the warp shed or by controlling the free length of the warp. [13]
Owen has pioneered the study of warp tension variations and felt that it is necessary to
measure the warp tension upon a single thread rather than upon the whole warp, as the later
would give average effects in which significant features might be concealed. He opined that
the tension is much greater at the bottom than at the top shed, and the beat-up with the falling
thread is stronger than with the rising thread, and consequence of the common practice of
depressing the closer shed. The inertia, or weight and size of the beam influences the form of
tension cycle which therefore vary vary a beam empties. He also stated that throughout one
turn of the beam, the tension in the single thread like varied by 40-50% of its mean value. He
also studied the effect of vibrating back rest which increases the tension in the lower parts of
the cycle and reduces it at the bottom shed. [14]
Snowden has measured warp tension under static condition. The behavior of such Mechanism
when running at weaving speed is often very different from what would be from the study of
the mechanism at rest or in slow movement. [15]
According to Neogi et al, peak tension on warp during weaving is high particularly during the
position of beat- The generation of high peak tension in the yarn is one of the main reasons
for warp To reduce peak tension the attachments of oscillating back rest and front rest was
developed, which not only improved the fabric cover but also eliminated the reed mark. [16]
Neogi et al have also studied the variation of tension amongst the yarns of both the healds with
both the shed timings and the lifting pattern. Irrespective of shed timings and lifting pattern, the
warp tension at the bottom position of the shed is always appreciably higher than at top
position. With 1 up- 1 down leasing, if the timing of shed is set late the maximum tension in a
pick cycle (which is at beat-up) is much reduced. This is expected to cause lower breakage of
the warp yarns without affecting the cover of the fabric. This shed timing has possibly another
advantage ie, since the shuttle can have more time to cross the shed, picking can be made
smoother causing less damage to the shuttle and the shuttle box accessories. [17]

3. Methodology
3.1. Overview
This thesis is conducted in order to determine the causes of loom stoppage, effect of loom
stoppage in weaving process and effective steps to take for minimizing this problem.
In order to answer these research goals I need to select respondents and obtain their view in
line with this topic. Selected participants answered a survey questionnaire structure. Along
with primary data I also made use of secondary resources in the form of published articles
and literatures to support the survey.
The Descriptive method of research is used for this study. It means the method is to gather
information’s about the present existing condition. The emphasis is on describing rather than
on judging or interpreting. The aim of descriptive research is to verify formulated suggestions
that refer to the present situation in order to expound it. The descriptive approach is quick and
practical in terms of the financial aspect. Moreover, this method allows a flexible approach,
thus, when important new issues and questions arise during the duration of the study, further
investigation may be conducted. Descriptive research on the other hand is a type of research
that is mainly concerned with describing the nature or condition and the degree in detail of
the present situation. This method is used to describe the nature of a situation, as it exists at
the time of the study and to explore the cause/s of particular a phenomenon. The aim of
descriptive research is to obtain an accurate profile of the people, events or situations. With
this research type, it is essential that the researcher already has a clear view or picture of the
phenomena being investigated before the data collection procedure is carried out. The
researcher used this kind of research to obtain first hand data from the respondents so as to
formulate rational and sound conclusions and recommendations for the study. The descriptive
approach is quick and practical in terms of the financial aspect.
3.2. Data collection

For this research, two types of data were gathered. These included the primary and secondary
data types. The primary data were derived from the answers the participants gave during the
survey process. The secondary data on the other hand, were obtained from published
documents and literatures that were relevant to personality questionnaire. With the use of the
survey questionnaire and published literatures, this study took on the combined quantitative
and qualitative approach of research. By means of employing this combined approach, the
study was able to obtain the advantages of both quantitative and qualitative approaches and
overcome its limitations.
3.2.1. Primary Sources
After gathering all the completed questionnaires from the respondents, total responses for
each item were obtained and tabulated. Physical visit, personal contacts, participant’s
willingness to participate in the discussion help to get proper information’s for the analysis.

3.2.2. Secondary Sources
We have explored the following secondary sources to meet the objectives of the report-
Data inventory of different loom in weaving section.
Data inventory of different government organizations regarding clothing, trading
houses.
On-line news archive of newspapers and news agencies home and abroad.
Annual report of different factories.
Books, journals, magazines available in online and library.

4. Experimental Work
This thesis is conducted in order to determine the causes of loom stoppage like warp stop,
weft stop, bobbin stop and effect of loom stoppage in weaving process and effective steps to
take for minimizing this problem. In order to answer these research goals, we have to do
some experimental work. These are given below:
4.1. Data Collection of Warping

4.1.1. Details about Warping Machine Studied
Details Specification
Machine Name Warping Machine
Brand Name Prasant West Point
Serial No 223
Origin India
Year 2014
Speed 1000 Rpm
Creel Capacity 660
Beam Dia 40”
Creel Type H
Air Pressure 6 Bar
4.1.2. Data collection Procedure of Warping

For collecting the data of warping, at first we select a four fabric construction and by helping
of supervisor and helper we collect some primary data of warping like total ends, creel
capacity, set length. Then our main experimental work is started. In warping floor, there are
six warping machine is run but we work for only two machine. For collecting stoppage data,
we spent 24 hours or 3 shifts in front of the machine and noted the no of stoppage from
warping machine monitor one by one. The data are given below:
Warping
Stoppage Total Stoppage
Construction
No of Beam
Total Ends
Set length
Last 500 mtr

1st 1000 mtr
2nd length
Creel
Width
Count
Count
Warp
Sl
Grey
Weft
EPI
PPI
01 77 53 9RS+10OE 9OE 65” 4650 388 24060 12 23 125 45 193
02 147 70 16KW 150D poly+40D lycra 68” 5870 367 33000 16 68 153 111 332
03 124 60 14RS 20OE+70D Lycra 67” 5400 386 36090 14 23 128 76 227
04 145 70 20KW 150D poly+40D lycra 63” 6630 414 24750 16 55 83 27 165
Table-01: Data Collection of stoppage in warping
4.1.2.1. Causes of Stoppage in Warping
During warping data collection we found different causes which are responsible for warp
breakage like-
Spinning faults.
Tension variation in yarn.
Package fault.
Excessive pressure.
Improper placing of creel and flanged bobbin.
4.2. Data Collection of Sizing

4.2.1. Details about Sizing Machine Studied
Details Specification
Machine Name Sizing Machine
Brand Name Prasant West Point
Serial No 277
Origin India
Year of Manufacturing 2016
Speed 120 Rpm
No of Squeeze Roller 06
No of Emersion Roller 02
No of Size Dryer 16
Creel Capacity 16
Preparation Tank Temperature 110*C
Cooking Time 30-40 min
4.2.2. Data collection Procedure of Sizing

For collecting the data of sizing, at first we find out the four fabric construction of which we
already collect warping data. Then by helping of supervisor and helper we collect some
primary data of sizing like total ends, viscosity and pick %. Then our main experimental
work is started. In sizing floor, there are two sizing machine is run and we work for both of
the machine to collect data. In sizing process, our main responsibilities are to collect the data
of no of sizing beam and set length before and after sizing. Finally we collect all data with the
help of production manager one by one. The data are given below:

4.2.2.1. Data Collection of Sizing for Construction-“01”:
SL Sizing
Construction
Total Ends
M/c speed
Set length
Viscosity
Pick%
Beam no
Length
sizing
after
Width
Count
Count
Warp
Grey
Weft
EPI
PPI
T3 2406
R15 2231
14 645
13 2406
01 77 53 9RS+10OE 9OE 65” 4650 24060 22 13% 7% 191 2406
R44 2406
234 2406
204 2406
160 2187
192 2187
T43 2236
Total 11 23922
SL Construction Sizing
Total Ends
M/c speed
Set length
Viscosity
after sizing
Pick%
Beam no
Length
Width
Count
Count
Warp
Grey
Weft
EPI
PPI
R29 3000
R42 3000
211 3000
115 3000
03 147 70 16KW 150D poly+40D lycra 68” 5870 33000 22 16 9% 280 3000
22 3000
R62 3000
48 3050
197 3050
209 3050
52 2700
Total 11 32850

4.2.2.3. Data Collection of Sizing for Construction-03:
Construction Sizing
Total Ends
M/c speed
Set length
Viscosity
Pick%
SL
Length
Width
Count
Count
Warp
sizing
Beam
Grey
Weft
after
EPI
PPI
no
25 2187
222 3062
345 3062
64 3062
03 124 60 14RS 20OE+70D Lycra 67” 5400 36090 22 13% 9% R36 3062
254 3062
T35 3062
T25 3062
T36 3281
275 3281
122 3281
302 2980
Total 12 36444
Construction Sizing
Total Ends
M/c speed
Set length
Pick%
SL
Beam no
Viscosity
Length
Count
Count
Warp
sizing
Grey
Widt
Weft
After
EPI
PPI
50 3700
87 1060
01 3800
R73 3500
04 145 70 20KW 150D poly+40D lycra 63” 6630
24750 22 16 9% 56 3800
31 3800
171 2570
189 2530
Total 8 24760

4.3. Details of Loom Stoppage in Weaving Process
4.3.1. Details of Loom Studied

Experiments are carried out on looms with the specifications and the looms were set to
produce different type of denim fabrics. In this experiment, there are two types of looms are
used one is Rapier and another is Air-jet. There are 12 looms are used in this experiment
where six looms are Rapier and six looms are Air-jet. Six Air-jet looms like48, 68, 89, 40, 96,
104and Six Rapier looms like 08, 87, 97, 12, 26 and 106are respectively. The specifications
of 12 looms which are carried out the experiment are given below:
Sl Details Air-Jet Rapier

No of loom used 06 06
1 Brand Name PICANOL PICANOL
2 Model Name Picanol Omni Plus-800 Picanol OptiMax-2P, 4P
3 Speed 700 (2), 750 (2), 800 (2) 520 (2),510 (2),550 (2)
4 Tension setting KN 2.50, 3.00 2.25, 2.50
5 Reed Width occupied 67.65”, 65.75” 63.25”, 68.35”
6 Loom Number 48, 68, 89, 40, 96, 104 08, 87, 97, 12, 26, 106
4.3.2. Data collection Procedure of Weaving

For collecting the data of weaving, at first we need to select the construction of fabric of
which we are already collect the data of warping and sizing by helping of supervisor and
helper. Then we select the no of loom which are used to produce denim fabric with specific
construction with the help of production officer. In weaving process, our main responsibilities
are to find out the different stoppage like warp stop, weft stop, bobbin stop, manually stop
and their stoppage time. Then our main experimental work is started.
4.3.3. Data Collection of Warp Stoppage
4.3.3.1. Data Collection of Warp Stoppage for Loom No-48, 68, 89

In weaving floor, at first we select the fabric “Construction. Then we have to find out the no
of looms which are used to produce fabric under this fabric Construction and then we select
“Loom No-48, 68, 89. In weaving floor, we have to spent 24 hours or 3 shifts in front of the
machine to collect warp stoppage and their stoppage time. Then we collect the data with the
help of operator who operates this loom and note this data to the paper. The data are given
below:
Constructions No. of Warp Stoppage/day (min)
Loom
No
G
E
T
P
P
P
Shift “A” Shift “B” Shift “C”

a
o
r

Stops
Stops
Stops
(min)
(min)
(min)
Total
Total
Total
0.58 3.62 4.45
1.54 0.52 2.65
1.52 3.44 1.77
48 77 53 9RS+10 9OE 65” 3.62 2.32 9.9 2.95 27.59 15 41.11
OE 3.05
5
4.07
3.65
2.08 0.87 2.19

2.17 1.54 0.40
3.17 0.77 2.90
3.75 2.12 2.92
68 77 53 9RS+10 9OE 65” 3.08 21.8 5.3 0.82 17.03 21 44.13
OE
1.84 3.35
2.17 2.20
2.29 2.25
1.25
0.29 1.29 1.95

0.90 2.5 2.18
0.49 1.72 4.34
2 5.29 2.25
89 77 53 9RS+10 9OE 65” 0.62 23.5 1.65 12. 0.45 12.46 22 48.41
OE 45
9.45 2.29
2.34
1.54
5.52
0.35
Average 7 16.3 4 9.21 7 19.03m 19 44.5
Times min Times min Times in Times min
Total 58 133.65
Table-02: Data Collection of Warp Stoppage& Warp Stoppage Time
“Loom No-40, 96, 104. In weaving floor, we have to spent 24 hours or 3 shifts in front of
the machine to collect warp stoppage and their stoppage time. Then we collect the data with
the help of operator who operates this loom and note this data to the paper. The data are given
below:
Constructions No. of Warp Stoppage/ day (min)
L
o

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Stops
Stops
Stops
(min)
(min)
(min)
Total
Total
Total
0.72 1 2.34
1.74 0.50 0.49
1.77 0.55 6.82
150D 5.32 1.22 3.82
poly+40D 2.85 1.05 1.80
lycra
40 147 70 16KW 68 1.75 15.3 2.94 14.79 2.04 36.25 29 66.34
”
1.15 2.97 1.49
0.42 2.12
2.62 1.87
1.52 2.69
8.98
1.79
3.15 0.95 1.27

150D 0.94 2.19 4.09
96 147 70 16KW poly+40D 68 1.34 1.72 1.15
lycra ”
32.0 37.4 2.10 18.7 2.04 8.45 15 64.62
4 7
6.62
3.57
1.55
3.12 1.15 1.17

2.79 1.10
1.29 1.09
104 147 70 16KW 150D 68 1.57 16.0 1.15 3.36 13 20.58
poly+40D ” 7
lycra 3.02
1.17
1.24
0.85
1.02
Average 6 22.94 6 11.54 6 Times 16.02 19 50.51
Times min Times min min Tim min
es
Total 57 151.54
Table-03: Data Collection of Warp Stoppage & Warp Stoppage Time

machine to collect warp stoppage and their stoppage time. Then we collect the data with the
below:
Constructions No. of Warp Stoppage/day (min)
Shift A Shift “B” Shift “C”
Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
3.1 1.08 2.53
3.25 3.75 1.56
08 124 60 14RS 20OE+70D 67” 2.74 13.87 2.58 9.16 6.6 17.4 13 40.4
Lycra 1 4
4.78 1.75 4.11
2.61
4.98 3.03 1.67

87 124 60 14RS 20OE+70D 67” 0.65 1.75 1.87
Lycra
2.76 11.99 3.36 8.14 1.28 18.5 12 38.6
3
3.6 12.87
0.81
4.24 14.78 1.38

3.54 0.32 1.7
1.71 3.53 1
97 124 60 14RS 20OE+70D 67” 6.94 24.03 3 31.2 2.95 15.2 22 70.5
Lycra 1 6
1.44 7.98 1.55
2.84 1.6 1.9
3.32 1.27
1.45
2.06
Average 5 16.63 4 16.17 6 17.05 16 49.85
Time min Times min Times min Times min
s
Total 47 149.5
7
the machine to collect warp stoppage and their stoppage time. Then we collect the data with
below:
Constructions No. of Warp Stoppage/Day (min)
Total stop time

Loom No
Grey Width
Weft Count
Total Stop
Count
Warp
EPI
PPI
Stops
Stops
Stops
(min)
(min)
(min)
Total
Total
Total
0.49 0.65 1.15
0.45 1.62 0.32
2.05 0.65 2.62
1.54 1.18 2.20
150D
12 145 70 20K 63” 0.89 5.74 1.27 12.25 2.62 19.92 25 37.91
poly+40D
W lycra
0.32 3.27 3.32
1.54 0.34
2.07 4.12
2.65
0.54
0.04
2.62 2.55 2.75

1.7 3.24 1.2
2.69 2.02
0.25 1.82
7.26 0.34
150D
106 145 70 20K 63” 2.75 31.05 3.95 18 42.26
poly+40D
W lycra
6.29
3.02
1.54
1.62
4.15
1.70
0.49 1.79 1.54

1.89 3.62 2.59
150D 2.62 5.20 0.75
26 145 70 20K poly+40D 63” 1.62 8.17 2.65 17.15 0.45 11.55 17 36.87
W lycra
1.55 1.15 6.22
1.2

Constructions No. of Warp Stoppage/Day (min)
Total stop time

Loom No
Grey Width
Weft Count
Total Stop
Count
Warp
EPI
PPI
Stops
Stops
Stops
(min)
(min)
(min)
Total
Total
Total
1.54
Average 5 7.05 9 20.15 6 11.80 20 39.01
Times min Times min Times min Tim min
es
Total 60 117.04
4.3.3.5. Causes of Warp Stoppage

During data collection from 4 tables, we find many cause of warp stop which can be a result
of uncontrolled room temperature and relative humidity, poor quality yarn, excessive count
variation, broken or missing ends, excessive loom speed, uncontrolled warp tension. Other
causes can be due to knots on warp yarn, wrong drawing of ends through the heald, poor size
pick-up, loose ends, fly stuck onto threads and abrasive effect of the drop wires and the
heddles, insufficient shade toughing, if weavers fail to attend the warp breaks immediately,
late shed timing that causes tension imbalance at beat-up, the warp stop motion is not
working properly in the machine, accidental mixed-up of counts in winding and warping.
4.3.3.6. The summary of the warp stoppage study can be given in the following table:
Avg. no. of stops
Avg. no. of stops
Avg. no. of stops

time in Shift – A
time in Shift – C
time in Shift – B
Avg. no. of total

Avg. stoppage
Avg. stoppage
Avg. stoppage
stoppage time
in shift – A
in shift – C
in shift – B
Avg. total
Constructions stops
77 x 53/(9 RS + 10 OE) x 9 OE – 7 16.3 4 9.21 7 19.03 19 44.5

3/1 Twill Times min Times min Times min Times min
147 x70/16 KW x(150 Poly+40D 6 22.94 6 11.54 6 16.02 19 50.51
Lycra) – 4/1 Satin Times min Times min Times min Times min
124 x60/14 RS x(20 OE+70D 5 16.63 4 16.17 6 17.05 16 49.85
Lycra) – 3/1 Twill Times min Times min Times min Times min
145 x70/20 KW x(150 Poly+40D 5 7.05 9 20.15 6 11.80 20 39.01
Table-06: Summary of warp stoppage study
4.3.4. Data Collection of Weft Stoppage

4.3.4.1. Data Collection of Weft Stoppage for Loom No-48, 68, 89
machine to collect weft stoppage and their stoppage time. Then we collect the data with the
below:
Constructions No. of Weft Stoppage/Day (min)
Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Stops
Stops
Stops
(min)
(min)
(min)
Total
Total
Total
1.18 3.42 0.6
0.88 2.75 1.54
1.6 0.9 0.62
0.74 0.49 0.88
48 77 53 9RS+10OE 9OE 65” 0.50 5.44 0.45 9.98 2.05 12.45 23 27.91
0.54 0.25 0.44
1.72 1.37
4.2
0.40
0.39
0.32 0.37 0.50

0.44 2.74 0.20
68 77 53 9RS+10OE 9OE 65” 0.45 1.25 1.34
0.29 3.7 4.36 0.19 7.08 21 15.14
0.52 0.77
0.54 1.84
0.44 0.29
0.70 2.17
0.34
0.44
0.29 0.50 0.34

0.40 1.34 0.50
1.95 5.72 1.84 1.34 7.07 18 14.63
1.85 0.62
89 77 53 9RS+10OE 9OE 65” 0.39 0.88
0.29 1.50
0.55 0.62
0.37
0.90
7 4.95 4 5.39 10 8.67 21 19.30
Times min Times min Times min Ti min
Average me
s

62 57.91
Total
Table-07: Data Collection of Weft Stoppage & Weft Stoppage Time
4.3.4.2. Data Collection Procedure of Weft Stoppage for Loom No-40, 96, 104
the machine to collect weft stoppage and their stoppage time. Then we collect the data with
below:

Loom No
Total Stop
Total stop
Width
Count
Count
Warp
Weft
Grey
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
0.72 0.39 0.32
1.05 0.42 0.72
1.02 0.62 0.65
3.07 0.49 0.42
1.85 0.62 4.40
150D
poly+40D 68” 4.05 0.60 0.62
40 147 70 16KW lycra 0.45 21.56 0.40 3.54 0.37 8.32 31 33.42
2.12 0.45
0.65 0.37
0.97
0.42
0.55
0.92
0.55
3.14
0.82 0.34 0.62

0.44 0.35 3.05
0.05 0.44 0.50
96 147 70 16KW 150D 68” 0.94 6.81 0.35 2.88 1.32 8.32 24 18.01
poly+40D 0.32 1.40 0.95
lycra 2.12 0.92
0.42 0.69
0.27 0.27
0.67
0.76
0.54 0.45 0.15

1.50 0.44 0.27

Loom No
Total Stop
Total stop
Width
Count
Count
Warp
Weft
Grey
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
104 147 70 16KW 150D 68” 0.45 5.82 0.35 5.2 0.29 0.71 17 11.73
poly+40D 0.55 0.39
lycra 0.65 2.25
1.29 1.32
0.39
0.45
Average 11 11.39 6 3.87 7 5.78 24 21.05
Times min Times min Times Tim min
es
Total 72 63.16
4.3.4.3. Data Collection of Weft Stoppage for Loom No-08, 87, 97

In weaving floor, at first we select the fabric Construction. Then we have to find out the no
machine to collect weft stoppage and their stoppage time. Then we collect the data with the
below:
Loom No

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
0.50 0.45 0.38

0.75 3.67 0.38
1.25 0.60 4.70 0.50 15.79 11 21.74
08 124 60 14RS 67” 11.7
20OE+70D
8
Lycra
2.05
0.70
0.65 0.24 0.75.

1.35 0.48 0.34
1.37 1.2 0.65
0.28 6.09 1.92 0.44 3.41 16 11.42

Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
87 124 60 14RS 20OE+70D 67” 2 0.34
Lycra 0.44 0.54
0.35
0.68 1 1.05
0.98 4.43 0.28 2.31 0.54 5.46 12.2
97 124 60 14RS 20OE+70D 67” 0.67 0.75 0.24
Lycra
0.98 0.28 0.32 17

0.37 0.28
0.75 0.85
2.18
Average 5 3.92 3 2.97 7 8.22 15 15.45
Times min Times min Times Tim min
es
Total 44 45.46
4.3.4.4. Data Collection Procedure of Weft Stoppage for Loom No-12, 26, 106
the machine to collect weft stoppage and their stoppage time. Then we collect the data with
below:
Loom No

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
0.37 0.45 0.59

12 145 70 20KW 150D 63” 0.62 0.42 0.45
poly+40D 0.37 0.35 1.12
lycra 0.50 1.35
0.44 2.3 0.25 8.22 2.16 19 12.61
2.29
0.54
0.50

Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
0.29
0.54
1.24
0.19 0.24 1.02

0.60 0.57 1.04
1.27 7.5 0.29 2.06
8
150D
106 145 70 20KW 63” 5.52 1.12 5.54 11 15.18
poly+40D
lycra 1.19
2.22
0.40 0.67 0.86

26 145 70 20KW 150D 63” 1.02 1.4 0.67 0.86 4 2.95
poly+40D 2
lycra
Average 4 3.76 6 4.81 2 1.69 11 10.24
es
Total 34 30.74
4.3.4.5. Causes of Weft Stoppage

During data collection from 4 tables, we find many cause of weft stop which can be a
result of broken or missing picks, i nserting pick in a wrong shed after mending a weft break,
the main nozzle spray yarn time and opening time do not match, the selvedge yarn
on the left side or other side is loose, the main nozzle is installed incorrectly, weft
preload is insufficient, the closing time of the electromagnetic needle is too early,
the main nozzle is blocked by cotton yarn and the pressure is too low, weft yarn
winding shape is not good or winding hardness is not appropriate. Weft yarn
quality is poor with yarn defects, joints, flying cotton velvet and other attachment,
The power of shear and blow is too strong, weft release angle is too small, weft
yarn has weak yarn, if weft yarn is not normal, the twisted yarn on the right side is
loose, the shape or position of the weft reaches the probe is not correct, the cable of
probe head has problem, or the probe's steel reflex surface is not clean, poor
sensitivity of the probe head, detection board is troublesome, the gap between
probe head and reed is not appropriate.

4.3.4.6. The summary of the weft stoppage study can be given in the following table:
Avg. no. of stops
Avg. no. of stops
Avg. no. of stops

time in Shift – A
time in Shift – C
time in Shift – B
Avg. no. of total

Avg. stoppage
Avg. stoppage
Avg. stoppage
stoppage time
in shift – A
in shift – C
in shift – B
Avg. total
stops
Constructions
77 x 53/(9 RS + 10 OE) x 9 OE – 7 4.95 4 5.39 10 8.67 21 19.30

3/1 Twill Times min Times min Times min Times min
147 x70/16 KW x(150 Poly+40D 11 11.39 6 3.87 7 5.78 24 21.05
124 x60/14 RS x(20 OE+70D 5 3.92 3 2.97 7 8.22 15 15.45
Lycra) – 3/1 Twill Times min Times min Times min Times min
145 x70/20 KW x(150 Poly+40D 4 3.76 6 4.81 2 1.69 11 10.24
Table-11: Summary of weft stoppage study.
4.3.5. Data Collection of Bobbin Stoppage
4.3.5.1. Data Collection Procedure of Bobbin Stoppage for Loom No-48, 68, 89
machine to collect bobbin stoppage and their stoppage time. Then we collect the data with the
below:
Constructions No. of Bobbin Stoppage/Day (min)

Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
0.24 1.20 5.72

2.17 0.79 1.15
48 77 53 9RS+10OE 9OE 65” 2.41 0.72 2.71 0.92 11.38 9 16.5
3.59
0.90 1.05 1.03

68 77 53 9RS+10OE 9OE 65” 21.8 22.7 1.34 4.46 0.67 1.7 7 28.86
0
2.07
2.68 1.72 1.25

1.55 3.19 1.39


Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
89 77 53 9RS+10OE 9OE 65” 4.23 2.75 9.74 1 3.64 9 17.61
2.08
Average 2 9.78 3 5.63 3 5.57 8 20.99
es
Total 25 62.97
Table-12: Data Collection of Bobbin Stoppage & Bobbin Stoppage Time
4.3.5.2. Data Collection of Bobbin Stoppage for Loom No-40, 96, 104
the machine to collect bobbin stoppage and their stoppage time. Then we collect the data with
below:
Loom No

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
2.50 1.47 0.80

40 147 70 16KW 150D 68” 2.69 9.37 1.44 4.46 1.25 8.23 22.06
poly+40D
lycra
3.09 1.55 0.89 11
1.09 5.25
1.52 0.85 2.77

96 147 70 16KW 150D 68” 1.90 4.41 0.85 2.99 5.76 11.02
poly+40D
lycra
0.99 6
0.42 1.29 1.74

2.05 3.10 0.99
104 147 70 16KW 150D 68” 5.05 13.1 4.39 1.57 12.6 30.14
poly+40D 1 4
lycra
1.85 2.45 13

Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
2.19 5.89
1.55
Average 4 8.96 2 3.23 4 8.87 10 21.07
es
Total 30 63.22
4.3.5.3. Data Collection Procedure of Bobbin Stoppage for Loom No-08, 87, 97
machine to collect bobbin stoppage and their stoppage time. Then we collect the data with the
below:
Loom No

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
4.88 3.34 2.87

08 124 60 14RS 20OE+70D 67” 1.70 6.58 2.17 6.28 2.95 8.44 9 21.3
Lycra
0.77 0.75
1.87
5.75 2.45 5.29

87 124 60 14RS 20OE+70D 67” 3.1 13.0 1.55 5.36 1.32 6.61 9 25.01
Lycra 4
1.9 1.36
2.29
2.22 1 1.62
1.9 1.75 3.5
97 124 60 14RS 20OE+70D 67” 4.12 1.42 5.49 2.95 9.39 10 19
Lycra
1.32 1.32
Average 3 7.91 3 5.71 3 8.14 9 21.77

Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
Times miin Times min Times min Tim min
es
Total 28 65.31
4.3.5.4. Data Collection of Bobbin Stoppage for Loom No-12, 26, 106
the machine to collect bobbin stoppage and their stoppage time. Then we collect the data with
below:
Loom No

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
150D 1.12 3.20 (min)

1.43
12 145 70 20KW poly+40D 63” 1.17 2.29 4.40 12.79 1.43 16.51
lycra 5.19 6
150D 1.37 2.15 2.05

106 145 70 20KW poly+40D 63” 1.39 5.4 1.09 3.24 2.05 10.69
lycra 2.64 6
150D 1.49 1.04 0 3

26 145 70 20KW poly+40D 63” 1.49 2.82 3.86 5.35
lycra
Average 2 3.04 2 6.63 1 1.16 5 10.85

es
Total 15 32.55
4.3.5.5. Causes of Bobbin Stoppage

During data collection from 4 tables, we find many cause of weft stop which can be a result
of the main nozzle spray yarn time and opening time do not match the selvedge yarn on the
left side or other side is loose, the main nozzle is installed incorrectly.
4.3.5.6. The summary of the Bobbin stoppage study can be given in the following table:
Avg. no. of stops
Avg. no. of stops
Avg. no. of stops

time in Shift – A
time in Shift – C
time in Shift – B
Avg. no. of total

Avg. stoppage
Avg. stoppage
Avg. stoppage
stoppage time
in shift – A
in shift – C
in shift – B
Avg. total
Constructions
stops
77 x 53/(9 RS + 10 OE) x 9 OE – 2 9.78 3 5.63 3 5.57 8 20.99
3/1 Twill Times min Times min Tim min Times min
es
147 x70/16 KW x(150 Poly+40D 4 8.96 2 3.23 4 8.87 10 21.07
Lycra) – 4/1 Satin Times min Times min Tim min Times min
es
124 x60/14 RS x(20 OE+70D 3 7.91 3 5.71 3 8.14 9 21.77
Lycra) – 3/1 Twill Times min Times min Tim min Times min
es
145 x70/20 KW x(150 Poly+40D 2 3.04 2 6.63 1 1.16 5 10.85
Lycra) – 4/1 Satin Times min Times min Tim min Times min
es
Table-16: Summary of the bobbin stoppage study
4.3.6. Data Collection of Others Stoppage
4.3.6.1. Data Collection Procedure of Others Stoppage for Loom No-48, 68, 89
machine to collect others stoppage and their stoppage time. Then we collect the data with the
below:
Constructions No. of others Stoppage/Day (min)
Loom No

Wa
Tot
Tot
We
unt
EP
Gr
Co
sto
PP
rp
ey
al
al
ft
I

Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
2.38 3.69 0
0.55 6.02
48 77 53 9RS+10OE 9OE 65” 3.45 11.85 9.71 0 21.56
0.39 7
1.08
0.34 8 0.20
1.08 16.1 1.59
5
1.74 45.0 199 16
5
68 77 53 9RS+10OE 9OE 65” 0.94 40.62 1.52 78.5 200 319.9
4 .79 5
10.3 2.79
9
21.9 5.03
4
4.19
0.94 1.49 0.37

4.79 2.54 0.55
89 77 53 9RS+10OE 9OE 65” 0.55 6.28 4.03 0.44 3.3 10 13.61
0.60
1.34
Average 5 19.58 3 30.76 3 68.0 11 118.37
Times min Times min Times 3 Times min
min
Total 33 355.12
Table-17: Data Collection of others Stoppage & others Stoppage Time
the machine to collect others stoppage and their stoppage time. Then we collect the data with
below:
Loom No

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)

Loom No Shift “A” Shift “B” Shift “C”
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
150D 0.47 1.72 1.79
40 147 70 16KW poly+40D 68” 1.22 5.35 0.40
lycra 0.64 1.05 1.07
0.49 5.49
7.35 16.32 8.12 2.65 22.44 19 46.88
0.86 11.0
4
3.27
0.79
0.89
0.34
1.32 0.55 5.87

0.65 0.70 5.25
96 147 70 16KW 150D 68” 0.94 7.25 1.45 2.7 2.95 14.07 11 24.02
poly+40D 0.92
lycra
3.42
0.84 0.50 0.59

104 147 70 16KW 150D 68” 0.82 5.83 0.50 0.95 2.04 8 8.37
poly+40D
lycra
0.22 0.5
3.95
Average 6 9.8 min 2 3.77 4 12.85 13 26.42
Times Times min Times min Tim min
es
Total 38 79.27
machine to collect others stoppage and their stoppage time. Then we collect the data with the
below:
L
o

Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
1.05 3.34 2.84
08 124 60 14RS 20OE+70D 67” 1.05 1.84 8.7 2.95 5.79 6 15.54
Lycra
3.52
0.29 1.29 2.2

87 124 60 14RS 20OE+70D 67” 0.44 1.92 4.46 3.04
Lycra
2.1 5.24 9 11.8
0.45 1.25
0.92
0.37 0 1.07
97 124 60 14RS 20OE+70D 67” 0 1 2.84
Lycra 0.37 4 3.21
0.77
Average 2 1.17 2 4.38 2 4.62 6 `10.18
Times min Times min Times min Times min
Total 19 30.55
the machine to collect others stoppage and their stoppage time. Then we collect the data with
below:

Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
0.64 1.65 0
3.27 2.22
12 145 70 20KW 150D 63” 0.34 2.04
poly+40D 3.22 2.09
lycra
1.65 3.72
1.65 10.77 0.75 68.1


Loom No
Grey Width
Weft Count
Total Stop
Total stop
Count
Warp
time
EPI
PPI
Total
Total
Total
Stops
Stops
Stops
(min)
(min)
(min)
2
1.12 0 26 78.89
0.45
13.4
9
30.1
9
0.54
0.49
1.04
1.95
3.09
0.72
7.5
0.42
1.4
0.50 0.84 0.50

3.19 1.60 1.12
106 145 70 20KW 150D 63” 7.74
poly+40D 3.69 2.44 26. 9 33.11
lycra 98
1.60
16.0
2
26 145 70 20KW 150D

poly+40D 63” 0 2.62 2.62 1.70 1.7 2 3.96
lycra 0
Average 3 4.82 7 24.39 2 9.56 12 38.65
es
Total 37 115.96
4.3.6.5. Causes of Others Stoppage

During data collection from 4 tables, we find many cause of weft stop which can be a result
of the cable of probe head has problem, or the probe's steel reflex surface is not clean, low
pressure of the machine, mechanical & electrical problem, poor sensitivity of the probe head,
detection board is troublesome, the gap between probe head and reed is not appropriate.

4.3.6.6. The summary of the others stoppage study can be given in the following table:
Avg. no. of stops
Avg. no. of stops
Avg. no. of stops

time in Shift – A
time in Shift – C
time in Shift – B
Avg. no. of total

Avg. stoppage
Avg. stoppage
Avg. stoppage
stoppage time
in shift – A
in shift – C
in shift – B
Avg. total
stops
Constructions
77 x 53/(9 RS + 10 OE) x 9 OE – 5 19.5 3 30.76 3 68.03 11 118.3

3/1 Twill Times 8 Times min Times min Times 7 min
min
147 x70/16 KW x(150 Poly+40D 6 9.8 2 3.77 4 12.85 13 26.42
124 x60/14 RS x(20 OE+70D 2 1.17 2 4.38 2 4.62 6 `10.1
Lycra) – 3/1 Twill Times min Times min Times min Times 8 min
145 x70/20 KW x(150 Poly+40D 3 4.82 7 24.39 2 9.56 12 38.65
Table-21: Summary of the other stoppage study

5. Result and Discussion
The results were analyzed so as to find the different stoppage like warp, weft, bobbin and
others stoppage, their time and their causes. These results can be used as a guide for weavers
working under similar working environments.
5.1. Analysis of stoppage in Warping

The study reveals that, there is an upward trend of stoppage occurrence when we go from
coarser yarn to comparatively finer yarn in warping (except 20 KW). It is mentionable that,
the set length was found to be comparatively lesser in case of warping of 20 KW yarns,
which in turns results in comparatively lesser stoppage during warping.
01: Count VS No of stops in Warping

Figure-01:
5.2. Analysis of Stoppage in Weaving
5.2.1. Analysis of Warp Stoppa

Stoppage
5.2.1.1. Relation between warp yarn Count and Warp Stoppage

The study reveals that there is no significant relationship found between the warp count and
no of warp stops as shown in figurefigure-01.
01. Again stoppage time does not also have any
significant relationship with regards to warp yarn count. But it is mentioned that in case of
construction-44 (having 20KW in warp) has a significantly lower extent of stoppage time even
with the highest no of warp stops. It may be occurred due to lowest amount of bunch
breakage or under loaded operator.

Figure-01:: Relation between wa
warp yarn Count and Warp Stoppage
5.2.1.2. Relation between Warp thread density (EPI) and Warp Stoppage
The study reveals that there is no significant relationship found between the warp thread
density and no of warp stops as shown in figure-02.. Again stoppage time does not also have
any significant relationship with regards to warp yarn thread density. But it is mentioned that
in case of construction-4 4 (having 145 EPI in warp) has a significantly lower extent of
stoppage time even with th the highest no of warp stops. It may be occurred due to lowest
amount of bunch breakage or under loaded operator.
Figure-02: Relation between warp thread density & Warp Stoppage

5.2.1.3. Relation between Shift and Warp Stoppage
Again regardless of count and construction there is another important finding of this study
and that is, with respect to no. of stoppage, about 32.5% of the total warp stoppage occurred
in A – Shift, 32.5% in B – Shift and 35% in C – Shift respectively (Table-06).. Therefore, it is
clear from the study that, there is no significant effect of shift on warp stoppage in weaving.
5.2.2. Analysis of Weft Stoppage
5.2.2.1. Relation between Weft yarn Count and Weft Stoppage

In this study, the construction with 9 OE cotton yarn in weft is responsible for highest weft
stoppage (on an average 39% as in Table –11) and other two constructions with weft yarn of
respectively (20 OE + 70D Lycra) and (150D poly + 40D Lycra) have lower rate of weft
stoppage
toppage (on an average 28% and 33% respectively as in table –02). ). From this analysis it is
clear that, 100% cotton yarn is more likely to have weft stoppage than Lycra yarn.
5.2.2.2. Relation
tion between PPI (Weft Thread Density)
Density and Weft Stoppage
The study reveals that there is a downward trend of average stoppage time and average no. of
weft stops
ops as shown in the (figure no-03)
no with regards to weft thread density.
Figure-03: Relation between weft thread density & Weft Stoppage
5.2.2.3. Relation between Shift and Weft Stoppage

and that is, with respect to no. of stoppage, about 37.5
37.5% of the total weft stoppage occurred
in A – Shift, 26.5% in B – Shift and 36% in C – Shift respectively (Table-11).. It is clear from

the above finding that weft stoppage occurs comparatively lower in B – Shift, which indicates
weaving performance with respect to weft yarn, was found to be better in B – Shift.
5.2.3. Analysis of Bobbin Stoppage
5.2.3.1. Relation between Weft yarn Count and Bobbin Stoppage

In this study, the construction with (20 OE + 70 D Lycra) of weft yarn contain cotton yarn in
bobbin is responsible for highest bobbin stoppage (on an average 28% % as in Table –11) and
other two constructions with weft yarn of respectively 9 OE and (150D poly + 40D Lycra)
have lower rate of bobbin stoppage (on an average 25% and 24% respectively as in table –
02). From this analysis it is clear that, cotton yarn is more likely to have bobbin stoppage than
Lycra yarn.
5.2.3.2. Relation between PPI (Weft Thread Density) and Bobbin Stoppage
The study reveals that there is no significant relationship found between the weft thread
density and no of bobbin
bbin stops as shown in figure-04.
figure Again stoppagege time does not also have
any significant relationship with regards to weft yarn thread density. But it is mentioned that
in case of construction-44 (having 70 PPI in weft) has a significantly lower extent of stoppage.
It may be occurred due to under load
loaded operator.
Figure-04:: Relation between PPI (Weft Thread Density) and Bobbin Stoppage
5.2.3.3. Relation between Shift and Bobbin Stoppage

and that is, with respect to no. of stoppage, about 35% of the total bobbin stoppage
page occurred
in A – Shift, 32% in B – Shift and 33 33% in C – Shift respectively (Table-16).. It is clear from
the above finding that bobbin stoppage occurs comparatively lower in B – Shift, which
indicates weaving
eaving performance with respect to weft yarn, was found to be better in B – Shift.

5.2.4. Analysis of Others Stoppage
5.2.4.1. Relation
elation between Shift and Others Stoppage
and that is, with respect to no. of stoppag
stoppage, about 38% of the total others stoppage occurred in
A – Shift, 33% in B – Shift and 26% in C – Shift respectively (Table-21).. It is clear from the
above finding that bobbin stoppage occurs comparatively lower in C – Shift, which indicates
weaving performance with respect to weft yarn, was found to be better in C – Shift.
5.2.5. Comparative study of warp and weft breakage

The study reveals that the no. of warp stop is higher than the no. of weft stops. But
interestingly the stoppage time for warp stops is dramatically higher than the stoppage time
for weft stops. This is because, a single warp stops requires much more time to repair than the
requiring time for a single weft stops as shown in figure-05
figure & 06. Again in warp stops, there
could be bunch breakage which requires a great extent of requiring/ stoppage time, whereas
in weft no bunch breakage occurs.
Figure-05:: Comparative
Comp study of warp & weft stoppage

Figure-06:: Comparative study of warp & weft stoppage time (min)
6. Conclusion
In this study we tried to find out different types of stoppage like warp stops, weft stops,
bobbin stops and other stoppages
stoppage and their mending time. We also tried to find out the
relationship of weaving stoppage with warp count, warp thread density, weft ft count, weft
thread density etc.. But there have been some limitations i.e., the survey was conducted in a
very short time so it is not possible
ssible to collect more information, only the big and the reputed
factories, suppliers are consider here as sample, huge numbers of factories are engaged to
produce woven fabric and different types of loom are used. So it was not possible to visit
different industries, so there are some limitations in this report, they didn’t want to disclose
their business policy, this was unavoidable scenario in maximum case, lack of experience in
this field, lack of proper personnel to conduct this interview program, lack of appropriate
sufficient data regarding export oriented woven fabric in internet. Another limitation of this
study is the person’s private information were not disclosing here, which could be very much
useful. If anybody wants to further study about loom stoppage, we suggest them that they
follow our work.

7. References
1. http://www.fibre2fashion.com/industry-article/2687/critical-efficiency-analysis,
2 Oct. 2017
2. http://www.educarnival.com/analysis-of-woven-garment-industry-of-bangladesh,
5 Oct. 2017
3. M. JWERAN, March 15, 1983, Reduction of Warp breaks on Weaving Looms by
modification of the mode of Beat-up.
4. A. N. M. Masudur Rahman & Md. Ruhul Amin, June 2011, Efficiency Analysis of
Rapier Loom, International Journal of Basic and Applied Science IJBAS- IJENS, Vol
– 11, No. 03. Page 44.
5. Mr. Tusar C. Patil, October 2016, Control of weft breakage for cotton and polyester
weft yarn, International Journal on Textile Engineering and processes ISSN 2395-
3578, Vol. 2 Issue 4.
6. Vicky Ashok Patil, Sujit Shrikrushnarao, GulhaneRanjit N Turukmane&Rajendra
Patil, January,2017, Productivity Improvement of Loom Shed by Optimizing Relative
Humidity, International Journal on Textile Engineering and processes, Vol.3, Issue 1.
7. Nkiwane, L and Marashe S. 2012, Loom Speed and Tension to Reduce Warp and Weft
Breaks in Air Jet Weaving, NuSpace Institutional Repository, PP. 1-8.
8. P. Ganesan and S. Hariharan, Critical efficiency analysis in projectile looms, http://
www.fibre2fashion.com/industry-article/2687/critical-efficiency-analysis.
9. Aby Chummar, Soni Kuriakose, George Mathew, January 2013, Study on Improving
the Production Rate by Rapier Looms in Textile Industry, International Journal of
Engineering and Innovative Technology (IJEIT), Vol. 2, Issue 7.
10. Mike Kos, Correctly Identifying and Avoiding Weft Stoppage,
http://www.fibre2fashion.com/industry-article, 20 Oct.2017
11. S Mukherjee & K N Chatterjee, 18 April, 2011. Reduction of warp breakage by
effective control of strain on warp yarn, Indian Textile Journal-August 2007.
12. Marks R & Robinson ATC: Principle of Weaving, The Textile Institute, Manchester,
1976.
13. Greenwood K: Weaving: Control of Fabric Structure, Merrow Publishing Co Ltd,
1975.

14. Owen A E: J Text Inst, 19, 1928, T 365.
15. Snowden DC, & Chamberlain NH, J. Text. Inst., 39, 1956, T23.
16. Neogy S K: IJIRA, 7th Technological Conference, 1976.
17. Neogy S K: Textile Trends, December, 1980.

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Faculty of Engineering

Department of Textile Engineering

Study on Loom Stoppage in

Course code: TE-417 Course title: Project (Thesis)

A thesis submitted in partial fulfillment of the requirements for thedegree

Advance in Fabric Manufacturing Technology

Gazi Md Abul Hashem Md Shamim Hossain

This is to certify that the above declar

©Daffodil International University I

Gazi Md. Abul Hashem

©Daffodil International University II

This project is on “Study on Loom Stoppage in Weaving Process”. In woven readymade

©Daffodil International University III

1.1 Background of the study .............................................................................................................. 1

1.2. Rational of the study ................................................................................................................... 2

1.3. Scope of the study ....................................................................................................................... 2

1.4. Limitations of the study .............................................................................................................. 3

2. Literature Review ......................................................................................................................... 4

3.1. Overview .................................................................................................................................. 11

3.2. Data collection ......................................................................................................................... 11

4. Experimental Work .................................................................................................................... 13

4.1. Data Collection of Warping ..................................................................................................... 13

4.1.1.Details about Warping Machine Studied ................................................................................ 13

4.1.2. Data collection Procedure of Warping ................................................................................. 13

4.2. Data Collection of Sizing ......................................................................................................... 14

4.2.1. Details about Sizing Machine Studied ................................................................................... 14

4.3. Details of Loom Stoppage in Weaving Process ....................................................................... 17

4.3.1. Details of Loom Studied ....................................................................................................... 17

4.3.2. Data collection Procedure of Weaving ................................................................................. 17

4.3.3. Data Collection of Warp Stoppage ....................................................................................... 17

4.3.4. Data Collection of Weft Stoppage ........................................................................................ 22

4.3.5. Data Collection of Bobbin Stoppage .................................................................................... 28

4.3.6. Data Collection of Others Stoppage ..................................................................................... 32

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5.1. Analysis of stoppage in Warping ............................................................................................. 38

5.2. Analysis of Stoppage in Weaving ............................................................................................ 38

5.2.1. Analysis of Warp Stoppage .................................................................................................. 38

5.2.2. Analysis of Weft Stoppage ................................................................................................... 40

5.2.3. Analysis of Bobbin Stoppage ............................................................................................... 41

5.2.4. Analysis of Others Stoppage ................................................................................................ 42

5.2.5. Comparative study of warp and weft breakage .................................................................... 42

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1.2. Rational of the study

1.3. Scope of the study

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2.1. Reduction of warp breaks on loom by modification of the mode of beat-up

2.2. Efficiency Analysis in Rapier Loom

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2.4. Productivity Improvement of Loom Shed by Optimizing Relative Humidity

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2.6. Critical efficiency analysis in projectile looms

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2.8. Correctly identifying and avoiding weft stoppages

2.9. Reduction of warp breakage by effective control of strain on warp yarn