Maintenance

1. a. Explain the factors that affect the fatigue life of the textile machinery.
b. Discuss the elimination of six crippling shop floor losses in a textile
mill with an effective maintenance management system.

1. a. Factors affec�ng the fa�gue life of tex�le machinery include:

- Material quality: Poor quality materials lead to faster deteriora�on and shorter
fa�gue life.

- Design considera�ons: Proper design can distribute stress more evenly,

reducing fa�gue.

- Opera�ng condi�ons: Overloading, improper lubrica�on, and excessive

vibra�on can accelerate fa�gue.

- Maintenance prac�ces: Regular maintenance can prevent wear and tear,

extending fa�gue life.

- Environmental factors: Temperature, humidity, and exposure to chemicals can

degrade materials and shorten fa�gue life.

1. b. Elimina�on of six crippling shop floor losses in a tex�le mill through effec�ve
maintenance management involves:

1. Planned maintenance: Implemen�ng scheduled maintenance to prevent

breakdowns and down�me.

2. Predic�ve maintenance: Using data and analy�cs to predict machinery failures

and schedule maintenance proac�vely.

3. Training and skill development: Ensuring operators and maintenance staff are
well-trained to detect issues early and perform maintenance effec�vely.

4. Spare parts management: Ensuring availability of cri�cal spare parts to

minimize down�me.
 5. Root cause analysis: Iden�fying and addressing the underlying causes of
machinery failures to prevent recurrence.

6. Con�nuous improvement: Regularly reviewing maintenance processes and

implemen�ng changes to op�mize efficiency and effec�veness.

2. a. Explain the Ozone and Heat as a mode of failure for the high-speed
weaving Machine.
b. List down the atributes of a sound maintenance policy in a rotor
spinning yarn manufacturing company in Bangladesh.

Answer

a. Ozone and Heat as Modes of Failure for High-Speed Weaving Machine:

• Ozone:

• Ozone is a reac�ve gas that can lead to degrada�on of rubber and

plas�c components in the weaving machine.

• It causes cracking and deteriora�on of belts, seals, and other

elastomeric parts, leading to malfunc�on.

• Regular inspec�on and replacement of vulnerable parts are essen�al

to prevent ozone-induced failures.

• Heat:

• Excessive heat in the weaving machine can lead to thermal

expansion, causing misalignment and wear on cri�cal components.

• Overhea�ng can result in motor failure, damage to electronic

components, and reduced lubrica�on effec�veness.

• Implemen�ng cooling systems, ensuring proper ven�la�on, and

monitoring temperature levels are crucial preven�ve measures.

b. Atributes of a Sound Maintenance Policy in Rotor Spinning Yarn

Manufacturing Company (Bangladesh):
1. Regular Inspec�ons:

• Conduct rou�ne inspec�ons to iden�fy poten�al issues before they

escalate.

• Inspect key components such as rotors, bearings, and belts for signs
of wear or damage.

2. Predic�ve Maintenance:

• U�lize predic�ve maintenance techniques, such as vibra�on analysis

and infrared thermography, to an�cipate and address poten�al
failures.

3. Training and Skill Development:

• Provide ongoing training for maintenance personnel to keep them

updated on the latest technologies and best prac�ces.

• Ensure a skilled workforce capable of handling modern rotor spinning

equipment.

4. Spare Parts Management:

• Maintain an organized inventory of cri�cal spare parts to minimize

down�me in case of equipment failure.

• Establish rela�onships with reliable suppliers to ensure �mely

availability.

5. Documenta�on and Record Keeping:

• Keep comprehensive records of maintenance ac�vi�es, including

inspec�ons, repairs, and equipment history.

• Use data to analyze trends and make informed decisions for

con�nuous improvement.

6. Emergency Response Plan:

 • Develop and implement a robust emergency response plan to
minimize down�me during unexpected breakdowns.

• Ensure quick access to necessary tools and resources for efficient

troubleshoo�ng.

7. Collabora�on with Equipment Manufacturers:

• Foster strong partnerships with equipment manufacturers for access

to technical support and updates.

• Stay informed about recommended maintenance prac�ces provided

by the manufacturers.

8. Environmental Considera�ons:

• Implement measures to mi�gate environmental factors that could

affect equipment performance, such as dust control and humidity
regula�on.

9. Budgetary Planning:

• Allocate sufficient budget for maintenance ac�vi�es, considering

both preven�ve and correc�ve measures.

• Priori�ze investments based on cri�cality and poten�al impact on

produc�on.

10.Con�nuous Improvement:

• Regularly review and refine the maintenance policy based on

performance data and industry advancements.

• Encourage feedback from maintenance personnel for con�nuous

improvement.
4. a. Find the humidity and working conditions in a spinning and weaving
mill with the need for proper maintenance of Air ambient conditions.
b. Define the Humidification related terms: Relative Humidity (R.H.%),
Sensible < Heat, Latent Heat, Evaporative Cooling.
 c. Explain the merits and demerits of a modern Humidification System
for a weaving shed housed with high speed weaving floor.

Ans==

a. In a spinning and weaving mill, maintaining proper air ambient condi�ons is

crucial for op�mal produc�on. Humidity levels must be controlled to prevent yarn
breakage and ensure worker comfort. Working condi�ons should include
controlled temperatures and rela�ve humidity levels to avoid adverse effects on
equipment and materials.

b. Rela�ve humidity (R.H.%) is the amount of water vapor present in the air
rela�ve to the maximum amount the air can hold at a given temperature. Sensible
heat refers to heat that can be measured with a thermometer. Latent heat is the
heat absorbed or released during a change of state. Evapora�ve cooling occurs
when water evaporates, removing heat from the surrounding air.

c. Merits:

1. Enhanced yarn quality: Maintains op�mal humidity levels, reducing yarn

breakage.

2. Worker comfort: Creates a comfortable working environment by controlling

humidity levels.

3. Energy efficiency: Modern systems are energy-efficient, reducing opera�ng

costs.

Demerits:

1. Ini�al cost: Installa�on can be expensive.

2. Maintenance: Requires regular servicing for op�mal performance.

3. Environmental impact: Some systems may consume large amounts of water,

impac�ng water resources.
 5. a. Discuss about the design of a centralized air conditioning system
with air washer humidification system plants for a Textile mill using-
Return and Supply air ducts, Rotary Filter, Eliminator, Heater, Fresh air
damper, Return air damper, Eliminator and Heater.
b. Classify the kinds of proactive maintenance.

Answer

a. The centralized air conditioning system for a Textile mill includes:

1. Return and Supply Air Ducts:
• Return ducts collect air from the space and deliver it to the air handling
unit (AHU).
• Supply ducts distribute conditioned air back to the designated areas.
2. Rotary Filter:
• Used to trap large particles from the incoming air, preventing damage
to the system components.
3. Eliminator:
• Removes moisture from the air to control humidity levels.
4. Heater:
• Raises the temperature of the air to the desired level, crucial for
comfort and process requirements.
5. Fresh Air Damper:
• Regulates the introduction of outside air, ensuring a controlled
ventilation rate.
6. Return Air Damper:
• Controls the proportion of recirculated air, aiding in energy efficiency.
7. Eliminator (again):
• Plays a role in removing additional moisture from the return air.
8. Heater (again):
• Maintains or adjusts the air temperature as needed.
b. Kinds of Proactive Maintenance:
1. Preventive Maintenance:
• Regularly scheduled tasks to prevent equipment failure.
2. Predictive Maintenance:
 • Using data and analytics to predict when equipment is likely to fail,
allowing for timely interventions.
3. Condition-Based Maintenance:
• Monitoring equipment condition in real-time and performing
maintenance based on specific indicators.
4. Reliability-Centered Maintenance (RCM):
• Prioritizing maintenance tasks based on the impact of equipment
failure on the overall system.
5. Total Productive Maintenance (TPM):
• Involving all employees in the maintenance process to maximize
equipment effectiveness.

6. a. Interpret an energy management program for a tex�le industry from

ISO energy management system.
b. Explain different steps to be taken for energy conserva�ons regarding
ligh�ng used in a tex�le mill.

Ans===

a. An energy management program for a tex�le industry based on ISO

energy management system involves establishing energy policies,
conduc�ng energy audits, se�ng energy performance indicators,
implemen�ng energy-saving measures, and regularly monitoring and
reviewing energy performance. By adhering to ISO standards, the tex�le
industry can systema�cally manage energy consump�on, reduce waste, and
improve overall energy efficiency, leading to cost savings and environmental
sustainability.

b. Steps for energy conserva�on regarding ligh�ng in a tex�le mill include:

switching to energy-efficient LED bulbs, maximizing natural ligh�ng through
windows and skylights, using mo�on sensors to control ligh�ng in unused
areas, implemen�ng automa�c �mers to turn off lights when not in use,
and conduc�ng regular maintenance to ensure lights are func�oning
 op�mally. These measures help reduce energy consump�on and lower
electricity costs while maintaining adequate ligh�ng levels for opera�ons.

7. b. Differen�ate between FIFO and LIFO method.

c. Briefly discuss the Work related Musculo-Skeletal Disorders (WMSDs).

ANS==

7. a. Iden�fy the hazard associated with numbering on cut panel in garments

industry and give some solu�on to minimize it.
Ans==
. Hazard associated with numbering on cut panels in the garment industry:
Solutions to minimize the hazard:
1. Standardize numbering system: Implement a standardized and clear
numbering system for cut panels, ensuring consistency across all production
stages.
2. Quality control checks: Conduct regular quality checks at each stage of
production to verify the accuracy of numbering on cut panels.
3. Training and supervision: Provide adequate training to staff responsible for
numbering panels and ensure proper supervision to minimize errors.
 4. Use of technology: Consider implementing barcode or RFID technology for
tracking cut panels, which can help reduce human errors in numbering and
tracking.

8. a. Define (i) EOQ (ii) Inventory (iii) Ergonomics (iv) Stock

b. U�lize HIRARC to explain risk control hierarchy of a dyeing mill.

Ans==

a. (i) EOQ (Economic Order Quan�ty) is the op�mal order quan�ty that
minimizes total inventory costs, balancing ordering costs and holding costs.
(ii) Inventory refers to the stock of goods or materials held by a company for
produc�on, processing, or sale. (iii) Ergonomics involves designing
workplaces and equipment to op�mize human performance and prevent
injuries. (iv) Stock refers to the total amount of goods or materials held by a
business at a specific point in �me.

b. HIRARC (Hazard Iden�fica�on, Risk Assessment, and Risk Control) is a

systema�c approach to managing workplace hazards. In a dyeing mill, the
risk control hierarchy involves elimina�ng hazards where possible,
subs�tu�ng hazardous processes with safer alterna�ves, implemen�ng
engineering controls (e.g., ven�la�on systems), adop�ng administra�ve
controls (e.g., training programs), and providing personal protec�ve
equipment (PPE) as a last resort to mi�gate risks effec�vely.

Fall-22

1. a) Give examples of different inventory types from tex�les and clothing

industries.
b) Analyze the basic economic order quan�ty (EOQ) model with
assump�ons and necessary figures.

Ans==
a) Examples of inventory types in the textiles and clothing industries include raw
materials (e.g., fabric, yarn), work-in-progress (partially completed garments), finished
goods (completed garments ready for sale), and accessories (buttons, zippers, labels).

b) The basic Economic Order Quantity (EOQ) model determines the optimal order
quantity that minimizes total inventory costs. It assumes constant demand, constant unit
cost, and no order or holding costs variability. The formula is EOQ = √((2 * Demand *
Ordering Cost) / Holding Cost per Unit).

2. a. What are the basic principles of ergonomics? in 30 words

Ans== The basic principles of ergonomics involve designing tasks, tools, and
environments to fit human capabili�es and limita�ons, promo�ng comfort,
safety, efficiency, and overall well-being in various work se�ngs.
3. a) Define the pollution and list down the categories of pollution.
b) Classify the occupational hazards.
c) Criticize the risk control hierarchy to address the hazards.

Answer

a) Pollution is the introduction of contaminants into the natural environment, causing

adverse effects. Categories of pollution include:
1. Air Pollution: Contamination of the air with harmful substances like gases,
particulate matter, and chemicals.
2. Water Pollution: Introduction of pollutants into water bodies, such as rivers,
lakes, and oceans, leading to deterioration of water quality.
3. Soil Pollution: Presence of pollutants in the soil, often from industrial waste,
agricultural chemicals, or improper disposal of waste.
4. Noise Pollution: Excessive or disturbing noise that can have negative effects
on human health and the environment.
5. Light Pollution: Over-illumination or misdirected artificial light, disrupting
natural light cycles and affecting ecosystems.
b) Occupational hazards can be classified into various categories:
 1. Physical Hazards: Include factors like noise, vibration, temperature extremes,
and radiation.
2. Chemical Hazards: Exposure to harmful substances such as toxic chemicals,
gases, and fumes.
3. Biological Hazards: Risks from exposure to bacteria, viruses, fungi, and other
microorganisms.
4. Ergonomic Hazards: Related to the design of workspaces and equipment,
potentially causing musculoskeletal disorders.
5. Psychosocial Hazards: Factors affecting mental well-being, such as stress,
harassment, and workplace violence.
c) Criticizing the risk control hierarchy:
The risk control hierarchy typically consists of three main steps: elimination or
substitution, engineering controls, and administrative controls. While it provides a
structured approach, some criticisms include:
1. Overreliance on PPE (Personal Protective Equipment): The hierarchy often
places PPE as a last resort. However, relying solely on PPE may not eliminate
or adequately control the hazard and could lead to a false sense of security.
2. Emphasis on Top-Down Approaches: The hierarchy may prioritize
managerial decisions over worker involvement, potentially overlooking valuable
insights from those directly exposed to the hazards.
3. Lack of Flexibility: The hierarchy may not account for the dynamic nature of
certain hazards and workplaces, requiring more adaptable strategies.
4. Limited Emphasis on Prevention: While the hierarchy addresses control
measures, more emphasis on hazard prevention could lead to safer work
environments in the long run.
In summary, while the risk control hierarchy provides a systematic approach, it is
important to consider its limitations and adapt strategies based on specific workplace
conditions and hazards.
4.a. a) Define resource efficiency.
b) Illustrate basic strategies for resource e�iciency with examples in tex�le
and clothing industries.
Ans=== a) Resource efficiency refers to maximizing the produc�vity of
resources while minimizing waste and environmental impact, aiming to achieve
more with less and sustainably manage natural resources.

b) Basic strategies for resource efficiency in tex�le and clothing industries

include implemen�ng recycling programs for tex�le waste, op�mizing energy
and water usage in produc�on processes, adop�ng eco-friendly materials, and
employing lean manufacturing techniques to minimize resource consump�on
while maintaining or improving product quality. For example, reusing tex�le
scraps to create new garments, inves�ng in energy-efficient machinery, and
reducing water usage through innova�ve dyeing techniques are common
prac�ces for enhancing resource efficiency.

Part b----------------------
1. a) Compare between predictive maintenance and preventive
maintenance.
b) Describe importance of maintenance in the sewing section.
c) Explain a suitable maintenance system for the spinning mill.

Answer

a) Predictive maintenance involves using data and analytics to predict when equipment
failure might occur and scheduling maintenance accordingly, often resulting in reduced
downtime and cost savings. Preventive maintenance, on the other hand, involves
regularly scheduled maintenance tasks performed to prevent equipment failure. The
main difference lies in the approach: predictive maintenance is proactive and data-
driven, while preventive maintenance is based on a predetermined schedule.
b) Maintenance is crucial in the sewing section to ensure the smooth operation of
machines and the production process. Regular maintenance helps to identify and
address issues before they escalate into major problems, thereby minimizing downtime
and increasing productivity. Properly maintained equipment also produces higher quality
products and reduces the risk of accidents or injuries to workers. Overall, maintenance
in the sewing section is essential for optimizing efficiency, maintaining product quality,
and ensuring a safe working environment.
c) A suitable maintenance system for a spinning mill would be a combination of
preventive and predictive maintenance, tailored to the specific needs of the equipment
and processes involved. Preventive maintenance can be implemented for routine tasks
such as lubrication, cleaning, and inspection, to prevent breakdowns and extend the
lifespan of machinery. Additionally, predictive maintenance techniques, such as
condition monitoring and predictive analytics, can be utilized to anticipate potential
failures and schedule maintenance proactively based on real-time data. This approach
helps to minimize unplanned downtime, optimize maintenance schedules, and
maximize equipment reliability and performance in a spinning mill setting.

2. a) Demonstrate the role of maintenance department in spinning mill.

b) Illustrate the procedure of maintenance planning for knitting section.

Answer

a) The maintenance department in a spinning mill plays a crucial role in ensuring the
smooth operation of machinery and equipment, which are essential for the production
process. Their responsibilities include:
• Preventive Maintenance: Regular inspection and servicing of machinery to
prevent breakdowns and ensure optimal performance.
• Reactive Maintenance: Promptly addressing any issues or breakdowns that
occur during production to minimize downtime.
• Predictive Maintenance: Using data analytics and monitoring systems to
anticipate potential equipment failures and schedule maintenance proactively.
• Spare Parts Management: Ensuring the availability of spare parts to minimize
downtime in case of equipment failure.
• Training: Providing training to machine operators and maintenance staff on
equipment operation and maintenance procedures to enhance efficiency and
safety.
b) The procedure for maintenance planning in the knitting section involves the following
steps:
 • Assessment: Evaluate the current condition of knitting machines and equipment
to identify any maintenance requirements or potential issues.
• Prioritization: Determine the priority of maintenance tasks based on factors such
as the criticality of equipment, production schedules, and resource availability.
• Scheduling: Develop a maintenance schedule that outlines when specific tasks
will be performed, taking into account production downtime and operational
requirements.
• Resource Allocation: Allocate manpower, materials, and tools necessary to
execute the maintenance plan effectively.
• Execution: Carry out planned maintenance activities according to the schedule,
ensuring adherence to safety protocols and quality standards.
• Documentation: Record maintenance activities, including inspections, repairs,
and replacements, for future reference and analysis.
• Review: Regularly review and update the maintenance plan based on feedback,
performance metrics, and changes in production requirements to continuously
improve efficiency and reliability.

3. a) Define Humidification, COP, and Psychometry.

b) Interpret importance of air conditioning in spinning mill.
c) Demonstrate material handling equipment used in textile sector.

Answer

a) Humidification: Humidification is the process of adding moisture to the air to increase

its humidity level. This is commonly done in indoor environments to maintain a
comfortable and healthy atmosphere, as excessively dry air can lead to issues such as
respiratory discomfort, static electricity buildup, and damage to sensitive materials.
COP: COP stands for Coefficient of Performance, which is a measure of the efficiency
of a heating, ventilation, and air conditioning (HVAC) system. It represents the ratio of
useful heating or cooling provided by the system to the amount of energy consumed. A
higher COP indicates a more efficient system.
Psychrometry: Psychrometry is the study of the properties of air and the relationships
between temperature, humidity, pressure, and other characteristics. It is particularly
important in HVAC engineering for designing systems that control air quality and
comfort.
b) The Importance of Air Conditioning in a Spinning Mill:
Air conditioning in a spinning mill is crucial for several reasons:
1. Temperature Control: Spinning mills often house heavy machinery that
generates a significant amount of heat. Air conditioning helps regulate the
temperature to ensure optimal working conditions for both machinery and
workers.
2. Humidity Control: Maintaining the right level of humidity is essential for the
quality of yarn production. Too much or too little moisture in the air can lead to
issues such as yarn breakage, static electricity buildup, and poor yarn quality.
Air conditioning systems with humidification and dehumidification capabilities
help control humidity levels effectively.
3. Worker Comfort and Productivity: Comfortable working conditions contribute to
higher productivity and employee satisfaction. Air conditioning creates a more
comfortable environment by regulating temperature and humidity, reducing the
risk of heat-related illnesses and fatigue.
4. Equipment Performance: Consistent temperature and humidity control provided
by air conditioning systems can help prolong the lifespan of spinning machinery
and prevent costly breakdowns due to overheating or moisture-related
damage.
c) Material Handling Equipment Used in the Textile Sector:
Material handling equipment plays a vital role in the textile industry for efficient
movement, storage, and handling of raw materials, intermediate products, and finished
goods. Some common types of material handling equipment used in the textile sector
include:
1. Conveyors: Belt conveyors, roller conveyors, and overhead conveyors are
used for transporting materials between different stages of production, such as
 moving raw materials to processing machines or transferring finished products
to packaging areas.
2. Forklifts: Forklifts are indispensable for lifting and moving heavy loads, such as
bales of cotton or rolls of fabric, within the textile mill or warehouse.
3. Pallet Jacks: Pallet jacks, also known as pallet trucks or pump trucks, are used
for lifting and moving palletized loads of yarn, fabric, or finished goods.
4. Automated Guided Vehicles (AGVs): AGVs are programmable robotic vehicles
that can transport materials autonomously within a textile facility, reducing the
need for manual labor and improving efficiency.
5. Hoists and Cranes: Overhead hoists and cranes are used for lifting and
positioning heavy equipment, rolls of fabric, or other materials in textile
manufacturing plants.
6. Stackers and Destackers: Stackers and destackers are specialized equipment
used for stacking and de-stacking materials such as fabric rolls or finished
goods pallets in storage areas or during loading/unloading operations.
These material handling equipment not only streamline production processes but also
contribute to overall safety, efficiency, and productivity in the textile industry.

4. a) Describe modem summer air condi�oning system with figure for a

tex�le tes�ng laboratory.
b) Explain floor prepara�on for spinning mill with necessary diagram.

Answer

a) Modem Summer Air Condi�oning System for Tex�le Tes�ng Laboratory:

The modern summer air condi�oning system for a tex�le tes�ng laboratory
typically involves a combina�on of HVAC (Hea�ng, Ven�la�on, and Air
Condi�oning) components to ensure op�mal condi�ons for tes�ng. Here is a
concise descrip�on with a simplified figure:

• Components:
 1. Chiller Unit: This central component cools the water or refrigerant
used in the system.

2. Air Handling Units (AHUs): These units distribute the condi�oned

air throughout the laboratory.

3. Ductwork: Network of ducts to carry the condi�oned air to various

areas.

4. Thermostats and Sensors: Monitor and regulate temperature and

humidity levels.

5. Control Panel: Manages the opera�on of the en�re system.

• Opera�on:

1. The chiller unit cools the water or refrigerant.

2. The chilled water or refrigerant is circulated to the AHUs.

3. AHUs distribute condi�oned air through ductwork.

4. Thermostats and sensors maintain desired temperature and

humidity levels.

5. Control panel oversees the system’s opera�on and adjustments.

b) Floor Prepara�on for Spinning Mill

• Steps:

1. Leveling and Smoothing: Ensure the floor is level and smooth to

prevent vibra�ons and uneven stress on machinery.

2. Epoxy Coa�ng: Apply epoxy coa�ng for durability, ease of cleaning,

and protec�on against spills.

3. Marking and Layout: Clearly mark designated areas for different

processes, machinery placement, and walkways.
 4. An�-Slip Flooring: Install an�-slip flooring in areas prone to
moisture or spills to enhance worker safety.

5. Adequate Drainage: Implement proper drainage systems to prevent

water accumula�on and damage to machinery.

6. Electrical Layout: Plan and mark electrical outlets strategically for

machinery and equipment placement.

7. Safety Signage: Install clear safety signage indica�ng restricted

areas, emergency exits, and important instruc�ons.

Ensuring a well-prepared floor is essen�al for op�mizing workflow efficiency

and maintaining a safe working environment in a spinning mill.

Part a

1. a. Elaborate the fundamental requirements of preven�ve maintenance for

a tex�le mill.
b. Interpret the maintenance related manpower norms in a weaving mill.

Answer

1. a. The fundamental requirements of preven�ve maintenance for a tex�le

mill include regular inspec�on of machinery, �mely lubrica�on,
calibra�on, cleaning, and replacement of worn-out parts to prevent
breakdowns and ensure con�nuous opera�on.

b. Maintenance-related manpower norms in a weaving mill involve determining

the op�mal number of maintenance personnel based on factors such as the size
of the mill, the complexity of machinery, produc�on volume, and the required
maintenance tasks. This ensures efficient maintenance opera�ons without
overstaffing or understaffing.
2. a. Explain the spinning components on which condition-based
maintenance is applicable.
b. State the usage of spindle tape in a ring frame machine with
schematic diagram.
Ans==
a) Condition-based maintenance applies to various spinning components such as
bearings, belts, gears, and sensors. By monitoring factors like vibration, temperature,
and wear, maintenance can be scheduled based on actual equipment condition rather
than fixed intervals, optimizing maintenance efforts and reducing downtime.

b) Spindle tape in a ring frame machine is used to transfer power from the motor to the
spindles, facilitating yarn winding. It wraps around the motor pulley and spindle pulleys,
ensuring smooth rotation and controlled tension during the spinning process. See the
schematic diagram below:

3. a. Demonstrate the types of flat belt and its usage in textile machine.
b. Interpret the types of flat belt drive with proper schematic diagram.
c. Show the tolerances in a table for the flat belt in width and also in
length.

Answer

a. Types of flat belts used in textile machines include:

i. Cotton Belts: Made of cotton fabric, suitable for light-duty applications.
ii. Rubberized Belts: Cotton belts coated with rubber for increased durability and grip.
iii. Leather Belts: Used for heavier loads due to their strength and flexibility.

b. Types of flat belt drives:

i. Open Belt Drive: Belts run on pulleys in the same plane, with no guard.
ii. Cross Belt Drive: Pulleys are at an angle, providing a more compact design.
iii. Quarter Turn Belt Drive: Pulleys are at a right angle, enhancing efficiency.

c. Tolerances for flat belts:

| Parameter | Tolerance |
|-------------|-------------|
| Width | ±0.5 inches |
| Length | ±1% |
Note: The schematic diagram link should be replaced with an appropriate source or
illustration.
 4. a. Explain the necessity for proper air condi�oning in a spinning and
weaving mill.
b. Define the humidifica�on related terms: Latent heat, Evapora�ve
cooling.
c. Explain the merits and demerits of a modern Humidifica�on System for
a weaving shed housed with high speed auto-coner machine.

Answer

a. Proper air condi�oning in a spinning and weaving mill is essen�al to maintain

op�mal temperature and humidity levels. This ensures consistent yarn quality
by preven�ng fiber breakage, sta�c electricity, and uneven moisture content,
leading to improved produc�on efficiency.

b.

• Latent heat refers to the energy absorbed or released during a phase

change without a temperature change. In humidifica�on, it’s crucial for
the water vaporiza�on process.

• Evapora�ve cooling involves the reduc�on of air temperature through

water evapora�on, commonly used in humidifica�on systems to control
the environment in tex�le mills.

c.

• Merits of a modern Humidifica�on System: Improved yarn quality,

reduced sta�c electricity, enhanced worker comfort, and increased
produc�vity.

• Demerits: Ini�al installa�on cost, maintenance requirements, and

poten�al issues like over-humidifica�on affec�ng certain processes.

5. a. Interpret a plan-do-check-act for energy efficiency according to the adapted

Energy Star guidelines.
 b. Demonstrate the weaving floor covering proper�es with examples.

Answer

a. A plan-do-check-act (PDCA) cycle for energy efficiency, according to adapted

Energy Star guidelines, involves:

Plan: Assess current energy usage, set specific energy efficiency goals, iden�fy
areas for improvement, and develop a comprehensive plan to achieve those
goals.

Do: Implement energy-saving measures outlined in the plan, such as upgrading

to energy-efficient appliances, improving insula�on, and op�mizing hea�ng and
cooling systems.

Check: Regularly monitor energy consump�on to ensure that implemented

measures are effec�ve in reducing energy usage. Compare actual results to the
set goals and adjust strategies as needed.

Act: Take necessary ac�ons based on the findings of the checking phase. This
may involve further refining energy-saving strategies, inves�ng in addi�onal
technologies, or realloca�ng resources to maximize efficiency.

b. Weaving floor coverings can possess proper�es such as durability, aesthe�c

appeal, ease of maintenance, and sustainability. For example, a carpet made
from recycled materials showcases sustainability by reducing waste and energy
consump�on in manufacturing. Addi�onally, its durability ensures longevity,
while its design enhances the aesthe�c appeal of the space. Such proper�es
make it a prac�cal and environmentally friendly choice for floor covering
solu�ons.

5. 6. a. Discuss about the design of a centralized air condi�oning system with

air washer humidifica�on system plants with proper iden�fica�on.
b. Classify the kinds of humidifiers used in tex�le mills:

Answer
a. The design of a centralized air condi�oning system with an air washer
humidifica�on system involves the integra�on of air handling units, ductwork,
cooling coils, filters, humidifiers, and controls. The air washer humidifica�on
system typically comprises a water tank, pump, distribu�on pipes, and media
pads. Iden�fica�on of components includes specifying the capacity of the
system, type of cooling media, airflow rates, water supply requirements, control
strategies, and energy efficiency measures.

b. Humidifiers used in tex�le mills can be classified into three main types:

1. Atomizing or ultrasonic humidifiers: These devices produce a fine mist by

breaking water into �ny droplets, which are then dispersed into the air.

2. Steam humidifiers: These systems boil water to produce steam, which is

released into the air to increase humidity levels.

3. Evapora�ve humidifiers: These units use a fan to blow air through a wet
wick, pad, or filter, causing water to evaporate and humidify the air.

7. Briefly discuss the types of occupa�onal hazards.

Answer=

Types of occupa�onal hazards include:

• Physical Hazards: Such as noise, vibra�on, radia�on, and temperature

extremes.

• Chemical Hazards: Exposure to harmful chemicals like toxic substances,

gases, vapors, and fumes.

• Biological Hazards: Risks from exposure to bacteria, viruses, fungi, and

other microorganisms.

• Ergonomic Hazards: Related to poor worksta�on setup, repe��ve tasks,

and improper li�ing techniques.
 • Psychosocial Hazards: Stemming from workplace stress, harassment,
violence, and poor organiza�onal culture.

• Safety Hazards: Associated with slips, trips, falls, machinery accidents, and
electrical hazards.
8. a. Identify the hazard associated with storing materials in store
section of a garments industry and develop some ways to minimize
it.
b. A local distributor company expects to sell about 22000 pes of
carton of certain size to the next year. Annual carrying cost per order
is $18 , ordering cost is $102 and lead time is three days. Distributor
operates 200 days per year. Show optimum order quantity, total cost,
ROP and frequency of order per year.

Ans==
a. Hazard identification and minimization in the store section of a garments
industry:
Hazard: Fire risk due to flammable materials, such as fabrics and chemicals.
Ways to minimize:
1. Implement fire-resistant storage solutions for materials.
2. Install fire suppression systems and equipment.
3. Conduct regular fire drills and provide staff training on fire safety.
4. Store flammable materials in designated areas with proper ventilation.
5. Use proper labeling and storage guidelines for hazardous materials.

b. Optimum order quantity, total cost, Reorder Point (ROP), and frequency of
order per year:
Given data:
• Expected annual demand (D) = 22,000 cartons
• Carrying cost per order (H) = $18
• Ordering cost (S) = $102
• Lead time (L) = 3 days
Therefore, the optimum order quantity is approximately 494 cartons, the total cost is $9252, the
reorder point is 660 cartons, and the frequency of order per year is approximately 44.52 orders.

8. a. Define (i) Accident (ii) Inventory-management (iii) GHS (iv) Incident

b. Utilize HIRARC to explain risk control hierarchy of a dyeing mill.

Ansss===

a..(i) Accident: An unplanned event resul�ng in injury, damage, or loss.

(ii) Inventory management: The supervision and control of inventory levels to
op�mize efficiency and minimize costs.

(iii) GHS (Globally Harmonized System): A standardized system for the

classifica�on and labeling of chemicals to ensure global hazard communica�on.

(iv) Incident: An event that could have or did result in injury, ill health, damage,
or loss.

b. HIRARC (Hazard Identification, Risk Assessment, and Risk Control) in a dyeing

mill involves:

• Identifying hazards such as chemical exposure, machinery accidents.

• Assessing risks associated with each hazard.
• Implementing control measures like proper chemical handling procedures,
machine guarding.
• Reviewing and monitoring controls to ensure effectiveness and compliance
with safety standards.