TABLE - 32 Sitra Norms For Spin. Roving Content Per Bobbin ...€¦ · TABLE - 32 Sitra Norms For Spin. Roving Content Per Bobbin in Fly Frames Bobbin Full Bobbin Roving Lift (L)

Sitra Norms For Spin. TABLE - 32

Roving Content Per Bobbin in Fly Frames

Bobbin Full Bobbin Roving

Lift (L) Diameter (D) Content

(inches) (inches) (kg.)

10 4 1/2 0.60

10 5 0.75

11 4 1/2 0.70

11 5 1/2 1.00

12 5 0.90

12 6 1.30

12 6 1/2 1.50

12 7 1.75

14 7 2.05

The above figures will roughly follow the relationship

Roving Content (Kg.) = 3 x L x D2

1000

TABLE - 33

Sliver Content per Can in Draw Frames

Can Size Can Content

Diameter x Height (inches) (Kg.)

36 x 12 7.8

36 x 16 13.8

42 x 16 16.1

42 x 18 20.4

42 x 20 25.2

42 x 24 36.3

42 x 36 81.6

42 x 40 100.8

48 x 16 18.4

48 x 24 41.5

48 x 40 115.2

1 The sliver content (kg.) for different can sizes tabulated above can be approximately calculated using the

following formula :

1.5 x Height x Diameters 2

1000

2 The figures are also applicable to cards can. However, in the case of card cans, mills generally maintain

10 to 15 % lighter contents than those indicated here .

PAGE - 78

TABLE - 34

Number of Machine Units Required to Balance 1000 Spindles in Ring Spinning

Carded Count

Count Fly Draw Frame Cone Winder

Frames Fin. Del. Cards Scutchers Drums

Spindles HS SHS HP Su HP MYC EYC EYCS Auto

10s 168 1.28 0.62 3.21 1.71 0.34 39.9 44.9 53.2 18.3

14s 112 0.86 0.42 2.17 1.15 0.23 36.9 43.1 51.2 17.6

16s 98 0.75 0.37 2.12 1.13 0.21 35.9 39.9 47.4 19.4

18s 66 0.66 0.32 1.86 0.99 0.19 39.6 50.4 60.1 19.4

20s 61 0.61 0.30 1.71 0.91 0.17 49.8 58.2 69.1 20.8

24s 53 0.51 0.25 1.35 0.72 0.14 40.3 48.4 57.3 16.4

30s 46 0.42 0.21 1.16 0.63 0.11 33.4 40.6 48.2 17.0

36s 41 0.36 0.18 1.01 0.55 0.09 30.3 34.3 40.6 14.0

40s 37 0.33 0.18 0.87 0.47 0.08 29.4 36.5 43.2 14.3

60s 32 0.24 0.11 0.65 0.35 0.05 26.7 34.1 40.0 11.6

80s 29 0.17 0.11 0.50 0.25 0.04 30.1 41.4 49.3 10.5

100s 25 0.13 0.08 0.42 0.21 0.03 22.2 31.4 36.2 10.0

20s VSF 48 0.75 0.36 2.10 1.12 0.22 61.3 71.6 85.0 25.6

31s VSF 34 0.47 0.23 1.28 0.70 0.12 38.0 45.4 54.0 19.4

40s VSF 30 0.39 0.21 1.02 0.55 0.09 34.4 42.8 50.5 16.7

VSF - Viscose Staple Fibre

Fly Frames : High Speed ; Draw Frames HS : High Speed ; SHS : Super High Speed (with Autoleveller); Card HP : High

Page 81

Sitra Norms For Spin. production; SuHP; Super High production (with Autoleveller) ; Cone Winders Conventional : MYC : With Mechanical

Yarn Clearers ; EYC : With Electronic Yarn Clearers ; EYC-S : With Electronic Yarn Clearers & Splicers ; Auto :

Automatic Cone Winding ; Reels SHPR : Single hank Plain ; DHPR : Double Hank Plain ; DHCR : Double Hank Cross

1 The above balancing is based on the relevant production rates given in Tables 1 to 11,17,18 & 20. Normal

waste percentages have been allowed for ;

2 All departments including reeling are assumed to work equal number of hours .

TABLE - 35

Number of Machine Units Required to Balance 1000 Spindles in Ring Spinning

Combed Count

Count Fly Draw Frame Cone Winder

Frames Fin. Del. Cards Scutchers Drums

Spindles HS SHS HP Su HP MYC EYC EYCS Auto

14s 109 0.94 0.65 2.82 1.50 0.30 40.2 46.9 55.8 19.2

16s 98 0.85 0.59 2.84 1.51 0.29 40.2 44.8 53.2 21.8

18s 67 0.74 0.52 2.48 1.32 0.25 44.4 56.5 67.3 21.7

20s 63 0.69 0.48 2.32 1.24 0.23 56.8 66.3 78.8 23.7

24s 54 0.54 0.38 1.85 0.99 0.19 46.4 55.7 66.0 18.9

30s 46 0.45 0.31 1.58 0.86 0.15 38.1 46.4 55.0 19.4

36s 39 0.39 0.32 1.37 0.75 0.12 34.7 39.2 46.5 16.0

40s 43 0.36 0.29 1.18 0.64 0.10 33.4 41.5 49.1 16.3

60s 33 0.24 0.18 0.84 0.45 0.06 28.9 36.9 43.3 12.5

80s 30 0.17 0.12 0.65 0.33 0.05 32.8 45.1 53.7 11.4

100s 24 0.12 0.09 0.52 0.26 0.03 23.5 33.2 38.3 10.6

120s 19 0.09 0.07 0.46 0.22 0.02 20.9 27.9 32.7 8.7

Fly Frames : High Speed ; Draw Frames HS : High Speed ; SHS : Super High Speed (with Autoleveller); Card HP : High

production; SuHP; Super High production (with Autoleveller) ; Cone Winders Conventional : MYC : With Mechanical

Yarn Clearers ; EYC : With Electronic Yarn Clearers ; EYC-S : With Electronic Yarn Clearers & Splicers ; Auto :

Automatic Cone Winding ; Reels SHPR : Single hank Plain ; DHPR : Double Hank Plain ; DHCR : Double Hank Cross

1 The above balancing is based on the relevant production rates given in Tables 1 to 10,12,17,18 & 20. Normal

waste percentages have been allowed for ;

2 All departments including reeling are assumed to work equal number of hours .

3.the number of high-speed combers(8 head each) required to balance 1000 spindles : 20s - 1.81; 30s - 1.11;

40s - 0.75; 60s - 0.47; 80s - 0.32; 100s - 0.22 & 120s - 0.17.

PAGE - 79 TABLE - 36

Hanks to be recorded on Hank Indicators on Ring Frames

Hanks Hanks Hanks

Count per 8 Count per 8 Count per 8

Hours Hours Hours

Carded Combed

16s 10.9 20s VSF 13.1 16s 12.1

20s 10.9 31s VSF 11.1 20s 12.4

30s 10.0 40s VSF 10.3 30s 11.3

40s 9.0 40s 10.1

50s 8.7 60s 8.9

60s 8.2 80s 7.9

80s 7.3 100s 6.9

100s 6.5 120s 6.3

VSF - Viscose Staple Fibre

* Allowance given only for doffing, no account being taken of maintenance stoppages.

1. Hank indicator reading afford a simple & effective mean of excersing control on spindle speed & machine stoppages

in ring spinning. The table above gives the production in hank which will be recorded on hank indicators if standard

spindle speed & tpi are maintained.

2. Production per 8 spindle speed 1

hours as shown = * * (1 - d) hanks

on hank indicator tpi 63

where 'd' is the proportion of machine stopped time due to doffing.

3. At least 90% of ringframes should achive standard hank every shift.

Page 82

Sitra Norms For Spin. 4. The spindle speed & tpi correspond to those given in table 11 & 12. For arriving at the standard production rates

given in this tables,allowances must be made for yarn contraction as well as pneumafil waste, maintenance

stoppages & idle spindles.

TABLE - 37

Total Number of workers to be Engaged for 1000 Spindles for Reeled & cone Yarns

Workers per 1000 spindles (per shift)

Count Reeled yarn Cone yarn

SHPR DHPR DHCR conventional Auto

winder with Winders

MYC

16s 11.3 9.6 9.7 7.6 5.9

20s 10.4 8.7 8.8 6.3 5.0

26s 8.7 7.3 7.4 5.0 4.0

30s 8.2 6.8 6.9 4.4 3.5

40s 7.1 5.5 5.7 3.3 2.6

60s 6.0 4.5 4.7 2.5 2.0

80s 5.1 3.8 4.0 2.0 1.6

100s 4.4 3.3 3.5 1.7 1.4

SHPR : single hank plain reeling DHCR : double hank cross reeling

DHPR : double hank plain reeling MYC : mechanical yarn clearers

1. The figures given above include all the categories of workers engaged from mixing to bundling & baling in case of

reeled yarns, & from mixing to cone packing in the case of cone yarns. For combed count the extra requirement of

workers may be added to the above figures.

2. Production rates & work assignment are in accordance with the relivant norms given in this publication. Method of

processing is assumed as follows: single process blow room with automatic lap doffing, high production cards,

high speed draw frames(two passages), high speed fly frames & high speed ring frames(new or converted),

followed by reeling or cone winding as the case may be.

Definiutions & Explantory Notes about the Various Productivity Measures Developed by SITRA

Adjusted HOK

The HOK(that is he operative hours engaged to produce 100 kg. of yarn) is adjusted to a common count of 40s by

multiplying the actual production in different counts by the relevant conversion factors.

The conversion factors are the ratio of HOK of individual count to that of 40s count under the

given working conditions. Specifically, the production rates, work assignment, etc.,correspond to the norms detailed

in this publication. These conversion factors are different for different department & for the count of 40s, it is unity for all

departments. Another major practical advantage of method is that it is not required to obtain a break up of the operatives

according to each count.

The production so converted is termed 'standardised production'. Thus the adjusted hok is calculated from :

Operatives hours

Total of the standardised ring spinning * 100

production in individual counts

PAGE - 80

UPTO SPINNING

Standard HOK

The total standard HOK of 19.0 is attainable under the conditions specified in footnotes to table 39

Definiutions & Explantory Notes about the Various Productivity Measures Developed by SITRA (contd.)

Expected Hok

The HOK achievable for a particular level of modernisation by making the best use of the machinery work

assignments equivalent to those of the standard. This figure also is in terms of 40s count. Where the degree of

modernisation is on par to that taken for the standard (Table 39), the total expected HOK would be the same as the

standard HOK , that is 19.0. On the other hand, if the machinery is less modern than that assumed,then the expected

HOK would be higher than 19.0.

Production per Spindle Adjusted to 40s

Production per spindle in ring spinning converted to 40s count can be determined by means of conversion

factors are given in Table 38. Method of working out the production per spindle adjusted to 40s is also outlined in the

notes preceding that table.

OHS Adjusted to 40s

Operatives per 1000 spindles adjusted to 40s count, and is arrived at from :

HOK Adjusted to 40s X production per spindle adjusted to 40s.

800

For standard HOK and OHS for different departments, refer to Table 39.

Page 83

Sitra Norms For Spin.

POST SPINNING

Cone Winding

a. Roto - coner type ( conventioanl winder with mechanical yarn clearers )

The standard production per tenter per 8 hours in 40s count is 97 kg. Which gives 8.2 as the standard HOK for

40s (800/97)

b. Automtic Cone Winding

The standard production per tenter per 8 hours in 40s count is 332 kg. Which gives 8.2 as the standard HOK for

40s (800/332)

Reeling

Double Hank plain Reeling (DHPR) has been taken as being adopted in the standard mill. The standard production

per reeler in DHRR in 40s count is 30.8 kg. Per 8 hours and based on this, the standard HOK for 40s DHPR works out

to 26.0 ( 800/30.8)

NOTES TO TABLE 38

1. The conversion factors given are the ratios which the production per spindle is 40s count ( I.e. 95g) bears to the

production per spindle in the respective counts ( refer to Tables 11 & 12 for the production rates in different counts).

However,in working out the values given in this table, the production per spindle figures were taken correct to four

decimal places. Thus, the conversion factor for 20s is :

Production per spindle in 40s = 94.965 .= 0.412

Production per spindle in 20s 230.488

Example : If the production per spindle obtained by a mill in 20s count is 170g., then the corrosponding 40s converted

figure is : 0.412 X 170 = 70.0 g. Against the standard of 95.0 g in 40s count.

2. To obtain a combined converted production per spindle for all the counts produced in the ring spinning department,

the production per spindle for each count is converted 40s , then each of these converted figures is multiplied by

the rspective spindle shifts, and finally a weighted average is taken.

3. It is also possible to arrive at this combined figure without working out the converted production per spindle for each

count. For eample, let us suppose that in a month a mill recorded the following yarn production figures in different

counts : 20s : 5000 kg ; 40s : 10000 kg. And 60s : 15000 kg. Let us further assume that the total spindle shifts

corrosponding to this yarn production were 542700. Applying the conversion factors given in the table, the

production per spindle is converted to 40s as shown below.

(5000 X 0.412) + (10000 X 1.000) + (15000 X 1.647) X 1000 = 67.7 g

542700

4. Some mills, particularly producing coarser ranges of counts, may prefer to apply 20s conversion rather than 40s

The factor for such 20s 20s conversion can easily be derived from from those given in the table since it involves

merely multiplying the tabulated values by a constant

PAGE - 81

5 Where a combined 20s conversion alone is desired, the 40s conversion factorsthemselves can be sed as

illustrated above; only yhe final figure need be multiplied by 2.4268 to change it to 20s conversion. The 20s

converted production per spindle figure for the illustrative example given above will be : 67.7 x 2.4268=164.3 g.

6 The production per spindle adjusted to 40s can also be expressed as an index in terms of the standard

production per spindle of 95.0 g. For the illustrative example shown in 3 , the production index would be :

(67.7/95) x 100 = 71

Which means that the production per spindle obtained is only 0.71 times the standard . Since the production

per spindle determined by spindle speeds, tpi and machines efficiencies which prevail in the mill, it will be

useful to be able to resolve the production index into these components factor. Thus production index can

be broken into :

Production = Speed x Twist x Efficiency

index index index index

Reference may be made to be relavent SITRA publications for the method of working out these indices

and their interpretation .

TABLE - 38

Factors for Converting Production per Spindles to 40s Count

Carded Combed

Count Factor Count Factor Count Factor Count Factor

6s 0.131 34s H 0.692 12s 0.216 60s 1.512

8s 0.166 36s 0.864 14s 0.269 62s 1.589

10s 0.198 38s 0.932 16s 0.297 64s 1.666

12s 0.235 40s 1.000 18s 0.340 70s 1.906

Page 84

Sitra Norms For Spin. 14s 0.293 40s H 0.884 20s 0.362 80s 2.257

16s 0.334 40s VSF 0.854 20s H 0.338 90s 2.693

18s 0.381 42s 1.025 22s 0.415 100s 3.237

20s 0.412 44s 1.093 24s 0.455 120s 4.254

20sH 0.381 46s 1.168 25s 0.483 30sP/C 0.628

20s HT 0.826 47s 1.206 26s 0.513 50sP/C 1.165

20s VSF 0.335 48s 1.245 28s 0.570 60sP/C 1.523

22s 0.475 50s 1.292 30s 0.592 60sP/CHT 2.273

24s 0.524 60s 1.638 30sH 0.550 80s P/C 2.271

25s 0.557 60s HT 2.376 32s 0.652 90s P/C 2.693

26s 0.587 60s VSF 1.561 34s 0.711 30sP/V 0.544

28s 0.656 62s 1.720 34s H 0.660 40sP/V 0.721

30s 0.676 64s 1.805 36s 0.755 60sP/V 1.230

30s H 0.601 70s 2.064 38s 0.819 80sP/V 1.883

31s VSF 0.612 80s 2.461 40s 0.880

32s 0.724 84s 2.633 40sH 0.791

34s 0.793 100s 3.420 55s HT 2.098

H : Hosiery HT : High Twist VSF : Viscose Staple Fiber

P/V : Polyester Viscose P/C : Polyester Cotton

The above conversion factors are based on the production rates given in Tables 11 and 12 .

TABLE - 39

HOK & OHS for Different Departments for Achieving a Total HOK of 19.0

Department (Adjusted to 40s count ) HOK OHS

Mixing & Blow Room 1.9 0.23

Cards 2.0 0.24

Drawing 0.7 0.08

Fly Frames 2.1 0.25

Ring Frames 12.3 1.46

Total 19.0 2.26

Ring Frame tenters including reserve

tenters & relivers for 24 hours working 6.2 0.74

Ring frame doffers includind sweepers 3.2 0.7

Ring frame 'others' comprising cleaning gang,

jobbers,doff carriers & mainteance workers 2.9 0.35

Production per spindle per 8 hours adjusted to 40s(g.) 95.0

1. The level of modernisation assumed is as follows : single process blow room with automatic lap doffing,high prodution

cards,high speed draw frames (two passages) high speed fly frames & high speed ring frames (new or converted)

2. The production rates correspond to those given else where in this publication (I.e. Tables 1 to 12)

3. Work assignment & ancillary operatives assumed are shown in table 26.

4. The HOK for combers including that for combing preparatory may be taken as 2.5

PAGE - 82 TABLE - 40

Total HOK Production per Spindle & OHS Norms

for Some Major Counts

Count Total Production per Operatives per

HOK Spindle per 1000 Spindles

8 Hours (g) (OHS)

16s 14.0 284.4 5.0

20s 14.0 230.5 4.0

26s 16.3 161.7 3.3

30s 16.6 140.5 2.9

40s 19.0 95.0 2.3

60s 24.5 58.0 1.8

80s 30.0 38.6 1.4

100s 36.3 27.8 1.3

1. For work assignment corresponding to the above total HOK,reference may be made to table 26.

2. Production per spindles figures are the same as given in table 11.

3 HOK x P

OHS =

800

TABLE - 41

HOK Norms for Rotor Spinning

Count Mixing & Cards Drawing Rotor Total

Page 85

Sitra Norms For Spin. Blow room Spg.

6s 1.6 0.6 0.5 1.0 3.7

7s 1.6 0.6 0.5 1.2 3.9

8s 1.6 0.6 0.5 1.4 4.1

10s 1.6 0.6 0.5 1.4 4.1

12s 1.6 0.6 0.5 1.8 4.5

14s 1.6 0.6 0.5 2.0 4.7

16s 1.6 0.6 0.5 2.4 5.2

20s 1.6 0.6 0.5 2.7 5.6

1. While arriving at the HOKs for the preparatory department,the folowing sequence of processing has been taken:

Stack Mixing,Blow room,Chute feed Cards,& high speed draw frames with two passages.

2. The work assignment taken for the various preparatory deparment are as follow:

Mixing : one man uptp 20,000 kg of lap for 26 shifts of 8 hours each.

Blow room : one tenter for 10 chute feed cards, subject to a maxmimum of 20,000 kg of sliver production

Cards : 10 chute feed cards per tenter, subject toa maxmium of 20,000 kg of sliver production.

Drawing : 10 high speed deliveries per tenter; Front roller speed : 350 mpm.

3. The production rates for rotor spinning are given in table 21.The tenter work assignment taken are:2 sides in 4s to 8s,

3 sides in 10s to 18s & 4 sides in 20s.The ancillary labour compliment is assumed as 0.50 operative per 1000 rotors.

TABLE - 42

HOK for Different Department for an EOU/High -Tech Mill

of 30,000 Spindles to Attain Two Levels of Very High

Productivity : 15 & 12 HOK (40s count)

15 HOK 12 HOK

Department/ HOK Work Assignments/ HOK Work Assignments/

Category Operatives Operatives

Mixing Attendant 0.9 1000 kg. Of finished - bale plucker used

laps per shift

Blow Room Tenter 0.5 One back attendant and one 0.3 one bale plucker

scutcher attendant per 3 operator

scutcher to a maximum of

3650 kg. of lap production

per shift

Carding Tenter 0.4 10 super high production 0.3 Upto 12 chute feed cards

cards with auto doffing & with auto doffing and auto-

automatic waste evacuation matic waste evacuation

(Maximum of 2000 kg. Of sliver (Maximum of 2000 kg. Of

production per shift) sliver production per shift)

Drawing Tenter 0.4 5 deleivaries of very high speed 0.4 5 deleivaries of very high speed

autoleveller draw frames per autoleveller draw frames per

tenter ( delivery speed-500 mpm) tenter ( delivery speed-500 mpm)

PAGE - 83

TABLE - 42 (Contd.)

HOK for Different Department for an EOU/High -Tech Mill

of 30,000 Spindles to Attain Two Levels of Very High

Productivity : 15 & 12 HOK (40s count)

15 HOK 12 HOK

Department/ HOK Work Assignments/ HOK Work Assignments/

Category Operatives Operatives

Flt Frame Tenter 0.8 3 frames of 120 spindles 0.6 4 frames of 120 spindles

each per tenter each per tenter

(Spindle speed - 1200 rpm) (Spindle speed - 1200 rpm)

Fly Frame Doffer 0.6 1200 spindles doffs per 0.5 1200 spindles doffs per

Doffer (1.5 kg bobbin content) Doffer (1.5 kg bobbin content)

Ring Frame Tenter 4.3 2016 Spindles per tenter 3.3 2520 Spindles per tenter

15% relievers production per 15% relievers production per

spindle: 100 g. per 8 hours. spindle: 105 g. per 8 hours.

Ring Frame Dofffer 3.2 4500 spindles doffs per doffer 2.6 5500 spindles doffs per doffer

( cop content :55 g.) ( cop content :55 g.)

Overlookers and 4.0 45 Operatives per day 4.0 45 Operatives per day

Maintenance from blowroom to ringframes from blowroom to ringframes

Operatives

Page 86

Sitra Norms For Spin. Total 15.0 12.0

Note : In a mill havng ring frames equipped with built in automatic doffing device , a total HOK of about 10 can be

attained .

GENERAL NORMSEXPANDED CONTENTS

I FINANCE

Cost of production and Profit margin

Symptoms of Sickness and Health

II RETURNS FROM MODERNISATION

Investment Treated as Revenue Expenditure

Investment Capitalised

Investment Pay-Back Period.

III ENERGY

Energy Consumption in Different Departments in a Modren Mill ( 40s count )

Calculation of UKG for 40s count ( Modern Mill )

Energy Consumption for Various Levels of Modernisation

Electrical System Performance

lllumination Level Required in LUX

Allowable Harmonic Level in Electrical System

Units per Litre of Oil for Generators ( ULO )

Working Pressure to be Maintained in Compressors

Boiled Flue Gas Parameters

IV STAFF AND NON - PRODUCTION OPERATIVES

Staff Employment in Various Departments

Number of staff Suggested for a 30,000

Spindle Mill

Norms For Non - Production Operatives

V CONSUMPTION RATE OF MAJOR STORE ITEMS

Consumption of Major Spinning

Accessories and Spares

VI OTHERS

Absenteeism

Product Standarisation

Process stock

PAGE - 84 I FINANCE

The cost of production and profit under nomal trading conditions are given in Table 1 for a Standard

Spinning Mill and an Average Mill.

TABLE - 1

Cost of Production And Profit Margin(40s count)

As % of Sales Revenue

Components of Cost Standard Mill Average Mill

Raw material 56.0 57.0

Salaries and Wages 9.0 11.0

Stores 3.0 3.5

Power 11.0 11.5

Other costs 6.5 6.5

Interest 6.5 5.5

Depriciation 4.0 3.0

Total 96.0 98.0

Profit Margin 4.0 2.0

TABLE - 2

Symptoms of Sickness and Health

Perticulers Sick Healthy

Page 87

Sitra Norms For Spin. Salaries and wages more than 15% less than 10% of

of sales revenue sales revenue

Production per Spindle 75 g. or less More than 85 g.

per shift 8 hours

(adusted to 40s count)

Labour Productivity Less than 75% More than 90% of

of SITRA norms SITRA norms

Spindle Utilisation 85 % or less More than 90%

Net Profit / Loss Less than 1% Profit even during

profit or loss recession

during normal

trading conditions

II RETURNS FROM MODERNISATION

First - year savings, by which it is meant the saving to be earned from modernisitation in the first year, that

would make the investment breakeven are shown in Tables 3 and 4.

Assumptions:

The figures reported in Tables 3 & 4 have been obtained from the mathematical expression developed by

SITRA, substituting the following values : tax rate 35% (plus 10% surchage) depriciation allowance 25%, increase in

savings as a result of rise in price 7.5% a year compounded, interest rates 15% and 18%, increase in savings due

to operating inferiority 3%. No separate allowance is considered for additional expenses like erection , insurance,

sales tax, etc., since all these form a part of the machinery cost.

Investment Treated as Revenue ExpenditureTABLE - 3

First-Year- Saving to Break Even as % of Investment

When Treated as Revenue Expenditure

Number of 15 % Intreest 18 % Intreest

Years of Salvage Value* Salvage Value*

Life 10% 20% 30% 10% 20% 30%

7 16.2 13.2 10.2 18.0 14.7 11.4

10 12.1 9.9 7.7 13.9 11.4 8.8

12 10.6 8.7 6.7 12.4 10.2 7.9

15 9.2 7.5 5.8 11.0 9.0 7.0

20 7.8 6.4 4.9 9.8 8.0 6.2

25 7.1 5.8 4.5 9.1 7.5 5.8

* Resale value of the machine being replaced as percentage of the investment.

Cosider a proposal to replace an old ring frame with a new one at a cost of Rs.2000 per spindle. If the resale

value of the old machine is Rs.400 per spindle (20% salvage value) and the life of the new machine is 15 years, then the

first year saving to break even the investment should be Rs.150 (7.5% of Rs.2000) per spindle at 15% interest rate

and Rs.180 (9.0% of Rs.2000) per spindle for 18% interest rate.

PAGE - 85

Investment Capitalised TABLE - 4

First-Year- Saving to Break Even as % of InvestmentInvestment Capitalised

Number of 15 % Intreest 18 % Intreest

Years of Salvage Value* Salvage Value*

Life 10% 20% 30% 10% 20% 30%

7 19.6 16.6 13.6 22.0 18.7 15.4

10 14.5 12.2 10.0 16.8 14.3 11.7

12 12.6 10.7 8.7 15.0 12.7 10.4

15 10.9 9.2 7.5 13.3 11.3 9.3

20 9.3 7.9 6.4 11.8 10.0 8.2

25 8.4 7.1 5.8 11.0 9.3 7.6

* Present worth of terminal salvage value of the new machine.

Investment Pay Back Period

Pay - Back Period (I,e., The investment simply divided by the estimated savings per year) is frequently used

to assess weather the investment is sound or not. Pay-back period calculated in this manner does not , however,

indicate the munber of years which will actually take for the recovery of the investment if the interest rate as well as

Page 88

Sitra Norms For Spin. the taxes are taken into account . The relationship between the two is shown in Table 5.

TABLE - 5

Actual Number of Years Required to Recover

Investment with Interest Vs. SimplePay - Back Period

Actual Simple Pay - Back Period ( Years )

Pay - Back Treated as Treated as

Period Capital Investment Revenue Expenditure

(years) 15% 18% 15% 18%

Interest Interest Interest Interest

7 5.1 4.5 6.2 5.6

10 6.9 5.9 8.3 7.2

12 7.9 6.7 9.4 8.0

15 9.2 7.5 10.9 9.1

20 10.8 8.5 12.8 10.2

25 11.9 9.1 14.1 11

Note : Salvage value 10%.

The actual Pay - back period to breakeven is 15 years as against a simple pay - back period of about 9 years

when the investment is capitalised and about 11 years when the investment is treated as revenue expenditure . The

interest rate in both the cases is 15 %.

Note : For mathematical expression to calculate First-Year break even saving, refer "MODERNISATION IN

SPINNING" 1996 SITRA monograph .

PAGE - 86

III ENERGYThe Kilo Watt hours (kWh) for running machines in different departments are given in Table 6 and the number

of units per kg. of yarn production (UKG) for 40s count in Table 7 .

TABLE - 6

Energy Consumption in Different Departments

in a Modern Mill ( 40s Count )

kWh for Production Productiom

Department 8 Machine Rate per 8 hours required for 100kg.

Running (40s) of Yarn ( kg.)

Hours

Blow Room 200 1350 Kg. Per scutcher 112

Very High

Production Cards 69 250 Kg. Per card 105

Drawing

1st Passage 26 300 kg. Per delivery 104

2nd passage 24 550 kg. Per delivery 104

(Autoleveller)

Page 89

Sitra Norms For Spin. Fly Frame 56 2.6 Kg. per spindle 103

(120 spindle

per Frame)

Ring Frame 100 95 g. per spindle 100

(440 spindles)

Auto Winding 160 6.5 Kg. per drum 100

(60 drums)

TABLE - 7

Calculation for UKG for 40s count ( Modern Mill )

Department Units (kWh) Consumed in Different Department

For 100 Kg. of Yarn

Blow Room 200 x 112 = 8.3

1350 x 2

Very High Production 69 x 105 = 29.0

Cards 250

Drawing :

1st Passage 26 x 104 = 4.5

300 x 2

2nd passage 24 x 104 = 4.5

(Autoleveller) 500

Fly Frames 56 x 103 = 18.5

2.6 x 120

Ring Frame 100 x 100 = 239.2

(With OHC) 440x 0.095

Auto Winding 160 x 100 = 41.0

60x 6.5

Humidification = 60.0

Compressors = 32.0

Lighting and Others = 18.0

Total Units for 100 Kg. Of Yarn 455.0

UKG ( units per Kg, of yarn) = 4.6

Note : Standard UKG for a mill having conventional machines like high production cards , non - autoleveller draw

frames and conventional cone winders and achieving a production rate of around 90 g. ( adjusted to 40s ) is

about 3.6 .

PAGE-86

TABLE - 8

Energy Consumption for Various Levels

of Modernisation

Units per 100 Kg.

Modernisation Level of Yarn

( 40s )

Blow Room with rotary filter 9

Very High Production (VHP) card with 34

Automatic Waste Evacution System (AWES)

Chute Blow room line and VHP cards with 47

AWES

Fly Frame with Over Head Cleaner (OHC) 20

Long Length Ring frame with individual OHC 252

Modern Humidification Plant with automatic 85

controls

Comber with AWES 6

Ring Doubling Frames 83

Two or One Twister 290

For a Mill with Open End Spinning 110

Page 90

Sitra Norms For Spin. Producing 10s average count

TABLE - 9

Electrical System Performance

Good Average Poor

NETWORK PARAMETERS

1. Transformer Loading 50 - 60% 70-80% <40% or > 90%

2. Pf at transformer terminal point About 0.95 < 0.9

unity

OPERATING PARAMETERS :

3. Motor Loading in Spinning About 75% <60% or > 95%

Machines (at full doff stage) 85%

4. Motor Terminal Voltage 415-440V 400V < 380 V

I) In spinning Doubling

Humidification,TFO,cone winding

and Pneumafil motors

ii) In Blowroom,perparotory and 400V 390V <370V

other motors laoded <50%

5. Motor no load power 3-5% of 6-8% of > 8% of

rated KW rated KW rated KW

6. Motor surfae temp. <85°C 85°-100°C > 115°C

7. Motor surrounding temp. <35°C 35°-40°C >40°C

8. Supply Frequency 50 Hz 49 Hz < 48 Hz or

> 52 Hz

Total loss in electrical Network < 3 % of power handled

Cable loss alone < 1 % of total power transported.

Motor Burnouts

Motor burnouts should be less than one per 1000 spindles per year .

TABLE - 10

Illumination Level Required in LUX

Department Good Average Poor

Blowroom , Humudification 50 40 < 25

Plants and Packing

Preparatory 70 50 < 40

Spinning, Doubling and TFO 100 75 < 60

Post Spinning and Inspection 150 100 < 60

room

PAGE-87 TABLE - 11

Allowable Harmonic Level in Electric System

Total Harmonic Individual Harmonic

System Voltage Distortion (%) Distortion ( % )

( kV ) ( THD ) Odd Even

Harmonic Harmonic

0.41 5 4 2

6.6 & 11 4 4 1.75

33 & 66 3 2 1

132 1.5 1 0.5

TABLE - 12

Units per Litre of Oil for Generators ( ULO )

Generators Capacity ULO

Above 1000 kVA > 4.0

Below 1000 kVA 3.5 - 4.0

High Speed 3.7 - 4.0

Page 91

Sitra Norms For Spin. Slow Speed 3.5 - 3.6

TABLE - 13

Working Pressure to be Maintained in Compressors

Section Pressure (Kg./cm2)

Operations of Machines 6 - 7

Cleanings 3 - 4

TABLE - 14

Boiler Flue Gas Parameters

Gas Standard

CO2 12 % - 14 %

O2 2 % - 3 %

IV STAFF AND NON - PRODUCTION OPERATIVESThe norms for staff and non - production operatives employed in different departmennts of a spinning mill are

presented in Table 15 and 16 .

TABLE - 15

Staff Employment in Various Departments

Staff Employed

Departments per 10,000 Spindle

Shifts

Production 1.44

Engineering 0.22

Managements Services1

0.33

Personnel 0.44

Selling and Distribution 0.33

Other Administration2

1.11

Total 3.87

1. Include Quality Control, Stores, Cotton godown, Computer services etc.

2. Include Mill Office, Corporate Office, Finance, Secretarial Functions etc.

For examples staff required for a 30,000 spindle mill, working 7 days a week and 3 shifts a day, will be 35.

The appoximate break - up of staff strength wiil be as given on as follows.

PAGE-88

Number of Staff Suggested for a 30,000 Spindle Mill

Department Function Designation Number of Total

Suggested

Production Manager 1

Spinnig Master 1

Prod. Supervisors 7

(2 per shift and

1 for reliving)

Assistant Spinning 1

Master - Maintenance

Assistant Spinning 1

Master - Quality

Control

Clerical 2 13

Engineering Electrical Supervisors 1

including

generators

Page 92

Sitra Norms For Spin. Electronics Supervisors 1 2

Management Cotton Assistant 1

Services Godown

Store Store Keeper 1

System Analyst 1 3

Personnel Labour Officer 1

Welfare

Time Office Clerk 3 4

( ESI, PF & Wages)

Selling and Sales Assistant 2

Distribution Excise Clerk 1 3

Other Accounts Officer 1

( Administration) Cashier 1

Assistant 1

Cost Accountant 1

Office Manager 1

Assistant 2

Stenographer 1

Purchase Assistant 1

Relieving Clerk 1 10

Total 35

TABLE - 16

Norms for Non - Production Operatives

Department Operatives Employed Norms

Electrical/ Per 10,000 spindle shifts 1.5

Generator/

Humidification

Watch and Ward Per 100 Employes 2

Attender/Office Depends on size of mills 2 - 6

Boy/Peon

QC Investigators - do - 1 - 6

Store Attender - do - 1 - 4

Ticket boy/

Dispensary/

Yard Cleaning/ - do - 3 - 7

Gardening/

Sanitation/Canteen

Drivers Depends on the number of vehicles

owned

Guest House Depends on the needs of outlying places

Non - production operatives required for a 30,000 spindle mill, Working 7 daya a week and 3 shifts a day,

spinning 40s count and employing about 350 workers will be 35. The approximate break-up of operatives is given below :

PAGE-89

TABLE - 16 ( Contd.)

Norms for Non - Production Operatives

Department / Function Number Suggested

Electrical/Generator / humidification 14

Watch and Ward 7

QC Investigators 4

Store Attender 1

Office Attender/Peon/Drivers 4

Sanitations/Canteen/Ticket boy, etc. 5

Total 35

V. CONSUMPTION RATE OF MAJOR STORE ITEMS

Stores expenses including packing materials cost account on the average for 3% of the sales turnover.

Consumption rate of the major sotr items is given in Table 17.

Page 93

Sitra Norms For Spin. TABLE - 17

Consumption of Major Spinning Accessories and Spares

Consumption per 10,000 spindle

Item Unit shift

Ring Frame

1. Top Roller Cots NO 7

2. Top Sunthetic Aprons NO 5

3. Bottom Synthetic Aprons NO 8

4. Synthetic Spindle Tapes NO 2

5. Travellres NO 900

Lubricants Litre 0.2

1. Spindle Oil Litre 1.4

2. Other Oils Kg 0.3

3. Grease

Draw Frame

1. Top Rooler Cots in Draw Frames No 2.5**

2. Sliver Cans -all Departments No 4.0**

Fly Frame

1. Top Roller Cots No 1.0*

2. Top Synthetic Aprons No 0.9*

3. Bottomm Synthetic Aprons No 0.9*

General items

1. Belt No 0.25

2. Bearings No 0.65

3. Gears No 0.20

VI. OTHRES

1. Absenteesim

Absenteeism in its most widely used sense refres to the failure of an employee to report to work when work

is available to him. It consist of three components.

a) Loss of pay leave sanctioned by management or authorised absence.

b) Absence without prior permission of management or unauthorised absence.

c) Certified sickness most commonly known as ESI leave. This component include absence due to sickness

annd accident , but excludes maternity leave.

The suggested norms for absenteeism are given Table-18.

PAGE-90

TABLE - 18

Ratings for Absenteeism Performance.

Absenteeism Rate Rating

in percentage

upto 7 Excellent

7.1 to 11 Good

11.1 to 15 Average

above 15 Below average

Workers absence during strike, lock out, bandh and layoff should be exclude. Similarly worker's on earned

leave and maternity leave causual leave or noot to be considered as absentees.

Page 94


Computation of Rate of Absenteeism

Number of operative shifts lost due to absenteeism during the year 100

Number of operative shifts schelude to work during the year

2. Product Standaadisation

The guidelines for achieving a high dgree of product standaradisation in a 30,000 spindle are :

*- Restrict the total number of counts spun in a year to 8

*.- Produce 3 permanent count in not less than 75% of the spindle and 2 other counts in the remaining spindles.

*- Run at lest half of the ringframe in the same count during the whole year.

*.- Number of new counts spun in year must not exceed 3.

3. Process Stock

The total process stock in spinning increases with the count to the extent of 5 days production for 20s, 7 day's

production for 40s, 10 days production for 60s, 12 days production production for 80s and 15 days production for 100s in

the case of cone yarns. As for reeled yarns, the stock would be higher by oner day as compared to that of cone yarn

in the corrosponding counts.

The End

99

Page 95


SITRA NORMS FOR SPINNING MILLS

EDITION - 2002

TYPED BY

R. SONAR , M. PATEL , N. PATEL

FROM - S.Q.C. Department , P.S.S.G. Ltd . Shirpur

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CSP will be lower by 20 to 30 % ( 20 % at a D/S ratio of 0.7 and 30% at a D/S ratio of 1.1 ) .

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Reels

SHPR DHPR DHCR

6.9 4.9 4.9

5.7 4.0 4.2

5.6 3.9 4.0

5.4 3.7 3.9

5.8 4.1 4.2

5.2 3.6 3.7

4.8 3.4 3.5

4.5 3.0 3.1

4.5 2.9 3.1

3.9 2.5 2.7

3.4 2.1 2.3

3.0 1.9 2.0

4.3

3.3

2.9

Page 177


Reels

SHPR DHPR DHCR

6.2 4.4 4.5

6.3 4.4 4.5

6.0 4.2 4.3

6.6 4.7 4.8

6.0 4.2 4.3

5.5 3.9 4.0

5.1 3.5 3.6

5.1 3.3 3.5

4.2 2.7 2.9

3.7 2.3 2.5

3.2 2.0 2.1

2.9 1.8 1.9

Page 178

Documents

TABLE - 32 Sitra Norms For Spin. Roving Content Per Bobbin ...€¦ · TABLE - 32 Sitra Norms For Spin. Roving Content Per Bobbin in Fly Frames Bobbin Full Bobbin Roving Lift (L)