YARN REALISATION -A critical

analysis

by

A.Kanthimathinathan, CEO,WINSYS SMC

Learning goalsLearning goals Role played by Moisture contentRole played by Moisture content Expectation from Expectation from

Openers/CleanersOpeners/Cleaners Expectation in a CardExpectation in a Card Expectation from CombersExpectation from Combers Understanding Customer Understanding Customer

requirementsrequirements

YARN REALISATIONYARN REALISATION

YARN REALISATIONYARN REALISATION How best mills has used the How best mills has used the

resource called `RAW MATERIAL`resource called `RAW MATERIAL` Ratio of `output of yarn vs input Ratio of `output of yarn vs input

of Mixing`of Mixing`

Deciding factors-YRDeciding factors-YR Customer SpecificationCustomer Specification Raw material QualityRaw material Quality Type of MachineryType of Machinery

Customer SpecificationCustomer Specification Yarn Imperfections in terms of Yarn Imperfections in terms of

Periodical imperfections/Classimat Periodical imperfections/Classimat faultsfaults

Yarn HairinessYarn Hairiness Yarn unwinding PerformanceYarn unwinding Performance Yarn Strength in CSP/RkmYarn Strength in CSP/Rkm Yarn ElongationYarn Elongation

Raw Material QualityRaw Material Quality 2.5% Span length/Mean Length2.5% Span length/Mean Length FinenessFineness Fiber strengthFiber strength Fiber MaturityFiber Maturity Trash ContentTrash Content SFC(n)-Ignored by majority of the SFC(n)-Ignored by majority of the

millsmills

Raw material QualityRaw material Quality

SFC(n)SFC(n)

Varies from 16% to 37%Varies from 16% to 37% Fine counts-16 to 22%Fine counts-16 to 22% Medium counts-20 to 24Medium counts-20 to 24 Coarser counts- 22 to 28 Coarser counts- 22 to 28

Raw material QualityRaw material Quality For other parameters mills know For other parameters mills know

the level of the specifications the level of the specifications they require to spin their Yarn they require to spin their Yarn meeting customer requirementsmeeting customer requirements

Raw Material QualityRaw Material Quality

Role of LengthRole of Length Spinning performance and Spinning performance and

contribution to Yarn strengthcontribution to Yarn strengthRole of finenessRole of fineness Feel of the Feel of the

fabric/Hairiness/Strength/Running fabric/Hairiness/Strength/Running performanceperformance

Raw material QualityRaw material Quality

Impact of Trash contentImpact of Trash content When ginning is done properly, When ginning is done properly,

Mills will get a `clean cotton ` with Mills will get a `clean cotton ` with Least trashLeast trash

In Imported PIMA we have only In Imported PIMA we have only 1.2% trash content1.2% trash content

Indian Ginneries fool their Vendors Indian Ginneries fool their Vendors

Raw Material QualityRaw Material Quality Indian Government has taken so Indian Government has taken so

many measures to improve Ginneriesmany measures to improve Ginneries Precleaning/Post cleaning/Automation Precleaning/Post cleaning/Automation

etcetc Ginneries take commercial stand and Ginneries take commercial stand and

they don’t use Pre/post cleaners they don’t use Pre/post cleaners which are established practices which are established practices across the worldacross the world

Handling Trash Handling Trash ContentContent Removal of trash from compressed Removal of trash from compressed

bales require proper opening(takenc bales require proper opening(takenc are of by first openers like are of by first openers like MBO/CLP/AFC/MC/SC/UC/VCMBO/CLP/AFC/MC/SC/UC/VC

Seed trap removes full and Broken Seed trap removes full and Broken seedsseeds

Final beaters remove fine trash Final beaters remove fine trash particlesparticles

Handling Trash Handling Trash ContentContent Cards take the role of removing Cards take the role of removing

fine trash embedded with fine trash embedded with Bunches as well as Individual Bunches as well as Individual fibersfibers

Role of each segment in CardsRole of each segment in Cards

Role of LickerinRole of Lickerin To remove leafy/broken To remove leafy/broken

seeds/heavy particles if anyseeds/heavy particles if any Preferentially no damage to the Preferentially no damage to the

fiberfiber To individualize the fiberTo individualize the fiber

Role of SFLRole of SFL

Remove fine fragmented seed Remove fine fragmented seed particles clinging with short fiber particles clinging with short fiber as well as loose trashas well as loose trash

Role of Flat topsRole of Flat tops Preferential Removal of fine Preferential Removal of fine

fragmented seeds/Leafy fragmented seeds/Leafy husks/Short fiber associated with husks/Short fiber associated with trashy particlestrashy particles

Does the job without damage to Does the job without damage to fiberfiber

Customer Customer RequirementsRequirementsYarn ImperfectionsYarn Imperfections--Waste level at BR/CardsWaste level at BR/Cards-Type of Machinery/Drafting-Type of Machinery/Drafting-Type of process-Type of process-Fineness of cotton-Fineness of cotton-Mixing neps-Mixing neps-Noil level-Noil level-Type of Autoconer-Type of Autoconer

Customer Customer RequirementsRequirementsYarn StrengthYarn Strength Twist levelTwist level Fiber length/Fiber finenessFiber length/Fiber fineness SFC(n) in Drawing sliverSFC(n) in Drawing sliver RH in departmentsRH in departments Drafting QualityDrafting Quality

Customer Customer RequirementsRequirementsYarn HairinessYarn Hairiness Type of SpinningType of Spinning Type of YarnType of Yarn Type of Traveller/RingType of Traveller/Ring Lift Lift Lappet diaLappet dia Fiber FinenessFiber Fineness

Customer Customer RequirementsRequirementsYarn Classimat FaultsYarn Classimat Faults Type of SpinningType of Spinning Fiber opening efficiencyFiber opening efficiency Sliver trash contentSliver trash content Exhaust QualityExhaust Quality OHTC performanceOHTC performance

Mixing PrecautionsMixing Precautions Incoming bales moisture content Incoming bales moisture content

should be 7 to 7.5%. If high there should be 7 to 7.5%. If high there will be loss.will be loss.

Avoid Storage in outside areas.Avoid Storage in outside areas. Cotton godown roof spraying during Cotton godown roof spraying during

summer/24 Hours conditioning summer/24 Hours conditioning under fog master in Blow roomunder fog master in Blow room

Good cotton in yellow picking Good cotton in yellow picking

BLOWROOMBLOWROOM No. of beating points depends onNo. of beating points depends on

trash %, mic. Etc.trash %, mic. Etc. White waste in droppings.White waste in droppings. Beater chocking.Beater chocking. Bales moisture conditioning in B/R Bales moisture conditioning in B/R

department.department.

BLOWROOMBLOWROOM Lint loss in BRD while new mixing, Lint loss in BRD while new mixing,

setting changessetting changes Proper synchronization of B/R m/cs. Proper synchronization of B/R m/cs.

(ERM luminar duct should not be (ERM luminar duct should not be empty)empty)

Excessive suction in AWES and Excessive suction in AWES and cotton goes in suction.cotton goes in suction.

Micro dust exhausts suction too Micro dust exhausts suction too high.high.

CARDINGCARDING

Lint in droppings. Lint in droppings. Chute beater chockingChute beater chocking Between card, with in card waste Between card, with in card waste

variation.variation.(b/w cards variation + OR – 0.5%)(b/w cards variation + OR – 0.5%)

Excessive suction in AWES and Excessive suction in AWES and web goes in suction.web goes in suction.

CARDINGCARDING B/R & Carding set the waste % initially B/R & Carding set the waste % initially

while new mixing and maintain upto while new mixing and maintain upto exhaust of mixing. (Visual inspection, exhaust of mixing. (Visual inspection, Periodical waste % checking)Periodical waste % checking)

Chute micro dust exhausts suction too Chute micro dust exhausts suction too high.high.

Running cards in slow speed (like DK Running cards in slow speed (like DK series) cause high wasteseries) cause high waste

COMBER COMBER Between heads noils % variation.Between heads noils % variation. Higher noils % than STD.Higher noils % than STD. SFC based noils %.SFC based noils %. Possibilities to reduce noils % with Possibilities to reduce noils % with

out compromising quality.out compromising quality.

DRAWING DRAWING White waste in blower waste.White waste in blower waste. Excessive positive clearer waste.Excessive positive clearer waste.

SIMPLEX SIMPLEX Excessive positive clearer waste.Excessive positive clearer waste. Excessive roving waste.Excessive roving waste.

SPINNING SPINNING Double gaiting.Double gaiting. Use of damaged ring tubes.Use of damaged ring tubes. Poor work practice by doffers Poor work practice by doffers (like delayed doffing and cause top (like delayed doffing and cause top

adoss, low clearance in bottom)adoss, low clearance in bottom) Under winding coils (4-5 coils).Under winding coils (4-5 coils). Low cop content. (Ring dia. & Lift)Low cop content. (Ring dia. & Lift)

WINDING / WINDING / AUTOCONER AUTOCONER Excessive hand hard waste.Excessive hand hard waste. Rogue EYCRogue EYC Improper clearance curve.Improper clearance curve. Poor paper cones.Poor paper cones. Oil stained / removal of yarn from Oil stained / removal of yarn from

heavy weight cones.heavy weight cones.

GENERAL GENERAL Daily monitoring of BRD, Card waste Daily monitoring of BRD, Card waste

& Noils % by quantity extracted Vs & Noils % by quantity extracted Vs production out put.production out put.

Maintaining proper R.H% in all Maintaining proper R.H% in all departments.departments.

(Prep – 55 to 60%, Spg – 50-55%, (Prep – 55 to 60%, Spg – 50-55%, A/C – 60-65%)A/C – 60-65%) Variations in Month end closing stock.Variations in Month end closing stock.

GENERAL (Contd.)GENERAL (Contd.) Excess gives away in finished Excess gives away in finished

goods.goods. (Cone, hanks)(Cone, hanks)

Error in weighing scale. Error in weighing scale. (Insufficient calibration) (Insufficient calibration)

Excess in II quality.Excess in II quality. Installing YCP.Installing YCP.

GENERAL (Contd.)GENERAL (Contd.)

Using mixing oil for flies control & Using mixing oil for flies control & reducing invisible loss. reducing invisible loss.

Allowed invisible loss 0.8 to 1.0% Allowed invisible loss 0.8 to 1.0% due to variation in incoming due to variation in incoming cotton and despatch yarn. cotton and despatch yarn.

Container, Lorry before & after Container, Lorry before & after loading weight checking. loading weight checking.

GENERAL (Contd.)GENERAL (Contd.) Excessive soft waste cause Excessive soft waste cause

reprocessing and further loss in back reprocessing and further loss in back process.process.

BRD, Card waste % increase and BRD, Card waste % increase and reduce comber noils. reduce comber noils.

Customer based yarn quality (not Customer based yarn quality (not giving big importance for giving big importance for imperfections) based on fabric quality. imperfections) based on fabric quality.

UQC settings based on fabric quality in UQC settings based on fabric quality in terms of contamination & faults. terms of contamination & faults.

GENERAL (Contd.)GENERAL (Contd.) Trend charts display for Y.R%, Trend charts display for Y.R%,

Dept wise waste %, and Soft Dept wise waste %, and Soft waste %.waste %.

High hard waste, soft waste and High hard waste, soft waste and sweepings due to negligence of sweepings due to negligence of workers, rough handling of workers, rough handling of materials, bad storage and poor materials, bad storage and poor working conditions.working conditions.

Yarn Realisation-40s C-Yarn Realisation-40s C-CompComp YR can be YR can be

increased by increased by controls on Waste controls on Waste monitoring from monitoring from Blow room itself.Blow room itself.

Each Zone has Each Zone has the task of the task of `specific type of `specific type of waste` removalwaste` removal

Best In CPQ 72.5

Cotton 100% Bunny

Yarn Realisation-60sCYarn Realisation-60sC

Better YR doesn’t Better YR doesn’t mean mean

loss in YQ or loss in YQ or Poor YSPPoor YSP

Best In CPQ 71.2Cotton Used MCU5Yarn imperfections

293

YSP +Rs 3 over Average

Mills Current level-74%Mills Current level-74% Count pattern -Medium SC and CCount pattern -Medium SC and C Target planned -3% improvementTarget planned -3% improvement

Improved areasImproved areasCard waste Zonewise analysis revealed Card waste Zonewise analysis revealed

SFD waste is abnormally high at the SFD waste is abnormally high at the level of 2%.Reduced to 0.5%level of 2%.Reduced to 0.5%

Case Study by WINSYS Case Study by WINSYS SMC-Yarn RealisationSMC-Yarn Realisation

Hard Waste:Retrained the Hard Waste:Retrained the workforce and reduced the hard workforce and reduced the hard waste from 0.9 to 0.6%waste from 0.9 to 0.6%

In Semi combed Variety mills has In Semi combed Variety mills has not done Conditioning. Effectively not done Conditioning. Effectively restarted.restarted.

Sweepings found to be 0.8%-Sweepings found to be 0.8%-Unusually high.On checking it is a Unusually high.On checking it is a mixture of Usable waste .Reduced mixture of Usable waste .Reduced the same to 0.5% levelthe same to 0.5% level

Case Study by WINSYS Case Study by WINSYS SMC-Yarn SMC-Yarn RealisationRealisation

Finally the mills is able to exceed Finally the mills is able to exceed its expected target of 3 and its expected target of 3 and achieved 3.5%.achieved 3.5%.

Final YR -77.5%Final YR -77.5%

Case Study-YR contd..Case Study-YR contd..

Monitoring & Maintaining Moisture Monitoring & Maintaining Moisture content in Mixing and outgoing yarncontent in Mixing and outgoing yarn

Monitoring and Maintaining Moisture Monitoring and Maintaining Moisture content in Saleable wastecontent in Saleable waste

Strict monitoring and control of Strict monitoring and control of AWES waste level by visual checks AWES waste level by visual checks in Compactors-weeklyin Compactors-weekly

Efforts taken on other YR Efforts taken on other YR studiesstudies

Tare weight control in PackingTare weight control in Packing Weighment of Mixing at the time Weighment of Mixing at the time

of Layingof Laying Ensuring 65 to 70 % in Packing Ensuring 65 to 70 % in Packing

departmentdepartment

Efforts taken on other YR Efforts taken on other YR studiesstudies

THANK YOUTHANK YOU