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Study on Improving the Production Rate by Rapier Looms in Textile Industry Aby Chummar, Soni Kuriakose, George Mathew

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Study on Improving the Production Rate by Rapier Looms in Textile Industry Aby Chummar, Soni Kuriakose, George Mathew ISSN: 2277-3754 ISO 9001:2008 Certified International Journal of Engineering and Innovative Technology (IJEIT) Volume 2, Issue 7, January 2013 Study on Improving the Production Rate by Rapier Looms in Textile Industry Aby Chummar, Soni Kuriakose, George Mathew the company. It is mainly manufactured by the shuttle looms. Abstract— In India the textile industry is growing very fast. Conventional shuttle looms are mainly used during the Most of the earlier established textile industries are using weaving process in the industry. All these shuttle looms are conventional shuttle looms for the production of the cloth. But the too old. In these present conventional shuttle looms, it is advancement in the technology made the textile industry more competitive. The effective usage of the new methods of the necessary to pass a shuttle weighing around half a kilogram weaving technology, which is more energy efficient, makes the through the warp shed to insert a length of weft yarn which production more economical. It is found out that the usage of the weighs only few grams. The shuttle has to be accelerated conventional looms badly affects the cloth production. This study rapidly at the starting of picking cycle and also to be focuses on identifying the problems associated with the low decelerated, stopped abruptly at the opposite end. This production by the shuttle loom and suggesting suitable methods process creates heavy noise and shock and consumes by which these problems can be reduced. considerable energy. Beat-up is done by slay motion which again weighs a few hundred kilograms. The wear life of the Index Terms—Greige Fabric Picks, Rapier Loom, Shuttle Loom. picker and checking mechanism is also limited due to heavy shocks. The small weft package in the shuttle requires I. INTRODUCTION frequent replenishments and for each loom stoppage there is a possibility of one defect. Due to the defects in the looms the The science of textiles predates recorded history. rate of production was reduced. Low speed of the loom is also Archaeologists have found evidence that man has fabricated a reason for the low production rate of the machine. The low coarse cloth from various fibers for at least 20,000 years and speed of the machine increases the operating time there by intricate textiles have been found in tombs in Egypt and Asia increasing the consumption of electrical energy. So during that have been dated to several thousand years before Christ. the present global scenario of energy conservation, Many of the processes which were developed in ancient times alternatives for the conventional methods have to be are still used in remote areas of the world today [1]. However, identified. with the advent of the Industrial Age, rapid developments in Table I: Factors Affecting Low Production Rate and Their machinery and textile manufacturing techniques have Percentage advanced the science of textiles more in the past one hundred years than in all of previous history [1]. Today's sophisticated CAD/CAM controlled machines result in high-speed, low-cost and large-volume textile production [1]. Looms are Factor Seconds affected Percentage the important machines used for cloth production. The (s) (%) different looms used for the production of the cloth are shuttle looms, rapier looms, jet looms, etc. The power looms are used for weaving terry towels and bed sheets. Techniques used for Speed 170 68 the production process in the industry are Warping, Sizing, Beam Drawing, Weaving, Cutting, Un-winding, and checking Yarn 39 15.6 in warehouse, Folding, Recounting, Grading and sorting, Bailing or packing [1]. The main energy forms used in a Break down 22.5 9 textile industry are grid electricity, wood, and small quantity of coal [5]. The electricity is used for power looms, doubling machines, winding machines, warping machines and lighting. Man 11 4.4 Wood is used as fuel for boilers, thermic fluid heaters, and chulhas for hot water generation. Environment 5.64 2.2 II. PROBLEM DISCRIPTION A study on a garment industry was carried out in a leading Total 250 100 garment manufacturing company in Kerala. The study mainly focused on 382 shuttle looms. Over the years, the company was involved in production of garments and Greige fabric. Greige fabric is one of the critical products manufactured in 107 ISSN: 2277-3754 ISO 9001:2008 Certified International Journal of Engineering and Innovative Technology (IJEIT) Volume 2, Issue 7, January 2013 Fig 1: Fish Bone Diagram For Low Production Rate Fig 2: Pareto Chart For Low Production Rate When a problem occurs in a system, its causes should be III. METHODOLOGY identified for the problem to be fixed. Ishikawa Cause and In the study picks generated by randomly selected shuttle Effect (CE) diagrams are popular tools to investigate and looms are analyzed. Each machine was observed for 600 identify numerous different causes of a problem. A Cause and seconds. The time taken for generating picks and the time Effect (CE) diagram can be used as a guideline to allocate during the stoppage of the loom is also noted. The noted time resources and make necessary investments to fix the problem is classified into operating time and no operating time. In the [4]. The percentage by which each Factor affects the low operating time it was identified that the picks generated by production rate is shown in the Pareto chart in fig 2. the looms are lower than the ideal pick rate which is calculated using (1). The main causes for the low pick rate are identified by plotting the cause and effect diagram in fig 1. 108 ISSN: 2277-3754 ISO 9001:2008 Certified International Journal of Engineering and Innovative Technology (IJEIT) Volume 2, Issue 7, January 2013 Table II: Average Ideal Pick Rate for 1 Month Ideal pick Ideal pick Ideal pick rate for SI No Month Days Total time rate for 1 rate R 382 looms hour 1 Jan 31 40920 5728800 2188401600 8400 2 Feb 29 38280 5359200 2047214400 8400 3 Mar 31 40920 5728800 2188401600 8400 4 Apr 30 39600 5544000 2117808000 8400 5 May 31 40920 5728800 2188401600 8400 6 Jun 30 39600 5544000 2117808000 8400 7 July 31 40920 5728800 2188401600 8400 Total 15036436800 58800 Average 2148062400 8400 Table III: Average Actual Pick Rate SI no Month Actual pick Actual production time(hours) 1 Jan 1142819000 187623.55 2 Feb 1031957000 172153.13 3 Mar 1176865000 192250.03 4 Apr 1027278000 186235.92 5 May 1195498000 188752.3 6 Jun 1212026000 189237.23 7 July 1365925000 196576.11 Total 8152368000 1312828.27 Average 1164624000 187547 changes in their production strategy by identifying the major IV. RESULTS AND DISCUSSION types losses and by suggesting necessary remedies for Table V shows the distribution of cost for the production of reducing it. 1 meter of cloth in the textile industry and it is also Actual rate of production represented in the pie chart in fig 6. Yarn is important raw The production rate of the looms is analyzed by the picks material used for the production of the greige fabric. The generated by the looms. Ideally a pick is obtained by the loom company cannot compromise the quality of the yarn used. The when the shuttle moves from one beating arm to another. The actual picks generated by the machine for 7 months are cost of yarn depends on the international market conditions. obtained from the company log book and it is shown in the Thus it is difficult to reduce cost f fyarn. Thus for reducing the cost production the industry itself have to make necessary Table IV: Energy Consumption of Machines Energy SI Machine consumption/hr no (units) 1 Cimcco power loom 382 109 ISSN: 2277-3754 ISO 9001:2008 Certified International Journal of Engineering and Innovative Technology (IJEIT) Volume 2, Issue 7, January 2013 2 Sulzer loom 48.4 3 Sizing,cooking,storage,boiler 47.94 4 Pirn winding 22.2 6 Humidification plant 21 5 Warping machine 17.45 7 Bailing 15 8 Cone winding machine 3 9 Folding machine 2.2 Total 559.19 Table III. The Actual Production Time For Generating The calculation of the ideal pick rate is shown in the Table II. 1164624000 Picks By 382 Shuttles Looms Also Shown In The There is a noticeable difference between the ideal picks and Table III. the actual picks generated. Ideal rate of production Ideal pick rate is the number of picks that the machine is Ideal pick rate for 1 s = (8400/3600) = 2.33 capable of finishing when the loom operates with full efficiency. The ideal pick rate is calculated by using (1). The Time for 1 pick motion = 1/ 2.33= 0.43 s speed of the machine is 140 rpm and the working hours per day are considered as 22 days. Ideal pick rate=speed × time (1) Fig 4: Pareto Chart for Energy Consumption Ideally for making 1164624000 picks the machine requires Table V: Factors Affecting Production Cost of 1 Meter of Cloth 139108 hours. But actually it takes 187547hours. This is due Si no Factor Cost % to various losses arising from different regions of production. Thus the machine non-operating time is 48439 hours. The 1 Yarn 40 non-operating time is the time where the machine stops its production due to yarn breakage, pirn changing, machine 2 Energy 32 failures etc. Thus the total production rate of the machines is reduced. The reasons for low production rate are shown in the 3 Employ 18 fish bone diagram in figure 1. The details about the factors affecting low production rate and its percentage are shown in 4 Others 10 table I.
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