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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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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. Conventional shuttle looms are mainly used during the

Abstract— In India the textile industry is growing very fast.
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

necessary to pass a shuttle weighing around half a kilogram

competitive. The effective usage of the new methods of the weaving technology, which is more energy efficient, makes the

through the warp shed to insert a length of weft yarn which weighs only few grams. The shuttle has to be accelerated rapidly at the starting of picking cycle and also to be decelerated, stopped abruptly at the opposite end. This process creates heavy noise and shock and consumes considerable energy. Beat-up is done by slay motion which again weighs a few hundred kilograms. The wear life of the picker and checking mechanism is also limited due to heavy shocks. The small weft package in the shuttle requires frequent replenishments and for each loom stoppage there is a possibility of one defect. Due to the defects in the looms the rate of production was reduced. Low speed of the loom is also a reason for the low production rate of the machine. The low speed of the machine increases the operating time there by increasing the consumption of electrical energy. So during the present global scenario of energy conservation, alternatives for the conventional methods have to be identified.

production more economical. It is found out that the usage of the conventional looms badly affects the cloth production. This study focuses on identifying the problems associated with the low production by the shuttle loom and suggesting suitable methods by which these problems can be reduced.

Index Terms—Greige Fabric Picks, Rapier Loom, Shuttle
Loom.

I. INTRODUCTION

The science of textiles predates recorded history.
Archaeologists have found evidence that man has fabricated coarse cloth from various fibers for at least 20,000 years and intricate textiles have been found in tombs in Egypt and Asia that have been dated to several thousand years before Christ. Many of the processes which were developed in ancient times are still used in remote areas of the world today [1]. However, with the advent of the Industrial Age, rapid developments in machinery and textile manufacturing techniques have 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 the important machines used for cloth production. The 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 the production process in the industry are Warping, Sizing, Beam Drawing, Weaving, Cutting, Un-winding, and checking in warehouse, Folding, Recounting, Grading and sorting, Bailing or packing [1]. The main energy forms used in a 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. Wood is used as fuel for boilers, thermic fluid heaters, and chulhas for hot water generation.

Table I: Factors Affecting Low Production Rate and Their
Percentage

Factor Speed
Seconds affected
(s)
Percentage
(%)

  • 170
  • 68

  • Yarn
  • 39
  • 15.6

  • 9
  • Break down
  • 22.5

  • Man
  • 11
  • 4.4

Environment
Total
5.64 250
2.2

II. PROBLEM DISCRIPTION

100

A study on a garment industry was carried out in a leading 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 Effect (CE) diagrams are popular tools to investigate and identify numerous different causes of a problem. A Cause and Effect (CE) diagram can be used as a guideline to allocate resources and make necessary investments to fix the problem [4]. The percentage by which each Factor affects the low production rate is shown in the Pareto chart in fig 2.
In the study picks generated by randomly selected shuttle looms are analyzed. Each machine was observed for 600 seconds. The time taken for generating picks and the time during the stoppage of the loom is also noted. The noted time is classified into operating time and no operating time. In the operating time it was identified that the picks generated by 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.

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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 rate for 1 hour
Ideal pick rate R
Ideal pick rate for
382 looms

  • SI No
  • Month
  • Days
  • Total time

1234567
Jan Feb Mar Apr May Jun
31 29
40920 38280 40920 39600 40920 39600 40920
5728800 5359200 5728800 5544000 5728800 5544000 5728800
2188401600 2047214400 2188401600 2117808000 2188401600 2117808000 2188401600 15036436800 2148062400
8400 8400 8400 8400 8400 8400 8400 58800 8400
31 30 31 30

  • July
  • 31

Total Average

Table III: Average Actual Pick Rate

  • SI no
  • Month
  • Actual pick
  • Actual production

time(hours)

1234567
Jan Feb
1142819000 1031957000 1176865000 1027278000 1195498000 1212026000 1365925000 8152368000 1164624000
187623.55 172153.13 192250.03 186235.92 188752.3
Mar Apr May

  • Jun
  • 189237.23

196576.11 1312828.27
187547
July Total Average

changes in their production strategy by identifying the major types losses and by suggesting necessary remedies for reducing it.

IV. RESULTS AND DISCUSSION

Table V shows the distribution of cost for the production of
1 meter of cloth in the textile industry and it is also represented in the pie chart in fig 6. Yarn is important raw material used for the production of the greige fabric. The company cannot compromise the quality of the yarn used. The cost of yarn depends on the international market conditions. Thus it is difficult to reduce cost f fyarn. Thus for reducing the cost production the industry itself have to make necessary

Actual rate of production

The production rate of the looms is analyzed by the picks generated by the looms. Ideally a pick is obtained by the loom when the shuttle moves from one beating arm to another. The actual picks generated by the machine for 7 months are obtained from the company log book and it is shown in the

Table IV: Energy Consumption of Machines

Energy consumption/hr
(units)
SI
Machine no

  • 1
  • Cimcco power loom
  • 382

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ISSN: 2277-3754

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International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013

  • Sulzer loom
  • 48.4

2

  • 3
  • Sizing,cooking,storage,boiler
  • 47.94

Pirn winding
Humidification plant Warping machine
Bailing
22.2
21
46578
17.45
15
Cone winding machine
Folding machine
Total
3
2.2
9

559.19

Table III. The Actual Production Time For Generating
1164624000 Picks By 382 Shuttles Looms Also Shown In The
Table III.

The calculation of the ideal pick rate is shown in the Table II. There is a noticeable difference between the ideal picks and the actual picks generated.

Ideal rate of production

Ideal pick rate is the number of picks that the machine is capable of finishing when the loom operates with full efficiency. The ideal pick rate is calculated by using (1). The speed of the machine is 140 rpm and the working hours per day are considered as 22 days.
Ideal pick rate for 1 s = (8400/3600) = 2.33
Time for 1 pick motion = 1/ 2.33= 0.43 s

  • Ideal pick rate=speed × time
  • (1)

Fig 4: Pareto Chart for Energy Consumption

Ideally for making 1164624000 picks the machine requires
139108 hours. But actually it takes 187547hours. This is due to various losses arising from different regions of production. Thus the machine non-operating time is 48439 hours. The non-operating time is the time where the machine stops its production due to yarn breakage, pirn changing, machine failures etc. Thus the total production rate of the machines is reduced. The reasons for low production rate are shown in the fish bone diagram in figure 1. The details about the factors affecting low production rate and its percentage are shown in table I. Fig 2, the pareto chart shows that the low speed of the machine is the major factor affecting for the low production

Table V: Factors Affecting Production Cost of 1 Meter of Cloth

  • Si no
  • Factor

Yarn
Cost %

  • 40
  • 1

234
Energy Employ Others
32 18 10

110

ISSN: 2277-3754

ISO 9001:2008 Certified

International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013

rate of the machine. Because of the low speed of the machine smooth transition of even highly fancy yarns like embroidery

  • the required production rate cannot be attained. The
  • low and slub. The rapier loom is upgrade from shuttle-looms to

speed of machine will increase the total production time the world of modern weaving system and shuttle-less followed by increase in cost of production. Out of the 600 weaving. Rapier looms has been designed to replace the old seconds analyzed in different machines selected randomly, shuttle looms without any major changes to the existing approximately 250 seconds are nonproductive time, and the infrastructure [2][3][5][7]. The Immediate benefits of remaining are productive time and the factors affecting the selecting rapier looms are [2][3][7] production of machine is shown in Table I. Due to the movement of the shuttle in the loom, smooth sequence of weaving is disturbed which affects the maximum running speed and hence machine production. The pareto chart for the energy consumption is shown in the fig 4. A 1HP motor is used for driving the shuttle looms. It is found out from the fig 4 that cimcco power loom consumes 66% of total energy consumption of the industry. The low speed of the machine is due to the age of the machines, working condition of the machines, and the increased weight of the shuttle in the machines. Because of the low speed of the machine the consumption of energy by the machine increases. The electrical energy consumption for the different machines in the industry is shown in the Table V. It is found that the energy consumed by the shuttle loom is higher than any other machine in the industry. The reduced speed of the machine will increase the time of production and the lead time of the product is also increased. So to maintain increased production the speed of the machines has to be increased. To increase the speed of the machine, an improved way of production has to be followed. This improvement can be attained by the

replacement of the conventional shuttle looms by the “Rapier looms”.

 No need for new buildings or any new infrastructure.  Could fit in place of your current shuttle-looms.  Configured specially keeping in mind the skills of power-loom operators.
 No special training required for loom operators.  Immediate reduction of man-power and laborers.  20% subsidy under Technology Up gradation Fund
Scheme (TUFS) on certified looms.

Proposed energy efficient equipment (Rapier looms) Description of equipment

The rapier looms offer unparalleled versatility when it comes to yarns. From the finest counts of cotton to the thickest Industrial yarns and can handle anything thrown at its negative rapier head. The soft-pick gear system enables

Fig 5: Cost of Factors Affecting Production of 1 Meter of Cloth in %

Fig 6: Reduction in the operating time

Speed

So the time for 1 pick by the rapier loom can be reduced to
The normal speed of the conventional power looms is 0.27 seconds from that of the conventional shuttle looms. around 140 RPM, where as in rapier looms, the speeds up to 220 RPM (actual), this machine gives up to 3 times more productivity than the conventional power looms.

Pick rate of rapier loom
Improvement in production rate

The average picks generated by the conventional shuttle looms are 1164624000. For producing this much amount of picks the ideal time taken by the shuttle looms are 139108 hrs.
The speed of the rapier looms is 220 RPM. Thus the ideal The time for obtaining 1164624000 picks by the rapier looms pick rate of 1 rapier loom can be obtained using (1) as 13200. is approximately 87247 Hrs. Thus by rapier loom the machine

111

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International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013

AUTHOR BIOGRAPHY

operating time can be reduced to 51761 Hrs. Thus from the fig 6 it is clear that 37% reduction in the total operating time is obtained. When comparing with the shuttle loom 57.5% more pick is obtained by the rapier loom.

Aby Chummar, Post Graduation Student, Dept. of Mechanical Engineering, Mar Athanasius College of Engineering, Kothamangalam, Kerala.

Cost savings

In Kerala the cost of one unit of electrical energy = 4
 Energy consumed by 382 shuttle looms (1 hp motor) per hour = 382 kWh

Soni Kuriakose, Associate Professor, Dept. of Mechanical Engineering, Mar Athanasius College of Engineering, Kothamangalam, Kerala.

George Mathew, Assistant Professor, Dept. of Mechanical Engineering,

 For the conventional looms total cost of energy consumed = 212557024

Mar Athanasius College of Engineering, Kothamangalam, Kerala.

 Total energy consumed by the rapier looms =
33366554 kWh
 The total cost of energy consumed by rapier looms =
133466216
Thus by the rapier looms cost saving of 79090808 can be obtained in one month from the electrical saving itself.

V. CONCLUSION

To exist in a competitive world of industries, producing products at a low price with good quality is necessary. Accepting new technology, the production cost can be reduced, at the same time the rate of production can be increased. This study identified the problem of high energy consumption of electricity by the usage of shuttle looms in a garment industry. It suggested a remedy of replacing the aged shuttle looms with the automatic rapier looms for increasing the rate of production, thereby reducing the time of operation of machine and reducing the total lead time in production. Thus cost of production can be reduced. By rectifying other reasons noted in the cause and effect diagram in Fig1 production rate can be again improved. Further studies on the rapier looms can be helpful for the multi color weft insertion which will increase the variety of product according to the fluctuation market conditions.

REFERENCES

[1] Ryuta Kamiya, Bryan A. Cheeseman, Peter Popper, Tsu-Wei
Chou, “Some recent advances in the fabrication and design of three-dimensional textile performs: a review” Composites Science and Technology 60, 33-47, 2000.

  • [2] Dr.V.M.Patil1, P.D.Bhanawat, “Techno-economics
  • &

advances of shuttle-less weaving technology”, IJSID, 2012, 2 (1), 77-89.

[3] Subhankar Maity, Kunal Singha, Mrinal Singha, “Recent

Developments in Rapier Weaving Machines in Textiles”, American Journal of Systems Science 2012 ;( 7-16).

[4] R. Ufuk Bilsel, Dennis K.J. Lin, “Ishikawa Cause and Effect
Diagrams Using capture Recapture Techniques,” Quality Technology & Quantitative Management Vol. 9, No. 2, pp. 137-152, 2012.

[5] A. N. M. Masudur Rahman & Md. Ruhul Amin, Efficiency analysis in rapier loom (2000).

[6] Bill Carreira –“Lean manufacturing that works”. [7] Bureau of Energy Efficiency, “Detailed Project Report on Auto
Loom/Rapier Loom” (2000).

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    Staff Research Study 27 Office of Industries U.S. International Trade Commission India’s Textile and Apparel Industry: Growth Potential and Trade and Investment Opportunities March 2001 Publication 3401 The views expressed in this staff study are those of the Office of Industries, U.S. International Trade Commission. They are not necessarily the views of the U.S. International Trade Commission as a whole or any individual commissioner. U.S. International Trade Commission Vern Simpson Director, Office of Industries This report was principally prepared by Sundar A. Shetty Textiles and Apparel Branch Energy, Chemicals, and Textiles Division Address all communications to Secretary to the Commission United States International Trade Commission Washington, DC 20436 TABLE OF CONTENTS Page Executive Summary . v Chapter 1. Introduction . 1-1 Purpose of study . 1-1 Data and scope . 1-1 Organization of study . 1-2 Overview of India’s economy . 1-2 Chapter 2. Structure of the textile and apparel industry . 2-1 Fiber production . 2-1 Textile sector . 2-1 Yarn production . 2-4 Fabric production . 2-4 Dyeing and finishing . 2-5 Apparel sector . 2-5 Structural problems . 2-5 Textile machinery . 2-7 Chapter 3. Government trade and nontrade policies . 3-1 Trade policies . 3-1 Tariff barriers . 3-1 Nontariff barriers . 3-3 Import licensing . 3-3 Customs procedures . 3-5 Marking, labeling, and packaging requirements . 3-5 Export-Import policy . 3-5 Duty entitlement passbook scheme . 3-5 Export promotion capital goods scheme . 3-5 Pre- and post-shipment financing . 3-6 Export processing and special economic zones . 3-6 Nontrade policies .
  • Textile Manufacturing

    Textile Manufacturing

    Textile Manufacturing Industry Overview Not all textile manufacturing industries produce hazardous you suspect that you generate a waste that is not included in this waste. If, however, you use hazardous solvents and materials summary, contact your state hazardous waste management agency containing toxic chemicals, you might be subject to Resource or EPA Regional office for assistance. Conservation and Recovery Act (RCRA) requirements covering the generztion, transportation, and management of hazardous waste. Waste Minimization An effective waste minimization program can reduce the costs, The following textile manufacturing industry segments are liabilities, and regulatory burdens of hazardous waste manage- covered by this summary: ment, while potentially enhancing efficiency, product quality, and community relations. Waste minimization techniques that can Broad woven fabric mills and wool mills, including help you reduce the amount of hazardous waste that you generate dyeing and finishing include: Knitting mills and knit goods finishing Other dyeing and finishing textile mills Production planning and sequencing Floor covering mills, including dyeing and finishing. Process/equipment adjustment or modification - Raw material substitution Loss prevention and housekeeping Hazardous Wastes from Textile Waste segregation and separation Manufacturing Recycling. Most ofthe hazardous waste generated by textile manufacturers results from the use of solvents. Solvents are used in the dry- Training and supervision of employees implementing waste cleaning of synthetic fiber knit fabrics and woven and wool fab- minimization techniques is an important part of your successful rics; in specialty operations such as tricot and lace splitting or program. Call the RCWSuperfund Hotline toll-free at 800424- solvent scouring; in dyeing operations; and in some finishing op- 9346 (or TDD 800-553-7672for the hearing-impaired) for waste erations for impregnation or coating of textile fibers.
  • A STUDY of AUTOMATIC SHUTTLE LOOM DYNAMICS and POWER CONSUMPTION of ITS VARIOUS MECHANISMS a THESIS Presented to the Faculty Of

    A STUDY of AUTOMATIC SHUTTLE LOOM DYNAMICS and POWER CONSUMPTION of ITS VARIOUS MECHANISMS a THESIS Presented to the Faculty Of

    A STUDY OF AUTOMATIC SHUTTLE LOOM DYNAMICS AND POWER CONSUMPTION OF ITS VARIOUS MECHANISMS A THESIS Presented to The Faculty of the Division of Graduate Studies By Surjit Sen In Partial Fulfillment of the Requirements for the Degree Master of Science in Textile Engineering Georgia Institute of Technology August 1976 A STUDY OF AUTOMATIC SHUTTLE LOOM DYNAMICS AND POWER CONSUMPTION OF ITS VARIOUS MECHANISMS Approved: ,A/. Amad Tay€»bi ~zf- L, Howard Olson ^X H. L. Johnson Date Approved by Chairman: 4*c&i I£,/$'< 6 11 ACKNOWLEDGMENTS I would like to express my sincere appreciation to my thesis advisor, Dr. Amad Tayebi, for his guidance and assistance in writing this thesis. I would also like to express my gratitude to Dr. L. Howard Olson for his assistance and for serving on my reading committee. Appreciation is also expressed to Professor H. L. Johnson for his advice and for serving on my reading committee. TABLE OF CONTENTS Page ACKNOWLEDGMENTS . ii LIST OF TABLES j_v LIST OF ILLUSTRATIONS v SUMMARY vii Chapter I. INTRODUCTION . 1 II. THEORETICAL ANALYSIS OF PRIMARY FLY SHUTTLE LOOM MECHANISMS 5 III. ENERGY CONSUMPTION MEASUREMENTS AND PROPOSED NEW MECHANISMS FOR THE FLY SHUTTLE LOOM 46 IV. DISCUSSION AND CONCLUSION 56 V. RECOMMENDATIONS 58 APPENDIX 59 BIBLIOGRAPHY ....... 66 iv LIST OF TABLES Page Specifications of Draper X - 2 Loom Used for Experimental Work 3 Detailed Specifications of Draper X - 2 Loom 9 Average and R.M.S. Values of Various Kinematic and Dynamic Parameters for the Slay Mechanism (Draper X - 2 Loom) . • 29 Shedding Mechanism Details (Draper X - 2 Loom) ...
  • Australian Superfine Wool Growers Association Inc

    Australian Superfine Wool Growers Association Inc

    AustrAliAn superfine Wool Growers’ Association inc. AustrAliAn superfine Wool Growers Association inc. AnnuAl 2015-2016 www.aswga.com 1 | Annual 2015/2016 Australian Wool Innovation On-farm tools for woolgrowers Get involved in key initiatives such as: • Join an AWI-funded Lifetime Ewe Management group to lift production - www.wool.com/ltem • Join your state’s AWI extension network - www.wool.com/networks • Benchmark your genetic progress with MERINOSELECT - www.wool.com/merinoselect • Reducing wild dog predation through coordinated action - www.wool.com/wilddogs • Training shearers and woolhandlers - www.wool.com/shearertraining • Enhanced worm control through planning - www.wool.com/wormboss • Getting up to scratch with lice control - www.wool.com/lice • Flystrike protection and prevention - www.wool.com/fl ystrike VR2224295 www.wool.com | AWI Helpline 1800 070 099 Disclaimer: Whilst Australian Wool Innovation Limited and its employees, offi cers and contractors and any contributor to this material (“us” or “we”) have used reasonable efforts to ensure that the information contained in this material is correct and current at the time of its publication, it is your responsibility to confi rm its accuracy, reliability, suitability, currency and completeness for use for your purposes. To the extent permitted by law, we exclude all conditions, warranties, guarantees, terms and obligations expressed, implied or imposed by law or otherwise relating to the information contained in this material or your use of it and will have no liability to you, however arising and under any cause of action or theory of liability, in respect of any loss or damage (including indirect, special or consequential loss or damage, loss of profi t or loss of business opportunity), arising out of or in connection with this material or your use of it.