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    Process Control in Spinning

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    Sandeep Meena
    This document discusses process control in spinning, with a focus on quality assurance. It outlines the key steps, which include setting norms, monitoring raw materials and the process, and inspecting the final product. Various quality attributes are monitored at different stages, like sliver count and uniformity. Process parameters like machine conditions and waste levels are also monitored. Deviations from norms trigger corrective actions. Count variability is controlled by monitoring individual operator performance and investigating causes of shifts from targets. The document provides guidelines for charkha spinning and monitoring yarn count strength product as a quality metric.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Process Control in Spinning

    Uploaded by

    Sandeep Meena
    52 views31 pages
    This document discusses process control in spinning, with a focus on quality assurance. It outlines the key steps, which include setting norms, monitoring raw materials and the process, and inspecting the final product. Various quality attributes are monitored at different stages, like sliver count and uniformity. Process parameters like machine conditions and waste levels are also monitored. Deviations from norms trigger corrective actions. Count variability is controlled by monitoring individual operator performance and investigating causes of shifts from targets. The document provides guidelines for charkha spinning and monitoring yarn count strength product as a quality metric.

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    23645907 Process Control in Spinning

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    This document discusses process control in spinning, with a focus on quality assurance. It outlines the key steps, which include setting norms, monitoring raw materials and the process, and inspecting the final product. Various quality attributes are monitored at different stages, like sliver count and uniformity. Process parameters like machine conditions and waste levels are also monitored. Deviations from norms trigger corrective actions. Count variability is controlled by monitoring individual operator performance and investigating causes of shifts from targets. The document provides guidelines for charkha spinning and monitoring yarn count strength product as a quality metric.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    52 views31 pages

    Process Control in Spinning

    Uploaded by

    Sandeep Meena
    This document discusses process control in spinning, with a focus on quality assurance. It outlines the key steps, which include setting norms, monitoring raw materials and the process, and inspecting the final product. Various quality attributes are monitored at different stages, like sliver count and uniformity. Process parameters like machine conditions and waste levels are also monitored. Deviations from norms trigger corrective actions. Count variability is controlled by monitoring individual operator performance and investigating causes of shifts from targets. The document provides guidelines for charkha spinning and monitoring yarn count strength product as a quality metric.

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    PROCESS CONTROL IN

    SPINNING
    Prof. R. Chattopadhyay
    IIT, Delhi



    QUALITY ASSURANCE IN SPINNING
    STEPS

    Setting of Norms

    Quality of incoming raw material to te !a"i


    Institution

    Process #onitoring an" Control

    Ins$ection of final $ro"uct



    #ATERIAL %L&'
    Transportation of
    Sliver / roving
    Internal transportation
    CENTRAL SLI(ER
    PLANT
    Raw cotton
    !a"i
    Institution )
    !a"i
    Institution*
    !a"i
    Institution+
    ,istri-ute" s$inning
    in .illages
    Institutional
    s$inning
    Transportation of
    sliver or roving
    (illage )
    (illage *
    (illage + (illage n
    Charkha
    ) * + / )0

    PR&CESS
    In$ut &ut$ut
    Monitor
    Com$are
    against norm
    Correcti.e
    action
    #onitor
    Process $arameters
    1Interme"iate $ro"uct
    caracteristics1#acine
    con"itions1'or2 $ractice 1
    $rocess waste
    Com$are
    against norm
    Correcti.e
    action
    #onitor
    Com$are against
    norm
    PR&CESS C&NTR&L

    QUALITY &% INC&#ING RA'
    #ATERIAL T& CENTRAL SLI(ER PLANT

    Test of raw cotton in terms of $ysical $arameters


    an" acce$t if com$ara-le wit norms

    Careful trans$ortation 3 storage of cotton -ales

    Cec2 sli.er or ro.ing $arameters i4 e


    Count an" count C(5
    Tras 5 3 Ne$s

    Cec2s on material an"ling "uring $ac2aging an"


    loa"ing on truc2s
    6 Transfer sli.er into $olytene -ags
    6 Put ro.ing -o--ins into $olytene -ags
    6 Trans$ort sli.er cans7 $olytene -ags
    containing sli.er or ro.ing on to te truc2s4
    6 Pro$erly co.er sli.er cans7 $olytene -ags
    containing sli.er or ro.ing on truc2s

    QUALITY &% RA' #ATERIAL RECEI(E, 8Y
    !9A,I INSTITUTI&N

    Cec2s on material an"ling "uring Unloa"ing from



    truc2s
    6 Careful unloa"ing of $ac2ages
    6 Careful internal trans$ortation to a.oi" "amage
    6 Pro$er storage an" segregation of sli.er1 ro.ing
    to a.oi" acci"ental mi:ing

    Cec2s on "eli.ere" sli.er 1 ro.ing


    6 'eiging of $ac2ages
    6 Cross cec2ing of a.erage count

    ,ISTRI8UTU&N &% R&(ING &R
    SLI(ER T& T9E SPINNERS
    - Ensure tat te sli.er or ro.ing corres$on"s to
    te count to -e s$un4
    ;
    6 Te $ac2age is co.ere" in $olyetylene seet4
    I
    n 6 Instruction a-out careful an"ling of $ac2age
    "uring way -ac2 to .illage4


    C9AR!9A SPINNING GUI,ELINES
    a< 'or2 $ractice relate"
    I4 Running of Car2a
    6 Run at a slow s$ee" in te -eginning an" ten
    raise s$ee" an" maintain s$ee" at a con.enient
    le.el4
    6 Co.er te car2a once s$inning is o.er4
    6 Te -ro2en en" soul" -e $iece" =>oine"<
    $ro$erly4 A 2not is to -e a.oi"e" as it -ecomes
    too large wit res$ect to te yarn "iameter7
    wic "eteriorates fa-ric a$$earance

    II4 Lea #a2ing
    6All te sections of te lea soul" -e ma"e from
    same yarn count4
    6Te en" of te yarn soul" -e inserte" in to te
    inner $ortion of te lea4
    6Leas soul" -e $ro$erly store" in $lastic -ags or
    fa-ric -ags wit count wise segregation -y colour
    mar24
    6If $ossi-le7 lea -un"les soul" -e segregate"
    wile storing accor"ing to te ty$e of fi-res use"
    or count to a.oi" acci"ental mi:ing4

    -< #aintenance relate"
    6%ollow a s$ecifie" maintenance sce"ule in terms
    of cleaning an" oiling4
    6To$ roller $ressure soul" -e cec2e" at regular
    inter.als4
    6Cec2 te con"ition of te a$rons an" "ri.ing
    -elts =mall< an" a">ust if necessary4
    -< Parameters selection
    6 Select $arameters -ase" on $ast e:$erience tat
    suits te raw material4


    QUALITY ATTRI8UTES T& 8E
    C&NTR&LLE, IN !9A,I YARN

    A.erage Count an" It?s C(5

    Lea CSP

    Yarn Une.enness

    Im$erfections

    Soft an" ar" twiste" $ortion

    %aults

    Pote

    !acara

    #oore

    ,agi

    8a2ar

    Slu-s

    Possi-le reasons for "eterioration in @uality

    Caracteristics an" occurrence of faults



    PR&CESS C&NTR&L &% C9AR!9A
    SPUN YARN

    ,etection of significant sift in @uality le.el

    In.estigation on te causes of "e$arture

    Ta2ing reme"ial action imme"iately to set te $rocess


    -ac2 to normal

    #onitoring stages an" Caracteristics to
    -e monitore"
    YARN STAGE
    6A.erage count an" count .aria-ility
    6Uniformity
    6Im$erfections
    6Count Strengt Pro"uct =CSP<
    INTER#E,IATE STAGES
    Sli.er
    6Sli.er count an" its .aria-ility
    6Sli.er uniformity
    6Sli.er cleanliness


    Ro.ing
    6Ro.ing count an" its .aria-ility
    6Ro.ing uniformity
    6Ro.ing cleanliness
    Process Performance
    6'aste le.el
    6En" -rea2s in car2a
    6 Pro"ucti.ity

    ,etection of sift in yarn countA
    E:am$leA
    Nominal Count B *0 Nm
    A.erage weigt of lea B C0 gm
    Count C( 5 B )0
    S4,4 of count B Cgm
    'arning limit B #ean * S4,4 B C0 )0
    B D0 gm an" /0 gm
    Action limit B #ean +* S4,4 B C0 )C
    B DCgm an" +Cgm

    L
    e
    a

    w
    e
    i
    g

    t


    =

    g
    m
    <
    &$erator I,
    Lower 'arning Limit =L'L<
    U$$er Action Limit =UAL<
    U$$er 'arning Limit =U'L)
    Lower Action Limit =LAL<
    C0 g
    /0 g
    +C g
    D0 g
    DC g
    Sift

    L
    e
    a

    w
    e
    i
    g

    t


    =

    g
    m
    <
    &$erator I,
    Lower 'arning Limit =L'L<
    U$$er Action Limit =UAL<
    U$$er 'arning Limit =U'L)
    Lower Action Limit =LAL<
    C0 g
    /0 g
    +C g
    D0 g
    DC g

    L
    e
    a

    w
    e
    i
    g

    t


    =

    g
    m
    <
    &$erator I,
    Lower 'arning Limit =L'L<
    U$$er Action Limit =UAL<
    U$$er 'arning Limit =U'L)
    Lower Action Limit =LAL<
    C0 g
    /0 g
    +C g
    D0 g
    DC g

    '9AT ACTI&N IS T& 8E TA!EN

    %or case I
    6'rong ,raft Cange Pinion = ,CP<
    6Ina".ertent cange in "raft constant
    6'rong count of sli.er or ro.ing

    %or case II
    6Count of sli.er 1 ro.ing su$$lie" is to -e .erifie"
    6Too coarse an" too fine sli.er 1 ro.ing are to -e
    wit"rawn
    6,raft on car2as are to -e a">uste"


    Control of Count (aria-ility
    &$era
    tor
    No4
    Count (alues of Lea No4
    1 2 3 4 5 6 7 8 9 10
    )
    *
    +
    /
    C
    D
    E
    F
    G
    )0

    Calculation of witin an" -etween count C(

    REAS&NS %&R 9IG9 8ET'EEN &PERAT&R C&UNT
    (ARIA8ILITY =C(8&<

    ,ifference in a.erage an2 of sli.er1 ro.ing use"4

    ,ifference in te total "rafts in te car2as

    ,ifference in effecti.e "rafts -etween s$in"les of car2as


    "ue to cot sli$$age4

    Ro.ing stretc
    REAS&NS %&R ,I%%ERENCE IN A(ERAGE SLI(ER 9AN!
    ,ifference in waste le.el an" mecanical "raft in car" -rea2er
    or finiser "raw frame4

    ,I%%ERENCE IN A(ERAGE R&(ING 9AN!

    ,ifference in sli.er an24

    ,raft "ifference in s$ee" frames4

    ,ifferences in waste le.el in car"4



    ,I%%ERENCE IN A(ERAGE ,RA%T IN C9AR!9AS

    'rong "raft constant in car2a or wrong cange


    $inions

    ,ifference in effecti.e "raft witin a car2a


    6Sli$$age of to$ rollers7 ina"e@uate roller $ressure4
    R&(ING STRETC9ING

    Ina"e@uate ro.ing twist7 low inter fi-re coesion


    =s$ecially wen fi-res are sort<7"efecti.e -o--in
    ol"er

    YARN UNI%&R#ITY 1 UNE(ENNESS
    )4 A routine cec2 on all te sam$les recei.e" may not
    -e $ractica-le4
    *4 &nly wen yarn sam$les for any new lot arri.es 7 te
    test can -e carrie" out -y ran"omly selecting +0 leas
    from as many o$erators as $ossi-le4

    REAS&NS %&R UNE(EN YARN

    Incorrect setting of -rea2 "raft on ,1%7 S1% or car2a4

    Ina"e@uate to$ roller $ressure4

    'ear1"amage" a$ron or cots4

    Eccentric to$ roller y in car2a4

    9ig sort fi-er $ercentage in sli.er or ro.ing4

    Too wi"e setting in te front Hone of car2a4

    Sli$$ing a$ron4

    YARN APPEARANCE

    Su->ecti.e assessment -ase" on .isual cec2 of yarn


    -oar"s on yarns recei.e" from o$erators wen fres
    yarn lots are recei.e" from tem for a new mi:ing 4

    #aintain a recor" accor"ing to o$erator I,


    REAS&N %&R P&&R APPEARANCE

    9ig yarn une.enness

    #any e:cessi.ely se.ere tic27 tin $laces an" ne$s


    in te yarn

    Presence of too many im$urities li2e see" coat7


    lea.es7 stal2s etc in te yarn

    C&RRECTI(E ACTI&NS T& 8E TA!EN

    Cec2 te o.erall con"ition of te car2a an" roller


    setting

    Re$lacement of "efecti.e "rafting rollers or a$rons

    Cleaning of accumulation of stray fi-res on "rafting


    elements7 ring7 tra.elers7 gears etc soul" -e a.oi"e"4

    Roller sli$$age -ecause of low $ressure or $resence of


    oil on roller surface is to -e a.oi"e"4

    Ne$s in sli.er to -e maintaine" as $er te norms

    Cleanliness of te sli.er

    Yarn Count Strengt Pro"uct =CSP<
    &$erator I,
    LWL
    UAL
    UWL
    LAL
    )000
    D/0
    ED0
    gm
    )*/0
    )+D0
    L
    e
    a

    w
    e
    i
    g
    h
    t

    (
    g
    )
    A.erage CSP B )000 for count */ ; +D Nm
    CSP C(5 B )*7 CSP S4,4 B )*0
    UAL B )000 I + )*0 B )+D0
    U'LB )000 I * )*0 B )*/0
    LAL B )000 6 + )*0 B D/0
    L'LB )0006 * )*0 B ED0

    Action to -e ta2en
    Case IA Points fall -elow te lower Action Limit or
    continues to fall in -etween 'arning an" Action Limit
    for many o$erators4
    Case IIA Points are "istri-ute" wit a wi"e scatter4
    Case IA A re$eat cec2 on te yarn su$$lie" -y te
    o$erator wose estimate" CSP .alue fall -elow te
    action limit is to -e $erforme"4 At least D leas are to -e
    teste" an" te a.erage is to -e foun" out4 If te a.erage
    is foun" to -e still lower7 ten reme"ial measures soul"
    -e ta2en4


    P&SSI8LE REAS&NS %&R L&' A(ERAGE CSP

    6Ina"e@uate twist in te yarn4
    6%iner yarn count4
    6'ea2 fi-res in mi:ing4

    Twist an" count testing of te same are to -e
    $erforme" to fin" out weter te twist is really low
    or te count is fine4 Te lower twist coul" -e
    attri-ute" toA
    Lower s$in"le s$ee" "ue to sli$$age7 wic can -e
    "ue to
    Loose "ri.ing cor" of s$in"les4
    Accumulation of oil1grease on cor"
    "ri.ing te s$in"les =mall<4

    Reasons for finer yarn
    69iger total "raft4
    6Te finer sli.er1ro.ing su$$lie"4

    If count an" twist are as $er nominal .alue -ut
    CSP is still foun" to -e less7 ina".ertently a sli.er1 ro.ing
    may a.e -een su$$lie" from a mi:ing in wic te
    fi-res are intrinsically wea24
    Reasons for high strength variation
    ; Intermittent sli$$age of to$ roller in te car2as4
    ; (aria-ility in -etween yarn count $ro"uce" on
    "ifferent car2as4

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