PROJECT 4:
INCREASING RING PRODUCTION LEVEL
This R&D project is intended for increase ring production level. Increasing Production level is provided by optimum quality, minimum costs and increasing productivity. The important factor is machine for determining Ring production levels.
Production level of ring yarn machine is called to "gram/spindle-hr".
Gram/spindle-hr=Rpm*Tex*60*eff./(TPM*1000*100)
Table 3: Production Level Control
# |
Parameter |
Unit |
Control Point and tests |
1 |
Spindle speed |
RPM |
Spinning Performance Test |
2 |
Twist |
TPM |
Average upper semi-length |
3 |
Yarn count |
Tex |
Customer |
4 |
Efficiently |
EFF% |
A-Breakage /1000-spindle hr |
|
|
|
B-time of change mechanical train (min) |
|
|
|
C-frequency of doffing |
|
|
|
D-percentage of free turn spindle |
|
|
|
E-workload |
A |
Percentage of short fiber |
|
|
|
Mechanical Status |
|
|
|
Technical Data /Mechanical Settings |
|
|
|
Yarn tension cN/tex |
|
|
|
Infrequent defaults/100km |
|
|
|
RKM CV% |
|
|
|
E% |
|
|
|
|
|
|
B |
Doffing team |
|
|
|
Automatic Doffing |
|
|
|
Another Status |
|
|
|
|
|
|
C |
Mechanical Status |
|
|
|
Roving bobbin measures |
|
|
|
Bobbin weight |
|
|
|
|
|
|
D |
Mechanical Status |
|
|
|
|
|
|
E |
Breakage/1000-spindle hour |
|
|
|
Training |
|
|
|
Machine Length |
|
|
Fibre MIX selection |
|
|
|
Fiber Data |
|
|
|
Draft Zone Setting |
|
|
|
Spin Plan |
|
|
|
Spinning Mill Data Bank |
|
|
|
Measures to Improve Productivity |
|
|
|
Productivity Analyses |
|
|
|
Prdn 1.0 |
|
|
|
OPH 1.0 |
|
|
|
4.1PRDN-1.0
The purpose of this program is to increase production levels, compute production and efficient in all stage of production. Thanks to this pc-program, factors, which effected production, are analyzed scientific and production levels are increased systematic. From this purpose, the database, which 500 great firms use, is used. So a databank is improving about technical parameters of production. Mill labours have opportunity to analyze extensively to production levels with Prdn-1.0. Prdn-1.0 provides to classify and analyze about machine no, machine type, lot no, date, Tpi, RPM, spindle number data and their operation (=, <, >), (<>, =<, >=). These classifying and analyzing are used in the database and also technical analysis. For example:(Date>=11.11.99 and Date<=11.12.99 and Machine no=30 or Machine no=45 and lot no=01-45 and Tpi>=20 and Ne=30)
Prdn-1.0 has following programs.
Mill selects suitable program of them as carding or combing etc. There is a technical analysis section in this program. This section consists of filter windows, summary grill window, documentation and listing section and graphic analysis windows. The other windows of technical analysis function as select operation in the filter window.
4.2Out of production time analysis
In ring mill units' productivity are followed with stoppage analysis monthly. This is called UDS. Out of production percentage must be maximum %5,5. So efficient is %94,5. If the mill works under this value, there is some problem in the mill. Therefore daily and monthly UDS analysis of each shift are done and then causes of stoppages are determined with Pareto Analysis.
Knowledge Based Quality Systems Proses Optimization and R&D Projects for Textile Mills