PROJECT 6:

YIELD PERFORMANCE IMPROVEMENT

Table 4: Yield Performance Stages

Process Optimization	a	Decreasing raw material costs in existing blend by Yield Performance Pc-programs	3
	b	Improving combed yarn quality in existing blend by Comber Data Pc-programs and decreasing costs through decreasing combing waste	1
	c	Decreasing costs through minimizing breakages in existing blend by Spinning Performance Pc-programs	2
	d	Decreasing costs through decreasing roving waste with minimizing breakages in existing blend	1
	e	Getting zero default with minimum cost through implementing bobbin upper tube analysis and DPEA	3
	f	Decreasing direct work costs	1
	g	Decreasing direct energy costs	1
	h	Decreasing indirect costGs through implementing Knowledge Based Management	1
	i	Decreasing costs through increasing efficient and production levels in existing blend by Prdn 1.0 and Spinning Performance 1.0 pc-programs	3

Raw material cost consists of four factors.

1. Raw material unit cost
2. Yield performance
3. Stock amount and monthly interest
4. Waste amount and waste unit price.

For reducing raw material costs,

• Increase raw blending performance to maximum level.
• Stock control is done as economic order system.

In the mill firstly yield performance is achieved to get standard level in present condition. For this, Waste Category System and pc-program are implemented from blending to bobbin. On the all stage of process this system control that when and where waste is out of standard through forming waste control system with statistical method in the mill. Yield performance is controlled hard without this system. Therefore waste category system and pc-programs are advantage to get minimum raw material cost. Waste category system is different according to different mill. But it helps as controlling breakage in the 1000-spindle-hr in the ring and roving. Process optimization and R&D project are implemented through obtained knowledge from waste control system. Other advantage of this system is to control each blending systematically.

In the mill reducing cost depend on Mill Control Systems must be established for guarantee and improve quality. This control system must be supported with pc-programs to work efficiently in a short time.

Waste was considered important at past. But now it becomes important through increasing rivalry in international trade market. Therefore in the mill productivity must be increased. Factors, which effect productivity, are checked over again. It is important to be careful that HOK (labour time for 100 kg yarn) must be reduced. For this, factors of obstructed production increase must be achieved to get optimum level. Waste control system effects HOK and costs. If waste increase, HOK will increase and then productivity will reduce. And also production level will reduce. For these reasons costs will increase. It is not solve that you use this waste in the open-end production. In the waste of combing %2 decrease is equal %2 production increase. This pc-program purpose is to control yield and mill performance with checking over waste systematically. This program was developed through carry out researches in the textile industries in last years.

Waste control system begins bale and goes on packing. Program has process control tests and waste standard computing. And measured values are compared between result of process control and standard. Waste Control System is control system in itself to collect waste in order, classification and interfere.

Waste control system has relation with process control tests. The advantage of Waste Control System and Pc-programs are listed as such,

1. Classify all waste as useful or useless
2. Classify wastes as category and amount
3. If see off standard state about any waste category, cause of them will be eliminate
4. Determine priority procedure for implement process improving in the yield performance increasing.
5. If see off standard state about any process, to have interfere probability instantly.
6. Determine real unit yarn costs.
7. Have test probability to analyze different blending performance.

So applying waste control system provides to increase production levels. For example pnomophil waste increase shows to increase breakage and also work load. In this way time of problem solving is reduced minimum.

Necessary raw material amount for producing 1000 kg yarn is depend on yield performance.

Raw material amount = producing yarn (100 + waste%/100).

Necessary improving workings are done for increasing yield performance trough the place of low performance are determined to benefit from Waste Category System. However Process Optimization Workings are also applied. While examining carding and combing processes, waste percentage by Pareto analysis is listed as maximum part blow-room and card later ring and roving.

  Knowledge Based Quality Systems             Proses Optimization and R&D Projects for Textile Mills