Mid Assignment on

Production Calculation and efficiency comparison of different winding

machines with your own recommendation for production improvement

Course code : Tex-205

Course title : Weaving Technology

Submitted by
Name: Nusrat Jahan
Id:191003060
Batch:191(D2)
DEPT.Textile Engineering.

Submitted to
Name: Md. Faisal Mahmud
Designation: Lecturer
DEPT.Textile Engineering
Introduction:
Winding:
Winding process  can be defined as the transfer of spinning yarn from
one package to another large package (cone, spool, pirn etc). On the
other hand it can be defined as the transfer of yarn from ring bobbin,
hanks etc into a convenient form of package containing considerable
long length of yarn. A process accumulating yarn on a package to
facilitate the next process is called winding.

History:

The continuous filament winding process was developed in the 1970s

through joint efforts by Danish inventor Frede Hilmar Drostholm, who
invented an advancing mandrel machine, and Agnar Gilbu of
Sandefjord, Norway, who envisioned the continuous filament winding
process for fiberglass pipes and tanks. The production method was
adopted by Vera Fabrikker (at that time a subsidiary of Sandefjord-
based global paint supplier Jotun) in 1965, but, initially, the process
was used only to make tanks. In 1968, Vera Fabrikker supplied the first
pipes to customers. Veroc Technology AS was established in 1977 as a
joint venture between Vera Fabrikker and Owens Corning (Toledo,
OH, US). Veroc customer Amiantit (Dammam, Saudi Arabia)
reportedly acquired the technology from Owens Corning in 2000,
which had by then acquired a new name: Flowtite Pipe and Tank AS.
More historical details are available here.

The ingenious process involves a cantilevered, horizontal rotating

mandrel system. Customizable to a range of pipe diameters, the
mandrel is made up of longitudinal beams fitted with small outward-
facing roller bearings, a series of discs (sized to the pipe to be
produced) that support the beams and a steel “band,” or endless loop.
As the mandrel rotates, the steel band, which is about 2 inches/51 mm
wide, is wound over the beams by a placement head on the mandrel’s
supported end. As it is wound, the band also is pulled and, therefore,
moves over the roller bearings in the axial direction, advancing toward
the other (open) end of the mandrel. At that end, an exit head directs
the band back through the mandrel’s core to the supported end, where
the placement head directs it onto the mandrel again. In this way, the
wound band forms a continuously advancing, smooth tool surface onto
which the pipe materials are applied, via filament winding heads on
either side. The wound pipe is pulled along by the advancing band
through a heated zone near the mandrel’s open end to cure. Then the
cured pipe exits the mandrel system, and the continuous pipe is cut to
the desired length. The technology can currently fabricate pipe up to
4m/13 ft in diameter.

Winding Calculation
Slub – catcher settings:

1. Fixed Blade = Carded – (2.0 to 2.5) x Diameter

Combed – (1.5 to 2.0) x Diameter.
2. Oscillating Blade = Smooth micro-set – 25% more than
above
3. Serrated Blade = 100% more than the above.
4. Electronic yarn clearer = 3 cm x 3 Diameter

For Blended yarn = 10 to 15% more settings

Yarn clearer efficiency = 100 present (Faults removed )/(Faults

Present)*100
Knot factor = (Total Breaks during winding(at faults))/No of
Breaks due to objectional faults

Retained splice strength = Strength of spliced joint * 100

/Strength of parent yarn

Winding Tension = 0.1 x Single strength in grams

Optimum spindles / winder N = (4.8 * Y)/S OR

Expected efficiency E = 4500 * Y / (S * N(12 + 98))

Expected production P = (13 Y/(12+98) * C)/winder per 8 hrs in kg

Y = Length / Bobbin (meters.) B = breaks per bobbin

S = Winding speed (meters./min) C = English count

What is Winding Efficiency in Weaving?

The percentage expression of the ratio of the actual production to the

calculated production is termed as winding efficiency. It should be noted
here that, actual production is lower than calculated production.
 Winding efficiency calculation in weaving
Winding Efficiency Calculation Method Followed in Textile
Weaving Industry:
Winding efficiency can be calculated by using the below
formula:

Winding Efficiency= {(Actual production/ Calculated production)

×100}

1. In case of cotton,
Production Calculation of Winding (per hour) ,

   Surface speed of winding drum (yds/min) × 60 × Number of drum ×

Efficiency × Waste
=…………………………………………………………………....
………………...………… (Lbs/hr)
                                              840 × Yarn count

Or,

   Quantity of yarn per spindle(yds/min) × 60 × Number of spindle ×

Efficiency × Waste
=…………………………………………....………………..…....
……………….…………… (Lbs/hr)
                                           840 × Yarn count

Or,

= Quantity of yarn per spindle(yds/min) × 60 × 8 × Number of spindle

(spindle)

Example: 
Find out the production per 8hrs of an Auto cone winding machine from
the following data:

 Drum Speed: 2400 R.p.m

 Dia of Drum: 3 Inch
 Yarn Count: 30s
 Efficiency : 68%

Solution:
Production/spindle/8hrs,

   Surface speed of winding drum (yds/min) × 60 ×8 × Number of drum

× Efficiency
= ………………………………………………………………....
………………………… (Lbs/8hrs)
                                           36 × 840 × Yarn count

   3.14 × 3 × 2400 × 60 × 8 × 68
= ……………………………………………. (Lbs/8hrs)
         36 × 840 × 30 × 100
= 8.13 (Lbs/8hrs)

So, Production/spindle/8hrs is 8.13lbs.

2. In Case of Jute,
Production Calculation of Winding (per hour) ,

   Surface speed of winding roller (inch/min) × 60 × count × Number of

spindle × Efficiency
= ………………………………………………………………………....
……………………… (lbs)
                                                      36 × 14400
Example: 
Find out the production per shift of a Spool winding machine from the
following data:

 Number of spindle: 20
 Surface speed of winding roller = 165 yds/min
Solution:
Production/spindle/shift,

   Surface speed of winding roller (yds/min) × 60 × count × Number of

spindle
=…………………………………………………………………………..
.………… (spindle)
                                                  14400

   165 × 60 ×8 × 20
=…………………………… (spindle)
          14400

=110 (spindle)

So, Production/spindle/shift is 110

3. In Case of Tex System,

Production Calculation of Winding (per hour) ,

 Surface speed of winding roller (cm/min) × 60 × Count × Number of

spindle × Efficiency
=…………………………………………………………………………..
…………………………(gm)
                                                              100 × 1000

Machine Efficiency,

       Actual Production

= ………………………………… ×100
   Calculated Production

Example: Find out the calculated production per shift of a winding

machine from the following data:

 Actual production: 90 spindle

 Number of spindle: 20
 Efficiency: 80%

Solution:
Calculated production per shift,

    Actual production

= …………………………
          Efficiency

   90 × 100
= …………….
      80

= 112.50 spindle

So, Calculated production per shift is 112.50 spindle.

How to Calculate Efficiency of a Production Line?

To know the performance of a garment factory, and a comparative study
of the sewing line performance, we measure production line efficiency.
So, like individual operator efficiency, measuring the efficiency of a
production line is important for a factory. Daily line efficiency shows
line performance.

Production Line Efficiency Calculation - Information

required
To calculate the efficiency of a line for a day, you will need the
following data (information) from the line supervisor or line recorder.
1. Number of operators – how many operators worked in the line in a day

2. Working hours (Regular and overtime hours) – how many hours

each of the operators worked or how many hours the line run in a day

3. Production in pieces – How many pieces are produced or total line

output at the end of the day

4. Garment SAM – What is the exact standard minute of the style

(garment)

Once you have above data you have to calculate following

Information -

 a. Total minutes produced by the line: To get total produced minutes,
multiply production pieces by garment SAM
 
b. Total minutes attended by all operators in the line: Multiply the
number of operators by daily working hours and convert total hours
into total minutes (multiplying by 60).

Now, calculate line efficiency using the following formula:

 Line efficiency (in percentage) = (Total minutes produced by the line

*100) /(Total minutes attended by all operators)
An Example - Calculating Production Line Efficiency
Let's calculate the line efficiency of one production line.
48 operations worked in a line for 8 hours. They produced 160 garments
and SAM of the garment is 44.25 minutes.

Here,
Total minutes produced = (160 x 44.25) = 7080 minutes
Total minutes attended = (48 operator x 8 hours x 60) = 23040 minutes
Efficiency% = (7080 x100)/23040 % = 30.729%

For more example, refer to the following table. Data calculation formula
has been given on the header row of the table

Total

No. of Working line output Garment minutes Total Minute Line

Operator hours (production) SAM attended  produced Efficiency (%)
(A) (B) (C) (D) (E=A*B*60) (F=C*D) (F/E*100)

48 8 160 44.25 23040 7080 30.73

48 11 240 44.25 31680 10620 33.52

34 8 300 25 16320 7500 45.96

35 11 400 25 23100 10000 43.29

35 11 329 25 23100 8225 35.61

34 8 230 25 16320 5750 35.23

34 8 200 35 16320 7000 42.89

35 11 311 35 23100 10885 47.12

34 11 340 35 22440 11900 53.03

Winding Requirements
 Minimum fault: During winding always should be observed if
yam fault become less. (To minimize the yam faults).
 No damage of yarn: There is a dame of yarn i.e. the yarn
must not be damaged in any way in the winding process.
 Easy unwinding: Yarn to be wound so that it can be unwound
easily.
 Suitable size and shape of the package: Size and shape
should be proper.
 Economical condition: The package size should be
controlled the particular economic requirements.
 Avoid excess loosened and tightness: Should be taken care.
 Cheap cost of the package: The package should be cheap.
Above all the process must be profitable.

Objectives of Winding
Elimination of disturbing yarn faults such as long thick places,
long thin places, short thin places and short thick places.

 To get the continuous length of yarn on cones for weaving

process.
 To wax the yarn during the winding process.
 To get the high efficiency of the machine, that is high
production level.

Winding machines are classified based on the materials they are

winding, some major types are:
  Coil winding machine
 Film winding machine
 Rope winding machine
 Paper winding machine
 Foil winding machine
 Roll slitting machines
 spool winding machine
 cop winding machine

All of these, the best types of winding machine for high production
rate and efficiency, I recommend automatic coil winding machine.

HOW CAN AUTOMATIC COIL WINDING MACHINE

INCREASE THE WORK EFFICIENCY?
Winding machines, which are also referred to as winders are the most
commonly used equipment for winding cords, twines, coils, or wires.
The equipment used for winding coils are known as the coil winding
machines. Depending on the requirement of the winding process, these
equipment can come in a variety of types and capabilities. There are
both manual hand-operated, as well as automatic coil winding machine
available in the market. In most applications, automatic coil winding
machines are preferred over their manually operated counterpart. Why?
Are you intrigued to know? The following post will explain some
beneficial features of the automated coil winding machines, and also
explain how they help increase the efficiency of work.
 
What are the Benefits of Using Automatic Coil Winding
Machine?

Here are some striking beneficial features of automatic coil winding

machine that make them popular in a number of applications:
1. These coil winding machines have a better versatility than their
manual counterparts. Besides, they are easy to install and operate, and
have a lower failure rate.
2. Unlike manual winding machines, they have the capability to
deliver stable operation.
3. They help reduce the labor requirement for operation. This helps
reduce the labor, as well as production costs considerably.
4. These automatic winding machines can be used to wind various
types of wires, such as ac, dc, data lines, etc.
All these beneficial features increase the efficiency. However, there are
other two major factors that add to the efficiency. These two factors are
explained in the following section of the post.
What Major Factors of the Automatic Winding Machines Help
Increase Efficiency?
The following are two major factors, apart from the benefits, which help
increase the overall work efficiency of these coil winding machines:
 Multi-Spindle: The automatic winding machines feature multi-
spindles, which enable the equipment to wind multiple coils at a time.
 Multi-Tasking: These automatic machines have the capability to
carry out multiple tasks, and processes at the same time. Thus, several
industries have discarded their traditional, manually-operated winding
machinery, and replaced it with the automatic ones.
The two factors explained above help save a considerable amount of
time in coil winding, which can be used for other important tasks.
When Can You Use the Automatic Coil Winding Machine?
You can use these extremely beneficial winding equipment in the
following applications:
1. In telecommunication industries to run transformers
2. In electrically driven motors
3. For production of transformers in electrical industries
4. In electrical devices like solenoids
All the beneficial features explained above, are the reasons why they are
preferred in the most applications, over the hand-operated coil winding
machines. These automatic equipment can be sourced from several
manufacturers or suppliers in the US. However, before making the
purchase, you need to ensure whether the supplier is capable of
providing quality equipment. Among the few experienced and trusted
suppliers and manufacturers, Armature Coil Equipment (ACE) is the one
you can trust.
Conclusion:
There are many way to know about the winding efficiency and to
calculate the production rate of winding. In the above I explain how to
know about efficiency for different types of winding machine.
From this I get to know about the high efficiency winding machine with
high production which can help a company to get high production
without any faults.
So, I just recommend the automatic coil winding machine for high
production rate and efficiency than the other winding machine. And why
I recommend this machine I just explained it earlier.