Design and Optimization of Process in Spinning Mill to Improve Quality and Productivity of Yarn

Abstract

Food, shelter and clothing are very basic needs of human beings. Cloths are used by the human beings to protect themselves from light, wind and rain and other environmental factors. Cloths are manufactured from the cotton. In spinning mill industry raw cotton is processed to produce yarn. At present condition quality and productivity of yarn is very important factor and lot of mills failing to achieve the quality as per standards due to this the spinning mills are in financial crisis. In India many spinning mills have stopped their production. So it has direct impact on economical condition of farmers, mill workers and the people who are connected directly or indirectly to spinning mill industry. As it’s affecting the life of many people it is very important to do research work in this field but still now this topic is not touched by researchers in large context. This is the reason why this research work initiated. Various continuous improvements processes are used in industries. Instead of applying single method at one time if we use two methods in integrated approach which compliments each other that will give benefits of both methods in single attempt. To achieve the fine quality of yarn the continuous improvement processes can be used like Six Sigma and Theory of Constraints. If we combine six sigma and theory of constraints and apply over a system as an integrated method that would give us benefits of both methodologies in single attempt with saving of time, money and man power and in results we can achieve fine quality of yarn with increased plant productivity and efficiency which will leads to profitability of mill. In this research by applying the integrated model bottleneck processes were found out and optimum solution is provided by doing improvements in processes. The process capability analysis was done before and after improvements done so we can measure the performance of system. Yarn properties such as unevenness, imperfection index, count variation, hairiness, strength, short fiber content are considered as parameters to measure effectiveness of system. In current system before improvements done there was lot of variation in values of this parameters and by reducing this variations integrated approach leads towards the profitability of spinning mill.