Final_Report_Summer_Internship.PDF

Summer Internship Project
Semi mechanization of Pit Loom 1
Sharda Exports,Meerut(201301)
Project Report on
Semi Mechanization of Pit loom
Duration: May 12, 2016- July 11, 2016
Under The Guidance of: Submitted by:
Mr.D.K.Jain Amit Singh
Sharda Exports IIT Roorkee

Certificate
This is to certify that Amit Singh student of B.Tech. III Yr. Production
and Industrial Engineering, Department of Mechanical and Industrial
Engineering, IIT Roorkee have satisfactorily completed the project “Semi
Mechanization of Pit Loom” under the guidance of Mr.D.K.Jain.
The project work was carried out between May 12, 2016 and July 11, 2016.
Certified By:
Mr.D.K.Jain

Acknowledgement
I would take this opportunity to thank Mr D.K.Jain, Sharda Exports, my
project guide for this valuable guidance, suggestions and encouragement. I
am very grateful to Mr. Deepak Sharma of Sharda Exports, for their kind
help and essential provided to me as per my requirements.
I thank all the Production staff and AVG Staff and rest of the Sharda
Exports community for their valuable information and assistance provided.
Finally, I would like to thank Mr. Aditya Gupta (MD) for providing me this
opportunity to work as a summer intern in Sharda Exports.

Loom: Loom is a machine or device which is used to produce woven
fabric by interlacement of warp and weft yarn. Ginning, opening, cleaning,
carding, combing, drawing, spinning, winding, warping, sizing, beaming
are the process prior to weaving.

Short Description of Loom is given below:
Heald/Heddle: Wire or cords with eyelets that hold warp yarns in a
place.
Heald shaft/Harness: A wood or metal frame that holds the headl/heddles
in position in the loom during weaving. It is usually more than one.
Shuttle: This is a vehicle for weft & passes through the divided warp for
the interlacement of the warp & weft.
Shuttle box: Compartment of each end of the sley of a shuttle loom used
to retain the shuttle between picking motion.
Picker: It is a piece of leather or other metal placed in grooves or on a
spindle inside a shuttle box.
Beams: A cylindrical body with end flanges on which a multiple of warp
ends is wound in such way to permit the removal of these yarns as a warp
sheet.

Front rest: It is a fixed roller placed in front of the loom above the cloth
beam & act as a guide for the cloth to wind on to the cloth beam.
Lease rods: The division of warp yarn into one & one, two & two, & so on
is termed as lease. The two rods passed between the two successive
divisions of warp yarns are called lease rods.
Slay: It is the portion of loom that carries the reed and oscillates between
the harness & the fell of the cloth.
Reed: A comb like wire or device used to separate yarns on a loom & to
beat up the filling during weaving.
Treadle: The treadle is a paddle or lever under a loom with which a
thread is connected by means of cords.
Temple: Roller device on a loom that hold the cloth at a proper width to
prevent it from being drawn in too much by the filling.

Problem Identified
1.PROBLEMS: Movement of Reed is difficult for worker because he is
unstable on his seat and has to stretch forward to pull the reed towards
himself.
SOLUTION:Making the movement of reed vertical rather than horizontal
ADVANTAGES:
 No bending and stretching for the worker so the worker can
complete the given job in the less period because he doesn‟t feel
tiredness too early.

DRAWBACKS:
 Whole Design of the pit loom has to change.
 Movement of a shuttle is now impossible.
 Heddle Placement is now too complicated and they will hang
above the worker‟s head.
Because of these drawbacks, this project was discontinued.
SOLUTION:Use of spring mechanism to move to reed. Attaching springs
to the reed to the corners and this system is connected to the lever in such
a way that if we pull the lever it will exert the pressure on the spring system
and because of it spring provide the motion to the reed and therefore the
battening operation is performed.

ADVANTAGES:
 Improve the ergonomic of worker „ cause of pulling the reed
continuously, worker has to lean forward to pull it towards himself.
Because of it, the efficiency of worker reduce by time, may cause
some pain.
DRAWBACKS:
 Heavy structure. It may hurt the people around it.
 We can‟t control the force exerted by it.
 It may be damage the product.
DEPARTMENT: Production
GUIDE: Mr. Deepak Sharma

2.PROBLEMS:Motion of pedals in the Pit Loom is difficult and worker
has to in the standing position
SOLUTION:Computerising the motion of pedals. We can sync the
motion of pedals with motor and this motor is operated via computer
where we initially feed the data about the motion of pedals. Use of stepper
motor to control the motion of pedals. With a computer controlled
stepping, we can achieve very precise positioning and speed control.
ADVANTAGES:
 Now Worker has to focus on the carpet rather than on pedals.
 Body posture of a worker is now at the comfortable position.
 It will save the time.
 Save the energy exerted by the worker.
 Reduce the movement of a worker.

DRAWBACKS:
 Only applicable for two pedal system.
 No of pedals changes with design
 Costly.
 Worker needs time to pass the shuttle between the heddles and for
implement the thread placement in between them. We can‟t predict the
time taken for these steps.
 It is not necessary that the motion of pedals is continuous
throughout the design.
3.PROBLEMS: Rolls of Nivaar (The 2-inch odd strip made of strong
cotton threads – used to knit a traditional bed called „chaarpai‟) are not
placed properly in the storage section. They kept over one another.
Because of that Storage master didn‟t have the knowledge about the no. of
rolls and the size of nivaar.
SOLUTION:We can place them in the long metallic rods vertically.So
when there is need of nivaar, they just have to pull the one end of nivaar
and cut the required amount of nivaar. It didn‟t affect the other rolls

(Like That)
ADVANTAGES:
 Now we can differentiate according to their size.
 Easily to handle.
 No wastage of nivaar because now master has knowledge about the
counting of rolls.
 No misplaced.
DEPARTMENT: Storage

4.PROBLEMS:Worker uses the latex via a piece of wooden plank.
Adhesive Latex has some allergy problems so it affects the health of the
worker. Once it sticks to the hands or clothes it‟s very difficult to remove it.
SOLUTION:We can use the wiper instead of wooden plank
ADVANTAGES:
 Once the use of wiper is implemented it will increase the life of
working of hands of a worker.
 Now it will somehow protect the hands and clothes of worker
DRAWBACKS:
 Changing from plank to wiper is difficult to operate by a worker.
 Initially it will increase the process time.
 Still worker somehow manage to have contact with latex.
DEPARTMENT: Latex Department
GUIDE: Mr. Amit Sharma
5.PROBLEMS:In Finishing, a worker uses the broomstick to clean off the
dust and little pieces of clothes from the carpet. Because of the pointed tips
of the broomstick, sometimes it will damage the carpet. When the worker
uses the stick, the dust particles remains pile up near the finishing area and
make the department dirty. These dust particle may cause the allergy.

SOLUTION:Use of commercial vacuum cleaner for removing the dust
and other particles. After dusting, the dirt remains inside the the bag of the
vacuum cleaner. It has around 5L capacity which means it can clean
around 25 carpets in a single use.
ADVANTAGES:
 No damage to the carpet.
 It will keep the area clean around the finishing area.
 No health Issue.
DRAWBACKS:
 Cleanliness of carpet is not upto the mark.
 Time Consuming, According to workers.
DEPARTMENT: Packing and Finishing
GUIDE: Mr. Ranjan

6.PROBLEMS:Workers use the piece of cloth for pasting the strips. Again,
there are some allergy issue from the worker because of the latex.
SOLUTION:Use of brush instead of cloth for pasting the strips.
ADVANTAGES:
 It will protect the hands and clothes of worker.

DRAWBACKS:
 Time consuming, according to the worker because they are not
used to it. They have to handle the brush.
 After using brush, because of latex it will get hardened. If we any
chemical for restore the brush, it will damage the carpet because of
the smell of chemical.
DEPARTMENT: Binding Department

7.PROBLEMS:While pasting the strips on the gum sheet, worker didn‟t
realise that the strips are no proper align, until the manager told them. So
they stop there and start stretching the pieces so they become aligned.
SOLUTION:If We put the graph line on after some distance like after
every 1 inch or 2 inches it will help them to paste the strips properly.
ADVANTAGES:
 They didn‟t have to redo it.
 Save time.
DRAWBACKS:
 It will increase the costing of the gum sheet.
 Leather pieces have tendency to shrunk or expand while cutting.
DEPARTMENT: AVG

8.PROBLEMS:Movement of Reed is difficult for worker because he is
unstable on his seat and has to stretch forward to pull the reed towards
himself. This disturbs the ergonomics of a worker.
SOLUTION: Use of mechanism in which worker handles it from the seat
itself. The mechanism is something like this in which the oscillatory motion
of one link converted to oscillatory motion of reed in horizontal motion.
In this mechanism Reed is attached at end A so the joint A has
restricted motion in horizontal direction. The mechanism is designed in
such a way that Reed is at beaten position when the input link come
horizontal. The displacement of reed required in pit loom is generally 54
cm. 35o
movement of the input link gives the reed a horizontal motion of
54 cm.

Dimension of links (in cm):
AB=44.8 BC=15.3 BF=90.5 BE=73.5
EF= 18 CD= 72.1 KD= 7.2 KE=28.2
FH= 13.7 DH= 40.6 JG= 16.4 GF= 12.2
Width = 5 cm (Except for link BEF), Thickness=2 cm
Reed is heavy, long and it is freely hanged so it has to be moved
from both the ends moreover, it is not possible to place the mechanism in
the centre of reed as yarn are in place. So we place one mechanism at each
end of reed. The base of mechanism is attached on both sides to the
Base
Output To Reed
Input Link

platform where warp beam is attached.
The input link cannot be given on front side of the beam because of space
constraint. Input power is given from the worker to input link using ropes
attached from input link over the frame of loom.
ADVANTAGES:
 Body posture of a worker is stable.
 Proper Battening because every time force is same.
 No bending and stretching.
 Efficiency of a worker increase.

DRAWBACKS:
 Very Heavy model.
 More Links Involved so lots of friction may be involved.
 Time duration not changed enough.
 Very hard to implement.
9.PROBLEMS: It‟s difficult to copy the design of carpet from the design
sheet in leather cross stitching. Dimensions of carpet on which the design is
copied are 160*230 cm and 170*240 cm. There are two types of square
pieces are used to make the carpet, first 3*3 inch contains 25 holes and
second 2*2 inch contains 9 holes. They usually work on 160*230 cm with
2*2 inch piece which means 33*48 pieces. It means 14256(33*48*9) holes
in the carpet and the design sheet is of A4 size. So it hard to difficult to
copy the design from that sheet that containing the 14256 holes.
Also the designing team make the design in cms (2inch=5.08cm), the
dimension of square is 5*5 cm. That 0.08cm affects the grid system and
the design sheet because according to 5*5 cm pieces there are 32*46
pieces, and the distance between each holes also change. So one worker
make a carpet and manages the design on the pieces and and then same

carpet is used for further carpets.
SOLUTION:Introducing the graph system in the design sheet so that
worker know via grid system where to start and where to finish. For
example red colour thread is start from let say 14*17 and continues to
14*26. Now because of graph system he/she have to just find out the points
rather than counting.

Enlarging the design sheet. Rather than printing on one A4 sheet we can
print on the design on 4 or 6 A4 sheets so the details are easily visible to
workers.
Design sheet must be in the inches so that there are no changes further.
ADVANTAGES:
 Workers can start make many carpets of the same design at the
same time.
 Take less time.
 No pressure on eyes.
 They didn‟t have to count every time.
DRAWBACKS:
 Take some time to understand the process.
DEPARTMENT: Leather Cross Stitching
GUIDE: Mr. Amit Sharma And Mrs Julie

Final_Report_Summer_Internship.PDF

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