The document discusses various aspects of management and operations in a silk weaving shed. It provides guidelines for monitoring key performance metrics such as warp and weft breakage rates, loom efficiency, fabric defects, loom speeds, transfer failures, and waste levels. It also describes conducting daily and weekly rounds to check items like loom speeds, fabric defects, colored weft shades, and functioning of automatic looms. Maintaining proper humidity levels in the weaving shed is also discussed.

1. Government Sri Krishnarajendra Silver Jubilee
Technological Institute
..
Mohammed Zakir
Silk Technology
1SK19ST400

2. Index:
 Management of Loom Shed
 Plant Layout
 Ventilation and Humidification
 Lighting
 Material Handling

3. Management of Shed is required to monitor the qualitative performance of the incoming material,
in-process material and the finished product. This involves conducting of studies/tests, both routine
and special.
Management of Loom Shed:
Routine directions are as follows;
End breaks and operations:
Warp and weft breakage studies should be
conducted once a month for each count. The breaks
should be noted case wise. In the case of ordinary
loom, additional information regarding weft changes
should be noted. From the data collected, warp and
weft breakage rates, as also the weaver operations
can be calculated for each count.
Efficiency:
Loom-shed efficiency should be studied every day by conducting a snap round the department. If the number of
looms in the shed is more than 1000, the round may have to be split in two parts to cover all the looms.

4. Fabric defects:
A snap round should be taken every day in the department for observing fabric defects. The number of rounds
should be increased to 2-3 per day when the defects are excessive. While observing the loom for the incidence of
fabric defects, the type of defect should be noted on an observation sheet. This will provide information on the
commonly occurring types of defects and will also help to create quality consciousness among the weavers.
Speed checking:
Loom speeds should be checked at least once a month. The procedure to be followed is to rest a finger on the
picking shaft of a loom and count the strokes for two minutes. A maximum loss of 2 rpm from the rated speed
should be allowed.
Transfer failures:
Two percent of the total automatic looms must be studied every month of transfer failures, for one hour each. This
study can be combined with the breakage study. The incidence of the transfer failures and lashing-in would indicate
the performance of transfer mechanism.
Hard waste:
The hard waste level is to be calculated every month from records. This will show the general trend. It is suggested
to keep a watch on the level of sweeping waste as weavers are often found to throw waste indiscriminately on to
the floor.

5. Colored weft shade:
A round should be conducted once a day to cover all looms and the pirns kept on the looms should be observed for
shade variations. The weavers should be asked to segregate the light and dark pirns
Ordinary looms working with one shuttle:
A snap round should be taken once a week or fortnight in the entire shed and looms working with only one shuttle,
unworkable spare shuttle and spare shuttle under repair should be noted and the number expressed as a
percentage of total looms observed.
Functioning of Warp stop motion:
Every loom having a warp stop motion should be checked for its functioning once a fortnight or month. A snap
round taken in the loom shed once a week or fortnight will help to observe the functioning of the mechanisms of
automatic looms. This study can be combined with the snap study for fabric defects.
Survey of ejected pirns on automatic loom:
The ejected pirns at the looms should be observed during the transfer failure study for the presence of excessively
long length of yarn or absence of bunch.
Sortwise efficiency:
Sortwise efficiency should be calculated every month from records.

6. Labor employment:
The average labor employment should be calculated once a month. This will help in avoiding the use of more
than necessary labor force in the shed.
Fabric inspection:
About 2000 m each of grey and finished fabrics covering all the major sorts should be inspected every month
on the inspection table for quality and incidence of fabric defects. The data so collected should be analyzed
weaver wise and loom wise.
Humidity:
A careful monitoring should be exercised and periodical readings taken on the hygrometers placed in different
sections of the shed to maintain uniform relative humidity in the weaving shed all through the shift. Readings
of the hygrometer kept outside and inside the shed should be taken at the same time. These observations
may be carefully studied and used as guidance for controlling general humidity in the shed.
Reconciliation between yarn and fabric:
As a part of the management control, the SQC department should match the consumption of yarn and
production of fabric through monthly reconciliation statements. Such a procedure helps to provide a
continuous vigil on the entire production cycle and helps to assess the actual material losses in the form of
process waste, invisible waste and so on. A reliable method for reconciliation has been developed by BTRA

7. Plant Layout :
Plant layout is a “technique of locating different machines and plant services within the factory so that the greatest
possible output of high quality at the lowest possible total cost can be available”. Plant layout includes the
arrangement and location of work centres and various service centres like inspection, storage and shipping within
the factory building.
Need of Plant layout: Many situations give rise to the problem of plantlayout. Two plants having similar operations
may not have identical layout. This may be due to size of the plant, nature of the process and management’ scaliber.
The necessity of plant layout may be feel and the problem may arise when,
I. There are design changes in the product.
II. There is an expansion of the enterprise.
III. There is proposed variation in the size of the departments.
IV. Some new product is to be added to the existing line.
Factors Considered for Plant Layout: Layout for a plant must be decided by considering the following factors
i. Organisation.
ii. Location of departments.
iii. Type of product, method of production, production process.
iv. Production capacity.
v. Type of industry, like synthetic, analytic, conditioning or extractive.
vi. Grouping of machines.
vii. Material flow pattern.

8. Characteristics of an Efficient Layout:
The designing of a plant layout should be such that it should maximize the return and minimize the cost of
production. The following are the characteristics of a plant layout.
1. Smooth flow of production; Plant layout should be in such a way that there must be a smooth flow of
production. Raw materials and workers must have access to each machine without any difficulty and delay.
2. Maximum utilization of available space; An efficient plant layout must be such that may utilize the maximum of
the space available.
3. Facilities the movement of men, materials and machines, etc. ;There must be sufficient space left in between
different machines so that raw materials, workers and machines move very easily from one place to another,
without the fear of accident.
Types of Plant layout:
1. Product or Line Layout
2. Process or Functional Layout.
3. Fixed Position Layout.
4. Combination type of Layout.

9. 1. Process layout:
The distance between the departments must be as small as possible to minimise the material movement.
The machines that are similar are grouped in one section/ department. It must be convenient for supervision and
inspection.
Advantages:
• Investments on machines are reduced as they are general purpose machines.
• There is greater flexibility in the production.
• This layout provides better use of men and machines.
• It is easier to handle any breakdown of machines through taking the machine
to another machine station.
Disadvantages:
• Movement of materials is difficult.
• Requires more floor space.
2. Product layout:
In this kind of layout, the machines are generally arranged in a series based on the process sequence required
for manufacturing the garment. In this layout, the process starts at one side of the line and the assembled
product is delivered at another side of the line. In between, partly finished goods move automatically or
manually from one machine to another. The output of one machine becomes the input of the next machine.

10. Advantages:
• Materials handling is automated, hence reduction in materials handling
cost.
• Bottlenecks in production line could be avoided.
• The layout helps in better production control.
• It necessitates less floor space per unit of production.
Disadvantages:
• Expensive and inflexible layout.
• Breakdown of any machinery in a line could disturb the whole system.
3. Fixed position layout:
In this kind of layout, the product remains stationary in a fixed location, where men and machine have to move
toward it which is desirable as the cost of moving them is lower than the cost of moving the product.
Advantages:
Men and machines can be utilised for numerous kinds of operations manufacturing different products.
The investment on layout is less.
The costs of transportation for a bulky product are avoided.

11. Principles of Plant Layout:
While designing the plant layout, the following principles must be kept in view:
1. Principle of Minimum Movement: Materials and labour should be moved over minimum distances; saving cost and
time of transportation and material handling.
2. Principle of Space Utilization: All available cubic space should be effectively utilized – both horizontally and vertically.
3. Principle of Flexibility: Layout should be flexible enough to be adaptable to changes required by expansion or
technological development.
4. Principle of Interdependence: Interdependent operations and processes should be located in close proximity to each
other; to minimize product travel.
Conclusion:
In competitive environment, productivity of the industrial unit has got ultimate importance. Efficient plant layout is one
of the effective tool to enhance the productivity. Most plant layouts are designed for initial conditions of the business.
However these layouts provide many bottlenecks during growth period. Hence as long as capacity grows, it has to adapt
the internal and external changes for which efficient relayout is necessary.

12. Ventilation and Humidification:
Abstract: Air conditioning in spinning of fiber has many benefit, that enhance profitability of process &
product. Properties like dimensions, tensile strength, elastic recovery, electrical resistance, rigidity etc. of all textile
fiber whether natural or synthetic are influenced by moisture regain, which controlled by conditioning of air in
mill.
There are not many occasions where humidity is more of an issue than during the processing of textile. Get it
wrong and it can stop productions, damage machinery and harm staff. Get it right and you can maximize product
weights, improve quality and increase machine speeds. The automatic air conditioning system used today is user
friendly as well as efficient. Due to this proper and unique control on process without any interruption of humans.
there fore newly developing mill gives prominence to automatic air conditioning plant. Last few years many
conditioning companies developing new technologies and system for textile industries.
INTRODUCTION:
Spinning of yarn from cotton and then weaving or knitting cloth from the yarn is known to mankind millennium.
Another factor is human comfort, if atmospheric condition in mill is comfortable to worker then it is easy to get
maximum efficiency from worker.
NEED OF RH% CONTROL IN SPINNING:
Correct ambient conditions are essential to prevent degradation of textile material during a series of operation
right from beating in blow room to weaving. Yarn should have requisite properties so that the final product retains
its basic shape, size & strength.

13. When Humidity is High:-
Fiber tends to stick and lead to formation of laps on rolls which disrupt production process. Removal of laps is not
only a manual and time consuming process, but result in damage of machine part , especially the rubber material
(apron, top roller etc.).
When Humidity Is Low :-
Fiber become brittle and store electric charges generated because of friction between the fiber during their spinning
process, which affect fiber properties and machine too.
Hence along with maintenance of stable RH% condition, recommended for textile and also to maintain the
temperature level within range.
GENERAL REASONS FOR RH% AND TEMPERATURE CONTROL:-
• Dry air causes low regain, yarn with low moisture content are weaker thinner, more brittle & less elastic and
prone to generate static charge.
• Material at optimum regain has controlled properties, lower imperfections, more uniform yarn.
• Higher humidity reduces static problems and machine can run at higher speed.
• Textile weight are standardized at 60% RH and 20degree C , low humidity causes lower material weight and less
profit.
• Humidification reduces fly and micro dust, giving a healthier and more comfortable working environment

14. General recommendations of temperatures for
spinning
Advantages of using air humidification in the textile industry:
• Reduces production downtime
• Increases productivity and product quality
• Protects against dangerous electrostatic discharge
• Creates a healthy and pleasant working environment for
operational staff
• Reduces operating costs through energy-efficient generation
of cooling capacity
Note: When it comes to cotton products, increasing the relative humidity by 10% (from 60% to 70%RH) raises the
material’s elasticity by more than 15% (Source: Institute of Textile Technology, USA, humidity level 60%)
Textile ventilation systems includes:
• Dust filtering and treatment of exhaust air, including recovery and reuse of fibres.
• Correct environmental humidity according to the fabrics manufactured.
• Necessary ambient temperature.
• Optimal speed and direction of airflow.
• Minimum investment costs.
• Reduced operating and maintenance costs achieving automatic production and
appropriate services.
• Central vacuum cleaning installation.

15. Sectors of action considered:
• For yarn spinning.
• For fabric production.
• ​Dust removal.
Conclusion:-
There are many different issued involved with humidification and Ventilation of textile plant and as above
described in discussions, getting it wrong can be an expensive mistake. So to control process, production, quality,
comfort conditioning of air is necessary, even though humidification plant consumes 15% of energy of total
spinning plant. That 15% cost can be overcome by improving quality and production of yarn. In proper
conditioning, it is to work and control the production. As above mentioned condition of RH% and temperatures for
that specific process gives good efficiency and less machine maintenance.

16. Lighting:
Abstract:
Mostly all tasks or activities of human being depend upon the light. Good lighting is essential to perform visual
tasks efficiently. Each activity in the textile industry requires some lighting level on the work table. Adequate
lighting is an important factor in ensuring product quality, enhanced productivity, proper and safe working.
INTRODUCTION:
Lighting is an essential requirement in textile industries as well as all other industries. Light is just one portion
of the various electromagnetic waves travels through space. These waves have both a length and a frequency,
the values of which distinguish light from other forms of energy on the electromagnetic spectrum.
Lighting can be classified in following three categories:
i. Accent lighting: This lighting is mainly decorative and used for interior design, landscaping or highlighting
pictures or plants.
ii. Task Lighting: This type of lighting is required for performing various activities such as: reading, writing,
production process or inspection.
iii. General lighting: General lighting or ambient light is fall in between above mentioned two lighting and is
used for general illumination of an area.
Characteristics of good lighting are as under:
• Light should be of adequate intensity for the particular job.
• It should be equally bright throughout the workshop.

17. Good illumination (Aadequate and balanced levels) in textile industry have following benefits:
• Increase production
• Enhance quality of product
• Protecting health, eyes and nervous system of workers.
SOURCE OF LIGHT :
In the textile industries, basically two lighting sources are available [1,9]:
A. Natural light (such as day light)
B. Artificial light (tube lights, lamps etc.).
A. Natural light Natural light is mostly used as the main source of light during daytime in various industrial
buildings. It is best for working and reduces the energy consumption, but it varies from time to time within the
day, within the year and in conditions of the weather (sunny or cloudy). It also varies with the size and positions
of windows and moreover it is just not possible to regulate the intensity of natural light.
B. Artificial light sources are based on the following principles:
a. High Temperature type: these are oil or gas lamps and incandescent filament type lamps emit light when heated
to high temperature.
b. Fluorescent type: When certain materials exposed to ultraviolet rays, transform the absorbed energy into
radiation of longer wavelength lying within the visible range. Fluorescent lamps and the mercury vapour lamps work
on this principle.

18. SOURCES OF ARTIFICIAL LIGHTING AND OTHER COMPONENT:
i. Incandescent lamps
ii. Tungsten--halogen lamps
iii. Fluorescent lamps (tube)
iv. Sodium vapor lamps
v. Mercury vapour lamps
vi. LED lamps
OPTIMISATION INDUSTRIAL LIGHTING: To achieve the economy, efficient light source, good reflectors, and clean, well-
maintained and appropriate visual backgrounds for walls, ceilings can be selected. For optimizing industrial lighting
requires consideration of work tasks, environmental conditions and economic aspects . Innovation in the field of
lighting, has given rise to tremendous energy saving opportunities
CONCLUSION:
Lighting is very essential requirement in textile industries. Inadequate lighting at place of work can create problem in
human health and affect in production and product quality. Poor light can be cause of accidents. On the other hand,
too much light ‘glare’ and dazzling light can also cause health and safety problems. Proper and adequate illuminations
required for each task/ job/process to enhanced productivity and product quality, reduce accident and ensure the
safety and security in the mill. In the market various types of lamps are available. According to specific requirement,
proper lamps, other component and number of fittings can be selected. To achieve maximum efficiency of illumination,
efficient light source, good reflector, clean well maintained walls and ceiling are required

19. Material Handling:
Abstract:
Textile mills are using a large number of machines and processes. During conversion of raw material to end product;
material moves from one department to other, one machine to other machine and from one floor to other. Day by
day, To achieve the target of production, the mill management is facing the challenge of safe, efficient and economical
material handling. In this paper it is tried to provide the required knowledge of material handling in reference to
textile mills.
INTRODUCTION:
Material handling can be defined as: “art and science of conveying, elevating, positioning, transporting, packaging and
storing of materials.Starting from the time, the raw material (such as fibres for spinning unit or yarns for weaving/
knitting unit and fabrics for wet processing or garmenting units) enters the mill gate and goes out of the mill gate in
the form of finished products; it is handled at all stages within mill boundaries such as within and between raw
material stores, various section of production department, machine to machine and finished product stores.
Proper material handling offers benefits for:
i. improving productivity
ii. increasing the handling capacity
iii. reducing man-power.

20. FUNCTIONS OF MATERIAL HANDLING SECTION:
There are basically two functions of material handling section:
1. To select production machinery and assist in plant layout so as to eliminate as far as possible the need of material
handling. For examples: in a spinning mills chute feed cards, open end spinning machine, auto-doffing ring frames and
autoconer etc. reduce the material handling activities hence material handling cost.
2. To choose most appropriate material handling equipment which is safe and can fulfill material handling
requirements at the minimum possible overall cost. For example: Air conveyor pipes in within the blow-room and
between blow-room and cards, big size plastic container trolley for handling ring frame bobbins, cones and fabrics in a
textile mill.
PRINCIPLES OF MATERIAL HANDLING:
In general, principles of material handling are as under:
i. Minimize the movements involved in a production process.
ii. Minimize the distance moved by adopting shortest routes.
iii. In order to speed up the material movements, employ mechanical aids in place of manual labour.
iv. For moving optimum number of pieces in one unit; use the principles of containerization, unit load or
palletization.
v. Appropriate, standard, efficient, effective, flexible, safe and proper sized material handling equipments should be
selected.
vi. In order to minimize back tracking and duplicate handling; change in sequence of production operations.

21. CONCLUSIONS:
Although in the market a large variety of material handling equipment available in which some are very conventional
and some are modern. Modern material handling equipments are economical, safer and can handle more material in
unit time than conventional equipments. The material handling department basically perform two functions:
eliminate the need of material handling as for as possible by choosing appropriate production machinery, and choose
most appropriate material handling equipment which is safe, efficient and economical. The selection of material
handling mainly depends upon: Type of material to be handled, mill building, layout, speed & type of production
(mass prodn or batch production) and material flow pattern. There are two most important factors for analyzing or
solving a material handling problem are : Engineering factors and Economic factors
Material handling in weaving units:

22. Thank You
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