1. INTERNSHIP PROJECT – SPINNING UNIT 2
To Study Moisture Add In Viscose From Winding To Packing
Submitted by :
Mr. Sandesh Mahaling Teli.
(Student of DKTE’s TEI, Ichalkaranji.)
Submitted to :
Mr. S. K. Nagar
(Production Head)
VARDHMAN FABRICS BUDNI
2. ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and
organizations. I would like to extend my sincere thanks to Management and Unit Head Mr. T.C Gupta
I am highly indebted to Mr. Shivesh Gupta(Sr. VP), Mr. S. K. Nagar(AVP), Mr. Gopesh Singh(Sr. Manager), Supportive Staff and Mr. Vinod
Chourey (VP HR) for their guidance and constant supervision as well as for providing necessary information regarding the project & also for
their support in completing the project.
I would like to express my gratitude towards my parents & member of VARDHMAN FABRICS BUDNI for their kind co-operation and
encouragement which help me in completion of this project.
I would like to express my special gratitude and thanks to Organization for giving me such attention and time.
My thanks and appreciations also go to my colleague in developing the project and people who have willingly helped me out with their
abilities.
4. GENERAL INFORMATION ABOUT ‘RING SPINNING 2’
Production Capacity 34 Tons/Day
Average Count 29s
Total Spindle 55008
Spindle in PC Section 26208
Spindle in Cotton Section 28800
Utilization of Ring Frame 99%
No. of Spindle per Ring Frame in
Cotton Section
1440
No. of Spindle per Ring Frame in PC
Section
1248
Types of Fibres :
Mech 1 – Maharashtra, S6 – Gujrat
1.2D*38mm Semi-dull Polyester – Reliance
1.4D*38mm Semi-dull Polyester – Reliance
1.4D*38mm Optical White Polyester – Bombay
Dyeing
1.4D*38mm Optical White Polyester – Safar
Recycle
1.4D*38mm Optical White Polyester – (Recycle
fibre) – Reprave
1.2D*38mm Viscose – Birla Cellulose
5. MOISTURE ADD IN VISCOSE FROM WINDING TO PACKING
• CASE STUDY : 1
12 hours of preconditioning with one humidex and 6-8 hours of conditioning with 3 humidex.
Date 22/06/2022
Time 3:50 PM – 9:50
AM
Product Viscose
Lot no. V09
No. of trollies 1
Count 30 RYWC
9. • CASE STUDY : 2
12 hours of preconditioning with one humidex and one additional spray with cooler and 6-8 hours of
conditioning with 3 humidex.
Date 24/06/2022
Time 2:05 PM – 10:05
AM
Product Viscose
Lot no. V10
No. of trollies 1
Count 30 RYWC
13. • CASE STUDY : 3
12 hours of preconditioning with one humidex and one additional spray at top with two coolers and 6-8
conditioning with 3 humidex.
Date 24/06/2022
Time 10:30 AM – 6:30
AM
Product Viscose
Lot no. V10
No. of trollies 1
Count 30 RYWC
16. OVERALL SUMMERY
Stage Gram Percentage
Pre-condition moisture
add
37.5 1.589
Condition moisture add 34.75 1.45
Total moisture add 72.25 3.062
• Additional spray causes wetting of paper cone and water marks.
17. • CASE STUDY : 4
12 hours of preconditioning with one humidex with two coolers and 6-8 hours of conditioning with 3
and humid/cool outer atmosphere.
Date 07/07/2022
Time 10:15 AM – 8:15
AM
Product Viscose
Lot no. V10
No. of trollies 3
Count 30 RYWC
21. • CASE STUDY : 5
12 hours of preconditioning with one humidex with one cooler and 6-8 hours of conditioning with 3
and humid/cool outer atmosphere.
Date 11/07/2022
Time 10:15 AM – 8:15
AM
Product Viscose
Lot no. V01
No. of trollies 1
Count 27 RYWC
25. OVERALL SUMMERY
Stages
Moisture add (%)
Case 1 Case 2 Case 3 Case 4 Case 5
Pre-condition moisture
add
1.1684 1.4571 1.589 1.7389 1.44
Condition moisture add 0.56 0.99 1.45 1.85 1.89
Total moisture add 1.7299 2.4471 3.062 3.62 3.35
26. IMPROVEMENT SCOPE
To have a compact pre-conditioning room to have better moisture.
To cover the package core to avoid the wetting of cone.
To place cooler behind the humidex and not against the humidex.
27. IMPROVEMENT SCOPE
Avoid single trolly in front of humidex and spray (if used) for a long time to avoid water marks.
To reduce the height of humidex to 75% of trolly height and to expose the trolly lengthwise to have even
moisture.
To change the angle of humidex.
28. EFFICIENCY LOSSES ON WINDING MACHINE
• OBSERVATION NO : 1
• Observations : Sr. no. Parameters Time Attempts
1 Acceleration Loss 6 seconds 118
2 Doffing Loss 18 seconds 0
3 Cycle
Loss(Splicing)
7.5
seconds
66
4 Bobbin Change
Loss
9 seconds 54
Date 06/07/2022
Time 2:55 PM – 4:55
PM
Product Viscose
Machine No. 6
Drum No. 4
Count 30 RYWC
29. Parameters Cycle loss Bobbin Change Red Lights Bobbin waiting Alarm Machine Stops Total loss
Time(seconds
)
495 486 0 478 0 179 1638
1. Spindle Efficiency : 81.46%
A)Cycle loss =
(354+495+486)
7200
× 100
= 18.54%
B)Red Light loss =
0
7200
× 100
= 0%
2. System Efficiency : 82.99%
A)Doffing Loss =
750
7200
× 100
= 10.41 %
B)Alarm Loss =
0
7200
× 100
= 0%
C)Bobbin Waiting =
478
7200
× 100
= 6.6%
3. Machine Efficiency : 97.5%
A) Bobbin End =
129
7200
× 100
= 1.78%
B) Suction =
50
7200
× 100
= 0.7%
30. • Actual and Calculated Efficiencies :
Efficiency Actual Calculated
Spindle 82.1% 81.46%
System 84% 82.99%
Machine 97.6% 97.5%
Total 67.3% 65.9%
36. EFFICIENCY LOSSES ON WINDING MACHINE
• OBSERVATION NO : 3
• Observations : Sr. no. Parameters Time Attempts
1 Acceleration Loss 6 seconds 142
2 Doffing Loss 18 seconds 1
3 Cycle
Loss(Splicing)
7.5
seconds
112
4 Bobbin Change
Loss
9 seconds 53
Date 11/07/2022
Time 2:32 PM –
4:32PM
Product Viscose
Machine No. 6
Drum No. 4
Count 30 RYWC
37. Parameters Cycle loss Bobbin Change Red Lights Bobbin waiting Alarm Machine Stops Total loss
Time(seconds
)
840 477 95 26 0 845 2283
1. Spindle Efficiency : 74.48%
A)Cycle loss =
(426+477+840)
7200
× 100
= 24.20%
B)Red Light loss =
95
7200
× 100
= 1.319%
2. System Efficiency : 99.39%
A)Doffing Loss =
18
7200
× 100
= 0.25%
B)Alarm Loss =
0
7200
× 100
= 0%
C)Bobbin Waiting =
26
7200
× 100
= 0.36%
3. Machine Efficiency : 88.26%
A) Bobbin End =
845
7200
× 100
= 11.74%
38. • Actual and Calculated Efficiencies :
Efficiency Actual Calculated
Spindle 74.5% 74.48%
System 99.4% 99.39%
Machine 88.4% 88.26%
Total 65.46% 65.34%
40. EFFICIENCY LOSSES ON WINDING MACHINE
• OBSERVATION NO : 4
• Observations : Sr. no. Parameters Time Attempts
1 Acceleration Loss 6 seconds 153
2 Doffing Loss 18 seconds 1
3 Cycle
Loss(Splicing)
7.5
seconds
144
4 Bobbin Change
Loss
9 seconds 47
Date 13/07/2022
Time 2:30 PM – 4:30
PM
Product Viscose
Machine No. 6
Drum No. 4
Count 30 RYWC
41. Parameters Cycle loss Bobbin Change Red Lights Bobbin waiting Alarm Machine Stops Total loss
Time(seconds
)
1080 423 788 588 0 256 3135
1. Spindle Efficiency : 61.81%
A)Cycle loss =
(1080+423+459)
7200
× 100
= 27.25%
B)Red Light loss =
788
7200
× 100
= 10.94%
2. System Efficiency : 91.54%
A)Doffing Loss =
18
7200
× 100
= 0.3%
B)Alarm Loss =
0
7200
× 100
= 0%
C)Bobbin Waiting =
588
7200
× 100
= 8.16%
3. Machine Efficiency : 96.45%
A) Bobbin End =
220
7200
× 100
= 3.05%
B) Mast =
36
7200
× 100
= 0.5%
42. • Actual and Calculated Efficiencies :
Efficiency Actual Calculated
Spindle 61.2% 61.81%
System 91.1% 91.54%
Machine 97% 96.45%
Total 54.08% 54.57%
• More loss is due to false working of
splicer.
44. EFFICIENCY LOSSES ON WINDING MACHINE
• OBSERVATION NO : 5
• Observations : Sr. no. Parameters Time Attempts
1 Acceleration Loss 6 seconds 117
2 Doffing Loss 54 seconds 1
3 Cycle
Loss(Splicing)
7.5
seconds
100
4 Bobbin Change
Loss
9 seconds 62
Date 14/07/2022
Time 2:32 PM – 4:32
PM
Product Viscose
Machine No. 6
Drum No. 4
Count 30 RYWC
45. Parameters Cycle loss Bobbin Change Red Lights Bobbin waiting Alarm Machine Stops Total loss
Time(seconds
)
750 558 0 247 405 102 2062
1. Spindle Efficiency : 76.96%
A)Cycle loss =
(750+558+351)
7200
× 100
= 23.04%
B)Red Light loss =
0
7200
× 100
= 0%
2. System Efficiency : 90.14%
A)Doffing Loss =
54
7200
× 100
= 0.8%
B)Alarm Loss =
405
7200
× 100
= 5.63%
C)Bobbin Waiting =
247
7200
× 100
= 3.43%
3. Machine Efficiency : 98.58%
A) Bobbin End =
102
7200
× 100
=1.42%
46. • Actual and Calculated Efficiencies :
Efficiency Actual Calculated
Spindle 77.6% 76.96%
System 90.3% 90.14%
Machine 98.7% 98.58%
Total 69.16% 68.39%
49. IMPROVEMENT SCOPE
To asses the workers performance for their workload.
Machines should be checked in schedule for defective working drums for especially splicers.
Manual doffing should be avoided which can lead to two advantages:
Worker’s time can be devoted more in other operation.
Doffing loss will be reduced.
