Basics of Textiles | Research/ Review Paper | Textile Articles

Loom Down Time Reduction

Published: March 5, 2020
Author: TEXTILE VALUE CHAIN

Vilas Gharat

M.D. (Gharat & Associates.)

President (Textile Association India -Mumbai)

It has been observed that day by day Loom technology is improving at rapid speed resulting into very high-speed machines. There are many units installing such highspeed machines & unable to get desire production due to high machine down time.

Please find below Loom downtime analysis which has been carried out in one of modern weaving unit. The highest downtime is due to BEAM GAITTIG & hence I would like to present my paper on simple method of reduction of down time known as SMED.

What is S.M.D.

      It is known as SINGLE MINUTE EXCHANGE OF DIES & its Japanese technology developed by Mr. Shigeo Shingo. It is one of the lean methods for drastic reduction in changing time in production process.

It provides a rapid & efficient way of converting current product to next product in shortest time. It is “REVOLUTIONIZES BASIC CONCEPT OF ‘SET-UP CHANGE’.

Before explaining how it can be used in Beam Gaiting activities to reduce downtime, I would like to give you very common example of above method.

Generally, we require 5 to 10 mins to change car flat tire but in car race such as Formula One we observe all four tires & other activities are carried out by group of experts in few seconds. It is same method they are adopting known as SMED.

•  From the above it is very clear that we cannot afford to waste the time in a race. The operations are fast, tools are in its place and also man power

•        Replacing the Flat Tyre of Car

•        Find Jack, Tommy bar, spanner, in short tools.

•        Place & locate Jack below the car and lift the jack.

•        Loosen the nuts.

•        Remove the wheel

•        Bring another wheel

•        Locate & insert new wheel

•        Tighten the nuts.

•        Remove the jack & collect the tools.

•        Place it back in the car

•        Final tightening of the nuts

•        ABILITY TO DISTINGUISH: –

            It is very important to master the distinction between Internal & External activities. Please find chart of Internal & External activities of tire changing activities.

If you observe above chart you will notice that 50% activities are external which can be carried out earlier & kept ready to complete in actual changing time. The same method can be adopted in case of Beam Gaiting as mentioned below.

SMED FOR BEAM GAITING

     Please find below case study taken in one of modern textile unit having rapier looms with 20 shafts. Initially beam gaiting actual operations recorded in Video -noting step by step timings. Then the chart is prepared as mentioned below.

ACTIVITIES RECORDED OF FILM –

no. START END TOTAL activity
1 LOOM STOP
2     TENSION RELEASE/PKG REMOVAL/COVER OPENING
3       BEAM CUT/CLOTH WINDING/ TEMPLE LIFTING
4       REED REMOVAL
5       EMPTYING BEAM
6       BEAM UNLOADED
7       HEALD FRAME SUPPORT REMOVAL
8       REMOVING LENO AND MOUNTING ON STAND
9       TAKING AWAY EMPTY BEAM
10       TAKING OUT DROP PIN BARS
11       HEALD FRAME REMOVAL
12       SUCTION CLEANING STARTS
13       TAKING AWAYHEALD FRAME/ DROP PIN BAR AND REED
14       BRINGING CURTAIN
15       AIR CLEANING
16       WIDTH SETTING
17       FIXING REED PIECES
18       TAKING OUT OPENER
19       MAINTENANCE
20       SETTING TAPE GUIDE
21       REMOVING CURTAIN
22       MEASURING REED LENGTH / GREASING
23       TEMPLE PLATE SETTING / RAPIER HOOK FIXING
24       STROKE SETTING
25       CHECKING ALIGNMENT
26       BRINGING BEAM TROLLEY

27       BEAM LOADING STARTS
28       RAPIER FIXING(RH)
29       DROP-PIN FIXING  / COVER FIXING(RH RAPIER STROKE), FIXING BOTTOM H/F SUPPORT
30       ENDS STRAIGHTENING / TRANSFER TROLLEY OUT FROM LOOM
31       FIXING OF BEAM BARREL SUPPORT ROLLERS
32       PARALLELISING OF ENDS
33       BEAM LOCKED
34       REED FIXING
35       THREADING OF BEAM GAITING CLOTH
36       TYING OF KNOTS
37       HEALD FRAME TOP SUPPORT FIXING
38       PULLING OF WARP SHEET
39       RELOCKING OF BEAM
40       TEMPLE SETTING / THUMB ENDS FIXING / FEEDER THREADING
41       COVER FIXING (RH OPENER)/ BOTTOM H/F SUPPORT / SUCTION PIPE FIXING
42       MAIN MOTOR START / DESIGN FEEDING(PLAIN)
43       ENDS DRAWING STARTED
44       LOOM STARTED (PICKS INSERTED)
45       LENO FIXING (SPOOL)
46       LENO DEVICE FIXING
47       LENO SETTING
48       ENDS DRAWING STARTED IN HEALD WIRE
49       SPOOL ENDS DRAWING / DESIGN FEEDING / WEFT APPLIED AS PER PATTERN
 50       THREADING OF FALSE SEVEDGE
 51       MISSING HEALD WIRE FIXING
 52       LOOM STARTED / DROP PIN SUPPORT FIXING
 53       DOUBLE END AND PATTERN CHECKING (HEALD FRAME LIFTED IN SEQUENCE )
 54       LOOM STARTED
 55       CLOTH TORN
 56       WRONG DRAWN ATTENDED
 57       SAMPLE WORKED (FOR STOP MARKS )
 58       CONTRAST COLOUR SAMPLE WORKED
 59       LOOM  RUNNING IN
 60       SAMPLE CHECKING 0N SCREEN
 61       LOOM STARTED FOR PRODUCTION

Then all above activities are separated as Internal & External with time taken to complete those activities. The recorded film is shown in slow motion to team of loom shed beam gaiters’, fitters & supervisors. We had very long session of brain storming for how to carry out external activities in advance & execute at time of change in minimum time same as Formula 1 race video.

Finally, we carried out changes as per following chart & carried out following steps.

•        STEPS-1-PRESENT STATUS

•        VIDEO SHOOTING

•        STEP 2-

•        INTERNAL & EXTERNAL SET UP TIME

•        1. INTERNAL SET-UP.

•        THOSE ACTIVITIES WHICH NEED STOPPING THE EQUIPMENT,

•        LIKE, REMOVAL AND MOUNTING OF

•           BEAM.      

2. EXTERNAL SET-UP.

•        THOSE ACTIVITIES WHICH CAN BE CARRIED OUT WITHOUT STOPPING THE EQUIPMENT i.e. LOOM.

After conducting many trails, we could get following result with one-month summary. The earlier time for beam gaiting of 594 mins gradually reduced step by stem …

Step 1    594 Mins.

Step 2   269 Mins.

Step 3   112 Mins.

Final   49 Mins.

Saving 545 Mins. (9 Machine Hrs for every beam gating.)

SUMMARY

BEFORE AFTER
SR.NO AVG.TIME 594 45
       
1 INTERNAL ACTIVITY 60 22
       
2 EXTERNAL ACTIVITY 7 45
       
3 PARALLEL 30 47
       
  TIME 112 49

Hope you understood it clearly.  Please visit our website  www.gharatandassociates.com or send mail to  [email protected]  OR [email protected] in case of any inquiry.

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