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Manufacturing Excellence in Spinning Mills [Kõva köide]

(WINSYS SMC, Coimbatore, India)
  • Formaat: Hardback, 184 pages, kõrgus x laius: 229x152 mm, kaal: 453 g, 68 Tables, black and white; 11 Line drawings, black and white; 11 Illustrations, black and white
  • Ilmumisaeg: 20-Apr-2022
  • Kirjastus: CRC Press
  • ISBN-10: 1032191007
  • ISBN-13: 9781032191003
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  • Kõva köide
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  • Tavahind: 171,75 €
  • Säästad 25%
  • Raamatu kohalejõudmiseks kirjastusest kulub orienteeruvalt 3-4 nädalat
  • Kogus:
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  • Tellimisaeg 2-4 nädalat
  • Lisa soovinimekirja
  • Raamatukogudele
Manufacturing Excellence in Spinning MillsSuurem pilt
  • Formaat: Hardback, 184 pages, kõrgus x laius: 229x152 mm, kaal: 453 g, 68 Tables, black and white; 11 Line drawings, black and white; 11 Illustrations, black and white
  • Ilmumisaeg: 20-Apr-2022
  • Kirjastus: CRC Press
  • ISBN-10: 1032191007
  • ISBN-13: 9781032191003
Teised raamatud teemal:
Teised raamatud sellest sooduspakkumisest: Kevadine sooduspakkumine - kuni 31. maini üle miljoni raamatu kuni 25% soodsamalt
Püsilink: https://www.kriso.ee/db/9781032191003.html
Märksõnad:
"Manufacturing towards excellence in spinning mills aims to help the relevant organization to cut costs, improve throughput, effective utilization of resources and to safeguard the interests of stakeholders. Major aspects discussed includes quality assurance, production management, maintenance management of modern machinery and laboratory equipment towards achieving manufacturing excellence with benchmarking and industry norms. Relevant case studies are provided with dedicated chapters on training and development of employees, energy management and customer focus. Explains industry norms to benchmark any spinning mill against the manufacturing performance parameters. Includes: failure mode and effect analysis and total productive maintenance aspects, explores training and development standards in spinning mills, and discusses energy management and customer focus through effective techniques. Reviews SPDM, PDM Tools, Contamination index, Spin plan, Customer Satisfaction Index, Co-Creation, and HPT. This book is aimed at professionals and researchers in textile engineering and management"--

This book discusses quality assurance, production mngt., maintenance management of modern machinery and laboratory equipment towards achieving manufacturing excellence with benchmarking and industry norms in spinning mills. Case studies are provided with chapters on training and development of employees, energy management &customer focus.
Foreword xv
Preface xvii
Acknowledgments xxi
About the Author xxiii
1 Quality and Process Management in a Spinning Mill
1(72)
Learning Goals
1(1)
Introduction
1(1)
1.1 Spinning Mills-Flow Chart of Operations
2(2)
1.2 Quality of Incoming Raw Material (Cotton)
4(2)
1.3 Mixing Quality
6(2)
1.4 In-process Quality
8(18)
1.4.1 Blow Room
8(2)
1.4.2 Cards
10(1)
1.4.3 Pre-comber Draw Frames and Lap Formers
11(1)
1.4.4 Combers
12(2)
1.4.5 Finisher Draw Frames
14(1)
1.4.6 Speed Frames
15(2)
1.4.7 Ring Frames
17(4)
1.4.8 Ring Frames with Compact System
21(1)
1.4.9 Autoconers
22(1)
1.4.9.1 Electronic Yarn Clearers (EYC) in Autoconers
23(1)
1.4.10 Yarn Conditioning
24(1)
1.4.11 Packing
24(1)
1.4.12 Assembly Winding and Two For One Twister
25(1)
1.5 Classimat faults
26(1)
1.6 Package Defects - end Use Performance
26(1)
1.7 Process and Quality Audits
26(1)
1.8 Application of Statistical Techniques in Spinning mills
27(6)
1.9 Quality control Equipments in a Spinning mill
33(6)
1.9.1 Fiber testing equipments
33(1)
1.9.2 In-process materials testing equipments
34(4)
1.9.3 Final yarn testing equipments
38(1)
1.10 Final Lot inspection of products
39(1)
1.11 Key Performance Parameters (Quality) in each department
40(33)
CS1 Case study on "Higher level of End breaks in 40s Combed Compact Warp yarn"
41(1)
CS2 Case study on "Higher Unevenness in Finisher Draw frame sliver"
42(1)
CS3 Case study on "Increase of Clearer cuts in Autoconer in 60s Combed Compact Weaving yarn"
42(1)
CS4 Case study on "Increase in Foreign fiber (FD) cuts in Autoconers"
43(1)
CS5 Case study on "Increase of Yarn Count CV in 40s Combed Hosiery Yarn during Final Lot Inspection"
44(1)
Annexure I Quality Control Department Organogram for a Spinning Mill with 50000 Spindles
45(1)
Annexure II Model Quality Control schedule for Mills striving for excellence in Manufacturing
45(3)
Annexure III Estimation of Contamination Index in Raw Material
48(3)
Annexure IVA Evolution of Clearers
51(1)
Annexure IVB Classimat faults
52(2)
Annexure V Package defects
54(10)
Annexure VI Process Audit Format
64(2)
Annexure VII Quality Audit Format
66(2)
Annexure VIII Final Inspection Lot Report Model Format
68(5)
2 Maintenance Management in Spinning mills
73(34)
Learning Goals
73(1)
Introduction
73(1)
2.1 Types of Maintenance
74(1)
2.2 Breakdown Maintenance-First Generation Maintenance
74(1)
2.3 Planned Maintenance-Second Generation Maintenance
74(4)
2.3.1 Routine Maintenance
75(1)
2.3.2 Lubrication
76(1)
2.3.3 Replacement programme
76(2)
2.4 Preventive Maintenance
78(1)
2.5 Systems to enhance Maintenance of Assets/Machinery in Spinning mills
79(9)
2.5.1 5S System for shop-floor excellence
80(2)
2.5.2 FMEA-Failure Mode Effect Analysis
82(1)
2.5.3 TPM-Total Productive Maintenance
83(1)
2.5.3.1 Origin of TPM
83(1)
2.5.3.2 TPM implementation
84(3)
2.5.3.3 ZDQC-Zero Defect Quality Control
87(1)
2.5.3.4 Jidoka
88(1)
2.6 Predictive Maintenance-Third Generation Maintenance
88(4)
2.6.1 Smart predictive maintenance-SPDM (Third Generation Maintenance Extension)
90(2)
2.7 Smart Prescriptive Maintenance Framework-SPMF (Fourth Generation Maintenance)
92(15)
CS6 Case study on "Impact of Buffing Accuracy on Yarn Quality"
93(1)
CS7 Case Study on "Impact of Air leakage on Mis-splicing % in Autoconers"
94(1)
CS8 Case Study on "Process FMEA on Weak places in 80s Combed Compact Warp yarn"
94(1)
CS9 Case Study on "Impact of 5S implementation in a Spinning mill"
95(1)
CS10 Case Study on "Design FMEA in a Spinning mill"
96(1)
CS11 Case Study on "QAD-Maintenance interface"
97(1)
CS12 Case Study on "MTTR-Mean Time To Repair (TPM)"
98(1)
Annexure IXA Model Check list for effective Machinery Maintenance Audit-Online
99(3)
Annexure IXB Model Check list for effective Machinery Maintenance Audit-Offline
102(1)
Annexure X TPM Organogram
103(1)
Annexure XI TPM Gap Analysis Audit format
104(3)
3 Production Management in Spinning Mills
107(36)
Learning Goals
107(1)
Introduction
107(1)
3.1 Utilization Efficiency
108(2)
3.2 Production Efficiency
110(3)
3.3 Benchmarking
113(2)
3.4 Yarn Realization
115(5)
3.4.1 Invisible loss
117(1)
3.4.2 Best practices to achieve higher and consistent Yarn Realization & control on Saleable waste
118(1)
3.4.3 Measures to achieve Standard Yarn realization
119(1)
3.5 Manufacturing of Sustainable products
120(1)
3.6 Manufacturing of Value-added yarns
121(1)
3.7 Automation in Spinning Mills
122(21)
3.7.1 Automation towards Yarn Quality improvements
122(1)
3.7.2 Automation toward Production improvement
123(1)
3.7.3 Automation toward improving labor productivity
124(3)
CS13 Case Study on "Spindle point production improvement in 80s Combed Compact Weaving"
127(1)
CS14 Case Study on "Impact of Short Stretch in Compact Spinning Ring frame"
128(2)
CS15 Case Study on "Improvement of Spindle point production with Slim Tubes"
130(1)
CS16 Case Study on "Utilization Efficiency Improvement"
130(2)
CS17 Case Study on "Yarn Realization improvement"
132(1)
Annexure XIIA Model Spin plan
133(5)
Annexure XIIB Production formulae used in Spin plan
138(1)
Annexure XIII Model Mill Standard Document for Spindle Point Production in Grams /Spindle/8 Hours
139(1)
Annexure XIV Model Chart for Estimation of Yarn Realization
140(1)
Annexure XV Model Chart for Zone-wise Waste analysis for Cards
140(3)
4 Training and Development
143(14)
Learning Goals
143(1)
Introduction
143(1)
4.1 Definition of Training
143(1)
4.2 Chronology of the development of T&D
144(1)
4.3 Scope of training and development
145(2)
4.3.1 Development of employees by Human resource department
145(1)
4.3.2 Mechanisms for successful training and development system
146(1)
4.4 Management Development Programme
147(3)
4.4.1 Objectives of the Management Development programme
147(3)
4.5 HPT-Human Performance Technology
150(7)
CS18 Case Study on "Improvement in work assignment in Ring frame Through Re-training"
151(2)
CS19 Case Study on "Improvement in work Assignment in Autoconer department through Retraining"
153(2)
Annexure XVI Standards for Training period and Evaluation Measures
155(2)
5 Energy Management
157(18)
Learning Goals
157(1)
Introduction
157(1)
5.1 Power consumption in a Spinning mill
158(1)
5.2 Power consumption-Industry norms for Spinning mills
159(1)
5.3 Innovative projects for energy conservation
160(2)
5.4 Measures to reduce energy consumption in Compressors
162(2)
5.5 Power Quality-Harmonics
164(1)
5.5.1 Sources of Harmonics
164(1)
5.5.2 Effects of Harmonics
164(1)
5.5.3 Selection of Harmonic Filter
164(1)
5.6 Energy Audit
165(1)
5.7 Rewinding of Motors
166(1)
5.8 Energy Efficient Motors
166(2)
5.9 Renewable Energy
168(7)
CS20 Case Study on "Incorporation of MD Controllers"
169(1)
CS21 Case Study on "Energy Savings in AWES-Automatic Waste Evacuation System"
170(1)
CS22 Case Study on "Inverter control for Pneumafil in Ring frame"
170(2)
Annexure XVII Model chart for Standard Power consumption in a Spinning Mill with . 50400 spindles
172(1)
Annexure XVIII Test Procedure for Assessment of Rewound Motors
173(2)
6 Customer Focus
175(12)
Learning Goals
175(1)
Introduction
175(1)
6.1 Types of Customers of Spinning Mills
175(3)
6.1.1 Knitters
176(1)
6.1.2 Weavers
176(1)
6.1.3 Value addition customers like Double yarn/Plied yarn/Gassed yarn manufacturers
177(1)
6.1.4 Industrial Thread Manufacturers like Cotton sewing threads/Tyre cord fabric Manufacturers
178(1)
6.2 Customer Satisfaction
178(1)
6.3 Co-Creation
179(1)
6.4 Taylor-Made products
180(7)
CS23 Case Study on "Customer Service Environment-Take the Initiative"
180(1)
CS24 Case Study on "Customer Service Environment - Customer Service Horror Story"
181(1)
CS25 Case Study on "Customer Service Environment - `Do more than the Competition'"
182(1)
Annexure XIX Model format for Customer Satisfaction Audit
183(2)
Annexure XX Estimation of Customer Satisfaction Index
185(2)
7 Industry 4.0
187(12)
Learning Goals
187(1)
Introduction
187(1)
7.1 Industry 4.0-what does it bring to us?
187(1)
7.2 Evolution of the Industry 4.0
188(1)
7.3 Goals of the Industry 4.0
189(5)
7.4 Smart Manufacturing Spinners
194(5)
Annexure XXI Smart Manufacturing Spinners (Industry 4.0) Configuration
195(2)
Annexure XXII Payback estimation-Factors to be considered for Installation of Individual Spindle monitoring system
197(2)
List of Tables 199(2)
List of Case Studies 201(1)
List of Annexure 202(1)
References 203(2)
Index 205
A.Kanthimathinathan, is a Management Consultant for the Spinning Mills through his own outfit WINSYS SMC, operating from Coimbatore,India. He is a post graduate from in Textile Technology from PSG College of Technology, Coimbatore and later acquired PG Diploma in Personnel Management and Industrial Relations from NIPM, Calcutta. He has 42 years of experience in reputed Spinning mills and in a Research Association. He has more than thirty technical papers published in Industry and Research journals. One of the book, co-authored by him , won the `Best Book Award` from Textile Association of India. He is also one of the recipient of NRDC(National Research Development Council) Award for a joint contribution towards an UNDP sponsored project. He contributed for nine patents for product development while serving at SITRA (The South India Textile Research Association, Coimbatore). He had been deputed to Leeds University, UK and Clemson University, USA by SITRA on an UNDP sponsored project to study and acquire knowledge from academic experts . He had visited many mills in India and few mills abroad on technical consultancy visits through SITRA as well as his through his own Consultancy organization. He shared his technical knowledge through various platforms like National level textile Conferences, Seminars conducted by Research Associations, Textile Associations and Academic institutions etc. As a CEO, WINSYS SMC, he has conducted several technical seminars across India for the benefit of professionals serving in textile industries.