TERM PAPER OF Operation MANAGEMENT

TOPIC To study the production planning and control in textile industry

Submitted to: Lect. Sanjay Jindal Kaur SEM)

Submitted by: Jeewanjot MBA-433 (3rd RS1906A01 10902959

ACKNOWLEDGEMENT:-

I would like to thank all those who have encouraged me to complete this term paper on the topic "study of production planning & control in textile industry". I am grateful to Mr. Sanjay Jindal who acted as a source of inspiration in making the term project. I will never forget his support and words of wisdom. I am also thankful to Lovely Professional University in providing me the resources which helped me to complete this project.

TABLE OF CONTENTS.
1. ABSTRACT
2.

INTRODUCTION OF TEXTILE INDUSTRY.

COMBING. SPINNING WEAVING DYEING

3. PRODUCTION IN TEXTILE INDUSTRY

4. CONTROL 5. QUALITY CHECK 6. CONCLUSION. 7. REFERENCE

Abstract:
This term paper is to study of production planning and control in textile industry . Because of the special characteristics of the industry, that is mainly the multiphase process with multiple units per phase, different planning horizons and different production requirements for each phase, the scheduling of these systems becomes quite complex. Apart from a comprehensive presentation of the set of the modules the system is composed of, together with their interrelationships, the above characteristics are analyzed, and their impact on the production control system is explained. The industry has been developed following both vertical integration, particularly among spinning and weaving firms, and horizontal integration, promoted by the idea that a full line of textile products is necessary for effective marketing .

Indian Textile Industry

The textile industry is the largest industry of modern India. It accounts for over 20 percent of industrial production and is closely linked with the agricultural and rural economy. It is the single largest employer in the industrial sector employing about 38 million people. If employment in allied sectors like ginning, agriculture, pressing, cotton trade, jute, etc. are added then the total employment is estimated at 93 million. The net foreign exchange earnings in this sector are one of the highest and, together with carpet and handicrafts, account for over 37 percent of total export earnings at over US $ 10 billion. Textiles, alone, account for about 25 percent of Indias total forex earnings.

Indias textile industry since its beginning continues to be predominantly cotton based with about 65 percent of fabric consumption in the country being accounted for by cotton. The industry is highly localised in Ahmedabad and Bombay in the western part of the country though other centres exist including Kanpur, Calcutta, Indore, Coimbatore, and Sholapur. The structure of the textile industry is extremely complex with the modern, sophisticated and highly mechanised mill sector on the one hand and the handspinning and handweaving (handloom) sector on the other. Between the two falls the small-scale powerloom sector. The latter two are together known as the decentralised sector. Over the years, the government has granted a whole range of concessions to the non-mill sector as a result of which the share of the decentralised sector has increased considerably in the total production. Of the two sub-sectors of the decentralised sector, the powerloom sector has shown the faster rate of growth. In the production of fabrics the decentralised sector accounts for roughly 94 percent while the mill sector has a share of only 6 percent. 5

Being an agro-based industry the production of raw material varies from year to year depending on weather and rainfall conditions. fluctuates too. PRODUCTION SYSTEM OF TEXTILE INDUSTRY The Production System of any textile company is divided into mainly four division viz. Combing, Spinning, Weaving & Dyeing
COMBING DEPARTMENT

Accordingly the price

SPINNING DEPARTMENT PRODUCTIO N SYSTEM

DYEING DEPARTMEN T WEAVING DEPARTMENT

COMBING DEPARTMENT

In the Combing Department, the process starts with the Greasy wool which is more furnished and tends to convert into tops which is taken to Dyeing department. This process is diagrammatically explained below.
WOOL

SCOURING

DRYING

OILING

GILLING

COMBING

WOOL TOPS

TOP DYEING

RAW MATERIAL WOOL The processing of wool involves four major steps. First comes shearing, followed by sorting and grading, making yarn and lastly, making fabric. The wool used in making suiting in mainly imported from different countries like New Zealand, South Africa and major wool is imported from Australia (90%). In the suiting process Marino Wool is used at a very large extent. It originated from Spain and it was declared a priced possession by the Spain that it was a capital offense to export wool. Marino sheep produces the best wool. The staple is relatively short ranging from 1 to 5 but fiber is strong. The wool is tested before export by Australian Wool Testing Authority (AWTA). Characteristics: Natural, Animal Fiber Comfortable Versatile Lightweight Good insulator Washable Wrinkle-resistant Absorbent Easy to dye

Wool Quality Check

Length Average Length

: 50-70mm : 60 mm

Fineness Average Fineness Crease Content Vegetable Matter Moisture Bale Weight Bale Size CAMEL HAIR

: 17.5-24.5 microns : 21 microns : 12.37% : 1-2% : 16-18% : 450 Kgs Approx : 56 by 30 by 30.

Camel hair fabrics can be said as an ideal comfort, particularly when used for suiting fabrication, as they are especially warm but light in weight. Strength, luster and smoothness characterize camel hair. The best quality is expensive when used alone so it is often mixed with wool, thus raising the quality of the wool fabric by adding the fine qualities of camel hair. In some fabrics, which tend to be of high quality have 100% camel hair other than that it is mixed to be in an affordable price.

MOHAIR Mohair is the hair of an Angora goat, which used to be native of Angora where it got its name but now it is found in abundant is South Africa and the United States mainly in California and Texas. The Texas mohair is regarded as an excellent quality raw material. Its a long staple, 9-12 inch [230-300mm] long and represents a full years growth . The domestic fiber has a goat amount to coarse, stiff hair, known as Kemp which does not process readily or allow through penetration of dye. Mohair is a smooth, strong and resilient fiber. It does not attract or hold dirt particulars and tends to absorbs dye evenly and permanently.

Its used in giving fine decoration. Mohair fiber is more uniform in diameter than wool fiber. They are wrinkle resistant and is stronger that wool of other fibers.

CASHMERE The Cashmere goat has originated from the great Himalayas mountains region of Kashmir in India, Mongolia and china. The fleece of this goat has long, straight, coarse outer hair of little value, however, the small quantity of under hair or down is made into luxuriously soft wool like yarns with the characteristics highly napped one of its characteristics is that it is not sheared from the goat but is obtained by frequent combings during the shedding season. It has all the qualities of mohair and is used as an add-on with mohair hair.

SILK Silk is the very fine strand of fiber. It is a solidified Protein secretion produced by certain caterpillars to encase themselves in the form of cocoons, silk and wool is usually blended on a worsted system, producing a fine, tong yarn. It is one of the important materials used in the process. The fabric may have a soft sheen. They are light weighing, resilient, durable and drape well, silk wool blends are used for such apparel as suits, particularly summer weights. Silk provides strength and absorbency. Silk reduces weight and adds good hand.

MAN-MADE FIBRES USED:

VISCOSE RAYON A rayon fiber is composed of pure cellulose, the substance of which the cell walls of such woody plants as trees and cotton are largely comprised. We are more familiar with cellulose in the form of such product as paper.

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Rayon fibers are made from cellulose that has been reformed, or regenerated; consequently, these fibers are identified as regenerated cellulose fibers.

POLYESTER Polyesters are made from chemical substances found mainly in petroleum. Polyester fibers are strong, tough materials that are manufactured in a variety of colors, shapes and sizes. They are mixed with wool to make the fabric more cost effective. They are found mainly in 2 categories
Normal Polyester: The variety of polyester has good tenacity and moderate

luster
Low Pill Polyester: Due to its low tenacity this variety show lower pilling

tendency in fabrics

SORTING Sorting can be defined as dividing the fleeces of wool manually into various qualities according to the process requirement. Sorting divides the fleeces of wool into various mixtures on the basis of the fineness of length. Earlier the sorting operation was done in some company only. But now the bales that are imported are sorted already and the sorting department is eliminated permanently. The bale number, weight of bale, quality is written on the bale cover and when bales are come they are weigh and taken to store in the scouring department and storage. So the bales are now directly fed to scouring (wool washing) machines. SCOURING

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The principles underlying the scouring of wool or other material is purifying substance under the conditions employed with a minimum harmful effect on the textile material. Wool scouring is the process of washing wool in alkaline solution, soda mixture and hot water to remove the non-wool contaminants and then drying it. It has always been an important step in the wool processing train. A growing concern for the environment has led to increased demands on the scouring process. Pollution load associated with conventional emulsion scouring of greasy wool is extremely high entanglement or felting results in fiber breakage during carding, gilling, and combing and has two bad effects: it reduces the mean fiber length in the resultant top and decreases the combing tear or the ratio of top to noel. The tanks are allocated in such a position that the procedure is done on an automatic base and are allocated on a permissible distance and attached to each other. The first tank consists of soda mixture and alkaline solution the other two tanks preceding the first tank are of detergent. Silvotex A is mainly used in the procedure. Here the wool is cleaned intensively to reduce the maximum amount of impurities present in the wool. The last two tanks are extensively used for rinsing, in this procedure the detergent used in the previous tank is washed away and the wool tends to float above the water. During the process the wool tends to turn whiter and whiter while the impurities are separated.

DRYING After the scouring process is done the drying process comes into phase here the rinsed wool tends to dry but is not allowed to become absolutely dry. Usually about 12 to 16% of the moisture is left in the wool to condition it for subsequent handling. On an overall there are 8 dryers to do the process. One subsequent process takes around 12 minutes.

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BLOCK DIAGRAM OF WOOL WASHING MACHINE TANK NO.: I V

FEEDIN G UNIT BALE I Soda Ash

II DET

III DET

IV Wate r

V Wate r

Drye r

Delivery

SODA ASH-REMOVES OIL AND SUINT DET-DUST, DIRT, FOREIGN MATTER, SAND WATER-RINSING AND REMOVAL OF DET

Technical Inputs
Efficiency of the machine tends to differ anywhere from 40%-80%. Production around 400 - 450 kgs/hr. Dirty water drainage is after every 15 mins. Maximum capacity around 6000lts. Water Temperature around 55 to 60 C. Dryer Temperature around 85 to 110 c Impurities removed around 25% to 28% Moisture Content removed around 25% to 30%

OILING As wool is unmanageable after scouring, the fiber is usually treated with various oils such as 60% wool oil and 40% antistatic agent to keep it from becoming brittle and to lubricate for spinning operation. As for these process is very important oiling tends to help the fiber from not becoming hard or else it tends to break faster.

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CARDING Once wool has been scoured, it will have been carded before it can be spun into yarn. Carding is a process that passes the wool through a series of rollers covered with fine bristles or fine wire teeth. This process is to remove impurities such as burr, vegetable matters, dust, dirt (heavier than wool), to enable blending of various fibres and evening it out and to convert random bulk of fibres into rope like form called a sliver. It separates the wool out from tangles, clumps and staples and lays the fibers parallel and formed into a fine web. Sliver wrapping is checked after every 2 hrs. This process is mainly done resulting to the following: Opening of flocks to individual fibres Elimination of remaining impurities (trash particles) Elimination of short fibres Untangling the fiber Dust removal High degree of longitudinal orientation of the fibres

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GILLING Gilling has three main functions: It aligns the fibres approximately parallel in the sliver; It thins down a thick sliver so that it can be handled in a spinning frame; and, It blends the wool by combining several slivers into a single one.

Gilling is mainly done to paralyze the fibre so that the fiber tends to become more thinner. As of this process the weight reduction occurs in the sliver. A needle tends to penetrates through material it paralyses the material and the material becomes parallel its done 5 times to remove knots. There are several types of gill box. However, very simply, a gill box has two sets of rollers and the slivers are dragged from one to another through a series of moving combs. The feed rollers pick up the slivers and the delivery rollers rotate at a far faster speed, drawing out the combined slivers into a thinner single sliver. Pins are pushed into the sliver and move forward at an even speed with the fibres to control the acceleration of the fibres between the sets of rollers. When the pins are first thrust into the sliver, the feed rollers are still gripping the fibres. The pins are drawn through the fibres and comb them. COMBING Here Worsted yarns are spun from longer (three inches and longer) fibers that have been carded, combed and drawn. Combing machines further straighten the Wool sliver making the individual fibers lie parallel. The combing process also eliminates noils or shorter fibers which grow mostly on the belly of the sheep. (Noils are used in the production of less expensive woolen fabrics and for the 15

manufacturing of felt, a non-woven wool fabric). The wool tops created after these weigh around 8.5k.

COMBING DEPARTMENT FLOWCHART

Greasy wool PET Fiber PET Tow

Direct Bale Blending Scouring Carding Gilling (1) Gilling (2) Gilling (3) Grey Combing Gilling (4) Gilling (5) Wool Bump Top

Carding Gilling (1) Gilling (2) Poly Bump Top

Converter Gilling (1) Gilling (2) Gilling (2) Poly Bump Top

Top Dyeing Hydro Extractor R. F. Dryer Back Washing Opening Gilling

Defelting

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Grilling ( 4 ) Grey 5)

TOP DYEING PROCESS (POT DYEING MACHINE) Dyed loose tops may have to withstand both scouring and gilling. Since these are drastic processes, the dyes that can be used are limited to those possessing a high degree of fastness to wet treatments. Piece dyed materials have usually only to withstand relatively mild finishing processes, so the dyes used need not be especially fast to wet treatments, and light and bright shades can be produced. Brightness of shades, fastness to light and ease of application can be obtained fairly cheaply, but bright shades possessing all-round fastness usually require more expensive dyes which are less level dyeing and so are best applied at an earlier stage, Piece dyeing may also be impracticable on other grounds. Thus, with heavily milled materials, e.g. naval over coatings, piece dyeing would not give satisfactory penetration and permanent creases might be produced, so loose wool dyeing is necessary. Dyeing in the loose state is also necessary for mixture yarns or cloths, although for the latter the wool may be dyed in yarn form. When dyeing loose wool (and slubbing) perfectly even distribution of the dye is not essential, because the subsequent carding operation produce an even mixture of fibers, so less dyeing dyes with high fastness to wet treatments can be used. Loose wool dyeing is preferred in case where there is no special demand for high fastness to wet treatments. In the dyeing procedure first the material is loaded and water is fed to the machine. The chemicals are added and the machine runs for 10 min. Pre-dissolved dyestuff is added and the machine runs for another 10 min. The temp is raised to 98 C at the heating rate of 1.5 C/min. At 98 C after half hour acetic acid or formic acid is added for complete exhaustion of the dyestuff. Dyeing process is continued for

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another half hour. The remaining liquor is allowed to drain the material is cooled by circulating water than the material is taken out kept for drying and taken for color matching.

Technical Inputs For wool, speed of the conveyer is 4 m/min. For PET, speed of the conveyer is 5 m/min. After Hydroextractor Moisture content=6% After RF dryer Moisture content=4% (For wool and polyester) Hydro extractor: It is used to remove excess water. COMPUTER COLOR MATCHING: As the sample is ready it is taken to the sample department where the color matching process is done. Here computer color matching system is followed SPECTROPHOTOMETER. It is used to know the details about the fiber /fabric. SEQUENCE FOLLOWED FOR COLOR MATCHING:

Dyeing

Colour Matching

Approved by Deputy Manager of Dyeing

Approved by Senior Manager of Dyeing

Combing

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Final combed Samples

Colour Matching

Approved by Deputy Manager of Dyeing

Approved by Senior Manager of Dyeing

Final Sample Is Checked by Dyeing General Manager (Combing) & Senior Manager of Quality Control

Final Sample

Spinning

CENTRAL LABORATORY The central laboratory mainly functions for all kinds of testing, both physical and chemical. Testing of the material is done in the fibers & yarn.

DEVELOPMENT DEPARTMENT

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Four samples are made according to the requirement and the one, which matches the most, is sent to the party for their approval. However to cater to the needs of the domestic market designated as civil market colour of the dyed fibers are matched with that of the fabric. Steps Followed Imported samples is checked for count, shade etc (Generally two warp and two weft yarns are taken) Accordingly four samples are prepared i.e. A, B, C, D. The samples, which matches with the sample sent, by the party is send back for the approval.

DYES USED IN TOP DYEING

ACID MODERANT DYES: These are sodium salt of sulfonic acid. They are generally applied in presence of organic & inorganic acids. Hence they are called acid dyes. These dyes used when good washing fastness is considered. These are mainly used for wool, silk & protein fiber. METAL COMPLEX DYES: Metal complex dyes contain metal complex in their structure, hence they are called metal complex dyes. These dyes need not required any chemical salt during application. CHROME DYES: These dyes are capable of forming co-ordinate complex with heavy metal. These dyes are related to acid dyes but during application oleum salt are added as a mordant. In this mill sodium bicarbonate can be used as moderating agent. These dyes are used in wool dyeing only.
Conditioning 24 48 DEPT. TOPS FROM COMBING hrs

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NO

COUNT THE SPUN IF FINER

YES

Gilling 1,2,3,4 Gilling 1,2,3,4

Rubbing FM 7N Rubbing FM 5P

Roving Frame

Spinning Frame Steaming Winding Ply Winding Yarn Room

SPINNING DEPARTMENT

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CONDITIONING ROOM: The material from the combing department i.e. the recombed tops come to the conditioning room. In this room, humidity and temperature are maintained. Humidity = 85%. The tops are conditioned for 3-4 days to remove static charges in the material. After conditioning the materials is taken for spinning process. To avoid flying fibers as some fibers absorb moisture, they tend to stick together making the handling easier. To prevent loose fiber from combing out. The forces of friction are absorbed to a certain limit by the water in the fibers avoiding damage to the parts of the machine and the fibres themselves. After conditioning, 4 gilling passage are given to the material. RUBBING FRAME (FM-7N): There are two types of rubbing frames in the spinning section i.e. FM-7N and FM-5P. The coarser material goes to rubbing frame (FM-7N) and directly goes to the ring frame. The finer material goes to the intermediate rubbing frame (FM-5P), then goes to roving frame and then to the ring frame.

PROCESS SEQUENCE: Two ends are fed to the rubbing frame and these two individual ends are wound on the single package, which reduces material handling. The sliver is passed through the feed rollers and through the drafting system. Drafting part is of the double apron type. The bottom apron is plain rubber rolling along a cast iron table. Top apron is also of the same type and the fiber control is sit weighted. As the slubbing emerges from the nip of the rubbing rollers, each of which runs on endless leather bands, from the rubbers the roving passes through a funnel is then wound on the bobbin.

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RUBBING FRAME (FM 5P): It is a modern machine that eliminates the intermediate fly frame maching. The object of this frame is to deliver the slivers of less wrapping by drafting.

ADVANTAGES OF INTERMEDIATE RUBBING FRAME (FM 5P) The delivered material is in the sliver form; it can be collected in cans. So winding & twisting are eliminated. Due to zero twist in the sliver, fly frame runs at a higher speed ROVING The finer material is passed through the roving frame from which the roving is fed to the ring frame. Before the roving frame the finer material is passed through intermediate rubbing frame FM5. PROCESS SEQUENCE The sliver from the can is passed over the guide & then through the drafting system. The drafting system comprises of 2/2 (2 over 2) system as shown in the figure. The slivers are passed through the draft system taking care that a small tuft project beyond the draft roller. Delivery container is place between the draft apron and the front roller. Then the roving is passed through the hollow flyer arm and through the pressing finger on the bobbin. On the roving frame BM 14 there is an automatic cycle which consists of: Auto resting i.e. the winding up variation and programmer. Positioning the flyer for easier removal of the bobbin. Forming a reverse of the roving for picking up of the new bobbin. Separating the bobbin from the spindles so as to remove them from the machine.

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RING SPINNING

Objective of Ring Frame To draft the roving into a yarn of specified fineness as indicated by the count no. To insert sufficient twist in the yarn to bind the fibres together so that it can withstand the strain in later processes. To wind the twisted fibres on a bobbin to form a compact package.

STEAMING To allow stress and relaxing and twist setting in the yarn. So the bundle of fiber is twisted about its longitudinal axis. Due to its elastic nature it set back and thus becomes live which can snarl when tension is released. So, by steaming at high temperature these tensional forces are neutralized and yarn is heat set so that it can be processed without trouble. For steaming, ring bobbins are kept in an aluminum trolley and placed in an autoclave as per yarn quality. QUALITY CHECK Four bobbins from each machine are taken and checked for X% and wrapping. For wrapping 1 meter of roving is taken. Along with this TPM is also checked. By stretching the rove between the two points, it is required that fiber must be separated or come out without applying high tension. This is the sign as that required and optimum twist X% is between 4.0-4.2%

TWO FOR ONE TWISTER AT FABRIC STAGE

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 To obtain higher stability against wear. To obtain improvement in the fabric roller. To obtain good handle and visual characteristic. YARN ROOM After twisting & steaming, the yarn from the spinning department comes to the yarn room. The object of the yarn room is: To store the yarn. To note the necessary data about the stored yarn. To provide warp yarn for warping. To provide weft yarn for weaving. To store the remnants of the weaving department. ACTIVITIES CARRIED OUT IN THE YARN ROOM After spinning & doubling the yarn, the PPD department & yarn room in charge checks the yarn particulars. Only the correct yarn is given entry in the yarn room according to the correct shade no., lot no. Etc. The yarn is weighed & entered in the computer. There are in all 7 bins for storing the yarn. The yarn bundles are kept on the trolleys & the trolleys are kept in a particular bin. The humidity in the yarn room is the same as in TFO twister. The quantity of yarn required for warping is given to the yarn room by the warping section. The yarn is weighed and a receipt is given to the yarn room. For the warp yarn a white dispatch receipt is used while for the loom shed a yellow dispatch receipt is used. A total of 300 400 kg of yarn is to be sent to the warping section. WEAVING DEPARTMENT

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WARPING Warping is carried out to convert the predetermined package such as a cone or cheese into a sheet of yarn of specified length and width. This process is done to convert cheese cones into weaver beams. Weaver Beams are particularly used in warping process. MATERIAL HANDLING Trolleys to warping department carry the cheese or cones, which are taken from yarn room as per requirements. After reeling and when beam is produced it is carried on a trolley and stored in the department. Only the remaining packages are again carried to yarn room by trolleys and are stored there. Individual ends in the warp are uniformly spaced across the spaced width. Warping can be done in 2 ways. 1. Sectional Warping. 2. Direct Beam Warping

In textile company(Worsted mill), sizing operation is omitted, as all the yarns are doubled and have got a good resistance and are strong sufficiently. To get resistance wax is applied at

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warping. There are some another advantages of doing sectional warping, which are followed here over beam warping. Space required is less as compared to beam warping. Yarn breakages can be easily located. Time required is less due to the less no. Of ends. Fancy structures like rib; stripes etc. can be produced in the cloth. For e.g. in sectional warping, if we want to produce a beam of 4000 ends then 10 sections each of 400 ends can be made so as to get the required total of 4000 ends. DRAWING IN In weaving, it is necessary to space the warp threads properly in order to get the required compactness of the cloth. This is affected by passing the warp yarn through the dents of the reed of appropriate count so that the cloth woven from the warp may contain the required no. of threads. Passing the warp threads through the drop wires 9warp stop motion), a process known as DRAWING IN carries out heald wires and the dents of the reed. WEAVING PROCESS Weaving is the basic department for preparing a fabric by interlacement of warp and weft yarns. There are various looms for weaving available in the textile industry. In TEXTILE COMPANY, there are two types of looms- projectile (SULZER RUTI) and rapier looms (RIGID DORNIER/ FLEXIBLE NP) About 31000 meters of linear fabric is produced per day. There are total 112 looms working in three shifts. That means each loom is producing about 92 meters of fabric per shift. The number of machines according to make model and loom speed as given below:

SULZER-RUTI

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The Sulzer- Ruti i.e. projectile looms Are used for producing medium weight and heavier fabric such as trovin, supphire etc. while rapier looms are used for light weight and finer fabrics of finer count upto 150 Nm. The robust, practical, technologically advanced machine design has several key advantages:

Gentle yarn handling - outstanding fabric quality Low weft wastage - substantial cost savings Short style-setting times - higher productivity Less maintenance - higher efficiency

RAPIER WEAVING MACHINE In Rapier looms, the weft insertion element resembles a rapier or a thin bladed straight sword; hence the name Rapier Weaving. There are many varieties of Rapier systems such as single, double, flexible, rigid, and telescopic and two phases. A Rapier in its simplest form consists of a single rigid bar, solid or telescopic and a device called gripper head screwed at its feed end. Here the control over the weft is positive during the whole pick insertion cycle. The rapier may be also be of the rigidrod type or flexible, made of metal or plastic tapes. Flexible tapes invariably need guide meters inside the shed which emerge during the pick insertion and sink back into the sley before beat-up. The Rigid rapiers which include telescopic type remain suspended from the fulcrum and may get help from right upper warp sheet. FEATURES OF RAPIER WEAVING MACHINE Electronically controlled weft tensioner reduces the yarn tension especially during insertion. Automatic package switching device prevents the machine from being stopped in the even weft break between the package and weft feed. The weavers can repair the fault while the machine is running and reactivate the unit that has been stopped. Electronically controlled warp let-off and cloth take up units ensure a high degree of fabric regularity and prevents all kinds of start and stop marks.

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 Grippers are redesigned to ensure better clamping of the yarn and prevent rubbing against the warp yarns. Electronic monitoring control systems have simplified the communication with the machine and facilitated its easy handling by any one concerned with the operation of the machine.

FABRIC DYEING DEPARTMENT

FLOWCHART OF THE DEPARTMENT - PIECE DYEING

GREY PERCHING AND MENDING

PIECE DYEING

HYDRO EXTRACTION STENTERING PERCHING FINISHING

GREY PERCHING AND MENDING: After weaving, the fabric is to be taken for perching to find out the faults like broken ends, picks, floats etc. These faults are then rectified on the mending machine. GENERAL INFORMATION

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No. of tables for perching and mending: 2 No. of workers for perching and mending : 1/machine PIECE DYEING The fabric after grey perching and mending is taken for dyeing process. In this mill, there are various piece dyeing machineries to dye the fabric. These machineries are as follows: JET DYEING MACHINE They are four types of Jet Dyeing Machines in Textile company Brazzoli jet dyeing m/c Sanjay jet dyeing m/c Antares jet dyeing m/c. Calico jet dyeing m/c There are two types of piece dyeing: Open width form: Beam dyeing and Jigger dyeing Rope form: Over flow m/c

In the case of open width form, piece is moving while in the rope form, both the piece and the liquor are moving and in the case of the jet overflow dyeing, the liquor is stationary and the piece is circulating.

BRAZZOLI JET DYEING MACHINE: In Textile company, there is one Brazzoli dyeing m/c, which is used to dye all wool and poly wool only. Here acid dyes, metal complex dyes and chrome dyes are used for all wool whereas disperse dyes are used for polyester only.

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The fabric piece has to be stitched together and fed to the machine. After completion the dyeing, the pieces are unstitched, collected in a trolley and then carried to the next machine i.e. rope opener and hydro extractor.

Technical Inputs
Speed of Cloth Loading Capacity Volume : 60m/min : 300kg. : 3000-4500lt.

PROCESS: In this process, before feeding the material into the machine all the required chemicals are mixed in the side tank as per requirement and stir it very well with the help of stirrer. Then material starts to feed into the machine that is called batching of material. During batching insert into the machine and the material in chemical for 10 min. at room temp. Meanwhile take all the required dyes in dissolution tank and dissolve it by constant stirring. After that insert the prepared dye into the machine and start the program. There are various program numbers that are done for different type of material at different temp. CHECK ROOM The check room is provided to check the fabric structure and faults in the fabric according to the piece tick to pass further. The fabric width which is less than 10mm of the reed length is tolerated. A Max half hour is required to check the sample. If any fault occurs in the fabric then a memo is send to the quality control department. Workers: 3 workers/shift (3 shift) 1 in-charge of the check room. MENDING & PERCHING

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After weaving the Fabric, it is to be mended & perched before finishing. In the mending section, mendable faults like broken end, picks, floats etc. are rectified. After mending & perching, the fabric is sent to the grey house where the finishing processes start. There are 153 tables for mending & 6 machines for perching. In 1 shift, one piece is mended per table.

FINISHING PROCEDURE AFTER DYEING Textile finishing is a term used for a series of processes to which all bleached, minted & certain grey fabric are subjected before they are put in the market. Finishing includes the final treatment of every kind of fabric.

Objective Finishing processes are carried are carried out to improve the natural properties of the fabric. The primary object of finishing is to enhance the quality of the cloth, imparting the woven fabric a specific appearance a specific appearance & handle in order to make it attractive.

The finishing department receives the fabric from the fabric dyeing department. The processes of the finishing treatment differs according to the blends, shades etc. Finishing is carried out in two ways:

BRUSHING The material either from weaving section or from dyeing section comes to the dry finishing section for finishing purpose. For this material has to be through the brushing machine first.

Objective

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The fabric is in the grey condition before finishing and to remove the dust particles from the fabric, it is passed through a brushing machine. Brushing can also be termed as raising. Raising or brushing can be carried out to raise fibres surface termed as PILLS. Generally, the fabric is in the grey condition before finishing and to remove the dust particles from the fabric, it is passed through a brushing machine. In this machine, the fabric is passed through the brush rollers. The distinctive feature given to the cloth by raising is: Fibrous surface. Increased softness and fullness of handle.. Concealment of the threads and weave effects. Subduing of the colours. Softening the outline of the pattern in figured styles.

STENTER The stenter can be used for heat setting, drying and resin treatment. Before passing the fabric through the heating chamber, it is passed through a tank containing water and a softener. Pins on the conveyor grip the fabric properly before entering into the chamber. The drying chamber is heated by 10 coils. There are 10 blower fans to enhance the drying operation. Suction is provided for extracting the moisture. For heat setting, the temperature of the chamber is kept about 185C and for drying it is around 140C.

After hydro extraction of the fabric, it remains about 30% moisture. If this type of fabric is taken for perching and mending, then it will be very difficult to search very small defects from the fabric surface and will be very difficult to rectify certain defects. Hence stentering must be carried out to dry the fabric 100%. Stentering of the fabric is carried out on stenters only.

ADVANTAGES Imparting dimensional stability.

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Reducing tendency to creasing. Improving resistance to pilling. Achieving level dyeing and eliminating stain in the fabric.

CONTROL Before dry finishing, the fabric is semi-inspected i.e., the faults in the fabric are mended after wet finishing. There are 3 perching machine in the wet section. The machine used for inspection is known as perch. Perching consists of examining the cloth and marking with colored chalks. All imperfection should be eliminated in subsequent processes. The modern perch is designed so that the operator may give the cloth careful and through inspection with minimum efforts. The machine that is controlled either by a foot switch that can either start or stop the cloth instantly. The cloth passes before the operator at full width and free of wrinkles.

Inspection is made in two ways:

The goods between the light and the inspection examining against the light. Inspecting the surface of the goods only, with light on the goods. The importance

has been given to perching for inspection purpose much more commonly and regularly in textile mill.

FLOW CHART FOR THE FOLDING OF FINISHED GOODS MEASURING

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FOLDING

CUTTING

SELVEDGE STAMPING

WEIGHING

HAND ROLLING

TOP END STAMPING

PASSING

COMPUTER DELIVERY

PACKING

WAREHOUSE

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QUALITY CONTROL Quality control is an ongoing process, which starts right from the initial stages of fiber or yarn right up to finishing & final packing of the fabric.

OBJECTIVES Setting up standards by which strict quality check-up can be maintained. Co-ordination with departmental people for ensuring quality standards. Implementation of quality standards among the departments. To take preventive measures for maintaining the quality Along with all the above functions, to provide the management with production of high quality or with defects within the tolerance limit.

QUALITY CONTROL SYSTEM IN DIFFERENT DEPARTMENTS. COMBING: 1. Fineness testing (micron) 2. Length 3. %Grease 4. Foreign matter 5. Moisture content at different stages 6. Oil + total fatty matter (TFM) 7. Neps 8. Blend composition

SPINNING:

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Testing of sliver, roving, yarn for evenness Twist testing (TPM) Count testing (Nm) Moisture content testing Single yarn strength testing Lea strength testing Hairiness testing

WEAVING: Detection of faults usually on a running loom EPI & PPI in a grey fabric Study the causes for loom stoppage in different quality materials. Detection of faults like missing ends, missing picks, curly selvedges, temple marks & cuts, floats, wrong denting. Mending of all theses faults is done in the perching department.

DYEING:

Approving the shade by visual checking 1st & then with the help of computer colour matching. Identification of visual faults in a piece dyed fabric on a perching table & retreating the fabric to remove the faults. Checking the dyed fabric for washing fastness, light fastness, sublimation test (only for polyester material) etc.

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FINISHING: Width of the full finished fabric. Weight of fabric per sq. meter. Weight of fabric per linear meter. Piling test. Drape coefficient of fabric. Tensile strength testing. Seam slippage test. Washing & ironing test. Blend composition. Water repellence, oil repellence. Flame redundancy.

All the tests carried out in the quality control department help in giving the fabric an optimum quality as desired. They have the right to alter a particular process & take corrective measures in order to get an optimum quality fabric.

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CONCLUSION
This term paper analyzes the different process in production planning and control. After concluding the term paper I found that there is some strategy by which we can control the hole production planning which is necessary for the effective production planning. By the help of several links I studied and observe that without controlling we cant get maximum output and by using different production technique we can get maximum output in minimum input. we must take care different operation during production.

REFERENCE
(1) www.dmoz.org/Business/ (2) www.baselinemag.com (3) www.streetdirectory.com (4) expertpages.com (5) www.tandf.co./journals (6) www.eresourceerp.com Manufacturing (7) www.informaworld.com

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