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I. INTRODUCTION
The science of textiles predates recorded history.
Archaeologists have found evidence that man has fabricated
coarse cloth from various fibers for at least 20,000 years and
intricate textiles have been found in tombs in Egypt and Asia
that have been dated to several thousand years before Christ.
Many of the processes which were developed in ancient times
are still used in remote areas of the world today [1]. However,
with the advent of the Industrial Age, rapid developments in
machinery and textile manufacturing techniques have
advanced the science of textiles more in the past one hundred
years than in all of previous history [1]. Today's sophisticated
CAD/CAM controlled machines result in high-speed,
low-cost and large-volume textile production [1]. Looms are
the important machines used for cloth production. The
different looms used for the production of the cloth are shuttle
looms, rapier looms, jet looms, etc. The power looms are used
for weaving terry towels and bed sheets. Techniques used for
the production process in the industry are Warping, Sizing,
Beam Drawing, Weaving, Cutting, Un-winding, and checking
in warehouse, Folding, Recounting, Grading and sorting,
Bailing or packing [1]. The main energy forms used in a
textile industry are grid electricity, wood, and small quantity
of coal [5]. The electricity is used for power looms, doubling
machines, winding machines, warping machines and lighting.
Wood is used as fuel for boilers, thermic fluid heaters, and
chulhas for hot water generation.
Factor
Seconds affected
(s)
Percentage
(%)
Speed
170
68
Yarn
39
15.6
Break down
22.5
Man
11
4.4
Environment
5.64
2.2
Total
250
100
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013
III. METHODOLOGY
In the study picks generated by randomly selected shuttle
looms are analyzed. Each machine was observed for 600
seconds. The time taken for generating picks and the time
during the stoppage of the loom is also noted. The noted time
is classified into operating time and no operating time. In the
operating time it was identified that the picks generated by
the looms are lower than the ideal pick rate which is
calculated using (1). The main causes for the low pick rate are
identified by plotting the cause and effect diagram in fig 1.
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013
Table II: Average Ideal Pick Rate for 1 Month
SI No
Month
Days
Total time
Ideal pick
rate R
Ideal pick
rate for 1
hour
Jan
31
40920
5728800
2188401600
8400
Feb
29
38280
5359200
2047214400
8400
Mar
31
40920
5728800
2188401600
8400
Apr
30
39600
5544000
2117808000
8400
May
31
40920
5728800
2188401600
8400
Jun
30
39600
5544000
2117808000
8400
July
31
40920
5728800
2188401600
8400
Total
15036436800
58800
Average
2148062400
8400
Month
Actual pick
Actual production
time(hours)
Jan
1142819000
187623.55
Feb
1031957000
172153.13
Mar
1176865000
192250.03
Apr
1027278000
186235.92
May
1195498000
188752.3
Jun
1212026000
189237.23
July
1365925000
196576.11
Total
8152368000
1312828.27
Average
1164624000
187547
Machine
Energy
consumption/hr
(units)
382
109
ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013
2
Sulzer loom
48.4
Sizing,cooking,storage,boiler
47.94
4
6
5
7
8
Pirn winding
Humidification plant
Warping machine
Bailing
Cone winding machine
Folding machine
22.2
21
17.45
15
3
2.2
Total
559.19
The calculation of the ideal pick rate is shown in the Table II.
There is a noticeable difference between the ideal picks and
the actual picks generated.
Ideal pick rate for 1 s = (8400/3600) = 2.33
Time for 1 pick motion = 1/ 2.33= 0.43 s
Si no
Factor
Cost %
Yarn
40
Energy
32
Employ
18
Others
10
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013
rate of the machine. Because of the low speed of the machine smooth transition of even highly fancy yarns like embroidery
the required production rate cannot be attained. The
low and slub. The rapier loom is upgrade from shuttle-looms to
speed of machine will increase the total production time the world of modern weaving system and shuttle-less
followed by increase in cost of production. Out of the 600 weaving. Rapier looms has been designed to replace the old
seconds analyzed in different machines selected randomly, shuttle looms without any major changes to the existing
approximately 250 seconds are nonproductive time, and the infrastructure [2][3][5][7]. The Immediate benefits of
remaining are productive time and the factors affecting the selecting rapier looms are [2][3][7]
production of machine is shown in Table I. Due to the
No need for new buildings or any new infrastructure.
movement of the shuttle in the loom, smooth sequence of
Could fit in place of your current shuttle-looms.
weaving is disturbed which affects the maximum running
Configured specially keeping in mind the skills of
speed and hence machine production. The pareto chart for the
power-loom operators.
energy consumption is shown in the fig 4. A 1HP motor is
No special training required for loom operators.
used for driving the shuttle looms. It is found out from the fig
Immediate reduction of man-power and laborers.
4 that cimcco power loom consumes 66% of total energy
20% subsidy under Technology Up gradation Fund
Scheme (TUFS) on certified looms.
consumption of the industry. The low speed of the machine is
due to the age of the machines, working condition of the
machines, and the increased weight of the shuttle in the
machines. Because of the low speed of the machine the
consumption of energy by the machine increases. The
electrical energy consumption for the different machines in
the industry is shown in the Table V. It is found that the
energy consumed by the shuttle loom is higher than any other
machine in the industry. The reduced speed of the machine
will increase the time of production and the lead time of the
product is also increased. So to maintain increased production
the speed of the machines has to be increased. To increase the
speed of the machine, an improved way of production has to
be followed. This improvement can be attained by the
replacement of the conventional shuttle looms by the Rapier
looms.
Proposed energy efficient equipment (Rapier looms)
Description of equipment
Fig 5: Cost of Factors Affecting Production of 1 Meter of Cloth
The rapier looms offer unparalleled versatility when it
in %
comes to yarns. From the finest counts of cotton to the thickest
Industrial yarns and can handle anything thrown at its
negative rapier head. The soft-pick gear system enables
Speed
The normal speed of the conventional power looms is
around 140 RPM, where as in rapier looms, the speeds up to
220 RPM (actual), this machine gives up to 3 times more
productivity than the conventional power looms.
Pick rate of rapier loom
The speed of the rapier looms is 220 RPM. Thus the ideal
pick rate of 1 rapier loom can be obtained using (1) as 13200.
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ISSN: 2277-3754
ISO 9001:2008 Certified
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 2, Issue 7, January 2013
AUTHOR BIOGRAPHY
operating time can be reduced to 51761 Hrs. Thus from the fig
6 it is clear that 37% reduction in the total operating time is
obtained. When comparing with the shuttle loom 57.5% more Aby Chummar, Post Graduation Student, Dept. of Mechanical
Engineering, Mar Athanasius College of Engineering, Kothamangalam,
pick is obtained by the rapier loom.
Kerala.
Cost savings
Soni Kuriakose, Associate Professor, Dept. of Mechanical Engineering,
In Kerala the cost of one unit of electrical energy = 4
Energy consumed by 382 shuttle looms (1 hp motor) Mar Athanasius College of Engineering, Kothamangalam, Kerala.
per hour = 382 kWh
George Mathew, Assistant Professor, Dept. of Mechanical Engineering,
For the conventional looms total cost of energy Mar Athanasius College of Engineering, Kothamangalam, Kerala.
consumed = 212557024
Total energy consumed by the rapier looms =
33366554 kWh
The total cost of energy consumed by rapier looms =
133466216
Thus by the rapier looms cost saving of 79090808 can be
obtained in one month from the electrical saving itself.
V. CONCLUSION
To exist in a competitive world of industries, producing
products at a low price with good quality is necessary.
Accepting new technology, the production cost can be
reduced, at the same time the rate of production can be
increased. This study identified the problem of high energy
consumption of electricity by the usage of shuttle looms in a
garment industry. It suggested a remedy of replacing the aged
shuttle looms with the automatic rapier looms for increasing
the rate of production, thereby reducing the time of operation
of machine and reducing the total lead time in production.
Thus cost of production can be reduced. By rectifying other
reasons noted in the cause and effect diagram in Fig1
production rate can be again improved. Further studies on the
rapier looms can be helpful for the multi color weft insertion
which will increase the variety of product according to the
fluctuation market conditions.
REFERENCES
[1] Ryuta Kamiya, Bryan A. Cheeseman, Peter Popper, Tsu-Wei
Chou, Some recent advances in the fabrication and design of
three-dimensional textile performs: a review Composites
Science and Technology 60, 33-47, 2000.
[2] Dr.V.M.Patil1, P.D.Bhanawat, Techno-economics &
advances of shuttle-less weaving technology, IJSID, 2012, 2
(1), 77-89.
[3] Subhankar Maity, Kunal Singha, Mrinal Singha, Recent
Developments in Rapier Weaving Machines in Textiles,
American Journal of Systems Science 2012 ;( 7-16).
[4] R. Ufuk Bilsel, Dennis K.J. Lin, Ishikawa Cause and Effect
Diagrams Using capture Recapture Techniques, Quality
Technology & Quantitative Management Vol. 9, No. 2, pp.
137-152, 2012.
[5] A. N. M. Masudur Rahman & Md. Ruhul Amin, Efficiency
analysis in rapier loom (2000).
[6] Bill Carreira Lean manufacturing that works.
[7] Bureau of Energy Efficiency, Detailed Project Report on Auto
Loom/Rapier Loom (2000).
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