12 Chapter 4

CHAPTER- IV
CAPACITY UTILISATION IN PROCESS
4.1. Introduction
4.2 Spinning Process
4.2.1. Mixing process
4.2.2. Blow room process
4.2.3. Carding process
4.2.4. Drawing process
4.2.5. Simplex process
4.2.6. Spinning process
4.2.7. Doubling process
4.2.8. Cheese winding (twisting) process
4.2.9. Auto cone process
4.2.10. Cone winding process
4.2.11. Reeling process
4.2.12. Bundling &packing
4.3. Other Deportments
4.3.1. Quality Control Department
4.3.2. Yarn Packing Weighing
4.3.3. Yarn Godown
4.3.4. Warehouses
4.3.5 Issue of Material
4.4 Conclusion
Chapter - IV
CAPACITY UTILISATION IN PROCESS
4.1 Introduction
“Full utilisation of installed capacity is essential to improve the productivity and
to bring down the cost of production”.1 Under utilisation of capacity leads to wastage of
applied capital and resources, increases the cost of production and reduces the
competitiveness in the market.
The capacity utilisation is positively related to the magnitude of machine, power,

supervisor and labour intensity in production. This holds for both between-industries and
within-industries. Empirical results also indicate that traditional measures of capacity
utilization such as minimum capital output ratios and peak-to-peak are not appropriate
proxies for the short-run decision making of the firm regarding capacity utilization. As
compared to the estimates derived from the choice-theoretic frame work we find that the
traditional measures exhibit substantial bias.2
A firm’s productive capacity is the total level of output or production that it can
produce in a given time period. Capacity utilisation is the percentage of the firm’s total
possible production capacity that is actually being used.3
Capacity utilisation is calculated as follows:
Actual output per day (or per month or per annum)

Capacity utilization (%) = ----------------------------------------------------------------------
Maximum possible output per day (or per month or per annum)
For example, if a firm could produce 32,000kg per day, but is actually producing
16,000kg per day, its capacity utilisation is as follows:
16000 kg per day

Capacity utilization % = ------------------------- x 100 = 50%
32000 per day
1600
--------- x 100 = 50
3200
1 Gin. V.V., Labour Problems in Indian Industry; Asia publishing House, Bombay. 1960, Pp-69-70.
2 http://www.informaword.com/tenns-and-conditions-of-access. Pdf, p-765,
3 htto://www,tutor2u. net/business/production utilisation.htm.
79
This means that if a mill is able to produce 10,000kg yam per day, but it only
produced 7500kg yam per day, it would be operating at 75 percent efficiency. Capacity
(the amount a firm can make) depends upon the availability of the amount of buildings,
machinery, spindles, power and labour. When the mill is making full use of all its
resources, it is said to be working at full capacity utilisation.4
Any mass manufacturing technique has what may be termed a process capability
in terms of the minimum variability between individual units of production. The process
capability is generally determined by the quality of raw material, the level of technology
used for production, the mechanical condition of the machines and the competence of the
personnel.
In this chapter, the researcher intends to study the capacity utilization of textile
units in Davangere district, also to analyse causes of under utilisation in different
processes. Further, the researcher has covered four textile (2 mills) units. In production
processes there were 50 supervisors and others (operators, engineers, production
managers, masters and others). Among them 25 supervisors and others (50 percent) were
covered for personal interview to elicit information on various aspects of production
capacity utilisation in four units.
Total 25 supervisors and others were contacted by canvassing the interview

schedules across the individual belonging to different categories of processes and facts.
Therefore, several indicators of daily process (per day) of production capacity and per
day average production capacity utilization such as per unit were studied. An exhaustive
schedule containing questions particularly for supervisors and others, labourers and
power consumption was developed for the purpose of capacity utilization in these
categories.
Processes are shown in below the Table 4.1. This table reveals that there are a
total of 12 processes. The working duration is shown in the last column.
4 http://wikitextbook.couk/index. php/capacitv utilisation - (A-level-BS).
80
^ V
Table 4.1
Installed in the process and working duration in units
ACM Working
Process Ist Unit IInd Unit IIIrd unit SGT
duration
Mixing 1 1 1 1 GS-1
Blow Room 1 1 1 1 3 Shift
Carding 1 1 1 1 3 Shift
Drawing 1 1 1 1 3 shift
Simplex 1 1 1 1 3 shift
Spinning 1 1 1 1 3 shift
Doubling 1 0 0 1 3 shift
Cheese winding 1 0 0 0 3 shift
Auto cone 0 1 1 0 3 shift
Cone winding 1 0 1 1 3 shift
Reeling 1 1 1 1 GS-1
Bundling & packing 1 1 0 1 GS-1
Source: Field survey
Note: 1 = machine installed & working in process
0 = machine uninstalled in process
GS-1 = General Shift (8 hours)
3 shift = per day 3 shifts (per shift 8 hours)
4.2 Spinning Process

The process of spinning falls into two distinct stages, namely preparatory process
and actual spinning process. The preparatory process involves cleaning the cotton,
removing the extraneous impurities and parallelization of fibres. The second stage i.e.,
spinning stage involves drawing out the yarn into thin form and insertion of twist.
The size of the spinning section can be measured either by the number of spindles
installed or by the quantity of cotton consumed. They are of course, not perfect
measures, since spindles may be ring, mule or doubling and the quantity of cotton
consumed may vary according to the counts of yam spun and the proportion in which the
general grades of cotton are mixed.
Process of making yarn from fibre is by a combined drawing out and twisting
operation applied to the preparatory material which enters the operations.5 The
manufacturing process of ring spun cotton comprises of cotton testing, opening and
cleaning of cotton (Blow room), Removal of short fibres and impurities (carding),
Doubling and parallelization of fibres (Draw frames and Roving), parallelization of
fibres and twisting in spinning (Ring Frames) and clearing the yam faults and splicing in
5 Wingate Isabel B., Fairchild Dictionary of Textile, Sixth Edition, Universal Publishing Corporation,
Bombay, 1985.
81
the post spinning operations(winding), Folding the two yarns by giving the required twist
in Doubling process (Two for one Twisters).6
Selender is a tapered rod held in a vertical position on the side of spinning frame.
The rods or pins of a spinning machine known as the ring frame holding the plastic
bobbins on which the yam is wound as it is spun; such spinning is known as the ring
spinning. The capacity of a spinning mill is expressed in terms of the number of spindles
or rotors.7 A bobbin is placed on the spindle to receive the yarn as it is spun at high speed
giving a twist to the yarns this is called spindles. There are two types of yarns one is
simple yam and another one is blended yam. A continuous strand of textile fibres is
simple yam. The yam obtained by combining two or more different fibres in the yam
making process is called blended yam. The count of yam is the numerical designation
given it to indicate its size and the relationship of length to weight. Cotton testing which
is the raw material for manufacturing the cotton yam undergoes strict quality tests in
Quality Assurance Department (QAD) laboratories for checking the fibre length,
strength, Micronaire, Elongation percent, maturity and colour. After proper checking and
approval by quality assurance department short fibres will be issued to the further
process.
The role as well as the scope of process control is spinning becomes clear when
we consider the function of the spinning department. Obviously, the sole function of the
spinning department is to produce yam of desired quality in the required quantity and at
minimum cost.8
Open end machines are used with new technology for higher speed. However,
they can be used for limited counts only. The simplex and spinning processes are saved
here thus the labour complaints are reduced to a great extent which ultimately reduces
labour cost.9
The process of yam spinning falls into two distinct parts Viz., preparatory and
spinning. Proper preparatory process involves cleaning of cotton, parallelization of fibres
6 Anjaneya Cotton Mills, Quality Control and Yarn Conditioning Department, Davangere, 2006, pp-1-3.
7 Balaji Rao, Financial Analysis of Co-operative Spinning Mills of Gadag in Dharwad District of
Karnataka State, Unpublished Thesis, Karnataka University, Dharwad, 1995.
8 Garde, A.R., T.A. Subramanian, Process Control in Cotton Spinning; Ahmedabad Textile Industry’s
Research Association, Ahmedabad, 1978, p-1.
9 Prince Dhanaraj. P., Industrial Economics, with Special Reference to Cotton: Textile Mills, Reliance
Publishing House, New Delhi, 2002, p-57.
82
and attention; whereas spinning proper involves insertion of twist.10 The individual processes
are explained below in chart.
Chart 4.1
General process flow chart
10 Bhave, P. V., V Srinivasan, Cost Accounting in Textile Mills; Ahmedabad Textile Industry’s Research Association,
1974, p-15.
" Ibid, p-26.
83
Chart 4.2
Process flow chart of cotton textile in spinning units
Raw Material (Godown)

i
Mixing
1
Blow Room (opening & cleaning)
i
Carding (waste)
Drawing (Sliver)
Simplex^(Roving)
Spinning (Ring Frame)
T A __________________
}
i--------------------
Reeling (Honk yam) -Doubling cone winding auto cone
J
i
Bundling Twisting (cheese winding)
i
l
Baling Double cone winding
\
►Packing <--------------------
I
Store keeping
84
Cotton Godown
In these godowns the cotton bales are stored. The carpet area of cotton godowns
is lOOOsq.mtrs (50 x 20). The capacities of godowns are on an average 350 bales. The
weight of each bale is 170kg.
The bales are received at the door of the godown from the truck. The bales are
pushed to the floor then bales are carried simply by hand trolley and weighed. The
weighed bale is then taken for the storage in the godown. The equipment used to handle
the bales is called hand trolley or bale trolley. The average distance travelled by worker
is 20 meters. More workers required to unload the truck and keep the bales in godown.
4.2.1. Mixing Process
Cotton bales are issued on the mixing ratio, percentage prescribed by the raw
materials manager for different varieties.12 Usually various types of cottons are mixed
together in predetermined proportions instead of manufacturing yam from single cotton.

The purposes behind this are:
1. To take advantage of the desirable characteristics of each quality of cotton and
2. To obtain desired quality of yam at a minimum cost.
The machines used for mixing operations are blending hoppers and mixers.13
Blending of quantities of fibers from several lots to produce a uniform result is mule
spinning.
The type and proportion of the cotton to be used in making a mixing is decided
by taking into account the cotton prices as well as the previous experience of the mill
with the working of different cottons. There is an increasing use of instruments to
supplement the evaluation of cotton and in formulating mixings. While these methods
are certainly helpful in controlling mixing cost, but they cannot assure to reduce to the
minimum without any sacrifice in the quality. Any improvement in the methods of
evaluation, purchase of cotton and in the formulation of mixing is desirable. The
evaluation of cotton on the basis of instrumental testing of fibre properties and the use of
12 Prince Dhanaraj. P op.cit, p-57.

13 Bhave, P.V., V Srinivasan op.cit, p-15.
the test results in formulating mixings of minimum cost and desired quality are
described.14
Most yams are spun from mixings comprising two or three cottons; therefore the
formulation of mixings from the available stock of cottons can be based on fibre
characteristics. Most mills buy cotton over the year and not once in a year and therefore,
fibre data on lots purchased could be of use in making future purchases.
There are two methods in which data on fibre characteristics can be used in
practice for the control of mixing quality:
1. The specification of mixing quality in terms of the individual fibre properties

themselves, without specific reference to yam characteristics.
2. The specification of mixing quality in terms of an index which is calculated by using

the individual fibre characteristics, and which has been shown to be capable of predicting
any one important yarn characteristic.15
The table 4.2 shows that the total 8 machines were installed in both mills. Among
them 7 machines are utilized which shows 87.5 percent utilisation in mixing process. The
Anjaneya Cotton Mill (ACM) has 3 units. In these units all machines are fully utilised,
where as in Shri. Ganesar Textile (SGT) mill 4 machines are installed but 3 machines are
working which means 75 percent of machines are utilised.
The total Cotton production capacity of machines is 62,250kgs per day. But
actual total production capacity utilisation is 32,507.14kg per day in mixing process. The
production capacity utilisation is only 52.22 percent. The ACM Ist unit has 92.07 percent
(7,550kg) followed by in IIIrd unit it has 82.35 percent (7000kg), in IInd unit it has 45.06
percent (7,457.14kg) and the SGT has only 36.21 percent (10,500 kg) utilisation in this
process.
In mixing process a total of 4 supervisors and others are required and these 4
members are fully utilised. In the same process a total of 24 labourers are required, out of
them 22 labours are utilised, whereas in ACM Ist and IIIrd unit only 5 and 4 labours are
fully utilised respectively.
14 Garde, A.R., T.A. Subramanian. op.cit, p-16.

15 Ibid Pp-26-28.
86
Table 4.2
Capacity Utilisation in Mixing Process
'
I Vo. of Machines
Name of the unit Installed Utilisation Percent
ACM I 1 1 100
ACM II 2 2 100
ACM III 1 1 100
ACM Total 4 4 100
SGT 4 3 75.00
TOTAL 8 7 87.50
II Per day production ca parity (in kg)
Name of the Unit Capacity Utilisation Percent
ACM I 8200 7550 92.07
ACM II 16550 7457.14 45.06
ACM III 8500 7000 82.35
ACM Total 33250 24007.14 72.20
SGT 29000 10500 36.21
TOTAL 62250 32507.14 52.22
III No. of supervisors and others (per day)
Name of the unit Required Utilisation Percent
ACM I 1 1 100
ACM II 1 1 100
ACM III 1 1 100
ACM Total 3 3 100
SGT 1 1 100
TOTAL 4 4 100
IV No. of Labours (per day)
ACM I 5 5 100
ACM II 6 5 83.33
ACM III 4 4 100
ACM Total 15 14 93.33
SGT 9 8 88.89
TOTAL 24 22 91.67
V Per day power consum ption (in unit)
Name of the unit Available Utilisation Percent
ACM I 200 133.33 66.67
ACM II 200 142 71.00
ACM III 150 100 66.67
ACM Total 550 . 376.19 68.40
SGT 200 128.57 64.29
TOTAL 750 584.76 77.97
Source: Field Survey.
The total power consumption utilisation is 584.76 units (77.97 percent) in this
process. In SGT the lowest consumption of power is 128.57 units (64.29 percent). But in
87
ACM IInd unit 142 units (71.00 percent) of power consumption, which is the highest in
this process.
The production capacity is underutilised in both the mills. In SGT, production

capacity is too low, i.e. 36.21 percent. The main reasons are lack of appropriate
technology, more time is taken for cleaning purpose, repair of machines and others.
These reasons have led to underutilisation of production capacity.
4.2.2 Blow Room Process

Cotton enters into the first stage of preparatory department which is called Blow
room wherein a uniform mass of blending by machines and the cotton tuft size will be
minimized as low as possible. The impurities level is minimized by means of effective
cleaning by the machineries. Before issuing the cotton to the blow room department, the
contamination in the cotton is checked and removed by the intensive picking by the
skilled workers. Blow room workers produce blow room lap after blowing wastes like
seeds, leaves, dust soil and others. Bale cotton is found to a trash content of 6.8 percent
averaged over lOOg samples that had no seeds. When seeds are separated from another
lkg sample, they weighted l.lg. The trash content in the cotton is 6.8 and 1.1 percent,
among them an average 8 percent of the input are removed from raw cotton.
Process involves the following functions:
1. Cotton is opened into small lumps
2. Major impurities such as trash, sand, leaves and seeds are removed.
3. Cotton duly cleaned is collected in the form of a web of tangled fibres which is rolled
into a lap.
Cleanliness is a major factor determining yam quality. Low level of trash in

cotton and efficient cleaning in blow room and cards are the prerequisites to produce
yam free from foreign matter. Though in the conventional blow room lines a cleaning
efficiency of 80 percent in cotton with high trash and 70 percent in cottons with low
trash is achieved, in modem blow room lines the cleaning efficiency is much lower at 50
to 60 percent. The modem lines have achieved a high degree of opening which results in
88
better cleaning at cards. Impurities such as seed coat bits, immature and crushed seeds,
leaf bits etc., are better removed in carding rather than at blow room.16
The process involves several continuous operations and the product is measured
at the scutchers which is the last operation. It is known as "scutcher lap". Each product is
designated by a number indicating weight per unit length (in English system ounces per
yard). The laps produced have to meet desired standard viz., predetermined weight per
unit length, with a view to control variation in count.
The weight of lap will be about 24.5 kgs and length will be about 50 mts (1 lap =
24.5 kgs/50mts). The lap formed will be carried on to the carding department with the
help of lap trolley. This lap trolley can transport three laps at a time. There is little
possibility of any damage occurring to the lap, since the laps are stacked vertically in
blow room. Lap rods are generally stored with one end on the floor and the other end
often resting on the machine. This causes damage to the floor and also to the machine.
Sometimes a lap rod falls down causing injury to the operators. To overcome the above
problems, the mill uses lap rod storage.
a. Need for opening:
Since the raw material - the bale enters the spinning mills in highly compressed
form, the basic operation of spinning demands opening of the raw material. Apart from
opening we have to get rid of the impurities that a bale of cotton carries with it, due to
mechanical picking, improper method of storing introduction of saw gins and high
density baling. All this demands high degree of opening of the material and cleaning.
b. Need for cleaning
The term ‘cleaning’ in the technological sense means the process of releasing the
‘imprisoned impurities’ from the bale cotton. Though it is accepted that opening and
cleaning go hand in hand, modem blow room practice shows some departure from the
conventional ideas and there is tendency to consider opening and cleaning are two
distinct processes even if they take place in the same machine.17
16 Ratnam, T.V., K.P. Chellamani, Quality Control in Spinning: The South India Textile Research
Association Coimbatore, 1999, p-78.
17 Chattopadhyaya. R., Advances in Technology of Yarn Production-, Nodal Center for Upgradation of
Textile Education. ITI, Delhi, 2002, pp-3-4.
89
Table 4.3
Blow room Process Capacity Utilisation
I No. of macbines
Name of the Installed Utilisation Percent
unit
HBB 3 3 100
ACM I
SC 2 2 100
HBB 1 1 100
ACM II
SC 1 1 100
HBB 1 1 100
ACM III
SC — — —
HBB 5 5 100
ACM Total
SC 3 3 100
HBB 3 3 100
SGT
SC 1 1 100
HBB 8 8 100
TOTAL
SC 4 4 100
II Per day production capacity (in kg)
Name of the Unit Capacity Utilization Percent
ACM I 8200 7366.67 89.84
ACM II 9000 7328.57 81.43
ACM III 8300 6760 81.45
ACM Total 25500 21455.24 84.14
SGT 13000 10271.43 79.01
TOTAL 38500 31726.67 82.41
III No. of supervisors anc others (per day)
Name of the unit Required Utilization Percent
ACM I 1 0.5 50.00
ACM II 1 0.5 50.00
ACM III 1 1 100
ACM Total 3 2 66.67
SGT 1 1 100
TOTAL 4 3 75.00
Name of the unit Required Utilization Percent
ACM I 6 6 100
ACM II 9 8 88.89
ACM 111 4 3 75.00
ACM Total 19 17 89.47
SGT 8 8 100
TOTAL 27 25 92.60
V Per day power consumption (in unit)
Name of the unit Available Utilization Percent
ACM I 2350 958.33 40.78
ACM II 2350 1285.71 54.71
ACM III 2000 1060 53.00
ACM Total 6700 3304.04 49.31
SGT 2350 985.71 41.95
TOTAL 9050 4289.75 47.40
Source: Field survey
Note : HBB = Hopper Bale Blender
SC = Step Cleaner
90
The Table 4.3 reveals that in the blow room process, there are two steps, one is
Hopper bale blender and another is Step Cleaner. The Happer bale blenders have 100
percent utilisation in this process. It means 8 machines are working, except in ACM IIIrd
unit, because in ACM IIIrd unit advanced machine is used. It contains Happer bole
blender, Roller cleaner, Heavy particle separator and pinned opener. And in step
cleaners, total 4 machines are installed. All machines are fully utilized (100 percent).
The total cotton production capacity utilised is 82.41 percent (31,726.67kg). But
SGT is having 79.01 percent (1,0271.43kg) utilisation, which is low compared to ACM
Ist unit, which has achieved 89.84 percent (7,366.67kg) utilisation in this process.
In this process 4 supervisors and others are required whereas there are 3
supervisors. But in ACM, of supervisors and others have only 50.00 percent utilisation
in Ist and IInd unit. In ACM IIIrd unit and in SGT there is found 100 percent utilisation of
supervisors and others in this process.
The utilisation of labour is 92.60 percent, which consists of 27 labours out of

which 25 labours are utilised in this process. SGT and in ACM Ist unit have achieved
100 percent (8 & 6 labours) utilisation. Followed by in ACM IIIrd unit 75 percent (3
labourers) and IInd unit 88.89 percent (8 labourers) utilisation .
Regarding power consumption it can be said that all units have low level of
power consumption. Only 47.00 percent (4289.75 units) has been utilized. In SGT we
find 41.95 percent (985.71 units) power consumption followed by 40.78 percent (958.3
units) in ACM Ist unit.
In blow room process, power is under utilised. There are some reasons behind
underutilisation of power and capacity utilisation. These are lack of technology, repair of
machines, more time used for cleaning purpose, obsolete machines and high variation of
blow room lap weight, poor cleaning efficiency, cotton not opened properly and
excessive lint loss.
4.2.3 Carding Process
It is preliminary process in spun yam manufacture. This process removes most

of the impurities and a certain amount of short, broken or immature fibres. Blow Room
provides uniform feeding to carding machines. The cotton tuft lap passes through carding
91
machine for individualisation of cotton fibres into a oriented alignment. The impurities
will be removed by means of the licker, in selender beaters and Revolving flats. The
cotton lap will be converted into the form of sliver. Carding is important part of the
spinning. This is called "carding heart of the spinning". The blow room lap is converted
into sliver in the carding department using carding machine. Here the waste is around 5
percent of the input given. Importance of this process is well emphasized in the
maxim “to card well is to spin well". The functions of this process are:
1. The fibres which are in the lap form are brought into alignment and arranged in a
sliver form.
2. The impurities still lying in the laps and certain amount of short fibres are removed.
The final product of carding is delivered in the form of a sliver. The machine
which performs the aforesaid function is called a card or carding engine.18 The web of
cotton fibre is converted into rope like form called as sliver. There is also further
cleaning of cotton for micro dust and trash etc. The loose cotton is fed to each carding
machine through the ducts. The ducts are running over each carding machine. The loose
cotton is taken from blow room to carding through the ducts with the help of blowers and
is fed uniformly to all the carding machines.
The capacity of one can is 20kg of sliver. Therefore, the total number of cans of
sliver produced is 12 per shift per machine. The average distance moved by the card
tender is 20 meters and it takes 2 minutes per trip.
To move the sliver produced in carding section to drawing section, the cast and
caster wheels are used. As the floor is good, the cans can be moved smoothly to the
drawing sections and one can contains 4500 mts (20 kgs) of sliver. Two or more play
yarns are twisted together to form a card yam. And a term used for man made fibre yams
composed of many fine filaments. These yams make especially soft fabrics.
In a carding machine, there are two basic actions between the wire covered
interacting surfaces. These are called: Carding action and stripping action.
18 op.cit, SI No. 10, p-17.
92
1. Carding action: This action is a fibre separation process from fibre tufts held in
between two interacting wire covered surfaces.
2. Stripping action: This action is a fibre transfer process from one wire surface to the
other.19
The average level of waste and variation between individual cards is an important
factor that affects the quality as well as cost of production of yam. Cards being the last
point in the process (combed counts excluded) where neps and foreign matter are
effectively controlled. Most of the warnings relating to the blow room apply here as well.
However, there are more machines that are often closely packed and certain additional
warnings are in order.20
By analysing the Table 4.4 under carding process, a total 97 machines are installed out
of which 94 machines are utilised. In SGT there are 43 machines, but 42 machines are
utilised for this process. It means 97.67 percent utilisation in this process. Under ACM
54 machines are installed for carding process but 52 machines (96.30 percent) are
utilised.
The total cotton production capacity of this process is 33,750kg per day. Out of
this 29,953.33kg (88.75 percent) production is achieved which reflects underutilisation.
In ACM, total production capacity utilisation is 88.49 percent (20,396.19kg) and in SGT
it is 89.32 percent (9,557kg) in carding process.
Supervisors and others are fully utilised (100 percent) for this process. In this
process a total of 52 labours are required, but only 49 are employed leading to
underutilisation. Similarly in SGT it requires 24 labours but actually 22 labours are
employed in this process. In ACM 28 labours are required however 27 labourers are
working in carding process.
19 Chattopadhyaya, op.cit, p-58-59.

20 Peter. R. Lord, Handbook of Yarn Production Technology, Science & Economics: The Textile Institute
Wood Head Publishing Ltd., Cambridge, England, 2003, p-154.
93
Table 4.4
Capacity Utilisation in Carding Process

I 1 Vo. of Machines
ACM I 36 34 94.44
ACM II 10 10 100
ACM III 08 08 100
ACM Total 54 52 96.30
SGT 43 42 97.67
TOTAL 97 94 96.91
ACM I 7800 6833.33 87.61
ACM II 7750 6842.86 88.29
ACM III 7500 6720 89.60
ACM Total 23050 20396.19 88.49
SGT 10700 9557 89.32
TOTAL 33750 29953.33 88.75
III No. of supervisors and o thers (per day)
ACM I 1 1 100
ACM II 1 1 100
ACM III 1 1 100
ACM Total 3 3 100
SGT 3 3 100
TOTAL 6 6 100
ACM I 15 14 93.33
ACM II 9 9 100
ACM III 4 4 100
ACM Total 28 27 96.43
SGT 24 22 91.67
TOTAL * 52 49 94.23
ACM I 1950 766.67 39.32
ACM II 3500 2128.57 60.82
ACM III 1950 1160 59.49
ACM Total 7400 4055.24 54.80
SGT 3400 2028.57 59.66
TOTAL 10800 6083.81 56.33
94
In the same process, total power consumption capacity is 10800 units. But they
utilised 6083.81 units (56.33 percent) for this process. In ACM Ist 39.32 percent (766.67
units) units of power is used which is low compared to ACM IInd unit where power
utilisation is 60.82 percent (2,128.57 units), which is the highest in this process. And in
SGT power utilisation is only 59.66 percent (6,083.81 units) in carding process.
The power consumption is low under carding process. In ACM Ist unit power
consumption is only 39.32 percent. This leads to under utilisation of total production
capacity. Main reasons for under utilisation of production capacity are as follow: under
utilisation of installed machines, labours problems, non-adaptation of new technology,
more time used for repair, poor power situation, High card silver variation, Nep
formation problem, and Holes or patches in card web.
4.2.4. Drawing Process
Yam manufacturing process in which the sliver is elongated by passing it through

a series of pair of rollers, each pair of roller moving faster than the previous one. These
processes straighten the fibres and create greater uniformity. This process causes
parallelisation and improved blending of fibres by drafting. Several slivers are reduced to
the thickness of one sliver by means of drafting.
In this process six slivers are passed through draw frame to form one sliver with
the aim of better mixing, parallelisation of cotton fibres and good sliver formation. Here
also, cans with caster wheels are used for transporting the sliver to simplex department.
There are two pairs of draw frames out of one pair one machine is used for
breaker draw frames passage and the other for finisher draw frames passage.
The first passage breaker draw frame: The breaker draw frame is having 2
delivery heads. For each delivery 6 sliver are fed at the back of the machines carding can.
The capacity of one can is 13kg. The total cans produced from draw frame, these cans
are moved in second passage finisher draw frame which is near to breaker draw frame.
Breaker draw frame slivers are fed into the finisher draw frame for doubling and drafting
by a drafting rollers for effective parallelisation and for the improved sliver uniformity.
The second passage finisher draw frame: The 8 slivers from cans are fed for
each delivery of finisher draw frame. The capacity of one can is 8 kg. Drawing is one of
95
the key points from the point of view of controlling yarn count variation. Under good
working conditions, the variation in draw frame sliver contributes about half of the lea
count variation. Control of average count can also be effectively done at drawing. The
contribution by drawing to lea count variation and the basis for effective opinion changes
in drawing.21
A card sliver approximately contains 20,000 to 30,000 fibres in its cross section,
whereas the yam made from the sliver has normally 60-150 fibres in the cross section.
Obviously, the card sliver has to be thinned down to the required fineness of the yarn.
The large number of fibres has to be uniformly redistributed over longer length. The
card sliver has to be elongated by 200 to 300 times in a controlled manner. This
operation" drafting" has to be carried out in stages from draw frame to ring frame.
Drafting is the heart of drawing. We expect from drafting a high ledger of
flexibility to suit all raw materials, fibre lengths and sliver tanks etc. Simple and un
complicated constructions, a stable design with smooth running rollers (free of
eccentricity) optional control over the movement of fibres during drafting operations
high precision of operations and adjustments rapid and simple adjustability of roller
spacing and draft levels and ultimately of optional ergonomic design.22
In the drawing process there are two stages. First one is Breaker drawing and the second
is Finisher drawing. In total 23 breaker drawing machines are installed in the first stage
and we find a 100 percent utilisation. Breaker drawing machines are installed in all units
of ACM and SGT. But finished drawing machines are installed only in ACM Is1 and IIIrd
units and they are utilised cent percent.
It can be observed from the same table that the total capacity is 35,400kg per day
in drawing process. The capacity utilisation is 83.62 percent (29,600kg) which is

considered as normal. ACM IInd unit has lowest utilisation of 75.08 percent (6,757kg)
and in ACM IIIrd unit the utilisation i.e. 95.65 percent (6,600kg) where as in SGT
capacity utilisation is 82.11 percent (9,442.26kg) in this process.
21 Ratnam, T.V., K.P. Chellamani, op.cit, p-84.

22 Chattopadhyaya. R. op.cit, Pp.167-168.
96
Table 4.5
Drawing Process Capacity Utilisation
I 1 \o. of machines
ACM I BD 4 4 100
FD 4 4 100
ACM II * 6 6 100
ACM III BD 5 5 100
FD 4 4 100
ACM Total BD 15 15 100
FD 4 4 100
SGT * 8 8 100
TOTAL BD 23 23 100
FD 4 4 100
II Per day production capacity (in kg)
ACM I 8000 6800 85.00
ACM 11 9000 6757 75.08
ACM III 6900 6600 95.65
ACM Total 23900 20157 84.34
SGT 11500 9442.86 22.11
TOTAL 35400 29600 83.62
III No. of supervisors and of hers (per day)
ACM I 1 1 100
ACM II 1 0.5 50.00
ACM III 1 1 100
ACM Total 3 2.5 83.33
SGT 1 - -
TOTAL 4 2.5 62.50

ACM I 10 9 90.00
ACM II 8 8 100
ACM III 6 5 83.33
ACM Total 24 22 91.67
SGT 15 15 100
TOTAL 39 37 94.87
ACM I 1150 700 60.87
ACM II 1050 557.14 53.06
ACM III 850 360 42.35
ACM Total 3050 1617.14 53.02
SGT 1300 657 50.54
TOTAL 4350 2274 52.28
Note: BD = Breaker Drawing; FD = Finisher Drawing; * = Common Drawing
97
In this process four supervisors and others required. However, only 2.5 members
(62.50 percent) are employed. In SGT supervisors and others are not utilised in this
process. In ACM Is1 and IIIrd units utilisation is cent percent, followed by ACM IInd unit
where only 50.00 percent man power is utilised.
Total number of labourers required in both the mills is 39 members but these
have utilised only 37 labours (94.87 percent) in drawing process. In ACM IInd unit and
SGT, labours are fully utilised. But in ACM Ist and IIIrd unit, it is 90.00 percent and
83.33 percent utilisation respectively in drawing process.
The total power consumption in both the mills is 52.28 percent (2274 units),
which is an indicator of underutilisation. In ACM Is1 unit power consumption was 60.87
percent (700 units). In IInd unit, power consumption was 53.06 percent (557.14 units). In
SGT it was 50.54 percent (657 units) and in ACM IIIrd unit it was 42.35 percent (360
units) utilised in this process.
It is evident from the drawing process that production capacity is under utilised.
This is for the reasons that the number of supervisors and others are underutilised; under
consumption of power, obsolete machines, roller lapping problems, irregular selvedge,
and imparities in sliver. There was shortage of raw material during process activities.
4.2.5. Simplex Process
The draw frame finished sliver is drawn into the roller strands called Roving. In
this process drafting and twisting takes place. Drawing slivers are formed as roving ends
here they are wound in simplex bobbin and taken for spinning.
The purpose of this process is to attenuate the sliver into thinner and thinner
stands to achieve the desired ultimate yam. In this process, sliver is converted into
roving. In this department one machine is fed with 148 cans to get roving. The
equipments used to handle the materials are roving trolley, flyer carrier and empty
carrier.
Roving trolley is the open type. The bobbins are arranged neatly one over the
other so that damage can be avoided. The trolley has a capacity to transport 49 bobbins at
a time. Empty bobbins are used to bring back the empty bobbins formed in Ring frame
department. The processing is done over two or three stages called can fed inter process.
98
Mills having super high draft ring spinning do not have to employ at all the speed frame
processing.
Table 4.6
The Capacity Utilisation of Simplex Process
I 1 Vo. of Machines
ACM I 8 7 87.50
ACM II 5 5 100
ACM III 5 5 100
ACM Total 18 17 94.44
SGT 10 10 100
TOTAL 28 27 96.43
ACM I 7800 6700 85.90
ACM II 7500 6528.57 87.05
ACM III 7000 6480 92.57
ACM Total 22300 19708.57 88.38
SGT 10800 9242 85.57
TOTAL 33100 28950.57 87.47
ACM I 1 1 100
ACM II 2 2 100
ACM III 1 / 1 100
ACM Total 4 4 100
SGT 1 1 100
TOTAL 5 5 100
ACM I 29 27 93.10
ACM II 22 21 95.45
ACM III 21 20 95.24
ACM Total 72 68 94.44
SGT 40 39 97.50
TOTAL 112 107 95.54
ACM I 1000 641.67 64.17
ACM II 1350 850 62.96
ACM III 1350 540 40.00
ACM Total 3700 <2031.67 54.91
SGT 1500 1128.57 75.24
TOTAL 5200 3160.24 60.77
99
From the Table 4.6 it is clearly seen that in total 28 machines are installed in the
simplex process. Among them 27 machines are utilised, which is 96.43 percent
utilisation. Machines are fully utilised except in ACM Ist unit, where it is 87.50 percent
utilisation.
In the same process, the total production capacity is 33,100kg per day, whereas
the actual production is only 28,950kg per day (87.47 percent) in this process. In the
ACM it is 88.38 percent (19,708.57kg) and in SGT it is 85.57 percent (9242kg) in the
simplex process.
As is clear from the above Table in this process totally 5 supervisors are required
and we find that 5 supervisors are working in this process. In this process a total of 112
labours are required but only 107 labours are found working. The number of labours is
more in ACM which is more than in SGT in this process.
It can be clearly seen from the Table, the total power consumption capacity is
5200 units. However, the actual consumption is 3,160.24 units (60.77 percent). In ACM
IIIrd 540 units (40.00 percent) are utilised, it is the lowest in the process. In SGT power
consumption utilisation is 1,128.57 units (75.24 percent), which is the highest in this
process.
It is observed from the simplex process that production capacity is on an average

is under utilised. Production capacity is under utilised because power consumption is
low; more time is taken for cleaning purpose; delay in previous process in supply of
materials for next process, low level of operation and operators, obsolete machines,
inefficient management, high variation in roving hank, roller laps problem, ridgy bobbins
and slough off.
4.2.6. Spinning Process
A system of spinning employing the ring spinning frame which drafts the roving,
twist the yam, and winds it on the bobbin simultaneously and continuously. The process
of creating yams directly from slivers, involves opening the sliver and then bringing it all
together in a spinning element to form the yam in one single continuous process.
100
Subsequent drawing (drafting) and twisting of roving bobbins wounded in the
spinning bobbin at the higher rate of spindle speeds produces the cotton yarn, and the
yam will be ready for winding. It produces very fine counts of cotton. The action is
intermittent and slower than that of the ring spinning frame. Different counts of yam are
spun by changing the wheel, pulleys and parameters. Lower count yam is coarser and
higher count yam is fine which would with bobbins. This stage among the overall
processes is crucial and important because the quality and strength of the yam is
basically decided.23
After passing through the process enumerated above, the cotton is now fully
cleaned, thoroughly blended and having its individual fibres aligned parallel to each
other. It is thus made suitable for spinning into yam. During spinning,final twist is
inserted. The amount of twist to be inserted depends on the quality of cotton used and the
end use of yam. For instance, warp yarn is generally spun with higher twist as compared
to weft yam.24
All spinning machines have two sides. On each side there are 210 spindles. Total
number of spindles in one spinning machine is 420 spindles. Some modem spinning
machines have 540 spindles. Per spindle production capacity utilisation is 450 grams in a
day. In this department Ring frame doffer trolley is used. The trolley has two
compartments, one to keep the empty bobbins and the other to fill cops. This minimizes
the incidence of hard waste and doffing time. The method also helps to reduce the strain
for the doffers.
The weight of one empty paper tube is 80 grams. The net yam content would on
tube is 1 kg. The total weight of the one cone is 1.25 kg. A count is a measure of
thickness/finances of yarn. 840 yards of yam spun in one pound is called as one count.
The various count groups manufactured are l-10s, 11 -20s, 21-40s, 41-60s, 61-80s, 81s and
above lower counts indicate coarse yarn and the higher counts indicate fine yam.
Categories of count yam are as follow: coarse yam below 17s, medium B yam 17s-26s,
medium A yam 26s-35s, Fine yam 35s-48s and superfine yam 48s above.
9
23 Ratnam, T.V., K.P. Chellamani, op.cit op.cit, p-85.

24 Bhave, P.V., V Srinivasaii op.cit, SI No. 10, p-18.
101
It is the major part in the spinning mills. It is the last stage in the manufacture of
yam. The ring frame is used for this process. The roving is converted to the appropriate
level. The drafted out roving is then twisted by a ring and traveler arrangement. The
amount of twist inserted here is much larger than at any other stages so as to give it
sufficient strength for the end use. This being the last stage of spinning careful control
has to be maintained on the level of thickness i.e., yarn count and quality of the material
used.
Yam means a textile thread obtained by twisting of consecutively disposed and

straightened ultimate composite fibres. The yam is of many varieties. It is based on the
quality and variety of the cotton used for the production. The following Table 4.7 shows
unit wise capacity utilisation in the spinning process.
From the Table 4.7 it can be observed that in the spinning process, there are two
stages, first one is ring frame and the second is speed frame. In the ring frame a total
number of 131 machines are installed, these machines are fully utilised. In ACM a total
of 76 machines are installed and fully utilised. In SGT 55 machines are installed and they
are fully utilised. Under speed frame stage a total of 13 machines are installed and they
are fully utilised in this stage of process.
The cotton yam production capacity of ACM Ist unit is 7,700kg per day, but the
actual production is 6,733.33kg per day that the utilisation is 87.45 percent. In ACM IInd
unit capacity utilisation is 6,500kg per day (86.67 percent) and in IIIrd unit 6,000kg per
day (92.31 percent). But in SGT, capacity utilisation is 9,000kg per day (81.82 percent),
which is the highest in spinning process. Total cotton yarn capacity utilisation is
28,233.33kg per day (86.34 percent) in spinning process.
Totally 15 supervisors and others are required for this process. But only
13 (86.67 percent) are working in the process. In ACM Ist unit and in SGT supervisors
and others are under utilised. But in ACM IInd and IIIrd units have fully utilised the
supervisors and others.
102
Total 4.7
Unit wise Capacity Utilisation in Spinning Process
ii ........... --------------------------------——■ ------------ *--------------------- —— —
I No. of machines
ACM 1 RP 32 32 100
SP 3 3 100
ACM 11 RP 20 20 100
SP 3 3 100
ACM III RP 24 24 100
SP 3 3 100
ACM Total RP 76 76 100
SP 9 9 100
SGT RP 55 55 100
SP 4 4 100
TOTAL RP 131 131 100
SP 13 13 100
II Per dary production capacity (in kg)
ACM I 7700 6733.33 87.45
ACM II 7500 6500 86.67
ACM III 6500 6000 92.31
ACM Total 21700 19233.33 88.63
SGT 11000 9000 81.82
TOTAL 32700 28233.33 86.34
III No. of sapervisors and others (per day)
ACM I 4 3 75.00
ACM II 4 4 100
ACM HI 3 3 100
ACM Total 11 10 90.91
SGT 4 3 75.00
TOTAL 15 13 86.67
IV No. of Labours ( per day)
ACM I 116 115 99.14
ACM II 84 84 100
ACM III 86 84 97.67
ACM Total 286 283 95.95
SGT 195 190 97.44
TOTAL 481 473 98.34
ACM I 8600 6050 70.35
ACM II 12200 8785.71 72.01
ACM III 8900 6550 73.60
ACM Total 29700 21385.71 72.01
SGT 15000 11428.57 76.19
TOTAL 44700 32794.28 73.37
Source: Field survey.

Note : RP = Ring Frame
SP = Speed Frame
103
In the spinning process a total number of 481 labours are required but 473 are
working. In ACM total 283 labours (98.95 percent) are working in this process, followed
by 190 in SGT which means 97.44 percent utilisation. But in ACM IInd unit all labours
(84 numbers) are fully utilised in the spinning process.
In the same process, total power consumption capacity is 44,700 units, but only
32,794.28 units (73.37 percent) are utilised. In ACM total utilisation of power is 72.01
percent (21,385.71 units). In SGT power consumption in this process is 76.19 percent
(11,428.57 units). In this process in all units have same utilisation of power, it means on
an average utilisation is 73.37 percent in both units.
Spinning process plays very important role in both the mills. If spinning process
is under utilised it will effect overall performance of mills. As it is observed in this
process production capacity is.,under utilised. Main reasons for under utilisation in this '
process are: scarcity of skilled labourers, unskilled supervisors, traditional machines,
lack of raw material, power problems, ventilation, lighting, in-efficiency of operation
systems, uneven yam, between bobbin count variation, within - bobbin count variation,
crackers in the yam thick and thin places in yam and cork screw yam.
a. Yarn Conditioning Department
The purpose of yam conditioning is to apply the moisture at the high degree of
saturated temp in a specified time which enhances the twist stability and consistency in
the yam properties. The conditioning process will be highly useful for the further
processes at the customers end. Continuous testing and inspecting of spinning mill
operations to ascertain that all yarns meet established quality standards. ' The important
characteristics that determine yam quality are count strength, uniformity and
imperfections. The fineness of yam is usually expressed as its count, which represents
the number of hanks of 840 yards (or 7 leas) each, which would together weigh one
pound.
25 Anjaneya Cotton Mills, Quality Control and Yarn Conditioning Department, Davangere, 2006, p-2.
104
4.2.7. Doubling Process
It is a system of processing cotton through the combing machinery twice to
produce very high quality i.e. fine count yam. In this process two yarns are winded
parallel in cheese, these cheeses will be taken at the required quantity of weight as per
out requirements. For extra strength, the single yarn is doubled. Two cones are parallelly
wound on single cheese. After this, they are taken back to wind on cones. This comes
from the latest technology by which the function of doubling machine is done. Finished
doubled yam is produced here itself which eliminates the final winding section in total.
It refers to the process in which two or more single yams are spiraled uniformly
around each other by delivering them through a pair of rollers and twisting them together
by means of a revolving spindle. Yams are plied or combined to obtain greater strength
and smoothness, increased uniformity to obtain novelty or fancy effects.
This is a preparatory process for doubling. Ply winding is done either directly
from ring bobbins or from cones or cheeses. In the latter case, ring bobbin yam shall
have to be wound on to cones or cheeses.
It is observed from the Table 4.8 that under doubling process machines are
installed only in ACM Ist unit and in SGT. A total of 11 machines are installed but 10
machines are working in this process. Whereas in ACM 1st unit is having 8 machines and
SGT is having 2 machines. On an average 90.91 percent machines are utilised in this
process.
Production capacity in ACM Ist unit is 5,200kg per day and in SGT 950 kg per
day. Production capacity utilisation in ACM Ist unit is 4,650kg per day (80.42 percent)
and in SGT it is 575kg per day (60.53 percent), which is the lowest in this process. On an
average utilisation of production capacity is 5,225kg per day (84.96 percent) in doubling
process.
It is evidently seen from Table 4.8 that a total number of 2 supervisors and others
are required. They are fully utilised in ACM Ist unit and in SGT. Totally, 51 labours are
required to work in ACM and in SGT, but only 46 labours are working in this process. In
ACM Ist unit 31 labours are working followed by 15 labours in SGT.
105
Table 4.8
Utilisation of Ca >acity in Doubling Process
I 'fo. of Machines
ACM I 8 8 100
ACM II - - -
ACM III - - -
ACM Total 8 8 100

SGT 3 2 66.67
TOTAL 11 10 90.91
ACM I 5200 4650 89.42
ACM II - - -
ACM III - - -
ACM Total 5200 4650 89.42

SGT 950 575 60.53
TOTAL 6150 5225 84.96
III No. of supervisors and o thers (per day)
ACM I 1 1 100
ACM II - - -
ACM III - - -
ACM Total 1 1 100

SGT 1 1 100
TOTAL 2 2 100
ACM I 32 31 96.88
ACM II - - -
ACM III - - -
ACM Total 32 31 96.88

SGT 21 15 71.43
TOTAL 51 46 90.20
ACM I 2150 1341.67 62.40
ACM II - - -
ACM III - - -
ACM Total 2150 1341.67 62.40

SGT 450 221.42 49.20
TOTAL 2600 1563.09 60.12
106
The total power consumption capacity in doubling process is 2600 units but
actually 1563.09 units (60.12 percent) of power is consumed. In ACM Ist unit power
consumption is 1341.67 units (62.40 percent) and in SGT it is utilised 221.42 units
(49.20 percent) in the doubling process which reflects underutilisation.
Above table indicates that production capacity is under utilised in both the mills.
In this process the utilisation of labourers and machines is normal. Main reasons for
under utilisation of production capacity are: unskilled labours, power shortage, non
adaptation of new technology, non-conducive working conditions, Cork screw yam and
low yam strength.
4.2.8 Cheese Winding (Twisting) Process in ACM - 1st Unit
After winding of yams, cheese winding will be fed into the twisting machines
and the yam will be doubled and twisted based on the customer specifications. In this
process, two yams are winded parallel in cheese, these cheeses will be taken at the
required quantity of weight as per out requirements.
Table 4.9
Cheese Winding (twisting) Process in ACM-I unit (per day)

Sl.No. Particulars Available Utilisation Percent
1 No. of. Machines 2 2 100
2 Production capacity 5200 4683.33 90.06
3 No. of Supervisors 1 1 100
and Others
4 No. of Labours 12 12 100
5 Power consumption 350 141.67 40.48
The Table 4,9 provides the details in cheese winding (twisting) process only in
ACM 1st unit. In this process two machines are installed, and these machines are fully
(working) utilised. The production capacity is 5,200kgs per day, but in this process
production capacity utilisation is 90.06 percent (4,683.33kgs). In the process only 1
supervisor is required and fully utilised. Twelve labours are required and they are fully
107
utilised in this process. The power consumption capacity is 350 units but actually 40.48
percent of power consumption takes place.
As it is clear from the above Table 4.9 the production capacity is under utilised.
The power consumption is only 40.48 percent (141.67 units). Some reasons leading to
under utilisation of production capacity are repair problems, low labourer productivity,
low level of operation, out dated machines, high twist variations and low yam strength.
4.2.9 Auto Cone Process
The auto cone winder winds the yarn in a required form for storage,
transportation and further processing. Extraction of all disturbing faults and
objectionable faults from the yam and making the splicing (joints) for the better quality
are the functions of this machine. Auto cone speeds up output. The machine is fully
automatic using the latest technology which delivers yam spun on the cones.
Table 4.10 indicates that the auto cone process is found only in ACM IInd and
IIIrd units. In total 6 machines are installed and they utilised fully means cent percent
utilisation. The production capacity of this process in ACM IInd unit is 5,500kg and in
IIIrd unit it is 6,200kg per day. But in ACM IInd unit actual production is 4,800kg (87.27
percent) and in IIIrd unit it is 4,840kg per day (78.06 percent). Total capacity utilisation is
9,640kg per day (82.39 percent). It is considered as normal utilisation of production
capacity in auto cone process.
In the same process totally 4 supervisors and others are required. The ACM IInd
unit has 3 supervisors and others and they are fully working but ACM IIIrd unit has no
supervisors and others. In total 66 labours are required in the auto cone process and 64
labours (96.97 percent) are working. In ACM IInd and IIIrd units, 32 (96.97 percent)
labours are working in each unit in auto cone process.
108
Table 4.10
Capacity Utilisation of Auto Cane Process
I So. of Machines
ACM I - - -
ACM II 3 3 100
ACM III 3 3 100
ACM Total 6 6 100
SGT - - -
TOTAL 6 6 100
ACM I - - -
ACM II 5500 4800 87.27

ACM III 6200 4840 78.06
ACM Total 11700 9640 82.39
SGT - - -
TOTAL 11700 9640 82.39

ACM I - - -
ACM II 3 3 100
ACM III 1 0 0.00
ACM Total 4 3 75.00
SGT - - -
TOTAL 4 3 75.00
ACM I - - -
ACM II 33 32 96.97
ACM III 33 32 96.97
ACM Total 66 64 96.97
SGT - - -
TOTAL 66 64 96.96
ACM I - - -
ACM II 2550 1657.14 64.99

ACM III 2000 1250 62.50
ACM Total 4550 2907.14 63.89
SGT - - -
TOTAL 4550 2907.14 63.89
109
The utilisation of power on an average is 2,907.14 units (63.89 percent). In ACM
IInd unit, 1,657.14 units (64.99 percent) are utilised and in IIIrd unit 1,250 units (62.50
percent) are utilised.
Above table clearly indicates that there are variations in auto cone process. These
are on account of less number of supervisors and others and power consumption is low.
In this process there is normal utilisation of labour force. On the whole, production
capacity is under utilised because of non-adoption of new technology. The main causes
of under utilisation are low labour productivity, low level of operation, scarcity of power,
ineffective production management, excessive cuts, cone weight variation and faulty
splicing.
4.2.10 Cone Winding Process
It is a process of transferring yam from one type of package to another, e.g.,

from bobbins to cones or tubes. In this department, yams in cops are wound into cones.
One cone equals 1.25 kg or 1.89 kg of yam. The cones are used in the power loom sector
and the variety of yam required by power looms is supplied in cones. The following
Table 4.11 explains unit wise capacity utilisation in cone winding process.
From Table 4.11 it may be observed that in ACM Ist and IIIrd units three
machines are installed in each unit. Among them in ACM Ist unit 2 machines are
working and in IIIrd unit only one machine (33.33 percent) is working. In IInd unit, no
machine is installed. In SGT 4 machines are installed and they are fully utilised. In total
10 machines are installed, out of them 7 machines are working in this process.
The total production capacity is 14,000 kg per day in cone winding process but
capacity utilised is 68.38 percent (9,573.33kg). In ACM Ist unit 78.89 per cent (4,733.33
kg) and in IIIrd unit only 37.60 percent (940kg utilised) capacity is utilised. In SGT 70.91
percent (3,900kg) utilisation in cone winding process is found.
A total of 3 supervisors and others are required in cone winding process.

However, only 2 supervisors and others are used. In ACM Ist and IIIrd units supervisors
and others are fully utilised. In SGT one supervisor required but no supervisor is working
in this process.
110
Table 4.11
Capacity Utilisation in Cone Winding Process
1
I So. of Machines
ACM I 3 2 66.67
ACM II - - -
ACM III 3 1 33.33

ACM Total 6 4 66.67
SGT 4 4 100
TOTAL 10 7 70.00
II Per day production ca pacity (in kg)
ACM I 6000 4733.33 78.89
ACM II - - -
ACM III 2500 940 37.60

ACM Total 8500 5673.33 66.75
SGT 5500 3900 70.91
TOTAL 14000 9573.33 68.38
ACM I 1 1 100
ACM II - - -
ACM III 1 1 100

ACM Total 2 2 100
SGT 1 0 0.00
TOTAL 3 2 66.67
ACM I 56 36 64.29
ACM II - - -
ACM III 30 8 26.67

ACM Total 86 44 51.16
SGT 72 66 91.67
TOTAL 158 110 69.62
ACM I 750 300 40.00
ACM II - - -
ACM III 700 200 28.57

ACM Total 1450 500 34.48
SGT 950 621.43 65.41
TOTAL 2400 1121 46.71
Ill
Totally 158 labours are required in both the mills. On an average 69.62 percent
(110 labours) working in this process. In ACM Ist unit only 36 labours (64.29 percent)
are working, in IIIrd unit 8 labours (26,67 percent) are working. In SGT 72 labours are
required but 66 labours (91.67 percent) are working in cone winding process.
The power consumption capacity of both the units is 2400 units. However, only
46.71 percent (1,121 units) of power is used. In ACM total power consumption capacity
is 1,450 units, it has utilised 500 units (34.41 percent). In SGT power consumption
capacity is 950 units and it has consumed 621.42 units (65.41 percent) in cone winding
process.
From the above table it can be observed that there are significant differences in
utilisation in cone winding process. The production capacity is under utilised, because of
less number of machines, supervisors, labours and low power consumption. The other
common reasons are non adaptation of new technology, low labour productivity, low
level of operation system, in-efficient management, stitches in cone and end breaks
problems.
4.2.11 Reeling Process
The yam is wound on reels to get hank yam. It is a process used for supplying
yarn for handloom. It is also employed when yarn is to be bleached, dyed or mercerized
in hank form. It is a process of unwinding yam from cops or bobbins and rewinding on
to a revolving reel in the form of skeins or hanks (1 hank = 840 yams).26 In this process,
the yam is reeled to form a 'Hank'. The hanks are used only in handloom sector and the
variety required by handloom sector is reeled out in reeling section. After this process,
hanks are made into a bundle with the help of bundling machine and pressed with a
pressing machine by baling if The cones are placed into bags.
The Table 4.12 evidently shows that a total of 312 reeling machines are installed
in this process but only 304 machines are working, which on an average reflects 97.44
percent utilisation. In ACM totally 175 machines are installed, of which 174 machines
are working, which means 99.43 percent utilisation. In SGT 137 machines installed, out
of them 130 machines (94.89 percent) are working in this process.
26 Bhave, P.V., V Srinivasan op.cit, p-19.
112
Table 4.12
Capacity Utilisation in Reeling Process
I ■ ^o. of Machines
ACM I 93 92 98.92
ACM II 50 50 100
ACM III 32 32 100
ACM Total 175 174 99.43
SGT 137 130 94.89
TOTAL 312 304 97.44
ACM I 3200 3016.67 63.02
ACM II 2900 1700 58.62
ACM III 1750 660 37.71
ACM Total 7850 4376.67 55.75
SGT 5000 3857.14 77.14
TOTAL 12850 8233.81 64.08
ACM I 1 1 100
ACM II 1 1 100
ACM III 1 1 100
ACM Total 3 3 100
SGT 2 2 100
TOTAL 5 5 100
ACM I 93 92 98.92
ACM II 53 52 98.11
ACM III 33 32 96.97
ACM Total 179 176 98.32
SGT 110 106 96.36
TOTAL 289 282 97.58
ACM I 250 108.33 43.33
ACM II 250 128.57 51.43
ACM III 200 110 55.00
ACM Total 700 346.00 49.56
SGT 350 157.14 44.90
TOTAL 1050 504.04 48.00
The total production capacity is 12,850kg per day but capacity utilisation is
8,233.81kg per day (64.08 percent) in the reeling process. The ACM IIIrd unit has low
113
level of production capacity utilisation; it means 37.71 percent (660kg). The SGT has
77.14 percent (3,857.14kg), which is the highest production capacity utilisation of

reeling process.
In this process, a total 5 supervisors and others are required and they are fully
utilised. A total of 289 labours are required, out of which 282 labours are working in this
process. In ACM totally 176 labours (98.32 percent) and in SGT 106 labours (96.36
percent) are working in reeling process.
The total power consumption is 1,050 units, but 504.04 units (48.00 percent) are
utilised in both the mills under reeling process. The ACM IIIrd unit has utilised 55.00
percent (110 units) which is the highest utilisation of power consumption in this process.
In SGT 44.90 percent (157.14 units) of power utilisation is achieved.
All "facts" are under utilised in the reeling process, except supervisors. Power
utilisation is too low, when compared to production capacity number of machines and
labourers. These "facts" are causes for low level of profit of mills. Other reasons are
inappropriate technology, unskilled labours, low level of operation system, entangled
threads in hanks, length variation between hanks and excess threads in hank.
4.2.12. Bundling and Packing
Every cone will be undergoing through checking in Ultra Violet (UV) rays and
the defect free cones will be packed into the cartoons, or HDPE Bags or packed as a
pallets as per the customers requirements. Cone yam is packed in bags and cartoon
boxes. Hank yarn is packed in the form of bales through baling machine.
Yam to be sold is packed in bales or cone bags. For baling, hanks are bundled
and then made into a bale by means of a press. These are the processes involved in the
mill to finish the raw material into finished product, (i.e., yam).
The packing department is working in day shift only. In this department, cheeses
are packed into the carton. There are on an average four layers of cheeses; one layer is
eight cheeses and per cartoon is 64 kg. The cartons are moved from packing to yam
114
godown using flat trolley. One carton is carried and moved from packing department to
yam godown. The total number of trips is 190, distance moved per trip is 35 meters. The
time taken per trip is 5 minute. Two trollies are used to transport the cartons to the
godown.
Yarn is supplied to the market in two different forms hank yam and cone yam.
Hank yam is a convenient form for bleaching, dyeing, packing and transport but needs
winding before placing on the load. It is used by the handloom weavers. Cone yam,
however eliminates the need for winding and can be directly used in power loom.27
In the bundling stage, there are two stages, one is bundling and another one is baling. In
this process a total of 11 bundling machines are installed and all machines are working in
this stage. In ACM only Ist and IInd unit have bundling machines, which are working
fully that is cent per cent utilisation. In SGT, 3 machines are installed and all machines
are working. And also, in baling stage in ACM Ist, IInd unit and in SGT have each one
machines. All machines are working in this process.
In the bundling and packing process a total of 5 supervisors and others are
required and their services are fully utilised, that is, cent percent utilisation. ACM Ist unit
has one supervisor, IInd unit has two supervisors and in SGT two supervisors are working
in this process.
In total 52 labours are required, but only 44 labours (84.62 percent) are working
in bundling and packing process. In ACM 31 labours (83.78 percent) and in SGT 13
labours (86.67 percent) are working in this process.
27 Sidnekopp S. F., Analysis of Operational Efficiency of Co-operative Textile Mills in Karnataka State,
Unpublished thesis^ Karnataka University Dharwad, 2003, p.45.
115
Table 4.13
Capacity Utilisation (required) in Bundling and Packing Process
I No. of machines
Name of the unit Installed Utilisation Percent (%)
ACM I Bu 4 4 100
B1 1 1 100
ACM 11 Bu 4 4 100
B1 4 1 100
ACM III Bu - - -
B1 - - -
ACM Total Bu 8 8 100

B1 2 2 100
SGT Bu 3 3 100
B1 1 1 100
TOTAL Bu 11 11 100
B1 3 3 100
III No. of su lervisors and others (per day)
Name of the unit Required Utilisation Percent (%)
ACM I 1 1 100
ACM II 2 2 100
ACM III - - -
ACM Total 3 3 100

SGT 2 2 100
TOTAL 5 5 100
Name of the unit Required Utilisation Percent (%)
ACM I 21 16 76.19
ACM II 16 15 93.75
ACM III - - -
ACM Total 37 31 83.78

SGT 15 13 86.67
Total 52 44 84.62
Name of the unit Available Utilisation Percent (%)
ACM I 100 50 50.00
ACM II 100 50 50.00
ACM III - - -
ACM Total 200 100 50.00

SGT 150 85.71 57.14
Total 350 185.71 53.06
Note: Bu = Bundling, B1 = Baling
116
Total power consumption capacity is 350 units and total utilisation of power
consumption is 185.71 units (53.06 percent). In ACM Ist and IInd units, each unit has 100
units power consumption capacity but only 50.00 percent is used in each unit which
reflects under utilisation of power consumption in this process. The SGT power
consumption capacity is 150 units of which 85.71 units are utilised. It is the highest
power consumption utilisation in this process. The power consumption utilisation is
57.14 percent in bundling and baling process under SGT.
Table 4.13.1
Capacity Utilisation of Bundling and Packing
Name of
Particulars Capacity Utilisation Percent
the unit
HB&B 4200 2100 50.00
ACM I CP 8000 5734 71.68
Total 12200 7834 64.21
HB&B 2900 2356 81.24
ACM II CP 12500 9246 73.97
Total 15400 11602 75.34
HB&B — —
ACM III CP _ — —
Total _ — —
HB&B 7100 4456 62.76

ACM Total Cp 20500 14980 73.07
Total 27600 19436 70.42
HB&B 5500 4314 78.43
SGT CP 4800 4000 83.33
Total 10300 8314 80.72
HB&B 12600 8770 69.60
TOTAL CP 25300 18980 75.02
Total 37900 27750 73.21
Note: H B & B = Hank Bundling and Baling
C P = Cone packing
Table 4.13.1 reveals that the ACM Ist and IInd units have two kinds of processes,
namely Hank bundling and baling, and cone packing stages. In ACM total bundling,
baling and packing capacity is 27,600kg per day, but actual achievement 19,436kg in this
process. In SGT in both processes capacity is 10,300kg but it has achieved 8,314kg in
this process.
117
Total hank bundling and baling capacity is 12,600 kg but actual utilisation is
8,770kg (69.60 percent). And total cone bundling (manual) capacity is 25,300kg per day,
but utilisation is 18,980kg (75.02 percent) in this stage. The total bundling and packing
capacity is 37,900kg for both mills, but utilised capacity 27,750kg per day (73.21
percent). Bundling, baling and packing processes are important activities in both
the mills. Finishable and salable goods (yam) are packed in this stage. Above table
shows that the labourers and power consumption is under utilised, leading to under
utilisation in bundling and packing process. Before this process, if the production
capacity of other processes is under utilised, it affects bundling and packing process also.
4.3 Other Departments
4.3.1 Quality Control Department
The tests which have been identified to be of relevance in appraising the

performance and aesthetic requirements expected of a yam. Obviously, for any one given
yarn, the actual test value for any one of these characteristics is the total outcome of the
cotton used to spin it and the spinning conditions under which it was spun. Obviously
again, the relative contribution of cotton on the one hand and of the spinning conditions
on the other differ from one yam characteristic to another. This is the next step in the
task of characterizing cotton quality in relation to yarn quality. Therefore, to identify for
each one of the yam characteristics and the cotton characteristics, this can be said to be
-SQ
the foundation for that characteristic.
The various aspects relating to quality control are: raw material and process
control, spinning performance, control of count variation, yam realization and assignable
caused norms for variation quality characteristics from raw material. The yam, waste and
yarn realization, and applications of statistical techniques for analysis consideration and
interpretation of data also form an integral part of quality control.
5.3.2 Yarn Packing Weighing
The mills are using an electronic weighing platform. The capacity of the
weighing platforms is 1500kg. On these platforms cheeses are kept and weighed. Four
28 Subramanian. T.A., Cotton Quality in Relation to Yarn Quality; Ahmedabad Textile Industry’s Research
Association, ICMF, 1988, p-15.
118
cheeses are positioned in one layer. Such four layers are weighed together and the weight
is adjusted to 32kg by changing the cheeses on the each platform.
For weighing one person is employed from department. He takes two minutes to
weight the 64kg. The weight which is meant for one carton is packing platform. From
weighing platform the cheeses are transported to the packing departments which are an
average ten meters away from the weigh bridge. The box trolley is used for transporting
cheeses from Weigh Bridge to the packing department, A lot of 16 cheeses (35kg) are
taken to packing department in one box trolley.
5.3.3 Yarn Godown
This is the last department of the spinning mills where the cartons of yam
packages are stored. The carpet area of yam godown on an average is 1000sq.m (45x25).
The yam godowns are opened in day shift only. The cartons are delivered to the
purchasing party through the heavy vehicles i.e., truck. The delivery is made once in two
or three days. The cartons are transported from the yam godowns to the truck, which is
getting loaded at the delivery door of the godowns.
The same workers and same platform trolley of packing department are employed
for the loading of cartons to the truck. Therefore, no extra wages and equipments are
required to spend on yam godown. The average distance travelled is 15 meters. The
carton is lifted manually from the fork to the truck.29
5.3.4 Warehouses
Warehouses are the godowns which take the responsibility of keeping and storing
goods and providing ancillary in orders to help the manufacturers who technical and
economic reasons may not have their own storehouses. These warehouses are under
taken to preserve the goods in a scientific and systematic manner so as to maintain their
original value.30
Thus, we may say that a warehouse, a store depot, not in the strict sense of the
term but in a broader sense carry out following functions:
29 Joshi B.B. and N.S. Name, Material Handling in Textile Mills; Senaniya Publication (p) Ltd. Bombay
Edition, 1992, pp-4-42.
30 Desai S.S. & M.C., Industrial Economy of India', East-West Publication, Cochin, 1989, pp-20-25.
119
i. To keep the goods in safe custody till these are claimed back by their owner.
ii. To preserve the goods so that they do not loss their values, quantity and usefulness.
iii. To undertake these duties against prescribed charge known at rent paid by the owner
of the goods.
iv. To work as an agent of the owner: 1) Undertaking loading or unloading. 2) Arranging
carriage for transporting. 3) Classifying packing, packing dealing with purchasers
under instructions of the owner. 4) Providing other facilities in the export.
v. Types of material (classification): Raw material (cotton), consumable stores,
Machinery and equipments, inflammable stores, chemicals, furniture, general stores,
scrap material, packing material, fuel stock etc.31
5.3.5 Issue of Material

One of the major functions of store keeping is to make available the materials to
the various departments, whenever they are required by them. For a controlled but
prompt and efficient availability of materials to the various departments, certain
procedure is to be involved for store keeping function.
Materials are issued on a written requisition by the departments, which submit to
the storekeeper requesting him to issue the materials noted in the requisition slip. It is
known as requisition/demand/issue slip/note/indent and requisition voucher and may be
defined as an order on prescribed form to the materials required, duly signed, dated and
numbered by the requisitioning department.
5.4 Conclusion
To sum up, in this chapter researcher has taken 4 units. It is clear that these need
some constructive changes to improve their capacity utilisation. In these units there are
12 processes. Among these processes, in the carding process maximum utilisation is
found. Whereas, in the reeling process, capacity utilisation is minimum. On the whole it
can be said that in order to improve capacity utilisation it is necessary to fully utilise
installed capacity by making full use of machinery, maximum consumption of power,
adoption of new technology, shortening the duration of cleaning of machines,
improvements in the level of operating system, process by process increase in
productivity, recruitment of skilled labourers, proper training and effective management.
31 Mathur K.C., Material Management Practical, East-West Publication, Cochin, 1991, pp-28-29.
120

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CHAPTER- IV

CAPACITY UTILISATION IN PROCESS

4.2 Spinning Process

4.2.1. Mixing process

4.2.2. Blow room process

4.2.3. Carding process

4.2.4. Drawing process

4.2.5. Simplex process

4.2.6. Spinning process

4.2.7. Doubling process

4.2.8. Cheese winding (twisting) process

4.2.9. Auto cone process

4.2.10. Cone winding process

4.2.11. Reeling process

4.2.12. Bundling &packing

4.3. Other Deportments

4.3.1. Quality Control Department

4.3.2. Yarn Packing Weighing

4.3.3. Yarn Godown

4.3.5 Issue of Material

The capacity utilisation is positively related to the magnitude of machine, power,

Capacity utilisation is calculated as follows:

Actual output per day (or per month or per annum)

16000 kg per day

Total 25 supervisors and others were contacted by canvassing the interview

4 http://wikitextbook.couk/index. php/capacitv utilisation - (A-level-BS).

4.2 Spinning Process

Process flow chart of cotton textile in spinning units

Raw Material (Godown)

Spinning (Ring Frame)

4.2.1. Mixing Process

together in predetermined proportions instead of manufacturing yam from single cotton.

1. To take advantage of the desirable characteristics of each quality of cotton and

2. To obtain desired quality of yam at a minimum cost.

12 Prince Dhanaraj. P op.cit, p-57.

1. The specification of mixing quality in terms of the individual fibre properties

2. The specification of mixing quality in terms of an index which is calculated by using

fully utilised respectively.

14 Garde, A.R., T.A. Subramanian. op.cit, p-16.

Source: Field Survey.

The production capacity is underutilised in both the mills. In SGT, production

4.2.2 Blow Room Process

Process involves the following functions:

1. Cotton is opened into small lumps

Cleanliness is a major factor determining yam quality. Low level of trash in

a. Need for opening:

b. Need for cleaning

supervisors and others in this process.

The utilisation of labour is 92.60 percent, which consists of 27 labours out of

4.2.3 Carding Process

It is preliminary process in spun yam manufacture. This process removes most

18 op.cit, SI No. 10, p-17.

between two interacting wire covered surfaces.

this 29,953.33kg (88.75 percent) production is achieved which reflects underutilisation.

it is 89.32 percent (9,557kg) in carding process.

underutilisation. Similarly in SGT it requires 24 labours but actually 22 labours are

working in carding process.

19 Chattopadhyaya, op.cit, p-58-59.

Capacity Utilisation in Carding Process

Source: Field Survey.

4.2.4. Drawing Process

Yam manufacturing process in which the sliver is elongated by passing it through

Drafting is the heart of drawing. We expect from drafting a high ledger of