Achieving 99% Utilization in Spinning

1. An effective maintenance group has to be formed to do schedule maintenance activities

at right time effectively.
2. To go for latest machines by replacing older machines.
3. Surplus stock of spares to be provided to carry-out breakdown activities as quick as
possible.
4. At night shift machine breakdown is to be attended by the fitter, may be stayed at mill
premises or call from nearest place at the earliest possible time.
5. Planned stoppages to be studied carefully to reduce time consumption.
6. Possible cleaning works to be done when the machine is in running condition.
Appropriate tools to be arranged for all categories of cleaning.
7. Idle running of machines, idle running of spindles to be totally avoided.
8. Idle spindles to be corrected immediately. Spare aprons to be provided at each section
at machine cleaning time.
9. For traveler changing and doffing, specific time to be given. Accordingly all system and
training must be given.
10. During power shutdown, alternate power supply is to be given with lowest machine
stoppage time. Adequate diesel stock is to be maintained.
11. Necessary maintenance works, spare changes, electrical checking, belt changing, belt
tension checking etc. are to be combined with machine cleaning schedule.
12. During count changing and wheel changing time, each and every accessory like
bobbins, traveler, wheels, spacer etc. are to be brought to the machine in advance.
13. OHTC to be worked continuously without any unwanted stoppages. Spinning machine
may not be stopped to run the OHTC.
14. Fire fighting equipments are to be arranged in good condition always. If any fire
accidents occurred, it is to be put off immediately and to restart the machine as soon as
possible.
15. Machine cover to be suitably placed to avoid fluff accumulation and for the chances of
accidents to operator.
16. Doors and windows are to be operated as per requirements to avoid lapping, breakages
and idle spindles.
17. Air compressors are to be maintained well in order to give uninterrupted air supply to
machines.
18. Siders to follow zigzag piecing method to attend breakages with least running time of
unproductive break occurring spindles.
19. In the event of Apron cut, tape cut, etc. it is to be communicated to attender immediately
to take corrective action as quick as possible.
20. While patrolling by siders, roller lapping to be cleared first prior to piecing, to avoid
multiple breaks due to lashing.
21. Traveller tray must be used effectively, to piece the traveller missing spindle immediately
after fixing traveller.
22. An effective exhaust system and periodic sweeping process in between machines will
avoid lashing and multiple breakages.
23. Necessary training to be given for doffers to control doffing breakages below 3% after
doffing process.
24. Siders to leave the machine for emergency or at shift end after arriving other person for
carry out the job.
25. Surplus stock of reserve bobbins must be arranged to replace the exhausted bobbins
immediately without creating idle spindles.
26. If abnormal breakages occurred due to any cause, piecing to be done with the help of
other siders and doffers.
27. After festival and other stoppages, machine to be arranged and cleaned in advance to
start the machine at right time.
28. Unit replacement system to be followed at possible areas to reduce stoppage time for
rectification.
29. Damaged spindle tapes, loose tapes, half tapes, worn-out gear wheels, bearings etc. are
to be checked and replaced at machine cleaning time and to avoid unwanted stoppages
thereafter.
30. Drafting cleaning to be done at machine running time by section by section.
31. New mixing bobbins may be replaced along with new spindle empties during machine
running from one side of the machine to avoid bobbin changing stoppage time.
32. Buffed cots may be replaced at machine cleaning time or during machine running by
section by section.
33. Trial bobbins, trial travelers, trial spacers, etc. for 100 spindles may be changed during
running of machines without any stoppages in order to save remaining all spindle’s
production.
34. Proper counseling is needed for absenteeism to avoid overtime work and machine
stoppages due to man power shortage.
35. Machines may be worked on holidays by proper planning and precautionary steps taken.
36. Scientific workload to be assigned for operatives. Additional work load will lead for
absenteeism on next day. Overtime work may affect their efficiency on the next day.
37. The reason for labour turnover to be carefully analyzed and proper solution to be found.
38. Affordable welfare and working condition are to assured for operatives.
39. Operator handling must be made as smooth as possible so that voluntary involvement of
them can be easily expected.
40. Rewarding, appreciation, etc. will help more for team work at emergency time.
41. Roof leakages to be totally arrested then and there to avoid idle spindles.
42. Humidification, Exhaust systems, doors and windows are to be operated according to
the requirement of machine and operatives.
43. During frequent power interruption time, spinning machine load may be given from
genset.
44. Surplus stock of bobbins for all count spun to be ensured all time.
45. Partial running of spinning machine to be avoided except for the count run out machine.