BAHIRDAR UNIVERSITY

Ethiopian Institute of Textile and Fashion Technology

EiTex

DEPARTMENT OF TEXTILE ENGINEERING

HOSTING COMPANY: ADAMA SPINNING FACTORY

TITLE: ROVING BREAKAGE MINIMIZATION IN ADAMA SPINNING

FACTORY BY CHENGING WORN OUTFALSETWISTER AND
ALTERING WORKING CONDITION

Academic advisor: Mrs. TEKALIGN

Company advisor: Ato. MOHAMED KEDIR

Prepared by: AREGA DEBELA

ID: Bdu1106695

Submission date: 21/02/15 E.C

 DECLARATION
I, Arega Debela fourth year textile engineering student have under taken my best
internship experience in Adama Spinning Factory from a period of October 2016 to
February 2017 under the guidance of Mrs.Tekalign Academic Adviserand
Mrs.Mohammed company adviser.
I certify that my work is original and complied according to the internship report writing
guide line given by Industry linkage office of the institute.
As the student’s academic advisor, I certify that the internship report written by the
Student is his original work and complied according to guide line provided by the
Institute’s IIL office as my knowledge is concerned.

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Approval by Advisor

To the best of my knowledge and as understood by the student in the Research integrity
and Copyright Disclaimer, this project adheres to the provisions of copyright Disclaimer,
this project adheres to the provisions of guidelines, policies and legislations of the
Institute of Technology for Textile and fashion technology during his research work and
use of copyrighted material. The project is complete and can be presented to the project
evaluation committee.

Mrs. TEKALEGN
Name of Academic Advisor Signature Date
AREGA DEBELA
Name of Student Signature Date

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 ACKNOWLEDGEMENT
At first, I would like to thank almighty God for giving me the opportunity to complete
my internship. I also want to thank all the people, who have given their support and
assistance and extremely grateful to all of them for the completion of the report
successfully.

I would like to express my deep gratitude to the institute for giving me such chance to
experience overall practical skills and I am grateful to my academic advisor Mr. Tekalign
for guiding me during my stay in the internship and during my project work and report.

I would also like to express my heartfelt thanks to Industrial Engineer Mohammed Kedir
and for their extended support and guide throughout the study. I also would like to thank
everyone who has been willing to help me in the company.

I would like to express my deepest special thanks to those supported me necessary data
and the guide throughout the study. Finally, I want to thank my friends for give moral
encouragement during my study.

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 EXCUTIVE SUMMERY
The first part of the document describes the brief history, the overall production line flow,
and use and types of each machine for the processing. Adama spinning factory was
established in August 2008 E.C. The factory is established on 53,495 square meters of
land in adama (Nazareth) town, Oromia regional state, which is 110km away from Addis
Ababa the capital city of Ethiopia.

The second part deals about the roving breakage cause, or the project it concerns on
effect of roving breakage on machine as well as process parameter and company
production capacity, ways of improving this problem methods of the data collection and
representation concerned the problem and so on.

The third part of this document concerned about over all benefit gained from the
internship program, in terms of practical skills theoretical knowledge, communication
skills and team working with colleague, company working ethics, entrepreneurship and
so on.

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Table of content
DECLARATION.................................................................................................................................ii
ACKNOWLEDGEMENT....................................................................................................................iv
EXCUTIVE SUMMERY......................................................................................................................v
CHAPTER ONE.................................................................................................................................1
BACKGROUND OF ADAMA SPINNING FACTORY.............................................................................1
1.1. Brief History of the Company...............................................................................................1
Mission of the company.........................................................................................................2
Vision of the company............................................................................................................2
1.2. The Raw Material and Accessories Supplier and Raw Material Quality Parameters............2
1.2.1. The raw material...........................................................................................................2
1.2.2. Accessories and supplier...............................................................................................2
1.2.3. The raw material quality parameter.............................................................................3
1.3. The Overall Work Flow of the Company and Their Major Function.....................................5
1.3.1Their Major Function..........................................................................................................6
1.9 Departments of the Organization.......................................................................................16
1.9.1 Production Department...............................................................................................18
1.9.3 Research and Quality Assurance Service:.....................................................................18
1.9.4 Human Resource and Administration Department......................................................18
1.9.5 Finance department.....................................................................................................19
1.9.1 Activities performed Date Wise...................................................................................19
1.10 Main products and services..............................................................................................22
CHAPTER TWO..............................................................................................................................24
ROVING BREAKAGE MINIMIZATION IN ADAMA SPINNING FACTORY BY CHENGING WORN
OUTFALSETWISTER AND ALTERING WORKING CONDITION.........................................................24
2.1 INTRODUCTION...................................................................................................................24
2.2 Literature review................................................................................................................24
2.3 PROBLEM STATEMENT........................................................................................................25
2.4 OBJECTIVE OF THE PROJECT...............................................................................................26
2.4.1 General Objective........................................................................................................26

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 2.4.2 Specific Objective.........................................................................................................26
2.3 Methodology......................................................................................................................26
2.3.1 Material and equipment Used.....................................................................................26
2.3.2 Data presentation............................................................................................................26
2.4 Result and Discussions........................................................................................................30
2.5 Good performance during the task.....................................................................................30
2.6 Challenge............................................................................................................................31
2.7 Measure to overcome the challenge..................................................................................31
CHAPTER- THREE..........................................................................................................................32
OVER ALL INTERNSHIP BENEFIT................................................................................................32
3.2. These observations help me to understand the following:............................................32
3.2.1. How cone is fixed and its advantage...........................................................................32
3.2.2. How knotting is performed during winding and weaving...........................................32
3.3. Benefit gained in terms of improving practical skill...........................................................32
3.4. Benefit gained in terms of up grading theoretical knowledge...........................................33
3.5. Benefit gained interns of inter personal communication..................................................33
3.6. Benefit gained inters of improving team playing skill........................................................33
3.7. Benefit gained in terms of improving leadership...............................................................34
3.8. Benefit gained in terms of understanding about work ethics and related issue................34
3.9. Benefit gained in terms of internship skill.........................................................................34
CHAPTER FOUR.............................................................................................................................35
CONCLUTION AND RECOMENDETION..........................................................................................35
4.1 CONCLUSION......................................................................................................................35
4.2 RECOMMENDATION...........................................................................................................35
REFERENCE...................................................................................................................................36

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List of Table
Table 2.1: Evenness before test....................................................................................................27
Table 2.2: Evenness result after test.............................................................................................27
Table 2.3: Roving breakage before correction..............................................................................28
Table 2.4: Roving breakage after correction.................................................................................29

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List of figure
Figure 1.1: Over all work flow.........................................................................................................6
Figure 1.2: Bale lay down................................................................................................................7
Figure 1.3: Carding machine...........................................................................................................8
Figure 1.4: Drawing.........................................................................................................................9
Figure 1.5: rotor...........................................................................................................................10
Figure 1.7: Ring frame..................................................................................................................12
Figure 1.8: Winding machine........................................................................................................13
Figure 1.9: Doubling machine.......................................................................................................14
Figure 1.10: twisting machine......................................................................................................15
Figure 1.11: organizational structure............................................................................................17

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 CHAPTER ONE

BACKGROUND OF ADAMA SPINNING FACTORY

1.1. Brief History of the Company
Adama spinning factory was established in August 2008 E.C, by Ethiopian investors, Ato
Feleke Bekele and his spouse w/ro Meaza Tereda having traditional business, Mr.
FelekeBekele has started with a pinch in textiles by starting adama spinning factory, the
first 100% privately owned factory in Ethiopia. Adama spinning factory is a subsidiary of
adama development plc. The factory is established on 53,495 square meters of land in
adama Nazareth town, Oromia regional state, which is 110km away from Addis Ababa
the capital city of Ethiopia. The factory is near to the highway connecting the capital city
and the port of Djibouti. The total project investment incurred to date is about birr 160
million, financed by the development bank of Ethiopia and owners’ equity with 70% and
30% share respectively, but know a day the total project investment incurred to date is
about 320 million. The factory is well equipped with state of the art technology, being in
use by advanced western countries, for cotton yarn manufacturing. Most of the
machinery, various mechanical, electrical and electronics equipment are sourced from
renowned and most reliable Switzerland companies known as Reiter and luwa. The
company has a well-organized lab with a complete range of testing equipment from
Mesdan, Italy for testing all quality parameters from cotton fiber to yarn. The lab is
approved by the Ethiopian standards institute and an intensive quality test plan is being
practiced to ensure high quality at every stage of the process. Murata of Japan has also
supplied some machinery. The company has been certified with ISO-9001:2008 QMS
standards and also with WRAP certification. Adama spinning factory is concerned about
the green environment and therefore has designated some area by the factory building as
green area. It has a young committed workforce and an experienced technical team to
handle customers’ needs. Adama spinning factory is now looking for both forward and
backward integration. Currently, the factory has already owned 18,000 hectares of land
for cotton plantation and 44,000-meter square land for gin plant establishment. And also

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the factory has created job opportunities for 450 employees. The company also has socks
knitting machines.

The Factory has three operation lines:

1/ Open-End OE spinning
2/ Ring Frame RF spinning
3/ Reeling Mache line it produces 100% cotton yarn and Reeling Yarn of different
counts both for local and export markets. It has a total capacity of 10 tons per day at an
average count Ne24 and Ne18 of Ring span, Open End and reeling Yarn respectively.
Out of the total 3 tons are ring span yarn, 4 tons’ open end span yarn and 3 ton reeling
yarn per day.
The current product range is from Ne6 to Ne24 for open end line amounting 56%and
from Ne16 to Ne40 carded yarn and Ne20 to Ne60 combed for ring line amounting 44%
of the total production.
Mission of the company
Produce and supply 100% quality cotton yarn, socks and other textile products for local
and foreign markets at competitive price.

Vision of the company

Ensure profitability and sustainable growth by establishing efficient and modern
management and leadership practices that fit the global demand.

1.2. The Raw Material and Accessories Supplier and Raw Material Quality
Parameters
1.2.1. The raw material
The major raw material used in a spinning mill is cotton. In adama spinning factory the
major and the only raw material is cotton, and the company produce 100% cotton
products. The raw material (cotton) of adama spinning factory comes from different
ginning factory, to mix them and to get an acceptable yarn quality and to increase the
profitability of the spinning plant. Some of cotton suppliers of adama spinning factory are
mentioned below:

• Gondar

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 • Awash
• Humera
• Omo
1.2.2. Accessories and supplier
The major accessories for this company are:
• Spare parts
• oil
• Greases
• Different shape of cans
• cone
The spare part, PDP65 OIL and BE31-222 or Nippon grease are imported from:

• Germany and
• India
The other oils are coming from local market like:

• National OIL Ethiopia PLC

• Mobil
• Total
• Shell
1.2.3. The raw material quality parameter
 Spun length
Fiber length is also an important factor influencing spinning as the fiber fineness.
Productivity is influenced via end breakage rate and the quantity of the waste produced at
each stage. This fiber length problem originates from ginning and cleaning process.
Adama spinning factory measures the spun length of fiber by using instrument called
KVF/V class fiber and also as this factory the standard of spun length is greater than or
equal to 27mm.
 Short fiber content (SFC %)
Short fibres are responsible for both quality deterioration as well as economy of
processing. It is very important to measure and control the short fiber content in spinning

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operation. In adama spinning factory the standard percentage is less than 15 and it is
measured by instrument called KCF/V class fiber.

 Trash content
Cotton stock contains foreign material or trash such as vegetable matter, mineral material,
sticky contaminations and other foreign matter metal fragments, cloth fragments and
packing material. The trash not only results in low yarn realization, but also leads to
extreme disturbances during processing. Trash affects yarn and fabric quality. Therefore,
it is very important to know the amount of trash and the type of trash before deciding the
mixing. There for adama spinning factory check the trash by using instrument named
neps and trash indicator, the standard of the company is less than 400 and the unit is
No./gr.

 Micronaire
The fineness determines how many fibers are present in the cross section of a yarn of
given thickness and also determines the bending rigidity of fiber. Equipment used for
fineness test are: fiber fineness tester, balance, comber, and brush. But the factory use
instrument to test the fineness is named fiber fineness maturity meter, as this factory the
standard is 3-5 and the unit is Mgr./inch

 Fiber strength
The strength characteristics can be determined either on individual fibers or on bundle of
fibers. In practical however fibers are not used individually but in groups, such as in
yarns or fabrics. Thus bundles or groups of fibers come in to play during the tensile break
of yarns of fabrics. In adama spinning factory the standard is greater than 80 PSI and the
strength is measured by instrument called neps and trash indicator.

 Moisture content
As cottons used in the mixing come from different parts of the country, they may contain
different levels of moisture at the time of blending. Differences in moisture content of the
components may lead to inadequate cleaning and individualization of fibers resulting in a
yarn with higher incidence of imperfections and poor appearance. The problem can be

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minimized by a proper conditioning of the components to the ambient conditions at the
time of mixing.

 Color
The color of cotton fibers can be affected by rainfall, freezes, insects and fungi, and by
staining through contact with soil, grass, or the cotton plants leaf. Color also can be
affected by excessive moisture and temperature levels while cotton is being stored, both
before and after ginning. As the color of cotton deteriorates due to environmental
conditions, the probability for reduced processing efficiency is increased. Color
deterioration also affects the ability of fibers to absorb and hold dyes and finishes.
1.3. The Overall Work Flow of the Company and Their Major Function

Raw material store

Unifloc machine

Waste opener

Uniclean machine

R/F line
OE line

Uniflex machine

Unifloc machine

Vision

Vision
Carding machine

Carding machine

1 pass drawing

1 pass drawing Lap former

Doubling machine
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 2 pass drawing
Combing
2 pass drawing
Twisting machine
Roving machine

OE spinning
Yarn store
Ring spinning

Steamer machine
Winding machine

Reeling machine

Yarn store

Figure 1.1: Over all work flow

1.3.1Their Major Function
 Blow Room
Basic operations in the blow room:

 opening
 cleaning
 mixing or blending
 micro-dust removal
 Uniform feed to the carding machine.

Blow room installations consist of a sequence of different machines to carry out the
above said operations. Moreover, since the tuft size of cotton becomes smaller and
smaller, the required intensities of processing necessitates different machine
configuration.

 Bale lay-down
Received l/cotton bales from various origins from raw material store shall be laydown as
per the blending pattern.

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Same lots of bales shall be distributed along the length of lay-dawn to facilitate the
blending or mixing.

Figure 1.2: Bale lay down

 Unifloc
Extracting L/cotton material evenly from the bales. Cotton flocks will be plucked from
bales along the laydown to blend and mix from bales of different lots. Heavy particles
and metallic parts will be segregate on the way to uni clean machine. Semi-opening of
cotton tuft will be performed during plucking layer of cotton from the bales.

 Uniclean
 Trash and foreign materials in the L/cotton will be eliminated Or Cleaned.
 Tuft of cotton will be opened.
 Trash cleaned L/cotton will be feed to both OE and RF lines of mixing
machines.

 Unimix
 Blending and mixing of fibers L/cotton of different bales or lots will be
mixed at three points.
 Opening and cleaning of tuft of L/cotton.

 CARD
In the yarn manufacturing process, carding becomes after opening and cleaning of
fibers at blow room. Carding process is so important that it is called “the heart of
the spinning.”

 Objectives of the carding

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  Gently opening of fiber tufts right down to the individual fiber.
 Carding is done primarily to individualize fiber. Blow room machines
 Open fiber in the form of flocks and the card does the finishing
 Operation of opening by individualizing them.
 Untangling, orientation and parallelization of individual fibers into an
 Orderly, lengthwise position without causing fiber damage.
 Elimination of the impurities.
 Reduction in naps

Figure 1.3: Carding machine

 DRAWING (FIRST PASS)
The purposes of the drawing (first pass) machines are:

 Homogenize and parallelize the fibers and drafting the fiber of the feed
stock.
 Producing blended and improved evener sliver by feeding 48 slivers.
 Producing one evener sliver end by drafting 4 to 8 slivers ends and dust
removing.

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 Figure 1.4: Drawing

 UNILAP
The purposes of the UNILAP machine are:

 Producing of uniform loose stock from number of sliver ends.

 Fiber parallelizing and lap roll forming.

 COMBING
The purposes of the combing machine are: -

 Improving of yarn quality by extraction of impurities and naps.

 Improving of the effective staple length by intensive fiber parallelizing and

drafting.

 The discharging of short fibers which is critical for the production of finner yarn.

 Depositing or coiling of sliver in cans.

 DRAWING, SECOND PASS WITH AUTO LEVELER

The purposes of the drawing, second pass with auto leveler machine are:

 Producing blended and improved evener sliver with controlling the

feeding speed with auto leveler controlling system.
 Producing one evener sliver end by drafting 4 to 8 sliver ends.

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  Drafting the fiber of the feed stock, dust removing and coiling of sliver in
cans.

 ROTOR OE SPINNING
The purposes of the rotor OE machine are: -

 Opening and drafting sliver and combine single fiber to produce yarn of
the desired fineness.
 Reinforcing yarn by applying twist.
 Winding the produced yarn with paper or plastic cone to have more
packages up to 3kgs.
 Inspecting and cleaning of imperfection yarn by passing the yarn through
sensors.

Figure 1.5: rotor

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 ROVING
 The purposes of the roving operation are:
 To reduce the sliver to a suitable size of spinning
 To strengthen the thin strand of roving by means of twisting it.
 To wind the roving onto a bobbin
 Task of roving
 Attenuation of the sliver by drafting.
 Reinforcement of the roving by twist
 Winding of the roving on a material carrier bobbin that suitable for ring
spinning machine.

Figure 1.5: Roving

 RING SPINNING
The purposes of the ring frame operation are: -

 Draw the roving in the drafting system to its final count.

 Reinforce the slaver by twisting.
 Winding the produced yarn in a manner suitable for storage, transport and
further processing

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 Figure 1.7: Ring frame

 WINDING
The purposes of the winding operation are: -

 Winding the yarn from cops of 60-70 grams to paper or plastic cone to
have more packages up to 3kg
 Inspection and cleaning of imperfection yarn by passing the yarn through
sensors.
 To coat the yarn with waxing as required

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 Figure 1.8: Winding machine
 DOUBLING
The purposes of the doubling operation are:

Winding the desired length of yarn with cylindrical plastic tube.

Winding 2-4 yarn ends with cylindrical tubes producing double wound yarn suitable for
twisting processing.

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 Figure 1.9: Doubling machine
 TWISTER
The purposes of the twister operation are: -

Twisting 24 plied yarn and wound the produced plied yarn with paper or plastic cone to
have more package

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 Figure 1.10: twisting machine
 REELING
The purposes of the reeling operation are: -

 Winding yarn from cone to hank from.

 Reeled (hank) yarn rapped, packed to parcel package weighing 4.5 to 5 kg.

 STEAMER
It is used to steam yarn in the form of copes to increase strength, smoothness, softness
and decrease hairiness of yarn.

 Socks knitting section

There are two types of knitting machine depending on the needle bed available in the
company. These are double bed and single bed machine which are 54 in Number. All are
made in Italy in 1992 G.C. The machineries are imported in 2012 G.C; but it starts its
work in 2014 G.C and the performance of the Machineries is very low.

 Waste recycling in spinning department

The waste which came from all machines starting from blowing machines to winding
machines have their own line which is used to restore the waste in a separate room. All

15
machines have a tube line connected to the waste recycling room and the wastes are
pressed as a bale and they are used for sell only.

 Spinning maintenance and the store

Spinning department has its own maintenance store and mechanics, there even head
mechanics and senior mechanics for each machine. The company also uses plan
preventive maintenance to protect the machines from break and service them with in an
interval. To improve quality, the machines, clean every time when ever needed and also
routine serviced with their schedule. The department have its own spare part store.

1.9 Departments of the Organization

Adama Spinning Factory was six departments which directly accountable to the Factory
General Manager. In return, the General Manager is also accountable to Managing
Director of Adama Development PLC. The functions were categorized on the basis of the
nature of the processes.

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 Managing director

Advisory Board
Deputy Managing
director

Commercial Department Audit and Inspection Service

General Manager
Marketing

& Sales Procurement

Division Division

Property Administration

HR and Engineering Finance

Administration and Technic Department
Production
Research and
Department
Quality
Assurance
HR Division Electrical General
Service
Maintenance Spinning Accounts
Division

General Services Mechanical Yarn Management

Maintenance Processing Accounts

Figure 1.11: organizational structure

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1.9.1 Production Department: is designed including production division which directly
accountable to the department. The production division is monitors and controls the three
shift operations in which the shifts have organized and coordinated by three supervisors.
1.9.2 Commercial Department: is organized including property administration and
procurement division, and marketing and sales division. The sales and marketing division
was designed to carry out sales, both for local and foreign markets. Currently, the local
and foreign marketing processes are undertaken at head office level by Marketing Expert
being accountable to the Managing Director. As the marketing process is informally
shifted to the head office, currently the Factory is experiencing communication and
accountability related problems. Thus, the General Manager and Commercial Department
Manager have no adequate knowledge of the foreign and local market performance.
Engineering and Technical Department: was designed including Electrical and
Mechanical Maintenance Divisions. The divisions are directly accountable to the
department. As the name implies, the divisions were organized to carry out mechanical
and electrical related maintenances. Based on this design, the manpower was not
organized adequately to properly address the processes of utilities.

1.9.3 Research and Quality Assurance Service: was designed including Management
Information and Planning Division and Quality Assurance Division. The function was
organized to perform business planning, quality assurance and management information
sub processes which are functionally different and unrelated. Thus, it needs to
differentiate these unrelated sub-functions through redesigning the structure.

1.9.4 Human Resource and Administration Department: was designed including

Personnel and Training Division and General Service, which are directly accountable to
the department. Occupational safety and health management process and follow up of
safety equipment readiness were designed under general service. The process of
preparedness has no any relation with general service functions. Rather, the technical
aspects are related to Technical process, and the remaining inspection, observation and
health issues are related to human resource process

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1.9.5 Finance department: was designed including General Accounts Division and
1.9.6 Management Accounting Division. The divisions are directly accountable to the
department

1.9.1 Activities performed Date Wise

Human Resource& Administration Dep’t

 Planning, organizing, coordinating and controlling:

 Human resource planning activities

 Recruitment and selection activities

 Training and development

 Human resource data management

 Employee time management

 Labor relation

 Human resource audit

 Employee performance management

 Employee leaves medications and workmen compensation.

 Employee recognition and rewarding.

 Succession planning.

 Occupational safety and health management activities.

 Carry out employee transfer and promotional activities.

 Carry out employee disciplinary issues Establishing and revising.

 Organizational structure based on the labor market.

 Conducting the labor market assessments.

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  Counseling and coaching employees.

 Conducting the induction training to socializing the newly

 Employed employees to the working environment.

 Adopting new human resource management systems.

 Managing employee benefits.

 Carry out fleet management activities.

 Plan organize, coordinate and control housekeeping and

 Compound security related activities.

 Managing the canteen of the factory.

Finance Department

 Planning, organizing, coordinating and controlling

 Cash payments and collection

 Bank reconciliation general ledger posting

 Product costing and pricing

 Payroll management activities

 Preparing financial statements like cash flow statements, balance sheet

and profit and loss statements

 Managing working capital

 Conducting financial ratio analysis for management decision

 Conducting inventory physical counts

 Controlling both physical and financial assets of the factory

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  Preparing financial strategies

Commercial Department

 Conducting purchase analysis to choose best supplier

 Preparing supplier lists from sellers.

 Controlling the movement of final assets

 Managing both raw materials and finished goods stores

 Carry out the loading and shipping activities

Production Department

 Preparing weekly , monthly and yearly product on plan

 Receiving customers order and producing products as per their

requirements

 Carry out machine setting base on customers product requirements

 Conducting process super vision periodically

 Engineering& Technical Department

 Planning, organizing, coordinating and controlling the mechanical,

electrical maintenances and activities

 Carry out both break down and preventive maintenance.

 Preparing specifications for the purchase of spare parts

 Carry out machines and electric installation

Research& Quality Assurance Service

 Planning, organizing ,coordinating and controlling production process

inspection, product quality testing, consignment testing, business planning

21
 and performance management and management information related
activities

 Conducting process and finished goods inspection

 Conducting consignment testing for the purchase of new materials.

 Managing the factory’s physical laboratory

• Preparing strategic and annual operation plans

• Preparing reports for monthly and yearly performance of the factory

• Coordinating and controlling the business performance

• Managing information systems of the factory.

1.10 Main products and services

The main products are:
 Socks

 Open end and winding cones yarn for market

 Twisting yarn for market,

The main customers or the end users of its products or services

 From local market

 ZemeneYohannes GB PLC

 Almeda Textile PLC

 MNS Manufacturing PCL

 Ethio Japanese Synthetic Textiles

 Elias Tesfaye Textile & Garment

 Getahun Aytenfisu

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  DH Geda Dyeing & Bleaching

 DebreBirhan Blanket Factory

 Adama Garment Industry

 Ayka Addis Textile Investment Group

 Ethiopian Sewing Trade Factory

 EndalkachewAweke

 Yirgalem Addis Textile Factory PLC

 Kanoria Africa Textile PLC

 DLM PLC

 Mulat Mekonnen

 Arbaminch City Bazar

 DelelewDerzaYouka

 Trio Craft

 MerdokyosAsha

 MandoseEmero

 SABAHAR PLC

From foreign market

 North America

 South America

 Eastern Europe

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 CHAPTER TWO

ROVING BREAKAGE MINIMIZATION IN ADAMA SPINNING FACTORY BY

CHENGING WORN OUTFALSETWISTER AND ALTERING WORKING
CONDITION
2.1 INTRODUCTION
Roving is a continuous fibrous strand drafted from sliver and given cohesion by inserting
small amount of twist. It is drafted and twisted to be spun in to yarn or it is intermediate
process between sliver and yarn . In conventional ring spinning system, conversion of
sliver into yarn through a single step has not succeed since the total draft needed is in the
range of 300-500 which is difficult to apply on sliver in a single step and obtain good
quality.

Roving breakage is one of the major roving defects that affect the quality and quantity of
its product. It affects the machine productivity, when the machine stops frequently. And it
affects the material quality by reducing of roving strength, evenness and increase the
hairiness of the roving.

2.2 Literature review

Roving is a continuous fibrous strand drafted from sliver and given cohesion by inserting
small amount of twist. Roving breakage is one of the major roving defects. High
temperature and low relative humidity affects the material or roving by making it weaker,
thinner more brittle and less elastic and less elongate. [https. www. Adtextiles. blogspot.
com].

In conventional ring spinning system, conversion of sliver into yarn through a single step
has not succeed since the total draft needed is in the range of 300-500 which is difficult to
apply on sliver in a single step and obtain good quality.

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2.3 PROBLEM STATEMENT
Roving frame is the machine that necessary for ring spinning line. The roving frame with
minimum or standard breakage rate is also essential for good ring spinning line
production. But despite of this during my observation there is high sliver breakage rate in
adama spinning company due to the cause of insufficient twist, improper draft
distribution, fluctuations in temperature and humidity, are the main reasons for breakages
at speed frames. This end breakage affects the quality, efficiency and productivity of the
ring spinning line. The project also focus on minimizing breakage rate of sliver, moving
to the frame in Adama spinning company. And this affect the productivity and efficiency
of machine by reducing the running time of machine due to stoppage. And it is affects the
quality of the sliver by creating the piecing on the sliver surface. By Minimizing of the
breakage rate of the sliver we can reduce this problem. Eliminating this problem by
making automatic room conditioning, checking and changing the false twister machine
and balancing the flyer speed with bobbin speed. In this way it can upgrade the quality
efficiency and productivity of the roving frame.

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2.4 OBJECTIVE OF THE PROJECT
2.4.1 General Objective
 Minimizing of Roving End Breakage

2.4.2 Specific Objective

 To Improve roving Frame Machine Productivity by Reducing of the Machine
Stoppage.
 To increase the roving strength by reducing of knotted roving.

2.3 Methodology
During my observation I observed that there is high frequency of machine stoppage due
to roving breakage in Adama spinning company. This affects the company quality and
quantity of the product by Minimizing or reducing the roving breakage and improving the
quality and quantity and efficiency of the machine by measuring of roving strength,
roving hairiness and Temperature and humidity. During my observation by collecting
data before improvement of the problem and after improvement of problem is as follow.

2.3.1 Material and equipment Used

During my work I used the following material;

 100% cotton fiber

 0.9 ne count semi-combed sliver.
 Uster evenness tester machine.

2.3.2 Data presentation

During my observation. There is a lot of worn out (damaged) and sharpen false twister
machine. When roving rotate over this part it create friction on the material and increase
roving hairiness, decrease roving evenness and decrease roving strength. The other one is
the fluctuating of temperature and humidity that contrary with the standard which (25-27)
degree Celsius and (50-60) % relative humidity. But the company working room
condition is (35-40) degree Celsius and (25-30) % relative humidity. And the company
have not automatic conditioning system they allow indoor and outdoor air by guessing
once day and used for long time which 25% outdoor and 75% indoor air. These means

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raising the room temperature and decline the room relative humidity. This gives weaker,
thinner and more brittle and less elastic, less elongation of the material. So to prove this
problem i adjust the fluctuating of temperature and humidity based on the standard which
between 24-27 degree Celsius.

Table 2.1: Evenness before test

Samples CV% U% Count (ne)

Sample 1 5.1 4.56 0.9

Sample 2 5.3 4.39 0.9

Sample 3 6.0 4.14 0.9

Sample 4 5.0 4.22 0.9

Sample 5 5.5 4.25 0.9

Table 2.2: Evenness result after test

Samples CV% U% Count (ne)

Sample 1 4.40 3.54 0.9

Sample 2 4.25 3.29 0.9

Sample 3 4.30 3.12 0.9

Sample 4 4.18 3.20 0.9

Sample 5 4.11 3.31 0.9

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 Table 2.3: Roving breakage before correction
Days Total breakage Breakage per Idle spindle
100 spindle

20/11/14 21 5 13

21/11/14 22 5 12

22/11/14 21 5 8

23/11/14 20 5 9

24/11/14 19 5 8

25/11/14 20 5 10

26/11/14 18 5 11

27/11/14 20 5 9

28/11/14 18 5 8

29/11/14 20 5 10

From the above explained table the roving breakage is much greater than the standard
breakage that is 4 end break from 100 spindle in 1hrone hour. The data collected are
represented the breakage of roving continuously for 10 days in 1hr.

Total breakage in 10hrs =21+22+21+20+19+20+18+20+18+20=199

Mean= (X1+X2....Xn)/n

Mean= 199/10=19.9 this is the total breakage in 1hr in the company

There is 24 hrs.in a day = 24*(19.9) = 477.6

There is three shifts in a day therefore; 477.6/3=159.2=~159

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But standard breakage of roving frame machine is 4 in 1hr.

One day have 24 hours so there is 96 times in a day.

There is three shifts in a day therefore; 24 times in shift.

So as we can see from the analysis the roving breakage in Adama spinning company is
much more than that of acceptable limit or standard. Therefore this is affecting the
quality as well as quantity of the yarn in the company.

After the problem gets solved the following results has been founded as indicated below
in the tables:

Table 2.4: Roving breakage after correction

Days Total breakage Standard breakage Idle spindle
rate per 100 spindle

2/12/2014 11 5 12

3/12/2014 10 5 13

4/12/2014 8 5 8

5/12/2014 9 5 9

6/12/2014 10 5 8

7/12/2014 8 5 10

8/12/2014 9 5 11

9/12/2014 10 5 9

10/12/2014 7 5 8

11/12/2014 9 5 10

Total breakage = 11+10+8+9+10+8+9+10+7+9=91

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Mean=91/10=9.1 where as in the case before the problem is solved is 19.9

Total breakage in one day =24*9.1=218.4 but in the case of data before the problem
solved is 477.6

There is three shift in a day so 218.4/3= 72.8 in spite of this it is 159 before

So as we can see the deference its clear to understand which the result I found is more
close to the standard.

Major cause of problem

 Fluctuating of temperature and humidity

 Worn out or sharpen of the false twister

2.4 Result and Discussions

Roving frame machine is very necessary for ring spinning line. Because it is difficult to
change the sliver to yarn in conventional ring spinning in spite of its draft. And it also
affected by count variation, soft packaging and roving breakage.

So high roving breakage rate affect this necessary process by enhancing the stoppage
time of machine and degrading the productivity of the machines.in average 19.9
approximately 20 times broken in 1 hour and there is 1.5(one and half) minutes to knot
the broken roving so 20*1.5=30 minutes therefore from 1 hour the machine works only
30 minutes and in one shift 8*30=240min (4hrs) and 720min (12hrs) in a day. And
frequently Knott the roving affect the quality (strength) of the yarn.

2.5 Good performance during the task

• Since from my joining of Adama Spinning Factory, I tried my best to make good
communication with everybody in the company.

• I try to exercise the theoretical knowledge that I have been thought.

• I was good at interviewing company’s workers.

• I have attained almost all working days and I observed each problem of the
company.

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 • I have developed the practical aspects of textile factory with an excellent self
esteem.

2.6 Challenge
Computer service problem; there is no internet and computer access in the company to
write report and project. The city internet access is very expensive this can be increase
the cost of living life of internship.
While I was collecting the data. I had faced many challenges that could made
me late to do my task in a time because I does not get enough data.

2.7 Measure to overcome the challenge

To all problems above, I select the best and good ways or direction to perform the main
goal of internship program.
Avoiding the thinking of extravagancy, to stand the complex life load and avoid
unnecessary way of life.
Think the problem may face for forward life and how to pass these challenges
successfully.
Sharing with other class mates some materials like house rent and other to with stand the
life load.

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 CHAPTER- THREE

OVER ALL INTERNSHIP BENEFIT

3.1. Introduction

I of my internship schedule I have observed the entire process starting from raw material
store to finished fabric store. The raw material handling, the responsibility of each person
in each plant and section, process and machine parameter in each plant.

3.2. These observations help me to understand the following:

 How the raw material are being mixed during spinning process.

 How the spinning process are from blow room to winding.

 What to adjust when articles are changed in each spinning machine.

3.2.1. How cone is fixed and its advantage.

How dyeing process such as cone dyeing, hank dyeing , fiber dyeing and
fabric dyeing carried out.

3.2.2. How knotting is performed during winding and weaving.

 How grey fabric quality control is performed, what is the grey fabric fault and
how they removed.

 How the treatment and finishing process are performed.

 How the finished fabric quality control is performed and the grade is given for
finished fabric.

3.3. Benefit gained in terms of improving practical skill

 Practical weaving of different fabric design by using different types of machine.

 Try to solving problems and work flow practically.

 Practice how yarn knot and sliver knot.

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3.4. Benefit gained in terms of up grading theoretical knowledge

Develop the theoretical knowledge on the type of fiber, yarn and their effect on fabric
practically.

 Concerning fabric structure and design there are different types of grey fabric
produced in the company develop the theoretical knowledge practically that
produced by different harness.

 Develop basic process of production department.

 Develop the dyeing process of synthetic and natural fibers and different between
them.

 Concerning pretreatments and finishing.

 Develop knowing practically cause of waste and ways of avoiding produced

waste.

 I know material handling is the basic criteria for the product reduced.

 Practice how blow room, carding, breaker, combing, roving, ring, winding,
twisting dyeing, sectional warping, re winding and fabric weaving and
finishing take place.

3.5. Benefit gained interns of inter personal communication

 I learn from each section manager, worker, shift leader and supervisor:

 How I approach with employees.

 Understanding their diplomatic technical words with relative to scientific words.

 The ways of asking question that I have not understand during observation.

3.6. Benefit gained inters of improving team playing skill

 I avoid weight of work from one person.

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  Helping the workers.

 Working in order to fulfill the customer need within a specific time.

 Decreasing idle time of the machine.

3.7. Benefit gained in terms of improving leadership

 Leading work.

 Solving the problem faced.

 Handling the employees

3.8. Benefit gained in terms of understanding about work ethics and related issue
 Punctuality.

 Hard working Loyalty of work.

 Giving emphases of work.

 Work ethics is the basic necessary issue for every production steps in every
department of the company.

 Understanding the effect of worker on production.

 Practice how yarn and sliver knot.

 Practice weaving of different fabric design.

 Practice how machine is performed.

3.9. Benefit gained in terms of internship skill

 Job creativeness.

 Performing my task with plan.

 Develop the experience on the theoretical knowledge

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 CHAPTER FOUR

CONCLUTION AND RECOMENDETION

4.1 CONCLUSION

In general roving frame machine with; first, sharpen or damaged teeth of false twister,
have a great influence on breakage roving. When it is sharp or damaged it cut or break
the roving while it rotate around the surface of the roving to insert false twist.

Second, inappropriate air conditioning (fluctuating temperature and humidity) in the

roving frame machine working room is own negative effect. If the temperature is very
high and humidity is very low, the roving fiction increase and the material affected by
hariness. Roving lapped on bottom roller because it becomes hooted and may create
sweat on its surface and the inverse is true.

4.2 RECOMMENDATION

As indicated above on the conclusion section of the report all causes have their own
negative side effect so it is necessary to solve accordingly. Therefore, based on the
finding it is necessary to check the false twister or grommet by schedule and change the
sharpen and damaged grommet. The other cause of breakage could be improper condition
of the room so it is necessary to control the condition because it is necessary in cotton
spinning mill.

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 REFERENCE

1. Kline spinning book volume 3

2. The company speed frame machine manual
3. “https.www.Adtextiles.blogspot.com”
4. “https.www. textileschool.com”

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