DIRA DAWA UNIVERSITY INSTITUTE

OF TECHENOLOGY
SCHOOL OF TEX

Name ID NO

1 ADDISU

ADVISOR:
SUBMISSION DATE:
DIRA DAWA, ETHIOPIA

DECLERATION
 INTERN REPORT 2014

We are fourth year textile engineering student have under taken our internship experience in
Wuxi no one cotton textile plc from a period of February to May 2013 under the guidance of
Mr.Asnake .K(academic advisor) and Mr. Amanuial Zekarias(company advisor). We certify that
our work is original and compiled according to the internship report writing guideline given by
the industry linkage office of the institute.

As a student of academic advisor, I certify that the internship report written by the student is his
original work and compiled according to the guideline provided by the institute as far as my
knowledge is concerned.

ACKNOWLEDGEMENT
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The internship opportunity we had with Wuxi No one cotton Ethiopian textile PLC. was a great
chance for learning and professional development. Therefore, we consider ourselves as a lucky
intern as we were provided with an opportunity to be a part of it. Based on this we would like to
give much glory to the almighty God. Secondly, we would like to thank our academic advisor,
Mr. Asnake K. for his wise and outstanding advice. Also, we want to express our special thank to
Wuxi no one company, and to quality department head Mr. He and our company advisor Mr.
Amanuel Zekarias also we have a special thanks to the company employees’ colleagues from
textile engineering department supported us in our project work. We want to thank them for all
their help, support, interest, and valuable hints.

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ABSTRACT
This report and the project work consists the brief history and profile of our hosting company
which is Wuxi number one cotton textile plc. Including the main raw material used to produce its
main product. And the main customers that use its main product and main suppliers.
Consequently, its organizational structure and detail workflow of cotton yarn production
activities in each section and overall systems of the organization. The report also describes the
current practice and activities that takes place in production department and other main
supporting departments. In addition to the overall benefit that we gained during the internship
and the significance of the project are interms of improving and upgrading the practical skill,
theoretical knowledge, team playing skills, leadership skills, work ethics, internship skills, and
communication skills. The factor constraint their activities was also identified. Following this it
tried to describe the analysis made to solve those problems by using different techniques and
recommendation. Based on this, a project is designed to address those constraints. The aim of
this project is to minimize carding waste like nep short fiber, and dust and to improve the quality
of the carded sliver and yarn by applying different flat speeds on the carding machine. While the
other machine parameters were fixed. Five flat speeds (200, 240, 280, 320, and 360 mm/min)
have been used to produce slivers and yarns. Sliver yarn of two different counts (Ne60 and
Ne80) was produced for assessing the quality. The unevenness and tensile properties are found to
be best for flat speed 360 mm/min with significant increasing of waste percentage and increasing
the production. And the sliver waste is decreasing by giving training for the short training to the
operators and by maintains the machine properly the waste available in carding machine
decreases.

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LIST OF ACRONYMS

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Table of Contents
DECLERATION..............................................................................................................................I
ACKNOWLEDGEMENT..............................................................................................................II
ABSTRACT..................................................................................................................................III
LIST OF FIGURE..........................................................................................................................V
LISTS OF TABLES......................................................................................................................VI
CHAPTER ONE..............................................................................................................................1
INTRODUCTION...........................................................................................................................1
1.1 Background Of The Company...............................................................................................1
1.2 Row Material..........................................................................................................................2
1.3 Main Suppliers.......................................................................................................................2
1.4 Main Customer.......................................................................................................................2
1.5 Main Products........................................................................................................................2
The main product of Wuxi no 1 cotton textile plc. is cotton yarn..............................................2
1.6 Vision Of The Company........................................................................................................2
1.7 Mission Of The Company......................................................................................................2
1.8 Overall Work (Process) Flow Of The Company...................................................................3
1.8.1 Bale Store........................................................................................................................3
1.8.2 Blow Room......................................................................................................................3
1.8.3 Carding Machine.............................................................................................................5
1.8.4 Draw Frame Machine......................................................................................................6
1.8.5 Roving Machine..............................................................................................................8
1.8.6 Ring Frame Machine.......................................................................................................9
1.8.7 Winding Machine............................................................................................................1
1.8.8 Rotor Spinning Machine.................................................................................................1
1.9 Types And Model Of Spinning Machine...............................................................................2
1.9.1 Production Capacity........................................................................................................3
1.10 Overall Organization And Workflow..................................................................................4

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CHAPTER TWO.............................................................................................................................6
2. INSTALATION OF SIGNAL INDICATER ON RING FRAME MACHINE..........................6
2.1 INTRODUCTION............................................................................................................6
2.1.1 Work flow of the ring frame machine.............................................................................7
2.2 Statement of Problem.............................................................................................................8
2.3. Significance of the study.......................................................................................................9
2.4. Scope of the project...............................................................................................................9
2.5. Limitation of the project.......................................................................................................9
2.4 litterer Review........................................................................................................................9
2.5 Objectives of the project......................................................................................................10
2.5.1General objective............................................................................................................10
2.5.2 Specific objectives.........................................................................................................10
2.6Methods of Data Collection, Data presentation And Data analysis......................................10
2.6.1 Methodology.................................................................................................................10
2.6.2 Data collection methods................................................................................................13
2.6.3 Data Presentation...........................................................................................................13
2.6.4 Analysis of the Problem................................................................................................14
2.6.5 Cost analysis..................................................................................................................16
2.7 RESULT AND DISCUCTION............................................................................................16
2.9 Good Performance During Work Tasks...............................................................................17
2.10 Major Challenges and Measures Taken To Overcome It during Work Tasks...................18
2.11 To Solve These Problems the Following Measures are taken:..........................................18
CHAPTER THREE.......................................................................................................................19
3. OVERALL BENEFITS OF THE INTERNSHIP....................................................................19
3.1 Benefits Gained In Terms Of Improving Practical Skills................................................19
3.2 Benefits Gained In Term of Up Grading Theoretical Knowledge.......................................19
3.3 Benefits In Terms Of Interpersonal Communication Skills................................................20
3.4 Benefits Gained In terms of Improving Team Playing Skills..............................................20
3.5 Benefits Gained In Terms Of Improving Leader ship........................................................20
3.6 Benefits Gained IN Terms Of understanding About WORK Ethics and Related Issues....21

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3.7 Benefits Gained In Terms Of entreneurship Skills..............................................................21

CHAPTER FOUR.........................................................................................................................22
4. CONCLUSION AND RECOMMENDATION........................................................................22
4.1 Conclusion...........................................................................................................................22
4.2 Recommendation.................................................................................................................23
REFERENCE................................................................................................................................24

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LIST OF FIGURE

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LISTS OF TABLES

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 CHAPTER ONE

INTRODUCTION

1.1 Background Of The Company

Wuxi No.1 Cotton Mill was established in 1919 and has gained countrywide fame as a cotton
textile factory with nearly 102 years' development; the company becomes an industrial group
involving cotton textile production. The company is one of China's leading textile enterprises
with a total of 600,000 spindles and 600 looms. Its associated brand "TALAK" has been
registered in 55 countries and regions in Europe, Asia, and the United States. Wuxi No.1 Cotton
Mill signed to take part in a textile project with a total investment of $220 million in Dire Dawa
Industrial Park, Ethiopia on Nov 2, 2017. The cornerstone ceremony was held on Jan 16,
2018.The Company start production in the second half of 2019 with an ambition to export much
of its products to the international market. The company Found inside 52 hectares of land with
over USD 220 million spent, it has, so far, created more than 1500 local jobs in the area and is
expected to reach 3500 once it is fully operational. The company is to use 100 percent pollution-
free and environmentally friendly re-generated system within Ethiopia. The company is
equipped with the following number of machines. [1]

Table 1: No Of Machine In Wuxi No 1 Cotton Textile P.L.C.

No Machine Type No of Machines

1 Carding Machine 64
2 Draw Frame -1 Machine 8
3 Draw Frame-2 Machine 30
4 Lap Former Machine 4
5 Combing Machine 24
6 Roving Machine 30
7 Ring Frame Machine 212
8 Winding Machine 34
9 Open End (Oe) Machine 3
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1.2 Row Material

The main raw material in Wuxi no 1 cotton textile plc is 100% cotton which is imported from
china. The company is producing cotton yarn in different counts as the customer requested.

1.3 Main Suppliers

The main supplier of wuxi no 1 cotton textile plc are the following countrie

Brazil, USA, Australian and China.

1.4 Main Customer

Wuxi no 1 cotton textile plc is leading company in which its products are available in most part
of the world and its marketing system or product distribution is satisfactory. The main customers
are china, America, Korea, Japan, Europe, and Southeast Asia.

1.5 Main Products

The main product of Wuxi no 1 cotton textile plc. is cotton yarn.

1.6 Vision Of The Company

 To export by manufacturing 100% cotton products.

 To work through environmentally friendly processes

 To be best supply choice for leading retailer and brands abroad

1.7 Mission Of The Company

 To produce 100% cotton quality textile yarn

 to satisfy the customer’s need

 to expand the global marketing,

 to generating profit and benefiting all stake holders.

 play a vital role in the development of the country economy.

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 to support and develop Ethiopian textile by transferring practical skills and knowledge to
Ethiopians.

1.8 Overall Work (Process) Flow Of The Company

Bale Draw
Roving
Store Frame 2

Blow Ring
Combing
Room Spinning

Draw
Carding Winding
Frame1

Figure 1: Over All Workflow Of The Company

1.8.1 Bale Store

It is the place where row cotton is stored in the form of bale. In this company the raw material is
stored outside under the sun light.

1.8.2 Blow Room

It is the initial stage in spinning process. The name blow room is given because of “air flow” and
all process is done in blow room because of air flow.

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Figure 2: blow room

Functions of Blow Room Machines:

Opening: To open the compressed bales of fibers& to make the cotton tuft as small as possible.
Cleaning: To remove dirt, dust, broken seeds, broken leaves, and other foreign materials from
the fibers.

Mixing & Blending: Uniform mixing/blending of fibers of different varieties.

Processing of cotton from all sources and Machine is combination of pneumatic and electrical
systems.

bale opener: The raw material, bale, enters the spinning mill in highly pressed form to enable
optimum transport and storage conditions. Bale opener used for opening which must be precedes
the other basic operations because only well opened material can be effectively cleaned and
enable the fibres to be blended, they must be thoroughly opened. Bale opener used to prepare the
fibres for the carding and subsequent operations.

Uni separator: It is also known as heavy weight separator. It is used to separate the frightening of
the light (cotton part) with the seed of cotton and other heavy particles due to gravity and
pneumatic systems.

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Uni-cleaner: Machine It is used for fine cleaning, opening and de-dusting and forms a
homogeneous length and width, lap type feeding, and the air is extracted from this lamina chute.
The machine has opening and cleaning roller and guides the fiber over grid bars.

Electronic Metal Extractor The device, normally a fan between uni-cleaner and uni-mixer
machine and used for extracting the material by suction in which spark sensor detects smoldering
material and metal detector any kind of metal also used as fire extinguisher.

Uni-mixer Machine It is a mixing machine of 6 chute chambers into which the output material
of uni-clean is blown. Here chute chambers are filled successively and removed simultaneously.
The principle of this mixing machine helps to homogenous, intimate mixing of the opened cotton
in a minimum of space, even with unfavorable bale lay-down. This gives uniform long-term
mixing or blending of fibers. This machine is made up of three parts: Storage section
Intermediate section Delivery section.

Foreign Matter Detector Machine It detects the color of cotton other than white color; this
machine detects and separates from the white cotton and drops it as waste then is stored in waste
accumulator. This system is based on camera or electro-optical sensor.

Condenser Machine It is used to make cotton suits and distributes the raw material to carding
machines and used to cool down the hotter cotton due to the previous process.

1.8.3 Carding Machine.

Carding is a mechanical processing that disentangles, cleans, and intermixes fiber to produce a
continuous web or silver suitable for subsequent process in the yarn manufacturing process,
carding comes after opening and cleaning of fibers at blow room the process is considered so
important that carding is often called “the heart of spinning”.

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Figure 3: carding machines

Part of Carding Machine

1.Pipe ducting 7.Suction duct 13.Coverplates/grid

2.Feed chute 8.Main cylinder 14.Doffer

3.Transport roller 9.fixedcardingbars 15.Stripping device

4.Feed arrangement 10.flats 16.Calendar Rolle

5.taker-in/licker-in 11.Cleaning unit 17. Cans

6.Grid equipment 12.Fixed carding bars 18.Coiler

1.8.4 Draw Frame Machine

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Figure 4: Draw Frame Machine

It is a machine for combining and drawing slivers of a textile fiber. Drawing is the operation by
which slivers are blended, doubled and leveled. Normally 6 to 8 slivers are fed behind one
drawing machine and get a product in form of single sliver in cans, which has the same weight as
of single sliver. The purpose of doing this is that to create uniformity and average out the weight
of each sliver. This process is also called 8/8 process. Drawing section consists of two sub-
sections:

i) Breaker Drawing: During this process 6 or 8 sliver produced by carding machine are
parallelized to produce one sliver.

ii) Finisher drawing frame: it is done to give further strength and stability to the sliver. The
drawn sliver from breaker draw frame is again drawn. In this process the silver drawn in the
breaker draw frame further used.

Main Parts of The Draw-Frame

1. Creel 4. Bottom drafting roller

2. Creel roller 5. Top drafting roller
3. Sensing roller 6. Trumpet

7. Coiler calendar roller and coiler 9. Can changer

8. Auto leveler

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Function of Draw Frame Machine

Improvement in material evenness Parallelizing fibers Sliver blending and dust removal but the
finisher and breaker draw frame machines are not used currently because short staple fibers are
not suitable for them to prevent formation of fiber breakdown.

Figure 5: Draw Frame Machine

Lap Former
The lap former has the charge of developing the laps that is engaged to feed the comber machine.
The laps are achieved through combining or doubling a definite number of slivers from breaker
drawing passage such as- 16 to 32.

Combing
In staple fiber processing, combing is an optional process in the preparation of high-quality
yarns, also combed yarn needs less twist than a carded yarn. In combing degree of penalization is
improved and enables the yarn manufacturer to produce more uniform and consequently strongly
yarn

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Figure 6: Combing machine

Parts of combing machine

1. combing lap 8. circular brush

2. guiding plate with hinge 9. top comber
3. feed roller. 10. detaching cylinder
4. lower clamp 11. sliver forming funnel.
5. upper clamp 12. delivery roller
6. clamp pivot 13. sliver deflection roller
7. circular comber with combing
segment

1.8.5 Roving Machine

Roving machine is an intermediate machine that is used between the draw frame and ring frame
machine. The main purpose of this machine is to produce the roving package for the ring frame.
Roving machine where the sliver is subjected to one or more attenuated process and the
attenuated sliver receive a small amount of twist and is then wound on bobbins suitable for the
next process. Roving frame machine is used to change input sliver to output roving. Input sliver
which comes from two draw frame by can.

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Figure 7: Roving Machine

Main Parts of The Roving Frame

1. Sliver can 6. Spindle

2. Driven transport rollers 7. Bobbin
3. Drafting arrangement 8. Bobbin rail
4. Roving 9. lever
5. Flyer

1.8.6 Ring Frame Machine

The most flexible system from the viewpoints of fibres which can be used and most flexible
system from the extent of the yarn counts which can be produced.

Figure 8: Ring Frame Machine

Main Parts of The Ring Frame

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 Roving bobbin
 Leading part
 Holders
 Guide rails
 Drafting arrangements
 Collection of waste
 Thread guide
 Spindle
 Traveller
 Ring

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1.8.7 Winding Machine

Input fine yarn. Operation takes place wind up yarns which comes from ring frame. Output
reminded yarn spindle to cone. The use of this process is large amount of yarn in one cone
however there is no change in count that means produce the same count which comes from ring
frame machine.

Figure 9: Winding Machine

1.8.8 Rotor Spinning Machine

Rotor spinning is the last step to spinning process which means directly changes the sliver into
the yarn. It is a technology for creating yarn without using a spindle. It is a device which is used
to drafting fiber masses into individual fiber. It is also known as open-end spinning It is also used
for transporting and depositing the fibers to yarn end.

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Figure 10: Rotor Spinning machine

Output storeroom

In this room the output product is stored until the exporting process is done.

Figure 11: Storeroom

1.9 Types And Model Of Spinning Machine

Table 2: Machine And Their Model

Process Machine Model

Blow room Automatic bale JWF1011
plucker FA002A
BLENDOMAT
TRUTZSCHLER
Uni mixer JWF0007-70
Six step cleaners JWF1029
Single roller JWF1107
cleaner
Carding Carding DK903
JW1171
Pre draw Draw frame1  

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Lap former Lap former  

Combing Comber KAIEONE
End draw Draw frame 2 FA322B
Roving Roving FA415A
Ring spinning Ring JWF1510
Open end spinning Rotor RIETER R923

1.9.1 Production Capacity

Company average production is 140 ton per month and 1680 ton per year this means the annual
production capacity of the company in kg is 1680000 kg.

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1.10 Overall Organization And Workflow

general
manager

production head office

manager

purchasi
maintanance labrator finance ng and
operator department human
y resour import supply
departm leader depart
ent ce account and export departm
ment and cost logistic ent
leader leader departm departmen
electrical mechani t purchasi
ent
and AC cal ng
leader shift perso
shift leader nal account section
leader leader
section
shift securit cost import store
big team leader shift big managm and
leader y
leader team ent export
leader section
big team legal
team leader
leadr big section
team team
team leader leader
operator leader transport
operato
team and
r
operato leader logstic
r operato
r
Figure 12: Over All Organization Workflow
General Manager: Controls the overall activities of the company.

Production manager: make plan for the different work service. control and check the company
production.

Human Resource: -control, units and checks the development of worker skill and work program
regulates rule for the worker and control it

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Finance and Administration: Follow up and realize financial planning, perform beget
preparation, indicate the direction of financial sources of the company and controls the collected
finance.

Electrical Maintenance: Checking power, taking preventive maintenance and repair break
down maintenance. Prepare periodic schedule weekly, monthly, yearly. Perform routine service
like inspection, cleaning, oiling, and adjusting.

Mechanical Maintenance: Prepare periodic schedule weekly, monthly, yearly.

Perform preventive maintenance like inspection, cleaning, oiling, and adjusting.

Repair break down maintenance.

Marketing

Direct and control the activities of purchasing, sales, and stores divisions with particular
emphasis on the import of raw material.

Work out an action plan on the detail activities of the department and closely follow up its’
proper implementation.

Prepare tender documents both for local and international bids and finalize all the necessary
formalities in collaboration with the committee.

Company services

Transportation- the company has a service transportation system for its employers.

Launch- the company offers a recreation center(launch) for its employers.

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CHAPTER TWO

2. INSTALATION OF SIGNAL INDICATER ON RING FRAME MACHINE

2.1 INTRODUCTION
Spinning is a twisting technique to form a yarn from fibers by spinning machine such as the open
end ,the ring frame machine and other spinning technique but ring frame is one of the most
applicable spinning machine. So the main activities on ring farm are drafting of rove to the final
count, twisting of the fiber strand’s and package formation wound the yarn on the bobbin.

Figure 2. 1. Ring spinning machine

Other spinning technologies have been developed that are higher in productivity, but are lacking
in many aspects of the yarn desirable characteristics. Ring spun yarn has returned its position as
the system that produces the strongest finest, softest and most lustrous yarn and fabric. To spin
high quality yarn at high spindle speeds the fiber and its preparation have to be controlled to high
standards. The ring frame cannot spin superior yarn from inferior material or roving. In spinning
mill the performance of ring frame is measured with several parameters. The idle spindles, rogue
positions which repeatedly breaks and, end breakage rate ,end mending time are few critical
parameters worthwhile monitoring to measure the productivity of the ring frame . The control of
off-standard positions not only improve production. It primarily helps to sustain consistence
quality and improve further by systematic identification, so to to control this parameters control
the yarn brick is vital so to control we need a signal indicator. A signal indicter is the most

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widely applicable technology in our world not only in textile machine but also for most of
working zones eg cares chargers electric transfer areas .so when we use signal indicator in case
of yarn break we can consume the following:
 production loses
 Power of machine running
 Waste of textile row material

2.1.1 Work flow of the ring frame machine

The ring spinning machine has to draw the roving to its final count in the drafting system, impart
tenacity to the bundle of fibers by twisting it and wind up the resulting yarn in a suitable form for
storage, transport downstream processing.

Bobbin holder

Guide rail

Drafting
arrangement

Yarn guide

Anti-balloon

Ring rail and

traveler

Spinning cope

Figure 2. 2. Work flow of the ring frame machine process

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2.2 Statement of Problem

Ring frame is one of the hearts of the yarn production. During the production of yarn in ring
frame there are many yarn brake age due to several stopping reasons or problems like bobbin
holders, top and bottom aprons, breakage of spindle driving belt, pressure arm , top and bottom
roller , material shortage and batch change, operators negligence and other problems ( traveler ,
ring , spindle, lappet guide and cleaning). In such cases, the operators may not see the place
where the yarn brake is occurred. Therefore, they may not take correction as soon as the yarn
breaks. By the above cases the production of the machine will be minimized, and the waste also
maximum due to the yarn brake age- and sack by section nozzle and the Power lost to a spindle
and drafting roller is increased and also increase the time for searching of the braked yarn or
increase labor work.

A yarn is mostly break at the spinning triangle because of a week part of the yarn. The amount of
the fibers when loss is also high because amount waste incised by deliver speed it added by
13m/min. So a signal indicator is vital for ring spinning machine to minimize the above faults.
Therefore, the aim of this project is to design signal indicator in ring frame machine so as to
decrease waste, time lose, increase efficiency and production.

Figure 2. 3. Production lost by un splicing of yarn

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2.3. Significance of the study

The main significance of this project is a ring frame machine is long and widest in size it have
1200 spindles so it is difficult to control all spindles by two operator so to minimize work of
operator a signal indicator is vital for ring frame on each spindle to indicate the place which
yarn is break. to minimize time to searching the yarn spindle.

2.4. Scope of the project

.I want to install a signal indicator in ring frame for controlling five spindles at one indicator but
by the case company license I cold not use that . the company gives the opportunity only one
spindle so I will instill the indicator on a spindle in the twisting section. While investigating
waste minimize, production optimization labor work decreasing it get god productivity
profitability and the expected income considering the yearly expenditure and the total estimated
profit of goods.

2.5. Limitation of the project

 The main limitation of the project is:-It is difficult to install the design in the machine it is los
in space between two spindle.
 it is high maintenance cost

2.4 litterer Review

The ring frame machine is the most widely used machine in spinning technology because it
exhibit significant advantages from them. any material can be spun in any required finesse ,it
delivers a yarn with optimal characteristics ,it is an compatible and easy to master it is flexible
as regard quantities so in such cases we did not convert ring frame by other machine until so
we shoaled add a design and use it [1]. It is impossible to produce a modern ring frame machine
without yarn brake age. but we can minimize the braking conditions such as conditioning
working environment, maintenance the machine and after bark we can splicing immediately
we alter the production [3].
Monitoring equipment is now obtainable most spinning machines and spinning department so
in ring frame machine also these type of mongering equipment need to easiest the work of
operator [1]. Do/H13/14 warning or safety devices it is able to produce signal indicator when a
yarn is breakage .bobbin full indication error which happened on the ring machine. The ultimate

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goal of spinning technology is focused on productivity combined with adequate quality. For
spinning mill an increasing in spindle speeds leads to a increase the yarn strength will be
increased due to increasing tweets so in case the yarn brake age rat will be increased so to
minimize this the fibers type and the yarn count will affects. To minimize the dawn time of the
ring machine you shoaled be splicing the yarn in a short period of time.so to control the yarn
brake we shoaled use alight indicator [2].

Using a signal inciter light is so many advantages:

 Decries searching time of operator
 Dec rising the dawn time
 Shoetree period of splicing

2.5 Objectives of the project

Production is the main goal of the company to achieve the expected aim. In this project I will
achieve the following goals.

2.5.1General objective
 Installing of signal indicator in ring frame machine

2.5.2 Specific objectives

 To minimize waste of un twisted yarn get approximately even mass of bobbin
 To decreasing labour time for searching
 Increasing efficiency and production of ring frame

2.6Methods of Data Collection, Data presentation And Data analysis

2.6.1 Methodology
Materials used
In installation of signal indictor, I will have used the following materials
1 signal lamp
2 copper wire
3 iron plat

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4 step dawn transformer 220v to 5v (from charger)

5 plaster which is used for aliening materials
6 think plastic
Procured of modifying signal indicator
1 Make a design of the indicator

Figure 2. 4. Design of the project

2 materiel selection from deferent un available materials and removed machine parts like
electric weir charger lither lamps from the space which gets.

Figure 2. 5. Materials on selection

3 connecting material or design out the project by using attaching metal which is electric
transparent led and chalk is that transfer electric or not.

4 take measurements from machines and space selection

Before installing select the prefer able place which is prefer for installation and chalk the space is
that prefer able or not by talking a measurement

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Signal light
position
I Will install the
signal indicator on
the located pleat

Figure 2. 6. Place which signal install

5 Installing of the indicator

Put the indicator within the appropriate place and measurement by using plaster which used for
attaching of the design and machine parts.

Figure 2. 7. The signal indicators after installation

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2.6.2 Data collection methods

In order to gather the required data for this project both primary and secondary method of data
collection is applied. Thus method is the document review, observation, and interview was used.
The document review included the performance reports and registered of the Bahir dar textile
share company. The daily activities were observed and registered by my self. The company
advisor and individual employees in the factory were interviewed independently on situation the
overall situation and conditions of the working environment.

2.6.3 Data Presentation

The following data were collected from the section through by observation, interviewing
different workers and experts in different working positions in the mills.

Figure 2. 8. Un full bobbins on counting and measuring

Machine works at
 Yarn count =16Ne or39.9tex
 Delivery speed =13m/min
 Amount of hard west=5.2kg/shift
 Amount of soft west=39.5kg/shift
Table 2.1 No of full un full and empty

Dye Full Un full Empty bobbins

bobbins bobbins
1st 818 248 134
2nd 814 244 142
3rd 838 239 125
4th 804 260 136

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Table 2.2 Un full bobbins based on difference

Days Less than 48g 48-58g 58-68g 68-78g

Dey1 57 61 68 62
dey2 62 55 69 58
Dey03 64 57 52 66
dey4 53 61 70 76

un full bobbins based on difference fig un full bobbins on counting and measurement

2.6.4 Analysis of the Problem

Total production of the Company
Total production of the company =13m/min
= 13m/min*60min=780m/hr*8shifet
= (6240m/shift *120spindle *36.99)/1000
= 276.354kg/shift
B/c TEX *length in km=mass in g
Total production lose
As shown in the above table and picture this Mach amount of production lose is happened
because of operators did not see the brake yarn.
Table 2.33 Un full bobbins and there mass

Class limit Class xc F(xc)d1 F(xc)d2 F(xc)d3 F(xc)d4

bounder

1-18 0.5-18.5 17 969 1054 1088 901

18-28 17.5-28.5 10 610 550 570 610

28-38 27.5-38.5 10 680 690 520 700

38-48 37.5-48.5 10 620 580 660 760

X mean = f(xc)d1+ F(xc)d2+ F(xc)d3+ F(xc)d4

f1+f2+f3+f4
X=(3329+3396+3678+3521 )/(248+244+239+260)=13924/991=14.05

Ftom this average mass lose for each bobbin is =14.05g

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But mass lose one the machin=14.05g*1200=16860g

=16.86kg/doff

=16.86kg/doff*3doff/shift

=50.58kg/shift

But in adition to mass lose by un full bobbin there is also mass lose by idel spindle

That is

Mass loss by idel =acurat mass of full bobbin *no of idele spindle

48.5g/doff*134spindle

6499g/doff=6.499kg/doff=6.499kg/doff*3doff/shift

=19.5kg/shift

Total production lose =19.5kg/shift +50.58kg/shift

=70.35kg/shift

Pact=Ptho-Plos =276.354kg/shift -70.35kg/shift

=206kg/shift

Time lose of the company

Total production =276.35kg/shift

Loss production =70.35kg/shift

Production lose by an splicing=39.5kg/shift

276.35kg=8hr

39.5kg=xhr =

276.35kg*xhr=39.5kg*8hr x=39kg*8hr/276.35kg

X=1.143hr

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So1.14hr is lose due to an splicing .

But total lose is2.03hrs

2.6.5 Cost analysis

Local market
The Bahir dare textile Share Company sells 1kg of yarn by 80-104 birr weather its cotton,
polyester and their blends. Thus the average value is 92.0 birr per kg.
Therefore
1kg=92.0birr
70.35kg=k
K in kg=(70.35kg*92.0birr)/1kg = 6472.2birr/ shift
Loss percent =Plose/Ptho*100
=70.35/276.35*100%
=25.45%
loss percent to waste =Pwast/ptho*100%
=39.5kg/shift/276.35kg/shit*100% =14.3%

2.7 RESULT AND DISCUCTION.

As I understand an locking of the brake yarn an splicing is is the main causes of production loss
on ring frame machine in bahir dar textile share company.in order to study the an splice yarn on
the ring frame first all of I have to to study and collect data for braking rezones. They are seven
big causes that arise in stopping reasons for the problem of the yarn brake age as we have seen
above are;
 Bobbin holder
 Material shortage(roving shortage)
 Pressure arm and roller problem
 Breakage of spindle driving belt
 Operators negligence
 Bottom and upper apron
 Other problem like: traveler , ring, spindle and etc.

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As I understand in BDTSC the there big losses that arisen ring frame machine are : adjustment
and setting of machine parameters at the time of count change, Process defect pore and high
wastage., Ring frame machine run lower speed than recommended. The percentage ratio of
stopping reason for the idle spindle is different in quantity. However, an seeing of the praetor
and material changing or roving shortage is the major causes for this problem. Bottom and upper
apron, pressure arm is the next major problems. As I investigate and study using signal indicator
is the most profitable for the company. So whine we use it it indicate and correction is talks
place.for instanc whan roving is short age the yarn is brake so the signal is indicate the light and
the opraters see and roving.
2.8 Solutions of the Problems
in order to solve the problem that makes idle spindle and production losses ,the following action
must be applied.
1. Installing of signal indicator on the ring frame machine to control operators
So i cheek by installation of signal light
2.skill up gradation: this means the organization needs to arrange skill up gradation program for
the operator .so that they can gather information on the machine they operate. The operator can
attend their machine in the case of minor break down without waiting for the maintenance
person. this result save considerable amount of time.
3. Planning proper maintenance(schedule) for each of the ring frame machine.
4. Formulation of policy and objective: management with executive responsibility formulates a
policy on total production consistent with other policies of the organization management should
ensure that the policy is communicated and under stood by all level workers.
5.Full filling raw material like roving.
6.Education and training: the mill management must be employing an experienced trainer for
giving systematic training to one operator.
7. Installation of new machine by removing old machine.
8.commitment by top management: total production is a strategic decision taken by the
organization and needs total commitment of the top management.
9. Review: before actual kick off, the organization should determine the existing spare part.

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2.9 Good Performance During Work Tasks

Since I got to bahir dar Textile Share Company, I tried to make good communication to the
bahir dare textile engineers and the employees as a whole. Due to this smooth communication, I
performed to upgrade my practical knowledge beside to theoretical knowledge in bringing this
project outputs as its present form.

2.10 Major Challenges and Measures Taken To Overcome It during Work

Tasks
During performing my task in the company there were good and bad things that I have seen from
most f the company worker which encouraged me to act strategically to find out solutions.
However there were some challenges faced during my internship period. There were some staffs
that were blocking the existing profile of the factory due to less understanding of the internship
programs. Most machine are automatic. There is no library to refer about different tasks . luck of
materiel for producing my project like LED thin iron etc.

2.11 To Solve These Problems the Following Measures are taken:

Even though, there were very few factory workers who hide the company profile, I approaches
smoothly to the other volunteer workers to search the required information. By explaining about
internship program observing in detail the machine that do not have manual Working with
technicians and machine operators. Comparing the oldest machine with latest machines with
similar functions to understand the working principle of oldest machines.

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CHAPTER THREE

3. OVERALL BENEFITS OF THE INTERNSHIP

The objective of internship program is to develop practical skill of students additional to

academically theory knowledge. With certain limitations this objective was successful. From an
internship I got many advantages like improving practical skills, upgrading theoretical
knowledge, improving interpersonal communication, improving team work, understanding work
ethics relative to issue, improving leadership and entrepreneurship.

3.1 Benefits Gained In Terms Of Improving Practical Skills.

 Improving skills in workshop activities such as machine operations
 The other importance of this internship program is helps to know the new coming
technologies uses about spinning, weaving and finishing and function of each section
 Problem solving approaches and procedures in solving practical problem like spin
processing
 Control mechanism used
 Practice how to install the layout of different machines

3.2 Benefits Gained In Term of Up Grading Theoretical Knowledge

There are different courses that I have learned before joining to an intern ship and these courses
are help for practical performing. Among these:
 Develop the theoretical knowledge on the type of fiber, yarn and their effect on the fabric
practically
 Concerning fabric structure and designs, there are different types of fabrics produced in the
company and develop the theoretical knowledge practically that produced using different
hairiness.
 Principal of weaving
 Develop the basic process of production departments.
 Know handling the raw material is the basic criteria for the product produced
 Prove that maintenance department plays a great role in achieving expected production
 Know the difference between fiber, yarn, hank and fabric dyeing.

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 Know the difference between the short and long staple spinning department.

3.3 Benefits In Terms Of Interpersonal Communication Skills

At the beginning there was a communication gap between factory workers and me. But gradually
considering importance of communication, I gained acceptance in all workers of technique
section. Observing effect of personal communication skill helps to develop simple way of
communication with others.

I met different persons that have worked on their work place/position. These include
administration, plant manager, company owners, shift leaders, chiefs of each department and
operators. I learnt from them how to approach with employees, the way of asking questions that
have not under stood during observation, understanding their diplomatic/technical words with
relative to scientific words. Communicating and discussing with worker/employers and any other
persons in order to solve the problems in the company.

3.4 Benefits Gained In terms of Improving Team Playing Skills.

In order to produce The role of team playing is the basic one for production process of the
company in the expected product. Having good team playing work in the company can lead to
increase production and productivity of the company as well as improve good quality of
production.. Team playing skill is concerned with taking responsibilities in group and role of
individual as group member. This skill helps to solve problems occurred in the factory easily. In
a group member accepting group members’ idea and way of expressing idea for group members
play important role.

3.5 Benefits Gained In Terms Of Improving Leader ship

From the working condition of the factory the following effect of leader in doing tasks is
observed. How workers initiation towards work can be increased. Organizing group member
Way of ordering peoples and the value of giving responsibility for other sand taking
responsibility. Way of assembling workers and allocating for different tasks. solving the
problems faced and handling the employees

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3.6 Benefits Gained IN Terms Of understanding About WORK Ethics and

Related Issues
Internship program also shows me necessity of work ethics in working environment and worker
with good ethical skill gets reward in many ways.
 Punctuality
 Hard worker
 Loyalty for work
 Giving emphases for work
 The operators must wear a suitable working clothes
 The other importance is acceptance with other workers and boss.

3.7 Benefits Gained In Terms Of entreneurship Skills

Knowing conditions of factory and types of technologies used in factories helps to identify
required product in the market. Also during the internship ways of processing and mechanisms
used in the factory are observed. on the problem solving to decrease the idle time Job
creativeness
 Performing my task with plane
 Observing effect of piecing
 Re-forming my task with plane
 Establishment of business centers by own way

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CHAPTER FOUR

4. CONCLUSION AND RECOMMENDATION

4.1 Conclusion
As per the analysis and observation made on the bahir dar textile share company, I conclude that
production of the ring frame is decreased by 35% of the total production per shift due to
unlimited yarn break production flow and hills to workers due to high percentage of waste next
to raw material cost, in the cost of production of a spinning mill, even a marginal increase in
power cost per unit would have a significant impact on profit, because of this my analysis shows
the effect of idle spindles and unnecessary power consumption on the production of the ring
frame. So that the company losses about938 birr per shift this is the quensquence of the
following points. These are:
 Low orientation about the production as well as side way disadvantages
 Less coordination between one stage to the next one; like between ring frame and roving
frame this leads to roving shortage
 Most of the company operators are negligence.
 Material change problem, this exposed to high power consumption and machine
efficiency
 There is no inspection before running the machines
 The production and maintenance supervisors are not actively controlled the operators
 Luck of spare parts (apron, top roller, spindle driving belt )
 There is no effective cleaning
 There is no trained operators
 There is careless feeding and doffing
 Case by case, the reduction of these exceptional ideal time of spindle in overall
improvement in quality, increase in production, reduction in yarn faults and better splices
in winding.

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4.2 Recommendation
As manufacturers face an increasingly competitive global business environment, they seek
opportunities to reduce production costs without negatively affecting product yield or quality. As
we believe that good management and skilled man power is the key requirement to perform the
production activities of the company in order to improve production and productivities. But here
there are different problem that barred Production of the company especially in ring frame.
Therefore to solve this problem the company should be work the following suggestions correctly
 The management and the employers will be work with synchronized each other’s
 The Company must be prepared training center for the employers
 The organization needs to arrange a skill up gradation program for the operator, so the
operator can attend their machine in case of minor breakdown without waiting for the
maintenance personnel.
 The production head should have controlled the day today production of the section
 The management assign an expert for the specific responsibility, this shows that there is no
organized (specific) responsibility
 The production and maintenance workers should work synchronized
 They should represented/assign qualified, experienced and skill full production and
maintenance man power to solve the problem immediately.
 Enough spare part is equipped in the maintenance department for successful activities.
 The problem of unnecessary power consumption can be solved by shifting one machine per
day, because an average of 1000 spindles per day would idle
 Finally the company gives appreciation (rewards) for the best employers for better
production

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