IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)

e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 16, Issue 1 Ser. III (Jan. - Feb. 2019), PP 58-65
www.iosrjournals.org

Improvement of Ring Frame Spindle Utilization in Cotton Short

Staple Spinning: A Case Study of a Cotton Spinning Mill
J.K Musyoki1, P.N Muchiri2, J.N Keraita3
1
(Department of Mechanical Engineering, Dedan Kimathi University of Technology, P.O Box 657-10100 Nyeri,
Kenya)
2
(Department of Mechanical Engineering, Dedan Kimathi University of Technology, P.O Box 657-10100 Nyeri,
Kenya)
3
(Department of Mechanical Engineering, Dedan Kimathi University of Technology, P.O Box 657-10100 Nyeri,
Kenya)

Abstract: Spinning mills play a very significant role in backward integration of the textile value chain by
converting fibres into yarn for fabric production. Ring spinning is the most widely used short staple cotton
spinning system to produce yarn from cotton fibers and is used by 7 of the 8 spinning mills. Ring spinning mills
have been operating at low spindle utilisation between 67 to 80% which is below the recommended standard
norm of 98% resulting to yarn production loss occurring from frequent stoppages of the ring frame and increase
in the number of spindles running without producing yarn. This results in low spindle utilisation of the mill
which reduces the ring frame spindle hours used for yarn production. The overall objective of this study was to
improve ring frame spindle utilisation in terms of spindle hours utilized for yarn production in cotton short
staple spinning, by carrying out a case study in cotton spinning mill. The specific objectives were to analyse
ring spinning process production parameters, evaluate the factors affecting ring frame spindle utilisation and
formulate a productivity improvement method for spinning mills. The Research design adopted by this study was
a descriptive and quantitative case study. Pareto analysis was used to classify ring frame production losses
based on Overall Equipment Effectiveness (OEE) classification of major losses and Ishikawa diagram used to
carry out Root Cause Analysis of main causes of production loss. Failure Mode and Effects Analysis (FMEA)
technique was used to map the failures which occurred within the process that contributed to production loss
which were ranked using their Risk Priority Numbers (RPN). A questionnaire based on Grunberg (2007)
Performance Improvement Method (PIM) was used to analyse and evaluate mill production and management
practices. A production improvement method was recommended using 7level evaluation criteria of the PIM
technique. Pareto analysis revealed that Idling and minor stoppages accounted for 63% losses while breakdown
accounted for 22.8% of losses. Root Cause Analysis (RCA) identified use of manual doffing, lack of time
awareness, and delay in replacement of empty bobbins as significant factors that affected ring frame doffing
stoppage loss. It was recommended that a standardized procedure based on Single Minute Exchange of a Die
(SMED) technique for the doffing procedure would yield the highest results in minimizing ring frame stoppage.
A key finding from the study showed that utilisation of equipment for production in manufacturing was not just
the overall time the machine was running but about standardization of the entire process of production to
maximize utilization of the machine for output. Through this study spinning mills can apply the
recommendations to improve ring frame productivity in order to reduce the cost of production and improve
their competitiveness.
Keywords: Ring spinning, Ring Frame Spindle Utilisation, Performance Improvement, PIM Technique, Idle
spindles.
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Date of Submission: 24-01-2019 Date of acceptance:07-02-2019
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I. Introduction
The textile industry is an important component of manufacturing sector with greatest potential to create
employment and promote economic development1. Developing countries are characterized by increased demand
of apparels and textiles which cannot be met by local production. The gap is bridged by importation of low
priced products; in addition, imported Second Hand Clothes (SHCs) in some countries further supplements the
low market segment resulting to flooding of local markets 2. Ring spinning which uses the Ring frame is the
main spinning system is used by 7 in every 8 mills to produce cotton yarns for fabric production by knitting and
weaving factories3. The process of fibre to yarn conversion at the ring frame involves drafting, twisting roving
of fibres and winding the spun yarn on the bobbin and is the costliest stage in the spinning process flow
contributing 60% of the total cost of yarn production4. Mills therefore aim at maximizing the utilisation of ring
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 Improvement of Ring Frame Spindle Utilization in Cotton Short Staple Spinning

frame to reduce the overall cost of yarn production and improve competiveness of the textile products. The
standard operating norm for ring frame spinning mills aims at optimal spindle utilisation (SH) of 98%5.SH is the
ratio between the average spindle hours worked per day and the total number of spindles installed and therefore
measures the effectiveness of the ring frame and turns a comparison of actual production per shift against the
maximum possible production. SH is related to Overall Equipment Effectiveness (OEE) which is used in
manufacturing to quantify how well equipment performs relative to its designed capacity over a period of time
when it is scheduled to operate6,7,8. Ring frame spindle utilisation is the highest impact Key Performance
Indicator (KPI) influencing the efficiency of conversion cost of fiber to yarn in the ring spinning process, high
spindle utilisation leads to cost reduction per unit of production of conversion costs drivers such as overheads,
depreciation, interest, stores, power and wages and also increases profits due to the higher volume of production
and sales turnover. Spindle utilisation (SH) is the ratio between the average spindle hours worked per day and
the total number of spindles installed and therefore measures the effectiveness of the ring frame and turns a
comparison of actual production per shift against the maximum possible production. Ring frame spindle
utilisation is the highest impact Key Performance Indicator (KPI) influencing the conversion cost of fiber to
yarn in the ring spinning process, high spindle utilisation leads to cost reduction per unit of production of
conversion costs drivers such as overheads, depreciation, interest, stores, power and wages and also increases
profits due to the higher volume of production and sales turnover.The process of yarn production using the ring
frame are prone to cyclic stoppages due to stoppages for doffing of filled up yarn bobbins, frequent change
overs and setting adjustments. Breakages in the individual spindles of the ring frame due to idle spindles and
end breakages of the yarn during the production process further results to reduced spindle utilization of the ring
frame affecting the production levels and raising the cost of production. Improvement of ring frame spindle
utilization influences productivity and overall competiveness of the spinning mill and is necessary in the long
term sustainability of the textile industry.
Several studies have been carried out in the past to investigate the factors affecting production of yarn
in textile spinning and their effects on performance of various spinning mills producing yarn for various
weaving and knitting industries9. Research developed alternative open end (OE) spinning systems such as Rotor
and Air jet which featured higher yarn production rates of 120- 400m/min compared to the ring spinning speeds
of 20-30m/min which are 4-6 times less in production4. OE also gave advantage of and use drawn sliver as their
feed stock eliminating the preparation stages of roving formation and winding processes9. However, these
spinning systems were only suitable for production of medium and coarse count yarns.
Studies to improve the design feature of the ring–traveller investigated use of traveller made of alloys
and ceramics materials and use of surface coating to improve heat dissipation properties of traveller. The
traveller ring spindle speed was limited by the friction surface between the ring and the traveller develop high
pressure of up to 35N/mm2 during winding generating high temperatures of 400-500 0C which cannot be
dissipated by the low mass traveller in the short time limiting the maximum possible operating speeds for the
traveller to 40 m/min10. Higher traveller spindle speed exceeding the thermal stress limit resulted in drastic
change in wear behaviour of the ring and the traveller. Limitation in the size of the bobbin which can be mount
on the spindle while operating at the high spindle speed of 8,000 to 25,000 Rpm reduced the ring diameter to
42-48 mm resulting to increase the time and labour required for doffing. Modern ring frame feature also
advanced engineering improvements geared towards overcoming these drawbacks, such as automation of the
doffing process and integration of a link to winding. Research conducted in India by SITRA, recommend ring
spinning spindle utilization standard norm of 98% and indicate that a 1% increase in production per spindle
would lead to a saving of US$ 15,000 per annum for a 30,000 spindle mill5.
From the foregoing literature review no study has been undertaken to determine and analyse the factors
affecting the low spindle utilization in ring frame spinning mills and evaluation of production improvement in
ring frame spinning.

II. Research Methodology

The case study was carried out in a spinning mill producing cotton yarns using 16 ring frame machines
and two rotor spinning machines. The mill operated 24 hours daily on a day and night shift of 11 hours and 13
hours. The operational 15,072 ring frame spindles had an average daily production of 6800 Kgs translating to
0.451kgs per spindle compared to daily rotor production of 6.94 kg per rotor.
A systematic research methodology was designed to study ring spinning process, parameters and
identify Ring Frame production losses, losses were categorized and detailed study on the causes of production
loss and their impact on productivity of the ring frame undertaken. Moreover, a study of the mill production and
management practices was conducted to evaluate performance improvement techniques for the mill. A
preliminary study of the ring frame settings and process parameter was carried using basic 7 QC tools. A time-
based Pareto analysis of ring frame stoppages was conducted and used to determine production loss based on six
major productions on OEE. RCA was used to identify and classify causes responsible for production loss

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 Improvement of Ring Frame Spindle Utilization in Cotton Short Staple Spinning

contributing to low spindle utilisation in ring frame spinning. FMEA was carried out to detect the possible
failure modes related to the ring spinning process and prioritize them. The failure modes under each sub activity
was discussed and given the Risk Priority Number (RPN). Data related to productivity improvement and the
operational structure of the mill was collected through for evaluation of performance improvement. Grunberg
(2007) PIM technique was applied to come up with improvement method for the mill 10.

III. Resultand Discussion

Table no 1 shows the process parameters for the 16 ring frame operated by the spinning mill.

Table no 1Ring frame process parameters of the spinning mill

Ring Spinning process parameters UNITS Process parameters
Low High
Maximum Spindle Speed Rpm 16,000 20,000
Operating Spindle Speed Rpm 10,000 13,000
No. of spindles per ring frame No. 864 960
Yarn Count Ne 20 38
Twist per Meter Tpm 625 925
Break draft No. 1.21 1.21

Ring Spinning and Doffing Cycles

The spinning cycle was timed from the start of the running of the ring frame when yarn starts building
up on the bobbin to the time when ring frame automatically stops due to bobbins get filled up with yarn. The
doffing cycle was timed when the ring frame automatically stops up to the time when the machine was restarted
for the next spinning cycle. The Ring Frames automatically records the cycle process parameters such as
spinning and doffing cycles times automatically recorded were retrieved, recorded and analysed. The spinning
and doffing cycles had a mean time of 125.05 and 12.1867 minutes respectively as shown in Figure 1 and 2.
The mean weight of ring frame yarn bobbin in grams from 6 different ring frames spinning 20s was of 56.71525
grams representing a loss of 7.5847 grams per bobbin as shown in Figure 3.

140
120
100
80
60
40
20
0
SC1 SC2 SC3 SC4 SC5 SC6

Fig. 1 Ring Frame spinning cycle time

20

15

10

0
DC1 DC2 DC3 DC4 DC5 DC6

Fig. 2 Ring Frame Doffing Cycle time

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 Improvement of Ring Frame Spindle Utilization in Cotton Short Staple Spinning

70
60
50
40
30
20
10
0
RF 9 RF 10 RF 11 RF 12 RF 13 RF 14

Figure no 3shows average weight of ring frame yarn bobbin in grams from 6 different ring frames spinning 20 s

Ring Frame Stoppage and Idle Spindle Losses

A Pareto analysis was used to identify significant causes of production loss in ring spinning at the
frame and individual spindles. OEE was used to classify frame stoppage and idle spindles into five major classes
of production loss as shown in Table 2 and analysed in Figure 4. Idling and minor stoppages losses accounted
for 63.2 % and break down loses 22.8 %. The results were in line with the Pareto principle, which states that
20% of the causes are responsible for 80% of the production loss. Distribution of the main causes of Ring Frame
Stoppages is shown in figure 5. Investigation of spindle production loss due to idle spindles had end breakage
rate of 863.68 spindle minutes of ring frame stoppage in two shifts as shown in Figure 6.

Table no 2 shows analysis of major production losses in ring spinning

Cumulative
Classification of Loss Category Frequency Percentage
Percentage
Idling and minor stoppages A 97 63.2 63.2
Breakdown B 35 22.8 86
Set-up and adjustments E 20 0.6 86.6
Yield loss C 0.93 0.4 87
Reduce speed D 0.57 13 100

120 100.0%

90.0%
100
80.0%

70.0%
80
60.0%
Frequency (%)

60 50.0%
Frequency
40.0% Cumulative Percentage

40
30.0%

20.0%
20
10.0%

0 0.0%
A B E C D
Loss Category

Figure no 4 showsPareto Analysis of major losses in ring spinning

Percentage distribution of ring Frame

stoppage

Power Failure
23%

Doffing
64%
Count Change
13%

Figure no 5 shows distribution of main causes Ring Frame Stoppages

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 Improvement of Ring Frame Spindle Utilization in Cotton Short Staple Spinning

Roving exhaus t

Broken bottom apron

Type of spindle loss

Mis sing spi ndle Series1

End Break ages

0 200 400 600 800 1000

Spindle time in Mins

Figure no 6 shows analysis of loss in ring frame spindle hours due to idle spindles in spindle-mins

Cause and Failure Modes in Ring Spinning Production

Root Cause Analysis (RCA) was undertaken to find out factors of the ring frame doffing process that
contributed to low spindle utilization in ring spinning. Discussions with the mill management and engineers
identified the most significant causes of production loss in the doffing process shown in figure 17 a: (i). The
manual doffing procedure of the ring frame which was found to be significantly slow. (ii) Lack of time
awareness - the Ring frames automatically stopped when bobbin get filled up with yarn and operators took time
to start the process of doffing mainly due to lack of time awareness among the doffers (iii) Poor process of
removal of empty bobbins and simultaneously replacing them with empty coded bobbins (iv) Delay in
completion of the Preparation of empty codded bobbins for the ring frame delayed the process of starting
replacement of the filled up bobbins as the bobbins were not ready due to delay in completion of preparation of
bobbins (v)Shortage of bobbins or mix up of bobbins for counts, lots and codes, and (vii) delay Inspection of
the ring frame after replacement of empty bobbins and close monitoring of the stoppages of the ring frames
were also major contributors of doffing loss. The most significant factors identified to the ring frame doffing
were used as the inputs to the Ring Frame Doffing FMEA to find out the possible failure modes and rank them
in order of priority. Figure 4.8 shows potential failure causes and effects with highest RPN.

Man Material Management

Low skills of RF Empty bobbins not Poor supervision of

- Operators are of qualification - Shortage of same color bobbins - No proper coordination of teams
- operators not retrained - Empty bobbins not ready on supply container - doffers left to work on their own
Few RF operators Empty bobbin mix up Lack of standard
- Low number of inspection & patrol team - No order of keeping bobbin - No doffing procedure
- Lower number of doffers - Order not followed - procedure not followed
Lack of SoPs for Lack of empty bobbins Lack of monitoring of
- No SoP on allocation of operators - Delay in winding off yarn at the autoconer - Stoppages not recorded
- SoP not adhered to - Damage of bobbins - Stoppages not monitored
Lack of time awareness
- Delay in removal of full bobbins
- Delay in removal of full bobbins
Poor work attitude
- low motivation of operators
- poor teamwork
Ring Frame
Automatic stoppage of Doffing Loss
- Bobbin get filled up to the target yarn production
- the ring frame automatically turns off

Speed adjustment Failure of Manual doffing of the

- High RH - Slow process of the manual doffing
- Rise in end breakage - manual re-inspection of spindles
Count change for new Uncondusive work Replacement of
- Excessive fibre fly waste - Replacement of broken spindle drive tapes
- Lack of concentration due to prolonged exposure to high-noise
Ring traveller
level and draft roller apron replacemt

Measuremen = Significant Factor

Enviroment
t

Figure no 7 shows RCA of ring frame doffing process time loss

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 Improvement of Ring Frame Spindle Utilization in Cotton Short Staple Spinning

Table no 3shows potential failure causes and effects with highest RPN from Ring Frame Process FMEA
Potential failure cause Potential failure effect O S D RPN
Lack of enough bobbins for the ring frame Delay in replacement of full bobbins 8 7 7 392
Breakage of yarn during bobbin change Increased start end breakage 8 7 6 336
Lack of empty bobbins to start doffing Time loss due to delay in moving and 8 8 5 320
arranging empty bobbin tray
Mix up of speed frame lots and counts during Rejection due to yarn/fabric defect in 8 8 5 320
filling activities and piecing in the event weaving and dyeing
Gaiting done with yarn which is not running Mix-up of different lots and counts of 6 6 7 252
yarn
Deformation of cops Damaged yarn cops, increase in rejected 5 7 7 245
yarn cops
Mix in bobbin size, color and code Mix up in yarn counts and lots 6 7 3 126

Performance Improvement using Grunberg PIM Technique

Grunberg (2007) developed the PIM Method to Support Performance Improvement in industrial
operations, an improvement of Ljungsrom evaluation criteria which was used to evaluate improvement
measures for the potential failure causes and rate the most sustainable productivity improvement for application
for the mill. The PIM method was designed for the manufacturing sector to assist in formulation and selection of
the most suitable improvement technique that supports implementation of improvement where the methods are
applicable. The PIM compared 16 methods of Performance Improvement among them Five S, Single Minute
Exchanged of a Die (SMED) and Continuous Improvement (CI). PIM also proved to address more criteria than
other methods and had an advantage of involvement of the problem owner in selection and supporting the
implementation of performance improvement. It also addresses the important criteria of specialist
independency.
Mill performance measures were graded on 6 level criteria based on specialist independence,
competence supportive, implementation supportive, measurement based, objective supportive and
organizational supportive. The supporting scale had 5 levels namely 1, 2, 3, 4 and 5. The total score which
indicated the overall support for the improvement measures was used to come up with the strongest
improvement measure. Competence, implementation and organizational supportiveness had the highest
importance rating score for the spinning mill as shown in Figure 24. Specialist independence had the least score
which indicated that a performance improvement for the mill should be usable by non-specialist, must be easy to
understand, easy to use and supportive regarding communication of goals and results. According to Grunberg
PIM criteria (2007) the methods which partially fulfil this are Process mapping, SMED, Five S, CI and decision
support. The second least score was in measurement supportiveness which indicated that it was not easy to
measure, tuck and monitor performance which would form a basis for further improvement. To increase support
for measurements, the PIM premade forms and instructions were used to promote further understanding when
promoting the system. The average scores for overall PIM performance evaluation are shown in Table 4.

5.0

4.0

3.0
Average score

2.0

1.0

0.0
Specialist independent Competence supportive Implementation Measurement Based Object supportive Organisational
supportive supportive
PIM evalution criteria for Performance improvement
Fig. 8 Overall PIM Performance Evaluation of the mill based on PIM

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 Improvement of Ring Frame Spindle Utilization in Cotton Short Staple Spinning

Table no 4 showsoverall PIM Performance Improvement Evaluation

Overall PIM Performance Improvement Evaluation Average Score
Specialist independent 1.3
Competence supportive 4.8
Implementation supportive 4.4
Measurement Based 4.6
Object supportive 3.4
Organizational supportive 4.4
Overall mean 3.8

The PIM’s Method to Scoring Criteria to support performance improvement in industries was used to
evaluate the applicable performance improvement methods and techniques for the mill. The scoring criteria
allocated applicable numeric values to the method on the basis of; 1= weak or low support, 2= partly supportive,
strong support and Not applicable (N/A) and as shown in Appendix III: The results of the evaluation shown in
Table 5 recommended five performance improvement techniques/ method for the mill. Decision Support was
not competence supportive to the unique object supportiveness of the ring spinning process and was not
supported by organizational set-up of the mill. Process Mapping was not applicable to implementation
supportiveness, it is important that a proposed performance improvement technique has support amongst the
management and employees of the mill as much of the improvement work would be performed by employees of
the mill. SMED had the strongest support with an overall score of 13, the score was highest in implementation
and object supportiveness and had a score of 2 for specialist independent, measurement base and organizational
supportiveness. SMED and Fives S and Continuous improvement (CI) ranked highest with scores of 13, 10 and
12 respectively as shown in Table 6 and were most suitable improvement methods applicable for production
improvement for the mill.

Table no 5 shows evaluation of Performance Improvement methods based on PIM

Process mapping SMED Five S CI Decision
Support
Specialist Independent 2 2 2 2 2
Competency supportive 1 1 1 1 1
Implementation supportive N/A 3 3 1 N/A
Measurement based 2 2 1 2 2
Object supportive 1 3 1 1 N/A
organizational supportive 2 2 2 2 N/A

Table no 6 showsthe score of performance improvement methods for the mill

Method Process Mapping SMED Five S CI Decision Support
PIM Score 8 13 10 9 5

IV. Conclusions and Recommendations

Significant improvement of Ring Frame spindle utilisation would be achieved by minimizing machine
stoppage and improving utilization of the spindles during the running cycle of the machine. Minimizing of ring
frame stoppage time for doffing would yield the highest result. SMED was recommended as a performance
improvement technique for the mill to improve the process of frequent change-over and set-up adjustments
which occurred in ring spinning process. SMED was an easy to use tool for large improvement attempts and was
supported by the mill practices and procedures for improvement of spindle utilisation of the ring frame.
A doffing based set-up and change-over SMED procedure would yield the highest performance
improvement ring frames spindle utilisation at the mill. Important aspect of SMED involved separating external
activities; ring frame doffing process was modified to include 3 separation activities involving the pre-set up
external, internal and post external activities. The ring frame doffing pre-set up external activities whereto
completed before the stoppage of the machine without any loss in the ring frame operating time and included
identification, preparation, coding and packaging of bobbins in trolleys. The trolleys were to be kept near the
ring frame ready for doffing. The external process was to be enhanced to include identification idle and
defective spindle numbers and the cause. Secondly improvement in the internal resetting process of ring frame
which could only be done when the machine had stopped were achieved by recommendation of use of doffing
trolleys with separation for empty bobbins and ejected filled up bobbins. Two doffers to be assigned to doff the
frame from left to right at the same time. Doffers were to detach full cops from the spindle while simultaneously
replacing it with empty bobbin cop from the tray. The maintenance team was to be incorporated in the internal
set-up team to carry out spindle repairs such as drafting system replacement, spindle drive tape replacement to
minimize running idle spindles and production of defective bobbin in the next spinning cycle. Post external
activities where to be undertaken when the machine had been restarted. Internal activities of replacement of
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 Improvement of Ring Frame Spindle Utilization in Cotton Short Staple Spinning

exhaust roving, handling transportation and storage of full bobbins were converted into external activities.
Improvement in spindle utilisation would be achieved by doffing internal set-uptime into external set-up time.

Acknowledgement
The authors are sincerely thankful to the Ministry of East Africa Labour and Social Protection (MEAL&SP) for
funding the research.

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J.K Musyoki. “Improvement of Ring Frame Spindle Utilization in Cotton Short Staple
Spinning: A Case Study of a Cotton Spinning Mill.” IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE) , vol. 16, no. 1, 2019, pp. 58-65.

DOI: 10.9790/1684-1601035865 www.iosrjournals.org 65 | Page