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How to Calculate Yarn Production in Spinning Mill

How to Calculate Yarn Production Per Shift of 8 Hours
Amit Kumar Das
Founder of "টেক্সটাইল ম্যানিয়া" Blog
Pabna Textile engineering college, Pabna, Bangladesh
Cell: 01770 456240
Email: amitptec6th@gmail.com



Introduction:
 
Generally without overtime, production hour is 8 hour, From 9.00 am to 5.00pm. Within this period of time all types of regular scheduled production work happens. Production managers or Executive production merchandisers have to do exact calculation of expected production keeping in mind 8 work hour shift firstly. If the resulted quantity of production fails to ascertain the required quantity then they have to go for overtime.
Yarn Spinning Mill
Yarn Spinning Mill
So that, this 8 hour shift of calculation is one of the most crucial calculation for any production industry. Let’s see how to calculate this for an yarn manufacturer’s (ring spinning).

Mathematical Problem and Solution:

Problem: 01
Find out the TPI of 20 Number of Yarn?

Solution:

Given, 

Yarn’s Number =20
TPI=?

We know,

Twist per inch = TM x √ Yarn number or yarn count
= 4.5 x √ 20
= 20.12 (ANS.)

Problem: 02
Find out the TPI ,If spindle speed is 9000 r.pm, Front roller speed=203r.p.m and length of the circumference 3.25 inch.

Solution:

Given that,

Spindle speed = 9000r.pm
Front roller speed = 203
Length of the circumference 3.25 inch.
 

Turns per inch = Spindle speed÷(Front roller length of the circumference x Front roller speed)
= [9000 ÷ (203 x 3.25)]
=13.64 inch.(ANS)

Problem: 03
If 36s warp is spun with 4.5 twist factor at a spindle speed of 10000 rpm. What is the production per shift of 8 hours per ring frame having 400 spindles (Efficiency 90%) ?

Solution:

Turns per inch = √ 36 x 4.5 =27.0
Front roller delivery per minute = 1000 / 27 =370’’(Inch)
Yard per minute on one spindle = [ (370 ÷ 36) x { (60 x 8) ÷ 840 } ]
Hanks per spindle on per shift = [ (370 ÷ 36) x { (60 x 8) ÷ 840 } x (1 ÷ 36) ]
Total ring frame production = [ (370 ÷ 36) x { (60x8) ÷ 840 } x (1 ÷36)x (400÷1) ]

With 90% efficiency

Actual production = [ (370 ÷ 36) x { (60x8) ÷ 840 } x (1 ÷36)x (400÷1) x (90÷100) ]
= 58.8 lbs (pound)

Entire Calculation at one step,
= (10000÷27) x (1 ÷36) x { (60 x 8) ÷ 1 } x { 1 ÷ (840 x36) } x (400÷1) x (90÷100) ]
= 58.8 lbs (pound) (ANS)

Problem: 04
If 40s warp is spun with 4.5 twist factor at a spindle speed of 12000 rpm. What is the production per shift of 8 hours per ring frame having 500spindles (Efficiency 90%) ?

Solution:

Turns per inch= √ 40 x 4.5 =28.460
Front roller delivery per minute = 12000/ 28.460 =421.65 ’’ (Inch)
Yard per minute on one spindle = [ (421.65 ÷40) x { (60 x 8) ÷ 840 } ]
Hanks per spindle on per shift = [ (421.65 ÷40 ) x { (60 x 8) ÷ 840 } x(1÷40) ]
Total ring frame production= [ (421.65 ÷40 ) x { (60 x 8) ÷ 840 } x(1÷40)x (500÷1) ]

With 90% efficiency

Actual production = [ (421.65 ÷40 ) x { (60 x 8) ÷ 840 } x(1÷40)x (500÷1)x(90 ÷100)]
= 67.765

Entire Calculation at one step,
= [ (12000÷28.460)× (1÷40)×(60 x 8) × { 1 ÷ (840x40) } × (500÷1)×(90 ÷100) ]
= 67.765 lbs. (ANS)

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