A COMPREHENSIVE REPORT ON WARPING & LABORATORY By M.YASIR KARIM M.UBAID ULLAH USAMA BIN HUMAYOUN Sapphire Textile Mills Ltd. Unit 06, Flow chart of Warping Department Hierarchy: Warping In charge Assistant Supervisor Warper Assistant Warper Helper Flour Cleaner Responsibilities in warping department: Responsibilities of Warping Incharge: Planning of set. Provide the warper’s beam to sizing department in time. Monitoring the whole process To check report of machine performance regarding maintenance. To have complete knowledge of yarn source. Responsibilities of Supervisor: To give the warping plan to the warper. To perform all the activities of warping Incharge in his absence. To help the warping incharge in all the warping activities. Responsibilities of Warper: Correct Panel Feeding according to running set. To have keen observation on broken end, and mend it correctly. To check the shade variation if any, with the help of UV light. Responsibilities of Assistant Warper: To help the warper in smooth running of set. Responsibilities of Helper: To take the bags to the creel portion from yarn Godown. To fix the cone on creel, during creel loading To unload the creel and put out the paper cones into the separate bag. Responsibilities of Floor Cleaner: To clean the floor from fluff and dust. Warping Warping: Warping is the process in which we prepare a set of warper’s beam for the sizing machine. In warping following operations are carried out: Objectives: To wound the required length on warper’s beam. Manufacturing of a warp beam with required characteristics. Formation of parallel sheet of yarns wound on to beam. To convert smaller package into larger package. To prepare warper beam with required number of ends. Types of warping: 1) Direct Warping (High speed warping). 2) Indirect Warping (Sectional warping). Direct Warping WARPING M/C PARTS ARE DIVIDED INTO TWO PORTIONS. HEAD STOCK PORTION CREEL PORTION Head Stock Portion of Direct Warping: This is the section of warping machine in which warp sheet is wound on the warping beam. Its main components are Expanding Comb/Warping comb: It makes the entire warp thread parallel divides the yarns equally throughout the warp width and control the width of the warp sheet. The warping comb consists of no of steel pins which are grouped by segments. The no of segments depends upon the creel capacity. Different expandable combs which are available in STM 6 are: Segment 45, 54, 63 and 72 with needle pitch of 2 to 3 mm. Minimum ends run through the expandable combs are 560. Maximum ends run through the expandable combs are 1296. the pins are made of hard stainless steel, to avoid any type of wear and tear. Each comb consists of 9 dents. Why we not using below 560 ends. Because it produces a jherri in the warp beam and the no. of breakages will increase. Which will creates problem in sizing. The Comb moves up and down during warping process. Comb’s up and down movement is to reduce the wear and tear of needles. Each comb is associated with 3 motors Motor M2223: for its traverse motion Motor M2224: for its centre alignment Motor M2225: for its expansion and contraction which is attached the comb Guide Roller: To help the yarn to be parallel and to guide the warp sheet from comb to warper beam it has the movement due to the drag of yarn sheet and has a brake on the right side that is hydraulically controlled. Blow Pipe: It is operated with the help of pneumatic system Its function is to remove the fluff from the expanding comb. It also helps in straightening of yarn. If two or more yarns are overlapping each other than in the start of m/c it moves up and yarns are separated. The number of holes in the blow rod is 49 which blow air after the interval of every 8 sec. WARPER BEAM: Warper beam is of fixed length of 2400mm. Warp yarn is winded on the warper beam. It is positively driven. There is direct beam drive system in direct warping beam in driven directly from motor through gears as the beam diameter increases the warping speed and the tension on the yarn increases, to overcome this problem the surface speed of the drum and beam are made constant to keep the warping speed and yarn tension smooth and constant all the times. The brake is very effective and stops the machine instantly which is hydraulically controlled Wind Screen: It is operated with the help of pneumatic system It is to protect the operator from fluff. This covers the area of comb, guide roller and warping beam. During running state of the machine screen closes automatically and insuring protection for the operator. PRESSING DRUM: The pressing drum made of wooden hard paper. Its helps in compact winding on the warper beam. It applies force on the warper beam surface to maintain the density of the sheet It is negatively driven. And has a break on the right side that is hydraulically controlled. The function of this roller is to make the compact and smooth beam. It applies force on warper beam. The circumference of pressing drum is 1.57 meters of dia 50 cm. Pressing drum have an encoder at its left side with count the revolution of the wounded sheet It has the maximum value of 600daN and minimum of 200daN.normally 300daN is used depending upon the requirement. CREEL PORTION: Creel capacity There are 68 or 60 vertical rods .each of which contains 9 spindles to accommodate the cones. It has the capacity of Machine no.1 60*9*2=1080. Machine 2&3 68*9*2=1224 Vertical pitch It is the Vertical distance b/w 2 spindles of the same rod on the creel .it were 24cm. Horizontal pitch It is the Horizontal distance b/w 2 spindles on different rods .it were 24cm. Distance b/w two fixed rods It was 24cm Distance b/w two movable rods It was also 24cm. Creel portion of the machine consists of following parts. Spindles: Spindles are yarn package holding surfaces. In each column of creel there are 9 spindles. Tension rods: There are two types of rods Fixed tension rods Movable tension rods Fixed tension rods: No. of fixed tension rod is equal to the no of rods on each wing .these rods are stationary throughout the process. Movable tension rods: No. of movable tension rod is equal to the no of rods on each wing they can move forward(toward head stock) and backward(away from headstock).they move forward when the yarn is broken and move backward when the creel is changed. For the movement of the rods and also to control the movement is of rods there are two motors one on each wing .as the yarn breaks the rod moves forward . After repairing the Yarn as the m /c is restarted the rods moves towards there original position. The original distance b/w the rods as feed on to the panel Separate motor for each wing to control the tension in the yarn Balloon Breaking Rods: There are two balloon breaking rods present in front of yarn package, to avoid ballooning of yarn, during unwinding from package to avoid unnecessary tension on the yarn. Opto-Stop Sensor: Electromagnetic sensor is present to sense the vibration of yarn. When yarn breaks on machine, it sends electrical signals to machine, and machine stops. Source of light is infra red light Yarn passing through the sensor produces Air also blow from two consecutive Opto sensor rod after every six seconds to clean the fluff and dust Yarn Cutter: There are two cutters, which have the height equal to that of the creel. Its purpose is just to cut the yarn of the cones as the set has finished. But in STM 6 only it works on machine 3 while on other machines cutters are not working Motor and chain arrangement: For the movement of the creel there are two motors on the top of each wing This arrangement is used to change the creel. it is sense by the sensor to read the required rod. CREEL ANGLE OF DIRECT WARPING In direct warping creel is of v-type. And the angle subtended by one wing of the creel to the center of the warping m/c is called creel ANGLE; creel angle of all the three warping m/c is same. To calculate the creel angle of warping, at specific point on the both wings of the creel distance is noted and at that point distance b/w the two wings is also noted. And by applying trigonometric ratios creel angle is calculated. Observations and Calculations: C B DISTANCE BETWEEN TWO WINGS FROM FRONT = 140 CM DISTANCE BETWEEN TWO WINGS (C) = 1070 CM LENGTH OF WING (B) = 1605 EFFECTIVE DISTANCE BETWEEN TWO WINGS =1070-140 =890CM SINΘ = (C/2÷ B) Θ =SIN-1 445/1605) ANGLE OF ONE WING Θ = 16O CREEL ANGLE (TOTAL ANGLE B/W TWO WINGS) = 32O Downtime of warping 4.1.1. Types of Stoppages There are three types of stoppages which can occur on warping machine. — Cleaning stoppages — Production stoppages — Breakdown stoppages 126.96.36.199. Cleaning Stoppages These include cleaning of AC duct line and cleaning of warp stop sensor. The time analysis is shown here below. i. Cleaning of A.C Duct Line – Warping machine is stopped for cleaning the A.C duct line above the creel because when coarser count is run on warping machine, more fluff blows in the warping shed. Some of this fluff get stuck with the inner and outer part of the duct and finally falls down on the yarn and causes problems in the subsequent processes. Average time taken for cleaning the outer duct line of A.C. is 30 minutes ii. Cleaning of Warp Stop Sensors – Cleaning of the warp stop sensors is also Important because if the fluff is trapped in the sensor, it would cause the sensor to work improperly. In case of breakage the sensor won’t detect it and a warp end short would be produced in the beam. Time taken is 17 min Production Stoppages These stoppages are of two types 1. Fixed stoppages 2. Variable stoppages 1. Fixed Stoppages – These are the type of stoppages which are independent of the type of material, yarn quality and yarn count. The fixed stoppages that can occur on the warping machine are i. Warp Ends Cutting Time is .60 sec ii. Panel Setting Time is 1.5 min iii. Doffing Time is 2.00 min iv. Creel Move Time is 6 min 2. Variable Stoppages – These are the type of stoppages that changes with the change of material and yarn specifications. The variable stoppages that can occur on warping machine are as follows: These stoppages depends upon count and ends i. Sensor filling time is 6 – 8 min ii. Comb filling time is 6 – 9 min iii. Warp break repairing time is 57 sec Quality=20x16+70d/107x63 73” Quality ends= 7716 Length=5270m Ends per beam=643 Stoppages: Creel loading: First of all creel loading is done and cones are put up on the spindle of creel. Time for creel loading = 60min. Creel change: Creel change time = 6min Comb filling: Comb filling time = 6.56min Beam Doffing: When the required length is wound on the beam the previous yarns are cut and new beam is loaded Beam # Beam Total Other Average change stoppages stoppages Time to time(min) repair break on a beam(s) 1 2.3 4 19.5 45 2 2.1 4 0 53 3 2.57 3 0 65 4 3.10 5 3.10 56 5 2.8 0 .52 58 6 2.10 2 0 1.4 7 2.43 2 0 1.3 8 2.34 10 0 1.8 9 12.44 16 .5 .52 Downtime due to breakages = 75 min Creel loading time 60 min Other stops = 22 min Total operated time = 195 min Total down time = 75 +60 + 22 = 157 min Running time = 195 – 157 = 38 min Efficiency = 38/195 *100 =22% Hydraulic mechanism: Hydraulic mechanism is mostly used in breaking system where machinery is running at very high speeds. And hydraulic mechanism also used to lift heavy loads. Hydraulic mechanism in warping controls the hydraulics at serrated cones to stop the warper beam. It also controls the hydraulic break at guide rollers. There is a hydraulic mechanism in the head stock portion of the warping that comprises of the parts as follows; Hydraulic pump with motor Hydraulic reservoirs Solenoid valves Pressure lines If we see then 5 pressure lines are on the right side and 5 are on the left side. Two of each side is for the left and right brakes of the beam one line to push forward solution and other to push it back. One for the guide roller's brake. One for the drum brake. Remaining 4 is for the pressing drum assembly movement The motor on the right back of the head stock is used to pump the hydraulic oil .the pressurized oil goes to the solenoid valves then to the pressure lines then to place where job has to perform then come back through the pressure lines to the reservoir then to the pump. Hydraulic mechanism performs the following jobs: It is used to apply the brakes on the warper’s beam .directly brake is not applied to the beam. It is used to apply brake on the guide roller. It is used to apply the brake on the pressing drum. It is also used to push back and forward the drum assembly. Main pressure of the hydraulic mechanism is =110-130 bar Capacity = 17 litre / min Pressure on brake =75 bar Pressure on guide roller =50 bar Oil number 47 SHELL Pakistan ltd. Function of hydraulic system and detail working and description of all parts: Position Description 00A Load Accumulator 01A Motor and Pump 02A Discharge Press Roller Pressure 03A Charge Press Roller Pressure 04A Pressure Sensor Press Roller 05A Pressure Reducing Valve Beam Brake 06A Pressure Reducing Valve Press and Guide Roller Brake 07A Pressure Reducing Valve Guide Roller Brake 08A Beam Braking 09A Guide Roller Braking 10A Pres Roller Braking 11A Emergency Off 12A Kick Back 13a Beam Lower=Press On 13b Beam Rise=Press Roller Backward 14A Pressure Limiting Valve Beam Lowering 15A Shut Off Valve Beam Lowering 16A Indirect Press ON 17A Pressure Load Cell With Contacts/Load Accumulator/Emergency Stop 18A Throttle non Return Valve 19A Oil Filter 20A Throttle Non Return Valve 21A Throttle Non Return Valve 22A Hydraulic Block 23A Manometer 24A Connection Cabinet Valve 25A Flexible Tube Accumulator 12M 26A Flexible Tube Accumulator 3M 33A Drain Cock 37A Option Dyeing Beam 39A Adjustable Pressure Limiting Valve 40A Oil Level Meter M1 Measuring Point Main Pressure M2 Measuring Point Beam Brake Pressure M3 Measuring Point Guide Roller Brake Pressure M4 Measuring Point Guide And Press Roller Brake Pressure M5 Measuring Point Flexible Tube 3M(Accumulator Kick Back) M6 Measuring Point Flexible Tube 12M(Main Accumulator) Effect of Temperature and Humidity The temperature and relative humidity of the warping section should be proper and within the standards to improve the efficiency production of the warping process by decreasing the breakages in the yarn. Standard temperature and humidity values are given as follows: Standard temperature = (25-29) centigrade while in warping STM it was 33 centigrade Standard humidity = (60-70) % while in warping STM it was 40% With the increase of temperature from the standard values, breakages in yarn increases and also the workers efficiency decreases. So ultimately in this way warping process efficiency and production decreases. The temperature should be in standard limits for better efficiency and production. If the relative humidity decreases and goes below 55%, or increases and goes above 80% than the yarn breakages increases. So ultimately in this way warping process efficiency and production decreases. So the relative humidity should be in standard limits for better efficiency and production. Why temperature and relative humidity of the warping section is not proper in STM 6 Because of energy conservation concept and to give Full stress on yarn in warping due to low humidity and high temperature, so that the yarn max possible breakages can be trace out. So that the yarn not make problem in further process Yarn passage line diagram of direct warping Creel Tension rods Comb & Blow rod Tensioner & Opto sensor Guide roller Warper beam Balloon breaker Pressing roller Our Observations: Total no. of warping machines = 3 Maximum speed of machines = 1200 m/min Total motors in warping m/c = 11 Comb moving motors = 3 Warper beam motors = 3 Hydraulic pump motor = 1 Creel movement motors = 2 tension rod assembly = 2 Running Speed = (600-1000) m/min Inching speed= 20 m/min Machine # 1: Made = Switzerland Model = 2000 Creel Capacity = 1080 Working width = 2400 mm Machine # 2: Made = Switzerland Model = 2003 Creel Capacity = 1224 Working width = 2400 mm Machine # 3: Made = Switzerland Model = 2005 Creel Capacity = 1224 Working width = 2400 mm Warping Specifications: No of holes on blow rod=49 after every 8 sec Reaction time of yarn stop motion=5/100s Ac frequency=50-60hz No of motors on warping=11 Types of belt use on pulley=104 v-type Air pressure= 5bar Operating speed of machines = (20-1200) m/min Running speed = (700-900) m/min Width of beam= 2400mm fixed Flendges diameter=1000mm fixed Pressure applied by pressing drum=(200-600)daN Distance between two spindles or pitch=238mm Distance between balloon breaking rod and guide rod=140mm Distance between sensor point and tension bar=35mm Distance between spindle rod and balloon breaking rod=280mm Distance between rods= 2400mm Distance between b/w spindle rod and tensioner 6000mm Distance between headstock and creel = 14000mm Pre-tensioner running position=(0-50)mm Time-delay pre-tensioner=(0-20)s Height of creel=3000mm Total motors in warping m/c = 11 Comb moving motors = 3 Warper beam motors = 3 Hydraulic pump motor = 1 Creel motors= 4 DETAILS DESCRIPTION OF MOTORS CAPACITIES USED IN DIRECT WARPING: Creel Portion Motors: Package Transport Left: 0.37kwatt Package Transport Right: 0.37kwatt Pre-Tensioner Motor Left: 90watt Pre-Tensioner Motor Right: 90watt Head Stock Portion Motors: Hydraulic Pump: 0.55kwatt Beam Clamping Left: 0.3kwatt Beam Clamping Right: 0.3kwatt Main Motor: 15kwatt Comb Traversing Motor: 0.18kwatt Comb Displacement Left/Right Motor: 0.09kwatt Comb Expansion Motor: 0.06kwatt TOTAL LOAD 18.5 kwatt for warping machine Cones weight w.r.t there counts and Cone Dimensions Ne 1-8 cone weight 6.25 lbs Ne 9-10 cone weight 6.25 and 4.16 lbs Ne up to 30 cone weight 4.16 lbs Ne 30-40 cone weight 2.5 or 4.16 lbs Ne 40 -50 cone weight 2.08 or 2.5 lbs Ne above 50 cone weight 2.08 or 2.5 lbs Empty cone dia at tip 25 to 26 mm Empty cone dia at bottom 67 to 68 mm Length of paper cone 172 to 173 mm Empty paper cone weight 50 to 55 grams Cone dia at tip with yarn 180 to 186 mm. Cone dia at bottom with yarn 200 to 201 mm. Cone reminder standards in STM 6 For single ply yarn cone reminder 1.5% For finer count cone reminder 1% For 2 ply yarn cone reminder up to 2% For lycra cone reminder up to 3% Formulas used in Direct Warping: Efficiency Calculation: Total Stoppage time= it is noted with the help of stopwatch. Calculated time for running = length /beam x total no beams M/c speed Actual running time = calculated time + breaking time EFFICIENCY % = CALCULATED TIME FOR RUING X 100 ACTUAL TIME FOR RUNNING Set Calculations: No of beams = Total ends Creel capacity Ends/ beam = total ends No of Beams Set Length: Cone Length-Cone Remainder% of Cone Length *No of Creels No of Beams Cone length = Cone weight X 768.1 X count No of bags = Total ends X no of creels No of beams X cones/ bag Beam Length Calculations: Volume = 3.147 [D*2 - d*2] X W 4 Mass = Volume X Density Density (given) Weight (lbs) = Total length X Total ends/beam 768.1 X count Length (m) =1.33* (D2 - d2) * W *Count*Density No of Ends/beam Breaks Calculation: Lbs/Breaks=Total Ends*Length (m) Count*768.1*No of Breaks Breaks/10mm=No of Breaks*107 Total Ends*Length (m) Production Calculations: Production = Speed (m/min) * 60 * Time (hrs) Warping Faults: weak yarn: It causes the breakage of yarn. This fault can be identified visually by viewing the broken end of the yarn because when the yarn is broken then it has the broken end as the cotton is accumulated on it... Hair: It is the mixing of human hair in the in the cones. Paper cone damage: This is due to the mishandling of bags or cones. Cone short: Less amount of yarn is wound on the cone. Lapper: It is the entanglement of yarn during winding. Cut on cone: It is due to the mishandling of cones and it causes the breakage of yarn. Spare ends: This fault comes on comb and spare end causes the entanglement of side yarn and causes breakage. Nylon: It is due to the presence of nylon yarn. Slub: It is spinning fault and it causes coarseness of yarn at certain places. Fluff: Bad splice: Warping faults Selvedge demand Loose beam Short ends Extra ends Warping maintenance schedule 1. Daily maintenance: Cleaning of m/c with air is done. Checking of winding zone and pressing drum is done. Oil level is checked and serrated cones are also checked. Combs checking and cleaning is also done. Breaks of warper beam, pressing drum and guide roller are checked. Creel spindles, creel chain & its gear and thread cutter is also checked. 2. Weekly maintenance: Cleaning of wind shield, guide rollers, pressing rollers, trapezoidal threaded spindle and switch assemblies is done. Drive belts are checked and oil level is also checked. Checking of screwed connections is done. Re setting of maintenance intervals is also done. 3. Monthly maintenance: Cleaning and lubrication of trapezoidal threaded spindle is done. Quills lubrication is done and beam positioning is checked. Checking of comb and its traverse chain is done. Warp beams are checked and serrated cone bearings are greased. 4. Six-monthly maintenance: Oil and air filters are changed. Inspect and replace pressing drum, warper beam and guide rollers brake pads if necessary. Replace main motors belts if necessary. Check wind / winding zone air cylinders and H.P spring. Check beam clamping axial play. 5. Annual maintenance: Check and clean beam and pressing drum bearing and replace if necessary. Check and clean guide roll bearing and replace if necessary. Check and clean quill bearings and replace if necessary. Check brake caliper seals and replace. Check and clean serrated cone and replace if necessary. Maintenance faults in warping machine In warping machine some faults occurs most frequently and some faults may occur in years. But the main faults that can occur in any time in warping m/c are as follows. Sometimes combs movement is stopped due to comb moving switch‘s problem. Sometimes cutters don’t cut properly; this problem is most likely to occur. Breaking system of guide roller, warper beam, or pressing drum become loose due to hydraulic mechanism fault. Axial play in the beam clamping may also occur. Yarn tensioner problem may also occur. Pressing drums pressing force may also disturb some time. In driving motors of the m/c also some problem occurs. Sectional Warping Machinery specification of sectional warping Only one sectional warping m/c is present whose specifications are as follows. Made = Switzerland Model = 2003 Creel capacity = 800 Working width used = 2400 mm Maximum speed = 800 m/min Running speed = (500-600) m/min Maximum warper beam speed = 200 m/min Running speed = (110-130) m/min Creel type = H- type creel Minimum section width = 60 mm Maximum section width = 340 mm Distance between warp stop and drum = 463 cm Distance between spindle to spindle vertical= 17 cm Distance between spindle to spindle horizontal = 27 cm Spindle length = 24 cm Rod length = 223 cm Leasing comb width = 100 cm Traversing comb dents = 238 (1.5 mm/dent) Motors Detail on sectional warping machine: Beam drive= 22kwatt Drive for drum = 11kwatt Lift out left = 0.7kwatt Lift out right = 0.7kwatt Unclamping left = 0.7kwatt Unclamping right = 0.7kwatt Fan for beam drive side left (optional) = 80watt Fan for beam drive side right (optional) = 80watt Safety grill = 0.37kwatt Waxing device motor Warp sheet moving = 0.55kwatt Drive roll unit = 5.8kwatt Fan brake linking left = 0.37kwatt Fan brake linking right = 0.37kwatt Hydraulic pump = 7kwatt Machine shifting (stepper motor) Headstock axial motor = 0.37kwatt Headstock radial motor = 0.37kwatt Comb side adjustment = 0.56kwatt Hexing for lateral movement = 0.11kwatt Comb side changing Comb brightness adjustment Different parts of sectional warping machine Sectional warping m/c consists of a number of parts which are divided into three portions given as follows. Creel portion Head stock portion Winding potion Creel portion: Spindles Spindles are the packages or cone carriers. There are total 800 spindles present on the creel, So 800 packages can be used on the creel at a time. Balloon breaking rods: When the yarn unwinds from the cones with speed than balloons are produced so to minimize the effect of these produced balloons, balloon breaking rods are used. Yarn tensioners: Yarn tensioners, used on the creel are load tensioners. Their main purpose is to provide proper tension to the yarn. When the m/c stops due to yarn breakage than it stops the yarn to reduce the slackness. Yarn guides: Each individual yarn has separate set of yarn guides. Their main purpose is to separate the yarns so that entanglement not occur. These yarn guides are of ceramic material. Yarn sensors: These sensors are pin type and on their heads guides are present. When the yarn is passing over them they remain connected to a metallic rod, but when the yarn breaks, they bounce back and their connection with the metallic rods is disconnected, and m/c is stopped. Head stock portion: Lease rods: There are total 10 lease rods are present. These rods separate 8 different yarn sheets. Combs: There two combs in the sectional warping m/c. First comb is big in size and the second comb is smaller in size. In first comb from each dent only one end passes so it is separating the yarns. From second small comb (2-7) ends are passed from each dent this comb determines the section width. Guide roller: This is the small diameter roller in front of the small comb. Its purpose is to guide the yarns section to the winding drum. Pressing roller: It is present below the guide roller. It is also of small diameter it makes the proper contact with the yarns section and helps the proper and compact winding on the winding drum. Measuring feeler: This sensor is present just below the pressing roller. Its function is to measure the density of warp yarn wounded on the winding drum. Winding drum: This drum is of large diameter and dyed yarn sections are winded on it. It is tapered from one side. Tapering is done so that the sections of the yarn do not slip. Photo sensors: One photo sensor is present in front of winding drum and one is present in the back of drum. Each photo sensor consists of one emitter and one receiver opposite to each other. Their main function is workers safety, if any thing comes in b/w emitter and receiver than the sensor stops the m/c. Winding portion: Guide rollers: There are present two guide rollers in the back side of the winding drum. Their main function is to guide the warp sheet consisting of many sections, on the warper beam. Warper beam: Warp sheet consisting of many sections is winded on the warper beam. Maximum winding speed of the drum is 200 m/min but winding is done normally at 120 m/min. Pressing rollers: Their function is to press the warp sheet on the warp beam for compact winding. These rollers are actuated with the help of pneumatic system. Sectional warping maintenance schedules Sectional warping maintenance is done at different times as follows. Daily maintenance Weekly maintenance Monthly maintenance Three-monthly maintenance Six-monthly maintenance Daily maintenance: Overall cleaning of m/c is done. Check and clean evener roller. Check and clean waxing device roller & spindle support shaft and pressure device. Check spindle, spindle brush and reed. Check and clean yarn guides, tensioners & overall creel and creel movement is also checked. Weekly maintenance: Check oil level, hydraulic block and break system. Check and clean beam block and its shaft & check all belts. Oil pipes and its connections are checked. Check and clean reed and all the threaded shafts. Monthly maintenance: Oil level is checked. Air filters are checked and cleaned & drum breaks are checked. All the air lines are checked and measuring feelers are cleaned. Drum tracks and drum wheels are checked. Three-monthly maintenance: Inspection and greasing of feed spindle and reed head stock is done. Reed head stock guides, spindle head stock shaft, spindle beam lifting device, spindle support shaft and support guides and lifting assembly are checked and greased. Six-monthly maintenance: Hydraulic unit’s oil is changed. Beam block gear box oil is changed. Oil filters are changed. Change beam pressing device, Teflon roller and its bearing. Hydraulic mechanism use in sectional warping In sectional warping hydraulic mechanism is only used in the breaking system of the winding drum or section drum. Hydraulic breaks are present on both sides of the drum. Suggestions There should be creel cutters because lot of time is wasted, while cutting the creel manually it is the most important factor responsible for down time There should be some arrangement of fluff suction it causes a lot of problem while machine is running and also harmful for the worker The working of Opto sensor should be made proper, it has been observed that a lot of sensors of machine are out of order due to which when end breaks , the machine is not stopped at the time, due to which ends is buried inside the sheet which can cause problem in sizing There should be insect killing arrangement because some time the caught by the running yarn due to which they cause mark on yarn /breakages in yarn etc There should be proper balance of empty beams as a lot of time is wasted in searching the beams which disturb the process flow and increase work in progress The tension between rods is not uniform because some of rods have contact with lower plates or the rods are bent due to weight. Due to which there movement is opposed and causes bending of rods Beam flendges are not straight due to which beam causes a lot of problems like the sharp or bend edges which causes fiction between drum n beam flendges, may also damage other parts, results the time wastage. There should be proper air Conditioning without it proper amount of humidity can’t be maintained in the warp yarns, also can machine Heat up and may damage machine parts. There should be proper lightening arrangement on both machine 1 and 2 because it may decrease the visibility of broken yarns and also affect the operator eye sight which decreases the operator efficiency The air pressure pipe being used during cleaning should have fewer diameters which will give more pressure on air and less air consumption The current pipe diameter is 9 mm, it should be reduce upto 3mm as according to Bernoulli equation A1V1=A2V2 As the area decreases the velocity increases There should be some arrangement to prevent the warper beams from the fluff as the beams are stored near by the machine due to which all the fluff onto those beams . so for that purpose we use plastic sheets to cover the beams or we can also make separate sections of plastic sheets for beam storage which will effect in cleaning the environment of the mill Creel change sensor are also not in proper working condition due to which when changing the creel extra or less rods are moves which causes a lot of wastage in setting them back.