Improving the operation method
01▎Implementing the dedicated operation method
Spinning, roving, combing and other processes have been changed from the original The on-duty lathes were required to look after the cars and do the cleaning by themselves. Instead, full-time cleaners and on-duty lathes were set up to look after the cars. The division of labor was more detailed and professional, which reduced the workload of the on-duty lathes and increased their viewing capabilities. After the promotion of this operation method, the labor force is reduced by more than 30%.
02▎Promote the overall loading and unloading operation method of sliver and roving
Roving frame in the front spinning workshop The original method of changing cotton slivers in sections was less capable and labor-intensive. When changing strips and joints, there were hidden dangers such as tops and illegal operations, which caused quality fluctuations.
Nowadays, the sliver loading and unloading method after the roving frame has been changed to the overall loading and unloading method, from the original 20-tube section changing to 120-tube unified fixed-length overall sliver changing in one car. Let’s face it, the roving machine operator does not need to change strips and splices multiple times, and can have time to clean, patrol, and prevent defects. The improvement of this operating method has reduced the labor intensity of the turners on duty, and the number of stands per turner on duty for roving has increased from 2 to 4.
The pagoda segmented roving method originally implemented in the spinning workshop, if the on-duty lathes do not patrol in time, there is a high probability of empty rovings and woolen rovings, which can easily lead to thick warp, thick weft, etc. Yarn defects such as slubs require a lot of labor and require a lot of labor. In response to this situation, our company has improved the overall roving loading and unloading operation method. The lathes with higher operating skills are responsible for splicing and inspecting the trailers, and the rovings are no longer changed during the on-duty process. The lathes or male workers with relatively poor skills are responsible for transporting the rovings and dismantling the trailers after being trained.
The establishment of a full-time roving machine team, with a reasonable division of labor and clear and detailed work responsibilities, has reduced the burden on the spinning workers and added stands, making the operating technology more professional and single. Attention is more focused, the average number of spinning yarn turners has increased from less than 10 to more than 20, and the instantaneous end break has dropped from 2-4 pieces/set to less than 1 piece/set, improving output and production efficiency.
03▎Implementing the splicing and tying method before roving
Roving For front joints, because it is difficult to control the fiber length when tearing off the beard strips, the joint qualification rate is low, and it is easy to cause long and thin joints. Moreover, destructive tests have found that many front joints often appear to be qualified in thickness, but the fibers at the joint are smooth. If not handled properly, slub defects will still appear in the spinning process.
The front joint is unqualified or the pass rate is too low. Especially knitted varieties and direct weft varieties can easily cause long, thick, thin or single yarn horizontal weft, wrong weft, etc. on the cloth surface. In response to the above problems, our company switched to the roving front joint tying method, that is, after normal jointing in front of the roving machine, use yarn of the corresponding count to tie a 3-4cm button above the front joint, and let it break the yarn artificially. It has become a spun yarn joint with a relatively high qualification rate and relatively small harm, which better reduces the quality hazards caused by human operations.
04▎Use of foreign fiber separator
In the past three years, the company With an investment of nearly 100 million yuan, each production line is equipped with a foreign fiber separator, which basically solves the foreign fiber problem that is a headache for textile workers, improves product quality and per capita labor efficiency, and reduces the number of bag tearing workers by about 2,500.
05▎Experimental restoration integrated process reengineering
Post-processing tradition The process has been changed from the original work that can be completed in multiple steps such as cloth inspection, cloth repair, and cloth restoration to one person inspecting, repairing, and repairing the entire cloth at one time. The system of dedicated personnel responsible for the cloth has been implemented, and employees’ sense of responsibility has been enhanced, reducing the number of workers. This eliminates duplication of work, improves per capita labor efficiency, and saves 25% of labor.
06▎Promote the implementation of electric car tours for on-duty lathes in various textile processes
Our company contacted the relevant manufacturers and customized electric car tours to replace the traditional walking tours. We made many improvements in terms of the width of the car body and the comfort and safety of the seats, and finally developed a product suitable for textile values. Special electric vehicles for lathes to watch cars. With a 25% increase in the number of lathes’ stands, labor intensity is reduced, instant breakages are reduced, production efficiency is improved, product defect rates are reduced, and wage income is increased. It can be said that it kills multiple birds with one stone. Yes, it is currently being further comprehensively advanced.
Innovation in cleaning methods
07▎ Setting up full-time cleaners
On the basis of promoting the special operation method of dedicated personnel, setting up full-time cleaners in some processes such as spinning, roving, combing, etc., so that the on-duty workers can change from many years of handover The “old difficulty” of cleaning has been relieved. Dedicated personnel are responsible for cleaning. The work content is focused and standardized, and the cleaning pass rate has increased to more than 98%.
08▎Improve cleaning progress
In order to ensure product quality, The cleaning schedule of each process has been improved. The drafting cleaning of combing, drawing and other processes is changed from 2 hours to once every doffing. After cleaning, the strips are pinched and the empty bobbin is driven. The empty spindle cleaning in the spinning process is changed to cleaning above the middle yarn; the double twisting process The improvement is to focus on cleaning every time the doubling is changed or after doffing; other processes have also formulated a reasonable cleaning schedule, shortening the cleaning cycle, improving the cleaning quality, reducing human defects caused by cleaning, and reducing the yarn defect rate 50%.
09▎Innovative special cleaning tool
The can is the spinning It is the most widely used container in the factory. If it is not cleaned well, it will produce static tops.Cleaning the can has also become a big project. It used to take 2-3 people to work together and spend several days to clean it, which is time-consuming and labor-intensive. Therefore, after many experiments, we made our own special cleaning tool for the can, using a large rotating brush. Automatic cleaning, saving time and effort, cleaning evenly and thoroughly.
The cleaning of the brake device in the double twisting process has a greater impact on product quality. If you are not careful, it will cause oil flying or strong and weak twisting. For this reason, we have also gone through many tests , homemade special vacuum cleaner, simple to operate and effective.
In addition to the above methods, our company also provides splicing for combing, drawing, and roving processes, splicing for special varieties in the spinning process, yarn changing during the doubling process, and double twisting processes. We have carried out a series of systematic operating method improvements and management innovations such as raw jointing methods, fixed supply cross-mixing of pre-rolling, combing, and drawing processes, and weaving and reeding methods, and actively studied with relevant experts. Technical transformations such as “automatic replacement of rovings” will greatly reduce the labor intensity of employees, gradually realize automation and continuous functions on old equipment, and reduce labor costs to adapt to the current status of textile enterprises and meet customer needs.
Through the improvement of the operation methods of the above processes and the innovation of cleaning methods, the work content is optimized and combined, the work responsibilities are further refined, and the work process is simpler and more efficient, which not only reduces the inefficiency Labor has improved the quality of production, and the technical level of employees has also improved day by day. It has also achieved significant results in saving labor. The number of employees in the spinning department has been reduced from 75 to less than 50. </p
