saving tip Spinning-Textile, 500 units of Electricity/day and about 15000 L of water,

 Introduction:

The research and development (R&D) team has successfully completed several tasks aimed at continuous improvement and cost-saving measures. By utilizing the Total Quality Management (TQM) system and fostering a proactive mindset among the employees, achieved significant results in terms of cost savings and energy conservation. This progress report highlights the completed tasks and outlines future R&D initiatives. Completed R&D Tasks: Formation of TQM Team: A dedicated team was built to focus on continuous improvement and cost-saving initiatives. This team consists of enthusiastic individuals from various departments within the organization. Cost Savings: Through various R&D efforts, achieved cost savings of above Rs 5 million. These savings were accomplished by finding inexpensive alternatives to expensive and unavailable parts. Electricity Savings Target: The R&D team's goal was to save about 500 units of electricity daily. successfully identified areas for improvement and implemented measures to reduce energy consumption. Summary of Completed R&D Tasks: Blow Room: Repaired the damaged deflector motor of Blow Room CLC 3, allowing the line to continue operating without the need for a new costly deflector motor. Addressed fire hazards by working on Plucker, multimixer, B-60 m/c, and Luwa filter. Fire incidents in the Blow Room have been significantly reduced. Carding Department: Installed new suction hoods on machines to prevent fire caused by broken carding waste suction hoods. Designed and implemented cost-effective suction hoods using G.I. sheet, resulting in substantial cost savings. Air Conditioning Department: Developed a dust suppression exhaust air system to control particulate matter. Installed homemade misting systems in the carding and Auto cone air conditioning plants, eliminating the need for expensive equipment like an 18 kw pump inverter, water Pump, M.S header, showering pipes, about 144 showering nozzles and saving about 5000 liters of water drained monthly, and has save electric cost consumed by 18 kw pump in carding. Autocone humidification. saving electricity. Auto Cone Department: Same as made for Carding humidification, Initiated the design of an improved humidification plant to save electricity and reduce maintenance costs. The key point is that the main costly part required to make this system is the misting. a nozzle price Rs 22000/= and at least 12 were needed costs 264000/= are made in mill workshop with scrap. Comber Department: Replaced an expensive register with a cost-effective alternative, reducing expenses. Other Contributions: Installed a duct to redirect the hot air from the compact fan air increases department into the air-conditioning underground trench, reducing energy costs and maintaining RH% levels. Used inexpensive washers and found alternatives for tension motors to save costs. Utilized sensors at a lower cost to monitor equipment performance. Implemented undersize Rubbercot usage in the drawing simplex department, saving costs on rubber cots. Future R&D Tasks: Blow Room: Focus on finding energy-efficient alternatives to the rotary filter, which currently consumes significant electricity. Motivation and Rewards: To maintain the motivation and dedication of the R&D team, it is essential to provide appropriate incentives. Consider implementing a reward system where employees receive saving certificates or other forms of recognition upon the successful completion of improvement tasks. This approach encourages a proactive mindset and fosters a culture of continuous improvement. Conclusion: The progress made by the R&D team in the spinning mill demonstrates the significant potential for cost savings and operational improvements. Through the implementation of the TQM system and the active involvement of talented individuals from various departments, R&D team has successfully completed several tasks resulting in substantial cost savings and energy conservation. By continuing to monitor and support the team's efforts, it has been aimed to achieve even greater success in the future.

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