Research and development Textile Spinning for cost saving

 Research and development in a total quality management system requires a team of people who can complete any task willingly and voluntarily.

Such people exist in every organization. With just a little effort, they can be found and teamed up.

So far the Blow Room, Carding, Comber, TFO, Autocone, and Air Conditioning departments have completed some R&D tasks in the best way and have saved a lot of money by being part of the R&D team.

The team aims to find cheaper alternatives to expensive and unavailable parts.

Following are some of the R&D works completed so far:

1- Blue room foreman and his team,

When the CLC III waste deflector motor breaks, complete the operation of the machine by making a mechanical setting and saving the huge cast.

Deflector motor for waste control 1491.29 Euros, saving approximately Rs.96784.13.

2- Used a hose pipe instead of a suction hood on a carding machine to start thinking about removing costly and weak suction hoods with a strong and cheaper suction system. After success in this point, whole the system has converted Into max Rs 30000/card, and for 10 cards spent Rs 300000 only instead of above Rs  5 Million. saved about Rs 4.7 Million.

3- The air conditioning foreman installed the dust suppression system on the Lowa air filter to control the particulate matters of 1 and 2.5 u as the modern world is giving the system to control air-born particles, detrimental to human health.

4- The electrical Engineer has used an alternate sensor of Rs1600 against the imported price Rs/ local price 4900 saved Rs 3300

Fire system's water level sensors priced at 325 USD x 280x2 pcs= 182000Rs  replaced by sensor cost of Rs 270x2=554 delivery charges about 1000 Rs, saved  Rs181000.

5-Misting nozzles installed in the Open end, and including cost is Rs 5000, and a finer misting Nozzle of steel costs Rs 22000.

Now the fine misting nozzles are designed and made first with waste material and later made with Teflon bari which would not cost more than Rs 1000 now these are not purchased from outside but Ac Forman is made in the mill workshop. up till now above 10 nozzles have been made and installed in the open-end department.

Saved Rs about 22000x10=2200000-10000= Rs210000

6-Comber Foreman replaced the 200 pages register of cost Rs.700 with only three paper reports, costing not more than Rs.20. Saved Rs 680

7- TFO Foreman used a Rs.5 washer instead of a Rs.100 and later on the supplier himself reduced the price to Rs 20. The annual consumption of this washer is 1000 pcs, so instead of Rs 100000, its price became Rs 20000 only. saved Rs 80000

8-TFO foreman has started making Teflon Bush in the millwork shop.

Instead of Rs 400, it will be made at Rs 67 material cost only. saving will be 

9- TFO F man removed the tension motor which was due to some reason not available in import too, cost 45.2 $ and required were ...and save Rs.

Roller cover Fman has made the cot pressing machine by his own efforts.

The drawing Foreman used the undersized cots on the Breaker drawing to save the rubber cot's cost.

Blow Room forman worked hard in analyzing the root cause of Fire incidents. B-60, china mixer, Clc3, and the main cause was the low filter suction.

Low filter suction was controlled by interlocking filter-related motors and a timer on the dust fan which was also one of the big causes of low suction and finally was causing the fire incident.

Changing the broken suction hoods the fire incidents have been controlled to the maximum extent.