Driving Excellence and Delivering Measurable Results in a Spinning Unit

Introduction

  • A large spinning unit engaged Texcoms to implement an Operational Excellence program across its operations over a period of 6 months. With a capacity of 51,840 spindles producing 100% polyester yarn, the unit sought to address inefficiencies, improve product consistency, and establish sustainable systems.
  • The collaboration focused on achieving measurable improvements in productivity, quality, cost-efficiency, and equipment utilization through a structured, data-driven approach.

Problem Statement

The spinning unit was facing several operational challenges that hindered overall efficiency and profitability:

  • Inconsistent productivity levels across departments.
  • High levels of production waste and energy consumption.
  • Variations in yarn quality parameters.
  • Absence of standardized operating procedures (SOPs).
  • Skill gaps among operational staff and technicians.
  • Reactive maintenance practices affecting equipment uptime.

Action Taken

Key Interventions and Operational Enhancements 

  • Mixing SOP & Training

    • Soft wastecut before mixing.
    • Team trained to follow SOP for soft waste use.

  • Simplex & Roving Tension Control

    • Tension control improved
    • Lower creel tension
    • Worn-out aprons replaced
    • Flyer cleaned regularly
    • Piecing reduced with batch creeling
    • Better piecing method adopted

  • Blowroom System Optimization

    • Consistent feed through Unimix.
    • Smaller tuft size from bale plucker.
    • Suction pressure adjusted properly.
    • Heavy particle separator SOP applied.

  • Ring Frame Productivity Boost

    • Spindle speed optimized
    • SOPs followed for piecing and patrol
    • Faulty spindles and lashing fixed
    • Drafting and other key areas cleaned

  • Carding Improvements

    • Machine settingscorrected.
    • Suction and delivery tuned.
    • Damaged parts replaced.
    • Coiler cleaning improved.
    • Faulty cards fixed.
    • Sliver thickness issues corrected.

  • Link Coner & Quality Monitoring

    • Highcuts traced andfixed.
    • Bobbin rejection issue corrected.
    • Tension and speed fine-tuned.
    • Reduced variation between drums.

  • Draw Frame Enhancements

    • Suction pressureadjusted.
    • Better sliver joining and batch creeling.
    • Cleaning improved in draft zone.
    • Hooter cleaning organized.
    • Process settings made consistent.

  • Sustainability & Standardization

    •  SOPs standardized across units
    • Cleanliness routines followed
    • Fixed cleaning schedule for key machines
    • Regular training for staff
    • Machine settings made consistent

Key Milestones

Cost Impact - The Numbers Behind the Transformation

  • Unit Profile: 51,840 Spindles.
  • Average Count: 40s (100% PSF).

Conclusion

In today's cost-sensitive environment, Texcoms demonstrates thatOperational Excellence is not a one-time fix, but a long-termcommitment to profitability, quality, and sustainability. With deep expertise in machine optimization, process improvement, and operational support, Texcoms enabled the factory to achieve substantial gains in efficiency and product quality-setting new benchmarks in spinning performance.


Talk to our consultants to learn how Texcoms can drive similar results for your organisation.