Benchmarking to Breakthrough: A Spinning Unit’s Journey to Target Consistency

Project Background

In January 2025, a textile spinning and weaving unit launched a benchmarking program to enhance operational efficiency, reduce quality defects, and optimize manpower and energy usage. The program focused on setting monthly production targets, tracking machine performance, and implementing preventive and corrective maintenance. By July 2025, the unit operated 71.9 ring frames (out of 80 available) over 27 working days, achieving a production output of 3,321.5 bales, precisely meeting the planned target.

Objective

• Achieve 100% monthly production target.
• Improve ring frame utilization and yarn realization.
• Reduce defects such as spindle tape cuts, apron cuts, and yarn faults.
• Enhance autoconer efficiency to minimize imperfections.
• Control power consumption and UKG (units per kilogram) to reduce costs.
• Streamline manpower without compromising productivity.
  

Problem Statement

Before the benchmarking program, the mill faced several challenges:

• Low ring frame utilization, dropping to 66.5% in April 2025.
• High spindle tape cuts (59/day) and apron cuts (105/day) at the program's start.
• Elevated yarn faults, with 122 faults/100 km for 16s yarn in January 2025.
• Autoconer efficiency fluctuations, falling to 54.3% for 16s yarn in April 2025.
• High manpower dependence, with 684 workers in January 2025.
• Power consumption exceeding optimal levels, increasing cost per bale.
  

Actions Taken

Preventive and Corrective Maintenance

• Completed 3,512 maintenance activities in July 2025 (100% of planned).
• Activities included gearbox oil replacement, spindle centering, sensor replacements, and motor overhauls.
  

Process Optimization

• Sharpening and resetting of carding cylinders and doffers.
• Calibration of drawing frames, cot, and apron replacements.
• Improved winding and roving performance through cleaning and tension calibration.
  

Quality Improvements

• Repaired thick spots in carding (e.g., 53 spots corrected in a single machine).
• Monitored sliver unevenness, neps/gram, and roving stretch.
  

Manpower Efficiency

• Reduced workforce from 684 in January to 558 in July without production loss.
  

Energy Optimization

• Maintained power factor at 0.977.
• Reduced energy consumption to 385 units/bale (single yarn), 207 units/bale (double yarn), and 592 units/bale overall.
  

Results

Production

• July 2025 output: 3,321.5 bales, meeting the exact target (123 bales/day).
  

Machine Utilization

• Ring frame utilization improved from 66.5% (April) to 87.1% (July).
  

Yarn Realization

• Consistently high at 98.4–98.5%.
  

Defect Reduction

• Spindle tape cuts reduced from 59/day (Jan) to 1.1/day (July).
• Apron cuts reduced from 105/day (Jan) to 0.74/day (July).
• Yarn faults in 16s yarn dropped from 122/100 km (Jan) to 45/100 km (July).
  

Autoconer Efficiency

• Increased from 54.3% (April) to 72.1% (July) for 16s yarn.
  

Energy Performance

• Overall UKG reduced to 3.31, with single yarn at 2.17.
  

Manpower Productivity

• Production sustained with 18.4% fewer workers (684 → 558).
  

Key Takeaways

• Structured Benchmarking: Systematic tracking of performance metrics drives measurable improvements in efficiency and quality.
• Maintenance Focus: Preventive and corrective maintenance significantly reduces defects and enhances machine reliability.
• Process Optimization: Calibration and cleaning of critical equipment improve yarn quality and production consistency.
• Resource Efficiency: Strategic manpower rationalization and energy optimization can lower costs without sacrificing output.
• Quality Control: Targeted interventions in carding and winding processes effectively reduce yarn imperfections.

Conclusion