How to Calculate The Production Capacity of Yarn Splitter Machine
Production capacity calculation of yarn splitter machine is a basic work of textile production planning. Accurate capacity data can help production managers arrange production orders reasonably, formulate delivery schedule, match the front yarn supply and the back weaving or twisting process, and avoid the situation of equipment idling or order backlog. Many factories only roughly estimate the output according to the rated speed marked on the equipment nameplate, and the final actual output is far lower than the theoretical value, because the theoretical capacity does not take into account the yarn breakage shutdown time, bobbin change time, model change debugging time, equipment maintenance time and other loss factors. The calculation of yarn splitter machine capacity needs to distinguish theoretical capacity, actual operating capacity and available capacity.
The theoretical production capacity of yarn splitter machine refers to the maximum output under the ideal state without any shutdown, yarn breakage, bobbin replacement and parameter adjustment. The basic calculation logic is determined by the running speed of the equipment, the number of splitting strands and the fineness of the finished split yarn. The running speed of the yarn splitter machine usually takes meters per minute as the unit, representing the linear speed of the yarn passing through the splitting area. First, calculate the length of yarn produced per unit time, and then convert the length into weight according to the yarn count. It should be noted that the rated speed marked by the equipment supplier is the upper limit speed of the equipment. In actual production, most yarn varieties cannot run at the maximum speed for a long time. Running at the highest speed for a long time will lead to sharp increase of yarn breakage rate and accelerated wear of blades and bearings. Therefore, the actual operating speed set by the workshop is often 70% to 85% of the rated speed.
The actual operating capacity is obtained after deducting all kinds of shutdown loss time on the basis of theoretical capacity. The shutdown loss of yarn splitter machine is divided into fixed loss and random loss. Fixed loss includes the time required to replace the empty yarn bobbin, thread the yarn after bobbin change, and the time of order switching and specification debugging. This part of the time is predictable. For example, it takes 3 to 8 minutes to replace a set of yarn packages, depending on the operation proficiency of the operator and the structural design of the unwinding frame. Random loss is mainly the shutdown caused by yarn breakage, blade cleaning, sudden equipment minor fault. The yarn breakage rate is closely related to raw yarn quality, yarn type and equipment state. When processing high-quality polyester filament, the yarn breakage rate is low, while processing brittle fiber yarn, the yarn breakage shutdown times will increase significantly.
When making capacity statistics for yarn splitter machine, it is recommended to record the production data of a single machine continuously for 3 to 5 working days, and count four indicators: total running time, effective processing time, total output of qualified yarn and total weight of defective and waste yarn. The effective rate of the equipment can be calculated by dividing the effective processing time by the total attendance time of the shift. The effective rate of well-managed yarn splitter machine in large-batch stable production can reach more than 85%, while the effective rate may drop to 60% to 70% under the condition of frequent specification change and poor raw yarn stability. Production planners can use the effective rate of the equipment in the past period as the correction coefficient of capacity calculation, so that the scheduling plan is closer to the actual situation.
Capacity matching between multiple processes is also very important. The yarn splitter machine is in the pre-process link. Its output should match the processing capacity of the subsequent twisting machine or loom. If the splitting process capacity is too large, a large number of split yarn bobbins will be accumulated in the workshop, occupying storage space and increasing the handling work; if the splitting capacity is insufficient, the subsequent weaving machine will wait for yarn and stop production, resulting in greater loss. Some factories will set up a certain yarn buffer inventory between the yarn splitter machine and the post-process, but the inventory should not be too much, to prevent the yarn from being stored for a long time, absorbing moisture, dust and knotting.
Different operators will also bring differences to the output of the yarn splitter machine. Operators with skilled threading and bobbin changing skills can shorten the auxiliary operation time and reduce the auxiliary loss. Factories can carry out skill competition for operators, standardize the bobbin changing and threading action, optimize the operation path, and reduce the auxiliary time of a single operation. In addition, reasonable spare parts reserve can reduce the loss time caused by waiting for maintenance parts after the yarn splitter machine fails. If the vulnerable parts such as blades and tension rollers are out of stock, the equipment will stop for a long time, which will seriously affect the monthly capacity completion.
Many enterprises will expand the production scale by adding yarn splitter machine. When adding equipment, it is not only necessary to calculate the output increment brought by the new machine, but also evaluate the supporting capacity: whether the unwinding raw yarn supply can keep up, whether the number of operators is sufficient, whether the dust removal system, power circuit and workshop space can bear the load of new equipment. Blindly adding machines without matching supporting resources will lead to the new yarn splitter machine cannot run at full capacity, and the investment return cycle becomes longer.
Finally, the production capacity of yarn splitter machine is not a fixed value. With the aging of equipment, the wear of parts will increase the yarn breakage rate and reduce the effective rate. After overhaul and replacement of vulnerable parts, the effective rate will rebound. Therefore, the capacity benchmark data should be reviewed and updated every quarter, instead of using a fixed number for a long time to arrange production.
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