Article 1 : Reasons for Lean Cops in Spinning

Mr.M.R. Surendran, Factory Manager, Nallam Maniam Textiles (P) Ltd., Vellakovil

“Cops which are produced by the spinners mending yarn with repeated ends down consistently
Ignoring the root cause of the breaks – “ are Lean Cops. Lean Cops may be classified into two
categories
1 .Lean cops due to lapses in process control
2. Lean cops due to lapses in maintenance process
When we consider lapses in process control the following relatively attributes to lean
cops .Too much count variation. Count abnormally on finer side. These are against the lapses
in process as briefed here below:
1. Singles in drawing silver due to creel stop motion failure and due to workers not adopting
end to End piecing.
2. Pneumatic suction excess in drawing and simplex. Clearer hoods are not set in position.
3. Split up silver both in draw frame and simplex creel stage and in drafting zone. Split up
roving in Simplex frame
4. Abnormal stretches in drawing and simplex creel stage and in drafting and simplex creel as
well as roving stretches.
5. Improper layering of silver in draw frame cans and projected rivets which causes sliver tear
out casing singles in case of mills where end less cans are not in use.
In the case of lapses in maintenance process the following are to be looked into:
1. Abnormal sliver and roving irregularities due to mechanical disturbances at drawing simplex
and spinning gear units and individual bearing points.
2. Jerky motion of bobbin holder and subsequent creel stretches.
3. Creel guide rods with peeled off coated portion.
4. Roving guide clogged with waste.
5. Jammed top rollers.
6. Channeled bottom and top aprons, which causes fibre plucking and breaks.
7. Spacer opening either too open or too close.
8. Very low top roller pressure.
9. Damaged flutes on bottom fluted rollers, Knife cut and pits on top rollers.
10. Lappet out of centre
11. Groove formation on lappet hook
12. Peeled off coated portion in ABC ring, Damaged separator if ABC rings are not provided.
13. Usage of worn out rings Travellers
14. Worn out rings and eccentric rings
15. Spindle Vibration and spindle out of centre.
16. Loose Tapes and Improper Jokey Pulley tensioning.
Like wise we can list out reasons for Lean cops. Accordingly we should take Remedial action
timely diagnosing reasons sensibly. If not lean cops arrested to zero, market complaint from
sources like warping – knitting –Sizing and other processing centers are given warm welcome.
---------------------------------------------------------------------------------------------------------------------------