Smaller warp shed will reduce the warp threads tension to some extent. However, care should be taken to maintain uniform tension to ensure that the warp shed is of same depth from one end to another. Otherwise a few slack warp threads at the top shed will result in stitching and end cut by the projectile.

A reed with higher ratio of air to wire will give a greater flexibility. Similarly, if the beat-up line is nearer to the centre of the reed oversized knots will pass more readily because of greater flexibility of the reed wires. In the conventional loom beat-up line is much nearer to the bottom baulk of the reed. This will result in building up higher tension of warp thread if a bigger knot of that particular thread could not pass through the reed dent, and finally the end will break.

4. Principles of Sulzer Shuttleless Weaving

The basic mechanical principles of the Sulzer shuttles weaving machine are to be considered under the following four heads:

• Picking, or weft insertion system,
• Beating-up,
• Selvedge formation, and
• Weaving with one, two, three or four colours.

In the Sulzer weaving machine, the weft yarn is introduced into the cloth by means of gripper. A tuck-in selvedge is for med by drawing the cut weft end back into the open shed by means of tucking needles. The pick is then beaten up. The sley is not moved through cranks, but is then positively rocked about its centre through a saddle carrying two follower bowls, each bearing against the surface of matched cams.

The Sulzer Shuttleless weaving machine differs from the automatic shuttle loom in two respects, namely, (a) the method of weft insertion, and (b) the method of moving the reed and projectile track. Other motions including take-up and led-off are almost similar to known mechanisms.

5. Materials and Methods

5.1 General Details

No. Of looms : 30

Weft insertion type : Projectile

Loom type : Gripper projectile

Loom make : Sulzer

Loom model : P7100

Reed width : 135 inches

Loom speed : 280 290 rpm

The object of this project is to increase the efficiency and through that increase the productivity and profitability. To do so the efficiency is analysed by various parameters such as weaver efficiency, RPM, RH%, allocation of machine, etc. After the studies the results are produced through Pareto chart for easy analysis and understanding. After that the cause and effect diagram is drawn to find the overall causes and effects for the lower efficiency.

By considering various factors the design has been produced. The design is shown below and the factors considered will help in getting very high degree of excellence in results.

6. Result and Discussion

6.1. Analysis of Efficiency by Weavers

Here we have analysed the efficiency of different weavers. By analysing we can identify the inefficient weavers as well as the idle weaver. It will help to take corrective measures on the inefficient and the guilty.