DECLARATION

I, Amarech Yilma a fourth year Textile Engineering student, have undertaken my internship
experience in Edget yarn and sewing thread share company during the period of October 2015 to
February 2016 under the guidance of Belaynesh Zemene(Academic Advisor) and Ato
Tsegaye(company advisor). I declare that my work is original and compiled according to the
internship report writing guide line given by the Institute-Industry Linkage office of the Institute.

As the student’s academic advisor, I certify that the internship report written by the student is her
original work and compiled according to the guideline provided by the institute’s office as far as
my knowledge is concerned.

_Belaynesh Zemene_______ ___________ ____________

Name of the Academic Advisor Signature Date

_Amarech yilma____ ___________ ____________

Name of the student Signature Date

i
ACKNOWLEDGEMENT

First and foremost I want to thank GOD for helping me prepare this report and in general for the
knowledge and strength He offers me in my life time. Special thanks deserve to Bahir Dar
University, University Industry Linkage office, Ethiopian institute of textile and fashion
technology Department and Instructor my mentor, for giving me the chance to have an experience
on the practical work and getting better skills with theoretical knowledge. I am glad to say thanks
to my academic advisor Belaynesh Zemene for playing a big contribution on the whole successful
completion of my internship program and directing me to responsible people who I shall be meet,
as well as pointing towards important references and providing me with materials which supported
the completion of the four month internship program. I'm also thankful to EyerusalemYilma for
her valuable help.

ii
EXECUTIVE SUMMARY

My internship practice which I have been working in EYST S. C. from October 11, 2015 to
January 27, 2016 for the past four months. This report has different section and discusses main
departments and section in the hosting company including its history, its market, customer, overall
industry condition, our overall internship experience, tasks and the procedures we followed, the
practical and theoretical knowledge we gained including the challenges we faced while
performing those tasks.

The project contents four chapter, chapter one deals about the hosting company profile, historical
background, its vision, mission, raw material and accessory supplier, work flow, description of
each flow how to perform, customer, products, location, production equipment and machinery,
Organizational structure, and responsibility of functional areas its factory manager/owners,
finance and administration, marketing, production manager and purchasing department
responsibility.

Chapter two also discuss about project on effect of air conditioning in spinning section, its
introductions, objective, scope of the project, statement of problem, methodology, method of data
type, data analysis, result and discussion, detailed problems and main findings. While working on
my project thing are not going as expected or planned. There for the challenges that I faced and
solutions that I make to overcome thus difficulties are also include in this chapter of the project.

In third chapter of the report, it describes the overall benefits that I have gained from this
internship in terms of improving our practical skill, theoretical knowledge, communication skills,
team playing skills, leadership skills, work ethic, entrepreneurship skills and the final chapters
include conclusion and recommendation of the project.

iii
LIST OF FIGURES

iv
LIST OF TABLES

v
LIST OF SYMBOLS

vi
Contents
DECLARATION..................................................................................................................................i
ACKNOWLEDGEMENT.....................................................................................................................ii
EXECUTIVE SUMMARY...................................................................................................................iii
LIST OF FIGURES.............................................................................................................................iv
LIST OF TABLES................................................................................................................................v
LIST OF SYMBOLS...........................................................................................................................vi
CHAPTER 1......................................................................................................................................1
Back ground of Edget Yarn and sewing Thread manufacturing S.C...............................................1
1.1 History of the company...................................................................................................1
1.2 Company Description......................................................................................................1
1.3. Raw material and accessories..............................................................................................2
1.4. Material handling equipment in spinning department........................................................3
1.5. Quality test parameters.......................................................................................................5
1.6. Quality testing machines.....................................................................................................5
1.7. Overall work flow of the company.......................................................................................8
CHAPTER 2................................................................................................................................12
EFFECT OF AIR CONDITION PROBLEM IN SPINNING SECTION..................................................12
2.1 Background...................................................................................................................12
2.2 Statement Of Problem..................................................................................................13
2.3 Objective of this project................................................................................................14
2.4 Methodology................................................................................................................14
2.5 Scope of the project......................................................................................................15
CHAPTER 3....................................................................................................................................33
3....................................................................................................................................................33
3.1. Objective of internship......................................................................................................33
3.2. Benefits gained in terms of improving practical skill..........................................................33
3.3. Benefits gained in terms of up grading theoretical knowledge..........................................34
3.4. Benefits in terms of interpersonal communication skills...................................................34
3.5. Benefits gained in terms of improving team playing skills.................................................34

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 3.6. Benefits gained in terms of improving leadership.............................................................35
3.7. Benefits gained in terms of understanding about work ethics related issues.............35
3.8. Benefits gained in terms of entrepreneurship skills...........................................................35
CHAPTER 4....................................................................................................................................36
CONCLUTION AND RECOMMENDATION......................................................................................36
4.1. CONCLUTION.....................................................................................................................36
4.2. RECOMMENDATION..........................................................................................................37

viii
 CHAPTER 1

Back ground of Edget Yarn and sewing Thread manufacturing S.C.

1.1 History of the company

Edget Yarn and sewing Thread factory was established as a legal and independent entity in 1992
GC. Later on as a share company in July 2003 GC. Currently, it is acquired from privatization and
public Enterprise supervisory agency by Crown Textile Weaving S.C. and formed as Share
Company. Its production process is only spinning and the number of workers are 268. The
company came with its advanced textile technology to produce best quality and marketable
products with the aim of producing yarn. The company located in the area called Sarbet kebele 4
Addis Ababa, Ethiopia. The factory's production capacity per year is 1359 tone with different
count of yarn and 392 tone of yarn that are used for knitting. The factory produce 10−60 count of
reeling and winding yarn.

1.2 Company Description

 VISION
 To become an internationally reliable and leading company in textile sector.
 Mission
 Reducing loss and gradually become profitable thought satisfaction customer needs by
providing best quality yarn products at a reasonable price with efficient delivery service.
 To participate in global and local market by improving its quality of product as effective as
possible.
 Objective
 To manufacture yarn, from cotton natural fibers.
 To sell the products locally for different private company and plc
 Create employment opportunity
 Bring socio-economic change in the region in particular, for the country in general

Location of the company

1
Edget Yarn and Sewing Thread S.C. Located in small village named sarbet kebele 4, BP 456,
Addis Ababa, Ethiopia. For further detail please call 251 11 371 1988 and contact them directly.

Major product of the company

Now days the main product of the company is yarn with different count namely 10 and 21 count
of yarn sometimes 16 Ne count produce if the company had new orders from customers.

1.3. Raw material and accessories

 Raw material

The main raw material of the company is 100% cotton.

 Suppliers of the raw material

The company's raw material suppliers come from various areas of the country, the major
suppliers are from the areas listed here:

 Gondar
 Afar
 Awash
 Lucy private company
 North Omo
 Humera
 Gambaela

 Types of Accessories and their suppliers

The accessory used in this company has two types that are mechanical and electrical. The
mechanical accessory is including like bearing, shaft, belt, gear, travelers, cams, etc. and the
electrical accessories include cables, sensors, board, switch, etc. Generally this accessory is mostly
come from the local market.

2
 Spare parts Suppliers Location
Bearing YJ industrial machinery and tools A.A
Leather belt Ethio leather industry PLC (ELICO) A.A
Oil and grease Total A.A
Electric material Electric village trading PLC, Dama electrical trading A.A
PLC
Acrylic Genet Beru, Altaye Anegatu and children PLC A.A
Poly bag Zemenyehanuse general trading A.A
PPsheets Gemal Ahemed A.A
Belt Monerea Abdi, Aremise, Getuparalello A.A

1.4. Material handling equipment in spinning department

The main responsible of the department is to store all the raw material necessary for the
production of yarn. So, the company stores the material in well-organized system. To facilitate
materials movement, the company use different cards to material into and out of the store.

Fork-lift: - to transport cotton to the blow room and to transport end products to the store.

Rolling container: - to transport cops or winded yarn from ring frame machine to winding
machine and bobbin from roving machine to ring frame.

Can: - used to store and transport sliver from one machine to the other.
3
Trolley: - helps to store winded yarn temporarily and transport to reeling machine.

Pallet jack: - to transport finished packed material to the weight and to outside of the
Department that makes ready for fork-lift.

4
 1.5. Quality test parameters
1.5.1 The raw material quality test parameters

Before going through any production process, the raw material is evaluated by the help of a
number of distinct parameters that describe its quality. These parameters include:

 Fiber length ﴾staple length﴿

 Fiber strength
 Fiber color
 Grade (trash content)
 Moisture content
 Fiber stability

[Link] quality test parameters

Once the yarn is produced, its quality is also evaluated in order to insure a maximum quality
product.

 Yarn Twist using Yarn Twist Tester

 Yarn Count using Count Realer
 Yarn Strength using Strength Tester
 Yarn Elongation using Strength Tester

1.6. Quality testing machines

1. Shirley analyzer percentage trash tester

To determine the percentage of trash in a sample of cotton.

5
 2. Pressley fiber strength tester

To determine the strength of fiber.

3. Moisture content percentage tester

To determine the moisture content of cotton.

4. Strength and elongation tester

To determine the tensile strength and elongation of yarn.

6
 5. Yarn twist tester

Used to test the twist of the yarn.

6. Roving twist tester

It is used to test the roving twist.

7. Count reeler tester

It is used to determine the count of yarn.

8. Color test

7
Determine the cotton color by visual inspection.

The cotton color can be: -

 White
 Tinged
 Yellow stained
 Light gray
 Gray
1.6. How to brand the products

For 21 Ne For 10 Ne

E.L.F E.L.F

Date Date

Ne = 21GF Ne = 10WT

G.W = 81.09 G.W = 90.09

N.W = 81kg N.W = 90kg

ID = 594/535 ID = 594/535

1.7. Overall work flow of the company

The company has two production processes: Preparatory section and finishing section.

1.7.1. Preparation section

 Where the cotton is converted to sliver by using different mechanisms of conversion.

 The machines that assigned to perform these operations are: Blow Room, Card, First draw
frame, Second draw frame, and Roving machine.

The preparatory process

Bale opener Comb shield Duo cleaner Auto mixer

Opener

8
 Card feeder Draw frame 1 Draw frame 2 Roving frame

 Blow room

The section where the supplied bale is turn into a uniform lap of particular length after the bale is
check by Quality inspection method and fulfills the standard. It is the first step of spinning.

Objective of blow room

 Opening and cleaning

 Mixing or blending
 Micro-dust removal
 Uniform feed to the carding machine
 Recycling waste
 Carding

In the yarn manufacturing process, carding comes after opening and cleaning of fibres at blow
room. Carding process is considered so important that carding is often called “the heart of
spinning”.

Objective of Carding

 Individualization of fibres

 Elimination of Impurities and Dust

 Reduction in Neps

 Fibre Blending

 Draw frames

Draw frames are used after carding in yarn manufacturing process. In the case of combed yarn
manufacturing, draw frames are used before as well as after combing. The draw frame operation
divided in to two sections the First section (Draw frame 1) contains 5 draw frame machines, it
process the card sliver and deliver its output for next section of draw frame.

9
The second section (draw frame 2) contains the rest 6 draw frame machines, it process by
accepting the output of either draw frame 1 or comber machine sliver and finally deliver its
product to either open-end or roving machine.

Objective of the machine

 Improving material evenness

 Parallelizing fibres
 Blending
 Dust removal
 Roving Frames

The sliver which is produced from the Draw Frames that is thicker and it is not suitable to feed
into ring frames directly to produce yarn. For this reason the draw frames sliver is treated before
entering into the ring frames. The sliver is subjected to one or more attenuating process and the
attenuated sliver receives a small amount of twist and is then wound on bobbins suitable for
creeling at next process. Roving is a continuous- fiber strand drafted from a sliver and give
cohesion by either inserting a small amount of twist or compacting the fiber with an oscillating
apron.

Objective of Roving Frames

 Attenuation
 Twisting
 Winding
 To produce coarser yarn (Roving)
 To deliver coarser to ring frame

1.7.2. Yarn formation Section

Here is where the twisted sliver that made by the roving machine is converted by ring machine to
yarn and goes to winding machine to increase its strength. The machines that are assigned to
perform this operation are ring frame and winding.

 Ring Frames

10
Ring Frames is a universally applicable and uncomplicated machine in which any material can be
spun to any required fineness and it delivers a yarn with optimum characteristics regarding
structure and strength.

Objective of Ring Frames

 Drafting the roving until the required fineness is achieved

 Imparting strength by inserting twist
 Winding the twisted strand (yarn) in a form suitable for storage, transportation and further
processing
 Cone winding

The yarn supplied from the ring frames is wound from the spinning cops on to winding packages
convenient for reeling machine. Winding is a process in which small sizes of spinning cops are
wound together on to a suitable package in terms of length and shape.

Objective of cone winding

 To remove yarn faults such as thin and thick places

 To produce a well-shaped and firm packages free from loose coils on the ends
 Formation of suitable packages for Reeling machine
 Reeling machine

It produces a warp of seven ends in one. These warp ends are just used by the traditional local
weavers, and known with the name “DIR” by them. This machine uses the outputs of cone
winding machine as it is and the rewound package using a rewinding machine from the remained
yarn threads the outputs are immersed in to the deep wall water presented in the plastic bath for a
better binding-in and strength. And then after emersion time the conical package will be ready to
be taken to the reeling m/c, then a product will be formed and taken to the finished materials store
and then to local.

11
 CHAPTER 2

EFFECT OF AIR CONDITION PROBLEM IN SPINNING SECTION

2.1 Background

This project work will intend to assess the effect of air condition problem in spinning section. In
assessing the processing department I have taken EYST S.C. as sample for my survey.

Air condition is one of the most significant factors that have a great influence can affect
production and quality. Textile industries have entered into challenging competition of global
textile products that have high production. To enter in the global market and to have sustainable
economic development, good processing is essential. When we look into the situation of EYST
S.C. There is no good processing in spinning department by the problem of air conditioning
system.

Air conditioning is required for improving processes and materials apart from comfort for person
(works) life and electronic device efficiency of operation. A good Air conditioning system not
only cools a factory but help to control humidity. It is important in the factory to understand their
air conditioning system components, how they work and how to make sure operator install the
correctly sized system.

Air conditioning refers to the control of temperature, moisture content, cleanliness, air quality, and
air circulation, as required by occupants, the process, or product in the space and the movement of
indoor air. It cools the air when the weather is hot. It warms the air when the weather is cold. In
other words, air conditioning systems create a comfortable and healthy environment for the
people.

The aim of AC is uniformly distribute conditioning air to the spinning section, to remove the
broken ends, to increase quality of product and production I am doing my project on “effect of Air
condition problem in spinning section.” In EYST a lot of problems occur because of lack of air
conditioning. Cotton dust and noise are the two main environmental hazards which cause health
risk in spinning mill. Dust problem is more severe in spinning section.

12
 2.2 Statement Of Problem

Indoor air quality is a growing concern today. Concern with simultaneous control of all parameters
which are essential for the comfort of workers or for the proper performance of production and
quality in industrial process which has made proper air conditioning more important than ever.
Textile industries today are favorable to processing some objects and materials.

In EYST S.C. discomfort, unacceptable indoor air quality, low quality production, less production
capacity, yarn stickiness and yarn breakage are the potential problem because of extreme hot or
cold temperatures or lack of air condition system.

Specifically now a days the change in weather condition, the increase and decrease in the
temperature of EYST S.C, the increase in dust of cotton in spinning and the unpleasant dust for
eye and nose of the occupants are the main problems which need air conditioning design in the
factory. Dust consists of small, microscopic particles of various substances which are present as
suspended particles in air and sink slowly in to the materials, so that they can be transported to
distance and mixed with the product this ultimately affects the financial status of the company. It
causes delivering less production and less quality in which case the company ends up getting less
profits than others in the textile sector.

There are different causes arises for the problem of production loss because of the absences of air
condition system,

 Door of the room is always open

 The supplier duct has high amount of dust due to lack of inspection
 Unconditioned cotton
 Production loss is high

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 2.3 Objective of this project

 GENERAL OBJECTIVE
 To analyze the effect of air conditioning problem in EYST S.C.
 SPECFIC OBJECTIVES
 To specify the working room air condition,
 To increase productivity and quality of production,
 To minimize dust and fluff problem in cotton spinning and stoppage of the
machine,
 To regulate RH and temperature,
 To create good working environmental condition and cleaning of the room.

2.4 Methodology

2.4.1 Method of data collection

In order to gather the required data for this project data collection is done through two ways;

1. Primary data collection system

 Direct observation
 Formal Interview
 Informal interview with concerned persons such as company supervisor, operators in
the production and quality sections
 Systematic data collection, for by using ti

2. Secondary data collection system
 Written materials in the organization like reports, manuals as well as referring to books
and some related studies.
 Using the internet

14
 2.4.2 DATA PRESENTATION

The following data were collected from the section through by observation, interviewing
different Workers and experts’ in different working positions and by using stop watch in the
mills. These were looks like as follows:

Observation Number of Breakage Observation time Number of

Number Spindle intensity ﴾minutes﴿ idle spindle
1 440 53 30 5
2 440 66 30 6
3 440 71 30 1
4 440 43 30 8
5 440 65 30 1
6 440 51 30 7
7 440 75 30 3
8 440 72 30 1
9 440 69 30 2
Total 3960 565 34
Table1: breakage intensity of the ring frame within 30 minutes for nine different machines
observations

Therefore, the working spindles are 3926.

Outside air Blow room Carding room Draw frame Roving frame Ring frame

RH ﴾ Tw Td ﴾ RH Tw Td ﴾ RH ﴾ Tw Td RH Tw Td RH Tw Td RH Tw Td
%﴿ ﴾°c﴿ °c﴿ (%) ﴾°c﴿ °c﴿ %﴿ ﴾°c﴿ (%) (%) (%) (%) (%) (%) (%) (%) (%) (%)

96 14 15.5 68 18.5 23 74 23 26.5 45 18 26 41 18.5 27.5 40 18 27

66 11.5 16 66 15 22 56 18 24 56 18 24 45 18 26 51 19 26
69 9.5 14 46 13 20 78 24 27 51 18 26 47 17 25 42 16.5 27

70 13 15 68 14 22 63 16 21 49 15 23 41 16 26 53 18 26

Table 2: Effect of outside air on set point of hot and cold weather condition

2.5 Scope of the project

This project is limited on the effect of air conditioning problem in spinning section.

15
LITERATURE REVIEW

Introduction to air conditioning

One of the greatest engineering achievements of the 20th century was the development of air
conditioning. Air conditioning is the heating, cooling, dehumidification, humidification,
ventilation, and sterilization of air. Air conditioning regulates the air in a large building. Ac
innovations make the human population, significantly more comfortable and happy.

In 1906 Stuart Cramer first used the term “air-conditioning” as the explored ways to add moister
to the air in this southern textile mill. He combined moisture witch ventilation to actually
“Condition and change the air in the factories”, controlling the humidity so necessary in textile
plants.

Ventilation and air condition is the process of treating air so as to control simultaneously its
temperature, humidity, cleanliness and distribution to meet the requirement of the conditioned
space. Air conditioner manufactured air as it was first called was originally considered to simply
controlled humidity. Textile mills had a higher production rate, quality rate and to create save
working condition if the inside humidity could be managed.

Air conditioning controls the temperature, humidity, cleanliness and movement of indoor. Air to
more comfortable conditions it cools the air when the weather is hot, It warms when the air cold,
Comfort depends partly on humidity and air condition removes moisture from the air or adds as
need removing dirt and dust from air makes the air moves healthful. By controlling air
movement air condition brings fresh air in to a room and pushes out air.

An air conditioning system may use heating; cooling, humidifying, dehumidifying and filtering
units of combination of these depend up the outside weather.

The capacity of an air condition system is directly proportional to the heat load in the system.
The heat load consists of internal heat which is almost constant for textile mills and transmission
heat which varies from time to time and season.

In industry air conditioning improves the efficiency of workers. Employ stay move alert and
become less tired in air conditioned offices and factories. AC also protects workers against high
16
temperature and harmful dust. In stores and shops air conditioning keeps merchandise clean. It
also increases sales, because people like to shop in comfort.

Functions of air conditioning

Most air conditioning systems perform the following functions:

Provide the cooling and heating energy required.

Condition the supply air, that is, heat or cool, humidify or dehumidify, clean and purify, and any
objectionable noise produced by the air conditioning equipment.

Distribute the conditioned air, containing sufficient outdoor air, to the conditioned space.

Control and maintain the indoor environmental parameters–such as temperature, humidity,

cleanliness, air movement, sound level, and pressure differential between the conditioned space
and surrounding within predetermined limits.

Classifications of air conditioning

Based on major functions

Comfort air conditioning

Industrial or process air conditioning

Based on season of year

Summer air conditioning

Winter air conditioning

Year round air conditioning

Based on the system used for cooling or heating system

All water system

17
Air and Water system

All Air system

Based on equipment arrangement

Central air conditioning

Unitary air conditioning

Combination of central and unitary air conditioning

Comfort air conditioning

Provide occupants with a comfortable and healthy indoor environment. 'Comfort' is a very
subjective matter. Most people (90%) are comfortable when the air temperature is between 18-
22°C and the % saturation is between 40-65 %. this zone can be shown on the psychometrics
chart, and is known as the comfort zone. Outside air is quite likely to be at a different condition
from the required comfort zone condition. In order to bring its condition to within the comfort
zone we may need to do one or more of the following: - heat it; cool it; dehumidify it; humidify
it; or mix it.

Humidity

Temperature

18
Fig. Human Comfort Zone on psychometric chart

Importance of RH and temperature

The atmospheric conditions with respect to temperature and humidity play very important part in
the manufacturing process of textile yarns and fabric. The properties like dimensions, weight,
tensile strength, elastic recovery, electrical resistance, rigidity etc. of the fiber whether natural or
synthetic are influenced by moisture regain.

Moisture regain is the ratio of the moisture to the bone dry weight of the material expressed as a
percentage many properties of textile materials very considerably with moisture regain which in
turn is affected by the ambient relative humidity (RH) and temperature materials which is
effected by RH.A more humid environment makes people to feel better when they are sick and
have a congested nose. It also keeps skin hydrated. At other times, it is important to reduce air
moisture as much as possible. Moisture can damage fragile papers and fabrics. Regulating
humidity can relieve symptoms of sickness.

Not only does air conditioning bring in new air, but it also cleans that air. People living in
crowded cities experience air pollution frequently. A filtration system removes pollution, along
with other burdens from outdoors. A simple filter can do a lot.

Textile materials and air conditioning

Many physical properties of textile materials depend on moisture regain strength goes up with
relative humidity in the case of cotton but it goes down in the case of viscose. Present elongation
goes up with increase relative humidity for more textile fabrics. The tendency for the generation
static electricity due to friction decreases as relative humidity goes up, but this is particularly
serving in the case of synthetic fibers such as polymer. The properties of textile materials in
dimensional, mechanical and electrical indicated below.

Dimensional:

19
Fiber swelling in width more fabric made such fibers, when soaked in the water, the increase in
width of fibers leads to increase in diameter of constitutes yarns. Depending on the closeness of
spacing of the yarns this can leads to change in the dimensions of the fabrics.

Mechanical:

For the fiber such as wool and viscose, the tensile strength reduce as the moisture increasers
while cotton, flax, hemp and jute increases strength as their moisture content increases. Fabric
tearing strength is also affected by the fiber strength. So textile testes should be carried out in the
controlled atmosphere.

Electrical:

Moister content of fibers have effect on their electrical resistance. The resistance decreases with
increase moisture content .this means that static electrical charges are more dissipated when the
atmospheric relative humidity is high. At higher levels of relative humidity there is also a
tendency for the fiber to stick together to machine parts and this may case difficulties in the blow
room, high relative humidity may, therefore, affect opening and cleaning adversely. In the
spinning preparatory sections and ring frame, high relative humidity may lead to roller lapping
due to the tendency of fibers to stick to roller The moisture content of textile materials when they
are in equilibrium with their surroundings is determined by the amount of moisture in the air.
The atmospheric moisture level is normally expressed in terms of relative humidity .water
molecules evaporate from the bulk at a rate determined by the exposed surface area and the
temperature. Eventually the space above the surface reaches a stage when as many molecule s
are condensing on to the surface as evaporating from it.

Components of Air Conditioning System

The figure below shows the main components or equipment’s of an air conditioning system
which can be used for both heating and cooling systems.

20
 fig. Simple
Layout of Air Conditioning Components

Main lists of the equipment are: Boiler, Grill, Duct, Pump, Diffuser, Air filter, Air handler,
Supply fan, Water chiller, Cooling tower, Control system, Terminal device, Outdoor air intake,
Heating and cooling coils, Centrifugal duct collector, Exhaust and relief fans and air outlet, Self-
contained heating and cooling units, Mixed air plenum and outdoor air control, Humidification
and or dehumidification equipment’s are main components of air conditioning systems.

Generally the components of an air-conditioning system fall into four broad categories:

Source components loop

Distribution components loop

Delivery components loop and

Control components loop

Source components provide primary heating and cooling effect and include chillers, boilers,
cooling towers, and similar equipment.

21
Distribution components transport heating or cooling effect from the source(s) to the spaces that
require conditioning and include ductwork, fans, piping, and pumps.

Delivery components introduce heating or cooling effect into conditioned spaces and include
diffusers, baseboard radiators, fan-coil units, and a range of other “terminal” devices.

Control components regulate the operation of equipment and systems for comfort, process,
safety, and energy efficiency.

In central systems these components may be spread throughout a building. In local systems these
components are all packaged into a relatively small container.

DATA ANALYSIS

Table 1

We see that there are 565breakage of intensity on 9 machines within 30 minutes.

Let’s calculate the breakage intensity per hour

565 = 30 min

? = 1 hr. ﴾60 min﴿

= 565 * 60min = 1130 per hr.

30min

To calculate the breakage intensity per two shift

1hr. breakage = 1130 breakage intensity

16hr. breakage = ?

Breakage intensity per two shift = 16 hr. breakage*1130 = 18,080 per two shift

[Link]

22
And when we see the idle time that expend for searching of the end on the ring frame, the
operators will lose average 30 second per each breakage amending.

When we see this time lost per day on the 9 machines (440 spindles for each machine);

Idle time per two shift = breakage intensity per hr. * idle time for knot the end

= 1130 * 30 sec

=33,900 sec/ two shift

= 9.4hr. / Two shift

Theoretical production time/ two shift = number of spindle * working hour

= 3926* 16

= 17.4hr. / Two shift

But currently it work for = 17.4hr. – 9.4hr.

= 8hr. /shift

Therefore, percentage of production time loss = idle time per two shift * 100%

Theoretical production time/two shift

= 9.4hr per two shift * 100%

17.4hr. /shift

= 54%

Expected production per machine per shift =99.6kg

Expected Production per spindle= 20kg

For one machine Working spindle = total spindle−idle spindle

23
= 435spindles

Production / machine = 20kg*435

= 8700kg

Nine machine Production rate per shift = 9*8700

= 78,300kg

Production loss

8hr = 78,300 production rate

4.7hr = ?

=﴾4.7hr.*78,300﴿/8hr.

=46,001kg

Table 2

To calculate the moisture content and moisture regain of each spinning section

Moisture regain﴾MR﴿ = (W * 100)/D

MR﴾outside air﴿= ﴾14 *100﴿/15.5

= 90.3

MR﴾blow room﴿= ﴾18.5 * 100/23﴿

= 80.4

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MR﴾carding﴿= ﴾23 *100﴿/ 26.5

= 86.8

MR﴾draw frame﴿= ﴾18 * 100﴿/ 26

= 69.2

MR﴾roving frame﴿= ﴾18.5 * 100﴿/ 27.5

= 67.3

MR﴾ring frame﴿=﴾ 18 * 100﴿/ 27

= 66.7

Moisture content﴾MC ﴿= W *100

W+D

MC﴾outside air﴿= 14 * 100 = 47.6

14+15.5

MC﴾blow room﴿= 18.5 * 100 = 44.6

18.5 + 23

MC﴾carding﴿= 23 * 100 = 46.5

25
23 + 26.5

MC﴾carding﴿= 23 * 100 = 46.5

23 + 26.5

MC﴾roving frame﴿= 18.5 * 100 = 40.2

18.5 + 27.5

MC﴾ring frame﴿= 18 * 100 = 66.7

18 + 27

COST ANALYSIS

The company sales 1 cone by 81 birr, 1 cone wind 40 kg ring cop.

1cone = 2.3kg ﴾cone weight 1.4kg﴿

2.3kg = 81birr

46,001kg = ?

= 46,001*81kg =

2.3kg

=1,620,035.2 birr

RESULT AND DISSCUSION

26
From the above table data analysis we see that;

There are 18,080 breakages are appear per two shifts, due to the bale store relative humidity and
temperature is not comfort for cotton. Also, the dust and fluff particles that sticks with the
machine and sliver during processing are expose for the breakage of yarn.

To amend these breakages the operators expend 9.4 hr. per two shift of to search the appropriate
knotting point

For searching of the appropriate knotting point, total production will decrease by 54% due to
high amount of moister content of raw material may case to stick with the machine. During this
the machine will stop and then produce high production is impossible. And the company loss in
birr 1,620,035.2.

The cotton spends several days in the spinning mill on its way through the spinning process; the
moisture content of the fibers depends on the moisture content of the ambient air. The moisture
content is created by a combination of air temperature (°C or °F) and relative humidity (RH %).

Yarns sold with lower moisture content than the standard value will result in monetary loss.
Therefore the aim of yarn conditioning is to provide an economical device for supplying the
necessary moisture in a short time, in order to achieve a lasting improvement in quality.

If RH is too low, when cotton is being processed, fiber damage, fiber flies and deposits in the
spinning box. If RH is too high, this result in lapping on cylinders and opening rollers with all
fibers then results in an increase in the number of neps, thick places also, decrease the quality of
yarn and production.

As the above data observation and calculation, we see the moisture regain, moisture content,
temperature and relative humidity value, now let’s compare with the standard value.

27
 Standard value Calculated value

RH (%) Td (%) Tw (%) MR (%)MC (%)RH2 (%)Td2 (%)Tw2 (%)MR2 (%)MC2 (%)

Blow room
45 104 86 6.51 6 62 22 15 80.4 44.6

Carding40 105 87 5.97 5.5 68 25 20 86.8 46.5

Draw frame
56 100 86 5.97 5.5 50 25 17 69.2 46.5

Roving 56 100 86 6.51 6 44 26 17 67.3 40.2

frame

Ring frame
58 99 86 6.78 6.25 47 27 22 66.7 66.7

Table: the comparison between the standard and calculated value.

120

100

RH
80 Td
Tw
MR
60 MC
RH2
Td2
40 Tw2
MR2
MC2
20

0
blow room carding draw frame roving frame ring frame

28
Chart: the comparison between the standard and calculated value.

REMEDIAL SOLUTION TO SOLVE THE PROBLEM

I used Different action to increase the production, quality and comfort by solving the problem
happened.

I try to solve the problem by cleaning carding machine using compressor air that used for blow
room. I aware them machine be install correctly in the future because considerable amount of
heat is liberated in the spinning department from the processing machine.

The door of EYST is always open then the outside air enter in to the working room easily and
this air can disturbed the room relative humidity so, I told that, the workers to close the Door of
the room during working to control relative humidity and temperature of each section because air
can flow one room in to the other room easily,

I tried to do the company to have planned maintenance time In order to get high production; the
company has to be planned maintenance of machines. Due to lack of spare parts, machines are
not maintained properly and immediately.

I try to encourage the organization to arrange a skill up gradation program for the operator so
that they can gather the knowledge on the air conditioning system and machine they operate. The
operator can attend their machine in case of minor breakdown without waiting for the
maintenance personnel. This saves considerable amount of time.

The measurement that use to measure the temperature and relative humidity in the company is so
old and it does not work so I told them that the use of the machine and they bought it and the
company use it now.

In general, the amount of price to fulfill the above methods not more than loss of product due to
sliver breakage, machine idle time, maintenance problem and so on.

The important of air conditioning in each spinning section

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Blow room

Automatic continuous and intermittent waste removal

Separation of different waste qualities

Providing of the required under pressure at the machine

Maintaining of required room conditions

Carding

Separation of different waste qualities

Providing of the required under pressure at the machines

Integrated direct feeding of waste to recycling lines

Maintaining of required room conditions

Drawing and roving frame

Automatic intermittent or continuous waste removal

Separation of different waste qualities

Providing of the required under pressure at the machines

Maintaining of required room conditions

Ring Spinning

Pneumatic suction system

Optimized supply and return air distribution for a high efficiency spinning process

Energy saving design

Maintaining of required room conditions

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Provision for fresh air filtering against dust.

GOOD PERFORMANCE DURING WORK TASKS

Since I got to EYST S.C, I tried to make good communication to the Ethiopian engineer’s and
the employees as a whole. Due to this smooth communication, I performed to upgrade my
practical knowledge in bringing this project out puts as its present form.

SOME CHALENGES WHILE DOING MY PROJECT

During performing my task in the company there were good and bad things that I have seen from
most of company workers which encouraged me to act strategically to find out solutions.
However there were some challenges faced during my internship period. These include:

There was difficult to get internet access to search some information,

The space (office) problem to deal and discuss on some information’s with our friends,

There is difficult to get data about any machine due to lack of aware workers on each type of
machines,

There were some staffs that were blocking the existing profiles of the factory due to less
understanding of the internship programs,

Most machines have no manuals,

Temperature of the room

The workers not professional they work by experience that is difficult to collect data.

MEASURMENT TO FACE THE CHALLENGES

Even though there were very few factory workers who hide the company profile, I approached
smoothly to the other volunteer workers to search the required information,

31
The temperature adapted by time exposition,

The data collected by my own method by asking professional, observation and from recorded
data,

Observing in detail the machines that do not have manual,

Working with technicians and machine operators and getting idea from them.

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 CHAPTER 3

3.
3.1. Objective of internship

The objective of internship program is to develop practical skills of students additionally to

academically theory knowledge. With certain limitations these objective was success full. As its
object internship program has many use full out comes. From developing outstanding view of
working environment to understanding theoretical and practical skills the program is useful.

EYST S.C. has prepared me for my future career in that improving my practical skills, up grading
theoretical knowledge, improving interpersonal communication, improving team work,
understanding work ethics relative to issue, improving leadership and entrepreneur ship was
probably the biggest thing up to me.

 This project has important to me:

 To develop better work habits and improving team work
 To collect professional references
 To improve my communication skill
 Understanding work ethics relative to issue

3.2. Benefits gained in terms of improving practical skill

By this an internship period different activities taking place in the company and I have practice on
these activities. The main practical skills gained are;

 Practice on workshop activities such as machine operation.

 Problem solving approaches and procedures in solving practical problems like spinning
processing.
 Practice how to install the layout of different machines.
 Practice on Control mechanisms used.

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3.3. Benefits gained in terms of up grading theoretical knowledge

There are different courses that I have learnt before joining an intern ship and these courses are
help for practical performing, among these:

 Develop knowing practically causes of waste and ways of avoiding production of waste
 Develop the theoretical knowledge on the type of fiber, yarn and their effect on the fabric
practically
 Develop the theoretical knowledge specially on the long (worsted) spinning
 Prove that maintenance department plays a great role in achieving expected production
 Know handling the raw material is the basic criteria for the products produced

3.4. Benefits in terms of interpersonal communication skills

During this internship experience I did too many formal communications within the company
manager, production managers and quality heads to develop my communication skill very well in
addition to company operators. I have developed my personal communication skill at the end of
my internship program. I developed both oral and
communication skill. I got an experience on how to approach to people who works in the
company.

3.5. Benefits gained in terms of improving team playing skills

The role of team playing is the basic one for production process of the company in order to
produce the expected product. Having good team playing work in the company can lead to
increase production and productivity of the company as well as improve good quality of
production.

 I improved my team playing by;

 Avoiding weight of work from one person,
 Increasing production of the company using a small number of employers,
 Simplifying the works and speed up production process,
 Decreasing idle time of production,
 Work in order to fulfill the customers need within a specified time and
 Helping workers when they become tired
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3.6. Benefits gained in terms of improving leadership

When I was joined an internship program for three & half months, I have learned a lot during my
stay in spinning section, the production manager give as a good advice on the leader ship skill.I
learnt;

 Solving the problems faced,

 Handling the employees and
 Leading the works.

3.7. Benefits gained in terms of understanding about work ethics

related issues

An internship made me to have a strong willing to work, punctuality and hard working. With a
strong willing to work ethic I am always committed to the work and will stay until the task is
complete. The internship made me to avoid personal issues on work time and to keep my positive
attitude and I remember that I have smaller tasks to handle prior to my large, more important ones.

Internship enables me to act as advisers, professionals, provide recommendations for how to

resolve conflicts, increase worker productivity, and improve employee morale, among other
things. I am also learned on Industrial psychology which look at behavior that occurs within the
workplace, people who work in this field might study worker personalities and performances, or
the interactions between the individuals within a business.

3.8. Benefits gained in terms of entrepreneurship skills

 I have learned in my internship experience;

 Problem solving to decrease ideal time and
 Job creativity

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 CHAPTER 4

CONCLUTION AND RECOMMENDATION

4.1. CONCLUTION

As per the analysis and observation made on EYST S.C, I conclude that, this project analyzed for
the purpose of increase production, quality of the yarn and comfort of the worker .Since, air
conditioning system is one of the key parameters for gaining of highest production and quality of
yarn but in EYST Company there is no any air conditioning system. Percentage of production time
loss 54% due to unlimited idle spindles and 18,080 breakage intensity per two shifts. The
production loss is 46,001kg dust of cotton in spinning and the unpleasant dust for eye and nose of
the occupants are the main problems which need air conditioning.

EYST S.C. air conditioning system affect production because the cotton has high moisture then
the cotton stick to the machine at that time there is breakage of sliver or yarn so, the machine
cannot produce the required amount of production and quality there may be stoppage of machine
or the machine efficiency will decrease. The calculated relative humidity is above and below the
standard value but60% up to 65% is the recommended done due to these cases the cotton moisture
regain is vary.

The company has major problems occurring on air conditioning system. From those are:

 The company has not skill full man power on AC system

 There are carelessness of the operators
 The organization also did not taken permanent clarification for the occurred problems
 There are high breakage rate of slivers per hours on roving and ring machine
 Manually adjustment of relative humidity and temperature
 The company raw material or cotton is not conditioned in the store. 
 Each room of spinning department is not separately build.

In addition, the quality tester did not have that much knowledge. But they are performed the task
through experience and have not laboratory manual to guide them.

36
In general, when the company can be removed these types of challenges and start using air
conditioning properly it will be one of the profitable organization in the town as well as the
country.

4.2. RECOMMENDATION

I can recommend that this system should install in the company since it’s important in cost
effective, energy saved, increase production quality and the comfort of the occupants. Based on
the conclusion I recommended the following idea.

 Try to adjust the AC system of the department.

 Prepare the seminars for shift leaders and all operators in order to be profitable.
 Motivate the operators psychologically and ethically.
 Prepare laboratory manual for each machines of the department.
 The door of working room must be closed during working.

37