SPC-In Mill Traning Course

ITRU has developed a SPC-S ver 2.1Pc-program to be make useful for textile industry .This in Mill traning Course covers following items

  1. Frequency Distributions and Histograms
  2. Cumulative Frequency Diagrams
  3. Measurement Variation
  4. Confidence Intervals of Mean (Q95)
  5. Process Capability Studies
  6. Shewhart Variable Control Charts
  7. About Cp and Cpk
  8. Pre-control
  9. Attribute Charts -- Percent Defective and Number of Defects
  10. SPC-Charts (x-bar,q bar,s bar,rbar)
  11. Statistical Interpretation of Control Charts
  12. Methods of Problem Identification and Analysis
  13. How to Implement an SPC Program

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This project is developed through extensive mill work and mill surveys of weaving sheds which achieve more than 94% actual efficiency.It will be shown later that modern management of a weaving mill project is an essential engineering work for reducing manufacturing costs. The manufacturing costs in a weaving shed could be summarized as follows:

  1. a)Material cost
    -Warp per meter of grey cloth[SIZE DATA PC-PRG]
  2. b)Direct labor
    Number of looms per weaver
  3. c)Indirect labor
  4. d)Electricity
    Ligting procedures
    Kwhr/per loom
  5. e)Spare parts
    Mechanical breakdown frequency
  6. f)Total number of defects per 100 meter(COST OF FABRIC QUALITY)

In order to lower the production costs per meter of woven fabric the above mentioned cost factors should be minimized. Most of the weaving sheds check every meter of the grey cloth produced.Therefore,the aim is to have zero defects in the grey cloth.Nowadays,many mills are able to produce similar quality of the woven fabric.Therefore,the main issue is the cost of grey cloth per meter.

Competitiveness will be the main feature of the textile industry in 2000's and coming years.The main issue will be able to compete at international levels.It is clear from many international exhibitions that,the competition will be very brutal in the coming years.ITRU GROUP-International Textile Consulting & Management has foreseen these facts and has produced textile reports and PC-PROGRAMS for the textile industry and technology to meet the future requirements from today and [MODERN MANAGEMENT OF A WEAVING MILL] is such an example.

It is not very surprising that the textile mills having the same technology would in most of the cases lead to have verydifferent profit values.The actual performance of any millcould be determined by SALES VOLUME MINUS TOTAL COSTS DIVIDED BY THE TOTAL NUMBER OF EMPLOYEES.This ratio varies from mill to mill and country to country.The main influence of this profitability ratio is the management and organization of that management.The future of all mills will be dependent upon the existing management systems.Therefore,this project then put into action guarantees your mill's future in the competitive world bu ensuring following steps to be taken in your mill:

  • -Increasing your mill running efficiency
  • -Reducing manufacturing costs and spare parts consumption
  • -Improving productivity and quality level

Performance of ITRU GROUP LTD

  • Setting up a KNOWLEDGE BASED organization structure
  • Definitions of competences and job descriptions
  • Setting up a "Spare-parts control systeml
  • Check lists for supervisors
  • Defining work instructions to avoid competences and frictions

Operative hour per meter is related to number of loom allocated per weaver. As the number of loom per weaver increases OP-HR/Meter decreases. For this purpose ITRU GRPOUP LTD. has developed .Itru Time Studies ver 1.3 Pc Program

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    1.1 Introduction

    Manufacturing costs in a weaving shed is very important if a mill tries to be competitive in the market.ITRU GROUPLTD-International Textile consulting & Management has directed all his aims to reduce manufacturing costs through wellsophisticated textile technological PC-PROGRAMS and engineering works carried out in weaving mills.

    1.2 Factors affecting the manufacturing costs

    All manufacturing costs should be analysed per article woven per type weaving machine in the mill.Weaving mills could have different type of looms therefore cost calculations should be conducted according to type of weaving machine and article woven on that machine.From this calculation one could decide upon the most ecenomic weaving machine for that specific type of article.

    Warp yarn cost per meter of grey cloth: e1
    Weft yarn cost per meter of grey cloth: e2
    Machine hour per meter : c1
    Op-hour per/meter : c2
    Cost per machine hour(Electricity,spare parts etc): d1
    cost per/op-hr : d2
    total manufacturing cost=(e1+e2) +(c1*d1)+(c2*d2)

    In order to reduce manufacturing costs e1,e2,c1,c2,d1 should be reduced to a minimum. And contribution =sale price-total manufacturing costs.

    1.2.1 Machine hour per meter & Operative-hour per meter

    Machine-hour per meter depends upon the machine efficiency,speed and number of picks/cm.And it is clear thatmachine efficiency and speed determines mostly themanufacturing costs.Machine efficiency is determined by mainly frequency of warp and weft stoppages per 100,000 picks.To reduce the warp and weft stops we have developed following PC-PROGRAMS and technical mill data files:

    • optimum sizing costs and minimum warp-stops
    • optimum warp and weft stops
    • for optimum warp and weft stops and minimum fabric faults.

    Through these PC-PROGRAMS AND it becomes possible to improve production levels and reducing manufacturing costs.

    Operative hour per meter is related to number of loom allocated per weaver. As the number of loom per weaver increases OP-HR/Meter decreases. For this purpose ITRU GROUP LTD. has developed PC-PROGRAM. by means of excellent organization system that will be built by ITRU GROUP LTD-International Textile Consulting & Management assistance by your technical staff consistent and continous performance level will be achieved.


    This report has been prepared for many years of mill experience on projectile weaving looms .It helps mill management to solve the problems associated with warp preparation,sizing, weaving mechanisms and weft preparation .

    The report covers following chapters

    1. 1)Summary
    2. 2)Results of stoppages
    3. 3)Causes and remedies of stoppage in weaving
    4. 4)Causes and remedies of stoppages in sizing
    5. 5)Causes and remedies of stoppages in warping
    6. 6)Measures to improve efficiency in weaving Knowledge Based QM ver 1.0 Knowledge Based QM ver 2.0 Time Studies ver 1.0 Optimum Quality Minimum Manufacturing Costs

    ITRU GROUP LTD -International Textile Research Unit
    Serving to textile industry ,science and technology since 1992

    © 1992-2015 by Itru Group Ltd-International Textile Research Unit