HESSIAN FABRIC HAVING SPECIFICATION of 9 X 8 - 40 - 7Oz

HESSIAN FABRIC HAVING SPECIFICATION of 9 X 8 - 40 - 7Oz

PRODUCTIVITY NORMS

FOR

HESSIAN FABRIC HAVING SPECIFICATION OF 9 X 8 - 40” - 7oz

(IS2818:1971:1988; PART III)

Name of the Mill:

Date of Submission:

Period of Study:

Contact person:

Mobile No. and Email ID:

Production Capacity of Mill (Per Day):
Hessianb. Sackingc. Others

Average Production/day (Average of last quarter)
Yarn (quality wise) b. Fabric (quality wise)

CHAPTER 1

MACHINE AND PROCESS PARAMETERS

Table – 1: Softener (Warp and Weft)

Quality of Jute / Machine make / Date of Installation / No. of M/cs / No. of pairs of rollers / Delivery Speed (fpm) / Emulsion Application % / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11

Oil% in Emulsion:Non-Usable Waste % (Dry)(@16% MR):Non-Usable Waste % (Wet)(@16% MR):

Table – 2: Spreader (Warp and Weft)

Quality of Jute / Machine make / Date of Installation / No. of M/cs / Type of Feed (with/without Leader Roll) / Type of Machine (Pneumatic or oil pump) / Delivery Speed (fpm) / Draft / Emulsion Application % / Actual MR% / Convt. Sliver Wt. (lb/100 yd) @16 MR% / Eff.% / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15

Oil% in Emulsion:Non-Usable Waste % (Dry)(@16% MR):

Table – 3: Carding (Warp) –Breaker Card

Quality of Jute / No. of M/cs / Make and Date of Installation / Pair of rollers / Doubling
/Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @16% MR / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 16 % MR:Oil % of Droppings :

Table – 4: Carding (Warp) –Inter Card, If any

Proportion of Different Qualities of Jute / Make and Date of Installation / No. of M/cs / Pair of rollers / Doubling/
Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @16% MR / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 16 % MR:Oil % of Droppings :

Table – 5: Carding (Warp) –Finisher Card

Proportion of Different Qualities of Jute / Make and Date of Installation / No. of M/cs / Pair of rollers / Doubling/
Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @16% MR / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 16 % MR:Oil % of Droppings :

Table – 6: Carding (Weft) –Breaker Card

Quality of Jute / Make and Date of Installation / No. of M/cs / Pair of rollers / Doubling/
Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @16% MR / Efficiency% / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 16 % MR:Oil % of Droppings :

Table – 7: Carding (Weft) –Inter Card (If any)

Proportion of Different Qualities of Jute / Make and Date of Installation / No. of M/cs / Pair of rollers / Doubling
/Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @16% MR / Eff. % / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 16 % MR:Oil % of Droppings :

Table – 8: Carding (Weft) –Finisher Card

Proportion of Different Qualities of Jute / Make and Date of Installation / No. of M/cs / Pair of roller / Doubling/
Draft / Delivery Speed (fpm) / Actual MR% / Sliver Wt. (lb/100 yds) @16% MR / Eff. % / Production/m/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

Non Usable Wastage @ 16 % MR:Oil % of Droppings :

Table – 9: 1st Drawing (Warp)

Type of Machine / Make and Date of Installation / No. of Frames / No. of delivery/m/c / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sliver Wt. (lb/100 yd)@ 16%MR / Eff. % / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
SG / 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14
RG
PB

Droppings % @ 16 % MR:

Table – 10: 2nd Drawing (Warp)

Type of Machine / Make and Date of Installation / No. of Frames / No. of delivery/m/c: / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sl. Wt. (lb/100 yd)@ 16%MR / Eff. % / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15
SG
RG

Droppings % @ 16 % MR:

Table – 11: Finisher Drawing (Warp)

Type of Machine / No. of Frames / Make and DOI* / No. of delivery/m/c: / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sliver Wt. (lb/100 yd)@ 16%MR / Eff% / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15
SG
RG

Droppings % @ 16 % MR:*DOI: Date of Installation

Table – 12: 1st Drawing (Weft)

Type of Machine / Make and Date of Installation / No. of Frames / No. of delivery/m/c / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sliver Wt. (lb/100 yd)@ 16%MR / Eff. % / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
SG / 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14
RG
PB

Droppings % @ 16 % MR:

Table – 13: 2nd Drawing (Weft)

Type of Machine / Make and Date of Installation / No. of Frames / No. of delivery/m/c: / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sl. Wt. (lb/100 yd)@ 16%MR / Eff. % / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15
SG
RG

Droppings % @ 16 % MR:

Table – 14: Finisher Drawing (Weft)

Type of Machine / No. of Frames / Make and DOI* / No. of delivery/m/c: / Faller Drops/min / Doubling / DC/DP / Draft / Delivery Speed (fpm) / MR% / Sliver Wt. (lb/100 yd)@ 16%MR / Eff% / Production/M/c/8 hrs (MT) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15
SG
RG

Droppings % @ 16 % MR:*DOI: Date of Installation

Table – 15: Spinning (Warp)

Make and Date of Installation / Type of M/C (AD/SD) & Pitch / No. of M/c / Nominal Count@16%MR / Flyer/Spindle (rpm) / Flyer Type (Baxter) or
Ring / No. of Spindles/frame / DC/DP / TC/TP / Count (lb/spy)@16%MR / Actual TPI / MR% / Eff.% / Production/M/c/8 hrs (Kg) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15 / 16

Droppings % @ 16 % MR:*DOI: Date of Installation

Table – 16: Spinning (Weft)

Make and Date of Installation / Type of M/C (AD/SD) & Pitch / No. of M/c / Nominal Count@16%MR / Flyer/Spindle (rpm) / Flyer Type (Baxter) or
Ring / No. of Spindles/frame / DC/DP / TC/TP / Count (lb/spy)@16%MR / Actual TPI / MR% / Eff.% / Production/M/c/8 hrs (Kg) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14 / 15 / 16

Droppings % @ 16 % MR:*DOI: Date of Installation

Table – 17: Winding (Warp and Weft for Shuttleless looms)

Type of Machine / Make and DOI* / No. of Machines / Single side/
double side / Nominal Count (lb/spy) @ 16 % MR / Machine Speed (yd/m) / No. of Delivery / No. of Spindles/Winder / Eff.% / Production/winder/8 hrs (Kg) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12

WASTAGE:*DOI: Date of Installation

Thread Waste%

Droppings % @ 16 % MR

Table – 18: Cop Winding (Weft)

Type of Machine / No. of M/cs / Make and Date of Installation / Nominal Count (lb/spy) @ 16 % MR / Winding Speed (yd/min) / Total No. of Delivery / No. of Spindles/Winder / Eff.% / Production/winder/8 hrs (Kg) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11

Thread Waste%Droppings % @ 16 % MR

Table – 19: Beaming

Make and DOI* / No. of M/cs / Type (Group Drive/ Individual) / Machine Speed (ypm) / Total No. of threads in beam / Additional threads for selvedge / Laid Length (yd) / No. of Cuts/ beam / Wet Pick-up & Size Add on % (if any) / Avg. Beam MR% / Efficiency% / Production/M/c/8 hrs (yd) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14

*DOI: Date of Installation

THREAD WASTE%:

Size Ingredients and Composition

Please mention the Average Quality Ratio (QR) value before and after Sizing:

Table – 20: Weaving

Make / No. of Looms / Type of Loom / Reed Space (inch) / Reed Porter / Loom speed (ppm) / Loom Constant and Shot/change Pinion / Finish Length
yd / Shots/inch / Eff. % / Production/loom/8 hrs (Kg) / Motor HP / Motor RPM
(yd) / (Kg)
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12 / 13 / 14

Installed Looms:

Working Looms:

Utilization %:

Thread Waste %:

Loom Caddies %:

Table – 21: Damping

Make and Date of Installation / No. of M/cs / No. of Cloth Feed / Machine Speed (yd/min) / Production/m/c/8 hrs (yd) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7

Table – 22: Calendering

Make and Date of Installation / No. of M/cs / No. of Cloth Feed / Machine Speed (yd/min) / Production/m/c/8 hrs (yd) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7

Table – 23: Lapping Machine

Type of Machine / Make and DOI* / No. of Machines / No. of Feed / Machine Speed (strokes/min) / Lap Length (inch) / Production/m/c/8 hrs
(No. of Bags) / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9

Table – 24: Bale Press

Make / Type of Press (Oil/Hydraulic) / No. of Machines / Date of Installation / No. of Bags/bale / No. of Bales/8 hrs / Motor HP / Motor RPM
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8

Bale Details:

Bale Dimension:
Average Bale Weight (Net):
Type of Hoop (Iron/Plastic):
Weight of Hoop, Pin and Buckle:
No. of Hoops used in a bale:

CHAPETR 2

PROFORMA FOR BATCH MIX AND BATCH COST

1

Table – 25: Proforma for Batch Mix

Yarn Quality / Fibre Grade / Batch Mix %
Warp
Count (lb/spy): / Less Rejections:

Thread waste%
Caddies %
Any other%

Yield
Weft
Count (lb/spy): / Less Rejections:

Thread waste%
Caddies %
Any other%

Yield

Table – 26: Loading of Raw Jute

Fibre Grade / %
Fibre Quality:
Less (-)
Ropes & Habijabi
Downgrade
Cutting
Yield
Fibre Quality:
Less (-)
Ropes & Habijabi
Downgrade
Cutting
Yield

CHAPTER 3

PROFORMA FOR SLIVER WEIGHT CALCULATION AT EACH STAGE OF CARDING AND DRAWING

Table – 27: Sliver Weight and Process Parameters at each stage of Carding, Drawing

Sl. No. / Particulars / Warp
/Weft / Season 1 / Season 2 / Season 3 / Season 4 / Avg
1 / Average Weight of Morah kg / Warp
2 / Morah Feeding rate / Weft
3 / Spreader Sliver Weight (lb/100yd) & MR% / Warp
Weft
4 / Draft at Breaker Card & No. of Spreader Roll (Warp) / Warp
Weft
5 / Breaker Card Sliver Weight & MR% / Warp
Weft
6 / Dropping at Breaker Card / Warp
Weft
7 / Draft at Inter Card and No. of B/C feed roll / Warp
Weft
8 / Inter Card Sliver Weight & MR% / Warp
Weft
9 / Dropping at Inter Card / Warp
Weft
10 / Draft at Finisher Card and No. of I/C feed roll / Warp
Weft
11 / Finisher Card Sliver Weight & MR% / Warp
Weft
12 / Dropping at Finisher Card / Warp
Weft
Sl. No. / Particulars / Warp
/Weft / Season 1 / Season 2 / Season 3 / Season 4 / Avg
13 / 1st Drawing Weight (lb/100yd) & MR% / Warp
Weft
14 / Draft at 1st drawing and Doubling / Warp
Weft
15 / Dropping at 1st Drawing / Warp
Weft
16 / 2nd Drawing Weight (lb/100yd) & MR% / Warp
Weft
17 / Draft at 2nd drawing and Doubling / Warp
Weft
18 / Dropping at 2nd Drawing / Warp
Weft
19 / 3rd Drawing Weight (lb/spy) & MR% / Warp
Weft
20 / Draft at 3rd drawing and Doubling / Warp
Weft
21 / Dropping at 3rd Drawing / Warp
Weft

CHAPTER 4

PROFORMA FOR HANDS EMPLOYMENT

Table 28: Hands Employment

A) / Jute Department
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Jute Import Sardar
2 / Sangras/Tulandars/Sajandars
3 / Jute Issue Mazdoor
4 / Sweeper
Total:
Hands/Ton
B) / Batching
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Emulsion Plant Attendant
2 / Selection Sardar
3 / Selectors
4 / Jute Carrier (Selection to Softener/Spreader)
5 / Softener Sardar
6 / Softener/Spreader Feeder (Long Jute)
7 / Softener/Spreader Receiver (Long Jute)
8 / Jute Carrier (Softener to Pile)/Roll Carrier (Spreader to Pile)
9 / Pile Man (Long jute-if any)
10 / Jute Carrier (Pile to Knife)/ Roll Carrier (Pile to Breaker Card)
11 / Reliever (Softener/Spreader)
12 / Selection Mazdoor
13 / Sweeper
C) / Carding & Drawing
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Breaker Card Sardar
2 / Finisher Card Sardar
3 / Drawing Sardar
4 / Breaker Feeder (Jute)
5 / Root Cutter
6 / Breaker Card Receiver cum Finisher Card Feeder
7 / Breaker Card Receiver cum Inter Card Feeder
8 / Inter Card Receiver cum Finisher Card Feeder
9 / Finisher Card Receiver cum First Drawing Feeder
10 / First Drawing Receiver cum Second Drawing Feeder
11 / Second Drawing Receiver cum Finisher Drawing Feeder
12 / Finisher Drawing Receiver
13 / Carding Reliever
14 / Drawing Reliever
15 / Department Mazdoor
16 / Belt Man
17 / Sweeper & Dust Collector (Carding to Spinning)
18 / Picker including Jam Cleaner-Cards
19 / Picker-Drawing
20 / Waste Carrier
21 / Roll Carrier (Finisher Card)
22 / SQC Mazdoor
Total:
Hands/Ton
D) / Spinning
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Line Sardar
2 / Spinner
3 / Spinning Piecer
4 / Reliever for Spinner & Piecer
5 / Sliver Can Carrier cum Feeder
6 / Bobbin Carrier
7 / Bobbin Carrier Reliever
8 / Departmental Mazdoor
9 / Listing Man
10 / Felt Bob Cleaner
11 / Machine Cleaner
12 / Sweeper
13 / Blower & Humidification Man
Total:
Hands/Ton
E) / Winding
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Sardar -Warp
2 / Sardar-Weft
3 / Warp winder
4 / Weft winder
5 / Spool Carrying Coolie
6 / Bobbin & Spool Centre Cleaner
7 / Cop Godown Coolie
8 / Sweeper
9 / Precision Winder – if any
10 / Spool Carrying Coolie for P.Winding – if any
Total:
Hands/Ton
F) / Beaming
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Beaming Sardar
2 / Beamer
3 / Empty Beam Carrier
4 / Sweeper
5 / Starch Man
Total:
Hands/Ton
G) / Weaving
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Line Sardar
2 / Weaver
3 / Helper
4 / Cambman
5 / Moochi - Cobbler
6 / Dust Coolie
7 / Beam Coolie
8 / Department majdoor for weighing and cloth carrying
Total:
Hands/Ton
H) / Finishing
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Damping Feeder
2 / Damping Receiver
3 / Cloth Carrier(Damping to Calender)
4 / Calender Feeder
5 / Calender Receiver
6 / Cloth Inspection & Repairer
7 / Cloth Carrier (Calender to Lapping)
8 / Bale Arranger
9 / Lapping Feeder
10 / Lapping Receiver
11 / Lap carrier
12 / Hoop Cutter
13 / Press Man
14 / Pump Man
15 / Marker
16 / Packing Mazdoor
17 / Pack Sheet Cutter
18 / SQC Mazdoor
19 / Sweeper cum Dust Collector
Total:
Hands/Ton
I) Shipping
Sl. No / Basis / No. of Hands Required
1
Total:
Hands/Ton
J) / Mill Mechanic
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Line Mistry-Jute Spreader/Softener
2 / Line Mistry-Cards
3 / Line Mistry-Drawings
4 / Line Mistry-Spinning
5 / Vice Mistry - Card
6 / Vice Mistry - Drawing
7 / Vice Mistry-Spinning
8 / Roll Former Mistry
9 / General Mazdoor
10 / Preventive Maintenance Mistry
11 / Pin Boy - Card
12 / Pin Boy Drawings
13 / Oiler - Line shaft
14 / Oiler - Machines
15 / Carriage Mistry
16 / Tinsmith
17 / Blacksmith
18 / Welder-Gas
19 / Carpenter
20 / Welder-Electric
21 / Cork-Rubber roller Grinder
22 / Overhauling Mistry Spreader/Softener & Card
23 / Overhauling Mistry Drawing
24 / Overhauling Mistry Spinning
25 / Overhauling Mazdoor
Total:
Hands/Ton
K) / Factory Mechanic
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1 / Line Mistry-Winding
2 / Line Mistry-Beaming
3 / Line Mistry-Weaving
4 / Line Mistry- Finishing & Press
5 / Oiler - Line shaft
6 / Oiler - Winding & Beaming
7 / Oiler - Weaving
8 / Oiler Finishing & Press
9 / Beam Flange Repairer
10 / Major Breakdown Mistry
11 / Vice Man
12 / Overhauling & Preventive Maintenance Mistry
13 / Mazdoor
14 / Carpenter
15 / Loader Fitter (if any)
16 / Any other
Total:
Hands/Ton
L) / Workshop :
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1
Total:
Hands/Ton
M) / Electrical, General Engineering, Civil(Including Generator)
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1
Hands/Ton
N) / Monthly Paid & Other Hands(including Supervisor)
Sl. No / Occupation / Basis / hands per m/c / No. of Mc. Req. /100 Looms / No. of Hands Required
1
Hands/Ton

CHAPTER 5

PROFORMA FOR POWER CONSUMPTION

PER METRIC TON

Table 29: Power Consumption

Sl. / Machines / Utilisation Factor (UF) (%) / Rated Machine HP / Actual Machine HP / KWH Per M/c./8 hr. at UF / No. of Machine for 100 Looms / Total KWH
1 / 2 / 3 / 4 / 5 / 6 / 7
1 / Emulsion Plant
2 / Softener(if in use)
3 / Jute Spreader with Blower
4 / Compressor for spreader m/c [one m/c feeds -- spreader]
5 / Breaker Card
6 / Inter Card
7 / Finisher Card
8 / First Drawing
9 / Second Drawing
10 / Finisher Drawing
11 / Spinning Warp (100/104 Spindles)
12 / Spinning Weft(100/104 Spindles)
13 / Warp Winding (Scroll)
14 / Weft Winding (Scroll)
15 / Precision Winding (1 Spindle / M/c.)
16 / Beaming
17 / Loom
18 / Compressor for loom (if any- for shuttleless loom)
19 / Damping
20 / Calendering
21 / Lapping
22 / Press & Pump

______

Signature & Seal of the Mill

1