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    Bobbin Change Analysis and Possible Solutions

    Uploaded by

    Sharvari Shankar
    This document analyzes bobbin change issues that cause production bottlenecks and proposes solutions. It identifies that bobbin thread running out leads to defective products, downtime, and wasted materials. Proposed solutions include using thinner threads that require fewer changes, attaching extra bobbins to machines, standardizing bobbins and cases, and automating bobbin thread level detection to eliminate rework from unnecessary changes. The overall goal is to minimize bobbin-related problems hampering productivity.

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    Bobbin Change Analysis and Possible Solutions

    Uploaded by

    Sharvari Shankar
    31 views21 pages
    This document analyzes bobbin change issues that cause production bottlenecks and proposes solutions. It identifies that bobbin thread running out leads to defective products, downtime, and wasted materials. Proposed solutions include using thinner threads that require fewer changes, attaching extra bobbins to machines, standardizing bobbins and cases, and automating bobbin thread level detection to eliminate rework from unnecessary changes. The overall goal is to minimize bobbin-related problems hampering productivity.

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    BOBBIN_CHANGE_ANALYSIS_AND_POSSIBLE_SOLUTIONS.pptx

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    This document analyzes bobbin change issues that cause production bottlenecks and proposes solutions. It identifies that bobbin thread running out leads to defective products, downtime, and wasted materials. Proposed solutions include using thinner threads that require fewer changes, attaching extra bobbins to machines, standardizing bobbins and cases, and automating bobbin thread level detection to eliminate rework from unnecessary changes. The overall goal is to minimize bobbin-related problems hampering productivity.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    31 views21 pages

    Bobbin Change Analysis and Possible Solutions

    Uploaded by

    Sharvari Shankar
    This document analyzes bobbin change issues that cause production bottlenecks and proposes solutions. It identifies that bobbin thread running out leads to defective products, downtime, and wasted materials. Proposed solutions include using thinner threads that require fewer changes, attaching extra bobbins to machines, standardizing bobbins and cases, and automating bobbin thread level detection to eliminate rework from unnecessary changes. The overall goal is to minimize bobbin-related problems hampering productivity.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 21

    BOBBIN CHANGE ANALYSIS

    AND POSSIBLE SOLUTIONS

    The tasks of bobbin


    changing and winding
    have always been
    bottlenecks in the
    sewing process.

    What if Bobbin threads RUN OUT?

    Only limited amount of thread can be


    stored in a Bobbin.
    Bobbin thread DOES run out as you sew ?
    without noticing !
    There is no stitch Formed!!

    With No Bobbin Thread


    Need for change in bobbin Arises!
    ALSO, Various Wastes are produced.

    WASTES DUE TO BOBBIN


    CHANGE
    Unwanted needle holes and incomplete seams
    Automated sewing machine keeps running - on
    and on.

    Defective product.
    Downtime.
    Unusable material.

    OBJECTIVE
    To ensure that the bobbin is not the

    problem.
    Troubleshoot bobbin related problems that

    hamper the production

    Bobbin Change factors


    Stitch Length
    Seam Length
    Thickness Of the thread
    Bobbin Content
    Quality of bobbin
    Quality of bobbin Case

    POSSIBLE SOLUTIONS

    PROPOSE TO BUYER
    To avoid more number of bobbin change

    use thinner threads(100s and 120s) for the


    operation. At least for lengthy operations as
    they require less number or bobbin change
    as compared to thicker threads (30s and
    50s)
    To avoid need of bobbin change use chain
    stitch machines at the lengthy operations.
    And ultimately to completely eliminate
    rework due to Bobbin Change and also over
    winding

    KAIZENS

    OVER WINDING OF BOBBIN


    The over winding of bobbin is due to faulty

    bobbin stopper, the bobbin stopping spring


    being defective or no proper setting is done
    to the bobbin stopping mechanism.
    A Checklist of all asset numbers on the
    machine is taken checked section wise and
    change the mechanical setting of the
    bobbin winding stopper in order to solve
    the over winding issue.

    OVER
    WOUND
    BOBBIN

    A STOPPER
    ATTACHED TO AVOID
    OVER BINDING OF
    BOBBIN

    Spare Bobbin Box Attached to


    sewing Machine

    EXTRA BOBBIN TO EVERY


    OPERATOR
    Make sure that the extra bobbin is used only

    while stitching to eliminate the waiting time of


    winding after the bobbin exhaust and also to
    reduce the electricity consumption .
    Provision of 2 extra bobbins for double needle
    operator.

    Bobbin Delays due to changeover can be reduced byNew bobbin can be issued while sewing for

    a new style and when change in colour of


    bobbin is required.
    Also at time of pre-run, pre wounded

    bobbins should be passed among the


    operators.

    BOBBIN AND BOBBIN CASE


    STANDARISATION
    A bobbin tracking system can be

    maintained to check the right bobbin and


    bobbin case is used in write place.
    Asset id of the machine can be engraved
    on the bobbin and the asset ids should be
    followed.
    Incase of faulty bobbin or loss of bobbin a
    temporary bobbin should be issued until a
    new bobbin is issued at the machines
    asset id.

    AUTOMIZATIO

    INSTALLING BOBBIN CHECKER IN THE


    MACHINE
    Detect remaining thread in the bobbin

    automatically & accurately. Insert a


    measurement pin in a bobbin case at the
    time of sewing machine system thread
    cutting and detect the residual quantity of
    the lower thread. The setting of being
    located justifies the sensor, and the
    detection is possible. This step is to avoid
    rework due to bobbin change.

    END

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