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To cite this Article: Arup Ranjan Mukhopadhyay and Soumik Ray , 'Reduction of
Yarn Packing Defects Using Six Sigma Methods: A Case Study', Quality
Engineering, 18:2, 189 - 206
To link to this article: DOI: 10.1080/08982110600567533
URL: http://dx.doi.org/10.1080/08982110600567533
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Reduction of Yarn Packing Defects Using Six Sigma Methods: A Case Study
Arup Ranjan Mukhopadhyay and Soumik Ray
SQC and OR Unit, Indian Statistical Institute, Kolkata, India
manufacturing process, yarn is wound into conicalshaped packages called cones, and it is shipped to
customers in this format. Cones were being rejected
by customers due to unacceptable weight variation.
The work of the textile company to correct this
problem is presented here in accordance with the standard Six Sigma DMAIC (Define-Measure-AnalyzeImprove-Control) model (Pande, 2001).
DEFINE PHASE
Objective
This project reduces rejection during packing of
finished yarn cones through measuring the current performance level and initiating proper remedial action
thereafter.
Process
In this textile company, the final product is synthetic yarn. The company produces single and multifold synthetic white yarns from blends of manmade
fibers for apparel and industrial applications. The process to produce yarn consists of 10 sequential steps:
INTRODUCTION
This article originated when an Indian textile company identified packing rejection of yarn cones as its
major quality problem and decided to use Six Sigma
methods to correct the problem. At the end of its
Address correspondence to Arup Ranjan Mukhopadhyay,
SQC and OR Unit, Indian Statistical Institute, New
Academic Building, 203 B.T. Road, Kolkata 277 108, India.
E-mail: armukherjee@yahoo.co.in
189
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190
6.
7.
8.
9.
10.
The roving, the output of this step, is a continuous, slightly twisted strand of synthetic fibers.
Ringframe=spinning: The roving is attenuated to
the required size of single yarn; a suitable amount
of twist is inserted to the strand of fibers, and the
yarn is wound onto a bobbin for further use.
Savio winding: Ring frame bobbins are inputs, and
yarn cheeses formed after winding are outputs.
Through this winding under tension, any weak
places, fluffs, snarls, and bad knots in the yarn
are removed. This step is named Savio after the
make of the machine that performs the operation.
Assembly=doubler winding with length measuring
device (LMD): Two cheeses are fed and wound
in parallel under tension to form another cheese.
While winding, weak places, fluffs, snarls, and
bad knots in the yarn are further removed.
Two-for-one twister (TFO): Final cones or cheeses
are formed by twisting and winding, under
tension, the parallel yarns formed by the
assembly=doubler winding step.
Packing: Cones=cheeses are weighed, packed in
suitable containers, and dispatched to customers.
Figure 1.
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Figure 2.
Figure 3.
Figure 4.
191
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192
MEASUREPHASE I
Technical discussions concluded that the potential
factors, which have a bearing on yarn weight, were as
follows:
1.
2.
3.
4.
Count
Empty cheese weight
Moisture content % (M.C.%)
Length of yarn wound onto cone=cheese
Table 1
Specifications for gross cheese weight (kg) at the assembly
winding stage
Count
s
2=10 P
2=12sP
3=12sP
4=12sP
4=12sP
3=20sP
2=42sP
LSL
Target
USL
1.489
0.966
1.489
1.489
4.470
0.990
0.966
1.564
1.041
1.564
1.564
4.620
1.065
1.041
1.639
1.116
1.639
1.639
4.770
1.140
1.116
p
YieldAW YieldTFO 0:7433
p
29:37 2:221 lnPPM Breyfogle; 1999
Table 2
Specifications for gross weight (kg) at TFO stage
Count
s
2=10 P
2=12sP
3=12sP
4=12sP
3=20sP
2=42sP
2=42sP
LSL
Target
USL
4.350
4.350
4.350
4.350
2.050
0.925
2.050
4.500
4.500
4.500
4.500
2.100
1.000
2.100
4.650
4.650
4.650
4.650
2.200
1.075
2.200
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Overweight
drums
Underweight
drums
Total
out-of-specs
2=42sP
2=42sP, 2=57sLY
3=20sP
4=12sP, 2=10sP
4=12sP
3=12sP, 3=20sP, 2=12sP
7
7
0
2
4
8
0
0
0
0
0
0
7
7
0
2
4
8
28
28
Machine no.
1
5
9
10
11
17
Total
Total
drums
120
104
120
60
56
120
(20)
(20)
(20)
(20)
(20)
(20)
580 (120)
The figures in parentheses represent the number of drums that were inspected. Selection of the drums was random.
Table 4
Summary of out-of-specifications drums at TFO operation
Machine no.
Count
Overweight drums
Underweight drums
2=42 P
2=42sP, 2=57sLY
3=20sP
4=12sP, 2=10sP
4=12sP
3=12sP, 3=20sP, 2=12sP
3=20sP
3=20sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
7
7
0
2
4
8
0
0
0
0
0
1
11
10
8
7
8
7
0
0
0
0
0
0
3
0
2
0
1
1
0
0
0
0
0
0
7
7
0
2
4
8
3
0
2
0
1
2
11
10
8
7
8
7
59
13
72
2
5
7
8
11
22
25
27
33
34
51
60
64
65
66
70
71
72
Total
Total drums
120
104
120
60
56
120
132
120
132
144
144
132
120
120
132
144
120
132
(10)
(10)
(10)
(10)
(10)
(10)
(10)
(10)
(20)
(10)
(10)
(10)
(20)
(10)
(10)
(10)
(10)
(10)
2,172 (200)
The figures in parentheses represent the number of drums that were inspected. Selection of drums was random.
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Machine no.
Target
weight (kg)
Mean
weight
Standard
deviation
Samples
tCALC
p value
1.041
1.041
1.065
4.620
1.1091
1.1042
1.0960
4.6861
0.0157
0.0430
0.0315
0.0895
20
10
20
20
19.398
4.637
4.398
3.302
0.0000
0.0006
0.0000
0.0020
2=42 P
2=42sP
3=20sP
4=12sP
1
5
9
11
Conclusion
Process
Process
Process
Process
not
not
not
not
running
running
running
running
on
on
on
on
target.
target.
target.
target.
Yarn count
s
2=42 P
3=20sP
4=12sP
1
9
11
nL
nR
SL2
SR2
p value
Conclusion
10
10
10
10
10
10
0.0002
0.0015
0.0043
0.0002
0.0006
0.0053
1.0000
2.5000
1.2326
0.5000
0.0823
0.3736
Note: Because the other assembly winding machines were producing different counts at the two sides during the study
period, their variances were not compared.
Yarn count
s
2=42 P
3=20sP
4=12sP
1
9
11
XL
XR
nL
nR
tCALC
p value
Conclusion
1.116
1.095
4.628
1.103
1.097
4.742
10
10
10
10
10
10
1.964
0.138
3.672
0.0250
0.4000
0.0009
Note: Because the other assembly winding machines were producing different counts at the two sides during the study
period, their means were not compared. They were designed to be different.
Table 8
Comparison of variation of empty cheese weight (in kg) with gross cheese weight (in kg)
Target
Color of cheese
Deep blue
Yellow
Lemon yellow
Deep blue
Count
s
4=12 P
4=12sP
3=20sP
2=42sP
Average
SD
C.V. %
No. of obs.
Empty
Gross
Empty
Gross
Empty
Gross
Empty
Gross
50
50
50
50
0.064
0.218
0.064
0.064
4.620
4.620
1.065
1.041
0.0642
0.2176
0.0613
0.0636
4.6861
4.6861
1.0960
1.1042
0.0014
0.0021
0.0010
0.0014
0.0895
0.0895
0.0315
0.0276
0.03
0.05
0.09
0.14
1.94
1.94
2.96
2.65
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for n 2; D4 3:267
LCL D3 R 0
For 2/42s P,
CL R 455:6
MEASUREPHASE II
To validate the previous findings, data were collected further from assembly winding machines with
LMD attachments. This time the actual length of the
yarn on the cheese, as measured by rewinding, was
recorded along with set length, nominal count, actual
Figure 5.
UCL D4 R 1488:445
LCL D3 R 0
The gage capability and repeatability of LMD were
calculated to check its sensitivity on measuring yarn
length for both counts. The relevant calculations are
shown as follows.
R-chart for repeat measurements of yarn length measured by LMD-10 (count 4=12sP).
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Figure 6.
Montogomery; 2003
Table 9
Results of gage capability analysis
Count
s
4=12 P
2=42sP
b2reproducability ,
b
r2repeatability; r
and
(Because
r2gage b
2
b
rreproducability is nonexistent here as data are taken by
a single operator.)
Here, b
r2total is calculated for each count from the
rewound lengths (Table 10).
Therefore, inconsistent measurement of yarn
length by the LMDs attached with the assembly winding machines alone contributed about 44% to 49%
toward the product variability. This can be considered
as quite a significant amount of variation.
rgage
b
P=T %
310.4610 m
403.9007 m
122.30
45.44
Table 11
ANOVA for significance of regression
Table 10
Results of gage repeatability analysis
Variability
b
rtotal
b
rrepeatability
b
rproduct
b
rrepeatability =b
rproduct
4=12sP count
2=42sP count
700.7281 m
310.4610 m
628.1989 m
49.42%
997.9898 m
403.9007 m
912.6050 m
44.26%
Sum of
squares
Degrees of
freedom
Mean
square
Regression
Residual
0.117
0.039
1
28
0.117
0.001
Total
0.156
29
Source
81.985
0.000
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Moisture content
Count
Length
1.000
0.101
1.000
0.027
0.224
1.000
0.233
0.060
0.132
1.000
0.863
0.112
0.180
0.149
1.000
Table 13
Descriptive statistics for 4=12s polyester yarn
Samples
Mean
SD
Minimum
Maximum
30
30
30
30
30
1.555
64.533
0.473
3.033
7223.600
0.073
1.279
0.045
0.072
700.728
1.298
62.000
0.400
2.912
4576.000
1.654
66.000
0.500
3.184
7966.000
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Figure 7.
REFERENCES
Breyfogle, F. W. (1999). Implementing Six Sigma: Smarter
Solutions Using Statistical Methods. New York: WileyInterscience.
Montgomery, D. C. (2003). Statistical Quality Control. John
Wiley & Sons.
Montgomery, D. C. (2004). Design and Analysis of Experiments. John Wiley & Sons.
Pande, P. S. (2001). The Six Sigma Way. McGraw-Hill.
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Sl. no. Machine no. Nominal count (Ne) Actual count (Ne) Nominal weight (kg) Gross cheese weight (kg) M.C.%
Data collected from assembly=doubler winding with LMD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
11
11
11
11
11
11
11
11
11
11
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
11
11
11
11
11
11
11
11
11
11
10
10
10
10
10
10
10
10
10
10
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
2=12sP
3=12sP
2=12sP
2=12sP
3=12sP
2=12sP
3=12sP
2=12sP
2=12sP
2=12sP
3=20sP
3=20sP
3=20sP
3=20sP
3=12sP
3=20sP
3=12sP
3=12sP
3=20sP
3=20sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
3.128
3.163
2.922
3.000
2.908
2.993
2.929
2.994
2.977
2.973
5.762
3.917
5.953
5.646
3.924
6.036
3.889
5.853
5.658
5.952
6.881
6.783
6.728
6.981
4.108
6.975
3.514
3.901
6.942
6.756
3.298
3.030
2.931
2.980
2.881
2.987
2.846
2.959
2.993
3.165
2.849
2.958
2.885
2.880
2.960
2.955
2.938
2.927
3.006
3.049
4.620
4.620
4.620
4.620
4.620
4.620
4.620
4.620
4.620
4.620
1.041
1.564
1.041
1.041
1.564
1.041
1.564
1.041
1.041
1.041
1.065
1.065
1.065
1.065
1.564
1.065
1.564
1.564
1.065
1.065
4.620
4.620
4.620
4.620
4.620
4.620
4.620
4.620
4.620
4.620
1.564
1.564
1.564
1.564
1.564
1.564
1.564
1.564
1.564
1.564
4.696
4.566
4.568
4.652
4.746
4.526
4.608
4.662
4.638
4.620
1.485
1.870
1.510
1.391
1.502
1.501
1.557
1.492
1.481
1.451
1.110
1.102
1.111
1.105
1.564
1.091
1.557
1.582
1.102
1.112
4.862
4.678
4.772
4.718
4.700
4.850
4.700
4.790
4.700
4.650
1.584
1.600
1.662
1.582
1.568
1.626
1.590
1.632
1.654
1.606
0.5
0.5
0.5
0.5
0.6
0.5
0.6
0.5
0.5
0.5
0.7
0.7
0.7
0.6
0.6
0.6
0.5
0.7
0.6
0.5
0.4
0.4
0.4
0.5
0.6
0.4
0.5
0.6
0.4
0.4
0.6
0.7
0.6
0.7
0.7
0.7
0.6
0.6
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.5
0.7
0.7
0.7
0.7
(Continued)
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Sl. no. Machine no. Nominal count (Ne) Actual count (Ne) Nominal weight (kg) Gross cheese weight (kg) M.C.%
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
10
10
10
10
10
10
10
10
10
10
09
09
09
09
09
09
09
09
09
09
09
09
09
09
09
09
09
09
09
09
05
05
05
05
05
05
05
05
05
05
05
05
05
05
05
05
05
05
05
05
01
2=10sP
2=10sP
2=10sP
2=10sP
2=10sP
2=10sP
2=10sP
2=10sP
2=10sP
2=10sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=57sLY
2=57sLY
2=57sLY
2=57sLY
2=57sLY
2=57sLY
2=57sLY
2=57sLY
2=57sLY
2=57sLY
2=42sP
4.962
5.005
4.877
5.127
5.035
5.068
5.137
5.008
4.977
4.986
6.552
6.702
6.747
6.542
7.155
6.482
7.271
6.780
7.134
7.176
6.576
6.589
6.898
6.742
6.812
7.001
6.415
6.813
7.019
6.810
21.658
21.080
21.281
21.464
21.723
20.591
21.478
21.586
20.256
20.483
27.645
28.711
28.736
27.847
28.211
28.409
27.931
28.864
28.993
27.967
21.450
1.564
1.564
1.564
1.564
1.564
1.564
1.564
1.564
1.564
1.564
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.065
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
0.600
0.600
0.600
0.600
0.600
0.600
0.600
0.600
0.600
0.600
1.041
1.564
1.560
1.552
1.546
1.560
1.538
1.562
1.608
1.566
1.540
1.120
1.090
1.110
1.000
1.140
1.100
1.120
1.100
1.070
1.100
1.060
1.110
1.130
1.090
1.120
1.080
1.120
1.090
1.060
1.110
1.124
1.118
1.028
1.022
1.106
1.136
1.118
1.146
1.124
1.120
0.656
0.662
0.656
0.658
0.664
0.666
0.662
0.660
0.666
0.666
1.140
0.6
0.6
0.6
0.6
0.6
0.4
0.6
0.6
0.6
0.6
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.4
0.5
0.5
0.5
0.5
0.5
0.4
0.5
0.5
0.5
0.4
0.5
0.5
0.5
0.4
0.5
0.5
0.5
0.5
0.5
0.5
0.5
9.3
9.6
9.6
9.3
9.6
9.6
9.6
9.6
9.6
9.6
0.5
(Continued)
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Sl. no. Machine no. Nominal count (Ne) Actual count (Ne) Nominal weight (kg) Gross cheese weight (kg) M.C.%
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
21.107
21.478
21.025
21.365
21.485
20.964
21.114
21.330
20.709
21.073
22.291
21.135
21.679
21.571
21.665
21.358
21.274
21.848
21.372
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.041
1.080
1.040
1.134
1.092
1.108
1.128
1.124
1.102
1.116
1.118
1.100
1.122
1.102
1.102
1.090
1.086
1.120
1.102
1.084
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
19.963
20.604
21.309
20.923
21.239
21.156
20.212
20.087
20.703
21.365
20.617
20.870
21.136
21.730
20.856
21.578
20.250
21.803
21.709
21.372
20.352
20.506
20.461
21.114
21.593
20.789
20.480
21.053
19.951
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
2.18
2.16
2.10
2.02
2.12
2.10
2.16
2.02
2.08
2.12
2.12
2.12
2.12
2.12
2.14
2.10
2.14
2.06
2.10
2.10
1.08
1.14
1.10
1.08
1.06
1.08
1.08
1.08
1.06
0.6
0.5
0.5
0.5
0.5
0.5
0.5
0.6
0.6
0.6
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.6
0.5
0.5
0.5
0.4
0.5
0.5
0.5
0.5
0.5
0.5
0.4
33
33
33
33
33
33
33
33
33
33
33
33
33
33
33
33
33
33
33
33
64
64
64
64
64
64
64
64
64
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Sl. no. Machine no. Nominal count (Ne) Actual count (Ne) Nominal weight (kg) Gross cheese weight (kg) M.C.%
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
64
64
64
64
64
64
64
64
64
64
64
72
72
72
72
72
72
72
72
72
72
60
60
60
60
60
60
60
60
60
60
27
27
27
27
27
27
27
27
27
27
22
22
22
22
22
22
22
22
22
22
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
20.910
21.436
21.840
21.246
21.032
20.105
21.066
20.212
21.855
21.351
21.557
20.657
20.870
20.552
20.836
20.930
20.294
21.163
21.309
21.046
20.896
20.558
20.769
21.344
21.379
21.756
21.012
20.736
21.005
21.039
21.884
6.520
6.467
5.221
7.041
6.785
6.658
6.316
6.930
6.806
6.430
6.272
6.452
6.727
6.644
7.025
6.280
6.689
6.339
6.159
6.459
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
0.98
1.10
1.06
1.04
1.06
1.10
1.02
1.06
1.02
1.08
1.08
1.12
1.10
1.10
1.12
1.02
1.10
1.08
1.12
1.02
1.02
2.08
2.16
2.10
2.14
2.14
2.04
2.12
2.06
2.12
2.24
2.14
2.14
2.12
2.10
2.08
2.14
2.14
2.10
2.08
2.12
2.14
2.14
2.16
2.14
2.08
2.14
2.14
2.08
2.18
2.16
0.5
0.5
0.5
0.5
0.5
0.5
0.6
0.5
0.5
0.5
0.5
0.5
0.5
0.6
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.6
0.6
0.5
0.6
0.6
0.7
0.7
0.8
0.7
0.6
0.6
0.5
0.5
0.6
0.6
0.6
0.6
0.6
0.5
0.5
0.6
0.6
0.6
0.5
0.7
0.5
0.6
0.6
0.6
0.6
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Sl. no. Machine no. Nominal count (Ne) Actual count (Ne) Nominal weight (kg) Gross cheese weight (kg) M.C.%
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
71
71
71
71
71
71
71
71
71
71
11
11
11
11
11
11
11
11
11
11
66
66
66
66
66
66
66
66
66
66
25
25
25
25
25
25
25
25
25
25
65
65
65
65
65
65
65
65
65
65
34
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
3=20sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
21.135
21.344
22.531
21.260
20.716
21.059
20.513
20.591
20.843
20.663
20.591
20.263
21.443
20.896
20.442
21.302
20.749
20.716
20.250
20.657
20.422
20.571
21.288
21.478
21.032
20.856
21.436
21.032
21.796
21.478
6.136
6.216
6.666
6.496
6.116
6.387
6.257
6.624
6.343
6.787
21.156
21.094
21.745
20.591
20.062
21.493
21.818
21.101
21.295
21.309
21.344
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
2.100
1.10
1.08
1.10
1.10
1.10
1.08
1.10
1.04
1.04
1.10
2.04
2.16
2.16
2.12
2.08
2.14
2.08
2.10
2.16
1.82
1.08
1.18
1.12
1.08
1.18
1.06
1.04
1.08
1.08
1.08
2.18
2.14
2.12
1.82
2.18
2.10
2.08
1.52
2.14
1.54
1.10
1.08
1.10
1.14
1.16
1.10
1.08
1.12
1.08
1.08
2.18
0.5
0.6
0.6
0.6
0.5
0.5
0.6
0.5
0.6
0.6
0.7
0.7
0.7
0.6
0.5
0.6
0.6
0.7
0.7
0.7
0.6
0.6
0.5
0.5
0.6
0.6
0.6
0.6
0.5
0.5
0.5
0.6
0.5
0.5
0.5
0.7
0.7
0.5
0.6
0.5
0.5
0.6
0.6
0.5
0.5
0.5
0.5
0.6
0.5
0.5
0.6
(Continued)
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Sl. no. Machine no. Nominal count (Ne) Actual count (Ne) Nominal weight (kg) Gross cheese weight (kg) M.C.%
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
34
34
34
34
34
34
34
34
34
51
51
51
51
51
51
51
51
51
51
70
70
70
70
70
70
70
70
70
70
07
07
07
07
07
07
07
07
07
07
02
02
02
02
02
02
02
02
02
02
05
05
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
3=12sP
3=12sP
3=12sP
3=12sP
3=12sP
3=12sP
3=12sP
3=12sP
3=12sP
3=12sP
4=12sP
4=12sP
21.281
22.146
21.500
22.222
20.957
21.877
20.676
20.598
21.302
21.344
21.622
20.487
20.736
21.478
21.012
21.218
20.545
21.414
20.883
21.066
21.826
20.910
21.528
21.907
21.204
21.211
21.204
21.571
20.282
2.903
2.922
3.000
2.949
2.923
2.967
3.005
2.894
2.993
3.010
3.951
3.860
3.820
4.061
3.668
3.775
4.042
3.857
3.718
3.834
2.887
2.960
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
2.100
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
1.000
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
2.18
2.06
2.16
2.06
2.10
2.08
2.18
2.10
2.08
2.10
2.16
2.16
2.14
2.04
2.18
2.14
2.20
2.14
2.20
1.08
1.06
1.08
1.08
1.10
1.06
1.08
1.08
1.06
1.08
4.75
4.55
4.50
4.50
4.50
4.70
4.65
4.60
4.60
4.70
4.70
4.65
4.70
4.65
4.60
4.55
4.65
4.60
4.70
4.55
4.50
4.55
0.6
0.5
0.6
0.6
0.6
0.7
0.5
0.7
0.6
0.5
0.5
0.5
0.6
0.6
0.6
0.6
0.7
0.6
0.6
0.6
0.5
0.5
0.6
0.5
0.5
0.6
0.5
0.6
0.6
0.7
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.7
0.8
0.6
0.6
0.5
0.6
0.5
0.5
0.5
0.5
0.6
0.6
0.6
0.6
(Continued)
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Sl. no. Machine no. Nominal count (Ne) Actual count (Ne) Nominal weight (kg) Gross cheese weight (kg) M.C.%
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
Serial no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
05
05
05
05
05
05
05
05
08
08
08
08
08
08
08
08
08
08
2.952
3.077
2.888
3.092
3.077
3.082
2.997
2.972
3.178
3.025
2.990
2.997
3.003
3.061
3.088
2.993
2.916
2.890
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.500
4.75
4.65
4.65
4.45
4.55
4.45
4.50
4.45
4.15
1.05
4.30
4.40
4.30
4.60
4.50
4.45
4.60
4.55
Appendix B
Data on cheese weight at the assembly winding stage after rewinding
Nominal
Actual
Set
Actual
Gross
count (Ne)
count (Ne)
length (m)
length (m)
M.C.%
weight (kg)
1.098
1.084
1.096
1.092
1.102
1.112
1.106
1.056
1.104
1.118
1.104
1.084
1.082
1.136
1.134
1.122
1.200
1.112
1.118
1.100
1.400
1.134
1.174
1.122
1.072
1.086
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
2=42sP
21.855
21.344
21.267
21.840
21.803
21.636
21.774
21.687
21.450
21.988
21.789
21.636
21.716
21.281
20.611
21.018
21.302
21.884
21.302
21.730
21.101
20.162
20.763
22.003
21.066
20.624
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,500
36,418
36,417
36,360
31,724
36,667
37,134
36,425
36,714
36,778
36,583
36,724
35,793
36,613
37,224
36,594
37,234
38,213
36,793
36,405
36,614
36,584
36,640
36,500
36,594
36,574
36,965
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.4
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.4
0.5
0.4
0.5
0.5
0.6
0.6
0.6
0.7
0.6
0.6
0.6
0.7
0.6
0.6
0.7
0.7
0.6
0.7
0.7
0.7
0.8
0.6
Empty cheese
weight (g)
64
60
64
64
62
62
64
64
62
64
64
64
64
64
64
62
64
64
64
64
64
62
64
66
64
64
(Continued)
Downloaded By: [EPSCoR Science Information Group (ESIG) Dekker Titles only Consortium] At: 14:12
206
Serial no.
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Gross
weight (kg)
Nominal
count (Ne)
Actual
count (Ne)
Set
length (m)
Actual
length (m)
M.C.%
Empty cheese
weight (g)
1.130
1.112
1.102
1.106
1.618
1.568
1.550
1.572
1.548
1.614
1.654
1.572
1.584
1.640
1.570
1.514
1.570
1.558
1.614
1.614
1.448
1.588
1.568
1.584
1.582
1.524
1.298
1.570
1.552
1.544
1.568
1.572
1.358
1.542
2=42sP
2=42sP
2=42sP
2=42sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
4=12sP
21.855
22.268
21.386
22.071
3.018
2.936
3.054
2.944
2.965
2.912
3.078
3.000
3.184
2.929
3.093
3.011
3.082
2.972
2.972
2.974
3.089
3.165
2.945
3.083
3.081
3.045
3.040
3.137
2.997
3.065
3.066
3.006
3.129
3.024
36,500
36,500
36,500
36,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
7,500
36,795
36,974
36,074
36,773
7,400
7,432
7,966
7,386
7,336
7,402
7,832
7,393
7,377
7,406
7,610
6,531
6,559
7,533
7,500
7,413
7,034
7,581
7,581
7,788
7,457
7,289
4,576
7,322
7,296
7,334
7,400
7,231
5,227
7,516
0.4
0.4
0.5
0.4
0.5
0.5
0.4
0.5
0.5
0.4
0.5
0.4
0.4
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.4
0.5
0.5
0.5
0.4
0.4
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.4
64
62
64
64
66
64
64
66
66
64
64
66
66
64
64
66
62
64
64
66
64
64
62
64
66
64
66
66
64
64
64
62
64
66