End Breakage Analysis
topic
End breakage rate (EBR) analysis: (1) Map breaks by position — random distribution: material or environmental cause; clustered positions: machine cause (specific roller, ring, or spindle). (2) Break timing during cop build — high at start of build (bottom): winding tension too high; high at end of build (top): balloon tension too high, traveller too light. (3) Break time pattern — high at shift start: humidity or roving conditioning; increasing over shift: traveller wear. (4) Count effect — EBR increasing linearly with count: normal; sudden jump: wrong traveller weight.
Role
EBR analysis is the productivity engineer's primary tool — every 1 break per 100 spindle hours costs approximately 0.5% of machine production capacity. The EBR mapping and timing analysis described above allows engineers to prioritise corrective actions: if 20% of spindle positions cause 50% of breaks, fixing those 20% positions recovers most of the lost production. This Pareto-based analysis approach is applicable to any machinery-intensive manufacturing process.