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LEAD TIME REDUCTION IN TEXTILE INDUSTRY

-by S.Aravindha balaji (10mm04)

Guided by
Dr.D.Rajenthirakumar

Contents
• • • • • • • • • Introduction About project Objective About company Methodology NGP time study Kanban . Deliverables. References.

. • The kanban implementations& its integration will benefit in reducing the lead time of the end fiber. so NGP time study’s were done to compare it with sector specified standards to enhance production rate.Introduction: • The LEAN principles are easy to implement in the product industry as compared with semi-process industry like textile spinning were we have continuous machinery which is get multiple input points and output points in its passage from raw cotton to end fiber.

About project • Phase-I (completed)  Kanban implementation in the Ring winding section • Phase-II (IV-semester). • FUTURE state of VSM.1(NGP) .. ** source:.5. (Reprint 2006)page 223.  Kanban implementation in all other section and to integrate the same to reduce the lead time.para 2.  T he Needles – Guide Pin(NGP)** time study to increase the efficiency of the production and help in elevating the production rate.SITRA HAND MANUAL for textiles machineries.

– KANBAN implemtation& integration to achieve reduction in overall lead time. As both capacity and lead-time plays an vital role in converting an industry into lean-centric and operational excellence industry in every sector. – NGP time study related to productivity and critical to capacity constrains. .Cont… • In this phase the entire project will be separated in to two separate areas.

.objective • To reduce the LEAD TIME of the textile industry from 620 mins to 600mins within march 15 of 2012 using KANBAN method • To integrate all the sections to enhance the productivity by using SITRA sectioned parameters validation for textile machineries installed in the VSM spinning mill.

. Ltd. • The industry has high end clients like Madura garments. • The industry is the only Duplex operator in Salem region for the grade 40. Al-zammen exports Ltd. Salem • The industry was started in 1999.About company • Vaithi lingam spinning mills pvt.

• The obtained results were get compared with the standard values in SITRA norms for evaluation of current process.25mm dia is used is only selected for NGP . • The parameters like RPM vs thread tension graphs are plotted and its slope were taken as parameter of NGP. • The non value items like twin peaks are get identified using NGP only as they have more time than standard time to be utilized.Project methodology-1 IDENTIFICATION OF SECTIONS FOR NGP IDENTIFICATIONS OF PARAMETERS in NGP PERFORM THE NGP TIME STUDY IN SELECTED SECTIONS COMPARE/ANALYZE THE NGP VALUES WITH SITRA NORMS IDENTIFY THE NON VALUE ADDED ACTIVITY IN PRESENT OPERATIONS FORMULATE WITH NEW METHODS AND TRAIL -RUN • The various sections at which thread of at least 0. . • Both manual NGP time study and automatic with help of NGP counters were used in NGP with atleast 3 trails by automatic method. • The double peak operations were get reduced /eliminated to increase the production after Initial TRAIL-RUN.

Project methodology-2 Select the sections to introduce the KANBAN KANBAN feasibility study& CALCULATIONS. • The kanban calculations and its feasibility study using demand-feasibility analysis. • The entire firm level Demand –facility analysis will ensure the smooth integrations of all KANABN installed in every sections of the industry . • The actual kanban implementations were get done in this as islands of KANBAN limited to particular sections demand alone. KANBAN implementations in every selected sections Integrations of all KANBAN’S in entire plant • The other sections were huge lead time is used is selected for KANBAN implementations.

• After the graph is plotted the twin peak curve points are taken as odd points for improvement and get omitted. hole dia of machine etc which would then plotted ln graph as machine against thread values. mean thickness of the guide pin.NGP time study • Needle –Guide pin(NGP) time study is the study which should consider at least 6 parameters like torsion of thread. RPM of machine. . winding height.

• the graphs whose values shy below the SITRA values are should be termed as “underperforming” machines. • The methods to increase the performance of particular machines are sorted to included in TRIAL-RUN process.) • In the graph the slope values are compared in which the slope values of SITRA standards were done. .NGP time study(cont….

TRAIL 2(YPM) Torsion-A Torsion-B Torsion-C Torsion-D .TRAIL 1(YPM) M.NGP Graphs(RPM Vs TORSION) 800 780 760 740 720 700 680 A.TRAIL 1(YPM) M.

• The table format has been done for recording the one particular values against variable other parameter in every trail. • After this along with other parameter estimator it is plotted as graphs to find the twin peaks. .NGP study(manual) • The selected parameters are get noted down by careful calculation over the output and the machine settings.

NGP study(Automated) • Here also same operation of plotting the values as graphs were done the difference is the values were obtained directly from mill monitoring gauges fixed into every machine. • The process has been fully automated in the few modern machines which produce the results in graph format by the help of dedicated NGP time monitors preinstalled. • I would like to use Timer-pro for obtaining Automated values and graphs. .

corting section. .  simplex section. Draw frame section.KANBAN part • Apart from simulation of all sections using areana for lead time calculation. blowing room section. • this part has Mixing section(storage chamber). spinning section are the section in which kanban box’s and cards get to be implemented along with its integration in this phase.

. • KANBAN implementation and its integration in various sections seek Operators support which only be developed after long training and interaction sessions only. so timer pro has been used but that has the constraints like separate AV recording device and PC need which is costly.constraints • Obtaining values like manual RPM calculation for NGP time study is time consuming process.

visio i-grafx MS.0 Timer pro MS.Lean tools used • • • • • Arena 10.excel ( for simulation of sections) (for time motion values) ( for KANBAN integration) ( for VSM) (for NGP time study) .

Deliverables • Increased PRODUCTIVITY values of 1080 pales from present 1050 pales after comparing the NGP values with SITRA Values. . • Future state map with suggested kaizen’s for further improvements after project. • Reduced Lead time after kanban implementations from 620 mins to 600 mins.

. Journal for Industrial Technology . john deyst(vol 64. • Kanban made simple by productivity press.3 june 1997. • Lean principles for agile apparel production in integrated textiles company by Dr.2004 .ISBN-164-10-12-2954 .)(IJ textile advancements Nov 2009). no 2 august 2004.jan 2006).19.Vol 13. internation journal for textile manufacturing) • Lead-time reduction in large-scale machinery using maintaince plans.stier .international journal for industrial maintance.. journal of Industrial technology.. 1997.References • Lean manufacturing principles for improving production Efficiency by Auston Marmduke kilpatrick. KELLY ANN(pg203-364. Vol .No.a case study by kirkor bozdogan. • Adapting Lean Manufacturing Principles to the Textile Industry by GOFORTH.. • Lean for the Process industry byDr. Josef Oehmen (vol 23.1999.kenneth w.pg326-334).

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