Fazal Cloth Mills Unit No.

3 & 5

 Monthly Summary Report For the Month of July 17

1
Contents
 Executive Summery ------------------------------------------------Page-03
 Production Analysis Unit -3 ----------------------------------------------04
 Production Analysis Unit -5 ----------------------------------------------05
 Yield Analysis Unit-3 & 5 -------------------------------------------------06
 Yarn Quality Analysis Unit-3 & 5 ----------------------------------------07
 Customer Complaints Unit-3 & 5 ---------------------------------------09
 Store Consumption Unit-3 & 5 ------------------------------------------10
 New Challenges------------------------------------------------------------13
 Store Inventory Unit-3 & 5 ----------------------------------------------14
 Power Consumption Unit-3 & 5 ----------------------------------------16

2
 PRODUCTION UNIT-3
Particulars Bags Gain/Loss (+/-) % of Total Loss
Shutdown (WAPDA) (107.35) 50.06
EXECUTIVE SUMMERY Shutdown (GAS) (20.23) 9.43
Errection (77.12) 35.96
New Frame Running (2.30) 1.07
Compact Modifications (7.45) 3.47
TOTAL BAG LOSS (214.45) 100
PRODUCTION UNIT-5
Particulars Bags Gain/Loss (+/-) % of Total Loss
Shutdown (WAPDA) (149.85) 87.19
Shutdown (GAS) (19.90) 11.58
Count Change (2.12) 1.23
New Frame Running - 0.00
Compact Modifications - 0.00
TOTAL BAG LOSS (171.87) 100
YIELD
Yield Unit-3 & 5 (Cotton)
Cotton Issue Wt. Target Difference  
Pak Cotton 84.91 84.7~85 0 ~0.09  
Imported Cotton 90.73 91 (0.27)  
Yield Unit-5 (MM Fiber)
MM Fiber Issue Wt. Target Difference  
Polyester 98.85 98.8 0.05  
Viscose 97.60 97.5 0.10  
Acrylic 98.85 98.8 0.05  
STORE CONSUMPTION
Particulars Target Actual (Less) / Excess
Store Consumption (PK Rs) including Doubling 9,372,524 8,913,735 (458,789)
Store Consumption (PK Rs) Without Doubling 8,895,523 8,355,729 (539,794)
POWER HOUSE UNITS
Month WAPDA Unit-3 WAPDA Unit-5 Total WAPDA GAS KWH Total Unit 3
Jul-17 348,240 1,257,200 1,605,440 4,469,610 6,075,050
Elect. Unit per Frame per Day With Doulbing       166.2 1,179
Elect. Unit per Frame per Day Without Doulbing         1,091
 Yarn Production Analysis Unit-3:
Count wise detail of Cotton Yarn produced in month of July is as under:
Target Actual Bag Loss/Gain Bag's Loss/Gain
Count Cotton Target Bags Actual Bags Spindle Eff%
OPS OPS (Stoppages) (Low OPS)
20/1 COM HOS C.F USA/CF 12.09 12.11 178.27 178.27 0.00 0.37 100.0
20/1 COM HOS PK PAK 12.09 11.84 1204.06 1182.09 -21.97 -3.05 98.1
20/1 COM Wvg USA/CF 11.43 11.38 139.20 139.20 0.00 -0.57 100.0
20/1 COM Wvg Compt ELS 14.50 12.04 25.00 25.00 0.00 -5.1 100.0
21.5/1 COM Hos COMPT PAK 11.64 11.42 455.68 446.85 -8.83 0.39 98.1
22/1 COM Hos COMPT PAK 11.05 11.03 302.17 300.25 -1.92 1.37 99.3
24/1 COM Wvg Compt ELS 8.94 9.04 36.29 36.29 0.00 0.38 100.0
30/1 COM HOS USA/CF 6.66 6.47 1982.57 1950.35 -32.22 -24.72 98.3
30/1 COM HOS COMPT USA/CF 8.10 8.00 510.15 496.93 -13.22 6.87 97.4
30/1 COM WVG USA/CF 6.14 6.12 1137.16 1116.80 -20.36 17.42 98.2
30/1 COM Wvg COMPT USA/CF 7.53 7.68 435.90 425.00 -10.90 19.07 97.5
30/1 COM Wvg RX-300 USA/CF 6.14 6.13 232.59 229.75 -2.84 2.43 98.7
32/1 COM HOS COMPT PAK 7.16 6.98 2563.46 2494.70 -68.76 4.66 97.3
36/1 COM Hos COMPT PAK 6.13 6.11 37.37 37.37 0.00 -0.11 100.0
40/1 Com Wvg COMPT USA/CF 5.67 5.63 69.80 69.80 0.00 -0.46 100.0
40/1 COM HOS COMPT USA/CF 5.50 5.53 112.86 112.86 0.00 0.61 100.0
40/1 COM Hos Wvg RX-300 USA/CF 4.20 5.75 98.73 96.95 -1.78 27.86 98.1
40/1 COM Wvg COMPT PAK 5.30 5.60 162.72 160.75 -1.97 10.66 98.7
40/1 COM Wvg RX-300 PAK 3.97 5.05 898.38 881.90 -16.48 204.62 98.2
50/1 COM Wvg Compt ELS 3.57 3.60 222.27 219.80 -2.47 4.41 98.8
60/1 COM Wvg ELS 2.88 2.87 1188.51 1178.27 -10.24 7.34 99.1
60/1 COM Wvg COMPT ELS 2.83 2.89 137.38 136.88 -0.50 3.21 99.6
TOTAL       12130.51 11916.06 (214.45) 277.66 98.37

Bags not Produced due

Remarks
to Stoppage

Erection (77.12)

Modification (7.45)

New Fram Running (2.30)

Gas OFF (20.23)

4
Wapda Off (107.35)
Grand Total
(214.45)
5
 Yield Analysis Unit-3 & 5

Yield Unit-3 & 5 (Cotton)

Cotton Actual Target Difference Remarks 
(0.09)
Pak Cotton 84.91 85  
(0.27)
Imported Cotton 90.73 91  

Yield Unit-5 (MM Fiber)

MM Fiber Issue Wt. Target Difference  Remarks
Polyester 98.85 98.8
0.05
 

Viscose 97.60 97.5

0.10
 

Acrylic 98.85 98.8

0.05
 

6
Yarn Quality Analysis Unit 3 & 5
We are pleased to inform that in Unit -3 quality remained consistent / Improved and we are
producing on regular basis 26 cm Hwax, 30 Cm Hos Wax ,32 Cm Hos Wax, 36 / 40 Cm Hos Wax .Our
quality level i.e. Cv 10 Mtrs, IPI,S and other quality attributes are better than Nishat , Masood and
other Competitors .
All sensitive Hosiery customers including

Style Textile

Masood Textile

Combined Textile

Klash

are giving repeat orders and want to maintain long term regular business with Fazal cloth Unit 3 .
In last one year Unit 3 has supplied more than 115 Containers of Hosiery yarn to Style Textile and
have not faced any problem .

7
 Compact Warp yarn of 30s/40s and 60s Cpt is also being produced and
supplied on regular basis to Nishat and our group companies and is performing
well .
• In Unit 5, Where compact yarn was being used in weaving only, we are
producing Hosiery yarn as well. This Hosiery yarn being supplied to all well
known customers as mentioned above in detail of Unit # 3.
• Siro yarn is being produced and exported on regular basis and special
orders of 11/1 CM Siro has been repeatedly produced in Unit-5.
• Special yarns like Blends of Viscose:Cotton, Modal:Cotton & Tencel:Cotton
has also been produced regularly in Unit # 5. These special yarns has been
supplied to Hosiery and weaving customers and there seems no issue. In near
future, production of these special yarns will further increase as we have one
more Crossrol Blow Room line for this now.
• PV yarn has improved much and being consistently supplied to Faisalabad
Market without any issue.
Acrylic yarn and Viscose are also being produced in Unit 5 on regular basis
and performing well.
8
Customer Complaints

No Customer Complaint received in Unit 3 or Unit 5 for the month July 17.
A minor feed back regarding unclear date on some cone stickers is received from
Style Textile .
Style textile is asking to mention date on each cone sticker. We are manually
writing date on 6000 cone stickers/day of ‘6’ different counts for last one year.
Now Style textile is asking for printed date on every cone sticker which is very very
difficult to do, However we are working on this target .

9
 Store Consumption Unit 3 & 5
STORE CONSUMPTION
Description Target Actual (Less) / Excess

Store Consumption (PK Rs.) Mills Only

8,913,735 (458,788)
9,372,524

10
11
12
 New Challenges
• In Unit 3, we were having only 14784 spindles of Compact Machines (i.e. Total 14 Compact machines in Unit 3).
In last year the compact spindles increased from 14784 to 25296 compact spindles (i.e. 23 compact machines).
There is 71.1 % increase in Compact spindles.
Moreover due to more demand of Compact Hosiery yarn from style we are producing 285 bags of Hosiery yarn and main
portion of this is Compact Hosiery yarn .
As we know that in compact hosiery yarn , even slight variation is visible and can be a cause of customer complaint, so we have
to carry out extensive cleaning of mesh aprons and bottom steel rollers. All production staff including supervisors /
workers have to remain vigilant so that any fluff/dust accumulated on mesh apron or bottom steel roller should be
immediately removed . Every Compact machine is being cleaned thrice a month by air pressure to ensure maximum
cleaning of mesh aprons. Work load on production workers has increased . Since machines are changed from non-compact
to compact system the number of doffs have increased due to increased OPS. Although Count is a little bit on finer side but
on non-compact machines there is no issue of mesh apron cleaning and Bottom steel rollers lapping.
We are producing ‘3’ type of cottons for preparing Compact yarn on these 23 compact machines in Unit 3
i.e. Pak Cotton , CF Cotton and SP blend (for 60s Cpt) . All ‘3’ type of cottons require different Humidity levels,
e.g. CF Cotton requires low RH like 50 % and Pak Cotton requires almost 60% RH. When we increase RH% to 60% to improve
working of Pak Cotton, there is excessive lapping on CF Compact machines and when we decrease RH to 50% RH there is
excessive breakage on Pak Cotton Compact machines.
After every 2 hrs all compact machines are checked and 100 % checking of all spindles with torch is done/ensured by
production staff.
One year back we were running 5-6 counts in Unit 3, but at the moment we are running 11-12 counts in Unit 3.
In addition to this, there is addition of 912 Spindles also so the total spindles increased from 34656 to 35568.

13
 Department wise Store Inventory
for July-2017 is as under
Cost Center Amount (Rs.) Share %age Remarks

Blow Room 1,893,387.97 1.52  

Card Wire,
Card 32,709,175.90 26.32 Stationary Flat

Comber 8,385,614.80 6.75  

D/Simplex 6,175,096.48 4.97  

 Spindle Bolster ,
Ring 31,743,017.03 25.54 Titan Steel Rings

Roller Covering 5,250,014.14 4.22  

Auto Conner 10,103,788.04 8.13  

Bailing Press 155,086.35 0.12  

Doubling 1,101,651.62 0.89  

Electric 13,715,287.54 11.04  

Workshop 130,570.17 0.11  

Air Conditioning 1,638,845.68 1.32  

Laboratory 460,853.00 0.37  

Oil & Lubricant 703,355.98 0.57  

14
General & Stationary 10,112,354.80 8.14  
TOTAL 124,278,099 100  
       
Store Inventory of Unit 3 & 5 is high and we are working to control it .
Following reasons contributed to increased Inventory
• Duplicate codes for one item. Sometime item is present in store but due to multiple codes for one item the status
is shown Nil .
• Due to wrong codes items of one department are lying in other department .
In this month we have pointed out the items and provided list to Store Incharge for rectification .
• Shifting of Maximum Demands from local to imported items, also resulted in drastic increase in Inventory.
In Most cases imported items are 2.5 ~3 times costly as compared to local items . Since we cannot open LC
every month so have to keep stock for 6-8 months.
• Previously some delays in LC,S of card wire and Aprons/cots, due to cost comparisons of different sources, have
forced us to demand at once and then try to use items slowly keeping in view monthly budget and to break
department in 3 to 4 portions for decreasing LC amount in future demands.
• Spindle Bolsters are bought since life of spindle bolster in Unit 3 is almost 16 years and we installed one machine
and slowly using new to get maximum life of running bolsters. Moreover there was manufacturing problem in unit 5
bolsters and these are also being used slowly.
• Titan Steel Rings have been imported and 1-2 mcs/month are being installed as life of running steel rings has been
completed.
• Spare parts of Ring K-44 and G-32 are very costly, we have 30,000 spindles of ‘5’ different type of compacts
i.e. EST2, China Cpt, EST2.5, EST 3 and Rieter K44, so have to keep spare mechanical/Electric parts of Each type.
• We have ‘5’ different type of Auto Cone mcs i.e. Murata 7V ,Murata 21C ,Schlafhorst 338, Savio Polar, Savio Pulsar,
equipped with different types of splicers including Aqua splicers. Every machine has different Inverters and
Electrical/Mechanical Parts.
• We are working on Inventory and hopefully in next 6-8 months, there will be a significant decrease in Inventory.
An efficient processing of LC,S without delay will be Very helpful for us to maintain minimum inventory levels.15
 POWER CONSUMPTION UNIT-3 & 5
WAPDA UNIT-3 WAPDA UNIT-5 POWER HOUSE TOTAL
KWH KWH GENRATION
Share %age
WAPDA
Month Total Total TOTAL
Off Peak Peak Off Peak Peak Gas Diesel (Wapda Month WAPDA GAS Diesel
+ Gas+Diesel)
Jan 17 831480 161000 992480 1151600 237520 1389120 2381600 3718332 12736 6112668 Jan 17 38.96 60.83 0.21
Feb 17 449800 93440 543240 534560 102560 637120 1180360 4338320 4178 5522858 Feb 17 21.37 78.55 0.08
Mar 17 364880 70000 434880 0 0 0 434880 5661389 3254 6099523 Mar 17 7.13 92.82 0.05
Apr 17 191880 28720 220600 785360 165000 950360 1170960 4889458 10155 6070573 Apr 17 19.29 80.54 0.17
May 17 0 0 0 971520 170080 1141600 1141600 4889456 98997 6130053 May 17 18.62 79.76 1.61
Jun 17 0 0 0 181520 0 181520 181520 5809043 27799 6018362 Jun 17 3.02 96.52 0.46
Jul 17 288640 59600 348240 1062560 194640 1257200 1605440 4456032 13578 6075050 Jul 17 26.43 73.35 0.22
Aug 17                     Aug 17      
Sept 17                     Sept 17      
Oct 17                     Oct 17      
Nov 17                     Nov 17      
Dec 17                     Dec 17      

16