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.

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. so NGP time studys were done to compare it with sector specified standards to enhance production rate. The kanban implementations& its integration will benefit in reducing the lead time of the end fiber.

About project
Phase-I (completed)
Kanban implementation in the Ring winding section Phase-II (IV-semester).
FUTURE state of VSM. T he Needles Guide Pin(NGP)** time study to increase the efficiency of the production and help in elevating the production rate.. Kanban implementation in all other section and to integrate the same to reduce the lead time.
** source:- SITRA HAND MANUAL for textiles machineries. (Reprint 2006)page 223,para 2.5.1(NGP)

Cont
In this phase the entire project will be separated in to two separate areas.
NGP time study related to productivity and critical to capacity constrains. 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.

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.

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

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 0.25mm 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. Both manual NGP time study and automatic with help of NGP counters were used in NGP with atleast 3 trails by automatic method. The obtained results were get compared with the standard values in SITRA norms for evaluation of current process.

The non value items like twin peaks are get identified using NGP only as they have more time than standard time to be utilized.

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. KANBAN implementations in every selected sections Integrations of all KANBANS in entire plant
The other sections were huge lead time is used is selected for KANBAN implementations.

The kanban calculations and its feasibility study using demand-feasibility analysis.

The actual kanban implementations were get done in this as islands of KANBAN limited to particular sections demand alone. The entire firm level Demand facility analysis will ensure the smooth integrations of all KANABN installed in every sections of the industry

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, mean thickness of the guide pin, hole dia of machine etc which would then plotted ln graph as machine against thread values. After the graph is plotted the twin peak curve points are taken as odd points for improvement and get omitted.

NGP time study(cont.)

In the graph the slope values are compared in which the slope values of SITRA standards were done. 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.

NGP Graphs(RPM Vs TORSION)

800 780

760
740 720 700 680 A.TRAIL 1(YPM) M.TRAIL 1(YPM) M.TRAIL 2(YPM)

Torsion-A

Torsion-B

Torsion-C

Torsion-D

NGP study(manual)
The selected parameters are get noted down by careful calculation over the output and the machine settings. 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(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.

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

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

Lean tools used

Arena 10.0 Timer pro MS- visio i-grafx MS- 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. Reduced Lead time after kanban implementations from 620 mins to 600 mins. Future state map with suggested kaizens for further improvements after project.

References
Lean manufacturing principles for improving production Efficiency by Auston Marmduke kilpatrick., 1997,, Journal for Industrial Technology .Vol 13,No.3 june 1997. Lean for the Process industry byDr.kenneth w.stier .,2004 ., journal of Industrial technology, Vol .19. no 2 august 2004. Adapting Lean Manufacturing Principles to the Textile Industry by GOFORTH, KELLY ANN(pg203-364.)(IJ textile advancements Nov 2009). Lean principles for agile apparel production in integrated textiles company by Dr. Josef Oehmen (vol 23,jan 2006). internation journal for textile manufacturing) Lead-time reduction in large-scale machinery using maintaince plans- a case study by kirkor bozdogan, john deyst(vol 64,1999,pg326-334).international journal for industrial maintance. Kanban made simple by productivity press.ISBN-164-10-12-2954

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