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.

PERFORM THE NGP TIME

STUDY IN SELECTED
SECTIONS

Both manual NGP time study and automatic with

help of NGP counters were used in NGP with atleast
3 trails by automatic method.

COMPARE/ANALYZE THE
NGP VALUES WITH SITRA
NORMS

The obtained results were get compared with the

standard values in SITRA norms for evaluation of
current process.

IDENTIFY THE NON VALUE

ADDED ACTIVITY IN
PRESENT OPERATIONS

The non value items like twin peaks are get

identified using NGP only as they have more time
than standard time to be utilized.

FORMULATE WITH NEW

METHODS AND TRAIL
-RUN

The double peak operations were get reduced

/eliminated to increase the production after Initial
TRAIL-RUN.

The parameters like RPM vs thread tension graphs

are plotted and its slope were taken as parameter of
NGP.
The various sections at which thread of at least
0.25mm dia is used is only selected for NGP .

IDENTIFICATIONS OF
PARAMETERS in NGP
IDENTIFICATION OF
SECTIONS FOR NGP

Project methodology-1

Select the sections

to introduce the
KANBAN

The other sections were huge lead time is

used is selected for KANBAN
implementations.

KANBAN feasibility
study&
CALCULATIONS.

The kanban calculations and its feasibility

study using demand-feasibility analysis.

KANBAN
implementations in
every selected
sections

The actual kanban implementations were get

done in this as islands of KANBAN limited to
particular sections demand alone.

Integrations of all
KANBANS in entire
plant

The entire firm level Demand facility

analysis will ensure the smooth integrations
of all KANABN installed in every sections of
the industry

Project methodology-2

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
A.TRAIL 1(YPM)
M.TRAIL 1(YPM)
M.TRAIL 2(YPM)

740
720
700
680
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

THANK
YOU