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Presented By:
Group : 3 Ayushi Garg (2011052) Gagan Bhatia (2011073) Harleena Bhela (2011087) Sheetal Saxena (2011255)
Presented to:
Prof. Manimay Ghosh
INTRODUCTION
Established in 1996 ,expanded in fully automated plant in 2006. Use of the high quality material & machinery. Provide range of yarns to the customers in different sizes and thickness Engaged in the manufacturing and supply of Cotton yarn, Open end yarn and Ginned cotton yarn. 2 operational plantsa)Labor intensive plant employing 350 workers established in 1996 b)Fully-automated plant employing 50 workers established in 2006. Average Daily production-12 tonnes/day 90% production exported to Brazil, Australia ,etc. The costing of the yarn is based on:
1. 2. 3. 4. Raw material usage Electricity Unit usage Maintenance Cost Wages\Salary
OPERATIONS
Continuous production. Product layout: Machines set according to the sequence of operations. Fixed-time Model. Make to order model.
Labor Division
3 Labor shifts a)7am-3pm b)3pm-11pm c)11pm-7am Division of Labor-based on the nature of work 1.Contractual-Packaging 2.Permanent:Engineering,maintenance,HR, administration Wages paid on daily basis.
Quality parameters
Color
Primarily determined by conditions of temperature and/or humidity, cotton lint exposure to sunlight, and cotton varieties. The color of cotton ranges from white to yellowish and is classed into the groups "White", "Light Spotted", "Spotted Tinged" and "Yellow Stained", in descending order of quality
Length
Weather, nutrient deficiencies, as well as excessive cleaning and/or drying at the gin may also affect the fiber length.
Uniformity
Length uniformity is the ratio between the mean length and the upper half mean length of the cotton fibers within a sample
Strength
The fiber strength measurement is made by clamping and breaking a bundle of fibers from the same beards of cotton that are used for measuring fiber length. Results are reported in terms of grams per tex (tex unit =weight in grams of 1,000 meters of fiber). It expresses the force required to break a bundle of fibers one tex unit in size. Fiber strength is largely determined by variety.
LOOSENING
FILTERING Loosened cotton is filtered to remove any impurities. The impurities are collected in a separate dump box. The cleaned cotton is moved ahead in the process for conversion into finished material.
STORAGE & BUFFER The cleaned cotton is moved through pipelines to the storage area. The cotton is further moved through these boxes to the next step of process. In case of shortage of material there is a buffer stock which is stored in the lower half of these boxes so that process doesnt comes to a haul.
5.Auto Care sliber it is tested again in After being converted into single Section lab. 360 machines are placed to complete this process. Finally the sliber is rolled in the form of yarn. 1m of the cotton sliber = 100m yarn Uniform thickness The rolled yarns are steamed for 2 hours in the Seiger machine.
6.PACKAGING
Packaging
Waste elimination
Approximately 5% waste. Waiting time minimized. Recycling of waste except at final step. Dedicated engineers and maintenance staff for every machine responsible in case of breakdown.
CONCLUSION
Pros Cost & time saving. Uniform Quality. High Utilization & low wastages. Dedicated Staff. Continuous production. Cons Strength of the cotton yarn from automated plant is less than that of the labor-intensive plant. Inventory is ordered 6 months in advance.
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