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Presentation On The Monthly Production Report

The document is a monthly production report from the Yarn Dyeing unit of Akij Textile Mills Ltd. It summarizes the unit's production and consumption of dyes and chemicals for the past months. It identifies reasons for not meeting production targets such as shortage of orders, soft and hard winding machines, manpower, and inconsistent utility support. It outlines future plans to achieve targets such as getting larger orders, adding new machines, improving support from other departments, and ensuring steady utility supply. It suggests establishing a planning cell to improve coordination across departments.

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Komol Kabir
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2K views

Presentation On The Monthly Production Report

The document is a monthly production report from the Yarn Dyeing unit of Akij Textile Mills Ltd. It summarizes the unit's production and consumption of dyes and chemicals for the past months. It identifies reasons for not meeting production targets such as shortage of orders, soft and hard winding machines, manpower, and inconsistent utility support. It outlines future plans to achieve targets such as getting larger orders, adding new machines, improving support from other departments, and ensuring steady utility supply. It suggests establishing a planning cell to improve coordination across departments.

Uploaded by

Komol Kabir
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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AKIJ Textile Mills Ltd.

Golora, Manikgonj
We believe in continuous development

Presentation on the monthly production report

Prepared by Yarn Dyeing unit, Akij Textile Mills Ltd

ACKNOWLEDGEMENT:

First of all, we would like to thank the almighty ALLAH for blessing us & giving us strength to work properly. We would like to express my sincere gratitude & appreciation to the honorable Director, Mr. Sheikh Jamil Uddin sir. My heartfelt thanks to him for allowing me to present the monthly production report. we are also very grateful to the honorable Executive Director, Mr. M.R. Jamil sir for his guidance, encouragement & for enriching us with his thoughtful advice.

CONTENTS

Monthly production & consumption of the Dyes & chemicals


Last months achievement & the target production Reasons for the lack of production Future plans to achieve the goal Suggestion

MONTHLY PRODUCTION & CONSUMPTION OF THE DYES & CHEMICALS

Year

Month

Production (kg)

Dyes (kg)

Chemicals (kg)

Remarks

2011 2011 2011 2012 2012 2012 2012 2012 2012 2012

October November December January February March April May June July Total

2,484 17,398 54,967 47,458 50,944 47,910 72,574 91,444 48,645 67,802 501,626

150.5 874 1,8537 1,6005 1,0689 1,7882 2,3942 2,9139 1,6901 1,9909

1,057 17,057 31,725 28,645 25,297 40,768 39,661 71,533 25,086 32,075

MONTHLY PRODUCTION & CONSUMPTION OF THE DYES & CHEMICALS


90,100 80,100

70,100
60,100 50,100 40,100 30,100 20,100 10,100 Production(Kg) Dyes(Kg) Chemicals(Kg)

Amount in Kg

100

TARGET PRODUCTION & LAST MONTHS ACHIEVEMENT: :

The report of the last months production, maximum machine capacity & maximum production capacity is given below:

Maximum machine capacity day (approx.) Maximum allowable capacity (approx.) Target production day (approx.) Total production of Month of July Daily production

= 7,500 kg per

= 6,800 kg per day


= 6,000 kg per

=67,802 kg =67,802/29 =2,338 kg per day

REASONS FOR THE LACK OF PRODUCTION :

Shortage & size of order Shortage of soft winding machine Type of order Lack of consistency from the utility support (steam pressure, electricity, quality of soft water & compressor) Shortage of manpower Shortage of hard winding machine

SHORTAGE & SIZE OF ORDER :


Most of our buyers usually submit orders with shorter quantities. Here is a list of the orders that we have processed in the month of July.
Date of order
26/6/12 30/6/12 5/7/12 10/7/12 10/7/12 10/7/12 10/7/12 12/7/12 12/7/12 15/7/12 16/7/12 25/7/12 24/7/12 25/7/12 1/8/12 2/8/12 2/8/12 8/8/12

Buyer
Noor check York Fashion KFS Adnan fabrics Amin fabrics Far east starling Far east starling Newage Shagor Garments FCE BD Noor check SIGNET Bonded fashion KFS Adnan textiles NAZ knit wear Bonded fashion Unifill

Quantity
2,077 kg 21,700 kg 30 kg 577 kg 2,307 kg 623.5 kg 466.7 kg 2,822 kg 467 kg 56 kg 3,100 kg 140 kg 1513 kg 63 kg 1,300 kg 3,600 kg 50 kg 414 kg

SHORTAGE OF SOFT WINDING MACHINE


: This is one of the major reasons for the lack of production. We currently have soft winding machine (SSM) comprises 120 winding head in the yarn dyeing section. The average machine speed is kept 1200m/min.

So, the daily production -------

1200 X 120 X 60 X 24 X 1.09 X 0.85 = ----------------------------------------------------840 X 40 X 2.204 = 2,5936 kg per day.

Where, Machine speed Winding head Count of yarn

= 1,200m/min = 120 pcs = 40/1 (as for example)

SHORTAGE OF SOFT WINDING MACHINE


We have 3 soft winding machines (Preci-FX) in the spinning section, per machine is capable of producing 1100 kg of soft packages. 1200 X 60 X 60 X 24 X 1.09 X 0.72 = ----------------------------------------------------------840 X 40 X 2.204 = 1,100kg per day. Where, Machine speed Winding head Count of yarn The daily production (estimated) = 1,200m/min = 60 pcs = 40/1 (as for example) = 1,100 X 3 = 3,300 kg

The daily production (per machine) -

So, Total production of the soft package = 3,300 + 2,600 kg = 5,900 kg (approximately) This is the maximum estimated capacity of soft packages for the yarn count of 40/1.

SHORTAGE OF SOFT WINDING MACHINE


During recent past we observed serious shortage of soft winding packages due to satisfactory order received from outside parties, Where we have to depend only on SSM soft winding m/cs. We tried to manipulated with cone to soft winding in Preci-FX of spinning unit & we found serious problems which are as follows: Long carrying/handling of soft package. M/cs are occupied for cone to cone winding which causes shortfall of cop to cone winding in the spinning unit. Quality of soft package are not satisfactory.

To achieve the goal of producing 6 tons per day, the availability of the soft package is an essential. The batch scheduling, machine programs & most of all the production will be delayed if the soft packages are not prepared in time. Secondly, sometimes we do not get proper support from the spinning section. Especially in case for the order with a shorter lead time, the spinning department usually transfers the hard packages directly to the dyeing section.

LACK OF CONSISTENCY FROM THE UTILITY


The support of electricity was improved then the last few months but the steam pressure was inconsistent throughout. This has increases the dyeing period & reduced the production rate. Here is a log status of the last months utility problems
Date 4/7/12 4/7/12 4/7/12 7/7/12 7/7/12 7/7/12 8/7/12 Utility problems Low pressure in the compressor Low steam pressure Power failure Low steam pressure Low steam pressure Low steam pressure Low steam pressure Duration 2.00 pm to 4.00 pm 3.05 pm to 4.00 pm 1.30 pm to 3.00 pm 2.00 pm to 2.15 pm 3.15 pm to 3.45 pm 5.00 pm to 5.20 pm 1.30 pm to 3.00 pm Total hours 2 hours 55 min 1.5 hours 15 min 30 min 20 min 1.5 hours

14/7/12
16/7/12 17/7/12 17/7/12 17/7/12 17/7/12 17/7/12 17/7/12 20/7/12 24/7/12 28/7/12 29/7/12 30/7/12

Low steam pressure


Low steam pressure Power failure Low pressure in the compressor Low steam pressure Low pressure in the compressor Low steam pressure Low pressure in the compressor Power failure Low steam pressure Low steam pressure Power failure Power failure

6.45 am to 8.15 am
9.35 am to 11.00 am 10.00 am to 11.55 am 10.00 am to 1.20 am 2.00 pm to 3.30 pm 2.00 pm to 5.00 pm 5.20 pm to 7.00 pm 8.25 pm to 9.00 pm 9.20 pm to 10.00 pm 4.50 am to 5.50 am 2.00 pm to 3.00 pm 5.40 am to 6.00 am 9.00 pm to 9.22 pm

1.5 hours
1.5 hours 2 hours 3 hours 20 min 1.5 hours 3 hours 2 hours 40 min 35 min 40 mins 1 hours 1 hours 20 min 22 min

TOTAL

32.6 hours

SHORTAGE OF HARD WINDING MACHINE


We currently have hard winding machine (CW8-W) comprises 512 winding head. 550 X 512 X 60 X 24 X 1.09 X 0.85 ---------------------------------------------------------840 X 40 X 2.204 5071 kg per day

So, the daily production

= Where, The winding speed Winding head Count of the yarn

=
= =

550m/min
512 pcs 40/1 (as for example)

This is the maximum production capacity of hard winding machine for the yarn count of 40/1. From the above result, it is clear that, we are almost 1.5 tons shorter then the required hard winding capacity. Because for each day production we will be 1.5 tons shorter everyday & the load to clear previous order will be increased gradually. Thus we will be unable to maintain the lead time.

SHORTAGE OF MANPOWER
These are the working personnel required in the production:
Department No of machines 22 0 Designation Operator Helper Operator Helper In charge Supervisor Lineman / Operator Helper Operator Helper In charge Supervisor Lineman/Operator Helper Supervisor Packing helper Q.C. Q.C. helper ATO Lab asst. Lab helper Current no of employees( in 3 shifts) 21 22 0 18 1 0 3 18 3 16 0 0 4 41 3 15 3 8 2 5 8 Required on of employees( in 3 shifts) 33 42 4 24 1 3 4 24 4 30 1 3 4 50 3 30 4 12 3 6 10 Total shortage 12 20 4 6 0 3 1 6 1 14 1 3 0 9 0 15 1 4 1 1 2

Dyeing floor Batch section

Soft winding

Hydro & dryer

2&2

Hard winding

Packing Quality control

0 0

Laboratory

TOTAL

`191

295

104

FUTURE PLANS
These are the future plans which will help us to achieve the target production. Larger order quantity: Without larger order the target production cant be achieved. So, the marketing team has to give more effort to get orders of larger quantities. New soft & hard winding machines: We need at least 2 new soft winding & 2 new hard winding machines to fulfill our requirement. Support from the spinning section: The spinning department has to support us with the soft packages. They have to ensure us to give at least 3 tons of soft packages per day. Proper support from the utility department: We need uninterrupted power supply, proper compressor & steam pressure to maintain the in time production. Also the quality of the water has to be good to prevent faulty dyeing.

SUGGESTION:
We propose a planning cell or MIS department, whose job will be to communicate with the marketing department, to look after a buyers order from the start to end & to improve correlation between Spinning ,Dyeing & Weaving department.

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