presentation on the monthly production report

7/29/2019 Presentation on the Monthly Production Report

1/17

Presentation on the monthly production report

Prepared by

Yarn Dyeing unit,

Akij Textile Mills Ltd

AKIJ Textile Mills Ltd.Golora, Manikgonj

We believe in continuous development


2/17

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 alsovery grateful to the honorable Executive Director, Mr. M.R. Jam il si rfor

his guidance, encouragement & for enriching us with his thoughtful

advice.


3/17

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


4/17

MONTHLY PRODUCTION & CONSUMPTION OF THE DYES &

CHEMICALS

Year Month Production (kg) Dyes (kg) Chemicals (kg) Remarks

2011 October 2,484 150.5 1,0572011 November 17,398 874 17,0572011 December 54,967 1,8537 31,7252012 January 47,458 1,6005 28,6452012 February 50,944 1,0689 25,2972012 March 47,910 1,7882 40,7682012 April 72,574 2,3942 39,6612012 May 91,444 2,9139 71,5332012 June 48,645 1,6901 25,0862012 July 67,802 1,9909 32,075

Total 501,626


5/17

MONTHLY PRODUCTION & CONSUMPTION OF THE DYES &

CHEMICALS

100

10,100

20,100

30,100

40,100

50,100

60,100

70,100

80,100

90,100

Production(Kg)

Dyes(Kg)

Chemicals(Kg)

Amount

inKg


6/17

TARGET PRODUCTION & LAST MONTHS ACHIEVEMENT: :

The report of the last months production, maximum machine capacity &

maximum production capacity is given below:

Maximum machine capacity = 7,500 kg per

day (approx.)

Maximum allowable capacity = 6,800 kg per day

(approx.)

Target production = 6,000 kg per

day (approx.)

Total production of Month ofJuly =67,802 kg

Daily production =67,802/29

=2,338 kg per day


7/17

REASONS FOR THE LACK OF PRODUCTION :

Shortage & size of order

Shortage of soft winding machine

Type of orderLack of consistency from the utility support (steam

pressure, electricity, quality of soft water & compressor)

Shortage of manpower

Shortage of hard winding machine


8/17

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 Buyer Quantity

26/6/12 Noor check 2,077 kg30/6/12 York Fashion 21,700 kg5/7/12 KFS 30 kg10/7/12 Adnan fabrics 577 kg10/7/12 Amin fabrics 2,307 kg10/7/12 Far east starling 623.5 kg10/7/12 Far east starling 466.7 kg12/7/12 Newage 2,822 kg12/7/12 Shagor Garments 467 kg15/7/12 FCE BD 56 kg16/7/12 Noor check 3,100 kg25/7/12 SIGNET 140 kg

24/7/12 Bonded fashion 1513 kg25/7/12 KFS 63 kg

1/8/12 Adnan textiles 1,300 kg2/8/12 NAZ knit wear 3,600 kg2/8/12 Bonded fashion 50 kg8/8/12 Unifill 414 kg


9/17

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 dyeingsection. The average machine speed is kept 1200m/min.

1200 X 120 X 60 X 24 X 1.09 X 0.85

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

840 X 40 X 2.204

= 2,5936 kg per day.

Where,

Machine speed = 1,200m/minWinding head = 120 pcs

Count of yarn = 40/1 (as for example)


10/17


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

The daily production (per machine) = -----------------------------------------------------------

-

840 X 40 X 2.204

= 1,100kg per day.Where,

Machine speed = 1,200m/min

Winding head = 60 pcs

Count of yarn = 40/1 (as for example)

The daily production (estimated) = 1,100 X 3= 3,300 kg

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.


11/17


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 windingin 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 bedelayed 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.


12/17

LACK OF CONSISTENCY FROM THE UTILITY

The support of electricity was improved then the last few months butthe 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 Utility problems Duration Total hours

4/7/12 Low pressure in the compressor 2.00 pm to 4.00 pm 2 hours4/7/12 Low steam pressure 3.05 pm to 4.00 pm 55 min4/7/12 Power failure 1.30 pm to 3.00 pm 1.5 hours7/7/12 Low steam pressure 2.00 pm to 2.15 pm 15 min7/7/12 Low steam pressure 3.15 pm to 3.45 pm 30 min7/7/12 Low steam pressure 5.00 pm to 5.20 pm 20 min8/7/12 Low steam pressure 1.30 pm to 3.00 pm 1.5 hours

14/7/12 Low steam pressure 6.45 am to 8.15 am 1.5 hours16/7/12 Low steam pressure 9.35 am to 11.00 am 1.5 hours17/7/12 Power failure 10.00 am to 11.55 am 2 hours17/7/12 Low pressure in the compressor 10.00 am to 1.20 am 3 hours 20 min17/7/12 Low steam pressure 2.00 pm to 3.30 pm 1.5 hours17/7/12 Low pressure in the compressor 2.00 pm to 5.00 pm 3 hours17/7/12 Low steam pressure 5.20 pm to 7.00 pm 2 hours 40 min17/7/12 Low pressure in the compressor 8.25 pm to 9.00 pm 35 min20/7/12 Power failure 9.20 pm to 10.00 pm 40 mins24/7/12 Low steam pressure 4.50 am to 5.50 am 1 hours28/7/12 Low steam pressure 2.00 pm to 3.00 pm 1 hours29/7/12 Power failure 5.40 am to 6.00 am 20 min

30/7/12 Power failure 9.00 pm to 9.22 pm 22 minTOTAL 32.6 hours


13/17

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

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

840 X 40 X 2.204

= 5071 kg per day

Where,

The winding speed = 550m/min

Winding head = 512 pcs

Count of the yarn = 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.


14/17

SHORTAGE OF MANPOWER

Department

No of

machines Designation

Current no of

employees( in 3shifts)

Required on of

employees( in 3shifts)

Total shortage

Dyeing floor 22 Operator 21 33 12Helper 22 42 20

Batch section 0 Operator 0 4 4Helper 18 24 6

Soft winding 2In charge 1 1 0

Supervisor 0 3 3Lineman / Operator 3 4 1

Helper 18 24 6Hydro & dryer 2 & 2 Operator 3 4 1

Helper 16 30 14

Hard winding 4In charge 0 1 1

Supervisor 0 3 3Lineman/Operator 4 4 0

Helper 41 50 9Packing 0

Supervisor 3 3 0Packing helper 15 30 15

Quality control 0Q.C. 3 4 1

Q.C. helper 8 12 4Laboratory

ATO 2 3 1Lab asst. 5 6 1

Lab helper 8 10 2TOTAL `191 295 104

These are the working personnel required in the production:


15/17

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.


16/17

SUGGESTION:

We propose a plannin g cel l 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.


17/17

presentation on the monthly production report

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