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QUESTIONNAIRE FOR COSTS, OPERATIONAL PERFORMANCE AND YARN QUALITY:

INTER-MILL STUDY OF KEY FACTORS (October - December 2017)

Please read the following instructions before filling the worksheet:

1. This excel worksheet is designed to furnish the CPQ data of your mill for the period October to December 2017.

4. For any clarification on the questionnaire, please contact Mr.P.Subash, Senior Scientific Officer (09842233688) or Mr.J.Sreenivasan, Head - In-charge (09442121878) of Liaison and Consultation Division (0422-4215322)

33rd CPQ STUDY

Please enter the data in white space given in different tables.

2. Save the filled-in work sheet as file name 'CPQ33.xls' and send it as an e-mail attachment to lcsurvey@sitra.org.in (or) l&c@sitra.org.in on or before 15th January 2018.

3. Kindly send a DD / at par cheque / NEFT transaction for Rs 4720/- per mill (inclusive of 18% GST) towards participation fee on or before 15 th January 2018. For NEFT details click here.

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Mill information

Mill name

ISO Certified (Yes/No)

Installed capacity

Particulars Capacity

Ring spindlesOE rotorsDoubling spindlesTFO spindlesAuto winding drums

Particulars Ring spinning Rotor spinning

Avg. count (Ne)

Year of establishment

Composite (Yes/No)

Specify details about the certifications like ISO 9001, 14001, OHSAS 18001, 5S, TPM, etc.

Number of machines

No. of days worked during Oct. - Dec. 2017

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Mill staff who may be contacted for clarifications:Name

Designation

Mobile no.

E-mail

Name and address of the top executive to whom the study report as well as password is to be sent:

Name

Designation

Address

Pin code:

Phone no.: Land line

Mobile no.

E-mail id.

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1. Major counts particulars (October - December 2017)(Give for up to six major counts based on quantum of yarn produced)

Particulars Count 1 Count 2 Count 3 Count 4 Count 5 Count 6

Count (Ne)

Ring/OE yarn

Material

Blend proportion

Number of plies

Type of yarn

Compact (Yes/No)

Eli-twist (Yes/No)

Delivery Package

Export (Yes/No)

Twist

Special yarn 1

Special yarn 2

Count description

Others (slub, core spun etc.)

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2. Count-wise average yarn selling price and raw material cost (October - December 2017)(for the same six major counts as per item 1)

Particulars

Counts with specification #

Yarn production (kg)

A. Raw material cost

Avg. raw material cost (Rs/kg) Avg. clean raw material cost* (Rs/kg of yarn)

B. Ex- mill yarn selling price# (Rs/kg)‘*’ Weighted average cost of various components of raw material used including cost of waste added (if any), after taking into account price fetchable for waste and yarn realisation.

‘#’ Please deduct expenses like commissions, ocean freight, inland freight, L/C usance interest, sales tax, etc. from the gross price. In the case of export yarn, suitably adjust the ex-mill price for various incentives like DBK, DEPB, FMS, etc. and also for exchange fluctuations.

3. Count-wise yarn quality - Final package (October - December 2017)(for the same six major counts as per item 1)

Particulars

Counts

Count CV (%)

Strength CV (%)

CSP

Rkm (g/tex)Tensojet

Unevenness (%)

Thin (-50%)

Thick (+50%)

Neps (+200%)

Total

Hairiness index

Tensorapid/ Tensomaxx

Imperfections / 1000 m

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4. Yarn production, overall sale value and cost data (October - December 2017)

Parameters Ring yarn OE yarn Total

a) (i) Total yarn produced (kg)

(all the counts spun during the quarter) (ii) Estimated total yarn sale value for the total

yarn production (Rs) (based on ex-mill rate)

- quantity (kg)

- value (Rs)

- quantity (kg)

- value (Rs)

(iii) Net raw material cost [ b(i) - b(ii) ] (Rs)

c) Total spindle/rotor shifts worked -----

d) Total salaries and wages cost including all fringe benefits for 3 months (October - December 2017)

ParametersCategory

Workers (entire mill)

i) Avg. number of persons engaged per dayii) Avg. wage/salary (Rs)

/worker/day /staff/month

iii) Total cost to the company for 3 months (Rs)iv) Other wage expenses (contract, (Rs)

-------------------- conversion, overtime and training)v) Total (iii) + (iv) (Rs)

Total salaries and wages cost (Rs)

vi) On-roll strength (nos.)Note: For composite mills, provide up to post spinning section

b) (i) Total raw material consumed for the above yarn production

(ii) Salable wastes generated for the above yarn production

Staff (incl. admin, tech., clerical and HO)

(including all fringe benefits)

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e) Power cost details (for 3 months: October - December 2017)

i) Total consumption and cost: (including ring doubling/TFO/OE but excluding weaving/knitting/chemical processing)

Source Consumption (units) Cost (Rs) Cost / unit (Rs)

EB *

Captive- Diesel generator- HFO generator- Private power (exchange/gas power)-Others# 1. 2.3.

Total

*' Actual power consumed and cost including MD charge, service tax etc. before adjusting for WEG units (if any)'#' Specify like private hydel power, private bio-mass power, private coal power, solar power etc.

ii) a) In the case of Wind Electric Generator (WEG) power, if any amount is to be deducted for the period October - December 2017 from EB cost (excluding expenses like wheeling charges and annual maintenance charges) kindly specify (Rs)

b) Corresponding Wind Electric Generator (WEG) units for the above

c) Kindly mention the cost incurred by the mill for generating the above WEG units including transmission charge, wheeling charge, system operating charge, banking charges, etc. but excluding WEG interest and depreciation cost (Rs)

iii) Units consumed for the ring doubling / TFO processes

f) (i) (a) Total sanctioned demand from EB (in kVA)

(b) % of total power requirement it can meet

(ii) (a) Total genset capacity (in kVA)

(b) % of total power requirement it can meet

(iii) Total connected load (hp)

Note: For composite mills, provide up to post spinning sections for items (i) to (iii)

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g) Generator details

S. no.

Genset specifications Fuel

Make Year Type*

Overall total *' Specify HSD, furnace oil, natural oil, coal, biomass, etc.; '**' Including tax, transportation, etc.

No. of gensets (a)

Capacity/ generator (kVA) (b)

Total capacity (kVA)

(a) x (b)

Units/ litre (or) kg

Rate** Rs / litre (or)

kg

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5. Production particulars in ring frame / OE frame (October - December 2017)(for the same six major counts as per item 1)

Particulars

Counts

Make and model

Year of manufacture

Spindles/rotors per frame

Doffing system

Actual count (Ne)

Avg. prodn./spl. (or) rotor/8 hrs. (g)

Average spindle/rotor speed (rpm)

Actual tpi

Machine efficiency (%)

End breaks/100 spindle (or rotor) hrs.

Pneumafil waste / OE trash (%)

Lift x ring dia. (or rotor dia.# (mm))

Spindles (or rotors) per tenter

Spindle doffs / doffer

'#' If more lift, ring dia. and rotor dia are used in a particular count, kindly furnish the combination in which maximum no. of frames are running.

If compact yarn, mention the type of compacting system (Rieter, Suessen, Rocos, etc.)

Ring frames fitted with individual spindle monitoring system (Yes/No)

Ring frames fitted with roving stop motion system (Yes/No)Whether OE machine fitted with Auto-piecing (Yes / No)

Feed package weight (kg) [Roving bobbin content for ring yarn and sliver can content for OE yarn]

Delivery package weight (g) [cop content for ring yarn and cheese weight for OE yarn]

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6. Productivity particulars (October - December 2017)

Up to ring framesCone winding

Parameters Mill SITRA norms Mill

HOK* 12.0 Conventional cone winding 9.0

OHSAM* 1.65 Automatic cone winding 2.0

Overall prodn./spl./8 hrs. (g)* 110.0 '@' for tenters only

98.0 '*' adjusted to 40s count

98.0

'*' adj. to 40s - Kindly use the conversion factors corresponding to SITRA norms 2010

'#' Causes for the loss in spindle/rotor utilisation

S. no ParametersRing frame Open End

1) General cleaning

2) Routine maintenance

3) Electrical/mechnical repairs

4) Labour shortage

5) Power shortage

6) Lack of demand for yarn

7) Raw material shortage

8) Others

i)

ii)

iii)

iv)

Total loss in utilisation (%)

Whether mill is running 3 shifts a day? (Yes/No)

If no, specify the number of shifts in a day

I II IIIShift duration (hrs):

HOK * @

SITRA norms

Overall spindle utilisation (%)#

Overall rotor utilisation (%)#

% loss - Average of October to December 2017

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7. Count-wise production particulars in post spinning (for any six major counts during October - December 2017)

i) TFO twisters

ParticularsCount#

Local/ Export

Compact yarn (yes/no)

Make

Model

Year of manufacture

Spindles per frame

Feed package weight (g)

Delivery package weight (g)

Breaks/100 spl. hrs

Spindle speed (rpm)

Tpi

Machine efficiency (%)

Prodn./spl./8 hrs (g)

Spindles per tenter‘#’ For count description ---------> Click here

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ii) Automatic cone winding machines

ParticularsCount#

Local/ Export

Compact yarn (yes/no)

Make

Model

Year of manfacture

Type of feed*

Clearer make

Clearer model

Feed cop weight (g)

Delivery package weight (kg)

Average winding-on speed (mpm)

Drums per tenter

Machine efficiency (%)

Prodn./tenter/8 hrs. (kg)

Total clearer cuts/ 1 lakh metres

Total yarn joints/ 1 lakh metres

Cop rejection (%)

Repeater cycles (%)

Red light faults (%)‘#’ For count description --------->‘*’ RM - Round magazine / CBF- Continuous Bobbin Feed / LW - Link Winder

Click here

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8. Product diversification particulars for October - December 2017

S. no Type of yarn

1) Export

2) Combed

3) Hosiery

4) Doubled

Ring doubling

TFO

Eli-twist

5) Compact

6) Chemical processed

7) Gassed

8)

a) 100% cotton yarn

b)

c)

Total (a + b + c) 100 100

Note: Total of all the 8 items need not tally to 100.

9. Specify all the counts spun during October - December 2017

Ring spinning

OE spinning

Note: Different varities of yarns in a given count must be considered as separate counts. Example: 40s warp, 40s weft, 40s CH, 40s P, 40s P/V, 40s P/C, etc.

As % of total ring yarn

production

As % of total OE yarn

production

Others (specify)

100% non-cotton yarn (like P, P/V, Acrylic, VSF, etc.)

Cotton blended yarn (like P/C, P/V-C, V/C, A/C, etc.)

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10. Yarn realisation and raw material quality(for the same six major counts as per item 1); (Average of October - December 2017)

i) Yarn realisation and wastes

Particulars

Card waste (%)

Comber noil (%)

Hard waste (%)*

Sweep waste (%)*

Other wastes (please specify, if any)

Total 100 100 100 100 100 100

Note: Please furnish the waste percentage based on raw material consumption

'*' Up to post spinning

Yarn realisation$ (%)

Blow room waste (%) (including gutter/filter waste)

Invisible loss (%)#

$' For polyester cotton blends, cotton component realisation should be considered in the overall yarn realisation#' For gain, prefix the value with '+' sign

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ii) Average raw material quality

Particulars

Fibre properties - Cotton

Local/ Imported/ Both

ICC mode:

- 2.5% span length (mm)

- Uniformity ratio (%)

- Fibre strength (g/tex)

HVI mode:

- Upper Half Mean Length (mm)

- Uniformity index (%)

- Fibre strength (g/tex)

Fibre fineness (µg/inch)

Trash (%)

Neps/g

Short fibre content (n) (%)Synthetic fibre properties - Polyester

Cut length (mm)

Denier

Tensile strength (g/d)Synthetic fibre properties - Regenerated cellulose fibres

Name of the fibre

Cut length (mm)

Denier

Tensile strength (g/d)Synthetic fibre properties - Acrylic

Cut length (mm)

Denier

Tensile strength (g/d)

Name(s) of cotton varieties used and % age of each variety in the mixing

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11. Conversion cost - count-wiseKindly furnish the following cost parameters that prevailed during October - December 2017

(Cost : Rs/kg of yarn)

Parameters

Yarn selling price (Ex-mill) [a]

Avg. clean raw material cost [b]

Conversion cost

(i) Wages

(ii) Salaries

(iii) Power

(iv) Consumable stores

(v) Packing materials

(vi) Administrative overheads

(vii) Interest cost

(viii) Depreciation cost

Total conversion cost [c]

Profit/loss [d]

Notes (i) In case, item-wise conversion cost is not readily available, kindly furnish the total conversion cost (c).(ii) Please ensure that a = b + c + d.(iii) For SITRA method of estimation of count-wise conversion cost

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ParametersTotal yarn production (ring + OE) (kg)Total estimated yarn sale value (Rs)Net raw material cost (Rs)Total salaries and wages cost (Rs)Total power cost (Rs)No. of working days

Overall utilisation (%)Raw material cost- Rs/kg- % of sales- Rs/spindle/yearSalaries and wages cost- % of sales- Rs/spindle/yearPower cost- % of sales- Rs/spindle/year

Sale value Sale value (Rs/spindle/year)Average selling price/kg of yarn (Rs)

Contribution- Rs/kg of yarn- % of sales- Rs/spindle/year

Installed capacity [Spindles + (rotors x5)]Total spindle/rotor shifts [Spindles + (rotors x5)]

Your mill figure

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Details of count description and its abbreviations

Count description Abbreviation Count description

Rotor spun yarn OE Carded hosieryCombed Combed hosiery

100% polyester P Semi-combed100% viscose V Semi-combed hosiery100% acrylic A Organic cotton

Export

Double ply 2/ Polyester / cotton3 ply 3/ Polyester / viscose4 ply 4/ Polyester / Modal5 ply 5/ Cotton / viscose6 ply 6/ Cotton / acrylic

Polyester / viscose / cottonPolyester / viscose / acrylic

Compact Comp. Gassed Melange Mel. MercerisedOrganic Org. BleachedNeppy Neppy DyedCore spun Core spunSlub Slub

Example: 40s CH-EX, 50s C-COMP, 2/60s C-DHPR, 2/100s C-G-EX, 40s PV-HT

To continue entering the data, click here for "Data Entry Sheet"

Abbreviation Count description Abbreviation

KH High twist HTC Super High Tenacity SHTCH 'S' twist (Single yarn) STSC Eli-twist ETSCH Parallel yarn PLLORGEX

P/C Single Hank Plain Reel SHPRP/V Single hank cross reel SHCRP/M Double hank plain reel DHPRC/V Double hank cross reel DHCRC/A Four hank plain reel FHPRP/V/C Four hank cross reel FHCRP/V/A Five hank plain reel 5HPR

Five hank cross reel 5HCR

G Metric count NmMer French count NfB Tex count dTexD

Example: 40s CH-EX, 50s C-COMP, 2/60s C-DHPR, 2/100s C-G-EX, 40s PV-HT

SITRA method of estimation of item-wise conversion cost per kg of yarn

S No. Cost item

i) Power cost

ii) Wages cost

iii) Salaries cost

iv) Stores cost

v) Packing materials cost

vi) Overheads

vii) Depreciation cost

viii) Interest cost- Working capital- Term loans

'+' Tenters and doffers including mixing attendants'*' Maintenance operatives, materials handlers, jobbers, roller coverers, etc.'**' Watch and ward, drivers, peons, humidification plant operators, electricians, etc.To continue entering the data, click here or go back to "Data Entry Sheet"

SITRA method of estimation of item-wise conversion cost per kg of yarn

Count description

Spin plan and machine wise power consumptionFixed power like humidification, lighting etc. of the basis of spindle shifts.

of spin plan & work assignments. "Ancillaryoperatives"* allocation on the basis of respectivemachine shifts. Non-production** operatives - spindle shifts basis.

Spindle shifts.

Spindle shifts.

Cost per kg of yarn.

Spindle shifts.

Spindle shifts.

Sales turnoverSpindle shifts.

'+' Tenters and doffers including mixing attendants'*' Maintenance operatives, materials handlers, jobbers, roller coverers, etc.'**' Watch and ward, drivers, peons, humidification plant operators, electricians, etc.

Production operatives+ requirement on the basis

To continue entering the data, click here or go back to "Data Entry Sheet"

Particualars Details

Company name The South India Textile Research AssociationAddress Post Box No.3205, 13/37

Civil Aerodrome PostCoimbatore - 641 0140422-4215333

Phone no. 0422-4215333Fax no. 0422-2571896E-mail id.

GST detailGST no. 33AAAAT3433H1ZTARN no AA3303170143820

PAN no. AAAAT3433HTAN no. CMBT03065GService tax registration no. AAAAT3433H ST004

Bank name HDFC Bank Ltd.Bank address Kalapatty Main Road

Civil Aerodrome PostCoimbatore - 641 014.

Bank a/c. name The South India Textile Research AssociationBank a/c. no. 50100171403281Nature of a/c. Savings Bank Account (SB)RTGS code/IFSSwift code

accounts@sitra.org.in

HDFC0001068 HDFCINBBCHE