An ALFA Presentation

Presented by B Ramalingam

Executive Committee Member

• A registered society of the alumni of leather technology

program of University of Madras/Anna University

• Established in 1987, the association has over 1000 members,

who meet more than 60% of the requirement of trained

professionals

are

create

nurture

Professionals for leather industry

work for

Prosperity of leather

• To act as a Global resource hub for information on the world wide consumer

market for leather and leather based products like foot wear, travel ware, party

ware etc. and non-leather supplements to leather.

• To disseminate information on products and technology among technologists,

artisans, designers and retailers through an IT enabled mode.

• To act as a beacon for budding technologists, artisans and designers towards

guiding them to successful career in their chosen field of activity.

• To address societal issues like safe environment, animal care, safety at work and

safe & proper disposal of used leather products & non-leather foot wear.

• To act as an extended arm of the ALMA MATER (viz. A.C.Tech., C.L.R.I. ,Anna

University) in propagating the developments & achievements to the stake holders,

government & society.

• To promote fellowship among the alumni base of the AC Tech Leather and

Footwear technologists and promote professionalism in leather education,

research, industry and market and trade.

• ALFA identified a need to disseminate knowledge gained by its

members through experience, analysis, case studies, discussions

etc. on current areas of need.

• The need to increase tannery efficiency needs no elaboration.

The mechanism to be adopted needs to be discussed,

deliberated and options available implemented at the earliest

Need of improvement measures for Tanneries Efficiency.

Discussion Areas considered for Tanneries Improvement

Measures.

Traditional methods & its Pitfalls in the discussion areas.

Scope for Improvements from traditional methods.

Tools for Improvements.

Benefits of Change

• In a fast changing world we

need to keep evolving

continuously to remain

competitive or else will remain

static/sluggish.

• Need to make our workplace

better for employees and

other stakeholders, Also to

attract and retain talents.

• To grow and to improve

performance

Tannery automation

Quality Systems

Human Resource

Management

Process & Production

Machinery & Layout

Information Management

Current Scenario

Managed by

owners/proprietors

Technical and commercial

management based on

experience

Infusion of fresh talent at all

levels not planned

Lack of clarity on career

plan for employees

Pitfalls

• Failure to attract young talent

• Loss of talented managers and skilled workers to other sectors (IT, Chemicals, Automobiles, Electronics)

• Over dependence on individuals

• Lack of training and multiskilling

• Lack of Career plan and motivation results in inferior output

• Lack of pride due to unprofessional HR practices in poorly managed companies

Human Resource Management

• Professional HR manager

• Recruitment process

• Training and job rotation

system

• Career planning process

• Performance

Management system

• Conduct audits like

OSHAS, SA 8000, etc.

• Define a HR process

• Recruitment

• Job definition (KRA’s)

• Evaluation and

measurement

• Promotion

• Training and multiskilling

• Organization chart

Human Resource Management

• Setting up a system for HR prepares company for growth and

expansion

• Professional image to suppliers and buyers

• Productivity from individuals will be superior.

• Absence of favoritism/nepotism

Human Resource Management

Current Scenario

Lack of integrated

management in process/

production

Absence of overall quality

enforcement across

production

Lack of transparent setup

Quality systems are not part

of operations

Existence of Individual

dependency of quality

systems

Pitfalls

• Cost of poor quality not

captured.

• Traceability is difficult

• Scaling of Samples to bulk

• Selection in R/M issue, Semi-

finished vs Finished

• Area gain/loss

• Rejections, rework and causes

• Optimal use of resources not

achieved

• Machinery maintenance

• Machinery parts usage

Quality Systems

Quality circles - Workers,

supervisors, managers

5 S & Six Sigma

ISO 9001/14001/Kaisen

Business excellence model

/ Malcolm Baldridge

model

Measure at the source of

data

Analyze with previous time

period

Compare with

benchmarked industry

data

Execute improvement

measures

Repeat the process again

Quality Systems

• Consume right material at right quantity for production

• Reduce wastage, pilferage and obsolescence of materials

• Reduce rejection and rework

• Process optimization for higher yield

• Instituting production processes at every stage

• Culture of learning organization

Quality Systems

EFFECTIVE PRODUCTION/PROCESS

ENERGY SAVING

MACHINERY & Layout

LABOUR SAVING

• Average tannery making

upper leathers from skins

• 130 sqft per man day

• Benchmarked tannery

making shoe upper

leathers from skins

• 180 sqft per man day

• Lack of process

optimization/energy

saving /labor saving

measures

• Poor infrastructure

facilities

• Poor productivity labors

• Sub optimal efficiency

level

• Wet Blue store

• Pneumatic wet blue sorting table

• Use of pallets and fork lifts

• Use rack system to optimize labor and space

• Shaving

• Mechanical shaving dust removal and compact

• Mechanized reloading of shaving blades

• Dye house

• Mechanical loading of leather from mezzanine

• Mechanize unloading trolleys

• Use aqua mix as much as possible

• Buffing

• Mechanical briquetting of buffing dust

• Finishing

• Auto chemical dispensing system in pigment room

• Water scrubbers to clean auto spray chimneys

• Measuring

• Automatic stamping arrangement

• Above all Operator themselves should handle the leather in

certain operations. Do not provide helpers in operations like

Shaving, Setting, Buffing or in Assortment

• Plan with high-discharge/high-exhaustive provisions in

processes.

• Clearly earmark operation areas

• Eliminate encroachment of movement areas

• One machine's output to become input of next

• Storage area should be earmarked clearly

• Aqua mix for automating water consumption

• Monitor and control water use

• Improve process efficiency

Labor saving measures

• Floor level , wind flow, ventilation, lighting profiling of building

• Dye house to be on higher level

• Buffing unit to be placed to avoid dust blowing in

• Use sun light wherever possible for illumination

• Separate channels for collecting different effluents

• Material handling equipments

• Mechanized trolleys

• Electronic weighing systems

• Transportation from stores to dosing systems

• Separate product development cell

• Each machine to be owned by operator

Labor saving measures

• Use recyclable materials

• Encourage natural illumination

• LED/CFL/MHL lightings, use reflective fittings

• Energy efficient motors

• Soft starters or invertors type of equipment

• User screw compressors instead of reciprocating compressors

• Benchmarked Tannery

• Rs 4.10 per sqft maintenance and

energy costs

• Spares and Consumables Rs 1.93 per

sqft

• Fuel and Power Rs 2.04 per sqft

• Water – Rs 0.13 per sqft

Energy saving measures

• Maintain and Use auto mode in auto spray

• Use modern drums using less energy and high exhaustion

• Use timer and temperature controls in machines

• Recycle steam condensate

• All steam lines to be insulated

• Employ energy efficient aluminum pipeline for compressed air

• Compressor with pressure regulator and air drier

• Periodical maintenance of compressor

• Pipe selection based on application and capacity

Energy saving measures

• Boiler

• Air preheating arrangement using flue gases and heat exchanger

• Auto blow down arrangement to reduce heat loss/unspent fuel loss

• Use proper size and grade of goal

• Use High Volume Low Pressure pumps

• Use IR/Gas based drying instead of steam drying

• Ensure complete exhaustion of chrome and other chemicals in

drum

• Assess chrome content in wet blue for input control

• Check quality of incoming chemicals

Energy saving measures

Traditional

Data collection, collation,

analysis and reporting by

people

Handwritten job card, dc and

process sheets for controls

Information sent by post,

phone calls and fax to

buyers and suppliers

Pitfalls

• Duplication of data resulting

in multiplication of human

errors

• Time and labor intensive

analytical reports

• Wrong and illegible

documents leading to

confusion

• Costly communication (phone,

courier, fax) methods

• Critical information not

available at the right time

for decision making

Information Management Systems

Integrated Management

Software (ERP, SAP, etc.,)

Computer printed

Job card

Process sheet

Delivery Challan

Invoice, Packing List

Barcode, Radiofrequency ID

Punch cards or finger punch

for employees attendance

Capture data into computer

software only once

Generate documents and

reports automatically from

software

Communicate information

electronically by email, sms

Provide up-to-date

information for decision

making

Information Management Systems

• Notification on receivables & payables

• Commercial details follow-up for orders

• Import tracking

• Provide up-to-date information to buyers

• Day to day monitoring capacity utilization of each machine

• Accurate and realistic costing of production batch

• Plan and purchase chemicals – avoid over stocking and stock

outs

• Take corrective measures for area yield and up-gradation

Information Management Systems

Improved traceability of leather, delivery performance by

better planning and monitoring on daily basis

Reduce chemical consumption by comparing actual vs standard

process

Reduce wastage, pilferage and obsolescence

Analyze utilization of a purchase lot from receipt as raw/wet-

blue to shipment as finished leather

Complete and accurate costing of finished leather shipments

Reduce non-moving stock of chemicals

Information Management Systems

Advanced level

Middle level

Entry level

Systems/ Level Quality control Human resource Production/

Process/

Machinery

layout

Information

management

Entry level • Quality circles

• 5S

• Suggestion schemes

• Professional HR

manager

• Organization chart

• Employee welfare

activities

• Statutory

compliance

• As per

individual

unit

requirement

• Computers and

servers

• Spreadsheets

and basic

software

• Employee

attendance

punching

machines

Mid level • Kaizen

• ISO 9001/14001

• Recruitment

process

• Job description

• Training and

multiskilling

• PMS

• Job rotation

• Setting

organizational

culture

• As per

individual

unit

requirement

• Non-integrated

ERP

• FOXPRO

• Tally

Advanced

level

• Business excellence

model

• Malcolm Baldridge

model

• Six sigma

• Balance score card

• Career planning

• Succession

planning

• As per

individual

unit

requirement

• Integrated ERP

• SAP

• Oracle

• Barcode readers

Employing modern

techniques for

operations and

management will

help to reduce

costs, improve

efficiency and stay

competitive