Productivity Benchmarking-Goals Key Performance Indicators Reference Stds-PB Few Case Studies Route Map for PB Use of ERP

Manufacturing Excellence will be the Result of

Productivity Benchmarking

Market supremacy can be achieved only and only if

Organizations Excel in all their Performance Metrics

Honda City and Maruti

Park Dale mills used 2000 employees in 1980 to produce 1 lac kg per week

In 2014 the same volume is produced with 140 employees

When all mills find it difficult to cross 145 gps in Modern Ringframes in 40s Combed Hosiery, one group of mills in South broke the barrier and achieved 175 gps using Compact systems

Compact spindleage shoot up in southern mills, by Commercial exploitation

When Spg mills were at stress to achieve 5% profit margin one mill in Tamil Nadu consistently reported 10% profit for more than 5 years with Permanent employees.

It is only because of its ` No. 1` position in Combed Compact Weaving yarn Market with a command on Premium

When Mills were struggling to achieve imperfections below 70 in 30s CH with 74% YR, one mills near Dharapuram consistently achieved less than 50 imperfections with an YR of 77% and stood first in Export yarn Quality

Efforts taken :Ginning is controlled by them

Reduce Manufacturing Cost Better Use of Assets Top Quality &Efficiency (RFT) On time Delivery Service level Excellence Control on Inventory levels

Higher production per spindle(gps) Higher productivity per

employee(kg/employee or HOK) Higher yields(YR) Less energy to produce(Units per kg) Control on Consumables Control on Packing Cost

Utilisation Efficiency/Break up of Losses

Maintenance Repairs Traveller changes Lot changes Unscheduled power related stoppages

Build the required Quality into the product

Relate In process Q to final process Q

ZDQC-Zero Defect Quality Control

Identify potential failure points and plug it

Ratio of Actual no of days taken to deliver

to Committed no of days to deliver the lot

(Question of Survival in a Competitive Market)

Customer Satisfaction Index

Volume Flexibility After Sales Technical Support New product Development Taylor Made Quality(Ex) Customer Education/Training(LMW)

Raw Material In Process Finished goods Store Inventory

SIMA Technofacts Survey reports

SITRA CPQ reports

SITRA-30th CPQ report

“Mills has increased their Contribution per spindle per year by

35% over a period of 6 years”

SITRA 30th CPQ

Best Mills -Rs13760

Top 20% mills-Rs 9010

((Contribution=YSP-(RMC+PC+SWC))

SIMA Technofacts-In 6 years period,

Average gps has gone up from 93.6 to 102 Average Ut% has gone up by 2.8%(absolute

value) Average HOK has gone up from 22.5 to 16.8 As on Nov 14,the best level in HOK is 10.4

World`s Tallest Building as on today

863 Meters height

Elevators work at 18 m / sec speed(64 km/hr)

No of floors-163 Swimming pool,Mosque & Restaurant-at its

highest locations in the world

Abraj Al Bait tower-Saudi Arabia -601 m Taipei 101 tower -Taiwan -509 m World Financial Center,Shanghai -492 m Petronas towers, Malaysia -452 m Sears Tower, Chicago(25 years) -442 m

Determine what to Benchmark Define Benchmarking Standards Determine data collection strategies Develop Role and Responsibility Perform the Benchmarking operation Analyse the results Formulate Insights/Take Actions

Production efficiency - OutputUtilisation efficiency – Better use of

assetsYarn Realisation - Higher YieldsHOK/Kg per employee – Labour CostUkg -Power CostConsumables per 1000 spindles /day-R&M CostStore Inventory -Interest Burden

Mills Standards Mills Achieved Level Benchmarked level for the same count

In 60s Combed

Compact, few Mills are

achieving 78 gps comfortably

Best In CPQ

73

Top 20% 72

In 40s Combed Hosiery

Few Mills are achieving 155 gps

comfortably

Best In CPQ

148

Top 20% 148

Control On Endbreaks Spindle wise Monitoring Training of Tenters Training of Doffers Retraining of Tenters/Doffers Quality of Bobbin Machine Cleanliness(OHTC function)

Mills have taken lot of efforts to achieve 99.2

Careful planning of both electrical and Mechanical Maintenance is essential

Best In CPQ 99.2

Top 20% in CPQ

95.8

Amazing levels are achieved by winning mills in SIMA Technofacts survey 2014

RF Utilisation 99.25

GPS-Converted

127.6

HOK 10.4

Controllable Doff delays BreakdownsUncontrollable Power related(Mills are able to control this with DDF)Unpredictable Lot /Count Changes

TPM -Total Productive Maintenance

FMEA-Failure Mode Effect Analysis

Can help the mills to reduce Breakdowns to near zero.

YR can be increased by controls on Waste monitoring from Blow room itself.

Each Zone has the task of `specific type of waste` removal

Best In CPQ 72.5

Cotton 100% Bunny

Better YR doesn’t mean

loss in YQ or Poor YSP

Best In CPQ 71.2Cotton Used MCU5Yarn imperfections

293

YSP +Rs 3 over Average

Best levels are made possible by Management`s commitment on Automation as a strategy to Excel

Best In 2014 TF

10.4

Best In CPQ 9.3

Autoconer

Kg/Employee

SWC in Autoconer

Best In CPQ-60sC

428(90 D)

Best In CPQ-30sCH

624(70D)

Power Spent on Compressor is now controlled to 2.9%

Power spent on plant is controlled to 8%

Utilising all Machines as per Spin plan

Factor 60s C 67s CNo of RF 7 3gps 73 59Sx Reqd 1.65 0.6Drg Reqd 1.31 0.44Combers 1.72 0.58Cards 4.1 1.37Depending on the machines available , we should plan a required running shifts pattern for each count in preparatory.This will save energy as well as labour cost.

Lubrication practices

Replacement programme

Interlinking Quality and Maintenance

Target Level Rs 600+Rs 200

Current Level Rs 450-Rs 1400

Extension of Costly accessories like Card wires/Comber Unicombs

Mills are able to achieve 900 t in for Cylinder and Flat tops

With innovative products from LCC/TCC mills extend the life of SFL also upto 250 tonnes

With Offline grinding Flat tops can be extended upto 800 tonnes

State of Art mills with AD/LC

Count 40s CHAchieved gps-145Mills Target - 155

Control RF has been taken up for study Set pattern of speeds for achieving 155 gps Assessed the load taken by the Motor Found to be 110% Manufacturers are contacted to Correct

Invertor and Machine pulley combinations Mills current level is 157 gps by rearranging

pattern of speed

In one Unit the Utilisation Efficiency is 98.5

Mills Benchmarked Efficiency is 99.2

Break up of Losses has been studied and improved

Break up of Loss in Ut%

Before Study After Study

R.Maintenance-Electrical

0.1 Merged the operations at the time of Routine or preventive operations of the RF itself.Traveller changes are done at the time of Routine cleaning itself.Total loss due to Maintenance including TC-0.8 now

R.Maintenance -Mechanical

0.55

Preventive Maintenance- Mechanical

0.3

Preventive Maintenance -Electrical

0.05

Breakdowns 0.3 0Traveller Changes 0.2 0Total Losses 1.5 0.8

Mills Current Level-4.3

Mills Status-RF with AD and Modern Machinery in all departments

Mills Target-4.1

Power spent on compressor has been brought down from 4.1% to 3.4% by plugging Airleakages in Lap preparation in Comber Department and also in Autoconer

RH is displayed in broad &visible letters in Autoconers/Spinning departments.Shopfloor has been educated on Humidification plant efficient running

Ukg is brought down to 4 and being improved further.

Mills Current level-74% Count pattern -Medium SC and C Target planned -3% improvement

Improved areasCard waste Zonewise analysis revealed SFD

waste is abnormally high at the level of 2%.Reduced to 0.5%

Hard Waste was found to be abnormal due to poor work practices in RF.Retrained the workforce and reduced the hard waste from 0.9 to 0.6%

In Semicombed Variety mills has not done Conditioning.Effectively restarted.

Sweepings found to be 0.8%-Unusually high.On checking it is a mixture of Usable waste and Sweeps.Educated the sweepers and concerned department tenters.Reduced the same to 0.5% level

Finally the mills is able to exceed its expected target of 3 and achieved 3.5%.

Final YR -77.5%

Monitoring & Maintaining Moisture content in Mixing and outgoing yarn

Monitoring and Maintaining Moisture content in Saleable waste

Strict monitoring and control of AWES waste level by visual checks in Compactors-weekly

Tare weight control in Packing Weighment of Mixing at the time of Laying Ensuring 65 to 70 % in Packing department

Empowered Employee Beliefs and Attitudes Belongingness of Employees

Any reward/incentive/benefit system must be focussed on `Self development of Employees towards empowering him`so that he becomes `Mouth piece` for our units.

Education on Systems available to all employees through all channels of Communication

Short and brief meetings at villages where our Employees are concentrated

`We are thrilled by news that 160 employees are graduated in one group of Mills.One employee in that group Joined TCS too.`

Training and Retraining of Employees play a vital role in realising our ME/PB Goals

If Training system needs to be effective, Employee Retention is the Keyword

Data Collection plays a vital role in system towards Manfacturing excellence

Direct transmission of data without any manual intervention needs to be ensured wherever it is possible

One time entry and Precise data are the basis of ERP implementation

NVA`s must be eliminated at all levels of Hierarchy through ERP

Availability of Reports as Structured

Develop Alert Sytems

Deviation Levels to be attacked then and there

SWOT analysis Create Management Vision and Mission

Break up of Mission into Performance Objectives

Develop Suitable and Effective Performance linked Wage structure

Mock Implementation and Nodal wage increase-Communicate to employees and get feedback

Apply suitable corrections and Implement

Review periodically and revise targets in comparison to Benchmarked levels

Develop Customer Satisfaction Index

Implement essential pillars of TPM

Use Techniques of FMEA for reduction of Breakdowns in Machines and Quality

Training and Retraining of Employees with proper Communication tools

for Retention form the foundation of any System towards

MANUFACTURING EXCELLENCEThrough

PRODUCTIVITY BENCHMARKING

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www.winsyssmc.com