Reduction of Beam Gaiting Time (Set up time) in Rapier Looms @ one of India’s leading textile and apparel company with International brands
About SKNL Jagadia
Our Client is one of India’s leading textile and Apparel Company with expertise in multi-fiber manufacturing. The company has extended its presence in multiple product categories from Fabrics to Apparels and Home Textiles. As a company that caters to the entire spectrum of the socio-economic segment in the Indian market.
It is the manufacturer of blended fabrics for work-wear & daily wear. With strong brand equity and unique strengths, the brand has evolved to include fashionable blended suiting in line with work wear & daily wear for the common man of today. Besides the superior look and finish, the brand spells quality, durability and a value-for-money.
Its polyester viscose and polyester cotton blend fabrics are offered in over 150 basic shades – the largest spectrum of colours available. Serving the work-wear market, the brand provides sophisticated product and service.
Due to the intricacy of market order and Competitiveness, Client was under Pressure to produce and dispatch products in shorter delivery times. In the past a lot of effort has been put to reducing the cycle time and speeding up the output rate whilst totally ignoring the change overtime from one product to another. After studying the all processes within organization, Set up time in loom section was observed high and as their terminology it was called Beam gating time.
A. Data Collection & List out Internal and External Activities
- Statistical data collection methods for measuring machine setup time in Looms. After data collection and analysis, No of Set ups and set up time was observed high in rapier looms with compare to airjet looms. Production process flow and standard operation procedure are reviewed briefly before setting up the data collection table is done. The next step is to create a data collection table prior to collecting data and the time taken was measured by capturing videography of set up activity. And finally project statement was defined “Reduction of Beam Gaiting Time in Rapier looms from 167 Minutes to 90 Minutes.
- After Capturing Videography of set up activity, Videotape was watched precisely by all team members. Task Performed by operator 1 and operator 2 were list out by team members while watching videography. Also Movement of Operators were also calculated by making “Spaghetti Diagram”
Internal Means:- Those carried out when the machine has Stopped.
External Means:- Those carried out when the machine is running.
Total Internal Activity Time:- 147 Minute
Total External Activity Time:- 20 Minute
SPAGHETTI DIAGRAM OPERATOR-01
SPAGHETTI DIAGRAM OPERATOR-02
B. Converting Internal Activity to External Activity
In Order to convert internal activity to External activity, main focus is on the tasks related with material handling, information gathering, adjustment and control. In the Current State, we can see that the 10% are External Activities and 90% Internal Activities. Though Internall Activities are greater, our aim is to convert to more internal activities to External. One better suggestion for conversion is we can use the SMED trolley which will be prepared in advance with all required materials, rolls, tools, documentation e.g. which gives the better result. On the other hand we can also use the some methods of orientation, tool setting provisions etc.
C. Streamlining all aspects of the Operation
In the final Step the improvements studies were done and checklists were formed. The causes for recursive activities were searched as possible and ideas implemented to eliminate them were provided. Finally, the tasks will no longer be unpredictable time delays by use of the precise time records. Therefore, better Planning activities will lead to customer stratification.
- Set up time Reduced by 45%
- Productivity Improved by 10 %.