1. LEAD TIME REDUCTION IN
TEXTILE INDUSTRY
-by Guided by
S.Aravindha balaji Dr.D.Rajenthirakumar
(10mm04)

2. Contents
• Introduction
• About project
• Objective
• About company
• Methodology
• NGP time study
• Kanban .
• Deliverables.
• References.

3. Introduction:
• The LEAN principles are easy to implement in the
product industry as compared with semi-process
industry like textile spinning were we have
continuous machinery which is get multiple input
points and output points in its passage from raw
cotton to end fiber. so NGP time study’s were
done to compare it with sector specified
standards to enhance production rate.
• The kanban implementations& its integration will
benefit in reducing the lead time of the end fiber.

4. About project
• Phase-I (completed)
 Kanban implementation in the Ring winding
section
• Phase-II (IV-semester).
• FUTURE state of VSM.
 T he Needles – Guide Pin(NGP)** time study to increase
the efficiency of the production and help in elevating
the production rate..
 Kanban implementation in all other section and to
integrate the same to reduce the lead time.
** source:- SITRA HAND MANUAL for textiles machineries. (Reprint -
2006)page 223,para 2.5.1(NGP)

5. Cont…
• In this phase the entire project will be
separated in to two separate areas.
– NGP time study related to productivity and critical
to capacity constrains.
– KANBAN implemtation& integration to achieve
reduction in overall lead time.
As both capacity and lead-time plays an vital role in
converting an industry into lean-centric and
operational excellence industry in every sector.

6. objective
• To reduce the LEAD TIME of the textile
industry from 620 mins to 600mins within
march 15 of 2012 using KANBAN method
• To integrate all the sections to enhance the
productivity by using SITRA sectioned
parameters validation for textile machineries
installed in the VSM spinning mill.

7. About company
• Vaithi lingam spinning mills pvt, Ltd. Salem
• The industry was started in 1999.
• The industry has high end clients like Madura
garments, Al-zammen exports Ltd.
• The industry is the only Duplex operator in
Salem region for the grade 40.

8. Project methodology-1
IDENTIFICATION OF SECTIONS • The various sections at which thread of at least 0.25mm dia is
FOR NGP used is only selected for NGP .
IDENTIFICATIONS OF • The parameters like RPM vs thread tension graphs are plotted
PARAMETERS in NGP and its slope were taken as parameter of NGP.
• Both manual NGP time study and automatic with help of NGP
PERFORM THE NGP TIME STUDY counters were used in NGP with atleast 3 trails by automatic
IN SELECTED SECTIONS method.
COMPARE/ANALYZE THE NGP • The obtained results were get compared with the standard
VALUES WITH SITRA NORMS values in SITRA norms for evaluation of current process.
IDENTIFY THE NON VALUE
• The non value items like twin peaks are get identified using NGP
ADDED ACTIVITY IN PRESENT only as they have more time than standard time to be utilized.
OPERATIONS
FORMULATE WITH NEW • The double peak operations were get reduced /eliminated to
METHODS AND TRAIL -RUN increase the production after Initial TRAIL-RUN.

9. Project methodology-2
Select the sections to • The other sections were huge lead time is used is
introduce the KANBAN selected for KANBAN implementations.
KANBAN feasibility • The kanban calculations and its feasibility study using
study& CALCULATIONS. demand-feasibility analysis.
KANBAN • The actual kanban implementations were get done in
implementations in this as islands of KANBAN limited to particular sections
every selected sections demand alone.
Integrations of all • The entire firm level Demand –facility analysis will
KANBAN’S in entire ensure the smooth integrations of all KANABN installed
plant in every sections of the industry

10. NGP time study
• Needle –Guide pin(NGP) time study is the study
which should consider at least 6 parameters like
torsion of thread, RPM of machine, winding
height, mean thickness of the guide pin, hole dia
of machine etc which would then plotted ln graph
as machine against thread values.
• After the graph is plotted the twin peak curve
points are taken as odd points for improvement
and get omitted.

11. NGP time study(cont….)
• In the graph the slope values are compared in
which the slope values of SITRA standards
were done.
• the graphs whose values shy below the SITRA
values are should be termed as
“underperforming” machines.
• The methods to increase the performance of
particular machines are sorted to included in
TRIAL-RUN process.

12. NGP Graphs(RPM Vs TORSION)
800
780
760
A.TRAIL 1(YPM)
740
M.TRAIL 1(YPM)
720 M.TRAIL 2(YPM)
700
680
Torsion-A Torsion-B Torsion-C Torsion-D

13. NGP study(manual)
• The selected parameters are get noted down
by careful calculation over the output and the
machine settings.
• The table format has been done for recording
the one particular values against variable
other parameter in every trail.
• After this along with other parameter
estimator it is plotted as graphs to find the
twin peaks.

14. NGP study(Automated)
• Here also same operation of plotting the values
as graphs were done the difference is the values
were obtained directly from mill monitoring
gauges fixed into every machine.
• The process has been fully automated in the few
modern machines which produce the results in
graph format by the help of dedicated NGP time
monitors preinstalled.
• I would like to use Timer-pro for obtaining
Automated values and graphs.

15. KANBAN part
• Apart from simulation of all sections using areana
for lead time calculation,
• this part has
Mixing section(storage chamber),
blowing room section,
corting section,
Draw frame section,
 simplex section,
spinning section are the section in which kanban
box’s and cards get to be implemented along with its
integration in this phase.

16. constraints
• Obtaining values like manual RPM calculation
for NGP time study is time consuming
process, so timer pro has been used but that
has the constraints like separate AV recording
device and PC need which is costly.
• KANBAN implementation and its integration in
various sections seek Operators support which
only be developed after long training and
interaction sessions only.

17. Lean tools used
• Arena 10.0 ( for simulation of sections)
• Timer pro (for time motion values)
• MS- visio ( for KANBAN integration)
• i-grafx ( for VSM)
• MS- excel (for NGP time study)

18. Deliverables
• Increased PRODUCTIVITY values of 1080 pales
from present 1050 pales after comparing the
NGP values with SITRA Values.
• Reduced Lead time after kanban
implementations from 620 mins to 600 mins.
• Future state map with suggested kaizen’s for
further improvements after project.

19. References
• Lean manufacturing principles for improving production Efficiency
by Auston Marmduke kilpatrick., 1997,, Journal for Industrial
Technology .Vol 13,No.3 june 1997.
• Lean for the Process industry byDr.kenneth w.stier .,2004 ., journal
of Industrial technology, Vol .19. no 2 august 2004.
• Adapting Lean Manufacturing Principles to the Textile Industry by
GOFORTH, KELLY ANN(pg203-364.)(IJ textile advancements Nov
2009).
• Lean principles for agile apparel production in integrated textiles
company by Dr. Josef Oehmen (vol 23,jan 2006). internation journal
for textile manufacturing)
• Lead-time reduction in large-scale machinery using maintaince
plans- a case study by kirkor bozdogan, john deyst(vol
64,1999,pg326-334).international journal for industrial maintance.
• Kanban made simple by productivity press.ISBN-164-10-12-2954

20. THANK YOU