textile mill planning

TEXTILE MILL PLANNING
OBJECTIVES:


The subject of mill planning fulfill many objectives some of which are summarized below,
· COST REDUCTION by eliminating unnecessary processes and extra investment.
· To ESTIMATE THE INVESTMENT required for starting the business (mill).
· To ensure the FEASIBILITY AND SCOPE of the product.
· Gives direction of work to COMPETE THE MARKET.
· Properly working of all departments of the mill to INCREASE ROI (Return on Investment).
· To ease in CONTROLLING THE PROCESS efficiently.
· To make the business effective and INCREASE PROFITABILITY.
· EFFECTIVE USE OF TIME to get maximum efficiency and profitability.
REQUIREMENTS TO INSTALL A TEXTILE MILL
To install a new unit of a textile mill we must consider the following factors before going to start our business,
§ Data/information required
§ Feasibility and pre-feasibility
§ Capital (investment) required.
§ Financial and human resources.
§ Business requirements.
§ Capability to manage the business.
§ Skilled/experienced people required for performing the tasks.
§ Land and building
§ Machinery and material requirements
§ Market demands
1. DECISION MAKING FOR BUSINESS
It is said that “Correct Decision Is Half Success”. So, following factors must be understood before making a decision.
v There are three types of decisions
a. STRATEGIC DECISIONS (business policy, goals, targets etc)
b. TACTICAL DECISIONS (involve working methods/procedure and supervision etc.)
c. OPERATIONAL DECISIONS (managing all the operations efficiently and effectively)
v Keep in mind all the requirements of the business listed above.
v Check the availability of all financial and human resources.
v Investigate the competitor’s policies and quality levels.
v Determine payback period
v Make analysis of previous records
v Determine production level, whether it is domestic or world class production.
2. SITE OR LOCATION SELECTION
FACTORS AFFECTING SITE SELECTION:
Before selecting the site following points should be checked and analyze carefully to select the right place for the mill.
i. Near To Market: Site should be near to the market to minimize transportation cost and easy interaction with customer and consumers. It is helpful to minimize marketing and management problems.
ii. Infrastructure and Facilities: Available facilities in or outside the location directly affects the cost of production and profitability. These facilities include Gas, electric supply, water supply, roads, security, population, sewerage system etc.
iii. Govt. Taxes: Government taxes should be less.
iv. Amenities: Civic facilities (e.g. transportation) should also be available easily.
v. Land Availability: Required area and expansion area for the mill should be available at the location.
vi. Land Condition: The land should be suitable for construction and machinery working conditions. In the recipe of the soil, sand should be less and it should not be brittle and soft so that it did not disturb the level of flooring as well as machinery installation angle.
vii. Atmospheric Conditions: The atmospheric conditions affect working of the machines and processing of the material.
viii. Economic Factors: Site should be favorable economically. The cost of the land should be less. Transportation charges and government taxes also effects the cost of land.
ix. Availability of Manpower: Manpower should be available easily so that transportation cost of employees could be decreased.
ADVANTAGES AND DISADVANTAGES OF SITE SELECTION
i. Advantages
Selecting good site results in,
ü Low cost of purchasing
ü Reduction in investment to provide facilities.
ü Low transportation costs
ü Easy management of the resources (economical, social, human, etc.)
ü Easy interaction between market and mill.
ü More ROI
ü High profitability
ii. Disadvantages
Selecting wrong site results in,
ü High cost of purchasing
ü Low profitability
ü High investment
ü More management and marketing problems
ü Communication gap between mill and market
ü Less ROI
ü More payback period
ü High construction cost if not near to the city.

3. LAYOUT PLANNING
Layout of the mill can be categorized in two ways, mill layout and machine layout.
A. MILL LAYOUT
OBJECTIVES:
· Reduction of cost per unit of the mill.
· Make the working of the mill and machinery more easy and efficient.
· Easy and economical interaction between man and machine.
· Proper storage and transportation of waste and material.
· To provide space for working and other factors.
· Best utilization of land and building.
· To improve performance of man and machine.
· Easy handling of all processes.
IMPORTANT FACTORS:
i. Area Required:
Decide that how much area is required for the entire mill and its all departments. If you have planned to expand the mill later than it must be managed at the time of land purchasing.
ii. Raw Material Godown:
Raw material godown should be according to size of the mill and recommendation of management department.
iii. Finished godown:
According to the production of the mill and size of the products the finished godown size should be selected.
iv. Stores:
Store layout should be according to the requirements that how much stores are required in the mill? Main store size and number of sub stores also be indicated.
v. Technology:
The kind of technology used to produce finished goods must be considered. For example in spinning mill, whether you are using ring spinning system, open end spinning system etc.
vi. Departments:
¾ How many departments are required in the mill is the first question for further departmental planning.
¾ The size of the departments is another factor in the planning process.
¾ Then we have to decide that which sequence is more suitable for efficient working of machinery and manpower.
vii. Transportation area:
Following transportation areas must be considered in the layout,
¾ Passage between the machines.
¾ Passage for material transportation between the machines
¾ Transportation between different departments of the production departments as well as mill departments (e.g. management, finance, marketing, H.R.M etc)
¾ Passage for transportation of finished goods.
viii. Auxiliaries:
Following types of axillaries are also very important in layout planning. These should be according to the requirements.
¾ Sewerage system
¾ air-conditions
¾ Boiler
¾ Workshops (main workshop and sub-workshops)
¾ Cafeteria
¾ Offices (combined door department wise)
¾ Parking area
B. MACHINERY LAYOUT
Following factors are very important for machinery layout
¾ Machines used in the process determine the size of the department. So it should be decided before planning that what type of machines has to install.
¾ Machine dimension is also important while deciding department size.
¾ Area required per machine should be calculated.
¾ Total number of machines.
¾ Machinery layout should be according to manufacturer standards and conditions.

4. CONSTRUCTION PLANNING
COVERED AREA:
First of all decide how much area of land will be covered and then consult layout plan for further decisions.
CIVAL WORK:
¾ Floor Type
Machinery used in the textile mill is very important factor while we are starting floor work. Floor should be according to the machine manufacture’s requirements Floor should have enough strength to withstand the weight of the machine and its vibrations.
¾ Material For Construction
Material used for the construction should be according to the requirements of the object. Usually two type of material is used,
RCC (Reinforcement Concrete Construction)
RBC (Reinforcement Brick Construction)
Wood is used to reduce noise where noise is more.
¾ Digging And Evacuation
It is the first process of the construction. The extra mud and soil is removed from the land to start foundations.
¾ Foundations
Foundations are made according to the requirements of the walls and height of the walls. Foundation is usually wider than walls and penetrates inside the land 5-10 ft.
¾ Walls
Wall thickness, height, material and insulation should be according to the layout and machinery working conditions.
¾ Pillars
Pillars provide strength to the roof and share the load of the roof. Pillars should be strong and constructed at right angle.
¾ Roofing
Roofs of the mill should be water proof. It should be insulated with polythene or bitumen.
¾ Doors And Windows
Doors and windows should be pre planned i.e. whether it should be air-tight or not. Sizes are also being pre-planned.
¾ Fans
There are two types of fans. Air supply and air return fans. The sizes should be according to the requirements.
¾ Ducts
S-ducts (Supply ducts) and R-ducts (Return ducts) should be pre planned.
PUBLIC HEALTH:
ü Water disposal system and wash-rooms should be available for the sake of public health.
ü The temperature of the working area should not be hazardous for the workers.
ü Atmospheric conditions in the department should also favorable for the workers and other employees.
ü Furniture and other facilities should be available during rest time of the employers.

5. PRODUCTION PLANNING
A mill product can be either yarn, grey fabric, finished fabric, garments etc. Whatever will be the production type following factors are involved.
ü Raw material
ü Machines
ü Time
ü Manpower
ü Efficiency
i. MACHINE
¾ For a different variety of product different number of machines is required. For example in a spinning mill for fine yarn more number of machines is required as compared to coarse yarn.
¾ Speeds of the machine are also variable for different qualities.
¾ Time required to produce the required output also varies accordingly.
¾ These factors also affect efficiency of the machine.
ii. MATERIAL
¾ It is very important that what kind of raw material you are using. In a spinning mill fiber used to produce yarn effects many production factors including machine settings, speeds, efficiency, performance, yarn quality etc.
¾ The quality of the yarn to produce determines the characteristics of the raw material (fiber).
¾ Hence raw material determines the quality of the yarn. High quality yarns can not be produced with poor raw material.
iii. MANPOWER
¾ Manpower varies according to the requirement and management policies of the mill.
¾ However automation reduces manpower now-a-days.
¾ Human resource management (HRM) department manages the manpower.
iv. MANAGEMENT
¾ To manage how much production is required to achieve the target.
¾ Management of sale and purchase.
¾ Targets are set according to the capacity of the machine.

(Mid term exam)
6. SUPPROTING DEPARTMENTS
6.1. AIR CONDITIONING
The task of the air conditioning system is to control the temperature and moisture content of the air by one or more of the following processes:
¾ Heating
¾ Cooling
¾ Dehumidification
¾ Humidification
6.1.1. OBJECTIVE
¾ To maintain and control a specific temperature
¾ To maintain humidity of the department
¾ For process comfort
¾ Human comfort
¾ To support the process
¾ To support the working conditions
6.1.2. PRINCIPLE OF AIR-CONDITIONING
Air conditioners use chemicals that easily convert from a gas to a liquid and back again. This chemical is used to transfer heat from the air inside of a home to the outside air. The machine has three main parts. They are a compressor, a condenser and an evaporator. The compressor and condenser are usually located on the outside air portion of the air conditioner. The evaporator is located on the inside the house, sometimes as part of a furnace.
6.1.3. GENERAL PROCESS

AIR-CONDITIONING BY HUMIDIFICATION:
In this process water vapors or moisture is used to condition the air. Following steps generally involved in this process.
® Filtration of air with the help of filter to clean the air.
® Water sprays with the help of atomizer, to laden the air with moisture.
® Dampers (doors used to give air passage for transportation either from outside to inside or inside to outside)
® Diffuser (used to insert air in the ducts)

6.2. HUMIDIFICATION
6.2.1. OBJECTIVE
Textile humidification will:
¾ Improve regain
¾ Maintain yarn strength
¾ Reduce static build-up
¾ Maintain product weight
¾ Reduce fly and micro-dust
¾ Provide free cooling
¾ Maximize profit
6.2.2. IMPORTANCE
¾ Humidity control in the textile industry is essential in order to maintain product quality and reduce imperfections.
¾ A dry environment in textile manufacturing and storage facilities can have many serious implications
¾ 65-75%rH = maximum profits
6.2.3. HUMIDITY RANGE
In different departments humidity ranges are suggested as follows,

Spinning
Twisting
Winding
Weaving
Wool
50-85%
60-65%
55-60%
50-60%
Cotton
33-65%
50-65%
55-65%
70-85%
Man-made
50-65%
N/A
60-65%
60-70%

6.2.4. ADVANTAGES
6.2.4.1. REGAIN
® Dry air causes lower regain and this contributes to poor quality and lower productivity.
® By humidifying, the materials are kept at optimum regain and are less prone to breakage, heating and friction effects, they handle better, have fewer imperfections, are more uniform and feel better.
6.2.4.2. STATIC ELECTRIFICATION
® Dry materials create more friction and are more prone to static electrification.
® Higher humidity reduces static problems and makes materials more manageable increasing machine speeds.
6.2.4.3. YARN STRENGTH
Yarns with low moisture content are weaker, thinner, more brittle and less elastic.
6.2.4.4. FABRIC SHRINKAGE
® Low humidity causes fabric shrinkage.
® Maintained humidity permits greater reliability in cutting and fitting during garment creation
® It also contributes to the maintenance of specification where dimensions are important, such as in the carpet industry.
6.2.4.5. PRODUCT WEIGHT
® Textile weights are standardized at 60%rH and 20°C (68°F).
® Maintaining humidity will ensure low product weights don’t lead to lowered profits.
6.2.4.6. DUST
Humidification reduces fly and micro-dust, providing a healthier and more comfortable working environment.
6.2.4.7. COOLING
® A cold-water spray humidification system can provide an evaporative cooling effect of up to 12°C (54°F).
® This makes the environment more comfortable to work in and improves staff productivity.
6.3. COMPRESSOR
“A compressor is a machine which is used to get compressed air”. The pressure is set according to the requirements.
6.3.1. OBJECTIVE
¾ To obtain compressed air
¾ To make process simple, economical and easy.
6.3.2. TYPES
Ø Piston type (use reciprocal piston. Less speed and more noise)
Ø Rotary compressor (screw type and centrifugal)
Ø Individual compressors
Ø Centralized compressors
6.3.3. MEASURING UNIT
¾ Air quantity = m3/min
¾ Pressure = bar (1 bar =100kg)
6.3.4. USES
ü For cleaning purpose
ü To transfer material
ü To apply air pressure
6.4. BOILER
6.4.1. INTRODUCTION
A boiler is a vessel to boil water and to generate steam. Steam can be
¾ Saturated (wet steam)
¾ Un-Saturated (dry steam:
6.4.2. TYPES
Ø Package type
Ø Locomotive
Ø Tube type
Ø Water based
Ø Fire based
6.4.3. FUEL USED
ü Coal
ü Wood
ü Oil (furnace oil)
ü Gas
6.4.4. BURNERS
® Single fuel
® Double fuel (2 way burners)
6.4.5. TECHNOLOGICAL POINTS
ð Hard water causes scaling, so pure water should be used.
ð Chemical treatment, such as with acid or alkali, is done for de-scaling
ð Hot water should be supplied for quick steaming
ð Capacity of the boiler is 1-1000 ton
ð Efficiency range is 50-85%
ð REFRACTORY: ” special bricks used for safeguard or to avoid direct heating”
ð ECONOMISER: heat recovery unit
7. WASTE MANAGEMENT
7.1. WASTE
Waste is a broad term. Generally anything which did not contribute towards benefit or profit falls in waste category.
7.2. PRODUCTION
Waste can be produced in many ways. Resources of waste are,
¾ Faulty raw material,
¾ old and poor machinery,
¾ poor management
¾ poor cleaning efficiency
¾ bad environmental conditions
¾ Bad quality production causes product rejection etc.
7.3. TYPES
® Material waste (contamination, foreign material in cotton etc)
® Process waste (include hard waste, sliver and roving waste etc)
® Bad quality production waste (rejected material)
® Time waste
7.4. PLANNING
¾ Cotton should purchased free from waste
¾ Picking and ginning should be carefully monitored to avoid waste addition.
¾ Waste from ginning should not exceed above 4%
¾ Value addition by using the waste in cheaper items.
8. ENVIRONMENTAL PLANNING
8.1. INTRODUCTION
Environment of a mill contains many factors e.g. temperature, humidity, light etc. These all contribute to good working condition and increase in efficiency. So, environment of the mill should be planned so that it support in good working conditions.
8.2. TYPES
Ø Internal environment (inside in the mill)
Ø External environment (outside conditions)
8.3. FACTORS AFFECTING ENVIRONMENT
® Temperature
® Humidity
® Light
® Noise
® Air
® Fluff
® dirt and dust
8.4. EFFECTS OF ENVIRONMENT
Different factors affect the man and machine differently as shown in the following table.
FACTOR
STATUS
AFFECT ON
MAN
MACHINE
Temperature
High
Low efficiency, more nerves breakdowns
Quick heat-up, less efficiency and more maintenance
Low
Easy to work and more efficiency
slow heat-up, more efficiency
and less maintenance
Humidity
More
Difficult breathing and can’t work for long time.
More slippage of machine parts. Accumulation of moisture on machine.
slow heating of machine
Less
Easy to work
Less slippage of machine parts. Less Accumulation of moisture on machine.
Quick heating of machine.
Noise
More
Daffiness. Anxiety and depression.
Extra vibration in material being processed.
Less
Comfort in work.
Less vibration and smooth working
Fluff (dirt & dust)
More
Lungs, nose and throat diseases.
Accumulation on machine parts and causes different maintenance problems e.g. cleaning, lubrication, more resistance, energy loss and quick heating up.
Less
Fewer diseases. Healthy environment
Good working less maintenance

9. INVENTORY CONTROL
9.1. INTRODUCTION
Definition 1A company's merchandise, raw materials, and finished and unfinished products which have not yet been sold. These are considered liquid assets, since they can be converted into cash quite easily. There are various means of valuing these assets, but to be conservative the lowest value is usually used in financial statements.Definition 2The securities bought by a broker or dealer in order to resell them. For the period that the broker or dealer holds the securities in inventory, he/she is bearing the risk related to the securities, which may change in price.
http://www.investorwords.com/2589/inventory.html

9.2. TYPES
— Raw material inventory
— Work in process inventory
— Finished goods inventory
— Repairs and maintenance inventory
9.3. ENVENTORY CONTROL
— Economic order quantity is the level of inventory that minimizes the total inventory holding costs and ordering costs
— Therefore:
.
— Variables
· Q = order quantity
· Q * = optimal order quantity
· D = annual demand quantity of the product
· P = purchase cost per unit
· C = fixed cost per order (not per unit, in addition to unit cost)
· H = annual holding cost per unit (also known as carrying cost) (warehouse space, refrigeration, insurance, etc. usually not related to the unit cost)
— Note that interestingly, Q* is independent of P, it is a function of only C, D, H.
— Underlying assumptions
1. The ordering cost is constant.
2. The rate of demand is constant
3. The lead time is fixed
4. The purchase price of the item is constant i.e. no discount is available
5. The replenishment is made instantaneously; the whole batch is delivered at once.
EOQ is the level of the inventory where ordering cost and carrying cost remains equal.
9.4. TIPS FOR INVENTORY CONTROL
— Determine how much quantity is required for specific operation or process
— Schedule your production level with respect to time and decide when to order?
— Also indicate and plan number of orders for a specific period.
— Decide what type of stock is necessary and to what extent is needed to continue the process. For this purpose JIT (Just In Time) formula is very useful.
— Determine the consumption level of the whole unit.
— Enlist and analyze the cost, quality and process control for the inventory.
— Make a chart of STOCK QUANTITY Vs DAILY CONSUMPTION
— Timely order and delivery
— Determine maximum achievable targets.