Polyester is the most important synthetic fibre accounting for 70% of all man made fibre consumption. Globally, the industry is shifting to China and India, which are slated to be the two most important sourcing destinations for textiles
Contents:• Corporate File• Problem Definition• Tools To Be Used• Objectives• Project Work• Facts Of DTY Plant• Working Procedure• Suggestions
CORPORATE PROFILE• The history of Indo Rama Synthetics (India) Ltd. dates back to 1989.• Indo Rama has emerged as Indias second largest dedicated polyester manufacturer having carved a niche in the market place for its unmatched quality offerings.• The Company offers a wide range of polyester products which include (PSF), (POY),(DTY), (FDY) and Polyester Chips.• Equipped with a state-of-art integrated manufacturing complex at Butibori near Nagpur in Maharashtra• The Indo Rama Group has a strong presence in Indonesia, Thailand, USA, Nepal and Sri Lanka, besides India.• It has focussed business activities in the field of Textiles, Polyesters and Industrial Chemicals.
• Indo Rama has the countrys largest dedicated polyester manufacturing unit at a single location. The Company has an integrated manufacturing complex spread over 250 acres at Butibori, near Nagpur in Maharashtra.• Standing at the gates of an exciting world of opportunities, Indo Rama is rightfully equipped with a stunning 6 lakh tonne per annum polyester manufacturing capacity.
Problem Definition• Determining the idle time of operator working on machine.• Calculate standard cycle-time/denier.• Causes: Unskilled Labour.
Method Study• Method Study is the systematic recording and critical examination of ways of doing things in order to make improvements.Process of method study:• SELECT: The work to be studied.• RECORD: All the relevant facts of the present or proposed method.• EXAMINE: Those facts critically and in sequence systematically.• DEVELOP: The most practical, economic and effective method having due regard to all contingent circumstances.• INSTALL: That method as standard practice.• MAINTAIN: That standard practice by regular routine checks.
Time Study• Time study is a tried and tested method of work measurement for setting basic times and hence standard times for carrying out specified work. Its roots are back to the period between the two World Wars.• The aim of time study is to establish a time for a qualified worker to perform specified work under stated conditions and at a defined rate of working.• This is achieved by a qualified practitioner observing the work, recording what is done and then timing (using a time measuring device) and simultaneously rating (assessing) the pace of working.
OBJECTIVE• Identify the idle time of an operator working on a DTY machine.• Reduce the idle time of an operator working on a machine through time study and method study.
Project work• The Company offers a wide range of polyester products which include (PSF), (POY),(DTY), (FDY) and Polyester Chips in which our prime concern is DTY.• There are 49 machines assigned to a DTY plan consisting of 3 types: Himson, Barmag and Aalidhra.• They all produce 3 types of quality fibres: fine, coarse and super-coarse.
Draw Texturised Yarn• Draw Texturised Yarn (DTY) is a fully drawn, fully oriented polyester multifilament yarn with soft crimp, high bulk and texture with cotton feel and very high durability and retention properties.• This is manufactured by texturising partially oriented yarn using texturising machines.• DTY is suitable for fabric end uses like outer/inner garments, skin-clinging garments, furnishings, upholstery, etc.• This is a replacement of cotton and cotton blend yarns with very low moisture content.
Facts Of DTY Plan• Production:180 tons in three shifts requiring 173 tons of POY(To Soften).• Activities in DTY Plant:1. Pre-Doffing;2. Doffing;3. Threading;4. Splicing;5. Cleaning.
Working Procedure• Observe operator and worker and select one operator.• Recording the cycle-time of an operator/machine/denier.• One full POY cycle observation.• Work Elimentalisation.• Rating:-95%• Allowances:- 100 grams/5 tons.• Calculating the Idle time of an operator on a machine.• Rationalising the calculated time.
• Total 120 spindles & 120 bobbins.• Study one side of the machine and multiply the results for the other side.• Calculate the total productivity.• Repeat the above Procedure For 49 machines for improving the accuracy and confidence level.
Suggestions• Use Ear Plugs as the noise level of machine is very high(95 decibels).• Record the time very accurately using stop watch.• No break-time for observer during the working cycle-time of machine.
Future course of action• Apply Method Study and Time Study to increase productivity.• Reduce Cycle-Time by work elementation.• Reduce idle time by applying time study.
References• BOOKS: Introduction to work study.(ILO) Motion and time study by R.M.Barnes.