This document provides a summary of a project to identify ineffective time at an Indo Rama Synthetics polyester manufacturing plant. The objectives are to determine operator idle time, calculate standard cycle times, and suggest improvements. 49 draw texturized yarn machines will be studied using time and method study tools to rationalize times and improve productivity by reducing cycle times and operator idle time. Suggestions include using ear plugs due to noise levels and accurately recording times with stopwatches.

1. IDENTIFICATION OF
INEFFECTIVE TIME
GUIDED BY: SUBMITTED BY:
PROF. PRIYA KHANDEKAR GOPAL BHATTAD(42)
MOHIT MAHESHWARI(55)
PARIKSHIT AGRAWAL(58)
PIYUSH JAIN(61)
SHRIKANT ASAWA(77)
YASHOWARDHAN KOTHARI(87)

2. Contents:
• Corporate File
• Problem Definition
• Tools To Be Used
• Objectives
• Project Work
• Facts Of DTY Plant
• Working Procedure
• Suggestions

3. CORPORATE PROFILE
• The history of Indo Rama Synthetics (India) Ltd. dates back to 1989.
• Indo Rama has emerged as India's 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.

4. • Indo Rama has the country's 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.

5. Problem Definition
• Determining the idle time of operator working
on machine.
• Calculate standard cycle-time/denier.
• Causes:
Unskilled Labour.

6. Tools to be used
• Method study
• Time Study

7. 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.

8. 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.

9. 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.

10. 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.

11. 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.

12. 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.

13. • Operators on Machine:
Coarse(3 operators/2 machine);
Fine(1 operator/machine);
Super-Coarse(2 operator/machine).
• Cycle Time:
Coarse(32-34 hrs.);
Fine(45-47 hrs.);
Super-Coarse(22-24 hrs.).

14. IMAGE FOR DTY PLANT

15. 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.

16. • 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.

17. 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.

18. 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.

19. References
• BOOKS:
Introduction to work study.(ILO)
Motion and time study by R.M.Barnes.

20. THANK YOU