Study on Lean, Quality Implementation and Waste Management in Textile Mill

1. Quality Circle Project

2. • Universal Textile Mills / Jaipuria Silk Mills Pvt
Ltd
44 Gudahhati Main Road, Neralur Post,
Bengaluru 562107
• www.universaltextile.com

3. CONTENTS
• About The Company.
• Basic Processes.
• Existing problems.
• Problem Statement.
• Problem Definition,
Analysis &
Probable Solution.
• Future Course of Action

4. ABOUT THE COMPANY
• Jaipuria Silks has been associated with silks for around
40 years.
• Director: Abhay Jaipuria.
• Their product are silks and linen material. They do all
processing in-house: printing, dyeing, washing, ironing.
• They are working with around 30 countries.
• Major part of their products are exported to Europe
and US.
• Around 30% of raw material are produced in house
while rest are imported from China.

5. BASIC
PROCESS IN
THE TEXTILE
MILL
Washing
Yarn Dyeing
Winding
Warping
Weaving
Printing
Steaming
Finishing

6. THE EXISTING PROBLEMS
• Visual Management and Kanban problem
• Waste Management
• Quality in Core processes
• Vendor Management/Procurement
• Logistics
• Office and Accounts

7. FACTORS CONSIDERED FOR FINAL
SELECTION OF PROBLEM
• Cost involved
• Management’s Viewpoint on issues
• Time factor

8. PROBLEM STATEMENT
Universal Textile Mill is facing problems in the areas of
Visual Management, Waste Management
and Quality Aspects
ultimately resulting in increased costs
and reduced profits.

9. 1. VISUAL MANAGEMENT

10. ISSUES
1. Absence of proper identification and storage
of materials.

12. PROBABLE SOLUTIONS
• Employing location
labeling for
identification and
storage.

13. • Material
Identification
(colour) codes.

14. • Floor marking
tapes
showing
walkways and
restricted
areas.
• Floor marking
tapes showing
specific
storage areas.

15. 2. Absence of an Organized and Structured work
environment.

16. PROBABLE SOLUTIONS
• Systematic Cleaning
and Painting
Schedule.
• Introduction of 5S.

18. IN ADDITION, THE FOLLOWING CAN
BE CONSIDERED.
• Visual Displays:
– Recognizing
performances of
employees.

19. • CAPA for injuries.

20. • Weekly Rejection
rates, desired
targets, downtime
can be displayed.
• Vision, Mission
can be displayed
in the shop floor.

21. • Visual Control:
– Signs such as Warning, Danger signs, Safety signs, etc.

22. 2. WASTE MANAGEMENT
Textile Manufacturing

24. CURRENT SITUATION
• The products are exported to Europe and
America. As a result, products which do not
conform to the desired specifications are
rejected.
• This results in rejection of even slightly
defected products.
• The scrap is sold based on the weight.

25. TURN FABRIC SCRAP INTO YARDAGE

26. THREE BASIC STEPS
• Resale
• Recycle
• Conversion to Rags

27. GENERAL OBJECTIVES OF REDUCING
TEXTILE CUTTING WASTE
• Optimum, uniform width
• Maximum practical length
• Minimum defects
• Protective packaging, with clean, increased
ends at beginning and end of roll
• Minimum shade variation

28. TO STUDY..
• Reduce waste/costs associated with textile
cuttings
• Reduce waste/costs associated with common
recyclables (paper, plastic, etc.) and generate
revenue
• Reduce waste/costs associated with dyes and
chemicals

29. 3. QUALITY

30. QUALITY ASPECTS IN DIFFERENT
PROCESSES
A. Quality issues in the digital textile printing.
B. Quality issues in the digital jacquard looms for
yarn weaving.

31. A. DIGITAL TEXTILE PRINTING
• This is the technology that consists of printing
your designs on fabric, directly from your
computer, with no other additional step.

33. QUALITY ISSUES IN DIGITAL FABRIC
PRINTING
Defects Primary causes (Brain storming)
1. Specky / patchy dyeing Water drop on fabric and too much
foaming
2. Dark colored spot Incompatibility and high dye stuff
concentration
3. Dark or light selvedges Non uniform batching
4. Flushing/Wicking Low viscosity of print paste
5. Scrimps Fabric may creases underneath one of the
screens
6. Misfits Improper alignment of the screens

34. MEASURING DEFECTS USING CHECK SHEET TOOL
Defect Types/
Event Occurrence
Dates
TOTALSunday Monday Tuesday Wednesday Thursday Friday Saturday
Specky / patchy dyeing 11 16 6 15 5 24 6 83
Dark coloured spot 2 5 1 2 1 11
Dark or light selvedges 3 8 1 9 21
Scrimps 1 6 1 8
Misfits 1 1 1 4 7
Miscellaneous 2 1 1 4
Flushing/Wicking/Color 8 19 10 5 11 53
Colour out 2 1 3
Machine Stop 1 1
TOTAL 25 47 20 28 10 30 31 191

35. Frequency 83 53 21 11 8 7 4 3 1
Percentage 43.5 27.7 10.9 5.7 4.1 3.6 2.0 1.5 0.5
Cum % 43.5 71.2 82.2 88.0 92.1 95.8 97.9 99.5 100
Specky/PatchyDyeng
DarkorlightSlevedges
Flushing/Wicking
DarkcoloredSpots
Scrimps
Misfits
MachineStop
Colorout
Miscellanious
0%
20%
40%
60%
80%
100%
0
20
40
60
80
100
120
140
160
180
200
Cumulative%
Defects
Causes
Pareto Chart Of Quality Issues Recorded
Vital Few Useful Many Labels Cut Off % [42]

36. • From Pareto Analysis it was observed that “
71.2% of quality issues were caused due to
Specky / patchy dyeing & Flushing/Wicking”
• So these 2 issues will be considered for further
analysis

38. B. JACQUARD WEAVING
• Weaving is done by employing Jacquard looms
which involves the programmed raising of
each warp thread over the other depending
on the desired pattern.

40. QUALITY ISSUES IN DIGITAL
JACQUARD WEAVING
Defects Primary causes (Brain storming)
1. Yarn breaking Thread inconsistency
2. Coloured Flecks Presence of coloured foreign matter in
the yarn because of mixing
3. Slub (low twists yarn) Broken tooth in the chain of gear system
4. Broken pattern Wrong drawing in of threads, Incorrect
shedding
5. Double end Wrong drawing
6. Gout (Foreign material) Improper loom cleaning.

41. MEASURING DEFECTS USING CHECK SHEET TOOL
Defect Types/
Event Occurrence
Dates
TOTALSunday Monday Tuesday Wednesday Thursday Friday Saturday
Loose Threads
1 1 2 2 6
Coloured Flecks
2 2
Slub (low twists yarn)
6 5 3 9 4 7 34
Broken pattern
2 3 4 7 16
Double end
1 1
Gout (Foreign
material) 4 6 9 4 2 25
Yarn breaking
2 1 1 4
Miscellaneous
1 1 2
Hole/Cut/Tear
1 1
TOTAL 15 12 15 6 19 12 12 91

42. Frequency 34 25 16 6 4 2 2 1 1
Percentage 37.4 27.4 17.5 6.5 4.3 2.1 2.1 1.0 1.0
Cum % 37.4 64.8 82.4 89.0 93.4 95.6 97.8 98.9 100
Slub
Gout
Brokenpattern
LooseThreads
Yarnbreaking
ColouredFlecks
Miscellaneous
Hole/Cut/Tear
DoubleEnd
0%
20%
40%
60%
80%
100%
0
10
20
30
40
50
60
70
Cumulative%
DefectsFrequency
Causes
Pareto Chart Of Quality Issues Recorded
Vital Few Useful Many Cumulative% Cut Off % [42]

43. • From Pareto Analysis it was observed that “
78.5% of quality issues were caused due to
Slub, Gout & Brocken pattern”
• So these 3 issues will be considered for further
analysis

45. STEPS
 DONE
 Measuring the number of different defects over a period of
time.
 Using the Pareto analysis (80-20 concept) for finding the
most frequently occuring defects.
TO DO
• Then trying to find out the probable causes for those
defects using Why-why analysis and Fish Bone diagram.
• Finally finding the pursuable causes and eliminating them
in order to remove the overall problem.

46. FUTURE COURSE OF ACTION
• Generation of alternatives
• Choose the most feasible solution
• Evaluation of suggestions in terms of
• Cost of implementation
• Savings
• Impact on quality
• Implementation