Académique Documents
Professionnel Documents
Culture Documents
Presented By:
1. Raghvendr Omer (143190001)
2. Ashish Dubey (143190003)
3. Anshika Chaurasia (143190012)
1
TABLE OF CONTENTS:
1.
1. INTRODUCTION:
A terry towel is described as a textile product, which is made with loop
pile on one or both sides generally covering the entire surface or
forming strips, checks, or other patterns.
2. PRODUCT DETAILS:
A woven towel consists of five parts. These are the pile area, fringes,
beginning and end part, selvedge, border. The pile area is considered
the towelling part of the towel.
Product Specifications:
Product
Specifications
Length (cm)
Target
Ikea
Kohls
Walmart
140
140
140
140
Width (cm)
70
70
70
70
EPI
62
64
70
65
PPI
30
28
34
29
2/24 KW
2/24 KW
2/24 KW
2/24 KW
1/12 CW
1/12 CW
1/12 ZT
1/12 CW
1/10 OE
1/10 OE
1/10 OE
1/10 OE
GSM
450
490
500
450
Fabric Weight
441
480
490
441
Terry Type
3 Pick
3 Pick
3 Pick
3 Pick
Ground Weave
2/2 Plain Weave 1/1 Plain Weave 2/1 Twill Weave 1/1 Plain Weave
3. PROCESS FLOW:
Cheese Winding
After- treatment
Winding process
Warping
process
Sizing process
Weaving process
Weaving
machine
Dyeing
machine
4. PLANT LAYOUT:
14
Loom Section
(35 M/c)
Sizing Section
(1 M/c)
Warping Section
(2 M/cs)
TFO Section
(1 M/c)
Cheese Winding
(1 M/c)
Dyeing Section
(6 M/cs)
Humidity
Controllers
Finishing Section
(23 M/cs)
Designing
MILL YARD
QA
Department
Yarn Warehouse
15
Weaving Preparatory
Weaving
Dyeing
Finishing
Machine Name
No. of Machines
Cheese Winding
TFO
Direct Warping
Sectional Warping
Sizing
Looms
35
Dyeing Machine
Hydroextractor
Rope Opener
Stenter
Juki Machines
20
16
PLANT LOCATION:
Region Selected: Surat, Gujarat
Selection of Region:
Surat was considered for plant location due to the following reasons:
1. Supply of Raw Materials:
It is essential for our organization to get the raw materials supplied on- time, as our
company is a continuous manufacturing company working 24 * 7, thus requires, on- time
delivery of raw materials.
2. Proximity to Sea- Ports:
Ours company is dealing with foreign customers, thus it is required to serve them on time,
and so it is required that is closed to the sea- port.
3. Labor and Wages:
Skilled labor is easily available in that place.
4. Laws and Taxation:
Law and taxation rules of Gujarat State was quite flexible for setting the factory.
17
5. DEMAND FORECASTING:
Towel Demand Data
Month
1
2
3
4
5
6
7
8
9
10
11
12
Target
60000
55000
50000
49000
48000
58000
47000
46000
50000
61000
58000
59000
Ikea
120000
125000
115000
135000
115000
125000
106000
125000
110000
119000
124000
117000
Kohls
70000
74000
68000
75000
65000
72000
68000
62000
68000
65000
68000
71000
Walmart
150000
145000
155000
159000
144000
130000
160000
157000
162000
146000
139000
149000
Bathrobe Demand
Data
Walmart
59000
63000
60000
58000
62000
61000
59500
60500
57500
56500
59000
61500
18
Towel Forcast
Target
Forecast
Ikea
Forecast
Kohls
60000
60000
120000
120000
70000
70000
150000
150000
59000
59000
55000
58500
125000
121500
74000
71200
145000
148500
63000
60200
50000
55950
115000
119550
68000
70240
155000
150450
60000
60140
49000
53865
135000
124185
75000
71668
159000
153015
58000
59498
48000
52105.5
115000 121429.5
65000
69667.6
144000 150310.5
62000
60248.6
58000
72000
61000
60474.02
47000
51811.7
106000 117550.5
68000
59500
60181.81
46000
62000
60500
60277.27
50000
68000
57500
59444.09
10
61000
65000
56500
58560.86
11
58000
68000
59000
58692.6
12
59000
71000
61500
59534.82
Demand
Forecasted
for Next
Month
56013.37158
118712.455
68305.33283
148364.897
59534.82248
19
6. CALCULATIONS:
Maximum Capacity Calculation Per Day:
Number of looms = 35
Number of looms assigned for towel production = 25
Number of looms assigned for bathrobe production = 10
Towel Calculation:
Loom RPM = 550 rpm (on average)
Picks per inch = 34 (on average)
Length produced per shift per machine = Loom rpm * 60 * 8 *.75
39.37*PPI
= 550 * 60 *8 * .75 / (39.37*34)
= 147.92 mts
Length produced per day = 147.92 * 3 = 443.75 mts
Length produced in 30 days per 25 machines = 443.75 * 25 * 30 *.93(repair) = 309518 mts
Loom Width = 170 cm
Towel Length = 1.4 mts
Lines of towels produced per loom = 2
Thus, total length = 309518 * 2 = 619036 mts
Maximum number of towels produced with 75% efficiency per month = 619036 / 1.4 = 442168
20
Bathrobe Calculation:
Area required per bathrobe = 3 sq mts
Length produced in 30 days per 10 machines = 443.75 * 10 * 30 *.93(repair) = 123807 mts
Area produced per 30 days per 10 machines = 12807 * 1.6 = 198092 sq mts
Maximum number of bathrobes produced with 75% efficiency per month = 198092/3 = 66030
Dye Requirement Calculation:
Cost of dye = Rs. 2500 per 25 kg
% Shade depth requirement of towel on average = 2%
Requirement of dye for 1 month:
Customer
Target
Ikea
Kohls
Walmart
Walmart
Type
Towel
Towel
Towel
Towel
Bathrobe
Weight(g)
Demand
441
56013.3716
480
118712.455
490
68305.3328
441
148364.897
1200
59534.8225
Total Dyes Consumption
2% Shade
494.0379373
1139.639568
669.3922617
1308.578392
1428.835739
5040.483898
21
7. MRP:
DyesCone
Cones
& Chemicals
ofofdifferent
differentyarn
yarncount
counts
count
22
Target
Terry Towel LT-
Gross Requirement
7
14007
Scheduled Receipts
Projected on Hand
4002
6003
8004
10005
12006
Net Requirements
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
2001
100
100
100
100
100
100
Net Requirements
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
1/24 KW
LT- 1 day
2001
Gross Requirement
Scheduled Receipts
Projected on Hand
100
100
23
1/12 CW
LT- 1 day
214
214
214
214
214
214
Net Requirements
214
214
214
214
214
214
214
214
214
214
214
214
214
214
214
214
214
214
65
65
65
65
65
65
Net Requirements
65
65
65
65
65
65
65
65
65
65
65
65
65
65
65
65
65
Gross Requirement
Scheduled Receipts
Projected on Hand
1/10 OE
LT- 1 day
214
Gross Requirement
Scheduled Receipts
Projected on Hand
65
65
24
Dyes
Dyes LT- 1 Week
1 Week
Gross Requirement
2 Week
3 Week
4 Week
2245
2245
Net Requirements
2245
2245
2245
2245
Scheduled Receipts
Projected on Hand
1122.5
2245
2245
25
8. SCHEDULING:
Total number of looms: 35 (Toyota Air Jet 170 cm)
Customer
Type
Target
Terry Towel
IKEA
Terry Towel
Kohl's
Terry Towel
Wal-Mart
Terry Towel
10
Wal-Mart
Bathrobe
10
26
5040 kgs
Rs. 1000
100
2244.994432
Order Period
2 Weeks
Lead Time
1 Week
27
10. TPM:
TPM Policy Sameer Company is committed to achieve ZBAD (i.e.
Zero Breakdown, Zero Accident and Zero Defect) through the
elimination of all types of losses by adapting TPM Culture, with
enhanced people skill, company morale, asset life, productivity,
customer satisfaction & market capitalization in a Clean and Green
Environment.
All data related to the manufacturing is stored in SAP (System,
Applications and Products).
28
Waste
Projects Undertaken
Loom
False Selvedge
Loom
Yarn
Loom
Downgrade Towels
Dyeing
Torn
Dyeing
Re Processing
Finishing
Finishing
12. COSTING:
Fixed Assets
Land Cost
TFO
Direct BeamWarping Machine Cost
Cheese Winding and Sizing
Sectional Warping
Loom Cost
Dyeing and Finishing Machines
Construction Cost
Total Fixed Assets
Current Assets
Inventory
Cash
Account Receivable
Total Current Asset
Revenue
Target Towel
Ikea Towel
Kohls Towel
Walmart Towel
Bathrobe Towel
Total Revenue
Material Cost
Labor Cost
Overheads
INR
22500000
2000000
1500000
10000000
3000000
70000000
80000000
7500000
196500000
2000000
5000000
3000000
10000000
14003343
35613736
34152666
51927714
32744152
168441612
84220806
15500000
54220806
30
13. ROI:
Profit Margin
Assets
Income
Sales
Assets
Turn (16.8
Over
Sales
Cost
Fixed
Working
Employed
(8.6%)
(1.45
of
crore)
Crore)
Rate
(16.8
Capita
Material
Overheads
Current
crore)
Good
Capital
(0.81)
(20.65
crore)
(19.65
Sold
Liabilities
assets
Cost
(1
(5.4
crore)
(15.39
crore)
crore)
(8.4
(1crore)
crore)
crore)
(0)
crore)
31
Sizing
Weaving
Dyeing
Finishing
2.76
1.51
12
2.5
No. of Workers/ Mc
0.25
Process Efficiency
75%
80%
76%
70%
78%
80%
84%
Idle Time
25%
20%
24%
30%
22%
20%
16%
41.4
18.12
43.2
126
26.4
144
24
32
REFERENCE:
1.
www.academia.edu/26966090/Production_and_Processing_of_Terry_Towe
ls
2. http://texinfo.files.wordpress.com/2011/10/terry-towel.pdf
3. www.alibaba.com
4. www.tridentindia.com
5. www.huntsman.com
6. www.search.fibre2fashion.com
7. Tirupur market rate- Tirupur yarn rate (www.tirrate.blogspot.in)
8. www.nptel.ac.in
9. Textile Mathematics by R.Sen.Gupta
10. Woven Fabric Part-II by NCUTE
11. Class notes of forecasting and MRP
33
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