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Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd, Bhiwani

National Productivity Council , Bangalore

Confidential

REPORT ON

MANPOWER ASSESSMENT

At

GRASIM BHIWANI TEXTILES LIMITED(A Subsidiary of Grasim Industries Limited)

BHIWANI – 127 021

NATIONAL PRODUCTIVITY COUNCIL(Under Ministry of Commerce & Industry, Govt. of Ind ia)

REGIONAL PROFESSIONAL MANAGEMENT GROUP

BANGALORE





C O N T E N T S

Section Chapter Description Page No

AcknowledgementExecutive Summary 1

I Introduction 2

II Methodology 4

III Departmental reports

1 Elegant Spinning - Production 6

2 A Elegant Spinning – Mechanical Maintenance 85

2 B Elegant Spinning – Electrical Maintenance 107

3 BTM Spinning - Production 1094 A BTM Spinning – Mechanical Maintenance 181

4 B BTM Spinning – Electrical Maintenance 254

5 A Fiber Dyeing 256

5 B Yarn Development 286

6 Weaving - Preparatory 295

7 Weaving - Loomshed 315

8 A Weaving Maintenance - Mechanical 334

8 B Weaving Maintenan ce - Electrical 341

9 Weaving – QA 355

10 Checking, Mending And Finishing 362

11 Process House - Production 409

12 Process House - Maintenance 453

13 Logistics 467

14 Thermal Power Plant 502

15 Yarn Godown 528





ACKNOWLEDGEMENT

We wish to place on record our sincere thanks to the

management of M/s Grasim Bhiwani Textiles Limited, forhaving given us the opportunity to conduct a study onManpower Assessment in their plant located at Bhiwani. Inparticular, we sincerely thank Shri S. Krishnamoorthy

(President) and Shri Manmohan Singh (Unit Head) forhaving entrusted the study to us.

We are grateful to Shri R. Subramaniam (VP-Operations) for providing critical & valuable inputs during the study

and for ensuring that the study is carried out as per theschedule.

We express our sincere thanks to Shri Arun Verma (AVP –

HR & IR) and Shri Kaushal Tanwar (GM – HR & IR) forthe timely coordination provided by them during the study .

We acknowledge the valuable time & effort spared and thetimely provision of the information & data, by all theOfficers and Staff of the plant during the study.

We also credit all the employees for their cooperation to theNPC team during the study.

Bangalore M.L.Suryaprakash27 th March 2012 Regional Director





Executive Summary

The summary of the present and the proposed manpower for the variousdepartments studied is detailed in table 1.1 below. The manpowerproposed for the current level of production is 1679 against the presentdeployment of 1959.

The present and the proposed manpower numbers are basic manpower(without inclusion of any relief – off and leave).

Table 1.1

Summary of the Present and Proposed ManpowerS.No Department Manpower (Numbers)

Present Proposed

1 ELEGANT SPINNING - PRODUCTION 281 275

2 A ELEGANT SPINNING - MECHANICAL

MAINTENANCE

31 30

2 B ELEGANT SPINNING - ELECTRICAL

MAINTENANCE

14 14

3 BTM SPINNING - PRODUCTION 393 355

4 A BTM SPINNING - MECHANICALMAINTENANCE

38 33

4 B BTM SPINNING - ELECTRICAL MAINTENANCE 21 21

5 A FIBER DYEING 58 46

5 B YARN DEVELOPMENT 16 16

6 WEAVING - PREPARATORY 122 91

7 WEAVING – LOOMSHED 126 119

8 A WEAVING MAINTENANCE - MECHANICAL 5 6

8 B WEAVING MAINTENANCE - ELECTRICAL 18 16

9 WEAVING –

QA 7 710 CHECKING, MENDING AND FINISHING 249 184

11 PROCESS HOUSE - PRODUCTION 220 199

12 PROCESS HOUSE - MAINTENANCE 25 22

13 LOGISTICS 230 154

14 THERMAL POWER PLANT 70 69

15 YARN GODOWN 35 22

TOTAL 1959 1679





Chapter I – Introduction

1.1 The Aditya Birla Group (ABG) is an Indian multinationalconglomerate corporation headquartered in Mumbai, India. Itoperates in 33 countries with more than 133,000 employeesworldwide. The group has diversified business interests and isdominant player in all the sectors in which it operates such asviscose staple fibre, metals, cement, viscose filament yarn, brandedapparel, carbon black, chemicals, fertilisers, insulators, financialservices, telecom, BPO and IT services. The group is a US$35 billion conglomerate which gets 60 % of its revenues fromoutside India. The Aditya Birla Group has been adjudged the bestemployer in India and among the top 20 in Asia by the Hewitt-Economic Times and Wall Street Journal Study 2007.

1.2 The Aditya Birla Group is the world's largest player in the ViscoseStaple Fiber industry. Apart from viscose staple fiber, the groupalso owns acrylic fiber businesses in Egypt and Thailand, viscosefilament yarn businesses and spinning mills at several locations allover India and South East Asia. The Aditya Birla group is also amajor player in the branded garments market in India.

1.3 The Aditya Birla Group wanted to improve their productivity inthree of their textile units in India and accordingly they have

requested National Productivity Council (NPC) to take up the stud y.

1.4 M/s. Grasim Bhiwani Textiles Limited (GBTL) is a verticallyintegrated textile mill with two spinning division, one weavingdivision and a fabric processing division.

1.5 Scope of Grasim Bhiwani Textiles Limited (GBTL):

1.5.1 The scope of the study includes the assessment of manpower

(workmen only) for operating the BTM Spinning and ElegantSpinners having combined spindle capacity 35,728 nos. andother related & support functions e.g. maintenance,engineering and qualit y assurance.

1.5.2 The manpower assessment study shall also be conducted forthe workmen of weaving department of 140 looms andfabric processing having capacity of 15 lakhs meters permonth and related & support functions e.g. maintenance,engineering and qualit y assurance.

http://en.wikipedia.org/wiki/Multinational_corporation

http://en.wikipedia.org/wiki/Conglomerate_%28company%29

http://en.wikipedia.org/wiki/Mumbai,_India

http://en.wikipedia.org/wiki/Acrylic_fiber

http://en.wikipedia.org/w/index.php?title=Viscose_filament_yarn&action=edit&redlink=1




http://en.wikipedia.org/wiki/Acrylic_fiber

http://en.wikipedia.org/wiki/Mumbai,_India

http://en.wikipedia.org/wiki/Conglomerate_%28company%29

http://en.wikipedia.org/wiki/Multinational_corporation





1.5.3 The study will also cover the manpower deployed inlogistics (Warehouse and Dispatch) and Yarn Godownactivities.

1.5.4 The study will be limited to the manpower requirement of non-executive (workmen category) cadre employees of theplant operation.





Chapter II – Methodology

2.1 The manpower assessment study was carried out by a team of consultants of National Productivity Council, led by the Chief

Consultant and the individual consultants drawn fromthe

Bangalore office and New Delhi office. NPC deputed a team of four Consultants to carry out the detailed studies. The fieldstudies in Bhiwani were carried out from 16 t h November 2011till 14 t h January 2012.

2.2 The assignment was kicked off by an opening meeting with theunit head and the HOD’s of the various departments. The

methodology to be followed by the team, expectation from thevarious stakeholders and the various time lines were clearly

explained in the meeting. This was followed by a plant visit andinitial discussions amongst the team members. The followingsteps were followed for the detailed studies in the concernedareas.

2.3 The manpower requirement of Permanent and Contract

employees (other than maintenance) was determined by the

following process

2.3.1 Collection of the data regarding the activities, frequencies,

machine characteristics, for all the personnel involved in all thedepartments.

2.3.2 NPC consultants conducted detailed time and motion studies forall the jobs involving both the categories of workmen.

2.3.3 NPC also collected the requisite clarifications regarding theactivities carried out, frequency of occurrence and recordsmaintained through discussions with the employees, directobservation and also through perusal of past records and

documents.

2.3.4 The rest and relaxation allowances were computed based onILO recommendations and NPC's own experience in t his area.

2.3.5 The manpower was rationalized through reallocation of duties / tasks to even out the variations in work loads, if required.





2.4 The manpower requirement of Permanent and Contract

employees in the maintenance departments was determined

by the following process

2.4.1 Collection of the data regarding the activities, frequencies, andcrew deployed for the breakdown maintenance and preventiveactivities. NPC consultants conducted the time and motionstudies on a sample basis for the maintenance activities and theobservations made were applied to the preventive andbreakdown maintenance activities.

2.4.2 Appropriate rest and relaxation allowances were computedbased on ILO recommendations and NPC's own experience inthis area and applied to the various works.

2.4.3 For the general shift personnel who are predominantlyperforming preventive maintenance works and major breakdownmaintenance works, the manpower has been calculated for 80 %loading. The rationale is explained in the individualdepartmental sheets .

2.4.4 Work sampling studies were carried out during the shift for thecrew to determine the utilization of the personnel in the variousactivities, wherever required.

2.5 The report was submitted to the GBTL management on 20 t h February 2012. Detailed discussions were conducted with themanagement team of the GBTL which comprised of AVP(Operations), AVP (HR & IR) and the concerned HOD and apresentation was performed to the President. Based on theinputs provided during the discussions, appropriate changeswere made in the manpower deployment and the finalizedmanpower deployment is presented in this report.



________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

1.0 ELEGANT SPINNING - PRODUCTION

_________________________________________________________________________ _______________

National Productivity Council, Bangalore.

http://www.iceni.com/unlock-pro.htm




___________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

1.01.1

I II III G T I II III G T

1 Mixing Mixing man 7 7 7 - 21 6 6 6 - 18

Waste Sorter - - - 3 3 - - - 3 3

2 Blow Room Tenter 3 3 3 - 9 3 3 3 - 9

3 Carding. Tenter 3 3 3 - 9 3 3 3 - 9

4 Draw Frame Sider 2 2 2 - 6 2 2 2 - 6

5 Speed Frame Sider 3 3 3 - 9 3 3 3 - 9

Doffer 2 2 2 - 6 2 2 2 - 6

Jobber 1 1 1 - 3 1 1 1 - 3

Jam Cutter - - - 1 1 - - - 1 1

6Ring Frame Sider 9 9 9 - 27 9 9 9 - 27

Doffer 16 16 16 - 48 16 16 16 - 48

Doffer-Reliever 2 2 2 - 6 2 2 2 - 6

Jobber 1 1 1 - 3 1 1 1 - 3

Seggerator 1 1 1 - 3 1 1 1 - 3

Checker 1 1 1 - 3 1 1 1 - 3

ELEGANT SPINNING - PRODUCTIONManpower Deployment *

S. No Section / Work area DesignationPresent Manpower Proposed Manpower

Remarks

__________________________________________________________________________________________________________ _______________________







1.01.1




Remarks

Floor Cleanner 1 1 1 - 3 1 1 1 - 3

7 Autoconer Jobber 1 1 1 - 3 1 1 1 - 3

Checker 1 1 1 - 3 1 1 1 - 3

Winder 7 7 7 - 21 7 7 7 - 21

Winder -Reliever 1 1 1 - 3 1 1 1 - 3

Doffer 1 1 1 - 3 1 1 1 - 3

Bobbin Sorter 2 2 2 - 6 2 2 2 - 6

Floor Cleaner 1 1 1 - 3 1 1 1 - 3

8 Cheese Winding Winder-RJK 4 4 4 - 12 4 4 4 - 12

Winder-SSM 2 2 2 - 6 2 2 2 - 6

Winder-Reliever 1 1 1 - 3 1 1 1 3

Cone

winding(Rewinding - - - 1 1 - - - 1 1

9 Two-for-one(TFO) Jobber 1 1 1 - 3 1 1 1 - 3

Doff Carrier 1 1 1 - 3 1 1 1 - 3

Tenter 8 8 8 - 24 8 8 8 - 24

__________________________________________________________________________________________________________ _______________________







1.01.1




Remarks

Tenter-Reliever 1 1 1 - 3 1 1 1 - 3

Floor Cleaner 1 1 1 - 3 1 1 1 - 3

Sweeper - - - 1 1 - - - 1 1

10 Packing Checker - - - 3 3 - - - 3 3

Lot-Final Checker - - - 1 1 - - - 1 1

Packer - - - 6 6 - - - 4 4

11 Cone-Tipping - - - 1 1 - - - 1 1

12 Yarn Conditioning - - - 2 2 - - - 1 1

13 Quality AssuranceInvestigator 1

- - - 1 - - - 1 1

Checker 2 2 1 1 6 2 2 1 1 6

88 87 86 20 281 86 86 85 18 275

* The above manpower deployment table is for 30s Count.

Total

__________________________________________________________________________________________________________ _______________________







1.0

1.2

1.2.1

I

a)

b)

c)

d)

P r o d u c t i o n

( k g s ) / H o u r

P a r a m e t e r s

21

14.6

148

320

115.5

120

spindle/

machine

CARDING-LR

D/F Breaker

15 Kg/ Can

D/F Finisher

Speed frame

ELEGANT SPINNING - PRODUCTION

Proposed Changes & Observations

I n p u t p e r

s h i f t p e r

m a c h i n e

O u t p u t

Q u a n t i t i e s

Methodology

15 Kg/Can

4.8035 Kg/ Can 12.92

The machine efficiency and operator workload are depicted in the graph to findout the

optimum (where running efficiency & operative workload meets) number of machines to be

alloted per personnel.

It is assumed that machines are subject to stops at random and unpredictable intervals. It is

also assumed that the operator will service a machine with the minimum delay after the

machine has stopped, and that if two or more are stopped at one time,he will attend to themby taking the nearest first. This method of servicing is called random tending. Thomas F.O'

Connor, provided the table for calculating the machine efficiency and operators workload in

this type of multimachine assignment problem in the book: Efficiency and Productivity

Tables for Textile Machine Operation, Institute of Textile Technology,Virginia.

CARDING-

CROSSROL

170.67

462.00

15 kg/Can

2 Kg/ Roving

7.79

61.60

78.93

170.67

Carding,Drawframe and Speedframe

8.98

33.83

o u t p u t p e r

s h i f t p e r

m a c h i n e

The frequency values are taken from the following tables for the repsective sections:

M / C N a m e

In Carding, Drawframe and Speed frame sections, the operator is responsible for the

operation of more than one machine, if two machines stop at a time and require tenter's

attention simultaneously,one of the machine must wait until he completes his work on the

other. This time loss representing waiting time due to overlapping of machine stoppage is

called "Interference loss".

_________________________________________________________________________ _______________







1.0

1.2



1.2.1

II

a)

b)

c)

d)

e)

f)

= (b-1) / [ N{K+(b-1)C}]

The running efficiency is arrived by the following formula provided by the research paper.

The working pattern of operators in Ringframe, Autconer, Cheese winding and Two-for-

One(TFO) is entirely different from the preceding section.In this areas,the operator's services

the machine in a cyclical manner and attends to each machines(drums) as he comes to it.

The difficulty in dealing with these problems lies in calculating the effect of "interference"

which is the term used for incidence of simultaneous stoppages at several machines. In fact, if

the optimum number of machines is being controlled by one operative, the machine efficiency

required will be a marked feature.

The research paper "The Efficiency of N machines Uni-Directionally patrolled by

single operative" by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal

Statistical Society, (1957), has been used to arrive the machines running efficiency for the

different number of machines handled by the operators in the above sections considering the

following working methodology:

Ringframe, Autoconer, Cheesewinding and Two-for-One(TFO)

r = Running Efficiency, i.e the percentage of running time to total (stopped + running)

time.Stopped means time lost due to interference and breaks includes rectification of

breaks.

C - Time to repair and restart the machine

The operative walks round the machines in a defined order and repairs and restarts any

machine which is found stopped, passing after inspecting and/or servicing any machine

which is running. It is assumed that the machine stops at random with the same mean

frequency and independent of each other.

g - Random breakdowns in running time @ each machine/drum

N - Number of machines

K- Mean walking time from one machine to next machine, includes inspection time

b = exp(gNK)

The operator workload is calculated by multiplying the time taken for different activities to be

performed with the frequency of the activities for the allotted number of machines.

Methodology

_________________________________________________________________________ _______________







1.0

1.2



1.2.1

g)

h)

M / C N a m e

P r o d u c t i o n ( K g

s ) / H o u r

M a c h i n e P a r a

m e t e r s

O u t p u t

A v a i l a b l e h o u r s / S h i f t

M / C a v a i l a b l i t y l o s t %

M / C A v a i l a b i l i t y ( % )

T o t a l T i m e a v a

i l a b l e f o r

p r o d u c t i o n / S h i f t

I n p u t p e r s h i f t

( o f r e s p

e f f i c i e n c y ) p e r m / c

o u t p u t p e r s h i f t ( o f

r e s p e f f i c i e n c y ) p e r m / c

R/F 16.95

576

spindle/m

achine

60 gms

Bobbin8 8 92% 7.36 62.38 2079.20

Autoco

ner-

Murate

ch

77.5

60

spindle/m

achine

2 Kg

Cone8 30 70% 5.6 7233.33 217.00

Autoco

ner-

Savio

77.5

60

spindle/m

achine

2 Kg

Cone8 25 75% 6 7750.00 232.50

Cheese

Windin

g-RJK

150

160

spindle/m

achine

1 Kg

Cheese8 28 70% 5.6 420.00 840.00

TFO 10.2

156

spindle/m

achine

2 Kg

Cone8 2.5 97.5% 7.8 79.56 39.78

1.2.2

I

a)


Proposed Changes

Mixing Blenders:

In view of low utilisation (69.44 %), it is recommended to deploy six personnel instead of the

present seven personnel in a shift for three mixing blenders operation. The proposed

utilisation of six personnel would be 81.01%

The running efficiency values and operator workload are depicted in the graph to findout the

optimum (where running efficiency & operative workload meets) number of drums to be


Methodology

_________________________________________________________________________ _______________







1.0

1.2



1.2.2II

a)

III

a)

b)

IV

a)

1.2.3

Ia)

Yarn Conditioning Room

In view of low utilsation 39.77 % of two personnel,it is recommended to deploy one person in

the yarn conditioning operation.The proposed utilisation of the personnel would be 79.55%

Carding

It was observed that the carding tenter, dump the different coloured sliver waste collected

together in a single place near the machine. Say for example, brown colur with the black

colour waste. Hence,the waste is again to be segregated by waste sorter. It is recommended

that the tenter's should not mix the waste and advice to dump different coloured waste

separately.

Observations

Deploy four personnel as the packer instead of present six personnel. The proposed utilisation

of the group is 72.33 %.

Keeping in mind,the number of trolley and weighing machine,space constraint on the

packing table,and in order to prevent mixing, four personnel is recommended.

Packing - Packers

Carding Tenter:

Deploy two operator for carding machine operation and deployment as follows:

one operator - 12 crossrol machine

Second operator- 6 LR + 4 Crossrol machines.

The third operator is provided as the reliever for carding tenters(2 personnel),Drawframe

tenter(2 nos). Presently drawframe tenter is being relieved by jobber.

Proposed Changes

_________________________________________________________________________ _______________







1.0

1.2



1.2.3

IIa)

III

a)

Observations

The machine gets stopped because of lack of coloured cans. Bands are used presently to

differentiate count/colur. It was observed that there is no fixed standard for this.Hence, there

would be a chance of mixing. It is suggested to makke visual display of the colour

combinations(can colour+band colour) and their repsective count. Presentlyas there is no

proper visual board or colour standards,operators are waiting for the checker/jobber's help in

changing or using the cans.

Effective Co-ordination- Ringframe Doffers

Drawframe

From the field study, it has been observed that the time taken for count change in ringframesection purely depends on the people management skill level of doffer leader. During the day

of study, it was observed that because poor planning, the ringframe was stopped more than

two-three hours for count change In the middle, they have taken another machine for ring

travellours change. It affects the machine availability time for the production.

_________________________________________________________________________ _______________







1.0

1.3

S.No

1

2

3

4

5

6

7

8

9

10

11

12

1314

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

3536

37

38

39

40

41

42

Mixing Man ESP/W/01


Workload Sheets Summary

Area of work WLS Number

Carding Tenter ESP/W/05 & A

Cheesewinding-Winder(RJK) ESP/W/27

Blowroom Tenter-1&2 ESP/W/03

Blowroom Tenter-3 ESP/W/04

Cheesewinding-Winder(SSM) ESP/W/26

Drawframe -Sider ESP/W/06

Speedframe Tenter ESP/W/07

Speedframe Doffer ESP/W/08

Speedframe Jobber ESP/W/09

ESP/W/10Speedframe-Jam cutter

Packing -Packer ESP/W/38

Autoconer-Winder ESP/W/21 & A

Autoconer-Doffer ESP/W/23

QA-Checker ESP/W/42

QA- Investigator ESP/W/41

Cheesewinding-Winder Reliever ESP/W/28

TFO- Tenter Reliever ESP/W/33

Cheesewinding-Rewinding ESP/W/29

Cone tipping ESP/W/39

Yarn conditioning Room ESP/W/40

Autoconer-Bobbin Sorter ESP/W/24

Autoconer-Floor Cleaner ESP/W/25

Packing - Checker ESP/W/36

Autoconer-Jobber ESP/W/19

Packing -Lot Final Checker ESP/W/37

Ringframe-Checker ESP/W/17

Ringframe-Floor cleaner ESP/W/18

TFO- Tenter ESP/W/32

Ringframe-Sider ESP/W/11

Ringframe-Doffer ESP/W/12

Ringframe-Jobber ESP/W/15

Ringframe-Doffer Reliever ESP/W/14Ringframe-Doffer Leader ESP/W/13

Waste Sorter ESP/W/02 & A

TFO- Jobber ESP/W/30

TFO- Doff Carrier ESP/W/31

Ringframe-Segregator ESP/W/16

Autoconer-Checker ESP/W/20

TFO- Sweeper ESP/W/35

TFO- Floor Cleaner ESP/W/34

Autoconer-Winder Reliever ESP/W/22

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 7 7 7 -

Designation Proposed Manpower 6 6 6 -

Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

a 1 1 4.95 4.95

b 1 1 2.48 2.48

c 2 1 10.50 21.01

d 1 1 4.00 4.00

e 1 1 1.13 1.13

2

a 2 5 3.92 39.15

b 1 5 1.42 7.11

c 1 2275 0.026 59.32

d 1 2275 0.028 62.73

e 1 20 3.85 77.00

a 2 3 3.92 23.49

f 1 3 1.42 4.26

g 1 1225 0.026 31.95

h 1 1225 0.028 33.78

i 1 3500 0.08 280.00

3

a

b

4

a

b

3853500 0.11

1 3500 0.11 385

Cut the material vertically in the mixing bin,lift and feed

on blender belt conveyor

WLS No: ESP/W/01

WORK LOAD DETAILS SHEET

Elegant SpinningShifts A B C G

Mixing Room

Bring the chemical ( AS 400) from the plastic drum in

the presence of supervisor after weighing

Bring the chemical ( AS 200) from the plastic drum in

the presence of supervisor after weighing

Bring the hot water in a plastic drum from geyser

Blender

Mixing Boy

Activity Description

Spin Finish Solution preparation ( No 1 & 3)(in front

of shift incharge)

Do layering by spreading polyester and viscose on the

alternate layer by manually

Mix the AS-200 & AS-400 one by one in the hot water

Bring the polyester bags from respective area to near the

machine

Layering

Open the bales of polyester bags

Bring the viscose bags from respective area to near the

machine

Take the polyester from bags and put it on the belt

conveyor(feed end)

Open the bales of viscose bags

Take the viscose from bags and put it on the belt

conveyor(feed end)

To pickup the viscose from beater & spread in mixing

Spread the blender output (inside the bin) evenly by

manual

Second Toppling (Mixing)




manual

1

Keep the empty chemical cans in the respective area

Spray the spin finish solution uniformly on the every

layer of polyester fibre using spray pump


manual

First Toppling (Mixing)

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: ESP/W/01



Mixing Room

Blender

Mixing Boy


5

a

b

6

a

b

c

d

A 1869.52

B 17

C 2187.34

D 450

E 69.44%

F 6

G 81.01%

1 3500 0.11 385

Proposed Utilisation(%)

Target - 2500 Kg /person * 7 persons / shift =17500 kg / shift . Each batch have 5 steps. It

becomes 3500 kg batch ( 3500 * 5 steps = 17500 kg)

P/V (65/35) mixing is considered. Hence , 3500 *65% Polyester = 2275 kg / shift , 3500 * 35%

Viscose =1225 kg/ shift.

As minimum two personnel required per mixing room, six personnel is being recommended per

shift for three blowrooms.

Lot Change ( Shade Change)

Clean the bins before starting the mixing.

Final Toppling (Mixing)

Rest & Relaxation Allowances ( % )

1 1 62.17

Basic Workload per Shift ( in man minutes)

Clean the blender & beater

Clean the floor area around the machineTo remove the jam of beater & blender ( if any)


manual



62

Remarks:

Total Workload ( in man minutes )

Net Available man-mins

Present Utilisation(%)

Proposed Manpower per shift

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower - - - 1

Designation Proposed Manpower - - - 1

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 20 101.00 101.00

2 1 20 9.40 9.40

3 1 2 38.00 38.00

4 1 4 48.00 48.00

51 1 25.00 25.00

A 221.40

B 13

C 250.18

D 480

E 52.12%

F 1

G 52.12%

WLS No: ESP/W/02


ELEGANTShifts A B C G

PREPARATORY


MIXING

WASTE

SORTER/CARRIER


Putting waste from carding m/c into bags & weighing

Sewing the bags

Cleaning the area

Bring material from store(antistatic, stationery etc.)

Deliver waste report to post spinning and then to raw

material dept.


Remarks:






_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

12 238.64 477.29

2 2 26.57 53.14

3 2 4 42.40 84.80

4 2 20 bags 22.00 44.00

A 659.23

B 13

C 744.93D 480

E 77.60%

F 2

G 77.60%

GPREPARATORY

Cleaning the whole area with broom

Helping in weighing of bags

WLS No: ESP/W/02 A


ELEGANTShifts A B C

MIXING

WASTE SORTER


Waste sorting-Avg. waste coming in

=294.57KG/shift 120 KG

Placing the sorted out material in respective bags






Remarks:



_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 2 2 -

Designation Proposed Manpower 2 2 -

Sl.

No

Cre

w

Size

Freq/ machi

ne /

Shift

No of

machi

nes

Basic

Time

(Mins)

Total

Time

(Mins)

1

1.1 1 1 2 2.00 4.00

1.2 1 1 2 5.00 10.00

2 1 1002 2 0.073 146.29

3 1 78 2 0.23 35.884 1 78 2 0.15 22.78

5

1 78 2 0.13 20.59

6 1 76 2 0.36 54.26

7 1 76 2 0.15 22.34

81 78 2 0.21 32.45

9 1 1 2 2.00 4.00

10 1 1 2 2.31 4.62

11 1 2 2 4.00 16.00

12 1 0.44 2 90.00 79.20

13 1 1 2 4.00 8.00

A 460.42

B 15

C 529.48

D 450

E 58.83%

F 2G 58.83%

Lot change - 4 machine/(3 shifts*3 machine) = 0.44 /shift/machine

Machine Capacity - 155 kg/ hour * 8 hour * 80% machine availability= 992 kg /13 kg lap = 77

laps

Rejection (0.01%) = 992*0.01 = 9.92 kg/13kg lap= 1 lap





Total =992 kg+9.92 kg = 1002 kg

C

2

2

Enter the lap weight and number in the Lap

production Register


Proposed Manpower per shiftProposed Utilisation(%)

Remarks:

Keep the lap rod in the machine for new lap

At the shift end weigh the waste collected in the

carding section and collect it.

Break rejected laps into small tufts and feed them

Clean the machine and area around the machine at

the shift end and at intervals.

Clean the machine during lot change

Remove the lap rod from the machine and keep on

the weighing machine and ensure that lap weight is

under tolerance limit. +/-200 gms

Take the polycover and tie on the lap

Keep the lap in the respective zone

To adject the lap weight if found above the limits

Bring the materials from mixing bin room (vertical

cut) & feed on the machine lattice

Keep the spindle on machine stand for next lap

Blowroom-1&2

Tenter


Shift Changeover activities

Check the machine parameters like length

counter,count,batch,shade no etc

To counter check weight of 5 laps of out going shift.

WLS No: ESP/W/03


Elegant SpinningShifts A B G

Blowroom

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/ machi

ne /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1.1 1 1 2.00 2.00

1.2 1 1 5.00 5.00

2 1 1002 0.073 73.15

3 1 78 0.15 11.39

41 78 0.13 10.30

5 1 77 0.36 27.49

6 1 77 0.15 11.32

71 78 0.21 16.22

8 1 1 2.00 2.00

9 1 1 2.31 2.31

10 1 2 4.00 8.00

111 0.44 90.00 39.60

12 1 1 4.00 4.00

13

14

A 212.77

B 15

C 244.69

D 450

E 54.38%

F 1G 54.38%

Rejection (0.01%) = 992*0.01 = 9.92 kg/13kg lap= 1 lap

Total =992 kg+9.92 kg = 1002 kg

Lot change - 4 machine/(3 shifts*3 machine) = 0.44 /shift/machine




Remarks:

Target per shift /tenter - 992 kg/13 kg lap = 77 laps





At the shift end weigh the waste collected in the carding

Stop the machine and check when alarm arised

To inform the fitter/ electrician/supervisor if any

Enter the lap weight and number in the Lap production

Register

To adjust the lap weight if found above the limits

Break rejected laps into small tufts and feed them equally

Clean the machine and area around the machine at the


Blowroom-3

Tenter


Shift Changeover activites


WLS No: ESP/W/04



Blowroom

Bring the materials from mixing bin room (vertical cut)&

feed on the machine latice

Keep the lap rod in the machine for new lap

Remove the laprod from the machine and keep on theweighing machine and ensure that lap weight is under

tolerance limit. +/-200 gms


To counter check weight of 5 laps of out going shift.

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 3 -

Designation Proposed Manpower 3 -

Sl.

No

C l a s s i f i c a t i o n

F r e q / 8 h o u r s /

m a c h i n e

N o o f m a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e

( M i n s )

1t2 1 8 1.00 13 9.04

2t2 12.92 8 0.24 16 28.93

3 t2 12.92 8 0.31 13 35.87

4 t2 12.92 8 0.44 15 52.66

5t2 12.92 8 0.21 14 24.76

6t2 1.84571 8 0.90 14 15.20

7t2 1.84571 8 0.85 15 14.47

8t2 1.84571 8 0.79 15 13.40

9

t2 1.84571 8 0.18 13 3.00

11t2 4.8 8 0.63 13 27.34

12t2 4.8 8 0.35 13 15.01

13 t 0.144 8 2.00 13 2.60

10 t1 2 2 4.36 13 19.71

14 t2 4 1 1.74 13 7.86

15t2 1 8 0.50 13 4.52

16t2 4 1 3.52 13 15.92

17t1 1 1 0.60 13 0.68

18t1 1 1 1.02 13 1.15

B C

3 3

WLS No: ESP/W/05

Elegant

Spinning Shifts GSpinning


A

Bring the trolley with laps back to carding

section

Return back the lap rod and cover to blow

room section

Bring the empty can and keep on the

machine

Carding

Tenter


Reset the machine parameter at the shift

starting

Load new lap rod on the machine stand

from trolley/floor

Remove the lap cover from the lap

Feed the lap on the machine (from machinestand to roller)

Remove the empty lap rod from the

machine & place on the trolley

Move the empty trolley to blow room from

carding section

Load the new laps from blow room section

on the trolley (7 laps per trolley)

Move the filled can from the machine and

keep in the respective area

Attend the sliver cut problem

Check the suction hood working condition

Clean the bruce wheel at the shift end and

collect the waste

Move the waste collected to blow room

section yellow bag

Remove the suction hood waste (in the

blow room)

Bring the yellow bag from blow room

section

Clean the work area around the machines

3 3

_________________________________________________________________________ _______________







Department

Section



Sl.

No


F r e q / 8 h o u r s /

m a c h i n e


B a s i c T i m e

( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e

( M i n s )

B C

3 3

WLS No: ESP/W/05

Elegant



A

Carding

Tenter


3 3

19

t1 1 1 4.10 13 4.64

20 t 0.06 8 15.00 13 8.54Clean the machine at the time of lot change

Thomas O Connor table

8 94.36% 60.02%

T (M/C running time per cycle) = 480 mins per shift *8 machines = 3840 mins

The above values are depicted in the graph to find out the optimum (where running efficiency

& operative workload meets) number of drums to be allotted per personnel and presented

below:

Hand over the waste collected in the

carding section after weighment at the shift

end

11

93.13%

90.16% 78.85%

91.74%10

12 88.38%

t1(Average time in min taken by operator per mrh to perform necessary deferrable work

while m/c is running) = 26.18 minst2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c

is running ) = 267.98 mins

t (Average time in min taken by operator per mrh to perform non-deferrable work with the

machine stopped) = 11.15 mins

No of Machines Machine Efficiency(%) Operator workload(%)

9

84.32%

14 84.17% 93.68%

The machine efficiency and respective operative workload for the values above is found out

from the Thomas O' Connar table and tabulated below:

66.64%

72.94%

13 86.38% 89.28%

15 81.75% 97.50%

_________________________________________________________________________ _______________







Department

Section



Sl.

No


F r e q / 8 h o u r s /

m a c h i n e


B a s i c T i m e

( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e

( M i n s )

B C

3 3

WLS No: ESP/W/05

Elegant



A

Carding

Tenter


3 3

Lot change - 4 machine/(3 shifts*22 machines) = 0.06 /shift

From the graph, the optimum number of machine can be allotted per operator is 12 nos.

Remarks:

Two operator and one common reliever for Blowroom and carding

8 9 10 11 12 13 14

Machine Efficiency(%) 94.36% 93.13% 91.74% 90.16% 88.38% 86.38% 84.17%

Operator Workload(%) 60.02% 66.64% 72.94% 78.85% 84.32% 89.28% 93.68%

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%60.00%

70.00%

80.00%

90.00%

100.00%

E f f i c i e n c y ( % )

Carding-Crossrol

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower -

Designation Proposed Manpower -

Sl.

No


F r e q / 8 h o u r s /

m a c h i n e


B a s i c T i m e ( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e ( M i n s )

1 t2 1 7 1.00 13 7.91

2t2 12.92 4 0.24 16 14.46

3 t2 12.92 4 0.31 13 17.93

4t2 12.92 4 0.44 15 26.33

5t2 12.92 4 0.21 14 12.38

6t2 1.84571 4 0.90 14 7.60

7t2 1.84571 4 0.85 15 7.23

8t2 1.84571 4 0.79 15 6.70

9t2 1.84571 4 0.18 13 1.50

10t2 4.8 4 0.63 13 13.67

11t2 4.8 4 0.35 13 7.51

12 t 0.144 4 1.20 13 0.78

13

t2 8.98 3 0.24 16 7.54

14 t2 8.98 3 0.31 13 9.35

15t2 8.98 3 0.44 15 13.73

16t2 8.98 3 0.21 14 6.45

17t2 1.28286 3 0.90 14 3.96

Carding

WLS No: ESP/W/05 A

Elegant

Spinning Shifts B G

Spinning

A




Bring the trolley (with laps) back to carding

section


room section




from trolley/floor


Crossrol


carding section

Remove the empty lap rod from the machine

& place on the trolley


carding section

Feed the lap on the machine (from machine

stand to roller)

Tenter


machine




Feed the lap on the machine (from machine

stand to roller)



LR


from trolley/floor


C

_________________________________________________________________________ _______________







Department

Section



Sl.

No


F r e q / 8 h o u r s /

m a c h i n e



A l l o w a n c e ( % )


Carding

WLS No: ESP/W/05 A

Elegant

Spinning Shifts B G

Spinning

A



Tenter

C

18t2 1.28286 3 0.85 15 3.77

19t2 1.28286 3 0.79 15 3.49

20t2 1.28286 3 0.18 13 0.78

21t2 7.79 3 0.63 13 16.64

22t2 7.79 3 0.35 13 9.14

23 t 0.2337 3 1.15 13 0.91

24 t1 4 3 1.06 13 14.37

25 t2 2 3 1.50 13 10.17

26 t1 4 3 1.61 13 21.8727 t1 2 3 2.49 13 16.88

28 t1 4 3 1.21 13 16.37

29 t1 2 2 4.36 13 19.71

30 t2 4 1 0.87 13 3.93

31t2 1 4 1.02 13 4.61

32t2 2 1 3.52 13 7.96

33 t1 1 1 0.60 13 0.68

34 t1 1 1 1.02 13 1.15

35

t1 1 1 4.10 13 4.64




Bring the trolley with laps back to carding

section


machine




Check the suction hood working condition


collect the waste

Remove the suction hood waste (in the blow

room)

Front side top-LR


Move the waste collected to blow roomsection yellow bag

Hand over the waste collected in the carding

section after weighment at the shift end

Front side wheel-LR

Front side bottom-LRBack side bottom-LR

side door-LR


room section

_________________________________________________________________________ _______________







Department

Section



Sl.

No


F r e q / 8 h o u r s /

m a c h i n e



A l l o w a n c e ( % )


Carding

WLS No: ESP/W/05 A

Elegant

Spinning Shifts B G

Spinning

A



Tenter

C

36 t 0.063 7 15.00 13 7.47Clean the machine at the time of lot change



t1(Average time in min taken by operator per mrh to perform necessary deferrable work whilem/c is running) = 95.66 mins

t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c


7 95.75%

Operator workload(%)

10 92.37%

94.76%





below:



11 90.93%

65.74%

90.60%

98.11%

9 93.64%

No of Machines Machine Efficiency(%)

74.36%

82.67%

8

_________________________________________________________________________ _______________







Department

Section



Sl.

No


F r e q / 8 h o u r s /

m a c h i n e



A l l o w a n c e ( % )


Carding

WLS No: ESP/W/05 A

Elegant

Spinning Shifts B G

Spinning

A



Tenter

C


Lot change - 4 machine/(3 shifts*22 machines) = 0.06 /shift/group

Remarks:

7 8 9 10 11

Machine Efficiency(%) 95.75% 94.76% 93.64% 92.37% 90.93%

Operator Workload(%) 65.74% 74.36% 82.67% 90.60% 98.11%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


Carding-LR+Crossrol

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower2 -

DesignationProposed

Manpower2 -

Sl.

No


F r e q / 8

H o u r s / m a c h i n e


s

B a s i c T i m e

( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e

( M i n s )

A

1 t2 33.83 2.00 0.43 13.00 32.88

2 t2 33.83 2.00 0.37 13.00 28.29

3 t2 33.83 2.00 0.20 13.00 15.29

4 t2 78.93 2.00 0.21 13.00 36.57

5 t 4 2.00 0.98 13.00 8.86

6 t 4 2.00 0.50 13.00 4.52

7 t 1.579 2.00 0.40 13.00 1.43

8 t 1.579 2.00 0.51 13.00 1.83

9 t 0.33 2.00 0.17 13.00 0.12

B 0.00

1 t2 170.7 1.00 0.15 13.00 28.93

2 t2 170.7 1.00 0.43 13.00 82.93

3 t2 170.7 1.00 0.58 13.00 111.09

4 t2 170.7 1.00 0.19 13.00 36.64

5 t 4 1.00 0.98 13.00 4.43

6 t 4 1.00 0.50 13.00 2.26

7 t 3.413 1.00 0.55 13.00 2.10

8 t 1.707 1.00 0.57 13.00 1.10

9 t 0.66 1.00 0.17 13.00 0.12

Clean drafting zone and filter box once in

every two hrs.

Piece the ends during breakages

Move the LDO/6 materials cans to the

Cherry Hara D/F


G

Change top rolls once in every two hours

Tenter

2

2

Remove the roller jam



WLS No: ESP/W/06

Clean the drafting zone and filter box

once in every two hours

Bring the full materials cans(Carding

sliver) from carding section

Replace the empty cans by the full slivercan & join the sliver in LDO/6

Return the empty cans to the carding

section & keep in the area earmarked

Do the lot change cleaning

A

2

2

Replace the empty cans by the materials

cans & join the sliver in Cherry Hara


Change top rolls once in every two hours

Place the empty cans in Cherry Hara for

doffingRemove the full cans from cherry hara &

keep the cans in Materials cans area

Elegant

Spinning Shifts C

Spinning

Finishing Section

Drawframe


Breaker

Place the empty cans in LDO/6 for

doffing

B

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower2 -

DesignationProposed

Manpower2 -

Sl.

No


F r e q / 8



s

B a s i c T i m e

( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e

( M i n s )


G

Tenter

2

2

WLS No: ESP/W/06

A

2

2

Elegant

Spinning Shifts C

Spinning

Drawframe


B

C t1 1 1.00 2.00 13.00 2.26



4

83.42%

Collect waste and hand over to mixing for

weighment

3

74.77%

66.02%





69.80%

83.42%

92.08%


T (M/C running time per cycle) = 480 mins per shift *3 machines = 1440 minst1(Average time in min taken by operator per mrh to perform necessary deferrable work while

m/c is running) = 2.26 mins



below:

5

6 57.83% 96.78%

No of MachinesMachine

Efficiency(%)Operator workload(%)

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower2 -

DesignationProposed

Manpower2 -

Sl.

No


F r e q / 8



s

B a s i c T i m e

( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e

( M i n s )


G

Tenter

2

2

WLS No: ESP/W/06

A

2

2

Elegant

Spinning Shifts C

Spinning

Drawframe


B

It is recommended that one operator per two breaker and one finisher machine.

Lot change - 4 R/F machine/day = 4/(3shifts*2 machine) = 0.66 /machine/shift

Remarks:

3 4 5 6

Machine Efficiency(%) 83.42% 74.77% 66.02% 57.83%

Operator Workload(%) 69.80% 83.42% 92.08% 96.78%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


Drawframe-Tenter

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower

3 -

DesignationProposed

Manpower3 -

Sl.

No

C l a s s i f i c a t i

o n

F r e q / 8

H o u r s

N o o f

M a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e (

% )

T o t a l T i m e

( M i n s )

1

t2 32 2 0.30 13 21.70

2

t2 32 2 0.17 13 12.29

3 t2 480 2 0.08 13 85.70

4 t1 4 2 3.17 13 28.66

5 t1 1 2 2.80 13 6.33

6 t1 1 1 2.70 13 3.05

7t1 240 2 0.08 13 41.76

8t 4 2 4.83 13 43.66

9

t 4 2 1.00 13 9.04

10

t 4 2 4.17 13 37.70

11 t 4.62 2 0.77 13 8.04

12t 2.31 2 0.91 13 4.75

13 t 2.31 2 0.60 13 3.13

14t 4.62 2 0.90 13 9.40

15

a

t2 0.26 2 36.00 13 21.15

bt2 0.26 2 20.40 13 11.99

WLS No: ESP/W/07

Elegant

Spinning Shifts G

Spinning

Speed Frame

Tenter


Idle spindle

Piece the ends of Finisher Sliver

Move the full DF cans from D/F can

storage area to S/F machine& replace

empty cans.

Keep the empty cans colour wise near

the D/F

Clean the draft zone

Clean the machine floor and area

Clean the machine floor (front side)

Clean the bottom and top clearer (while

machine is in running)

Lot Change

Put the Jodi in the empty rovings

Clean the bottom and top clearer at

every doff*

Clean the fan waste of S/F at every doff

Actually machine stops for 15 mins for

doffing. Extra time of (15-5.83=9.17

mins)

Other interruptions

Remove the Top/Bottom Roller jam

Piece the broken roving

3


3

CA B

33

Put the empty cans colour wise near the

D/F

Move the full DF cans from D/F can

storage area to S/F machine& put the

sliver from can to top roller

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower

3 -

DesignationProposed

Manpower3 -

Sl.

No


o n

F r e q / 8

H o u r s

N o o f

M a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e (

% )

T o t a l T i m e

( M i n s )

WLS No: ESP/W/07

Elegant

Spinning Shifts G

Spinning

Speed Frame

Tenter


3


3

CA B

33

ct 0.26 2 27.36 13 16.08

16

t 0.07 2 60.00 13 8.95

t1(Average time in min taken by operator per mrh to perform necessary deferrable work while


Machine

Efficiency(%)

64.21%


Calculation of workload using Thomas O Connor table:

2 82.54%



No of Machines

4 68.80% 107.04%


from the Thomas O' Connor table and tabulated below:

3 76.04% 88.72%






below:

Perform Count changing activity(replace

empty can with the full can, piece the

sliver with the roving &start themachine)

Piece the silver from top roller to roving

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower

3 -

DesignationProposed

Manpower3 -

Sl.

No


o n

F r e q / 8

H o u r s

N o o f

M a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e (

% )

T o t a l T i m e

( M i n s )

WLS No: ESP/W/07

Elegant

Spinning Shifts G

Spinning

Speed Frame

Tenter


3


3

CA B

33

No of D/F cans to be replaced (respective machine efficiency) - 50 per shift * 5 machine = 250

cans

Lot change - 4 R/F machine/day = 4/(3shifts*5 machine) = 0.26 /machine/shift

* For applying in the formula, machine stoppage time of 15 mins is considered in t.

S/F doffers replaces 150 cans . So only remaining cans to be replaced by sider. Hence, 100 cans/ 5

machine = 20 cans/machine

Whereas in Count change, all the activity is performed, when machine is in stopped condition.

Doffers helps during count change.

Count change - 1 machine / day = 1/(3 shifts* 5 machine) = 0.066 / shift / team

During lot change, half of the machine is running condition and they change the remaining half.

Machine gets stopped only hen piecing of sliver with roving done. It is considered that all the

activities for lot change has been performed only by the tenter.

Remarks:

2 3 4

Machine Efficiency(%) 82.54% 76.04% 68.80%

Operator Workload(%) 64.21% 88.72% 107.04%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


Speedframe-Tenter

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 18.67 8.67

2 2 2000

bobbin62.07 124.14

3 2 5 doffs 48.40 96.80

4 2 5 78.70 157.40

5 214 14.00 28.00

6 2 2000bobbin

20.00 40.00

7 2 166

cans37.35 74.70

8 2 4 17.40 34.80

9 1

10 1

11 1 3 30.00 90.00

A 664.50

B 13C 750.89

D 450

E 83.43%

F 2

G 83.43%

To put the empty S/F bobbins in the spindle

To keep the trolly of S/F Bobbins near the Rack

WLS No: ESP/W/08



SPEEDFRAME

DOFFER


To come on duty 15 min before shift start and report

to jobber.

To bring empty S/F bobbins from Rack in plastic

tapa

PREPARATORY

To do the doffing in S/F.

To keep all S/F Bobbins colour/lot wise wise in Rack

To creel full D/F Cans in S/F and put off Empty cans

.

10.00To keep the unwanted items in Unwanted box

To relieve the S/F sider for lunch

To clean Preparatory Deptt. With Floor cleanning

To keep the clg.items in clg. Box5 10.00


Rest & Relaxation Allowances ( % )Total Workload ( in man minutes )



Remarks:



_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 24.33 24.33

2 1 1 30.83 30.83

31 1 15.00 15.00

41

5 1

6 17

1

81 3 61.67 61.67

9

1 115.00 15.00

10 1 1 30.00 30.00

11

1 112.00 12.00

12 1 1 12.17 12.17

131

43.00 43.00

A 294.00

B 13

C 332.22

D 450

E 73.83%

F 1

G 73.83%

To attend Hand shortage at shift change time

To make attendence report of Preparatory Section and

hand over it time keeper.

WLS No: ESP/W/09


ELEGANTShifts A

20.00 20.00

To Check the wrapping of D/F of new lots

B C

To distrubite the Attandance Cards at the end of the

Shift

G

CARDING,D/F,S/F

JOBBER


To come 30 min before shift change and take charge of

deptt and write in charge Register.

30.00 30.00

To maintain house keeping during the shift.

PREPARATORY

Remarks:

Ensure colorwise segregation of S/F bobbin & D/F

cans

To lookafter all work of Preparatory Section workers

and maintain all systems 1

To see mateial setting and do lot change/count change

as per planning and Deptt Required

To attend all the abnormalities shown by incoming

shift at the charge time.

To relieve the D/F Tenter for lunch

To keep the D/F Material covered with polythene sheet

To Check the wrapping of Carding of new lots 4








_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 5 57.50 57.50

2 1 65 trolleys 232.05 232.05

A 289.55

B 13

C 327.19

D 480

E 68.16%

F 1

G 68.16%

WLS No: ESP/W/10



Remarks:

PREPARATOTY

Remove the trolley Jam








SPEEDFRAME

JAM CUTTER


Collect trolleys from the dept.

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower9 -

DesignationProposed

Manpower 9 -

Sl.

No

Crew

Size

Freq/

Shift

No of

Mach

ine

Basic

Time

(Mins)

Allowan

ce(%)

Total

Time

(Mins)

1 1 576 1 0.13 13 84.61

2 1 1 1 20.52 13 23.19

3 1 1 1 15.00 13 16.95

4 1 1 1 15.00 13 16.95

5

1 41.6 3 0.54 13 76.15

1 41.6 3 0.22 13 31.03

1 41.6 3 0.40 13 56.41

6

1 0.012 3 4.00 13 0.16

1 0.012 3 4.00 13 0.16

7

1 0.051 3 4.00 13 0.69

1 0.051 3 4.00 13 0.69

8

1 18.9 3 0.02 13 1.47

1 18.9 3 0.41 13 26.27

1 18.9 3 0.02 13 1.47

9 1 1 1 5.00 13 5.65

A 341.86

B 480

C 71.22%



Count change

Remove the top clearer, clean and keep

on the lammbaPut the top clearer on the machine after

the count change over

S/F Roving Change


Put the top clearer on the machine after

the count change over

Clean the creel

To attend idle spindles in his m/c

Remove roller lapping using hexablade

knifePiece the broken threads

Bring the S/F roving near the machine

from the S/F roving storage area

Replace the empty rovings with the full

roving

Keep the empty rovings back in the rack

To collect pneumafil waste and hand

over it to mixing for weighment at the

shift end.

Clean the Jockey pulley

Ringframe-LR 9

Roving thread piecing

Lot change

Remove the top clearer, clean and keep

on the lammba

C GSpinning


Clean the Top clearer

Clean Drafting zone

9

Sider 9 9

WLS No: ESP/W/11


Elegant SpinninShifts A B

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower9 -

DesignationProposed

Manpower 9 -

Sl.

No

Crew

Size

Freq/

Shift

No of

Mach

ine

Basic

Time

(Mins)

Allowan

ce(%)

Total

Time

(Mins)

Ringframe-LR 9

C GSpinning


9

Sider 9 9

WLS No: ESP/W/11



5

2880 (5*576) 77.55% 98.24%

2592 (4.5*576) 79.33% 91.48%

The above values are depicted in the graph to findout the optimum (where running efficiency


below:

Running Efficiency

(ρ) (%)

Operator

workload(%)

2304 (4*576) 81.20% 84.73%

2016 (3.5*576) 83.15% 77.98%

The running efficiency is arrived by the formula provided in the research paper : The

Efficiency of N machines Uni-Directionally patrolled by single operative by

Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal Statistical Society, (1957).

r = (b-1) / [ gN{K+(b-1)C}]

1728 (3*576) 85.20% 71.22%

The running efficiency is calculated using the above formula for different number of drums

and tabulated below:

No of Drums

g - 0.0004901, N - 1728 (3*576), C- 0.22 , K-0.03

1728

(3*576)

2016

(3.5*576)

2304

(4*576)

2592

(4.5*576)

Running Efficiency (ρ) (%) 85.20% 83.15% 81.20% 79.33%

Operator workload(%) 71.22% 77.98% 84.73% 91.48%

0.00%10.00%20.00%30.00%40.00%50.00%

60.00%70.00%80.00%90.00%

100.00%


Ringframe-LR

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower9 -

DesignationProposed

Manpower 9 -

Sl.

No

Crew

Size

Freq/

Shift

No of

Mach

ine

Basic

Time

(Mins)

Allowan

ce(%)

Total

Time

(Mins)

Ringframe-LR 9

C GSpinning


9

Sider 9 9

WLS No: ESP/W/11



* Time lost due to doffing,Travellours change,Lot/Count change and maintenance is collected from

the management

Speedframe rovings is changed mainly during the lot change and Count change. As the activities

are performed during lot & count change it is being considered under the doffers workload. But

small percentage(30%) of S/F rovings is being changed by sider ( while running).Number of

rovings to be feed per ringframe per shift equals to 63 rovings.

Actual Machine efficiency (%)=Machine Running hours* Running efficiency

EX: For 1728 Spindle Actual machine efficiency (%) = 7.36 hours *0.852 = 6.27 hours/shift

From the graph, the optimum number of drums to be allotted per operator comes to 3.5 to 4

machine. In practical , it is not possible to allocate 3.75 machine and also that the R/F

efficiency is critical. It is suggested to provide one operator for three machines.

Machine Efficiency: (Sample calculation)

Machine available hours * (Time lost due to doffing,Travellours change,Lot/Count change and

maintenance) = Machine running hours ( 8 hours * 92 % = 7.36 hours)

Remarks:

Count change - 1 machine / day = 1/(3 shifts* 26 machine) = 0.012 / shift

Lot Change- 4 machine / day = 4/ (26 machine*3 shift) = 0.0512 / shift

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

No of

Spindl

es/mac

hine

BasicTime

(Mins)

TotalTime

(Mins)

1 7 1 5.00 35.00

2

a 4 52 2.56 532.48

b 4 52 576 2.820 586.56

c 4 52 0.70 145.60

d 4 52 1.00 208.00

3

a 1 2 576 0.03 34.56

b 1 2 576 0.05 57.60

c 1 2 576 0.03 34.56

d 1 2 1 3.50 7.00

4

a 1 0.16 576 0.018 1.61

b 1 0.66 576 0.02 8.74

c 1 0.66 576 0.07 26.61

d 1 0.66 576 0.41 155.87

e 1 0.66 576 0.05 19.01

f 1 0.66 576 0.02 8.74

5

a 1 0.16 1 1.98 0.32

b 1 0.16 576 0.012 1.09

c 1 0.16 576 0.078 7.17

d 1 0.16 1.98 0.32

e 1 0.16 576 0.018 1.61

f 1 0.16 576 0.02 2.12

Put the new ring travellour in the spindle

Close the doom(2 sides)

WLS No: ESP/W/12


Elegant SpinningShifts A B GC

Spinning

Join the thread roving and bobbin

Take trays, got to autoconer area, Collect the

empty R/F bobbins from Autoconer storage

area,Reach the machine spot

Keep the collected R/F bobbin trays in the R/F

Bobbin changing

Remove the filled R/F bobbin from the spindle &

Put the empty R/F bobbin in the R/F spindle(144

spindle timing)

Arrange the S/F rovings from rack to trolley

Count Change

Bring the S/F roving near the machine from the

S/F roving storage area

Open the doom(2 sides)

Move the empty trolley back to S/F rovings area

Remove the lammba for the old count(288 spindle)

Put the new count lammab on the machine(288

spindle)

Clean the machine area after ring travellour change


S/F roving storage area(40 rovings/trolley)

Remove the empty S/F bobbins from the R/F &

Keep it in the trolley

Arrange the S/F rovings from rack to trolley


Put the S/F roving in the creel

Join the thread after ring traveller put

Lot Change

7

7

Remove the Old ring travellour from the spindle

Ringframe

Doffers


Shift Release activity

Ring Travellour Change

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

No of

Spindl

es/mac

hine

BasicTime

(Mins)

TotalTime

(Mins)

WLS No: ESP/W/12


Elegant SpinningShifts A B GC

Spinning

7

7

Ringframe

Doffers


g 1 0.16 576 0.05 0.01

h 1 0.16 576 0.07 6.45

i 1 0.16 576 0.41 0.07

j 1 0.16 576 0.02 2.12

6

1 1 2 10.00 20.00

1 1 806 0.02 14.11

1 1 806 0.04 31.34

7 1 2.00 14.00

7 1 1 5 63.00 315.00

A 2277.66

B 8

C 2459.87

D 480

E 73.21%

F 7

G 73.21%

Lot Change - 4 machine/day = 4/(3shifts*2 team) = 0.66 / shift / team

Count change - 1 machine / day = 1/(3 shifts* 2 team) = 0.16 / shift / team

Move the empty trolley to S/F rovings area

Cleaning

Remove the remaining threads from the S/F

To do the foot step area cleaning of the machine

Arrange the cleaned S/F roving from trolley to rack

Clean the doffing trolley wheel checking &

4 Doffings /machine /shift = 13*4 =52 times/ shift/ team

Rovings consumption- (62 rovings / machine/shift) * (13 machines / team )= 806 rovings / shift /

team

One doffing team consists of 7 doffers and one co-ordinator.

Relieve the sider for the break(Tea,breakfast or

lunch)

As reliever is provided, net available man mins becomes 480 mins. As the above activity frequency

is for 480 mins.


Rest & Relaxation Allowances ( % )(Total-13%-5% relieved by reliever+8%

added in the workload)


Net Available man-minsPresent Utilisation(%)


13 R/F machine for one doffing team

Rings travellor change- 2 machines / team /shift

Put the new S/F roving in the creel


Remove the empty S/F rovings from the R/F &

Keep it in the trolley

Remarks:


_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 15.00 15.00

2 1 2 63 125.00

2

3

4

A 140.00

B 13

C 158.20

D 450

E 35.16%

F 1

G 35.16%

The above job is supervisory in nature.





Remarks:

Discussing with the supervisors, siders

Perform the scheduled activities like ring travellours

change, machine cleaning and lot change/count

change with the doffers




WLS No: ESP/W/13



Spinning

Relieve the ringframe-doffers for breaks

Ringframe

Doffer-Leader



Co-ordinate the doffing team effectively for

minimising the machine downtime for changover

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 12 63 750.00

A 750.00

B 13

C 847.50

D 450

E 94.17%F 2

G 94.17%

Remarks:

WLS No: ESP/W/14


Elg SpgShifts A

Ringframe







Relieve-twelve ringframe-doffers for breaks

Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins .Total - 63

mins/shift/person

B C GSpinning



Reliever-Doffers

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 25.00 25.00

2 1 1 7.83 7.83

3 1 1 5.00 5.00

4 1 1 30.00 30.00

51 1 5.00 5.00

6 1 4 31.20 31.20

7

8

9

10

11

121 3 120.00 120.00

131

14 1

151 1 10.00 10.00

A 334.03

B 13

C 377.46

D 450

E 83.88%

F 1

G 83.88%

WLS No: ESP/W/15


ELEGANTShifts A B C

To attend hands shortage at shift change time.

To make attendance report of R/F and handover it

to time keeper.

To take the round of the deptt. With S/I

To distribute the work to the deptt. Worker, sider,doffer, reliever

RING FRAME

To collect the attendance catds of R/F workers.

To take the charge of S/F materials.

90.00

To look after all work of R/F workers and

maintain all systems in R/F section

To engage one hand for floor cleaning

To monitor dept. waste (20 % of shift time)

G

RING FRAME

JOBBER


To come 30 min before shift change and take

charge of dept. and write charge register

To make ringtraveller change and handover old rtr

to shift officer 10.00



To engage one hand for bobbin sorting

To see material settling and do lot change/count

change as per planning.



Proposed Utilisation(%)Remarks:

10.00

To help for gaiting

To distribute the attendance cards at the end of the

shift



_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 10.00 10.00

2 1

3 1

41

5 1

6

1

7 1 2 23.40 23.40

8 1 1 30.00 30.00

A 304.60

B 13

C 344.20

D 450

E 76.49%

F 1

G 76.49%

WLS No: ESP/W/16



RINGFRAME

RINGFRAME

BOBBIN SORTER


To come on duty 15 min before shift start and report to

RF jobber.



241.20

To clean the m/c top area in off ends side

To relieve RF checker For lunch.

241.20

To keep empty doffing tapas from A/C in proper way.

To repaire faulty RF bobbins and hand over to A/C.

To sort RF bottom bobbins and send it to A/C lotwise

To maintain house keeping in his work area during the

shift.

To sort RF bobbins lotwise and colorwise.

5 4 0 5 9

b o b b i n s






Remarks:

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 20.00 20.00

21 1

3 1 1

41 1 30.84 30.84

5 1 26.00 26.00

6 17

1

81 13.00 13.00

9 1

10 1

111 23.70 23.70

12

18.40 8.40

13 1 1 63.00 63.00

A 318.26

B 13

C 359.63

D 450

E 79.92%

F 1

G 79.92%

WLS No: ESP/W/17



RINGFRAME

94.80To Separate faulty RF bobbins and make their

report.

RINGFRAME

CHECKER


To come 30 min before shift change and report to

R/F jober

To check the colour code of S/F & RF bobbins and

new lots , final lots.. 25.00


13.52To write the RF hanks in hank Register.

To hand over Final lot material to A/C after

checking

25.00

To take charge of materials from B/R to R/F

To Check & make report of all lots running from

B/R to R/F.

To put sample of new lot in sample register

To check RF doffs during Shift94.80

To check lot change Clg. &shift M/C cleaning. in

R/F.

To make rport of idle spindles in R/F.13.52

To take the round of R/F after every 2 Hrs to check

the colour & write in the registerTo relieve the Bobbin sorter for Lunch & tea





Remarks:



_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 10.50 10.50

21 8 170.42 170.42

3 1 23 24.13 24.13

4 1 4 16.00 16.00

51 12 96.00 96.00

61 8 3.40 3.40

71 1 4.50 4.50

81 4 16.88 16.88

A 341.83

B 13

C 386.27

D 450E 85.84%

F 1

G 85.84%

Present Utilisation(%)Net Available man-mins

RINGFRAME

To clean floor in RF section in between m/cs and allies

out side the m/cs by Plate form brush

To collect roller bonda from RF waste boxes




To come on duty 15 min before the shift starts and

report to RF jobber.

WLS No: ESP/W/18


ELEGANTShifts A G

RINGFRAME

FLOOR CLEANER


B


Remarks:


To collect waste from Over head Blowers .

To do sorting of roller bonda, shadewise and keep them

in separate bags

To collect sweeping waste from floor and keep itseparate from other wastes.

To send Roller bonda waste, Swpg. Waste, & O.H.B.

waste to mxg. For weighment.

To move Magnet trolly in whole RF section to collect

old Rtrs from floor.

C

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1

2 1 1

3

1 1 45.00 45.00

4 1 1 40.00 40.00

5 1 1 12.00 12.00

6 1 4 32.00 32.00

7 1 1 35.00 35.008 1 1 45.00 45.00

9 1 1 15.00 15.00

A 249.00

B 13

C 281.37

D 450

E 62.53%

F 1

G 62.53%

WLS No: ESP/W/19


ELEGANTShifts A

Write down doff balance and R/F setup, autoconer

drum setup & change as per doff balance & R/F

setup

Collect all workers card and adjust hands

GPOST SPG

25.00 25.00Check running material, cone tip, bobbin color



B C

Check A/C idle drums and make a reportWrite m/c efficiency and production details

AUTOCONER

JOBBER


Take charge of his duty




Remarks:

Make attendance report

Syestematically adjust all empty & full tapa

All new lot sample pasted in sample register



_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1

21 1

3 1 1 45.00 45.00

41

10

samples30.00 30.00

5 1 1 30.00 30.00

61 1 60.00 60.00

71 1 46.00 46.00

8 1 1 15.00 15.00

9 1 1 15.00 15.00

101 1/3 36.00 36.00

A 302.00

B 13

C 341.26

D 450E 75.84%

F 1

G 75.84%

GPOST SPG

25.00 25.00Note all m/c settings drum wise, count wise, bobbin

and cone color in setting register and instruct

WLS No: ESP/W/20


ELEGANTShifts A

All new lot sample pasted in sample register

Check TFO m/c vereator and tension setting and

note in register

B C

AUTOCONER

CHECKER



Make cut report and hand over to shift supervisor

Check and note single pack material random cone

weight

Collect final lot from ringframe checker and check

Check each cone for faults and inform jobber and

shift supervisorNote cheese winding breakage and report to jobber

and shift supervisor

Make TFO m/c idle report





Remarks:



_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower1 1 -

DesignationProposed

Manpower 1 1 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Allowa

nce (

%)

Total

Time

(Mins)

11 26.61 0.75 13 22.55

2 1 26.61 0.10 13 3.01

31 7983 0.030 13 270.62

4 1 26.61 0.08 13 2.41

5 1 932 0.06 13 63.196 1 466 0.12 13 63.19

7

1 235 0.10 13 27.46

8 1 2 2.00 13 4.52

A 456.95

B 480

C 95.20%

The above values are depicted in the graph to findout the optimum (where running

efficiency & operative workload meets) number of drums to be alloted per personnel and

presented below:

70 97.83% 111.06%

60 98.92% 95.20%







No of DrumsRunning Efficiency

(ρ) (%)Operator workload(%)

r = (b-1) / [ gN{K+(b-1)C}]

g - 0.06469, N - 60, C - 0.09, K - 0.20

Collect the waste from the machine



Keep the empty tray aside

Attend the thread cuts in spindlesAttend the thread cuts in spindles

Take the empty auto cone from the machine

tray, remove the filled cone and put the

empty cone on the machine and start the

machine


Bring the R/F Bobbin tray from R/F storing

section ( in Tray)

Take the trays and keep on the trolley

Put the R/F Bobbins in the machine drum

Autoconer-Savio 1

Winder 1

WLS No: ESP/W/21



Post Spinning

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower1 1 -

DesignationProposed

Manpower 1 1 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Allowa

nce (

%)

Total

Time

(Mins)


Autoconer-Savio 1

Winder 1

WLS No: ESP/W/21



Post Spinning

* Time lost due to doffing,bobbin reject,extracycle,splice and bobbin change is collected from the

management

From the graph, the optimum number of drums to be alloted per operator is 60 drums

Remarks:

No of bobbins - 7750 bobbins/shift/60 drums

Rejection (3 %) - 7750 * 3% = 232.5 bobbins . Total - 7750 +233= 7983 bobbins /shift


Machine available hours * (Time lost due to doffing,bobbin reject,extracycle,splice,bobbin

change) = Machine running hours ( 8 hours * 76 % = 6.08 hours)


EX: For 60 drums, Actual machine efficiency (%) = 6.08 hours *0.9892 = 6.014hours/shift

60 70

Running Efficiency (ρ)

(%)98.92% 97.83%

Operator workload(%) 95.20% 111.06%

85.00%

90.00%

95.00%

100.00%

105.00%

110.00%

115.00%


Autoconer-Savio

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower6 6 -

DesignationProposed

Manpower 6 6 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Allowa

nce (

%)

Total

Time

(Mins)

11 24.83 0.75 13 21.05

2 1 24.83 0.10 13 2.81

3 1 7450 0.030 13 252.56

4 1 24.83 0.08 13 2.24

5 1 868 0.06 13 58.85

6 1 434 0.12 13 58.857

1 217 0.10 13 25.35

8 1 2 2.00 13 4.52

A 426.23

B 480

C Present Utilisation(%) 88.80%

5

The above values are depicted in the graph to findout the optimum (where running

efficiency & operative workload meets) number of drums to be alloted per personnel and

presented below:

70 98.08% 103.59%




r = (b-1) / [ gN{K+(b-1)C}]

60 99.09% 88.80%






tray, remove the filled cone and put the

empty cone on the machine and start the

machine


Bring the R/F Bobbin tray from R/F storing

section ( in Tray)

Take the trays and keep on the trolley


g - 0.062789, N - 60, C - 0.09 , K - 0.20




C GPost Spinning

Keep the empty tray aside

Attend the thread cuts in spindles

Attend the thread cuts in spindles

Autoconer-

Muratech6

Winder 6

WLS No: ESP/W/21 & A


Elegant SpinningShifts A B

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower6 6 -

DesignationProposed

Manpower 6 6 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Allowa

nce (

%)

Total

Time

(Mins)


C GPost Spinning

Autoconer-

Muratech6

Winder 6

WLS No: ESP/W/21 & A


Elegant SpinningShifts A B


EX: For 60 drums Actual machine efficiency (%) = 5.68 hours *0.9909 = 5.62 hours/shift

* Time lost due to doffing,bobbin reject,extracycle,splice and bobbin change is collected from the

management

Remarks:

No of bobbins - 7233 bobbins/shift/60 drums

3 % Bobbin rejection - 7449 bobbins /shift



Machine available hours * (Time lost due to doffing,bobbin reject,extracycle,splice,bobbin

change) = Machine running hours ( 8 hours * 71 % = 5.68 hours)

60 70

Running Efficiency (ρ) (%) 99.09% 98.08%

Operator workload(%) 88.80% 103.59%

80.00%

85.00%

90.00%

95.00%

100.00%

105.00%


Autoconer-Muratech

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 4 63 250.00

21 2 17.42 34.84

3 1 7 1.88 13.16

4 1 3 2.00 6.00

5 1 1 10.00 10.00

A 314.00

B 13

C 354.82

D 450

E 78.85%

F 1

G 78.85%

Clean the full machine with the compressed air(open the

pipe, clean and keep the pipe aside)

Yarn trap checking

WLS No: ESP/W/22


Elegant SpinningShifts A B C

Time for wax application per machine - 16.8 mins




Remarks:

Autoconer

Reliever-A/C Winder



Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63 mins/shift/person

GPost Spinning

Attend cutting drum jam(if any)

Collect the hard waste and handover and inform tosupervisor

Applying wax to machine is not considered ,because the activity is not being performed presently.




Relieve - Four autoconer-tenter's for breaks

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 26 0.33 8.58

2 1 26 2.01 52.26

3 1 26 0.330 8.58

4 1 51.23 0.38 19.47

5 1 15.37 1.67 25.676 1 51.23 0.28 14.35

7 1 7 1 7.00

8 1 3 63.00 189.00

A 324.90

B 13

C 367.14

D 450

E 81.59%F 1

G 81.59%

GPost Spinning

Collect cones from the autoconer belt

Keep the trolley near the cheese winding area(60

cones/trolley)

Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63

mins/shift/person

WLS No: ESP/W/23


Elegant SpinningShifts A B C

Autoconer

Doffer


Take the empty trolley from cheese winding area




Collect the empty autocones from rack and come to

machine(30 cones)

Arrange the cones on the machine slantingGo back to rack

Collect back the remaining cones of last batch if any

Total Cones - 1537 cones / (60 cones per trolley) = 26 trolleys

Relieve the winder-tenter for

breaks(lunch/breakfast/tea/personal needs)

Present Utilisation(%)Proposed Manpower per shift


Remarks:

Autoconer Muratech - 217 cones/shift * 6 machine = 1302 cones

Autoconer Savio - 235 cones/shift * 1 machine = 235 cones


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 55881 0.01140 637.04

2 1 32 0.94 30.00

3 1 16 2.000 32.00

4 1 16 0.75 12.00

5 1 32 0.16 5.17

6 1 2 0.69700 1.39

7 1 1118 0.04200 46.96

8 1 2 0.70000 1.40

9 1 1118 0.00700 7.83

A 773.79

B 14

C 882.12D 450

E 98.01%

F 2

G 98.01%

WLS No: ESP/W/24


Elegant SpinningShifts A

Clean the belt conveyor for jam and remove the

threads at the sides

Arrange the empty trays for segregation purpose(4 -5

different trays)

GPost Spinning

Autoconer

Bobbin sorter


B C

Sort the empty R/F bobbins @ autoconer belt

Take the full bobbins/half bobbins and put on the

autoconer tenter trays

Remarks:

No of bobbins fed per machine per shift - 7750 nos

Clean the spilled bobbins in and around the machine

Clean the bobbin for the remaining thread


Move the trays to Yarn conditioning room

Clean the bobbins using the thread cleaning machine

Come back to machine area

Segregate the bobbins colour wise

Rejection ( 3%) - 233 nos

Total bobbins to be sorted - 7750 +233 = 7983 nos *7 machines = 55881 nos

No of bobbins to be cleaned for the remaining threads using machine - 7983*2% *7 machines =

1118 nos


Total Workload ( in man minutes )Net Available man-mins




_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 10.00 10.00

2 1 2 24.00 24.00

3 1 5 225.00 225.00

4 1 1 20.00 20.00

A 279.00

B 13

C 315.27

D 480

E 65.68%F 1

G 65.68%

POST SPG

Check and do TFO overhead dust box cleaning.

Do sweeping and collect hard waste

WLS No: ESP/W/25



AUTOCONER

FLOOR CLEANER



Dispose scrap in scrap yard








Remarks:

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower4 -

Designation ProposedMan ower

4 -

Sl.

No

Crew

Size

Freq/

Shift/s

pindle

No of

spindle

Basic

Time

(Mins)

Allowa

nce

(%)

Total

Time

(Mins)

1 1 2.625 120 0.0600 13 21.36

2 1 2.625 120 0.3440 13 122.45

3 1 5.25 120 0.1570 13 111.77

4 1 5.25 120 0.0350 13 24.92

5 1 5.25 120 0.0270 13 19.22

6 1 5.25 120 0.0192 13 13.67

7 1 5.25 120 0.0200 13 14.24

8 1 2.625 120 0.228 13 81.16

9 1 1 1 15.000 13 16.95

A 425.72

B 480

C 88.69%

1

140 83.37% 102.89%

r = (b-1) / [ gN{K+(b-1)C}]

g - 0.01 , N - 120 , C - 0.228 , K - 0.05

120 85.40% 88.69%

130 84.37% 95.79%

The running efficiency is calculated using the above formula for different number of drums and

tabulated below:

No of DrumsRunning

Efficiency (ρ)Operator workload(%)

Total Workload per Shift ( in man minutes)



The running efficiency is arrived by the formula provided in the research paper : The Efficiency

of N machines Uni-Directionally patrolled by single operative by Mr.C.Mack,T.Murphy and

N.L.Webb,Journal of the Royal Statistical Society, (1957).

Bring the empty cheese cone from the

rack & keep on the machine

Move the trolley to cheese storage area

near the TFO

Attend the thread break

Clean the machine

Replace the empty auto cone with full

autocone & join

Replace the full cheese cone with empty

cheese cone

Write the number on the cheese coneusing chalk

Collect full cheese cone from machine

table and keep on trolley

4

Tenter 4 4


Keep the auto cone from trolley to the

machine table

Cheesewinding-

RJK4

WLS No: ESP/W/27


Elegant SpinninShifts A B C G

Post Spinning

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower4 -

Designation ProposedMan ower

4 -

Sl.

No

Crew

Size

Freq/

Shift/s

pindle

No of

spindle

Basic

Time

(Mins)

Allowa

nce

(%)

Total

Time

(Mins)

4

Tenter 4 4


Cheesewinding-

RJK4

WLS No: ESP/W/27


Elegant SpinninShifts A B C G

Post Spinning

* Time lost due to doffing,general cleaning,Lot/Count change,electrical and maintenance cleaning is

collected from the management

Machine available hours * (Time lost due to doffing,general cleaning,Lot/Count change,electrical and

maintenance cleaning) = Machine running hours ( 8 hours * 78 % = 5.76 hours)

Actual Machine efficiency (%)=Machine Running hours* Running efficiencyEX: For 120 drums Actual machine efficiency (%) = 5.76 hours *0.8540 = 4.919 hours/shift

Remarks:

To calculate operators workload,480 mins is taken as net available manmins. Because, one

person (operator or reliever) present near the machine for 480 mins.

The above values are depicted in the graph to findout the optimum (where running efficiency &

operative workload meets) number of drums to be alloted per personnel and presented below:



120 130 140

Running Efficiency (ρ) (%) 85.40% 84.37% 83.37%

Operator workload(%) 88.69% 95.79% 102.89%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


Cheesewinding-RJK

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 5 63 312.50

A 312.50

B 13

C 353.13

D 450

E 78.47%

F 1

G 78.47%

WLS No: ESP/W/28


Elg SpgShifts A B C G

Post Spinning


Cheese Winding

Reliever-Winder


Relieve-Five cheese winding-tenter for breaks

Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63

mins/shift/person







Remarks:

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1 1 75 cones 120.00 120.00

2 1100

bobbins64.00 64.00

4 1 98 cones 60.00 60.00

5 1 20 cones 30.00 30.00

6 12

lots(2kg)20.00 20.00

7 1 15 cones 20.00 20.008 1 72 cones 30.00 30.00

A 344.00

B 13

C 388.72

D 480

E 80.98%

F 1

G 80.98%








Processing of defective bobbins(R/F) for 2nd quality

Rewinding of SQC tested TFO cones

Processing of TFO broken tape, zero TPI(at top) to

2nd quality

Preparation of pair of final single cone

Remarks:

C GPOST SPG

Rewinding of single cones to remove jali, double etcRewinding of classimate cones

CHEESE WINDIN

REWINDER


Rewinding of packing rejection

WLS No:ESP/W/29


ELEGANTShifts A B

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1

2 1 1

3 1 1 36.28 36.28

4 1 3 46.46 46.46

5 1

6 1

7 1 4 27.40 27.40

8 1 5 22.50 22.50

9 1 1 79.65 79.65

10 1 1 5.00 5.00

11 1 2 11.00 11.00

12 1 4 12.00 12.00

13 1 1 55.31 55.31

14 1 1 13.27 13.27

15 1 1 12.50 12.50

16 1 1 12.50 12.50

A 382.42

B 13

C 432.14D 450

E 96.03%

F 1

G 96.03%

WLS No: ESP/W/30



POST SPG

22.00 22.00Cheese winding drum set as per TFO set up and

according to shift supervisor instruction.

CHEESE WINDING

& TFO

JOBBER


Come on his duty 30 mins prior to shift timings, take

over the charge26.55 26.55

Collect all workers' card and adjust all workers as per

supervisor instruction & manage hands shortage.

Give instruction to all winders about running cone

cheese , tfo tip, m/c count and lot.

Systematically adjust all empty and full trolleys

Check cheese winding idle drum and handover a reportto shift supervisor

2


Remarks:

Random Cheese weight

Note cheese winding doffing time & make production

report

Rewinding 4 cheese and inform related person about

any fault

Check and set cheese winding tension wt.

Check winder no. on cheese and tfo cone

Check hard waste per tenter

Count change slip receive by shift officer and particular

change by maintenance fitter

Bottom material collection and finish with winder help

Alloted m/c cleaning check & approve by shift

supervisor.

Aid 4 knotters in maintenance cleaning






_________________________________________________________________________ _______________







Department

Work Centre Present Manpower 1 1 1

Designation Proposed Manpowe 1 1 1

Sl.No

CrewSize

Freq/ Shift

Elemental Time

(Mins)

BasicTime

(Mins)

TotalTime

(Mins)

1 1 1 10.00 10.00 10.00

21 1 10.00 10.00 10.00

3 1 1 8.30 8.30 8.30

41

1312

Cones0.02 26.24 26.24

51 21.87 0.57

12.46

12.46

6

1 21.87 1.36

29.74

29.74

7

1 4.37 0.92

4.02

4.02

8

1 20 1.61

32.2

32.20

91 1312 0.02 26.24 26.24

101 1312 0.05 65.60 65.60

11 1 5 6 30.00 30.00

12 1 2 1 63.00 126.00

A 380.81

B 14

C 434.12

D 450E 96.5%

F 1

G 96.5%

Section

Ensure and keep all m/c head clean

Elemental time of loading 1 cone to trolley

WLS No: ESP/W/31


Elegant Spg.Shifts A B C G

Post Spg.

TFO

Doff Carrier


Come on his duty 10 mins prior to shift

Check and systematically arrange the

material lotwise in packing & YCS room.


Remarks:

Elemental time for Marking the Cones with

chalk in packing dept.

Elemental Time for placing the cones

lotwise in the packing area

Cleaning 5 trolleys per shift

Basic Workload per shift ( in man minutes)


Relieve- Two TFO tenter's for breaks

Standard Workload ( in man minutes )


Proposed Manpower per Shift

Movement time propotionate to 1312 times

the cone is fetchedMovement time propotionate to no. of trips

made to carry trolley to packing dept. &

coming back

Movement time propotionate to no. of trips

made to carry trolley to Yarn Conditioning

Room & coming back

Movement Time of carrying empty trolley

from the area where empty trolleys are kept

to the respective m/c for doffing & Vice-a -

versa.

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower8 -

DesignationProposed

Manpower8 -

Sl.

No

Crew

Size

Freq/

Shift

No of

machi

ne

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)

1

1 80.0 4 0.0782 13 28.28

2

1 80.0 4 0.5601 13 202.51

31 80.0 4 0.0790 13 28.57

41 39.8 4 0.0221 13 3.98

5 1 39.8 4 0.0147 13 2.65

6

1 39.8 4 0.2760 13 49.65

7 1 39.8 4 0.0380 13 6.83

8 1 19.9 4 0.4000 13 35.98

9 1 1 1 20.0 13 20.00

A 378.45

B 480

C 78.84%




r = (b-1) / [ gN{K+(b-1)C}]

g - 0.00027794 , N- 624 (4*156), C- 0.4 , K - 0.07








Attend the thread cut

Clean the machine

Bring empty TFO cone from the cone

room

Keep the cones on the machine

Remove the full TFO cone, place on the

machine holder & keep empty paper

cone & joinWrite the number on the paper cone


Bring the cheese winding cone from the

storage area, arrange on the machine

table, keep the empty trolley aside(per

cone)

Replace the empty cheese cone with thefull cheese cone & keep the empty

cheese on the machine table& tie

Collect the empty cheese cone and

arrange it on the rack colourwise

TFO-VJ 8 8

Tenter 8 8

WLS No: ESP/W/32



Post Spinning

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower8 -

DesignationProposed

Manpower8 -

Sl.

No

Crew

Size

Freq/

Shift

No of

machi

ne

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)


TFO-VJ 8 8

Tenter 8 8

WLS No: ESP/W/32



Post Spinning


& operative workload meets) number of drums to be alloted per personnel and presented

below:

From the graph, the optimum number of drums to be alloted per operator is 702 drums(4.5

machines).As it is difficult to breaks into half machine, it is recommended to assign four

machine per operator, keeping in view of machine utilisation.

Remarks:

Collection of full TFO cones from machine table to trolley is performed by doffers


Machine available hours * (Time lost due to general cleaning,count/lot change,idle and

maintenance cleaning,breakdown) = Machine running hours ( 8 hours * 98.5 % = 7.88 hours)

858 (5.5*156) 91.79% 106.85%

780 (5*156) 92.48% 97.51%

702 (4.5*156) 93.18% 88.18%

624 (4*156) 94.05% 78.84%

624

(4*15

6)

702

(4.5*1

56)

780

(5*15

6)

858

(5.5*1

56)

Running Efficiency

(ρ) (%)94.05% 93.18% 92.48% 91.79%

Operator

workload(%)78.84% 88.18% 97.51% 106.85%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


TFO-Tenter

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower8 -

DesignationProposed

Manpower8 -

Sl.

No

Crew

Size

Freq/

Shift

No of

machi

ne

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)


TFO-VJ 8 8

Tenter 8 8

WLS No: ESP/W/32



Post Spinning

* Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is



EX: For 624 spindles, Actual machine efficiency (%) = 7.88 hours *0.9405 = 7.411 hours/shift

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 6 63 378.00

21 1 10.00 10.00

3

A 388.00

B 13

C 438.44

D 450

E 97.43%

F 1

G 97.43%

WLS No: ESP/W/33



TFO

Reliever-Tenter


Relieve- Six TFO tenter's for breaks

Post Spinning

Collect the hardwaste and handover&inform to

supervisor

Perform the activities scheduled by supervisor/jobber

like assisting the tenter where two machine open at a

time , shift second quality cone to respective

area,single &fatta tar cheese creel in TFO,etc


Remarks:

Lunch-30 mins, Tea - 10 mins, Personal Intervention(5%) - 23 mins . Total - 63mins/shift/person







_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 10.00 10.00

2 1 2 24.00 24.00

3 1 5 325.00 325.00

4 1 1 20.00 20.00

A 379.00

B 13

C 428.27

D 450

E 95.17%F 1

G 95.17%







Remarks:


TFO

FLOOR CLEANER



Check and do TFO overhead dust box cleaning.

Do sweeping and collect hard waste

Dispose scrap in scrap yard

WLS No: ESP/W/34



POST SPG

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 4 57.76 231.04

2 1 16 0.96 15.36

3 1 16 2.00 32.00

A 278.40

B 13

C 314.59

D 480E 65.54%

F 1

G 65.54%

WLS No: ESP/W/35



Elegant Walk Path

Floor Cleaner


Clean the pathway using floor cleaning machine(from

Blowroom to TFO)

Post Spining

Drain the used water in the drain

Fill the water in the machine


Remarks:






_________________________________________________________________________ _______________







2.0 A ELEGANT SPINNING - MECHANICAL

MAINTENANCE

________________________________________________________________________________________





____________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

2.0 A2.1


Fitter - - - 1 1 - - - 1 1

Cleaner - - - 1 1 - - - 1 1

Sr. Fitter - - - 2 2 - - - 2 2

Cleaner - - - 2 2 - - - 2 2

Jr.Fitter 1 1 1 - 3 1 1 1 - 3

Sr. Fitter - - - 1 1 - - - 1 1

Jr.Fitter - - - 1 1 - - - 1 1

Cleaner - - - 1 1 - - - 1 1

Sr. Fitter - - - 1 1 - - - 1 1 Buffing Room

Fitter - - - 1 1 - - - 1 1

Jr.Fitter - - - 1 1 - - - 1 1

Cleaner - - - 7 7 - - - 7 7 Cleaning Gang

Running Fitter 1 1 1 - 3 1 1 1 - 3

Sr. Fitter - - - 1 1

Fitter - - - 1 1

Jr.Fitter - - - 2 2 - - - 2 2

Cleaner - - - 1 1 - - - 1 1

Sr. Learner - - - 1 1 - - - 1 1

2 2 2 25 31 2 2 2 24 30Total

11- - -

TFO

Autoconer&Cheese

Winding

Ring Frame4Main Gang

Blow Room

D/F & Simplex

Post Spinning

1

3

5

Carding2

ELEGANT SPINNING - MECHANICAL MAINTENANCEManpower Deployment


Remarks

_______________________________________________________________________________________________________ ________________________







2.0 A

2.2

2.2.1

a)

b)

c)

d)

e)

f)

-

-

-

-

-

-

-

-

-

-

g)

The manpower has been computed with a loading factor of 80 % for the maintenance personnel.

The 80 % loading has been considered to take into account the following:

Bring tools/materials from store Ex: oil,grease,waste cloth, new parts

Breakdown maintenance (Carding, Ringframe & Autowinding) data has been obtained for a

period of two months and the same has been extrapolated for a month.

Running maintenance data has been collected by detailed discussions with the incumbents andthe supervisory personnel and compared with check studies and estimated.

The sum of the preventive maintenance, breakdown maintenance(if any) and running

maintenance (if any) workload for the month gives us the total workload for the mechanical

personnel.

Rest & Relaxation allowance is already included as a part of activity time and presented against

the respective activities.

Prepare attendance

Write logbook

Arranging of tools & parts in tool room

Efforts variation required

Clean the tool room daily morning

The detailed time and motion study is recommended to arrive the standard time for the

activities,whatever timings considered here,based on the group utilisation technique.And cannot

taken for fixing standard times.

ELEGANT SPINNING - MECHANICAL MAINTENANCE


Methodology

Waiting for the machine for maintenance

The preventive maintenance data was collected for all the category of machines. Check studies

on a sample basis were carried out to ascertain the process being followed for the preventive

maintenance. The data gathered during check studies has been applied to the remaining

preventive maintenance activities in that section.

PF - Permanent Fitter(Sr.Fitter,Fitter,Jr.Fitter)

PH - Permanenent Helper/Cleaner

Discard the waste cloth to the waste area daily after maintenance work

Unavoidable delay. Ex: New activity cannot start after 4.30 pm as only 30 mins left for that day

Change dress

________________________________________________________________________________________






2.0 A

2.2



2.2.2

I

a)

b)

2.2.3

a)

b)

c)It is observed during the study that before all mechanical personnel arrived , the machine was

stopped for scheduled maintenance. Scheduled maintenance activity is started with few

personnel, then one by one joining the workplace. In Ringframe, Machine cleaning is carried out

by six personnel and each have their specific 96 spindle area to be cleaned. In this situation,

three helpers starts the activity early and finishes earlier, whereas the persons joined later

finishes their portion of 96 spindles later. Total machine stopped hour for maintenance

elongates because of this mismatch.

Total Time provided for Scheduled Maintenance

The time provided for scheduled maintenance activities are based on the company

experience/estimation. However, it was observed during the study that the actual time required

for the scheduled maintenance activities are less. So , it is recommended to go for in-depth time

and motion study and fix standards for the regular maintenance activities. This will help in

increasing the availability time of machine and also reduce maintenance personnel workloadfurther.

Autoconer & Cheesewinding

In view of low utilisation Fitters(38.41%) , it is recommended to deploy one fitter instead of the

present two fitter.

Proposed Changes

Scheduling & Planning

The activities to be so planned and performed that the time taken is minimized. Activities that

can be carried out in parallel have to be planned. It is observed in ringframe that maintenance

personnel, going to bring grease gun, gear box oil and parts to be changed. If the schedule

contain gearbox oil change, while coming itself it could have brought in the trolley.

Observations

During autoconer / cheese winding machine prevent maintenance activity, the respective

machine production operator is forced to idle. It is suggested that the production operator also

assist mechanical team while scheduled maintenance activities like cleaning with compressed

air, cloth for which no special mechanical skill required. Thereby, manpower further could be

reduced. It also helps in building sense of ownership.

________________________________________________________________________________________






2.0 A

2.3

S.No1

2

3

4

5

6

7

8

9

Autowinding&Cheese

winding

EMS/W/08

TFO EMS/W/09

Blowroom &Carding-

Running Fitter

EMS/W/03

Drawframe&Simplex EMS/W/04

Ring Frame-Running

Fitter

EMS/W/07

Ring frame-Cleaning EMS/W/05

Ring frame-Main Gang EMS/W/06

Blowroom EMS/W/01

Carding EMS/W/02




________________________________________________________________________________________





_____________________________________________________________________________________________________________________________________________________

_

Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

DepartmentELEGANT

SPGA B C G

Section Mechanical - - - 1F+1 H

Work CentreBlowroom &

Mixing- - - 1F+1 H

PF PH PF PH

1 Line Blender clg. 2 1 1 2.988 3 18 18

2 Hopper Feeder clg. 2 1 1 1.992 3 12 12

3 Conden. & Doffing Section Clg. 2 1 1 1.992 3 12 12

4 Scutcher Cleaning 3 1 1 2.988 3 27 27

5 Mixing Blender clg 2 1 1 2.988 3 18 18

6 Mixing Condenser cleaning 1 1 1 1.992 7 14 14

7 Gear Box/Shell Roll Checking 1/3 1 1 1.992 6 4 4

8 K. Beater Legs Change 1/9 1 1 3.984 3 1 1

9 V.F.O.Wire Change 1/12 1 1 5.976 1 0 0

10 Beater Cleaning by Petrol 26 1 0.996 1 0 26

11 Compactor Cleaning 26 1 0.05 1 0 1

12 Grid Bar Cleaning 4 1 1 1.992 1 8 8

13 Primary Filter Cloth Washing 4 1 1 0.996 1 4 4

14 Secondary Filter Cleaning 4 1 1 1.992 1 8 8

15 Running Problems(During General Shift) 26 1 1 1 26

A 152.33 153.52

B 166.4 166.4

C 91.54% 92.26%

D 1 1

E 91.54% 92.26%

WLS No:EMS/W/01


Shifts

Present Manpower

Proposed Manpower

Net Available man-hours per month(8*26*80% = 166.4 hours)


Proposed Manpower


Monthly

workload(Hours)

Total Workload per month ( in man hours )

S.

No Activity Description

Frequency/

Month

Crew Category Time

(in Hours)

No of

Machine

____________________________________________________________________________________________________________________ _________________________________

______ National Productivity Council, Bangalore.






_____________________________________________________________________________________________________________________________________________________

_

Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

PF PH PF PH

Monthly

workload(Hours)S.

NoActivity Description

Frequency/

Month

Crew Category Time

(in Hours)

No of

Machine

____________________________________________________________________________________________________________________ _________________________________

______ National Productivity Council, Bangalore.





________________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

DepartmentELEGANT

SPGA B C G

Section Mechanical - - - 2F+2H

Work Centre Carding - - - 2F+2H

PF PH PF PH

1 Full Setting 2 2 1 2.7 22 239.08 119.54

2 Cyl Wire Change 1/24 1 2 14.5 22 13.28 26.56

3 Doffer Wire Change 1/24 1 2 14.5 22 13.28 26.56

4 Flat Tops Change 1/30 1 2 5.4 22 3.98 7.97

5 Stn Flats(Back) Change 1/9 1 2 1.8 22 4.43 8.85

6 Stn Flats(Front) Change 1/15 1 2 1.8 22 2.66 5.31

7 Lic-in Wire Change 1/6 1 2 0.9 22 3.32 6.64

8 Cyl. & Doffer Wire Grinding 1/6 1 2 0.9 22 3.32 6.64

9 Coiler Overhauling 1/18 2 1 3.6 22 8.85 4.43

10 Clearer roller Clothing Change 1/12 1 1 0.5 22 0.83 0.83

Daily Works

11 CTC Cleaning 26 0 2 0.03 12 0.00 20.80

12 Stripping Brush Cleaning 26 1 0.025 12 0.00 7.80

13 Regular checkup and fill the log book 26 1 0.12 1 3.03 0.00

A 296.07 241.94

B 166.4 166.4

C 88.96% 72.70%

D 2 2

E 88.96% 72.70%



Running fitter in the carding section, performs the CTC cleaning with the general shift maintenance personnel at the general shift starting.

S.No

Activity Description Frequency/ Month

Crew Category


Proposed Manpower


Proposed

Manpower

Monthly workload(Hours)Time(in Hours)

No of Machine

WLS No:EMS/W/02


Shifts

Present

Manpower

__________________________________________________________________________________________________________________________ _______________________________







Department

Section

Work CentrePresent

Manpower1 1 1 -

DesignationProposed

Manpower1 1 1 -

Sl. NoCrew

Size

Freq/

Shift

Basic

Time

(mins)

Total

Workload

(mins)

1 1 8 3.00 24.00

2 1 8 2.45 19.60

3 1 4 7.04 28.16

4 1 1 3.00 3.005 1 1 2.06 2.06

6 1 1 25.00 25.00

7 1 1 20.00 20.00

8 1 1/3 20.00 6.67

9 108.00

A 212.49

B 450.0

E 47.22%

F 1

G 47.22%

Date Shift

No of

problems

Total

Time

(Mins)

03-Jan A 5 75

04-Jan A 3 35

08-Jan A 6 120

05-Jan C 5 10009-Jan B 10 190

12-Jan C 7 105

13-Jan B 6 105

10-Jan A 6 65

06-Jan C 10 21011-Jan B 6 120

64 1125

Lot change cylinder side checking

K-beater & MBO beater cleaning

Total Workload per shift ( in man mins )

Net Available man-mins per month




To assess the amount of time spent on attending running problems, the random samples shifts is

selected from the past log books(Jan-2012). The random number is generated and number of

problems attended and time spent for the problem is tabulated as follows:

Total

C GMechanical

Clean the primary ( 2nos)

Check the card speed, sliver weight, limit

Remarks:

Attend running breakdown(24% * 450mins =

108 mins/shift)

Write log book Front side bottom jam

CTC Cleaning(help the general shift gang),Flat

brush cleaning

Blowroom & Carding

Running Fitter


Clean the Compactor

WLS No: EMS/W/03


Elegant SpgShifts A B

_____________________________________________________________________________________________






Department

Section

Work CentrePresent

Manpower1 1 1 -

DesignationProposed

Manpower1 1 1 -

Sl. NoCrew

Size

Freq/

Shift

Basic

Time

(mins)

Total

Workload

(mins)

C GMechanical

Blowroom & Carding

Running Fitter


WLS No: EMS/W/03


Elegant SpgShifts A B

The average time to resolve a complaint works out to be 17.57 minutes.(1125/64)

The average arrival rate λ is 64/10 = 6.4 per shift and the average servicing rate μ = 8*60 /17.57

= 27.31 per shift

λ/μ = 0.2343= 24 %

_____________________________________________________________________________________________






DepartmentELEGANT

SPGA B C G


Work CentreDrawframe

&Simplex- - - 2F+1H

PF PH PF PH

A Draw Frame

1 Machine Clg. Of Cherry Hara 3 2 1 1.489 2 17.9 8.9

2 Machine Clg. Of LDO/6 2 2 1 2.978 4 47.6 23.8

3 Cots Buffing 1 1 1 2.978 6 17.9 17.9

4 Oil Change 1/4 1 1 0.5 6 0.8 0.8

5 Basic Gauge Setting 1/6 2 1 5.956 6 11.9 6.0

6 Coiler O.H 1/6 2 1 8.934 6 17.9 8.9

7 Gear Box O.H 1/12 2 1 8.934 6 8.9 4.5

B Simplex

1 M/C Cleaning 1 1/2

2 Bottom Apron Change 1

3 Top Apron Change 1

4 Gear Box Oil Change 1/45 Reducer Gear Box Oil Change 1/2

6 Cots Buffing 1/2 1 1 2.978 5 7.4 7.4

7 New Cots Change 1/18 1 1 5.956 5 1.7 1.7

Time(in Hours) No of Machine Monthly workload(Hours)S.No Activity Description Frequency/ Month

2 1 4.467 5

WLS No:EMS/W/04


Shifts

Present Manpower

67.01 33.50

Crew Category

Proposed Manpower

__________________________________________________________________________________________________________________________ ________________________________







DepartmentELEGANT

SPGA B C G



&Simplex- - - 2F+1H

PF PH PF PH

Time(in Hours) No of Machine Monthly workload(Hours)S.No Activity Description Frequency/ Month

WLS No:EMS/W/04


Shifts

Present Manpower

Crew Category

Proposed Manpower

8 Top & Bottom Apron Cleaning 1/3 1 1 2.978 5 5.0 5.0

9 Spindle Truing 1/4 2 1 8.934 5 22.3 11.2

10 Bottom Roll Truing 1/6 2 1 8.934 5 14.9 7.4

11 Arbour Greasing 1/6 1 1 2.978 5 2.5 2.5

12 Bottom & Top Clearer Cloth Change 1/12 2 1 8.934 5 7.4 3.7

13 Pressure Finger Change 1/24 2 1 11.912 5 5.0 2.5

C Daily

1

D/F 26 1 1.07 6 27.73 0.00

2 D/F Creel Cleaning 26 1 0.25 6 0.00 6.50

3 Head Stock Cleaning, Chalk powder applied -

Simplex,D/F26 1 0.42 5 0.00 10.83

4 Check both D/F,Simplex machine. Fill the log

book 26 1 0.50 13.00 0.00

5 Liquimix to Cots 26 1 0.25 6.50 0.00

6 Running Problems 26 1 1 26.00

A 329.26 162.93

B 166.4 166.4

C 98.94% 97.91%

D 2 1

E 98.94% 97.91%


Remarks


Proposed Manpower



__________________________________________________________________________________________________________________________ ________________________________







Department ELEGANT SPG A B C G


Work Centre Ringframe - - - 1F+6H

PF PH PF PH

A Ringframe

1 M/C Cleaning 1

2 Cots Change 1/9

3 Top Apron Change 1/24

4 Separator Washing 1/9 1 6 3.00 26 8.67 52.00

5 Top Apron Washing 1/6 0 2 3.00 26 0.00 26.00

6 Spindle Oil Change 1/9 1 1 3.00 26 8.67 8.67

7 Bottom Apron Change 1/9 0 4 1.50 26 0.00 17.33

8 Suction Tube Washing 1/6 0 4 1.50 26 0.00 26.00

9 Arbour Greasing 1/9 1 1 3.00 26 8.67 8.67

10 Semi Over Hauling 1/30 3* 9** 27.00 26 0.00 138.68

B TFO

1 Machine Cleaning 1

2 Centering Disc Cleaning & Greasing 1/23 Thread Guide Washing 1/3

4 Main Drive Shaft Bearing Greasing 1/3

5 Spindle Oil Topping 1/3 1 1 0.32 32 3.40 3.40

6 Spindle Oil Change 1/9 1 1 0.32 32 1.13 1.13

7 Variator Assly Washing 1/6 0 2 2.55 32 0.00 27.18

C Cheesewinding

1 Machine Cleaning 1 1 6 1.91 5 9.56 57.33

Monthly

workload(Hours)

1

WLS No:EMS/W/05


Shifts

Present

Manpower

Proposed

Manpower

6

S.

No

Activity DescriptionFrequency/

Month

Crew Category

1.5 26

Time

(in Hours)

No of

Machine

39 234

6 40.771 1.274 32 244.61

__________________________________________________________________________________________________________________________ ________________________________









Work Centre Ringframe - - - 1F+6H

PF PH PF PH

Monthly

workload(Hours)

WLS No:EMS/W/05


Shifts

Present

Manpower

Proposed

Manpower

S.

No

Activity DescriptionFrequency/

Month

Crew Category Time

(in Hours)

No of

Machine

2 Drum Polishing 1 1 1 2.55 5 12.74 12.74

A 132.59 857.74

B 166.4 166.4

C 79.68% 85.91%

D 1 6

E 79.68% 85.91%

Proposed Manpower




* from main gang

** two from main gang


Remarks

__________________________________________________________________________________________________________________________ ________________________________






_________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani


Section Mechanical - - - 1F+1 Jr.F

Work Centre Ringframe - - - 1F+1Jr.F

F Jr.F F Jr.F

A Ringframe

M/C Cleaning 1

Cots Change 1/9

Top Apron Change 1/24

Separator Washing 1/9

Top Apron Washing 1/6

Bottom Apron Change 1/9

Spindle Oil Change 1/9

Suction Tube Washing 1/6

Arbor Greasing 1/9

1 Drum Shaft Bearing Greasing 1/3 1 1

2 Variator Checking 1/3 1 03 C1, C2 Setting 1/3 2 0

4 Bottom Apron Setting 1/3 2 0

5 Fly Catcher setting 1/3 1 1

6 Bottom Roller Greasing 1/3 1 1

7 Delay Draft Checking 1/3 2 0

8 Drum Filter Cloth Wash 1/6 0 1

Proposed

Manpower

0.800 26

WLS No:EMS/W/06


Shifts

Present Manpower

R/F Cleaning Gang

6.936.93

S.


Frequency/

Month

Crew Category Time

(in Hours)

No of

Machine

Monthly

workload(Hours)

______________________________________________________________________________________________________________ __________________________






_________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani


Section Mechanical - - - 1F+1 Jr.F

Work Centre Ringframe - - - 1F+1Jr.F

F Jr.F F Jr.F

Proposed

Manpower

WLS No:EMS/W/06


Shifts

Present Manpower

S.


Frequency/

Month

Crew Category Time

(in Hours)

No of

Machine

Monthly

workload(Hours)

9 Jockey Pulley Greasing 1/9 1 1 1.60 26 5 5

10 Gear Box Oil Changing 1/6 1 1 0.80 26 3 3

11 Spindle Gauge 1/9 3 1 3.20 26 28 9

12 Ring Change 1/48 3 4.80 26 8 0

13 Lappet Hook Change 1/48 3 0.80 26 1 0

14 Spindle Tape change 1/24 2 2 3.20 26 7 7

15 Top Clearer Cloth Changing 1/24 2 2 9.60 26 21 21

16 Bottom Roller Truing 1/9 3 1 4.80 26 42 14

17 Semi Over Hauling 1/30 3 9* 14.40 26 33 22

A 154.14 87.83

B 166.4 166.4

C 92.63% 52.78%D 1 1

E 92.63% 52.78%

Proposed Manpower



Remarks:



* 7 personnel from cleaning gang

______________________________________________________________________________________________________________ __________________________







Department

Section



Sl. NoCrew

Size

Freq/

Shift

Basic

Time

(mins)

Total

Workload

(mins)

A

1 1 1 20.00 20.00

2 1 1 1/45 30.00 30.67

3 1 2/9 33.16 7.37

4 1 2/9 13.37 2.97

5 1 16/45 15.00 5.33

6 1 1 30.00 30.00

7 1 1 32.00 32.00

8 1 1 20.00 20.00

9 1 1 30.00 30.00

10 1 1 15.00 15.00

11 1 1 30.00 30.0012 1 1 30.00 30.00

B

1 1 7/15 30.00 14.00

2 1 1/15 30.00 2.00

3 1 1/5 25.00 5.00

C 126.00

A 400.34B 450.0

E 88.96%

F 1

G 88.96%

Remarks:

Count change depend on the count. For calculation it has taken maximum time

To assess the amount of time spent on attending running problems, the random samples shifts is

selected from the past log books(Jan-2012). The random number is generated and number of problems attended and time spent for the problem is tabulated as follows:

Attend running breakdown(28% * 450mins = 126

mins/shift)

Total Workload per shift( in man mins)Net Available man-mins per shift




TPI Change

Running Fitter


Go round to check the problem in ring frame

machine. Check spindle tape, bottom apron and

OHTC cleaning(13 OHTC/shift)

Ringframe

Cots Checking(8 machines/shift)

TFO

Count change

RT/NT Change

Mechanical

Check the needle bearing(8 machine/shift)

Drum pulley shaft cleaning(8 machines/shift)

Check the drum(26 machine/shift)

Count change

Ringframe&TFO

Change from NT to RT

Change the jockey pulley cover in reverse direction

TPI Change

Head Stock cleaning

Draft cleaning

WLS No: EMS/W/07


Elegant SpgShifts A B C G

________________________________________________________________________________________






Department

Section



Sl. NoCrew

Size

Freq/

Shift

Basic

Time

(mins)

Total

Workload

(mins)

Running Fitter


Mechanical

Ringframe&TFO

WLS No: EMS/W/07


Elegant SpgShifts A B C G

Shift

Total

Time(Min

s)A 170

A 110

B 155

C 200

B 80

C 165

B 205

A 115

C 50

B 100

1350Total

13-Jan

Date

06-Jan

07-Jan

08-Jan

10-Jan

The average arrival rate λ is 74/10 = 7.4 per shift and the average servicing rate μ = 8*60 /17.57 =

26.31 per shift

03-Jan

The average time to resolve a complaint works out to be 18.24 minutes.

11-Jan

12-Jan

λ/μ = 0.2812= 28 %

11

5

8

3

04-Jan

01-Jan

10

4

8

74

No of problems

8

7

10

________________________________________________________________________________________





__________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani



Work CentreAutoconer&

Cheese winding- - - 1F+2H

PF PH PF PH

A Autoconer


2 Bearing Centre Sleeve Silicon Oiling 1

3 Impeller and Wire Mesh Cleaning & Checking 1

4 Drum Polishing 1

5 Suction Fan Bearing Greasing 1/2

6 Magazine Assly. Cleaning & Resetting 1/12 2 1 1.88 7 2.19 1.10

7 Cam Drive Shaft Bearing Greasing 1/3 1 1 1.00 7 2.33 2.33

8 Auto Doffer Cleaning & Lubrication 1/2 1 1 1.00 7 3.50 3.50

9 Over Head Unit Cleaning & Checking 1/3 1 1 1.00 7 2.33 2.3310 Spindle Unit Opening Cleaning & Checking 1/9 1 1 4.00 7 3.11 3.11

11 Tension Assly & Shutter Cutter Opening & Clg. 1/6 3 1 4.00 7 14.00 4.67

12 Bearing Centre Greasing RH (Base) & LH (Nose) 1/10 1 1 4.00 7 2.80 2.80

13 Splicing Head Servicing 1/6 3 1 6.00 7 21.00 7.00

B Cheesewinding


2 4

R/F Cleanin Gan

2.00 7 8.06

Time

(in Hours)

No of

Machine

Frequency/

Month

Crew CategoryMonthly

workload(Hours)

56.00

WLS No:EMS/W/08


Shifts

Present

Manpower

Proposed

Manpower

S.


______________________________________________________________________________________________________________ ________________________












PF PH PF PH

Time

(in Hours)

No of

Machine

Frequency/

Month


workload(Hours)

WLS No:EMS/W/08


Shifts

Present

Manpower

Proposed

Manpower

S.


2 Drum Polishing 1

3 Pivot Bearing Oiling 1/6 1 1 0.50 5 0.42 0.42

4 Cradle Setting 1/6 1 1 2.00 5 1.67 1.67

5 Upper & Lower Guide Pulley Brg. Oiling 1/6 1 1 2.00 5 1.67 1.67

6 Upper, Lower pulley Setting 1/6 1 1 2.00 5 1.67 1.67

7 Tension Assly. & Cone Peg Setting 1/6 1 1 2.00 5 1.67 1.67

8 S.M.Ceramic Guide Setting 1/6 1 1 1.00 5 0.83 0.83

9 Tension Disc Cleaning 1/6 1 1 0.50 5 0.42 0.42

10 Over Head Blower O.H. 1/12 1 1 2.00 5 0.83 0.83

11 Gear Box Oil Change 1/12 1 1 5.00 2 0.83 0.83

Daily

12 Splicing Checking 26 1 0.0042 60 6.50 0.00

13 Cheese winding Drum Spray 4 1 0.0029 60 0.00 0.70

14 Auto Coner Bobbin Conveyor Belt Clg. 26 1 0.036 7 0.00 6.50

15 Autoconer Over Head Cleaning

16 1 Magitec 26 1 0.10 1 0.00 2.50

______________________________________________________________________________________________________________ ________________________












PF PH PF PH

Time

(in Hours)

No of

Machine

Frequency/

Month


workload(Hours)

WLS No:EMS/W/08


Shifts

Present

Manpower

Proposed

Manpower

S.


17 6 Pneumafil 26 1 0.06 6 0.00 9.78

18 Cheesewinding Over Head Cleaning

19 3 RJK 26 1 0.056 3 0.00 4.39

20 2 SSM 26 1 0.032 2 0.00 1.65

21 Go round and attend the idle spindle, Running 26 1 2.000 52.00 0.00

A 127.83 116.71

B 166.4 166.4

C 38.41% 35.07%

D 1 2

E 76.82% 35.07%


In view of low utilisation of helpers(35.07%), it is recommended to provide two helpers. This has been done mainly to reduce machine down time for

the scheduled maintenance activity. Two helpers involved mainly in machine cleaning, where full autoconer machine is stopped. For the fitter activities

like Tension Assly & Shutter Cutter Opening & Clg (only twelve drums stops at a time), one fitter and two helpers are proposed.


Proposed Manpower


PH- In autowinding includes Jr Fitter & helper.

Cheese winding Machine cleaning&drum polishing activities are performed by Ring frame machine cleaning gang. It is considered under theirworkload sheet.


______________________________________________________________________________________________________________ ________________________







DepartmentELEGANT

SPGA B C G


Work Centre TFO - - - 1F+1H

PF PH PF PH

Machine Cleaning 1

Centring Disc Cleaning & Greasing 1/2

Spindle Oil Topping 1/3

Spindle Oil Change 1/9

Thread Guide Washing 1/3

Variator Assly Washing 1/6

Main Drive Shaft Bearing Greasing 1/3

1 Machine Cleaning-Checking of Machine

from TFO Side1 1 0 0.69 32 21.95 0.00

2 Brake Roller Oiling 1/3 1 1 0.4262 32 4.55 4.55

3 All Gearing & Cam Box Checking 1/3 1 1 0.8524 32 9.09 9.09

4 Gear Shaft Bearing Greasing 1/4 1 1 0.8524 32 6.82 6.82

5Take-Up & PTR Shaft Bearing Greasing 1/6 1 1 0.8524 32 4.55 4.55

6 Spindle Brg Greasing 1/6 1 1 0.8524 32 4.55 4.55

7 PTR to Pigtail Setting 1/6 1 1 1.7048 32 9.09 9.09

WLS No:EMS/W/09


Shifts

Present

Manpower

Monthly

workload(Hours)

R/F Cleaning Gang

Proposed

Manpower

S.


Frequency/

Month

Time

(in Hours)

No of

Machin

e

Crew Category

_______________________________________________________________________________________________________ ________________________








DepartmentELEGANT

SPGA B C G



PF PH PF PH

WLS No:EMS/W/09


Shifts

Present

Manpower

Monthly

workload(Hours)

Proposed

Manpower

S.


Frequency/

Month

Time

(in Hours)

No of

Machin

e

Crew Category

8 Cradle Setting Checking 1/6 1 1 0.8524 32 4.55 4.55

9 Thread guide setting 1/6 1 1 0.8524 32 4.55 4.55

10CLM and Drop Wire Setting Checking 1/6 1 1 0.8524 32 4.55 4.55

11 Jockey Pulley Greasing 1/9 1 1 0.8524 32 3.03 3.03

12 Gearing OverHauling 1/18 1 1 1.7048 32 3.03 3.03

13 Gear Box Oil Change 1/18 1 1 0.8524 32 1.52 1.52

14 Over Head OverHauling 1/18 1 1 0.8524 13 0.62 0.62

Daily

15 T.F.O. Over Head Cleaning(Elgi Jacobi-12,Nugen-1no)Remove the waste, clean

with broom stick 26 1 0.06 13 0 19.25

16 Go round the all TFO machine,notedown the

problem in the log book 26*2 times

per day1 0.67 32 35 0

_______________________________________________________________________________________________________ ________________________







DepartmentELEGANT

SPGA B C G



PF PH PF PH

WLS No:EMS/W/09


Shifts

Present

Manpower

Monthly

workload(Hours)

Proposed

Manpower

S.


Frequency/

Month

Time

(in Hours)

No of

Machin

e

Crew Category

17 Attend th running problem identifed during

intial round26 1 1 1 1 26 26.0

18 Count Change 13 1 0.5 1 7 0

A 149.93 105.73

B 166.4 166.4

C 90.10% 31.77%

D 1 1

E 90.10% 63.54%


Proposed Manpower




_______________________________________________________________________________________________________ ________________________






___________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

2.0 B ELEGANT SPINNING - ELECTRICAL

MAINTENANCE

________________________________________________________________________________





_________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

2.0 B2.1


1 Shift Maintenance Electrician1 1 1 - 3 1 1 1 - 3

2 General Shift maintenance - Attending to all

Electronic break down of machine &maintain the parameter. Perform PM as per

the schedule

Electronic Tech.

- - 1 1 2 - - 1 1 2

3 Humidity plant Humidity

attendant 1 1 1 - 3 1 1 1 - 3

4 General shift maintenance - Perform

machine PM, Attend to the shift break down

Electrician

- - - 2 2 - - - 2 2

5 Motor maintenance Motor Fitter- - - 1 1 - - - 1 1

6 H.Plant & Air compressor U/Fitter - - - 1 1 - - - 1 1

7 Trench Cleaning Trench Cleaner- - - 2 2 - - - 2 2

2 2 3 7 14 2 2 3 7 14

Proposed ManpowerRemarks

Total

ELEGANT SPINNING - ELECTRICAL MAINTENANCEManpower Deployment

S. No Section / Work area DesignationPresent Manpower

_______________________________________________________________________________________________ ____________________







2.0 B

2.2

1 No changes proposed.

ELEGANT SPINNING - ELECTRICAL MAINTENANCE


________________________________________________________________________________






3.0 BTM SPINNING - PRODUCTION

_________________________________________________________________________ _______________







3.03.1


1 MIXING Mixing Man 7 7 7 - 21 6 6 6 - 18

Beater Opener 1 1 1 - 3 1 1 1 - 3

Waste Sorter - - - 1 1 - - - 1 1

2 BLOW-ROOM Tenter 4 4 4 - 12 4 4 4 - 12

3 CARDING Tenter 3 3 3 - 9 3 3 3 - 9

Lap Carrier 2 2 2 - 6 2 2 2 - 6

4 DRAWFRAME Jobber 1 1 1 - 3 1 1 1 - 3

D/F Tenter 3 3 3 - 9 3 3 3 - 9

5 SIMPLEX S/F Tenter 5 5 5 - 15 5 5 5 - 15

Doffer 3 3 3 - 9 3 3 3 - 9

Floor Cleaner 1 1 1 - 3 1 1 1 - 3

Helper / Reliever 1 1 1 - 3 1 1 1 - 3

6 RING-FRAME Doffing Reliever 3 3 3 - 9 3 3 3 - 9

Checker 1 1 1 - 3 2 2 2 - 6

Sider 13 13 13 - 39 13 13 13 - 39

Doffer 18 18 18 - 54 18 18 18 - 54

Doffer-Leader 3 3 3 - 9 3 3 3 - 9

Floor Cleaner 3 3 3 - 9 3 3 3 - 9

BTM SPINNING - PRODUCTIONMan ower De lo ment *


Remarks

__________________________________________________________________________________________________________ _______________________







3.03.1




Remarks

Runnning Fitter 1 1 1 - 3 1 1 1 - 3

7 AUTO-CONER Reliever 2 2 2 - 6 1 1 1 - 3

Material Man 2 2 2 - 6 2 2 2 - 6

Kirchi Man 2 2 2 - 6 2 2 2 - 6

Floor Cleaner 2 2 2 - 6 2 2 2 - 6

Helper in Savio

No. 71 1 1 - 3 1 1 1 - 3

Rejection Rewinder - - - 1 1 - - - 1 1

Winder 16 16 16 - 48 8 8 8 - 24

Jam Cutting - - - 1 1 - - - 1 1

8 CHEESE WINDER Winder 10 10 10 - 30 7 7 7 - 21

Leewha Winder 1 1 1 - 3 1 1 1 - 3

9 TFO Jobber 1 1 1 - 3 1 1 1 - 3

Reliever/Helper 2 2 2 - 6 2 2 2 - 6

Sr. Checker /

Jobber- - - 1 1 - - - 1 1

Tenter 12 12 12 - 36 12 12 12 - 36

10 PACKING Checker - - - 3 3 - - - 3 3

__________________________________________________________________________________________________________ _______________________







3.03.1




Remarks

Lot Final Checker - - - 2 2 - - - 1 1

Packer - - - 6 6 - - - 5 5

11 S.Q.C. Checker &Investiga 3 2 - 1 6 3 2 - 1 6

127 126 124 16 393 115 114 112 14 355

* The above manpower deployment table is for 30s Count.

Total

__________________________________________________________________________________________________________ _______________________







3.0

3.2

3.2.1

I

a)

b)

c)

d)

M / C N a m e

P r o d u c t i o n ( k g s )

/ H o u r

P a r a m e t e r s

O u t p u t

Q u a n t i t i e s

CARDING-

LR C1/315.9

12 Kg/

Can

D/F

Breaker78.26

10

Kg/Ca

n

D/F

Finisher209.17

14

kg/Can

Speed

frame66.55

108

spindle/

machine

1.3 Kg/

Roving

It is assumed that machines are subject to stops at random and unpredictable intervals. It is

also assumed that the operator will service a machine with the minimum delay after the

machine has stopped, and that if two or more are stopped at one time,he will attend to them

by taking the nearest first. This method of servicing is called random tending. Thomas

F.O' Connor, provided the table for calculating the machine efficiency and operators

workload in this type of multimachine assignment problem in the book: Efficiency and

Productivity Tables for Textile Machine Operation, Institute of Textile

Technology,Virginia.


62.61

119.53

409.54

BTM SPINNING - PRODUCTION

o u t p u t p e r s h i f t

p e r m a c h i n e

10.60

Methodology

The machine efficiency and operator workload are depicted in the graph to findout the

optimum (where running efficiency & operative workload meets) number of machines to be


Carding,Drawframe and Speedframe

In Carding, Drawframe and Speed frame sections, the operator is responsible for the

operation of more than one machine, if two machines stop at a time and require tenter's

attention simultaneously,one of the machine must wait until he completes his work on the

other. This time loss representing waiting time due to overlapping of machine stoppage is

called "Interference loss".


I n p u t p e r s h i f t

p e r m a c h i n e

7.71

52.17

167.34

38.03

_________________________________________________________________________ _______________







3.0

3.2 Proposed Changes & Observations


3.2.1

II

a)

b)

c)

d)

e)

Methodology

The working pattern of operators in Ringframe, Autconer, Cheese winding and Two-for-

One(TFO) is entirely different from the preceding section.In this areas,the operator's

services the machine in a cyclical manner and attends to each machines(drums) as he

comes to it.

The research paper "The Efficiency of N machines Uni-Directionally patrolled by

single operative" by Mr.C.Mack,T.Murphy and N.L.Webb,Journal of the Royal

Statistical Society, (1957), is used to arrive the machines running efficiency for the

different number of machines handled by the operators in the above sections consideringthe following working methodology:

- Random breakdowns in running time @ each machine/drum

N - Number of machines

The operative walks round the machines in a defined order and repairs and restarts any

machine which is found stopped, passing after inspecting and/or servicing any machine

which is running. It is assumed that the machine stops at random with the same mean

frequency and independent of each other.

The difficulty in dealing with these problems lies in calculating the effect of "interference"

which is the term used for incidence of simultaneous stoppages at several machines. In fact,

if the optimum number of machines is being controlled by one operative, the machine

efficiency required will be a marked feature.

The running efficiency is arrived by the following formula provided by the research paper.

= Running Efficiency, i.e the percentage of running time to total (stopped +

running) time.Stopped means time lost due to interference and breaks and

rectification of breaks.

K- Mean walking time from one machine to next machine, includes inspection time

= (b-1) / [ N{K+(b-1)C}]

C - Time to repair and restart the machine

Ringframe, Autoconer, Cheesewinding and Two-for-One(TFO)

b = exp( NK)

_________________________________________________________________________ _______________







3.0



3.2.1

f)

g)

h)

M / C N a m e

P r o d u c t i o n ( K g s ) / H

o u r s

M a c h i n e P a r a m e t e r s

O u t p u t

A v a i l a b l e h o u r s / S h i f t

M / C a v a i l a b l i t y l o s t

% *

M / C A v a i l a b i l i t y ( % )

T o t a l T i m e a v a i l a b l e f o r

p r o d u c t i o n

I n p u t p e r s h i f t o f r e s p

e f f i c i e n c y p e r m /

c

o u t p u t p e r s h i f t o f r e s p

e f f i c i e n c y p e r m /

c

R/F-

Texmaco8.75

440

spindle/

machine

58 gms

Bobbin8 9.50% 91.5% 7.32 49.27 1105.00

R/F-LR 10.17

432

spindle/

machine

58 gms

Bobbin8 9.50% 91.5% 7.32 57.26 1284.00

Autocone

r-Espero59.68

60

spindle/

machine

2 Kg Cone 8 30% 70.0% 5.6 5761.72 167.09

Cheese

Winding-

RJK

150

120

spindle/

machine

1 Kg

Cheese8 29% 71% 5.68 186.16 372.32

TFO-VJ 9.32

144

spindle/

machine

2 Kg Cone 8 4% 96.0% 7.68 71.56 35.78

TFO-

PRERNA9.32

144

spindle/

machine

2 Kg Cone 8 4% 96.0% 7.68 71.56 35.78

Methodology


The operator workload is calculated by multiplying the time taken for different activities to

be performed with the frequency of the activities for the allotted number of machines.

The running efficiency values and operator workload are depicted in the graph to findout

the optimum (where running efficiency & operative workload meets) number of drums to

be alloted per personnel.

_________________________________________________________________________ _______________







3.0



3.2.2

I

a)

II

a)

III

a)

b)

IV

a)

V

a)

b)

VIa)

VII

a)

It is recommended to allocate 60 drums per operator(6 machines) and 64 drums per

operator in the remaining to machines. The machine efficiency would be decrease where 64

drums allocated per operator.

Cheesewinding -Winder

Autoconer -Winder

Proposed Changes

Mixing Blenders:

Deploy five personnel as the packer instead of present six personnel. The proposed

utilisation would be 86.74%

Packing - Packers

In view of low utilisation (46.43% ), it is recommended to deploy one personnel as reliever

instead of the present two personnel who is presently releiveing autoconer winder in

machine 2,1,5 & 6. The operator workload would be reduced as the number of winders to

be relieved is become half.

It is suggested to deploy two cheker per shift as checker (three units) in ringframe section

instead of present one person per shift.

Based on utilisation (74.47 %), it is recommended to deploy six personnel instead of the

present seven personnel in a shift for three mixing blenders operation. The proposed

utilisation of six personnel would be 86.88%

From the analysis,it is found that the optimum number of drums to be assigned is 60 drums

per operator. At present, one operator is alloted 30 drums(in two machines 32drums/operator).

Autoconer -Reliever

Deploy one personnel for lot final checking activity instead of two personnel persently. The

proposed utilisation would be 94.33%

In BTM Spinning, the four cheese winding machines are in one section and two machines

are in unit-3. Based on the above findings, two personnel is recommended for unit-3

machines(2 nos) and five personnel for four machines in the unit-1 &2.

From the analysis,it is found that the optimum number of drums to be allocated is 120

drums per operator. At present, one operator is assigned 64,76,80 drums depends on the

machine capacity.

Packing - Lot final Checker

Ringframe -Checker

_________________________________________________________________________ _______________







3.0

3.3

S.No

12

3

4

5

6

7

8

9

10

11

12

1314

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

3536

37

BSP/W/09

BSP/W/07

Ringframe-Doffer BSP/W/14

Speedframe -Reliever BSP/W/11

Speedframe-Floor Cleaner BSP/W/12

Ringframe-Sider BSP/W/13 & A

Speedframe Tenter

BSP/W/23




Mixing Man BSP/W/01

Speedframe Doffer BSP/W/10

Drawframe-Jobber

Ringframe-Doffer Reliever BSP/W/16

Autoconer-Winder

BSP/W/22

Ringframe-Running Fitter BSP/W/17

Ringframe-Checker BSP/W/18

Ringframe-Floor cleaner BSP/W/19

Beater Opener BSP/W/02

Blowroom Tenter BSP/W/04

Waste Sorter BSP/W/03

Carding Tenter BSP/W/05

Lap Carrier

TFO- Jobber BSP/W/30

Ringframe-Doffer leader BSP/W/15

Cheesewinding-Winder(SSM) BSP/W/28

Cheesewinding-Leewha BSP/W/29

Autoconer-Reliever BSP/W/20

TFO- Tenter BSP/W/33 & A & B

TFO- Sr.Jobber BSP/W/32

BSP/W/06

Drawframe Tenter BSP/W/08

BSP/W/27

BSP/W/26Autoconer-Helper in Savio No.7

BSP/W/37QA- Checker & Investigator

Packing - Checker BSP/W/34

Packing -Lot Final Checker BSP/W/35Packing -Packer BSP/W/36

Autoconer-Material Man BSP/W/21

Autoconer-Kirchiman

Autoconer-Jam Cutting

TFO- Reliever BSP/W/31

Autoconer-Floor Cleaner BSP/W/25

Autoconer-Rejection rewinder BSP/W/24

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total Time

(Mins)

1

a1 1 4.95 4.95

b1 1 2.48 2.48

c 2 1 10.50 21.01

d 1 1 4.00 4.00

d 1 1 1.13 1.13

2

a2 5 3.92 39.15

b 1 5 1.42 7.11

c1 2275 0.026 59.32

d1 2275 0.028 62.73

e1 20 3.85 77.00

f 1 1225 0.12 144.12

g 1 41 2.07 84.87

h1 3500 0.08 280.00

3

a

b

4

a

b

5

Bring the hot water in a plastic drum from geyser

Mix the AS-200 & AS-400 one by one in the hotwater

WLS No: BSP/W/01


BTM SpinningShifts A B C G

Blender

Mixing Boy


Spin Finish Solution preparation ( No 1 & 3)(in

front of shift incharge)

Bring the chemical ( AS 400) from the plastic drum

in the presence of supervisor after weighing

Mixing Room

Bring the chemical ( AS 200) from the plastic drum

in the presence of supervisor after weighing

1 3500

Keep the empty chemical cans in the respective area

Layering

Bring the polyester bags from respective area to

near the machine

Open the bales of polyester bags

Take the polyester from bags and put it on the belt

conveyor(feed end)


manual

Spray the spin finish solution uniformly on the layer

of polyester fibre using spray pump

Fill the viscose in the bag from the viscose room

0.11 385.00Spread the blender output (inside the bin) evenly by

manual

Final Toppling (Mixing)

Move the bags from room to mixing room

Do layering by spreading polyester and viscose on

the alternate layer by manually

First Toppling (Mixing)

Cut the material vertically in the mixing bin, lift and

feed on blender belt conveyor

Second Toppling (Mixing)


feed on blender belt conveyor

1 3500 0.11 385.00Spread the blender output (inside the bin) evenly by

manual

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total Time

(Mins)

WLS No: BSP/W/01



Blender

Mixing Boy


Mixing Room

a

b

6

a

b

c

d

A 2005.03

B 17

C 2345.88

D 450

E 74.47%

F 6

G 86.88%

Target - 2500 Kg /person * 7 persons / shift =17500 kg / shift . Each batch have 5 steps. Itbecomes 3500 kg batch ( 3500 * 5 steps = 17500 kg)


feed on blender belt conveyor1 3500 0.11

62.17Clean the blender & beater

Clean the floor area around the machine

To remove the jam of beater & blender ( if any)

1 62.17

385.00Spread the blender output (inside the bin) evenly by

manual





Lot Change ( Shade Change)

Clean the bins before starting the mixing.

1

As minimum two personnel required per mixing room, six personnel is being recommended per

shift for three blowrooms.


Remarks:



P/V (65/35) mixing is considered. Hence , 3500 *65% Polyester = 2275 kg / shift , 3500 * 35%

Viscose =1225 kg/ shift.

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 19.00 19.00

2

a1 41 0.09 3.69

b 1 41 0.29 11.89

c 1 41 0.35 14.27

d 1 41 1.00 41.08

e1 41 0.38 15.38

f 1 41 0.05 2.05

3 1 3 15.00 45.00

A 152.36

B 14

C 173.68

D 450

E 38.60%

F 1G 38.60%



Remarks:

Viscose required per shift ( Mixing WLS sheet) = 1015 kg

Number of Viscose bags to be opened = 1015/ 25 bag = 41 bag/shift

Collect the empty bag, tags and keep aside

Clean the beater & bin (colour change)


Take the bags and move back to the belt conveyor

Open the bag (25 Kg / Bag)

Dump the viscose on the belt conveyor from bag

In the middle go to room and spread the opened the

viscose manually(time per bag)



Mixing Room

Viscose bag (Fibre dyeing section)

Move from belt conveyor of beater to bags storage

area(mean distance is considered)


Beater

Beater Opener


Clean the bow room walking path from (1-5) and area

under cleaning using the broom stick(lengthy)

WLS No: BSP/W/02



_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 357 KG 164.22 164.22

21 24 bags 16.80 16.80

31 24 bags 120.00 120.00

4 1 4 32.00 32.00

A 333.02

B 13

C 376.31

D 480

E 78.40%

F 1

G 78.40%



Remarks:



Weight the waste and maintain the record in the

register

Put the waste in the bags and placed in the waste

room category wise.

Department general work.




Sort out the waste shade wise and category wise

WLS No:BSP/W/03


BTMShifts A B C G

PREPARATORY

MIXING

WASTE SORTER


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/ machi

ne /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

a1 1 2.00 2.00

b 1 1 5.00 5.00

21 828 0.076 62.93

3 1 57 0.290 16.534 1 57 0.096 5.47

5

1 57 0.175 9.98

6 1 57 0.510 29.07

7 1 54 0.150 8.10

8 1 3 2.310 6.93

9 1 2 5.00 10.00

10 1 0.97 120.00 116.40

A 272.41B 15

C 313.27

D 450

E 69.61%

F 1

G 69.61%

Basic Workload per Shift ( in man minutes)Rest & Relaxation Allowances ( % )


Rejection (5%) = 54.33 *5% = 2.71 laps





Break rejected laps into small tufts and feed them equally

Clean the machine area at the shift end and at intervals.


Remarks:

Machine capacity - 107.63 kg / 14.5 kg lap = 7.42 * 7.33 hours = 54.33 laps

Bring the materials from mixing bin room (vertical cut)&

feed on the machine lattice

Keep the spindle on machine stand for next lapKeep the lap rod in the machine for new lap

Remove the laprod from the machine and keep on the

weighing machine and ensure that lap weight is under

tolerance limit. +/-200 gms


Mixing

Blowroom

Tenter


Shift Changeover activities


counter,count,batch,shade no etc

Counter check weight of 5 laps of out going shift.

Lot Change = 350 / month = 350 / (90 shifts*4 machine) =0.97 / shift/machine

WLS No: BSP/W/04




_________________________________________________________________________ _______________







Department

Section



Sl.

No


F r e q / 8 h o u r s /

m a c h i n e



A l l o w a n c e ( % )


1 t2 1 9 1.00 13 10.17

13 t2 7.68 9 0.24 16 19.35

14 t2 7.68 9 0.31 13 23.98

15 t2 7.68 9 0.44 15 35.22

16 t2 7.68 9 0.21 14 16.56

21 t2 10.64 9 0.63 13 68.17

22 t2 10.64 9 0.35 13 37.44

23 t 0.4256 9 1.15 13 4.98

24 t1 2 9 1.06 13 21.56

25 t2 2 9 1.50 13 30.51

26 t1 2 9 1.61 13 32.80

27 t1 2 9 2.49 13 50.65

28 t1 2 9 1.21 13 24.55

29 t1 1 2 4.36 13 9.85

31 t2 1 9 1.02 13 10.37

33 t1 1 1 0.60 13 0.68

34 t1 1 1 1.02 13 1.15

35 t1 1 1 4.10 13 4.64

36 t 0.149 9 15.00 13 22.73

WLS No: BSP/W/05


BTMShifts A B C G

Spinning

Carding 3 3

Tenter 3 3

LR




Front side wheel-LR


Feed the lap on the machine (from machinestand to roller)




machine




Front side top-LR


Front side bottom-LR

Back side bottom-LR

side door-LR



collect the waste


Move the waste collected to blow room

section yellow bag

Hand over the waste collected in the carding

section after weighment at the shift end

Clean the machine at the time of lot change

T (M/C running time per cycle) = 480 mins per shift *9 machines =4320 mins



_________________________________________________________________________ _______________







Department

Section



Sl.

No


F r e q / 8 h o u r s /

m a c h i n e



A l l o w a n c e ( % )


WLS No: BSP/W/05


BTMShifts A B C G

Spinning

Carding 3 3

Tenter 3 3






The machine efficiency and respective operative workload for the values above is found outfrom the Thomas O' Connar table and tabulated below:

No of Machines Machine Efficiency(%) Operator workload(%)

9 94.31% 83.57%




below:


Remarks:

10 93.27% 91.83%

11 92.10% 99.76%

9 10 11

Machine Efficiency(%) 94.31% 93.27% 92.10%Operator Workload(%) 83.57% 91.83% 99.76%

75.00%

80.00%

85.00%

90.00%

95.00%

100.00%

105.00%


Carding-LR+Crossrol

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11

17 per

lap man59.84 59.84

21

124 per

lap man97.96 97.96

31

17 per

lap man50.32 50.32

41 1 40.00 40.00

5 1 2 97.20 97.20A 345.32

B 14

C 393.66

D 450

87.48%

F 1

G 87.48%



Remarks:

Two personnel is recommended per shift for the carding section. The above workload sheet is for

single personnel



Creel the lap to the carding machine

Collect and send back the lap rod to the blowroom

section.

Relieve the card tenter for the lunch and tea break

General cleaning of the machine and lot changeBasic Workload per Shift ( in man minutes)



Carry the lap from blowroom section to the carding

machine.

WLS No: BSP/W/06


BTMShifts A B C G

PREPARATORY

CARDING

LAP MAN


_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 15.83 15.83

2 1 1 30.00 30.00

3 1 1 30.00 30.00

41 1 10.83 10.83

5

1

14.75 %

of 5.60

hrs

49.56 49.56

6 1 4 14.68 14.68

7

1

2 S/F

m/c & 4

D/F m/c

8 1 1

9 1 4 41.40 41.40

A 276.31

B 13

C 312.23

D 450

E 69.38%

F 1

G 69.38%

CP change in case of lot change


Help doffer & helper in lot change cleaning

Wrapping of new lot & checking for defect

Roller treatment

84.00 84.00

Cot belt treatment



Remarks:





Ensure the m/c are attended in case of

stoppages/breakdowns

WLS No: BSP/W/07


BTMShifts A B C

Drawframe &Simplex

JOBBER

GDrawframe &Simplex

Adjust hands shortage

Relieve 1 tenter for lunch


Collect cards from workers and take charge of the

dept.

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3

DesignationProposed

Manpower 3

Sl.

No


F r e q / 8

H o u r s / m a c h i

n e

B a s i c T i m e

( M i n s )

N o o f m a c h i n e s

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

A

1 t2 52.17 0.46 2 13 54.24

2 t2 52.17 0.40 2 13 47.16

3 t2 52.17 0.20 2 13 23.58

4 t2 62.61 0.24 2 13 33.96

5 t 4 0.98 2 13 8.86

6 t 4 0.50 2 13 4.52

7 t 3.7566 0.40 2 13 3.408 t 0.648 0.17 2 13 0.24

B

1 t2 167.34 0.25 1 13 47.27

2 t2 167.34 0.29 1 13 54.84

3 t2 119.53 0.26 1 13 35.12

4 t2 119.53 0.27 1 13 36.47

5 t 4 0.98 1 13 4.43

6 t 4 0.50 1 13 2.26

7 t 4.7812 0.55 1 13 2.97

8 t 4.7812 0.75 1 13 4.05

9 t 1.29 0.17 1 13 0.24

Breaker

Spinning

Drawframe

Tenter


3 3

3

Bring the full materials cans(Carding

sliver) from carding section

Replace the empty carding sliver canswith the full carding sliver can &piece

the sliver in LDO/6

Return the empty cans to the carding

section & keep in the area earmarked

Place the empty cans in LDO/6 for

doffing

Change top rolls once in every two

hoursClean the drafting zone and filter box

once in every two hours


Piece the ends during breakagesDo the lot change cleaning

Finisher

Move the LDO/6 material cans to the

Cherry Hara D/F(input)

Replace the empty cans by the

materials cans & join the sliver

Place back the empty cans in Cherry

Hara for doffing

Remove the materials cans from cherry

hara & Keep in Simplex areaChange top rolls once in every two

hours

Clean drafting zone and filter box once

in every two hrs.



3

BTM SpinningShifts

WLS No: BSP/W/08


A B C G

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3

DesignationProposed

Manpower 3

Sl.

No


F r e q / 8


n e

B a s i c T i m e

( M i n s )


A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

Spinning

Drawframe

Tenter


3 3

3 3

BTM SpinningShifts

WLS No: BSP/W/08


A B C G

C t1 1 3.00 1 13 3.39

65.29%






Efficiency(%)Operator workload(%)

Collect waste and hand over to mixing

for weighment







79.41%

89.12%

95.02%

5

4



below:

69.93%

62.14%

85.39%77.89%

3

6

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3

DesignationProposed

Manpower 3

Sl.

No


F r e q / 8


n e

B a s i c T i m e

( M i n s )


A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

Spinning

Drawframe

Tenter


3 3

3 3

BTM SpinningShifts

WLS No: BSP/W/08


A B C G

From the graph, Optimum number of machine to be alloted per operator is 4. But, the breaker

and finisher is a group of machine and also the layout of BTM(unit1,2 &3 away from each

other), it is not recommended to spilt and allocate to separate personnel.

The above workload sheet is for machine in Unit-1. It has been selected for calculation

,because the capacity of machine is high in unit-1 compared to unit-2 &3.

It is recommended that one operator per two breaker and one finisher machine.


Remarks:

3 4 5 6

Machine Efficiency(%) 85.39% 77.89% 69.93% 62.14%

Operator Workload(%) 65.29% 79.41% 89.12% 95.02%

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%


Drawframe-Tenter

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower5

DesignationProposed

Manpower 5

Sl.

No


F r e q / 8


N o o f M a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e ( % )

T o t a l T i m e

( M i n s )

1 t2 38.03 2 0.60 13 51.57

2 t2 38.03 2 0.22 13 18.91

3 t1 4 2 2.65 13 23.96

4 t1 4 2 1.65 13 14.92

5 t1 4 2 1.00 13 9.04

6 t 4 2 5.00 13 45.20

7 t 4.095 2 0.62 13 5.74

8 t 4.095 2 1.11 13 10.27

9 t 4.095 2 0.75 13 6.94

10

a t2 0.43 2 21.60 13 20.99

b t2 0.43 2 37.80 13 36.73

c t 0.43 2 90.00 13 87.46

11 t 0.098 2 60.00 13 13.29

1

2

3

4



Idle spindle

Remove the Top/Bottom Roller jam

Piece the broken roving

Move empty can near the D/FMove the full D/F cans from D/F can

storage area to S/F machine & put the sliver

on the top roller

Lot change

Perform Count changing activity(replace

empty can with the full can, piece the sliver

with the roving &start the machine)

Move the full D/F cans (from D/F can

storage area) to S/F machine & replace the

empty cans.

Clean the draft zone(green box front side)

Clean the top roller clearer cloth(back side)

Keep the empty cans colour wise near the

D/F can storage area


Clean the fan waste

Calculation of workload using Thomas O Connor table:


t1(Average time in min taken by operator per mrh to perform necessary deferrable work while m/c is running) = 47.91 mins

Machine stoppage for doffing





Piece the ends of Finisher Sliver

Piece the sliver with the roving

5

Tenter 5 5

Speed Frame 5

WLS No: BSP/W/09



Spinning

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower5

DesignationProposed

Manpower 5

5

Tenter 5 5

Speed Frame 5

WLS No: BSP/W/09



Spinning

Count Change = 80 / month = 80 / (90 shifts*9 machine) = 0.098 / shift/ unit

4 65.61% 94.32%


The above values are depicted in the graph to find out the optimum (where running

efficiency & operative workload meets) number of drums to be allotted per personnel and

presented below:

2 79.29% 56.99%


Efficiency(%)

Remarks:From the graph, Optimum number of machine to be alloted per operator is two.

3 72.79% 78.48%

Operator

workload(%)

Whereas in Count change, all the activity is performed, when machine is in stopped condition.

Doffers helps during count change.

Lot change is being performed for half of the machine and during that time the remaining half

machine is in running condition. Machine gets stopped only when piecing of sliver with roving

done. It is considered that all the activities for lot change has been performed only by the tenter.

2 3 4

Machine Efficiency(%) 79.29% 72.79% 65.61%

Operator Workload(%) 56.99% 78.48% 94.32%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%


Speedframe -Tenter

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

13 3600 216.00 648.00

2 3 3600 126.47 379.42

33 1 10.00 30.00

43 1 30.00 90.00

A 1147.42B 13

C 1296.59

D 1350

E 96.04%

F 1

G 96.04%

To clean the simplex machine (Bobbin rail and

spindle section)







Doffing of the rove bobbin at the doff of the

machine

Remarks:

SIMPLEX

Keep the doffed bobbin in the racks

Sorting the simplex waste and send it to the

blowroom section.

G

SIMPLEX

DOFFER


WLS No: BSP/W/10


BTMShifts A B C

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 6 tenter 378.00 378.00

A 378.00

B 13

C 427.14

D 450

E 94.92%

F 1

G 94.92%

6 tenter - (5 S/F & 1 D/F)







Relieve the machine tenter for lunch and tea break and

do the tenter activities during that time.

Remarks:

SIMPLEX


G

SIMPLEX

RELIEVER


WLS No: BSP/W/11


BTMShifts A B C

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Total

Sq.

meter

Freq/ shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 8234 4 350.00 350.00

A 350.00

B 13

C 395.50

D 450

E 87.89%

F 1

G 87.89%

WLS No: BSP/W/12


BTMShifts B C G

SIMPLEX

SIMPLEX

Floor cleaner


Clean the preparatory work area


A

1

1

Remarks:

24702 sq.feet = 8234 sq.met per shift







_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower13 -

DesignationProposed

Manpower 13 -

Sl.

No

Crew

Size

Freq/

Shift

No of

Machi

ne

Basic

Time

(Mins)

Allo

wanc

e

(%)

Total

Time

(Mins)

1 1 432 1.5 0.13 13 95.19

2 1 1 1 20.52 13 23.19

3

1 51.34 4 0.54 13 125.31

1 51.34 4 0.22 13 51.051 51.34 4 0.40 13 92.82

4

1 0.081 4 4.00 13 1.46

1 0.081 4 4.00 13 1.46

5

1 0.018 4 4.00 13 0.33

1 0.018 4 4.00 13 0.33

6

1 18 4 0.02 13 1.87

1 18 4 0.41 13 33.36

1 18 4 0.02 13 1.87

7 1 4 4 0.33 13 5.97

A 434.21

B 480

C 90.46%

5

13

Sider 13 13

WLS No: BSP/W/13



Spinning

Remove the top clearer, clean and keep on

the lammba

Put the top clearer on the machine after the

count change over


Top clearer cleaning

Ringframe-

LR(432 Spindle)13

Drafting zone cleaning

To attend idle spindles in his m/c

Remove roller lapping using hexablade

knife

Piece the broken threadsRoving cut join

Lot change





Count change


the lammba

Put the top clearer on the machine after thecount change over

S/F Roving Change

Bring the S/F roving near the machine from

the S/F roving storage area

Replace the empty rovings with the new

rovings

Place the empty rovings in the area

To collect pnumafil waste and hand over it

to mixing for weighment at the shift end.



= (b-1) / [ N{K+(b-1)C}]

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower13 -

DesignationProposed

Manpower 13 -

Sl.

No

Crew

Size

Freq/

Shift

No of

Machi

ne

Basic

Time

(Mins)

Allo

wanc

e

(%)

Total

Time

(Mins)

13

Sider 13 13

WLS No: BSP/W/13



Spinning


Ringframe-

LR(432 Spindle)13

1944 (432*4.5) 83.40%



No of SpindlesRunning Efficiency


- 0.000499, N - 1728 (432*4), C - 0.22, K - 0.03

1728 (432*4) 84.97% 90.46%

106.91%

Remarks:

Lot Change = 350 / month = 350 / (90 shifts*48 machines) =0.0812 / shift



below:

From the graph, the optimum number of spindle can be alloted per operator is 1728 nos

Count Change = 80 / month = 80 / (90 shifts*48 machines) = 0.018 / shift

Speedframe rovings is changed mainly during the lot change and Count change. As the activities

are performed during lot&count change it is being considered under the doffers workload. But

small percentage(30%) of S/F rovings is being changed by sider ( while running).Number of

rovings to be feed per ringframe per shift equals to 58 rovings.

98.69%

2160 (432*5) 81.89%

1728

(432*4)

1944

(432*4.5)

2160

(432*5)


(%)84.97% 83.40% 81.89%


0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


Ringframe-LR

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower13 -

DesignationProposed

Manpower 13 -

Sl.

No

Crew

Size

Freq/

Shift

No of

Machi

ne

Basic

Time

(Mins)

Allo

wanc

e

(%)

Total

Time

(Mins)

13

Sider 13 13

WLS No: BSP/W/13



Spinning


Ringframe-

LR(432 Spindle)13


Machine available hours * (Time lost due to doffing,pneumafil bonda,twist contraction

lost,Lot/Count idle spindle) = Machine running hours ( 8 hours * 0.915 = 7.32 hours)



* Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle is


_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower-

DesignationProposed

Manpower-

Sl.

No

C r e w S i z e

F r e q / S h i f t


B a s i c T i m e

( M i n s )

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

1 1 440 1.5 0.13 13 96.95

2 1 1 1 20.52 13 23.19

3

1 44.2 4.5 0.54 13 121.37

1 44.2 4.5 0.22 13 49.45

1 44.2 4.5 0.40 13 89.90

4

1 0.081 4.5 5.00 13 2.06

1 0.081 4.5 5.00 13 2.06

5

1 0.018 4.5 5.00 13 0.46

1 0.018 4.5 5.00 13 0.46

6

1 15 4.5 0.03 13 2.29

1 15 4.5 0.43 13 32.80

1 15 4.5 0.02 13 1.75

7 1 4 4.5 0.33 13 6.71

A 429.45

B 480

C 89.47%

-

Sider

- -

-

WLS No: BSP/W/13 A



Spinning

S/F Roving Change


the lammba


count change over


Top clearer cleaning

Ringframe-

Texmaco(440spindle)

Drafting zone cleaning

To attend idle spindles in his m/cRemove roller lapping using hexablade knife

Piece the broken threads

Bring the S/F roving near the machine from

the S/F roving storage area

Replace the empty rovings with the new

rovings

Place the empty rovings in the areaTo collect pnumafil waste and hand over it

to mixing for weighment at the shift end.


Roving cut join

Lot change

Count changeRemove the top clearer, clean and keep on

the lammba


count change over

Total Workload per Shift ( in man minutes)


_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower-

DesignationProposed

Manpower-

Sl.

No

C r e w S i z e

F r e q / S h i f t


B a s i c T i m e

( M i n s )

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

-

Sider

- -

-

WLS No: BSP/W/13 A



Spinning


Ringframe-

Texmaco(440spindle)

5


tabulated below:

No of SpindlesRunning Efficiency (ρ)

(%)

Operator

workload(%)




2200 (5*440) 81.65% 96.63%

= (b-1) / [ N{K+(b-1)C}]

- 0.0004981, N - 1760(440*4), C - 0.22, K - 0.03

1760 (4*440) 84.76% 82.31%

1980 (4.5*440) 83.18% 89.47%



1760 (4*440)1980

(4.5*440)2200 (5*440)



70.00%

75.00%

80.00%

85.00%

90.00%

95.00%

100.00%

E f f

i c i e n c y ( % )

Ringframe-Texmaco

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower-

DesignationProposed

Manpower-

Sl.

No

C r e w S i z e

F r e q / S h i f t


B a s i c T i m e

( M i n s )

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

-

Sider

- -

-

WLS No: BSP/W/13 A



Spinning


Ringframe-

Texmaco(440spindle)

Remarks:

Speedframe rovings is changed mainly during the lot change and Count change. As the activities are

performed during lot&count change it is being considered under the doffers workload. But small

percentage(30%) of S/F rovings is being changed by sider ( while running).Number of rovings to be

feed per ringframe per shift equals to 50 rovings.



Machine available hours * (Time lost due to doffing,pneumafil bonda,twist contractionlost,Lot/Count idle spindle) = Machine running hours ( 8 hours * 0.915 = 7.32 hours)

In BTM, there are six number of texmaco machine with 400 spindles are there. As only the number

spindles are less than the 440 spindle texmaco make. The above workload sheet is applicable to that

machines also.

Count Change = 80 / month = 80 / (90 shifts*48 machines) = 0.018 / shift

Lot Change = 350 / month = 350 / (90 shifts*48 machines) =0.0812 / shift



* Time lost due to doffing,pneumafil bonda,twist contraction lost,Lot/Count idle spindle is collected

from the management

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 6 6

Designation Proposed Manpower 6 6

Sl.

No

Crew

Size

Freq/

Shift

No of

Spindl

es/mac

hine

BasicTime

(Mins)

TotalTime

(Mins)

1 7 1 5.00 35.00

2

a 5 63 0.48 151.20

b 5 63 440 1.81 570.90

c 5 63 440 0.88 277.20

d 5 63 1.00 315.00

3

a 1 440 0.02 8.80

b 1 440 0.03 11.88

c 1 440 0.04 18.48

d 1 1 3.58 3.58

4

a 1 1.296 440 0.02 10.69

b 1 1.296 440 0.01 7.13

c 1 1.296 440 0.08 48.33

d 1 1.296 440 0.41 233.80

e 1 1.296 440 0.12 68.43

f 1 1.296 440 0.01 7.13

5

a 1 0.296 2 side 1.98 0.59

b 1 0.296 440 0.012 1.55

c 1 0.296 440 0.078 10.13

d 1 0.296 2 side 1.98 0.59

e 1 0.296 440 0.02 2.44

f 1 0.296 440 0.01 1.63

g 1 0.296 440 0.08 10.42

h 1 0.296 440 0.41 53.40

6

GSpinning

B

Ringframe

WLS No: BSP/W/14


BTM SpinningShifts A C

Bobbin change(Doffing)

Take trays, Collect the empty R/F bobbins from

storage area near entrance, Reach the machine

spot

Remove the filled R/F bobbin from the spindle &

Put the empty R/F bobbin in the R/F spindle

Keep the collected R/F bobbin trays in the R/FSorting area

Piece the roving with the bobbin

Doffer



6

Open the doom

Put the new count lammba on the machine

Count Change

Ring Travellour Change

Remove the Old ring travellour

Arrange S/F from racks to trolley



S/F roving storage area



S/F roving storage area(40 rovings/trolley)



Remove the empty S/F bobbins from the creel

and keep near the rack


Remove the lammba for the old count

1

machi

ne/unit

Clean the machine area after ring travellour

change using magnet bar

Put the new ring travellour

Arrange S/F rovings from racks to trolley(40

rovings)

Join the thread after inserting the new ring

Lot Change

Close the doom

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 6 6

Designation Proposed Manpower 6 6

Sl.

No

Crew

Size

Freq/

Shift

No of

Spindl

es/mac

hine

BasicTime

(Mins)

TotalTime

(Mins)

6

GSpinning

B

Ringframe

WLS No: BSP/W/14


BTM SpinningShifts A C

Doffer


6

i 1 0.296 440 0.12 15.63

j 1 0.296 440 0.01 1.63

6

a 1 1 5 9.00 45.00

b 1 1 5 3.01 15.06

c 1 1 5 2.71 13.54

d 1 1 5 2.87 14.36

e 1 1 5 0.99 4.95

f 1 1 900 0.04 34.99

g 1 1 900 0.05 47.82

A 2041.25

B 8

C 2204.55D 480

E 76.55%

F 6

G 76.55%

Lot Change = 350 / month = 350 / (90 shifts*3 Unit) =1.296 / shift/unit

As reliever is provided, net available man mins becomes 480 mins. As the above activity

frequency is for 480 mins.

Clean the creel plastic cover top area for fly

Spindle gap cleaning

Jockey pulley cleaning

Clean using the broom stick

Remove the empty S/F bobbins from the creel

and keep near the rack


Cleaning

Clean the creels (below the cover) area for fly

One Doffing team consist 6 Doffers and one Co-ordinating person.Each unit have one doffing

team.

Rest & Relaxation Allowances ( % )(Total-13%-5% relieved by reliever+8%

added in the workload)


No of rovings consumed per shift/unit = 900 nos ( from machine capacity)

Ring travellour Change -1 machine/ shift / unit


The doffers maximum workload is on Texmaco 440 spindle machine comapred to 400

spindle(texmaco) and LR (432 Spindle). Hence it has taken for calculation and shown above.



Clean the S/F empty rovings(using knife remove

the threads)Arrange the cleaned S/F empty rovings in the

racks

Count Change = 80 / month = 80 / (90 shifts*3 Unit) = 0.296 / shift/ unit


Remarks:

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total Time(Mins)

1 1 1 5.00 5.00

21 3 63.00 189.00

3

4

5

A 194.00

B 13

C 219.22

D 450

E 48.72%

F 1

G 48.72%

B C GSpinning

Ringframe

Doffer-Leader



WLS No: BSP/W/15


BTM SpinningShifts A

The above activitiy(3,4 &5) is supervisory in nature.





Relieve the Ringframe sider in that unit(Tea,Lunch

Or breaks)

Co-ordinate the doffing team effectively for

minimising the machine downtime for changover

Remarks:




Discussing with the supervisors, siders

Monitor and perform the scheduled activities like ring

travellours change, machine cleaning and lot

change/count change with the doffers

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 6 63 375.00

A 375.00

B 13

C 423.75

D 450

E 94.17%

F 1

G 94.17%

WLS No: BSP/W/16



Spinning



Remarks:



Relieve the ringframe-doffers for breaks


Ringframe

Reliever-Doffers





_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 96 93.12 93.12

2 1 6 120.00 120.00

31 1 90.00 90.00

A 303.12

B 13

C 342.53D 360

E 95.15%

F 1

G 95.15%

GRINGFRAME



WLS No: BSP/W/17


BTMShifts A B C

RINGFRAME

RUNNING FITTER


Check the ratched pawl of all the ringframe and TFO

machines

Change the machine particular as per the requirement

Attend the ringframe & TFO idle spindle due to

mechanical faults




Remarks:


_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 62.50 62.50

2 1 4 20.00 20.00

31 1 65.00 65.00

4 1 3 22.17 66.50

51 3 36.00 36.00

61 3 15.00 45.00

71 1 30.00 30.00

8 1 3 31.67 95.00

9 1 2 15.00 30.00

A 450.00

B 13

C 508.50

D 450E 113.00%

F 2

G 56.50%



Remarks:

Check the finisher drawframe wrapping

Give the lot information (New lot & Final Lot) to

the post spinning secetion

Check the lot final ringframe bobbins

Check the wrapping of the new lot taken at

ringframe

Take the sample from carding & ringframe and

paste them at the ringframe sample book

Complete the sample book from mixing layering

register

Check material for contamination

Hank Reading



RING FRAME

CHECKER


Check the running shade from blowroom to

ringframe



WLS No: BSP/W/18


BTMShifts A B C G

RING FRAME

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 10.50 10.50

21 3 46.80 46.80

3 1 4 128.00 128.00

4

1 2 52.00 52.00

5

1 1 31.20 31.20

A 268.50

B 13

C 303.41

D 450

E 67.42%

F 1

G 67.42%



Remarks:

Three floor cleaner is recommended in ringframe section of BTM. The above workload sheet is for

one floor cleaner.



Collect the ringframe bobbins from the auto winding

colour wise

Floor cleaning

Help the sider in replacing the empty simplex bobbin

with the full rove bobbin. (if Simplex bobbins

replacement are higher than 100)

Sort the ringframe waste shade wise and take the

sweeping waste to the blowroom section at the end of the shift.





Check the cleaning of the department at the shift start

WLS No: BSP/W/19


BTMShifts A B C G

RINGFRAME

RINGFRAME

FLOOR CLEANER

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 4 63 252.00

21 2 10 20.00

31 16 0.90 14.40

4 1 16 1.00 16.00

5

1 8 2.12 16.96

6 1 8 0.67 5.36

7 1 8 0.97 7.75

8 1 8 0.67 5.36

91 16 2.00 32.00

A 369.83

B 13C 417.91

D 450

E 46.43%

F 1

G 92.87%


No of doffs- 4 per shift per machine





Remarks:


Come back to workplace

Bring the empty autocone from the rack and arrange it

on the machine(60 cone/time)(two machine/reliever)

Move the trolley to loose packing area

Arrange the cones from trolley to ground


Maintain sample book for that particular machine(two

machine/reliever)



Arrange the trays after&before segregation

Collect the full autocone from the machine and arrange

it on the trolley(60 cones/trolley)( One

machine/reliever)

Autoconer

Reliever


Relieve - Four tenter's for breaks

WLS No: BSP/W/20



Post Spinning

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 2 2 2

Designation Proposed Manpower 2 2 2

Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 62 56.42 112.84

2 1 1 60.00 120.00

A 232.84

B 13

C 263.11

D 450E 58.47%

F 2

G 58.47%






Remarks:

To relieve 2 autowinding tenters for lunch



WINDING

MATERIAL MAN


To feed full R/F bobbins to auto winding m/cs

during the shift using trolleys ( 62 doffs per shift for

one material man)

WLS No:BSP/W/21


BTMShifts A B C G

POST SPG

_________________________________________________________________________ _______________







Department

Section


Designation Proposed Manpower 2* 2* 2* -

Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 124000

bobbins120.00 240.00

2 11200

bobbins16.20 32.40

3 1300

bobbins105.00 210.00

A 482.40

B 13C 545.11

D 450

E 60.57%

F 2

G 60.57%

Mending of workable bottoms rejected by 3 A/C

m/c and handing them to A/C operators.(300

bobbins/kirchiman)






Remarks:


Sorting empty bobbins into tapas (3 A/C m/c per

kirchi man)(24000 bobbins / kirchiman)

Cutting kirchi of 3 A/C m/c(1200 bobbins/kirchi

man)


POST SPGB C G

WINDING

KIRCHI MAN

WLS No: BSP/W/22


BTMShifts A

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 5 57.50 57.50

2

1

70

trolleys/

day

249.90 249.90

A 307.40

B 13

C 347.36

D 480

E 72.37%F 1

G 72.37%





Collect trolleys from the dept.

Remarks:

AUTOWINDING

Cutting the trolley Jam


G

AUTOWINDING

JAM CUTTER



WLS No: BSP/W/23


BTMShifts A B C

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11

100

cones159.29 159.29

21

256

cones24.92 24.92

31

100

bobbins64.00 64.00

41

98

cones53.10 53.10

51

20

cones26.55 26.55

61

2

lots(2kg 17.70 17.70

71

15

cones17.70 17.70

81

72

cones26.55 26.55

A 389.80

B 13

C 440.48

D 480

E 91.77%

F 1

G 91.77%

Remarks:


Rewinding of SQC tested TFO cones

Processing of TFO broken tape, zero TPI(at top) to

2nd quality

Preparation of pair of final single cone

Rewinding of single cones to remove jali, double

etc

Rewinding of classimate cones



Shifting of production of 1 savio m/c to packing

section

Processing of defective bobbins(R/F) for 2nd

quality


GPOST SPG




Rewinding of packing rejection

WINDING

REWINDER


WLS No: BSP/W/24


BTMShifts A B C

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11

6

rounds127.80 127.80

2 1 1 8.85 8.85

31 0.33 3.30 3.30

41

1200

cones14.40 14.40

5

1

20

pillers

& 40

tube

38.80 38.80

A 193.15

B 13

C 218.26

D 450

E 48.50%

F 2

G 48.50%






Remarks:



To shift sweeping of the shift to waste godown

To shift hard waste of all the three shift to waste

godown

To clean cheese winding empty cones and place in

racks colorwise

To clean tube lights and pillers falling in one's floor

area.

POST SPG

FLOOR CLEANER


To sweep area of post spg section

WLS No: BSP/W/25


BTMShifts A B C G

POST SPG

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 2 63 126.00

2 1 6454 0.01200 77.45

31 16 0.90 14.40

4 1 16 1.00 16.00

5 1 4 2.12 8.48

6 1 4 0.67 2.68

71 4 0.97 3.88

8 1 4 0.67 2.68

91 4 2.00 8.00

10 1 4 3.00 12.00

A 271.56B 13

C 306.87

D 450

E 68.19%

F 1

G 68.19%


No of bobbins - 6146 Bobbins /shift + 5% rejection (308 bobbins/shift) = 6454 bobbins/shift

Collect the full autocone from the machine and arrangeit on the trolley(60 cones/trolley)

Arrange the cones from trolley to ground

Bring the empty autocone from the rack and arrange it

on the machine(60 cone/time)

Bring R/F bobbins from the R/F area





Remarks:

Arrange the trays after&before segregation

Move the trolley to loose packing area

Come back to workplace


Relieve-Two tenter's for breaks


Post Spinning

Sort the bobbins(only in machine 7)



Autconer-Savio No 7

Helper


WLS No: BSP/W/26



_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)

11 30.25 0.50 13 17.09

2 1 3025 0.030 13 102.55

3 1 991.2 0.09 13 100.81

4

1 84 0.10 13 9.49

5 1 2 2.00 13 4.52

A 234.46

B 480

C 48.84%

5

Spinning

Autoconer 16

Winder 8

Collect the R/F bobbins from the trolley to

trays


Attend the idle drums


tray, remove the filled cone and put the empty

cone on the machine and start the machine


WLS No: BSP/W/27


BTMShifts A B C G



40 98.87% 64.81%






= (b-1) / [ N{K+(b-1)C}]

- 0.097943723, N - 30, C - 0.09, K - 0.2

30 99.96% 48.84%



No of Drums Running Efficiency (ρ) (%) Operator workload(%)

50 97.11% 80.78%

60 94.90% 96.74%

64 93.90% 103.13%

70 92.30% 112.71%



below:

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)

Spinning

Autoconer 16

Winder 8

WLS No: BSP/W/27


BTMShifts A B C G


* Time lost due to general cleaning,hardwaste removal,splicing is collected from the management

From the graph, the optimum number of drums can be alloted per operator is 60 nos

Remarks:

For 60 drums, Number of bobbins required - 5762 Bobbins/shift

Rejection (5%) - 5762 * 5% = 288 bobbins.For 30 drums -(5762+288) /2 = 3025 bobbins/30drums/shift.


Machine available hours * (Time lost due general cleaning,hardwaste removal,splicing) = Machine

running hours ( 8 hours * 77 % = 6.16 hours)


EX: For 60 drums, Actual machine efficiency (%) = 6.16 hours *0.9490 =5.845 hours/shift

30 40 50 60 64 70


(%)99.96% 98.87% 97.11% 94.90% 93.90% 92.30%

Operator workload(%) 48.84% 64.81% 80.78% 96.74% 103.13% 112.71%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


Autoconer

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower10 -

DesignationProposed

Manpower 7 -

Sl.

No

Crew

Size

Freq/

Shift/

spindle

No of

spind

les

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)

1 1 1.68 64 0.0663 13 8.06

2 1 1.68 64 0.1500 13 18.22

3 1 1.68 64 0.0663 13 8.06

4 1 1.68 64 0.0657 13 7.98

5 1 1.68 64 0.3650 13 44.35

61 3.36 64 0.0440 13 10.69

7 1 3.36 64 0.1060 13 25.76

8 1 3.36 64 0.0369 13 8.97

91 3.36 64 0.0500 13 12.15

101 3.36 64 0.0092 13 2.23

111 3.36 64 0.0083 13 2.02

12 1 2.688 64 0.280 13 54.43

13 1 1 1 15.000 13 16.95

A 219.87

B 480

C 45.81%

5

WLS No: BSP/W/28



Post Spinning

Cheesewinding 10 10

Tenter 7 7



Move the empty trolley to loose packing

Put the full autocone from ground to trolley

Move the trolley to Cheesewinding section

Keep the autocone from trolley to machine

Replace the empty autocone with full

Bring the empty cheese cone from the

rack&keep on the machine

Replace the full cheese cone with empty

Put the sticker on the cheese cone

Collect full cheese cone from machine table

and keep on trolley

Move the trolley to weighing machine &

Weigh the trolley

Move the trolley to respective count running

TFO machine area

Attend the thread break

Clean the machine





No of DrumsRunning Efficiency (ρ)

(%)

Operator

workload(%)




= (b-1) / [ N{K+(b-1)C}]

- 0.007308, N - 64, C - 0.28, K - 0.05

64 89.34% 45.81%

76 87.59% 49.77%

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower10 -

DesignationProposed

Manpower 7 -

Sl.

No

Crew

Size

Freq/

Shift/

spindle

No of

spind

les

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)

WLS No: BSP/W/28



Post Spinning

Cheesewinding 10 10

Tenter 7 7


In BTM Spinning, the four cheese winding machines are in one section and two machines are

in unit-3. Based on the above findings, two personnel is recommended for unit-3 machines(2

nos) and five personnel for four machines in the unit-1 &2.


Machine available hours * (Time lost due to doffing,worker's lunch,cleaning,Lot/Count change and

idle ) = Machine running hours ( 8 hours * 77.5 % = 6.2 hours)


80 87.02% 56.38%

90 85.63% 62.98%

80.49% 89.40%

100 84.28% 69.59%

110 82.98% 76.19%



From the graph, the optimum number of drum can be alloted per operator is 120 nos.

Remarks:

120 81.71% 82.80%

130

64 76 80 90 100 110 120 130

Running Efficiency (ρ) (%) 89.34% 87.59% 87.02% 85.63% 84.28% 82.98% 81.71% 80.49%

Operator workload(%) 45.81% 49.77% 56.38% 62.98% 69.59% 76.19% 82.80% 89.40%

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%


Cheesewinding

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower10 -

DesignationProposed

Manpower 7 -

Sl.

No

Crew

Size

Freq/

Shift/

spindle

No of

spind

les

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(Mins)

WLS No: BSP/W/28



Post Spinning

Cheesewinding 10 10

Tenter 7 7


60 60 60 60 80 40 40 76 76

1

60 60 44 44

As per the breakage data provided by the company,there is no difference in breaks frequency among

different makes(Textool,PSFMK and RJK) and very negligible difference in elemental times.Hence,the above workload is provided and applicable for all makes.

At present, the operator's stops the machine during lunch break. Same practice is being

proposed.Based on the above condition, reliever is not provided.

EX: For 120 drums Actual machine efficiency (%) = 6.2 hours *0.8171 = 5.066 hours/shift

Unit 1 &2

* Time lost due to doffing,worker's lunch,cleaning,Lot/Count change and idle is collected from the

management

Unit 3

80

Proposed manpower deployment is as follows: (each colour represents one personnel)

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 25.00 25.00

2 1 1 40.00 40.00

3 1 1 20.00 20.00

4

1 1 55.83 55.83

5

1 11 55.00 55.00

6

1 1 42.40 42.40

7

1 3-4 30.00 30.00

8 1 1 30.00 30.00

A 298.23

B 13

C 337.00

D 450

E 74.89%

F 1

G 74.89%Proposed Utilisation(%)

Remarks:


To adjust savio drums according to ringframe

color bobbins working in R/F section and make a

record of it with the help of savio relievers.

To adjust cheese winding drums as per programme

decided by shift incharge with the help of cheese

winders

To weigh the doffs of each cheese winder on

weighing scales one for Unit 1 and second for Unit

3. Record the cheese winder's production details in

production register.

To receive info. Regarding lot final from ring

frame during his shift from shift incharge then get

lot final data in sample book of that unit.

Idle spindle count



GPOST SPG


To take shift charge



To engage hands in the dept as per requirement

To identify hands shortage section wise

POST SPG

JOBBER


WLS No: BSP/W/30


BTMShifts A B C

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq /

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 10 63 630.00

21 1 10.00 10.00

31 30 0.54 16.08

41 30 2.36 70.80

51 30 0.54 16.20

6 1 30 1.16 34.80

A 777.88

B 12

C 871.23

D 450

E 96.80%

F 2

G 96.80%

No of trolleys = (37.28 cones / machine / shift) * 48 machines = 1790 cones/shift = 1790 / 60

cone/trolley = 30 trolleys


Remarks:


TFO

Reliever-Tenter


Relieve-Ten TFO tenter's for breaks(5 persons each)





Collect the hard waste and handover & inform to

supervisor

Collect full TFO Cones from the machine table, keep it

on the trolley(60 nos/trolley)



Move the full TFO Cones trolley back to packing

room(60 nos/trolley)

Bring the empty trolley from packing to respective

TFO machine(mean distance)

Arrange the TFO cones from trolley to ground floor

WLS No: BBSP/W/31



Post Spinning

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11

80

cones165.00 165.00

21 7 lots 40.00 40.00

31 10 lots 20.00 20.00

41 10 lots 38.33 38.33

51 7 lots 14.00 14.00

61

30

cones8.20 8.20

71

8-10

cones15.00 15.00

81 2 25.67 25.67

A 326.20

B 13C 368.61

D 480

E 76.79%

F 1


Remarks:


Lot run out from cheese winding section and record

it in dept. sample book

Lot final info. To packing after the lot final from

TFO by writing in packing sample book

Collection of defective cones from dept. for

mending accordingly

Baby cones of all new lots taken last day to yarn

development dept.

Checking for loose packing for savio final lots ,

shifted to cheese winding if found faulty.



GPOST SPG


Shifting of packing rejection cones to manual

winding m/c



New lot information in packing sample book by

writing lot no. shade no.

Lot run out from TFO section and record it in dept.

sample book

POST SPG

CHECKER


WLS No: BSP/W/32


BTMShifts A B C

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower12 -

DesignationProposed

Manpower 12 -

Sl.

No

C r e w S i z e

F r e q / S h i f t

N o o f

m a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

1

1 78.3 4 0.0762 13 26.96

2

1 78.3 4 0.5500 13 194.73

31 78.3 4 0.0706 13 24.98

4 1 39.2 4 0.0235 13 4.16

5 1 39.2 4 0.0157 13 2.78

6

1 39.2 4 0.2600 13 46.02

7 1 156 4 0.0314 13 22.11

8 1 18 4 0.4000 13 32.57

9 1 1 1.5 20.0 13 30.00

A 384.32

B 480

C 80.07%

5

WLS No: BSP/W/33



Post Spinning

Put the operator slip on the cone


12 12


Bring empty TFO cone from the cone room


Remove the full TFO cone,place on the


cone&join

TFO-VJ(156

Spindles/ Machine)12 12



table,keep the empty trolley aside(per cone)

Replace the empty cheese cone with the full

cheese cone & keep the empty cheese on themachine table& tie

Collect the empty cheese cone and arrange it

on the rack colourwise

TENTER

Clean the machine



tabulated below:






= (b-1) / [ N{K+(b-1)C}]

- 0.000253326, N - 624 (156*4), C - 0.4, K - 0.07

No of SpindlesRunning Efficiency (ρ)

(%)

Operator

workload(%)

624 (4 *156) 94.54% 80.07%

702 (4.5*156) 93.90% 89.72%

780 (5*156) 93.27% 98.08%

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower12 -

DesignationProposed

Manpower 12 -

Sl.

No

C r e w S i z e

F r e q / S h i f t

N o o f

m a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

WLS No: BSP/W/33



Post Spinning

12 12


TFO-VJ(156


TENTER

858 (5.5*156) 92.65% 109.19%

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower12 -

DesignationProposed

Manpower 12 -

Sl.

No

C r e w S i z e

F r e q / S h i f t

N o o f

m a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

WLS No: BSP/W/33



Post Spinning

12 12


TFO-VJ(156


TENTER

168 168 168 168 168 168 168 168 168 168

It is only suggested,actual deployment may be changed based on the machine efficiency required

.As in Unit1 &2 Different shades are running, allocation of common person leads to quality

problem. Hence separate personnel is being recommended,

Remarks:



Machine available hours * (Time lost due to twist contraction and idle spindle) = Machine running

hours ( 8 hours * 97 % = 7.76 hours)



From the graph, the optimum number of drum can be alloted per operator is 624 nos


EX: For 624 spindles, Actual machine efficiency (%) = 7.76 hours *0.9454 = 7.336 hours/shift* Time lost due to general cleaning,count/lot change,idle and maintenance cleaning,breakdown is


624 (4 *156)702

(4.5*156)780 (5*156)

858

(5.5*156)

Running Efficiency (ρ) (%) 94.54% 93.90% 93.27% 92.65%Operator workload(%) 80.07% 89.72% 98.08% 109.19%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


TFO-VJ (156 Spindles)

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower12 -

DesignationProposed

Manpower 12 -

Sl.

No

C r e w S i z e

F r e q / S h i f t

N o o f

m a c h i n e

B a s i c T i m e

( M i n s )

A l l o w a n c e

( % )

T o t a l T i m e

( M i n s )

WLS No: BSP/W/33



Post Spinning

12 12


TFO-VJ(156


TENTER

VJ VJ VJ VJ VJ VJ VJ VJ VJ VJ

144 144 144 144 144 156 156 156 156 144 144

VJ P p p p VJ Vj VJ Vj P P

144 144 144 144 156 156 156 156 144 144 144 144

P P P P VJ VJ Vj Vj VJ VJ VJ VJ

144 144 144 144 144 144 144 144 144 144

VJ VJ VJ VJ VJ VJ VJ VJ VJ VJ

144 144 144 140 140

VJ VJ VJ VJ VJ

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower-

DesignationProposed

Manpower -

Sl.

No

Crew

Size

Freq/

Shift

No of

machi

ne

Basic

Time

(Mins)

Allow

ance(

%)

Total

Time

(Mins)

1

1 83.48 4 0.0762 13 28.74

2

1 83.48 4 0.5500 13 207.53

31 83.48 4 0.0706 13 26.62

4 1 41.74 4 0.0235 13 4.44

5 1 41.74 4 0.0157 13 2.96

6

1 41.74 4 0.2600 13 49.05

7 1 168 4 0.0314 13 23.81

8 1 18.01 4 0.4000 13 32.57

9 1 1 1.5 20.0 13 30.00

A 405.72

B 480

C 84.53%

5

756 (4.5*168) 93.64%

840 (5*168) 92.98% 104.09%



below:

94.31% 84.53%




- 0.0002461, N - 672 (168*4), C - 0.4, K -0.07

672 (4 *168)



No of Spindles



(%)

Operator

workload(%)

94.31%


Clean the machine



Bring empty TFO cone from the cone room




cone&join





table,keep the empty trolley aside(per cone)

Replace the empty cheese cone with the full

cheese cone & keep the empty cheese on the

machine table& tieCollect the empty cheese cone and arrange

it on the rack colourwise

Post Spinning

TFO-VJ(168

Spindles/ Machine)- -

TENTER - -

WLS No: BSP/W/33 A



_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower-

DesignationProposed

Manpower -

Sl.

No

Crew

Size

Freq/

Shift

No of

machi

ne

Basic

Time

(Mins)

Allow

ance(

%)

Total

Time

(Mins)


Post Spinning

TFO-VJ(168

Spindles/ Machine)- -

TENTER - -

WLS No: BSP/W/33 A




Remarks:

From the graph, the optimum number of drum can be alloted per operator is 672 nos








672 (4 *168) 756 (4.5*168) 840 (5*168)



0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

E f f i c i e n c y (

% )

TFO-VJ(168 Spindles)

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower-

Designation ProposedManpower

-

Sl.

No

Crew

Size

Freq/

Shift

No of

machi

ne

Basic

Time

(Mins)

Allowa

nce

(%)

Total

Time

(Mins)

1

1 71.56 4 0.0680 13 21.99

2

1 71.56 4 0.5355 13 173.21

31 71.56 4 0.0690 13 22.32

4 1 35.78 4 0.0210 13 3.40

5 1 35.78 4 0.0140 13 2.26

6

1 35.78 4 0.2400 13 38.81

7 1 144 4 0.0280 13 18.22

8 1 16.46 4 0.5355 13 39.84

9 1 1 1.5 20.0 13 20.00

A 340.06

B 480

C 70.85%

5

WLS No: BSP/W/33 B



Post Spinning



cone&join


PRERNA(144

Spindle/Machine)- -

TENTER - -




table,keep the empty trolley aside(per

cone)

Replace the empty cheese cone with the

full cheese cone & keep the empty cheese

on the machine table& tie

Collect the empty cheese cone and

arrange it on the rack colourwise

Bring empty TFO cone from the cone





Clean the machine


648 (144*4.5) 92.51% 81.66%





= (b-1) / [ N{K+(b-1)C}]

- 0.00025, N - 576 (144*4), C - 0.535, K - 0.07

576 (144*4) 93.29% 70.85%




(ρ) (%)

720 (144*5) 91.75% 90.03%

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower-


-

Sl.

No

Crew

Size

Freq/

Shift

No of

machi

ne

Basic

Time

(Mins)

Allowa

nce

(%)

Total

Time

(Mins)

WLS No: BSP/W/33 B



Post Spinning

PRERNA(144

Spindle/Machine)- -

TENTER - -


792 (144*5.5) 91.00% 98.41%

Remarks:

Collection of full TFO cones from machine table to trolley is performed by relievers

864 (144*6) 90.26% 106.79%



below:









576 (144*4)648

(144*4.5)720 (144*5)

792

(144*5.5)864 (144*6)

Running Efficiency (ρ)(%)

93.29% 92.51% 91.75% 91.00% 90.26%

Operator workload(%) 70.85% 81.66% 90.03% 98.41% 106.79%

0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%


TFO-PRN

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1 1 1 15.00 15.00

2 1 1 12.67 12.67

31 3.56 3.56

4 1 1 5.00 5.00

51

1020

cones122.40 122.40

6

1

306

faultycones

70.38 70.38

71

510

cones30.60 30.60

A 259.61

B 14

C 295.96

D 450

E 65.77%

F 3

G 65.77%

PACKING

CHECKER


Confirm lot and count detail in sample register before

checking

Alloted lot sticker ready by SAP before checking

Checking individual cones and putting sticker

In case of a faulty cone - checking time

Paste a sample of new lot in sample register with

Final lot cone check in all packing dept. and do

separately

Take charge of packing area

WLS No: ESP/W/34


BTMShifts A B C G

PACKING


Remarks:







_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 114 1.57 178.60

2 1 114 0.82 93.10

3 1 114 1.00 114.00

41 1 15.00 15.00

A 400.70

B 13

C 452.79D 480

E 47.17%

F 1





Lot final Checker

B C

Write the details on the log book like b.no,shade color

Remarks:

Adjust the trolley weight & number of cones by

weighing

At the day end ,cross check & verify the quantity packed

and despatched



Write the details on the bag using marker


WLS No: BSP/W/35


BTM SpinningShifts A G

Packing


Packing Room

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 5344 0.07 356.27

21 167 0.13 21.43

31 167 0.83 139.17

4 1 167 0.13 21.43

5 1 167 1.57 261.63

6 1 167 0.07 11.13

71 167 0.53 87.68

8 2 167 1.43 478.73

9 1 167 0.30 50.10

10 1 167 0.82 136.94

11 1 167 0.47 77.93

12 1 167 1.10 183.70

A 1826.15

B 14

C 2081.81

D 480

E 72.28%

F 5

G 86.74%

Remarks:

No of cones / bag - 32 nos of 2kg each







Based on machine capacity number of bags to be packed - 167 bags

Take the covered cones from ground and keep on the

trolley

Adjust the cones for exact weight in the weighing

Take the white bag from area and spread it on the

box

Stitch the bags

Prepare the needle


Prepare the rope(take and extend)

Tie the bag with rope and keep aside

G

Move trolley from weighing machine to bag area

Put the cones from trolley into white bags

Packing Room

Packing Helpers


Put the individual cones in the LDPE bag

Move the empty trolley from weighing machine to

cone storage area

Packing

Move the trolley back to weighing machine

After discussion, it is found that the one kg cone packing is rare,hence not considered.

WLS No: BSP/W/36


BTM SpinningShifts A B C

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 6 lots

2

samples/f

ibre

15.57 15.57

2

1 4 shades

2

readings/

fibre

190.60 190.60

31 2 shades

2readings/

fibre

40.67 81.34

4

1 1 lot

20

readings/

Lot

58.44 58.44

5

1 4 drums

6

readings/

drum

31.46 31.46

6

1 4 lots

20

readings/

Lot

29.47 29.47

71 1 bag 32 cones 33.60 33.60

8

1All tested

lots5.58 5.58

9

1 22 m/c

2gm/sam

ple & 4

samples/ day

31.94 31.94

11

1 4m/c

2

sample/m

/c

12

1 4 m/c

5

readings/

m/c

44.13Card sliver wrapping check, report

preparation & disposal of samples

Sampling of card sliver samples for wrap

checking

44.13

Lab

Checker&Investigator


Sampling of fibre samples from fibre

dyeing deptt. & fibre godown.

Autoconer single yarn splice app. &

strength checking(All single pack lots),

collection of spliced yarn samples, pasting

them in the register, report preparation.

Autoconer single yarn splice app. &

strength checking(Drumwise), collection of

spliced yarn samples, pasting them in the

register, report preparation.

Fibre moisture content% checking-

Polyester & Viscose & disposal of

samples.

Fibre neps/gm checking- Viscose &disposal of samples.

WLS No: BSP/W/37


QA-BTMShifts A B Total

QAC G

Entry of all tested results of Splice & TPI

in lot history & information to all

concerned persons

Sampling of card sliver samples for neps

checking

Final Yarn TPI & TPI CV% checking(All

single pack & double pack)

Final Yarn case checking-weighment of

individual cones & yarn defects

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

13

1 2 m/c

2

samples/

m/c

14

1 2 m/c

5

readings/

m/c

15 1 1 m/cdelivery

5cans/m/c

16

1 1 m/c

20

readings/

m/c

delivery

17

1 5 m/c

5

bobbins/

m/c

18 1 5 m/c 5 m/c

19

1 1 m/c

10

bobbins/ m/c

201 1 m/c 1 m/c

21

1

7 lots(2

times/we

ek)

4

samples/

lot

221 1/6

5 m/c in

one day

23 1 7 m/c 7 m/c 15.03 15.03

24

1 1 lot

10

coness/lo

t

4.45 4.45

251 4 lots

6

cones/lot

261 1 lot

10

cones/lot

23.84 23.84Sampling of final yarn(double) cones for

yarn uster %, wrapping & TPI testing

Sampling of roving bobbins for wrapping

& CV% check 12.35 12.35

Simplex roving wrapping CV% check,

report preparation & disposal of samples

Sample preparation of roving for half lea

strength testing & carry them to BTM spg.

QA 10.76 10.76

Simplex roving half lea strength checking

at BTM spg. QA & report preparation

7.56 7.56Drawframe sliver wrapping checking,

report preparation & Disposal of samples

Sampling of Roving bobbins for wrapping

check 33.35 33.35

Simplex roving wrapping check, report

Sampling of drawframe sliver(finisher)

samples for wrapping & CV% checking

10.26 10.26Drawframe sliver wrapping checking,

report preparation & Disposal of samples

Sampling of drawframe sliver(finisher)samples for wrapping & CV% checking

Autoconer Yarn cuts per 100 km checking

Sampling of autoconer yarn cones for

wrapping checking

Sampling of final yarn(single) cones for

yarn uster %, wrapping & TPI testing

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

27

1All tested

lots19.19 19.19

28

152

samples

5

bobbins/s

ample29

1 26 m/c52

samples

30

1 4 lots

10

bobbins/l

ot

31

1 4 lots

20

readings/

lot

32

1 4 lots

3

samples/l

ot33

1 4 lots

3

samples/l

ot

34

1 1 lot

20

readings/l

ot

18.56 18.56

35

1 3 lots

20

readings/l

ot

55.68 55.68

36

1All tested

lots12.34 12.34

37

1 4 lots

10

bobbins/l

ot

Sampling of Ringframe yarn bobbins for

RKM testing & carry them to BTM spg.

QA

Final autoconer yarn wrapping check(all

single pack lots) & CV% , report

preparation & disposal of samples.

77.50

Ringframe yarn wrapping check, report


Ringframe yarn sampling of all new lots.

42.45

Ringframe yarn samples collection for

checking of blend%, washing fastness

&MFS checking at Lab

77.50

Entry of all card neps, card, drawframe,

simplex wrapping, autoconer yarn cuts in

lot history & information to all concerned

persons

Ringframe Yarn sampling(All m/c & all

sides)

42.45Sending & submitting the yarn samples to

process lab for blend% , washing fastness

& MFS checking & updating the results in

lot history register

Ringframe yarn wrapping & wpg. CV%

checking(All new lots), report preparation

& disposal of samples

Final double yarn wrapping & CV%

check, report preparation & disposal of

samples.

Entry of ringframe & final yarn wrapping,

yarn blend%, washing fastness, MFS in lot

history & information to all concerned.

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

38

1 4 lots

30

readings/l

ot

39

1 4 lots

10

bobbins/l

ot

401 4 lots

30readings/l

ot

411 4 lots

5

cones/lot

42

1 4 lots 10 kg/lot

43

1All tested

lots

44

1 4 lots6

cones/lot

45

1 4 lots150

km/lot

46

1All tested

lots

47

1 4 lots6

cones/lot

48

1 4 lots150

km/lot

Sampling of autoconer yarn cones for yarn

classifault testing & carrying them to BTM

classifault testing room

187.50 187.50

Autoconer yarn classifault testing, yarn

faults collection, pasting them in report,

report preparation & disposal of samples.

Sampling of final yarn cones for yarn

rewinding study

331.12 331.12

Final yarn rewinding study-checking on

m/c , yarn faults collection, pasting of yarn

faults in report, report preparation &

disposal of samples.

Entry of Ringframe yarn RKM, final yarn

RKM & rewinding studies in lot history &

information to all concerned persons.

Sampling of final yarn cones for yarn

classifault testing & carrying them to BTM

Classifault testing room.

96.00 96.00

Final yarn classifault testing-checking on

m/c, yarn faults collection, pasting of

gaults & report preparation & disposal of

samples.

Entry of final yarn classifault test results in

lot history & information to concerned

persons.

155.70 155.70

Ringframe yarn RKM & RKM CV%

checking, report & disposal of samples

Sampling of final yarn cones for RKM

testing & carry them to BTM spg. QA

Final Yarn RKM & RKM CV% checking,report & disposal of samples.

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

49

1All tested

lots

50

1 1/13

3 m/c in

one

round

511 1/13

3 m/c inone

round

52

1 1/13

6

samples/

m/c

53

1 1/13

2 m/c in

one

round

54 1 1/26 All m/c 1.44 1.44

55

1 1/26

2 m/c in

oneround

4.04 4.04

56

1 1/26

26 m/c in

one

round

3.46 3.46

57

1 1/26

26 m/c in

one

round

9.23 9.23

58

1 1/26

26 m/c in

one

round

6.92 6.92

591 1/13

8m/c inone

round

18.46 18.46

60

1 1/26

2 m/c in

one

round

9.23 9.23

17.31Autoleveller function checking-

wrapping,wpg. CV% & A%, report


Ring frame suction pressure checking &

report preparation

Ringframe cots checking & report

preparation

Ringframe spacer checking & report

preparation

Autoconer gauge setting checking & reportpreparation.

Cheese winding yarn tension checking &

report preparation.

M/c speed checking & report preparation

Simplex Top arm pressure & report

preparation

Sample preparation of Autoleveler function

checking

17.31

Entry of autoconer yarn classifault test

results in lot history & information to all

concerned persons.

Blow room lap weight checking, report

preparation

8.46 8.46Blow room lap CV% check, reportpreparation & disposal of samples

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

61

1 1/26

2 m/c in

one

round

2.31 2.31

62

1 1/26

4 m/c in

one

round

2.31 2.31

63 1 1/26 24 in oneround

12.69 12.69

64

1 1/26

8

samples/s

tudy

65

1 1/26

24

samples/s

tudy

66

1 1/26

8

samples/s

tudy

91.90 91.90

11 1 1 7.45 7.45

21 1 1 5.00 5.00

3

1 1 0.85 0.85

1 1 0.95 0.95

1 1 1.06 1.06

1 2 2.17 4.34

1 1 0.90 0.90

4

1 1 0.30 0.30

1 3 0.54 1.62

1 3 0.30 0.90

1 3 0.33 0.99Enter details in the UT

Uster % checking & print the result

Keep back the cans in carding section

Collect the sample can and come back to

QA

Enter the details in the UT machine

Cheese winding breakage study & report

preparation.

Carding

Reach carding section from QA

TFO breakage study & report preparation.

Knotter's knot quality checking, pastingthem in report & report preparation.

Samples preparation for Cardwise sample

study on same machine channel for each

individual card.

Cardwise study- classimat tests of RF yarn

samples (Testing at Classimate room at

BTM spg.) & disposal of samples.

InvestigatorClean the uster machine, work area , go

and bring mixing register

Enter the mixing composition and other

details in lot register from layering register

137.85 137.85Cardwise sample study- Uster checking of

card sliver, Drawframe sliver & Ringframe

yarn

Drawframe(Breaker &Finisher)

Come to drawframe section, collect two

can(breaker)

Come back to QA lab

Write on the can L/L,L/R

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

1 12 1.77 21.24

1 3 0.54 1.62

1 1 0.46 0.46

1 3 0.54 1.62

1 3 0.33 0.99

1 12 1.77 21.24

1 3 0.54 1.62

5 0.00

1 9 0.54 4.86

1 9 0.15 1.35

1 9 1.51 13.59

1 36 1.47 52.92

6

1 1 1.53 1.53

1 8

8 lot*10

reading/l

ot

1.13 9.04

1 1 0.67 0.67

1 8 1.22 9.76

1 8 14.10 112.80

1 8 0.50 4.00

1 1 5.00 5.00

7

1 8 0.35 2.80

1 8 0.26 2.08

Uster % checking & print the result(2 pass

per can*2 cans/machine*3 machine)

Move the simplex trolley to QA lab

Enter the details in the UT machine

Keep back the cans in the breaker section

Waiting for the cans (finisher)

Uster % checking & take the printout(4

readings/machine*9 machine)

Ringframe

Come to ringframe section, searching forthe product running machine

Collect the R/F bobbins(10

bobbins/machine*8 machine)

Collect two cans, Come to QA lab

Enter details in the UT

Uster % checking & print the result(2 passper can*2 cans/machine*3 machine)Keep back the cans in the finisher area

Simplex Machine

Come to simplex area from QA lab

Come back to QA lab

Enter the parameters in uster machine

Check the uster % ( 10 bobbins)(operator

workload)

Take the printout of the result

During the uster % machine cycle timefilled the yesterday report in the log book

Yarn Board Winder

Take the white board and fix on the

machine

Fix the yarn from bobbin to board and

switch on

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

1 8 0.39 3.12

1 8 0.80 6.40

8

0.00

1 2 1.04 2.08

1 20 0.15 3.00

1 20 1.00 20.00

0.00

9

1 6

6 lot*10

reading/lot

0.35 2.10

1 6 0.26 1.56

1 6 0.39 2.34

1 6 0.80 4.80

101 1 4.00 4.00

111 1 8.00 8.00

121 1 3.00 3.00

131 1 10.00 10.00

14

Take the white board and fix on the

machine

Single Yarn Uster% checking(materials

already brought to QA by checker)

Enter details in the UT machine

Fix date slip, remove the YBW board and

keep near the UT machine

Write details in the small slip to insert in

the YBW board

Enter the uster test results in lot history

register & file all reports

Remove the old and Connect the next

single yarn cone to the UT machine

Machine cycle time(2 lot*10 readings/lot)

During the machine cycle time,parallely

keep the old cones in the trolley)

Yarn Board Winder(Final Yarn)

Fix the yarn from cone to board and switch

on

Fix date slip, remove the YBW board and

keep near the UT machine

Write details in the small slip to insert in

the YBW board

Fill the D/F uster & spectrogram report

from quality report

Enter the daily production lot register datain excel sheet

Send the daily QA report through mail to

higher officials

Sampling of Packing materials

_________________________________________________________________________ _______________







Department

Section

Work CentrePresent

Manpower3 2 - 1 6


3 2 - 1 6

Sl.

No

Crew

Size

Freq/

Shift

Sample

Size

Basic

Time

(Mins)

Total

Time

(Mins)

Lab



WLS No: BSP/W/37



QAC G

1 1/13 120.00 9.23

1 1/13 120.00 9.23

1 1/13 60.00 4.62

1 1/13 60.00 4.62

A 2353.02

B 13

C 2658.92

D 2730

E 97.40%F 6

G 97.40%

Present Utilisation(%)Proposed Manpower per Day


Remarks:

Basic Workload per shift ( in man minutes)


Standard Workload ( in man minutes )


Sample the paper cone(embossed),Check

the weight,strength,Cone length, nose dia,

base dia (20 cone for 50,000 lot)

Sample the HM bag, Test

length,weight,gauge (10 readings for 150

kg)

Sample the HDPE bag, Test

length,weight,gauge (10 readings for 300

kg)

Sample the paper cone(plain velvet),Check

the weight,strength,Cone length, nose dia,

base dia (20 cone for 50,000 lot)

_________________________________________________________________________ _______________






________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

4.0 A BTM SPINNING - MECHANICAL

MAINTENANCE

_______________________________________________________________________________





______________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

4.0 A4.1


Fitter - - - 1 1 - - - 1 1

Helper - - - 2 2 - - - 1 1

Fitter - - - 1 1 - - - 1 1

Running Fitter - - - 1 1 - - - 1 1

Cleaner - - - 2 2

Flat Grinder - - - 1 1

Fitter - - - 1 1 - - -

Running Fitter - - - 1 1 - - -

Cleaner - - - 3 3 - - - 3 3

Fitter - - - 1 1

Helper - - - 1 1

Head Fitter - - - 1 1 - - - 1 1

Gauging Ftter - - - 1 1 - - - 1 1

Helper - - - 2 2 - - - 2 2

Duct Fitter - - - 1 1 - - - 1 1

Cleaner - - - 8 8 - - - 8 8

Cleaner Fitter - - - 1 1 - - - 1 1

Asst. Cleaner Fitter - - - 1 1 - - - 1 1

- 2

-

1

2

Common Cleaning

gang for Ringframe &

TFO

Ringframe5

Main Gang

1- -

1

Blow Room

1

- -

1

Carding2

Fly-Frame3

4 Buffing

BTM SPINNING - MECHANICAL MAINTENANCEManpower Deployment


Remarks

_________________________________________________________________________________________________ ________________________







4.0 A4.1


BTM SPINNING - MECHANICAL MAINTENANCEManpower Deployment


Remarks

Fitter - - - 2 2 - - - 2 2

OHB Fitter - - - 1 1 - - - 0 0

Cleaner - - - 3 3 - - - 3 3

Fitter - - - 1 1 - - - 1 1

Helper - - - 1 1 - - - 1 1

0 0 0 38 38 0 0 0 33 33Total

Winding6

TFO7

_________________________________________________________________________________________________ ________________________







4.0 A

4.2

4.2.1

a)

b)

c)

d)

e)

f)

-

-

-

-

-

-

-

-

-

-

g)

BTM SPINNING - MECHANICAL MAINTENANCE


Running maintenance data has been collected by detailed discussions with the

incumbents and the supervisory personnel and compared with check studies and

estimated.

The manpower has been computed with a loading factor of 80 % for the maintenance

personnel. The 80 % loading has been considered to take into account the following:

The detailed time and motion study is recommended to arrive the standard time for the

activities,whatever timings considered here,based on the group utilisation technique.And

cannot taken for fixing standard times.

The preventive maintenance data was collected for all the category of machines.

Check studies on a sample basis were carried out to ascertain the process being

followed for the preventive maintenance. The data gathered during check studies has

been applied to the remaining preventive maintenance activities in that section.

Methodology

Breakdown maintenance (Carding, Ringframe & Autowinding) data has been

obtained for a period of two months and the same has been extrapolated for a month.

The sum of the preventive maintenance, breakdown maintenance(if any) and running

maintenance (if any) workload for the month gives us the total workload for the

mechanical personnel.

Rest & Relaxation allowance is already included as a part of activity time and

presented against the respective activities.

PF - Permanent Fitter(Sr.Fitter,Fitter,Jr.Fitter)

PH - Permanenent Helper/Cleaner





Change dress

Prepare attendance

Write logbook

Unavoidable delay. EX:New activity cannot start after 4.30 pm as only 30 mins left

for that day



_______________________________________________________________________________






4.0 A

4.2



4.2.2

I

a)

II

a)

b)

III

a)

IV

a)

V

a)

Proposed Changes

Blowroom

In view of low utilisation(29.68%) of helpers in the blowroom section, it is proposed

to deploy one helpers instead of the present two helper with one fitter.

Cots Buffing

Drawframe & Simplex(Fly-Frame)

BTM-D/F & Simplex section, one separate fitter deployed for running problems &

change over activities. It is suggested to follow the same practice of all

members(fitter, cleaners) perform the routine checkups (for their sections) at the

starting of the shift and rectify(if problem any) the same before starting the scheduled

preventive maintenance activity. Incase of small running problems, the fitter can

attend the problem. This will not affect the scheduled maintenance activities as the

fitter involvement is less. In above that they have foreman to carryout the running

problems & breakdowns. This practice is already implemented in elegant spinning.

In view of low utilisation(19.69%) , it is proposed to deploy one fitter instead of the

present one fitter and one helper.

OHB Fitter

The incumbent is incharge for the OHB in the BTM Spinning section. The major

activity is collecting the dust accumulated from the OHB box & do overhauling of

the OHB. As single operator walking to all the OHB and collecting waste, it takes

nearly 3 hours per day. So, it is recommended that the respective section mechanical

gang carryout the maintenance of their sections OHB. This practice is being followedin Elegant Spinning. No separate personnel is being recommended for this position.

After the detailed discussion with the mechanical team and the management

personnel, the number of running problems through out the day are very minimal

compared to in elegant spinning. Hence, no personnel is deployed in shift for

attending the minor/running problems. The same is being considered and manpower

is suggested.

Carding-Flat Grinder

The utilisation of flat grinder is only 12.5%. So it is recommended that one flat

grinder cum cleaner, instead of flat grinder.

_______________________________________________________________________________






4.0 A

4.2



4.2.3

I

a)

b)

II

a)

III

a)

Multiple Activity Chart:

Multiple activity chart is used when more than one personnel is engaged for doing

one job. A multiple activity chart combined with SOP gives the sequence of activity

each has to perform. This reduces the idle time and increases the machine availability

time. It was observed during the study that such detailed Multiple Activity Chart

combined with SOP is not available as a result of which the time taken for scheduled

maintenance is much higher than required. Hence it is proposed that a detailed time andmotion study for regular maintenance activities has to be carried out and such Multiple

Activity Chart has to be made.

Instead of stopping machine two different times, the activity of cleaning gangs(S.No

1-6) could be performed, when machine stopped by gauging gang to carryout their

scheduled activities. As gauging gang working on gear part (removed geared from

machine and overhauling in the mechanical room), remaining part of the machine is

free for cleaning. It increases the machine availability to the production. Illustration

is provided in Annex-1

Ringframe - Oil Top up activity

The activity of oil topping is performed by eight personnel for their allotted spindle ( 55

Spindles per person). As there is presently only one can is available, all seven are idlewhile one person fills his allotted spindles and made machines to be stopped. The time

taken for oil topping could reduce drastically. Illustration is provided in Annex-2

Ringframe & TFO

There are two different gangs performing scheduled maintenance activity in

Ringframe section Called as Cleaning gang and Gauging Gang. Cleaning gang

performs activities from S.No 1 – 6 and Gauging gang performs activities from S.No

8 – 16.(in the monthly Schedule For Routine/ Preventive Maintenance List)

During the study and discussion, it is observed that machine is being stopped

separately by cleaning gang and separately by gauging gang to perform their

respective scheduled maintenance activities.

Observations

_______________________________________________________________________________






4.0 A

4.2



4.2.3

IV

a)

b)

V

a)

VI

a)

Observations

Break-hours

It is observed that in elegant spinning that mechanical workers first finishes their

activities and leaving for breaks , because of this the machine hours under

maintenance decreases. Whereas in BTM this good practice is not observed results

in the reduced hour machine availability for the production.

Total Time provided for Scheduled Maintenance

The time provided for scheduled maintenance activities are based on the company

experience/estimation. However, it was observed during the study that the actual time

required for the scheduled maintenance activities are less. So , it is recommended to

go for in-depth time and motion study and fix standards for the regular maintenance

activities. This will help in increasing the availability time of machine and also

reduce maintenance personnel workload further.

In Spinning mill, number of similar equipments are more ( 48 R/F,48 TFO) , and

activity also carried out once in a month/quarter, reduction of each minutes have big

impact in the machine availability to production. Illustration is provided in Annex-3

Pooling of Workforce

It is observed in BTM-TFO mechanical gang (1 Fitter+1 Helper) performs the

preventive maintenance activities. For example, thread guide setting and cradle drum

setting which takes 2.17 hours with two crew personnel. The same activity if carried

out by say four personnel, the machine down time for maintenance would be half of

the time taken(2.17/2 = 1.09 hours). In the same day, morning in cheese winding

section, with 3 helpers+1 fitter carried out machine cleaning activity. For that they

stopped cheese winding machine for 3 hours. By pooling this two group ( TFO-2

Personnel + Cheese winding - 4 personnel) , both the activity would have been

completed, but with the half of the both machine stopped presently. This type of

analysis is possible only when the multiple activity chart with activity

sequence(preceding/succeeding) of activity known.

_______________________________________________________________________________





_______________________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

Annex : 1

Section : BTM - Spinning - Ring Frame

RING FRAME

.NO ACTIVITY FrequencyApprox

Time

(hrs)*

Done

by

1 M/C Cleaning 15D +_15D 1.25 1.25 1.25

2 Spindle Oil 4 M + 15 D

Topping

3 Spdl.Oil Change 1 Y + 2 M 0.5 0.5 0.5

4 Bottom Apron 8 M + 2 M

Change

6 Middle Arbour 1 Y + 2 M 0.5 0.5

Greasing

7 Draft Gear 6 M + 1 M

Overhauling

8 Heart Cam As & when

Overhauling required

9 J.P.Ball Brg. 1 Y + 2 M

Greasing

10 Bottom Roll 1 Y + 2 M

Trueing

11 Lapet Hook 2 Y + 3 M

Change

12 Lifting OH 2 Y + 6 M 12

13 Spindle Gauge 8 M + 1 M 4 Require Prior scheduling

14 Rings Change 2 Y + 6 M

This practise is being follwoed in Elegant mechanical maintenance

15 Spindle Change 10 Y + 2 Y 12

Present Method Proposed Method

0.5

P e r f o r m e d b y C l e a n i n g G a n g

0.5 0.5

12

Same improvement idea holds good in TFO Section, where two gangs are involved.

Performed by Gauging gang

Performed by Cleaning gang

4

P e r f o r m e d b y G a u g i n

g G a n g

4

12

4

4

0.5 0.5

0.5

0.5

Savings per machine - 3.25

hours

2

4

Total Machine Stoppage -

1.25+0.5+0.5+0.5+0.5 + 4 = 7.25

hours

Total Machine Stoppage - 4

hours

__________________________________________________________________________________________________________________________________________________________







Annex : 2

Section : BTM - Spinning - Ring Frame

Activity : Spindle oil Topping

24 24

21 21

18 18

15 15

12 12

9 9

6 6

3 3

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Working ( Remove spindle, fill the oil & place back the spindle)*

Idle

Additionally cleaners avaialblity goes up

Waiting for the Oil can ( Forced Idleness)

Time saved per machine - 18 mins

Present Method ( with One oil Can) Proposed Method ( with four oil can)

T i m e ( m i n s )

T i m e ( m i n s )

Crew Size ( Cleaners) Crew Size ( Cleaners)

Total Cycle time per machine = 24 mins Total Cycle time per machine = 6 mins

_________________________________________________________________________________________________ ________________________






______________________________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

Annex : 3

Section : BTM - Spinning - TFO

T.F.O.

.NO ACTIVITY Frequency

x

TimeDone By

11Thread guide Setting

6 M + 1 M12 6 M + 1 M

13 Jokey Pulley Greasing 1 Y + 2 M 2.5 Total Machine Stoppage - 3 Hours

14 1 Y + 2 M

Total Crew(6 person) Utilisation - 1 hour

CONE WINDING & CHEESE WINDING

S.NO. ACTIVITY Frequency

ppro

xDone By

1

M/C Cleaning with

Upper & 15 D + 4 D

Lower Guide pulley

Oiling

2 Drum shaft brg.&greasi 6 M + 1 M 8 Total Machine Stoppage - 3 Hours

3 Yarn Path 3 M + 15 D

Setting

6 Yarn guide hook As & when

requiredGBTL -SPG-F-08 TFO Autoconer TFO utoconer TFO Autoconer

* Given by company persons

Machine

Stoppag

e Hours

3 3

Machine

Stoppage

Hours

1 2

Machine

Availablity

for

production

2 1

Manhour

s

Utilised

2 crew*

3

hours=

6

manhou

4 crew*3

hours=12

manhours

Manhours

Utilised

6 crew* 1

hours= 6

manhours

6 crew*2

hours=12

manhour

s

- -

3

P e r f o r m e d b

y T F O

G a u g i n g G a

n g

( 1

F i t t e r + 1 H e l p e r )

Total Crew(4 person) Utilisation

- 3 hours

Present Method Proposed Method

Total Crew(2 person) Utilisation

- 3 hours

Cradle, Drum Setting

Gear Overhauling

3

P e r f o r m e d b y

A u t o c o n e r C l e a n i n g

G

a n g

(

Autoconer Gang( 1 Fitter + 3

Helpers)

Total Crew(6 person) Utilisation - 2 hours

4

4

4

Total Autoconer Machine Stoppage - 2 Hours

Proposed Method ( 2TFO Gang

+ 4 Autoconer Gang)Present Method

Savings

6 Persons( 2 TFO

Gang + 4 Autoconer

Gang)

TFO Gang ( 1 Fitter + 1 Helper)

6 Persons(

2 TFO Gang

+ 4

AutoconerGang)

Total TFO Machine Stoppage - 1 Hours

__________________________________________________________________________________________________________________________________________________________







4.0 A

4.3

S.No

12

3

4

5

6

7

89

10

11

12

OHTC Fitter BSM/W/11

TFO BSM/W/12

Ring frame-Main Gang BSM/W/08Duct Fitter BSM/W/09

Autowinding&Cheese Winding BSM/W/10

Running Fitter- BSM/W/05

Cots Buffing BSM/W/06

Cleaning Gang-R/F&TFO BSM/W/07

Carding BSM/W/02

Flat Grinder BSM/W/03

Drawframe&Simplex BSM/W/04




Blow Room BSM/W/01

_______________________________________________________________________________






Department BTM A B C G

Section Mechanical - - - 1 F+2 H


Mixing- - - 1 F+1 H

PF PH PF PH

A Blowroom & Mixing

1 Line Blender Cleaning 1 1 1 3.0876 5 15 15

a) Clear the material from the machine and

stop the machine

b) Dismantle the grid bar

c) Cleaning the grid bar

d) Mantling of the grid bar

e) Cleaning of the beater and striping plate

f) Cleaning of the feed lattice

g) Cleaning of the inclined lattice

h) Cleaning of the bottom inclined lattice

i) Cleaning of the evener roller/lattice

j) Cleaning of the feed roll

k) Checking and greasing of the bearings

l) Close the cover of the machine and start

the machine


Time

(in Hours)

No of

Machine

Crew Category

WLS No:BSM/W/01

Present

Manpower

Proposed

Manpower

Shifts

S.


Frequency/

Month

Monthly

workload(Hours)

_________________________________________________________________________________________________ ________________________










Mixing- - - 1 F+1 H

PF PH PF PH


Time

(in Hours)

No of

Machine

Crew Category

WLS No:BSM/W/01

Present

Manpower

Proposed

Manpower

Shifts

S.


Frequency/

Month

Monthly

workload(Hours)

2 Hopper Feeder Cleaning 1 1 1 3.0876 5 15 15


stop the machine

b) Removal of the chain and belt

c) Opening and cleaning of the vibrating

door of the hopper feeder

d) Cleaning of the inclined lattice

e) Dismantling of the gearsf) Cleaning & checking of the gears

g) Mantling of the gears

h) Cleaning of the stripper roll

i) Cleaning of the evener roller/lattice

l) Close the cover of the machine and start

the machine

3 Condenser & Doffing Section cleaning.1 1 1 3.0876 5 15 15

_________________________________________________________________________________________________ ________________________










Mixing- - - 1 F+1 H

PF PH PF PH


Time

(in Hours)

No of

Machine

Crew Category

WLS No:BSM/W/01

Present

Manpower

Proposed

Manpower

Shifts

S.


Frequency/

Month

Monthly

workload(Hours)

k) Close the cover of the machine and start

the machine

4 Scutcher Cleaning 1 1 1 3.0876 5 15 15


stop the machine

b) Dismantling of the paddles

c) Cleaning of the paddles

d) Dismantling of the grid bar

e) Cleaning of the grid bars

f) Mantling of the grid bars

g) Mantling of the paddles

h) Gauging of the paddle gauge

i) Checking of the cone drum

j) Opening and Checking of the PIV gear

k) Checking of the calendar roll gear

l) Cleaning of the beater and striping plate

_________________________________________________________________________________________________ ________________________










Mixing- - - 1 F+1 H

PF PH PF PH


Time

(in Hours)

No of

Machine

Crew Category

WLS No:BSM/W/01

Present

Manpower

Proposed

Manpower

Shifts

S.


Frequency/

Month

Monthly

workload(Hours)

m) Gauge of the feed roll to beater and

striping plate to beater

j) Close the cover of the machine and start

the machine

5 Mixing Blender Cleaning ( Mixing

Blender -4 nos, viscose opener-1 No) 1 1 1 2.70165 5 14 14


stop the machine

b) Cleaning of the bottom lattice

c) Cleaning of the feed lattice

d) Cleaning of the inclined lattice

e) Cleaning of the bottom inclined lattice

f) Cleaning of the evener roller/lattice

g) Cleaning of the feed roll

h) Checking and greasing of the bearings

_________________________________________________________________________________________________ ________________________










Mixing- - - 1 F+1 H

PF PH PF PH


Time

(in Hours)

No of

Machine

Crew Category

WLS No:BSM/W/01

Present

Manpower

Proposed

Manpower

Shifts

S.


Frequency/

Month

Monthly

workload(Hours)

i) Close the cover of the machine and start

the machine

6 Mxg. Condenser Cleaning 1 1 1 1.5438 11 17 17


stop the machine

b) Cleaning of the cage

c) Cleaning of the striping roll

d) Cleaning of the mouth piece

e) Close the cover of the condenser

7 Gear box Oil Change 1/6 1 1 0.7719 12 2 2

a) Stop the machine and open the oil box

b) Removal of the old oil from the oil box

c) Cleaning of the gears

d) Putting of the new oil in to the oil box

_________________________________________________________________________________________________ ________________________










Mixing- - - 1 F+1 H

PF PH PF PH


Time

(in Hours)

No of

Machine

Crew Category

WLS No:BSM/W/01

Present

Manpower

Proposed

Manpower

Shifts

S.


Frequency/

Month

Monthly

workload(Hours)

8 K. Beater Legs Change ( Blow Room -

2 have one leg at Front & One leg at

back)

1/9 1 1 7.719 6 5 5


stop the machine

b) Removal of the KB Belt

c) Dismantling of the beater legs

d) Marking of the holes in the new beater

e) Drilling the hole in the beater legs

f) Fitting the beater legs on the beater

g) Balancing of the beater

h) Gauge the beater to feed roll and striping

i) Close the cover of the machine and start

9 Filter Bags Washing 1/3 1 1 0.38 21 3 3

a) Opening of the filter bags

b) Washing of the filter bags

c) Tight the filter bags on its position after

Performed by Carpenter.

_________________________________________________________________________________________________ ________________________










Mixing- - - 1 F+1 H

PF PH PF PH


Time

(in Hours)

No of

Machine

Crew Category

WLS No:BSM/W/01

Present

Manpower

Proposed

Manpower

Shifts

S.


Frequency/

Month

Monthly

workload(Hours)

10 Running Problems(During General Shift) 26 1 1 1 26

A 127.60 101.60

B 166.4 166.4

C 76.68% 30.53%

D 1 1

E 76.68% 61.06%




Proposed Manpower


_________________________________________________________________________________________________ ________________________









Work Centre Carding - - -1F+2H+1 Flat

Grinder

PF PH PF PH

Frequency/ Month

CrewCategory

WLS No:BSM/W/02


Shifts

Present

Manpower

Proposed

Manpower

No of Machine

Monthlyworkload(Hours)

S.No

Activity Description Time(in

Hours)

Overhauling

Cylinder Wire Change

Doffer Wire Change

Flat Tops Change

St.Flats ( Doffer ) change

Combing Segment Change

a) Allow to run out the machine

b) Stop the machine

c) Open the cover and Belts & whole machine

d) Remove lap roll, lap stand, Feed plate feed

roll,Lickerin,Undercasing

e) Remove the flats & Flat bend

f) Remove the old wire from Cylinder

g) Remove the old wire from Doffer

h) Take bare Reading of Cylinder and Doffer

i) Open all the gears

j) Fix mounting machine on Cylinder

k) Mount The cylinder

l) Fix mounting Machine on Doffer

26

2

23.227 69.681 3 21.441/24

_________________________________________________________________________________________________ ________________________










Grinder

PF PH PF PH

Frequency/ Month

CrewCategory

WLS No:BSM/W/02


Shifts

Present

Manpower

Proposed

Manpower

No of Machine


S.No


Hours)

m) Mount the doffer

n) light grinding on Cylinder and doffer

o) Put the new St doffer side and Combing Segment

p) Assemble whole the parts and fix on machine

q) Fix all the gears on machine

r) Put new stationary flats on machine

s) Reset all the gauge

t) Start the machine at slow speed for checking of

abnormal sound

u) Handover the machine to Production

3 Stationary Flats ( Licker-in ) change 1/9 1 2 2.144 26 6 12a) Remove licker in

b) Open all the stationary flats

c) Remove old Stationary Flats

d) remove Top and bottom Plate licker in side

e) Put new flats

f) Fix on machine

g) Fit the licker in on machine

h) Reset the gauge

_________________________________________________________________________________________________ ________________________










Grinder

PF PH PF PH

Frequency/ Month

CrewCategory

WLS No:BSM/W/02


Shifts

Present

Manpower

Proposed

Manpower

No of Machine


S.No


Hours)

4 Licker-in Wire Change 1/9 1 1 2.144 26 6 6

j) Open the licker in wire

k) Mount the wire on licker in

5 Cylender,Doffer Grinding(28 in the last one year) 2 1/3 1 2 2.144 1 5 10


b) Fix the grinder on doffer

c) Set the gauge for grinder

d) Run grinder without contact of doffer wire

e) Give the contact of grinder to doffer wire

f) Remove the grinder from dofferg) Stop the machine

h) Open the top and bottom plate and doffer side st flats

i) Reverse the direction of Cylinder

j) Put grinder on cylinder

k) Give the contact of grinder to cylinder

l) Stop the machine

m) Fix all the parts on machine

n) Reset the gauge

o) Start the machine

_________________________________________________________________________________________________ ________________________










Grinder

PF PH PF PH

Frequency/ Month

CrewCategory

WLS No:BSM/W/02


Shifts

Present

Manpower

Proposed

Manpower

No of Machine


S.No


Hours)

7 Clearer roller clothing change (7 in the last one year) 3/5 1 3 1.072 1 1 2


b) Stop the machine

c) Remove the clearer roll

d) Open the clothing

e) Mount the new clothing

f) Fix on machine

g) Reset the gauge

h) Start the machine

8 Gearbox oil change 1/8 1 1 1 26 3 3

9 Petrol Stripping 1 1 3 4.288 1 4 13

10 Developmental Machine- MMC&LR 1 1 3 4.288 1 4 13

11 Breakdown(from past record) 1 1 5.75 1 6 0

12 Running Problems 1 1 26 1 0 26

_________________________________________________________________________________________________ ________________________










Grinder

PF PH PF PH

Frequency/ Month

CrewCategory

WLS No:BSM/W/02


Shifts

Present

Manpower

Proposed

Manpower

No of Machine


S.No


Hours)

Proposed Method

13 Flat Grinding 20.8

A 130.51 360.90

B 166.4 166.4

C 78.43% 72.30%

D 1 3

E 78.43% 76.52%

Proposed Manpower

The running fitter attends the running problem only in the general shift. The running problem between 5pm to 8 am is attended by production

operator. The fitter is called whenever required depends on the problem. It also found that the running problems are very less and breakdown

is very minimal.

The activity of flat grinders are considered in the proposed method.





_________________________________________________________________________________________________ ________________________







Department

Section

Work Centre Present Manpower - - 1

Designation Proposed Manpower - - 0

Sl.No

CrewSize

Freq/ Month

Basic

Time

(hours)

No of

machin

es

Monthly

Workload

(hours)

11 1/24 4.80 26 5.20

2 1 1/24 4.80 26 5.20

3 1 1/24 4.80 26 5.20

4 1 1/24 4.80 26 5.20

A 20.80

B 166.4E 12.50%

F 0

G 0.00%

Number of carding machine - 26 Nos

It is suggested that flat grinder performs the scheduled works, the operator performs the flat

grinding activity.

Number of stationary flats per machine - 88 nos

The utilisation of flat grinder is only 12.50%. The activity of flat grinder is not time bounded like

machine has to start within given hours. As all the activities are outside work, it does not affect the

machine availability.



Flat Grinding

Remarks:


Remove the stationary flats from flats(88

nos)

Take bare reading and leveling(88 nos)

C



-

-

Grinding of all the flats(88 nos)

Flat Grinder

Clip all the flats(88 nos)

Frequency of flat grinding - once in two years


WLS No:BSM/W/03

BTMShifts A B G

Mechanical


_______________________________________________________________________________









& Simplex- - - 1F+3H

PF PH PF PH

A Drawframe

1 M/C Cleaning 2 1 2 1.42 11 14 62

a) Allow to run out the material

b) Stop the machine

c) Remove all the cans from machine

d) Put the Rexin and bench on machine

e) Remove the top roll from machine

f) Clean the top clearer cloth

g) Remove the jam of bottom

h) Remove the coiler cover

i) Clean all the coiler

j) Apply grease in bottom roll ,coiler,callenderroll and delivery roll shaft&gearing

k) run the machine

l) Stop the machine

m) remove fly and grease

n) Clean All the rolls and coiler from petrol

o) Apply Chalk powder in bottom roll

,coiler,callender roll and delivery roll shaft

p) Check the machine for any abnormality

q) Put top roll on machine

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)

S. No Activity DescriptionCrew Category Monthly

workload(Hours)Frequency/

Month

No of

Machine

_________________________________________________________________________________________________ ________________________











PF PH PF PH

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)



Month

No of

Machine

2 Coiler OH 1/2 1 2 1.42 11 8 16

3 Oil Change 1/2 1 1 1.42 11 8 8

4 Bottom Roll Trueing 1/2 1 1 2.84 11 16 16


b) Stop the machine

c) Remove all the cans from machine

d) remove the oil from gear box

e) Open the gearing and coiler

f) Open the gear box

g) Take out the all rolls

h) Clan the roll and slide gearing and Gear box,coiler with brush and kerosene

i) Check and roll true

j) Check wire rings and balls if faulty then replace

k) Apply grease in coiler

l) Reset the coiler

m) Clan the coiler plate from wall hold compound

n) put all rolls, coiler and gears in machine

o) Apply FCV powder where needed

p) Start the machine

_________________________________________________________________________________________________ ________________________











PF PH PF PH

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)



Month

No of

Machine

B Simplex

1 M/C Cleaning 1 1 3 4.49 10 27 135


b) Stop the machine

c) Take out all the flyer

d) Raise the pateli

e) Run the machine idle &apply grease in Bottom

roll

f) Clean the Excess grease from bottom roll

g) Raise the top arm and remove the cradle

h) Wash the top apron from surf i) Refix all the aprons on cradle

j) Apply lubricants on weight chain, lever chain

and lever bush & pateli bush

k) Stop the machine

l) Clean the top and bottom clearer cloth

m) Remove the jam from bottom roll

n) Clean all the gearing

o) Check all the bearing and gears

_________________________________________________________________________________________________ ________________________











PF PH PF PH

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)



Month

No of

Machine

p) Clean all the spindle wheel, bobbin wheel

Bobbin rail and Spindle rail& apply grease on

q) Close all the cover

r) clean all the flyer

s) Fit cradle on machine

t) Reset the Arm

u) Start the machine and down the petti

v) Apply spindle oil in spindle

w) Run the machine idle

x) Stop the machine

y) Then reclean all the grease and oil

z) Put flyer on spindleaa) Clean the flyer with rope and petrol

ab) handover the machine

2 Long Collar Cleaning 1/3 1 3 1.50 10 5 15


b) Stop the machine

c) Open the spindle cover

d) Open the spindle and take it out

e) Clean the collar from bottle brush

_________________________________________________________________________________________________ ________________________











PF PH PF PH

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)



Month

No of

Machine

f) Remove old oil from spindle housing

g) Put fresh oil

h) Refix the spindle in collar

i) Make them free

j) Set all the spindle wheel

k) Apply grease on spindle and bobbin wheel

l) Close the cover

m) Start the machine

3 Bottom Apron Change 1/9 2 0.25 10 0 1

4 Top Apron Change 1/18 2 0.25 10 0 0.285 Middle Arbor Greasing 1/12 2 0.17 10 0 0.28

6 Bottom roll gauge checking & Top arm

pressure setting1/6 1 1 1.50 10 2 2


b) Stop the machine

c) Check the Arm pressure and arm bar

_________________________________________________________________________________________________ ________________________











PF PH PF PH

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)



Month

No of

Machine

7 Spindle Trueing 1/6 1 1 1.50 10 2 2


b) Stop the machine

c) Take out all the spindle

d) True all the spindle

e) Clean all the long collar

f) Put spindle in collar

g) Make them free

h) Close the cover

i) Apply oil in long collar in running mode

j) Clean all the excess oil in stoppage mode

k) Run the machine

8 Bottom Roll Trueing 1/6 1 1 2.99 10 5 5


b) Stop the machine

c) Raise the top Arm

d) Take out the bottom roll

e) Clean all the bottom roll

f) Check all the bearing of bottom roll

g) Make all the true

_________________________________________________________________________________________________ ________________________











PF PH PF PH

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)



Month

No of

Machine

h) Fit on the machine

i) Apply grease in all rolls in running mode

j) Clean all the grease with petrol

k) Start the machine

9 Bottom Roll Trueing ( Front & middle) 1/24 1 1 2.99 10 1 1


b) Stop the machine

c) Raise the top Arm

d) Take out the bottom roll

e) Clean all the bottom roll

f) Check all the bearing of bottom rollg) Make all the true

h) Fit on the machine

i) Apply grease in all rolls in running mode

j) Clean all the grease with petrol

k) Start the machine

_________________________________________________________________________________________________ ________________________











PF PH PF PH

WLS No:BSM/W/04


Shifts

Present

Manpower

Proposed

Manpower

Time(in

Hours)



Month

No of

Machine

10 Developmental Machine(Drawframe 2 1 3 5.99 1 12 36

11 Running work(Draw frame &Simplex)Provided

in the schedule ( 2 days/month)2 1 3 5.99 1 12 36

C Proposed Method: 2 1 3 5.99 1

12 Activity of Running fitter is divided among

three helpers and one fitter ( 69 hours/month =

17.5 hours fitter & 52.5 hours helpers)

17.50 52.50

A 111.91 335.21

B 166.4 166.4C 67.25% 67.15%

D 1 3

E 77.77% 77.67%

In this section (Drawframe&Simplex) the fitter % utilisation is very minimal when compared to the other sections. In other section, the total

time of cleaning is approx one hour. In that involvement of fitter is also around 30-40 mins. Whereas in D/F & Simplex Machine cleaning

time is approx 4 hours(D/F) & 6 Hours(Simplex). In this situation, the work of fitter (40 mins) is very minimal.


Net Available man-hours per month(8*26*80% = 166.4 hours)Present Utilisation(%)

Proposed Manpower


_________________________________________________________________________________________________ ________________________






____________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

Department

Section



Sl.

No

Crew

Size

Freq/

Month

Basic

Time

(hours)

Monthly

Workload

(hours)

A

1 1 26 0.17 4.33

2 1 26 0.17 4.33

3 1 26 0.30 7.80

B

1 1 26 0.25 6.502 1 248 0.03 7.44

3 1 358 0.03 10.74

4 1 4 0.75 3.00

5 1 49 0.50 24.50

A 68.65

B 166.4

E 41.25%

F 0

G 0.00%

Count change = 147/3 = 49



Remarks:

Aprons Changed = 742/3 = 248

Cots Changed = 1072/3 = 358

Flyer ceramic bush changed = 11/3 = 4

Draw

frame&Simplex

Running Fitter


Count change

Drawframe:

Monitor the sliver @ Cherryhara & LR

Check the stop motion

Change the flyer ceramic bush

The activity is shifted to drawframe mechanical gang and considered there.

Data collected from past record (Sep'11 to Nov'11)

Take the sample for uster % checking to lab, wait

and collect the result

Change the apron

Simplex

Round checkup the machine for problem

Change the Cots




WLS No:BSM/W/05


BTMShifts A B C G

Mechanical

_______________________________________________________________________________






Department

Section

Work Centre Present Manpower - - 1F+1H

Designation Proposed Manpower - - 1F

Sl.

No

Crew

Size

Freq/

Month

Basic

Time

(mins)

No of

machine

s

Monthly

Workload

(mins)

1

1 1 5.00 2 10.00

1 1/3 0.17 21120 1173.33

2 1/3 0.17 10560 586.67

1 1 5.00 2 10.002 1/3 0.30 211 21.12

2

1 1/3 15.00 48 240.00

1 1/3 15.00 48 240.00

3

1 1 5.00 2 10.00

1 1/2 0.17 540 45.00

2 1/2 0.17 135 11.25

1 1 5.00 2 10.00

2 1/2 0.30 11 1.62

4

1 1/2 15.00 10 75.00

1 1/2 15.00 10 75.00

5 1

1 1/24 0.12 48 0.23

1 1/24 0.55 21120 484.00

1 1/24 0.23 48 0.471 1/24 0.25 48 0.50

1 1/24 0.15 21120 132.00

6 1

1 1/24 0.12 10 0.05

1 1/24 0.55 540 12.38

1 1/24 0.23 10 0.10

1 1/24 0.25 10 0.10

WLS No:BSM/W/06


BTMShifts A B C G

Mechanical

-

Cots Buffing-Ring Frame

Bring the cots trays from the machine area

Cots Buffer -


Cots Buffing

Room

Buff in the machine(machine cycle

time).Operator work only feeding

Prepare liquimix solution

Apply liquimix on whole sets

Grease the whole sets(50 pieces-19 mins*2crew

Apply liquimix on whole sets

Check the eccentricity machine(parallel doneKeep back the trays to machine area

Grease the whole sets(50 pieces-19 mins*2crew

size)

Second time buffing(25%)

Check the eccentricity machine(parallel done

during buffing)

Remove cots

Remove the bolt from machine

Buff in the machine(machine cycle

time).Operator work only feeding

Second time buffing(25%)

Keep back the trays to machine area

Soak the cots in that overnight&clean

Set the bolt on machine to remove cots

Cots Mounting-Simplex

Fix the new bolt on machine

Remove the bolt from machine

Fix the new bolt on machine

Fix new cots

Set the bolt on machine to remove cots

Remove cots

Prepare liquimix solution

Soak the cots in that overnight&clean

Cots Mounting-Ringframe

Cots Buffing-Simplex

Bring the cots trays from the machine area

_______________________________________________________________________________






Department

Section

Work Centre Present Manpower - - 1F+1H

Designation Proposed Manpower - - 1F

Sl.

No

Crew

Size

Freq/

Month

Basic

Time

(mins)

No of

machine

s

Monthly

Workload

(mins)

WLS No:BSM/W/06


BTMShifts A B C G

Mechanical

-

Cots Buffer -


Cots Buffing

Room

1 1/24 0.15 540 3.38

7

1 1/60 1.02 33 0.56

1 1/60 0.72 33 0.39

8

1 1/24 10.00 48 20.00

1 1/24 1.02 5280 223.67

1 1/24 2.48 5280 545.60

A 3932.41

B 9984.0

E 19.69%

F 1

G 39.39%

Fix new cots

Fix new cots

Cots Mounting -Drawframe

Remove spindle

Remarks:

Apply fevicol, fix the new cloth & dry

Total Workload per month ( in man mins )

Net Available man-mins per month(480*26*80%= 9984 mins)




Fix the green cloth on the top roller clearer

Soak the top roller clearer overnight

Remove the old cloth

_______________________________________________________________________________







Section Mechanical - - - 1F+1AF+8H

Work CentreRingframe &

TFO- - - 1F+1AF+8H

PF PH PF PH

A Ringframe

1 M/C Cleaning & Top Apron Change 2 2 8 0.99 48 189.6 758.4

a) Stop the machine

b) Lift out the top roller clearer

c) Lift out the top arm

d) Wrap out the rove bobbins

e) Cleaning of the bobbin holder caps

f) Dismantling of the pnumafil pipe

g) Cleaning of the front, middle & back arbor

h) Cleaning of the L-Bracket, apron bridge bar

and fluted roller

i) Back zone cleaning

j) Cleaning of the lifting, lifting pulley, lappet

rod, poker rod, porker rod tube.

k) Cleaning of the spindle and ring rail

l) Bolster jam cleaning

m) Mantling of the pnumafil pipes

n) Pressing of the top arms

o) Placing of the top roller clearer.

p) Dismantling of the draft gear

No of

Machine

Frequency/

Month

Monthly workload(Hours)Time(in Hours)S. No Activity Description

Crew Category

WLS No:BSM/W/07


Shifts

Present

Manpower

Proposed

Manpower

_________________________________________________________________________________________________ ________________________










TFO- - - 1F+1AF+8H

PF PH PF PH

No of

Machine

Frequency/

Month


Crew Category

WLS No:BSM/W/07


Shifts

Present

Manpower

Proposed

Manpower

q) Cleaning & Checking of the draft gear

r) Greasing of the machine & motor pulley

s) Checking of roving guide and spacer,

t) Cleaning of the gutter

Top Apron Change

a) Stop the machine & Dismantle the cradles

b) Removal of the old aprons

c) Insert the new apron in the cradles

d) Insert the cradle and start the machine

2 Spindle Oil Topping 1/4 8 0.083 48 0 8

a) Removal of the spindle

b) Dropping of the oil in to the spindles

c) Placing of the spindles on its position

3 Spindle.Oil Change 1/12 2 8 0.25 48 2 8

a) Removal of the spindle

b) Replacing of the oil in to the spindles with

the help of oiling machine

c) Placing of the spindles on its position

_________________________________________________________________________________________________ ________________________










TFO- - - 1F+1AF+8H

PF PH PF PH

No of

Machine

Frequency/

Month


Crew Category

WLS No:BSM/W/07


Shifts

Present

Manpower

Proposed

Manpower

4 Bottom Apron Change 1/8 0 8 0.25 48 0 12

a) Dismantling of the bridge bar

b) Removal of the old aprons

c) Insert the new aprons

d) Mantling of the bridge bar

6 Middle Arbor Greasing 1/12 0 8 0.153 48 0 4.89

a) Open of the arbor

b) Greasing of the arbor

c) Petrol wash of the arbor

7 Rings Change-Texmaco Developmental 2 2 8 0.79 1 3.2 12.6

8 Rings Change-LR Developmental m/c 2 2 8 0.79 1 3.16 12.64

9 Spindle Change 1/120 0 4** 9.5 50 0 7.0

10 Lifting OH 1/24 0 3** 9.5 48 0 16.8

B TFO

1 M/C Cleaning 1 2 8 1.02 48 98.04 392.16


_________________________________________________________________________________________________ ________________________










TFO- - - 1F+1AF+8H

PF PH PF PH

No of

Machine

Frequency/

Month


Crew Category

WLS No:BSM/W/07


Shifts

Present

Manpower

Proposed

Manpower

b) Stop the machine

c) Clean the adaptor

d) Down the cradle and clean them

e) Remove jam from drum &PTR and clean

them

f) Clean the Pig tail, J.Pulley.

g) Remove jam from J.Pulley and Drum Pulley

d) Clean separator from surf and Dhoti

f) Take out the pot

g) Clean the pot from surf and dhoti

h) Take out the spindle

i) Clean the spindle from dhoti surf j) Clean the thread guide

k) Clean the beam

l) Clean the drum pulley

m) Put spindle

n) Put pot

o) Reset the setting of pot

p) Clean and check all the gearing and if found

faulty the informed to foreman

_________________________________________________________________________________________________ ________________________










TFO- - - 1F+1AF+8H

PF PH PF PH

No of

Machine

Frequency/

Month


Crew Category

WLS No:BSM/W/07


Shifts

Present

Manpower

Proposed

Manpower

q) Apply grease on gearing

r) Close the cover

s) Start the machine

t) Clean the break

u) clean the machine

v) Handover to production

2 Spindle Oil Topping 1/2 1 1 0.25 48 6 6

a) Stop the machine

b) Taken out the pot

c) Taken out the spindle

d) Topping donee) Put Spindle

f) Put Pot

g) Start the machine

3 Spindle Oil Change 1/12 1 1 0.50 48 2 2

a) Stop the machine

b) Taken out the pot

c) Taken out the spindle

_________________________________________________________________________________________________ ________________________










TFO- - - 1F+1AF+8H

PF PH PF PH

No of

Machine

Frequency/

Month


Crew Category

WLS No:BSM/W/07


Shifts

Present

Manpower

Proposed

Manpower

d) Clean the spindle

e) Remove burnt oil from bolster

f) Put fresh oil

g) Put Spindle

h) Put Pot

i) Start the machine

4 Spindle Bearing Greasing-VJ 1/12 1 1 0.25 38 0.792 0.792


b) Stop the machine

c) Remove pot and spindle

d) Clean the spindle and pote) Apply grease in spindle bearing

f) Put spindle

g) Put pot


5 Spindle Bearing Greasing-Prerna 1/4 1 1 0.25 10 0.625 0.625


b) Stop the machine

_________________________________________________________________________________________________ ________________________










TFO- - - 1F+1AF+8H

PF PH PF PH

No of

Machine

Frequency/

Month


Crew Category

WLS No:BSM/W/07


Shifts

Present

Manpower

Proposed

Manpower

c) Remove pot and spindle

d) Clean the spindle and pot

e) Apply grease in spindle bearing

f) Put spindle

g) Put pot


A 305.38 1241.95

B 166.4 166.4

C 91.76% 93.30%

D 2 8

E 91.76% 98.31%

* Out of three helpers, one are from cleaning gang.

** Out of four helpers, two are from cleaning gang.



Proposed ManpowerProposed Utilisation(%)


_________________________________________________________________________________________________ ________________________








Section Mechanical - - - 2 F+ 2 H


TFO- - - 2 F+ 2 H

PF PH PF PH

1 Draft Gear Overhauling 1/6 2 2 2.4 50 39.57 39.57

a) Stop the machine and dismantle the whole draft

gear system

b) Washing of the gears, bearing, stud and stud key

with kerosene oil

c) Mantling of the whole draft gear system

d) Start the machine and checking the gear system

2 Heart Cam Overhauling(Texmaco M/c only)1/3 1 1 1.2 32 12.66 12.66

a) Stop the machine and dismantling of the heart cam

assembly

b) Checking and cleaning of the heart cam, heart cam

shaft, ball bearings, plate wheel, ratchet pawl &

c) Mantling of the heart cam assembly

d) Start the machine and check the movement of the

heart cam

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month

Crew CategoryS. No Activity Description

Time(in Hours)

No of

Machine


_________________________________________________________________________________________________ ________________________










TFO- - - 2 F+ 2 H

PF PH PF PH

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month


Time(in Hours)

No of

Machine


3 Heart Cam Overhauling-Develop-Texmaco1/3 2 2 1.0 1 0.67 0.67

4 J.P.Ball Brg. Greasing 1/12 2 2 2.4 48 18.992 18.992

a) Stop the machine and dismantling of the jockey

pulley system

b) Greasing of the jockey pulley

c) Mantling of the jockey pulley

d) Dismantling of the cover of the pedestal

e) Cleaning of the pedestal

f) Greasing of the pedestal

g) Mantle the cover of the pedestal

h) Setting of the jockey pulley, T.R Pulley and drum

pulley and tapi) Start the machine and check the machine

5 J.P.Ball Brg. Greasing-Texmaco Developmental

m/c1/12 2 2 0.5 1 0.08 0.08

6 J.P.Ball Brg. Greasing-LR Developmental m/c1/12 2 2 1.0 1 0.17 0.17

_________________________________________________________________________________________________ ________________________










TFO- - - 2 F+ 2 H

PF PH PF PH

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month


Time(in Hours)

No of

Machine


7 Bottom Roll Truing 1/12 2 2 7.1 48 56.98 56.98

a) Open of the bottom roll bearings of the reserved

b) Washing of the bottom roll with petrol with the

c) Fitting of the bearing in the bottom roll

d) Roll to roll joining

e) Truing of the bottom roll

f) Stop the one side of the machine and remove the

bottom roll from the machine

g) Mantling of the new trued roll to the machine

h) Start the that side of the machine

i) Repeat the steps from a to h for other side of the

machine

8 Bottom Roll Truing-Texmaco Developmental

m/c 1/12 2 2 1.0 1 0.17 0.17

9 Bottom Roll Truing-LR Developmental m/c1/12 2 2 4.0 1 0.67 0.67

10 Lappet Hook Change 1/24 2 2 2.4 1 0.20 0.20

_________________________________________________________________________________________________ ________________________










TFO- - - 2 F+ 2 H

PF PH PF PH

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month


Time(in Hours)

No of

Machine


a) Stop the machine and dismantling of the lappet

hook

b) Rough fitting of the new lappet hooks

c) Lappet gauge of the lappet hook

11 Lappet Hook Change-Texmaco Developmental

m/c1/24 2 2 1.0 1 0.083 0.083

12 Lappet Hook Change-LR Developmental m/c1/24 2 2 1.0 1 0.083 0.083

13 Lifting OH 1/24 2 3* 7.1 48 28.488 32.4

a) Stop the machine and dismantle the lappet rail

b) Dismantling of the separator

c) Dismantling of the ring rail

d) Dismantling of Lifting pulley, lappet rod, pocket

rod, pocker rod tube

e) Dismantling of the ball bearing of the lifting pulley

f) Washing of lappet rod, pocker rod tube, ring rail

head bracket

g) Mantling of the lifting pulley with new bearing

_________________________________________________________________________________________________ ________________________










TFO- - - 2 F+ 2 H

PF PH PF PH

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month


Time(in Hours)

No of

Machine


h) Complete assembling of the lappet rod, pocker rod

tube, ring rail head bracket

i) Ring rail fitting & lappet rail fitting

j) Ring rail height gauge and lappet rail height gauge

k) Spindle gauge and lappet gauge

l) Fly catcher gauge

m) Separator fitting and start the machine

14 Lifting OH-Texmaco Developmental m/c 1/24 2 2 4.0 1 0.33 0.33

15 Lifting OH-LR Developmental m/c 1/24 2 2 4.0 1 0.33 0.33

16 Spindle Gauge 1/8 2 2 2.4 48 28.488 28.488

a) Stop the machine and dismantling of the separator

b) Cleaning of the poker tube and lappet rod

c) Ring rail height gauge

d) Lappet rail height gauge

e) Spindle gauge

f) Lappet gauge

g) Fly catcher gauge

h) Fitting of the separator and start the machine

_________________________________________________________________________________________________ ________________________










TFO- - - 2 F+ 2 H

PF PH PF PH

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month


Time(in Hours)

No of

Machine


17 Spindle Gauge-Texmaco Developmental m/c 1/8 2 2 0.5 1 0.125 0.125

18 Spindle Gauge-LR Developmental m/c 1/8 2 2 1.0 1 0.25 0.25

19 Rings Change 1/24 2 2 7.1 48 28.49 28.49

a) Stop the machine and dismantle the separator

b) Remove the ring rail and cleaning of the ring rail

c) Change the ring with new one

d) Cleaning of the lappet rod & pocker rod tube

e) Fitting of the ring rail

f) Ring rail height gaugeg) Lappet rail height gauge

h) Rough ring gauge

i) Final r ing gauge

j) Lappet hook gauge

k) Fly catcher gauge

l) Fitting of the separator

m) Start the machine and check the movement

20 Rings Change-Texmaco Developmental m/c 1/24 2 2 1.0 1 0.083 0.083

21 Rings Change-LR Developmental m/c 1/24 2 2 1.5 1 0.125 0.125

_________________________________________________________________________________________________ ________________________










TFO- - - 2 F+ 2 H

PF PH PF PH

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month


Time(in Hours)

No of

Machine


22 Spindle Change 1/120 2 4** 7.1 50 5.935 6.75

a) Stop the machine and dismantle the ABC Ring rail

b) Dismantle the separator

c) Loose the bolster

d) Bolster open with spindle

e) Fitted the new bolster with spindle

f) Tight the bolster

g) Open the spindle

h) Oiling the bolster

i) Fitting the spindle in to the bolster j) Ring rail height gauge

k) Lappet Height gauge

l) ABC ring rail height gauge and fitting

m) Dismantling of the ABC rings rail

n) Ring gauge

o) Lappet gauge

p) Fly Catcher gauge

q) Fitting of the separator

r) ABC ring rail fitting and start the machine

_________________________________________________________________________________________________ ________________________










TFO- - - 2 F+ 2 H

PF PH PF PH

WLS No:BSM/W/08


Shifts

Present Manpower

Proposed

Manpower

Frequency/

Month


Time(in Hours)

No of

Machine


A 222.96 227.69

B 166.4 166.4

C 67.00% 68.42%

D 2 2

E 67.00% 68.42%

** Out of four helpers, two are from cleaning gang.

Proposed Manpower



* Out of three helpers, one are from cleaning gang.



_________________________________________________________________________________________________ ________________________







Department

Section


Designation Proposed Manpower - - 1

Sl.No

CrewSize

Freq/ Month

Basic

Time

(hours)

No of

machin

es

Monthly

Workload

(hours)

1 1 2 0.35 48 33.60

2 1 2 0.25 48 24.00

3 1 7.75

4 1

A 65.35

B 166.4

E 39.27%

F 1






Remarks:

-

Duct Fitter

G

Major idle attend

Ringframe


Mechanical

-

Assist the Foreman in attending breakdown

WLS No:BSM/W/09


BTMShifts A B C

Clean the Pn pipe,Clean all the duct

To check the all spindle lock

_______________________________________________________________________________








Work CentreAutoconer &

Cheesewinding

- - - 2F+3 H

PF PH PF PH

A Autowinding

1 M/C Cleaning & Cleaning of Base Adaptor 2 1 3 1.19 7 16.59 49.77

a) Stop the machine

b) Dismantle the magazine

c) Cleaning of the machine with the air pressure

d) Cutting of the adopter jam

e) Conveyor belt plate is removed from the machine for

cleaning

f) Cutting of the jam on the conveyor belt pulley

g) Cleaning of the Jalid) Cleaning of the head stock

f) Checking of the suction and conveyor belt

g) Cutting of the jam on material trolley or repairing of the

bearing in case jammed

h) Checking of the machine as per the check sheet and

attend if found any abnormality.

2 Winding. Head Cleaning & Oiling 1/3 1 3 0 7 0.92 2.77

Open the cover

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o


Crew CategoryFrequency/

Month

No of

Machine

Monthly

workload(Hours)

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

Fix the yarn trap on machine

6 S licer Servicin 1/4 3 3 7 0.00 16.59

Open the splicer

Open the cover

Open the introducer

Clean the introducer

Open the preparatory of splicer

Clean the Splicer

Check the chamber cover and chamber cover spring

Assemble the splicer

Fit on spindle

7 Magazine cover cleaning 1/6 1 3 1 7 0.81 2.42

Remove the magazine

Remove the magazine cover

clean the magazine cover assembly with petrol

Grease on magazine cover rod and spring

Clean the magazine cover

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

Fix the magazine cover

Mix the magazine

8 Cradle setting 1/6 2 1 7 0.00 1.61

Stop the machine

loose the bolt

Put the cone

Reset the gauge by 5 mm on base side

Reset the gauge by 4 mm nose side

Tight the boltstart the machine

9 Bobbin Peg Overhauling 1/4 3 2 7 0.00 8.30

Open the bolt

Open the bobbin peg

cut the jam

Clean the bush of bobbin peg lever

Fix the bobbin peg

Tight the bolt

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

Open the winding head

Open the fitting

Open the suction arm

Open the lock of fitting

taken out the shaft of fitting

Clean the all the suction arm assembly

Clean the fitting and suction arm with surf

Added silicon oil

Refix the suction arm assbly

Fit it on the Suction arm and fittingRest the setting of suction arm

Start the machine

12 Clutch OH 1/12 2 4 2 7 1.84 3.69

Stop the machine

open the cover

remove the clutch belt

Open the clutch bolt

Take out the clutch

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

Clean the clutch with petrol

Apply grease on clutch

Clean the base of clutch

Fit the clutch and

Fit the Belt

Reset the clutch

Start the machine

13 Splicer OH 1/12 2 4 2 7 1.84 3.69

Stop the machineOpen the splicer pipe

Open the splicer

Open the splicer cover

Clean the splicer with Petrol

Apply OKS 475 Hs grease on Splicer

Close the cover

Fix splicer on the machine & pipe

14 Tension Disc Clg ,Setting & OH 1/6 2 4 1 7 1.84 3.69

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

Open the tension assly

Open the tension disc ,piston

Clean the tension disc and piston

Apply oil on piston

Fix the disc and piston in tension assembly

Clean the tension assembly

Fix on machine

15 Tension Assembly Clg & Oiling 1/12 2 4 1 7 0.92 1.84

Open the tension asslyOpen the tension disc ,piston

Clean the tension disc and piston

Apply oil on piston

Fix the disc and piston in tension assembly

Clean the tension assembly

Fix on machine

16 Adaptor Greasing 1/6 1 3 1 7 0.92 2.77

Remove the adaptor

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

Clean the spring

Clean the adaptor

Clean the machine arm

Nose side jam removal

Fix it back on machine

B Cheese Winding

1 M/C Cleaning with Upper & Lower Guide pulley

Oiling2 1 3 2 7 33.71 101.12

a) Allow to run out the materialb) Stop the machine

c) Remove the Swing plate and Swing plate cover

d) Remove the jam from Drum & Drum Shaft

e) Remove jam from adaptor

f) Remove the jam of stop motion shaft

g) Clean the whole machine from bottle brush

d) Open the upper and lower guide pulley

f) Clean the upper and lower guide pulley

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

g) Apply oil and fit on the machine of both the guide pulley

h) Lubrication on all the points

i) Complete all the missing spare

j) Fix the swing plate and swing plate cover on machine

k) Check all the belts and pulley

l) Start the machine and handover it to Production

2 Drum shaft brg. Greasing 1/6 1 3 6 7 7.49 22.47

a) Allow to run out the materialb) Stop the machine

c) Loose all the drums

d) shift the drums

e) Open the bearing cover

f) Taken out the burnt grease

g) Put fresh grease

d) Check all the bearing if found faulty then replace

f) Close all the bearing cover

g) Set the cradle and drum

_________________________________________________________________________________________________ ________________________










Cheesewinding

- - - 2F+3 H

PF PH PF PH

WLS No:BSM/W/10


Shifts

Present Manpower

Proposed Manpower

Time

(in

Hours)

S.

N

o



Month

No of

Machine

Monthly

workload(Hours)

h) Start the machine for 5 min

i) Stop the machine

j)

Then clean the drum and bearing cover with petrol for

removing the greasing

k) Start the machine and handover it to Production

3 Yarn Path Setting 1/3 2 3 7 0.00 14.98

a) Check the yarn path

b) If found any problem then reset them

4 Adopter Greasing & Drum cradle setting 1/3 1 2 7 0.00 5.15


b) Stop the machine

c) Fit the cheese in Cradle & check

d) If faulty then reset

e) Start the machine and handover it to Production

5 Drop Needle Change 1/10 3 3 7 0.00 6.74

_________________________________________________________________________________________________ ________________________







Department

Section


Designation Proposed Manpower - - 0Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(mins)

No of

machin

es

Total

Workloa

d (mins)

1

1 1 3.95 22 86.96

2

1 1 3.68 10 36.81

3

1 1 3.87 7 27.07

4

1 1 3.91 9 35.19

5 1 1 112.50 1 112.50

A 174.76

B 360.0

E 48.55%

F 0

G 0.00%

B C

OHB Fitter-


Autoconer,Chee

sewinding,TFO

Net Available man-mins per shift(480*80% = 360 mins)


Stop the OHTC,Clean the waste box of

OHTC,remove the dust accumulated, clean the filter

with emery sheet, Clean the outer surface of OHTCusing cloth,brush,Check the suction of OHTC,clean

Festo

Remarks:



with emery sheet, Clean the outer surface of OHTC

using cloth,brush,Check the suction of OHTC,clean

the fly in the rail, check whole the waste discharge

system

WLS No: BSM/W/11


BTMShifts A

Jacobi






system

Autoconer

Cheesewinding/Rewinding

G

-

Mechanical

Overhaul the OHTC machine(once in two month)


Total Workload per shift ( in man mins)







system

_______________________________________________________________________________






Department

Section


Designation Proposed Manpower - - 0Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(mins)

No of

machin

es

Total

Workloa

d (mins)

B C

OHB Fitter-


Autoconer,Chee

sewinding,TFO

WLS No: BSM/W/11


BTMShifts A G

-

Mechanical

No of

machines Area

4 TFO

3 Unit-3

15 R/F1 Winding

Cheese Winding - 5 nos

Ring frame(unit-2) - 5 nos


1

Festo

Unit-3

R/F

Instead of providing one separate personnel for OHTC maintenance with 51.06% utilisation, it is

recommended that the activity could be performed by the respective section's maintenance gang. It

increases the respective gang utilisation and reduces the separate manpower required.

Total OHTC in BTM

Savio- 8 Nos

TFO (unit1 &2) - 8 nos

No of

machines

TFO


TFO(unit-3) - 7 Nos

Leewa

Jacobi

Area

4

1

5

_______________________________________________________________________________








Work Centre TFO - - - 1 F+ 1 H

PF PH PF PH

1 Gear Oil Change (VJ - 38 M/cs) 1/12 1 1 1.00 38 3.17 3.17

a) Stop the machine

b) Open the cover of gear box

c) Remove old oil

d) Clean all the gears

e) Check all the gears

f) Put fresh oil

g) Check the oil pump

d) Close the cover

f) stop the machine

g) Stop motion, Dropper

2 Gear Oil Change(PRN-10 M/c) 1/6 1 1 1.00 10 1.67 1.67

a) Stop the machine

b) Open the cover of gear box

c) Remove old oil

d) Clean all the gears

e) Check all the gears

f) Put fresh oil

g) Check the oil pump


Time(in Hours)

Proposed

Manpower


CrewCategory

WLS No:BSM/W/12


Shifts

Present

Manpower

S.No Frequency/

Month

No of

Machine

_________________________________________________________________________________________________ ________________________










PF PH PF PH


Time(in Hours)

Proposed

Manpower


CrewCategory

WLS No:BSM/W/12


Shifts

Present

Manpower

S.No Frequency/

Month

No of

Machine

d) Close the cover

f) stop the machine

3 Stop motion, dropper setting, Adopter Greasing

Setting1/6 1 1 1.81 48 14.44 14.44


b) Stop the machine

c) Take out the all adaptor

d) Clean all the adoptor&Cradle

e) Apply grease in cradle

f) Pur adaptor in cradle


d) Down all the dropper wire

f) Check the stop motion and reset stop motion


5 T.R. & P.T.R. Greasing 1/6 1 1 0.76 48 6.06 6.06


b) Stop the machine

c) Clean burnt grease from TR&PTR

_________________________________________________________________________________________________ ________________________










PF PH PF PH


Time(in Hours)

Proposed

Manpower


CrewCategory

WLS No:BSM/W/12


Shifts

Present

Manpower

S.No Frequency/

Month

No of

Machine

d) Open all nipple

e) Apply fresh grease from pump in TR&PTR

f) Tight the nipple


h) Clean all the excess grease

i) Handover the machine to production

6 Tin Roll Bearing Greasing(Only VJ-38 M/cs) 1/6 1 1 1.44 38 9.15 9.15

a) Stop the machine

b) Open the nipple

c) Apply grease

d) Tight the nipple

e) Start the machine

f) Clean all the excess grease

g) Handover the machine to production

7 Belt Guide roller Greasing(Only PRN-10 M/cs) 1/6 1 1 2.17 10 3.61 3.61

a) Stop the machine

b) Allow to run out the material

c) Remove the nipple from guide roller

_________________________________________________________________________________________________ ________________________










PF PH PF PH


Time(in Hours)

Proposed

Manpower


CrewCategory

WLS No:BSM/W/12


Shifts

Present

Manpower

S.No Frequency/

Month

No of

Machine

d) Check all the duide pulley if faulty then replace

e) Apply grease in all guide rolls, Tension pulley and

main pulley

f) Start the machine

8 Thread guide Setting, Cradle, Drum Setting 1/6 1 1 2.17 48 17.33 17.33


b) Stop the machine

c) Insert cone in cradle

d) Down the cradle on drum

e) Set the cradle and drum

f) Set the thread guide in middle portion of drum

g) Check the setting through yarn from trum to thread

guide


9 Jokey Pulley Greasing 1/12 1 1 1.00 48 4.00 4.00

a) Stop the machine

b) Apply grease in j.Pulley through pump and nipple

c) Start the machine

_________________________________________________________________________________________________ ________________________










PF PH PF PH


Time(in Hours)

Proposed

Manpower


CrewCategory

WLS No:BSM/W/12


Shifts

Present

Manpower

S.No Frequency/

Month

No of

Machine

10 Gear Overhauling 1/12 1 1 2.89 48 11.55 11.55

a) Stop the machine

b) Take out all the gears and bearing and stud

c) Clean all the gears stud and bearings

d) Check and replace all the defective gears stud and

bearing

e) Clean all the gear end

f) Put grease in stud

g) Fix all the gears

d) Apply gears on all gears

f) Start the machine and check for abnormal sound

g) Close the cover

h) Handover to production

11 Pig tail Setting 1/12 1 1 2.89 48 11.55 11.55

a) Stop the machine

b) Remove the material from Pigtail

c) Tie dori from off end to gear end

d) Clean the pig tail

_________________________________________________________________________________________________ ________________________










PF PH PF PH


Time(in Hours)

Proposed

Manpower


CrewCategory

WLS No:BSM/W/12


Shifts

Present

Manpower

S.No Frequency/

Month

No of

Machine

e) Set the Pigtail

f) Cheek &set the alignment from spindle to Pigtail

g) Remove the line dori

d) Start the machine

12 Attend Developmental machine 1 1 1 6 1 6.00 6.00

13 Attend Idle Spindle at the shift starting 26 1 0 2 1 52.00 0.00

14 Count Change in TFO (during General Shift) 1 1 1 0.5 1 0.50 0.50

15

Repair & rectify the parts removed from the

machine (in the room)1 1 1 6 1 6.00 6.00

A 147.03 95.03

B 166.40 166.40

C 88.4% 57.1%

D 1 1

E 88.4% 57.1%




Proposed Manpower


Total Number of machine: VJ-38 Nos, PRN-10 Nos

_________________________________________________________________________________________________ ________________________







4.0 B BTM SPINNING - ELECTRICAL

MAINTENANCE

________________________________________________________________________________





_________________________________________________________________________________________________________________________ Manpower Assessment Study Report of Grasim Bhiwani Textiles Ltd,Bhiwani

4.0 B4.1


1 Shift maintenance Shift Electrician 1 1 1 - 3 1 1 1 - 3

2General shift maintenance Gen. Electrician - - - 2 2 - - - 2 2

3 Shift maintenance - Electronics Electronic 1 1 1 - 3 1 1 1 - 3

4 Humidity plant Humidity Attendan 1 1 1 - 3 1 1 1 - 3

5 General shift maintenance Gen.Fitter - - - 3 3 - - - 3 3

6 General shift maintenance Helper - - - 1 1 - - - 1 1

7 Motor maintenance Motor Winder - - - 1 1 - - - 1 1

8 Over head blower maintenance OHB Fitter - - - 1 1 - - - 1 1

9 Gutter cleaning Gutter Cleaner - - - 3 3 - - - 3 3

10 Motor maintenance Motor Fitter - - - 1 1 - - - 1 1

3 3 3 12 21 3 3 3 12 21

BTM SPINNING - ELECTRICAL MAINTENANCEManpower Deployment


Remarks

Total

_______________________________________________________________________________________________ ____________________







4.0 B

4.2

1

BTM SPINNING - ELECTRICAL MAINTENANCE


No changes proposed.

________________________________________________________________________________






5 A FIBER DYEING

________________________________________________________________________________________






5.0 A

5.2

5.2.1I

II

III

Deploy three personnel per shift for radio frequency drier instead of present four

personnel per shift.

The utilisation of individual batch of operator are less, mainly because of HTHP

dyeing cycle time constraint.

Hence, it is recommended to form a pool of workers to minimize the forced idleness.

Based on the workload analysis, It is recommended to deploy five personnel for

above machines and their combined utilisation would be 82.66%

The present manpower deployment in the Stemping and Hydroextractor are as

follows:

Manual Stemping & Hydro (120 Kg & 280 Kg ) - 3 person/shift

HTHP Dyeing Machine Operator:

Radio Frequency Drier

Machine Stemping (700 kg) - 2 person/shift

Machine Stemping (320 kg) - 1 person/shift

FIBER DYEING


Proposed Changes

In view of low utilisation of HTHP dyeing machine operator, it is recommended to

provide a group of three people for five(HTHP-1,2,3 4&5) machines. They relieve

each other for lunch, tea and personal needs.

Stemping & Hydroextractor:

________________________________________________________________________________________






5.0 A

5.3

S.No Area of work1 HTHP Dyeing M/c -1

2 HTHP Dyeing M/c -2,3 & 4

3 25 Kg Sample HTHP Dyeing M/c

5

4Stemping & Hydroextractor M/C-

120 & 280 Kg

5 Stemping & Hydroextractor M/C-

320 Kg

6 Stemping & Hydroextractor M/C-

700 Kg

7 Propsoed Workload for Stemping

&hydroextractor

8 Radio Frequency dryer/Steam

Dryer -Polyester Batch

9 Radio Frequency dryer/Steam

Dryer -Viscose Batch

10 Store Man

11 Yarn Preperation

12 SSM Winding M/c

13 Floor Cleaner

14 Sap Data Entry operator

15 Maintenance FD/MAINT/01

FD/W/03

FD/W/05

FD/W/12

FD/W/13

FD/W/11

FD/W/08

FD/W/09

FIBER DYEING


WLS NumberFD/W/01

FD/W/10

FD/W/04

FD/W/06

FD/W/07

FD/W/08 A

FD/W/02

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 5 1.50 7.50

21 5 2.52 12.60

31 5 4.00 20.00

4 1 5 0.20 1.00

51 5 2.66 13.30

61 5 1.76 8.80

7 1 5 1.38 6.90

8 1 5 1.42 7.10

91 5 2.12 10.60

10 1 5 0.18 0.90

11 1 5 1.95 9.76

12 1 5 0.58 2.90

131 5 3.42 17.10

14 1 5 3.00 15.00

A 133.46

B 12C 149.47

D 450

E 33.22%

F 1

G 33.22%

WLS No: FD/W/01


Fibre DyeingShifts A B C G

HTHP- M/C 1

Take color & chemical according to drug slip from the

store

Mix colors in the addition tank, manually open/close the

water lines and mix

Transfer to main vessel

HTHP Machine-100 Kg

Operator


Check Drugs Slips and intructutions of supervisor before

start new lot

Take fresh water and mix liquid chemicals and transfer to

main vessel

Take fresh water and again mix chemical and transfer to

main vessel

Collect sample to check pH, show to supervisor

Fill the log book

Drain water from the main vessel, Mix chemicals in main

vessel and switch off once water level reaches



Drain the solution from main vessel, open the lid

Take crane, lift the carrier and keep it on the ground

Write in the log book

Drain water from sample port, collect sample fibre from

port, dry the fibre and make sample

Show to supervisor for approval





Remarks:

As this machine is semi automatic and two level system, the activities required operators

involvement is more than the remaining ( HTHP-2,3 & 4) machines.

________________________________________________________________________________________






Department

Section

Work CentrePresent

Manpower

3 3 -

DesignationProposed

Manpower1 1 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(mins)

11 1 0.84 12 0.94

2 1 1 0.87 12 0.97

31 1 0.22 12 0.25

41 1 7.08 12 7.93

51 1 0.94 12 1.05

6 1 1 0.67 12 0.75

71 1 0.80 12 0.90

8 1 1 1.20 12 1.34

91 1 1.37 12 1.53

10

1 1 2.33 12 2.61

11 1 1 3.00 12 3.36

12 1 5 2.00 12 11.20

131 1 1.50 12 1.68

141 1 2.52 12 2.82

WLS No: FD/W/02


Fibre DyeingShifts A


HTHP-2,3 & 4B

Remove the hook, close the lid of the main vessel

HTHP operator attends more than one machine(in the proposed method). As the operator is

responsible for the operation of more than one machine,if two machines requires operators

attention simultaneously,one of them must wait until he completes his work on the other.This time loss representing waiting time due to overlapping of machine stoppage is called

"Interference loss".

Thomas O Connor table is used for estimating this interference loss in the textile mills.

C G

Lift the carrier from ground and keep inside the

main vessel

Collect sample fibre from sample port(at the end

holding time-10 mins prior) , dry and make

sample

HTHP Machine

Operator

Check Drugs Slips and intructutions of supervisor

before start new lot

Add chemicals and colors based on theprogramme in the main vessel & wait to mix

properly and maintain the water level

Note down the details in the log book

Take color & chemical according to drug slip

from the store

Handover to supervisor for checking/verification

3

1

Open the HTHP vessel, put hook, take crane and

join the hook(carrier) with the crane

Lift the carrier and place it on the ground

Note down the parameters in the logbook

Collect solution from sample port for pH

checking, Show to supervisor

Remove the crane joint, Put on the loaded carrier

Open the stock tank water and close and operation

in the panel board

________________________________________________________________________________________






Department

Section

Work CentrePresent

Manpower

3 3 -

DesignationProposed

Manpower1 1 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Allow

ance

(%)

Total

Time

(mins)

WLS No: FD/W/02




HTHP-2,3 & 4B C G

HTHP Machine

Operator

3

1

151 1 2.20 12 2.46

A 39.80B 9

C 358.24

D 1440

E 24.88%

F 1

G 65.34%



Remarks:

Proposed Utilisation(%) From O'Conner Table

Total Cycle time - 147+11.42 = 158.42 mins

The lowest cycle time shade is selected, because the requirement operator involvement is more in

the smallest cycle. When one operator handles more than one machine, then the activities become

random in nature and interference comes into the picture. Hence , we have used the interference

table to arrive the number of machine one operator can handle.

Light & Medium Shade -Polyester batch ( Standard cycle time collected from company)


Activity sequence depends only on the Shade of batch is processing whether

Light,Medium,dark,heavy dark and special shade.

The activities performed by the operators(HTHP-2,3&4) are same in nature.

No of batches( 3 batch per operator*3 operators=9 batch per shift)

t2 (Average time in min taken by operator per mrh to perform non-deferrable work while m/c is

running) = 27.01 mins(Sum of S.No 8 to 15)

From Thomas O'Conner table ,

Remove the fibre of last batch from sample port

and put new batch fibre in the port

Net Available man-mins(480*3 =1440 mins)

Machine Efficiency, E = 80.44 %

Operator workload,B, as a fraction of a clock hour = 0.6534

Machine Cycle time - 147 mins

Loading/unloading Time - 11.42 mins

t (Average time in min taken by operator per mrh to perform non-deferrable work with the machine

stopped) = 12.79 mins (Sum of S.No 1 to 7)


________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 2 1.05 2.10

21 2 1.62 3.24

3

1 2 2.17 4.34

4 1 2 1.23 2.46

5 1 2 1.37 2.74

61 2 1.23 2.46

7 1 2 1.10 2.20

81 2 2.55 5.10

9 1 2 3.14 6.28

10 1 2 0.26 0.52

11 1 2 0.40 0.80

12 1 2 1.47 2.94

13 1 2 0.57 1.14

141 2 2.02 4.05

151 2 0.84 1.68

161 2 5.46 10.92

17 1 2 1.32 2.64

18 1 2 0.41 0.82

19 1 2 1.01 2.02

201 2 0.50 1.00

211 2 3.00 6.00

22 1 2 1.05 2.10

WLS No: FD/W/03



HTHP - No 5

Take crane,Lift the carrier from the vessel and keep it on

the ground

Come down,keep the empty chemcial can,discuss with

the supervisor regrding the next batch,get programme

slip

Take small trolley,move near to the carrier

HTHP Machine-25 Kg

Operator


Open the sample port cover,main vessel cover and switch

on

Remove the lid cover,open the lid cloth

Remove the bale from the carrier and keep it on the

trolley

Move near the hydroextractor-1

Place the plate inside the hydroextractor and lift the bale

and put it on the hydroextractor

Push the bales evenly and close with the cloth and closethe hydro with the lid

Close the locks of the hydroextractor

Keep the lid in place and trolley aside

Take empty bag,weigh 25 kg of fibre

Move the fibre near to the carrier

Take the cloth from the table and spread around the

carrier

Take the carrier plate and keep inside the carrier& wet

the clothLoad the bale inside the carrier and spray the water &

press manually

Close the cloth & tie

Keep the lid tightener and tight

Throw bale cover outside and clean the area

Take the chemicals and colors from stores,come near to

the machine

Take the water in main vessel by switch on/off(open

valves)

Mix chemcials in the main vessel

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: FD/W/03



HTHP - No 5

HTHP Machine-25 Kg

Operator


231 2 1.41 2.82

241 2 0.56 1.12

25 1 2 1.02 2.04

26 1 2 1.44 2.88

27 1 2 0.20 0.40

281 2 0.40 0.80

29 1 2 2.00 4.00

3072.00

311 2 3.25 6.50

32

1 2 2.40 4.80

33 1 2 4.00 8.00

34 2.00

351 2 2.04 4.08

36 1 2 5.06 10.12

37 1 2 2.32 4.64

38 1 2 2.30 4.60

39 1 2 5.00 10.00

40 1 2 5.00 10.00

41 1 2 0.48 0.96

42 1 2 1.00 2.00

431 2 1.13 2.26

A 149.57

B 13

C 169.01

D 450

E 37.56%F 1

G 37.56%

Mix the acid solution to the main vessel

Unoccupied time(waiting for holding time to complete)

Take the water in the additional tank manually operating

and mix the acetic acid



Waiting for the mixing to be proper and operations in the

panel board

Lift the loaded carrier using crane from the ground and

keep inside the main vessel


After holding time,drain the finish solution and close the

valve&operation in control panel

Transfer the solution to main vessel

Put the finsih solution in additional tank

Fill the log book

Hot wash drain

Cold wash drain




Drain hot water

Remove steam,collect sample from sample port and

close

Dry the sample by keeping on the top of HTHp main

vessel & prepare sample

Remove the OH crane,tighten the lid

Increase the water level by operating valves manually

Close the lid of the main vessel

Open & close the valve of the port and maintain water

level

Fill the log book

Machine Cycle time(For Light & medium shade)10

mins prior to the end of holding time

Show the sample to the supervisor and discussion

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: FD/W/03



HTHP - No 5

HTHP Machine-25 Kg

Operator


The machine cycle time(heating,cooling) where the physical involvement of the worker is not

considered.

The HTHP-5 (25 kg smaple machine) will be operational,only when the programme is scheduled by

PPC.

The above incumbent performs the above activity when there is a scheduled planning. The

remaining time,the incumbent acts as a reliver for HTHP-1,23, & 4 operators.

Remarks:

________________________________________________________________________________________






Department

Section

Work Centr Present Manpower 3 3 3 -


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

A

1

2 5 3.00 30.00

21 5 1.00 5.00

31 5 3.72 18.60

4 1 5 2.28 11.40

52 5 6.00 60.00

6 2 5 2.75 27.50

7 2 5 3.05 30.50

8 2 5 4.30 43.00

9 1 5 5.00 25.00

B

11 10 2.68 26.80

2 1 10 2.14 21.40

31 10 3.80 38.00

4

1 0.00

5 1 10 1.52 15.20

61 10 2.00 20.00

72 10 2.00 40.00

81 10 3.00 30.00

9 1 1 2.10 2.10

10 2 1 11.00 22.00

11 1 1 4.00 4.00

WLS NO: FD/W/04



Hydroextractor & Stemping

Fibre denier and bale number write down into program

register in Front of lot no.

Stemping 120 Kg& 280 Kg

Clean the filter cloth and set into dyeing carrier as per shade

color (dark or light)

Place the bottom Carrier plate inside the carrier

Helper


Stemping - 120 Kg Batch - Manual Stemping

See the Noted prog. from prog. register and take instructions

from supervisor to fill fibre in dyeing carrier ,Bring the fibre

and Weight according to program (check denier and bale

number)

Fill the fiber after hand open as per the programme( 1 person

manually stemping) & wet fibre properly during filling

After half loading of bale, put a plate into carrier

Fill the 2nd half of bale into the carrier

After bale loading, close the lid and filter cloth tightly

After complete the filling work clean batching area andpreparation for next lot

Hydro extractor

After receiving the dyed fibre carrier- open the lid ,Change

the hanging from old one to new carrier

Open the filter cloth

Take out the first plate of fibre cake and fill into hydro

extractor, close the lid and lock of hydro

Run the hydro according to type of fibre and instructions of

supervisor ( Machine Cycle time)( Parallel operator performsother activity)

Bring the empty trolley

After completetion of hydro (stop the M/C) open lock , lid

and take out the extracted fibre cake

Move the trolley with fibre & paste the slip of information

about lot and keep aside

Clean hydro extracting area with water and broom stick

Clean the Carrier plates with chemical cloth and water

Clean the carrier drum with chemical dipped cloth and water

Clean the carrier lid with chemical dipped cloth and water

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS NO: FD/W/04





Helper


12 1 1 10.00 10.00

C

1

2 3 4.81 28.86

2 1 3 1.00 3.00

31 3 4.41 13.23

4 1 3 2.28 6.84

52 3 7.21 43.26

6 2 3 1.73 10.38

72 3 5.37 32.22

8 2 3 3.63 21.75

91 3 10.00 30.00

D

11 6 2.68 16.08

2 1 6 2.14 12.84

31 6 4.00 24.00

4

1 6

5 1 6 1.52 9.12

61 6 4.03 24.18

72 6 2.00 24.00

8 1 6 3.00 18.009 1 1 2.10 2.10

10 2 1 11.00 22.00

Dry the cloth by putting in the Hydroextractor

Stemping -280 Kg Batch - Manual Stemping

See the Noted prog. from prog. register and take instructions

from supervisor to fill fibre in dyeing carrier ,Bring the fibre

and Weight according to program (check denier and bale

number)

Fibre denier and bale number write down into programregister in Front of lot no.




Fill the fiber after hand open as per the programme & wet

fibre properly during filling (Manual Stemping)

After loading half carrier, put a plate into carrier


fibre properly during filling (Manual Stemping)After full loading, close the lid and filter cloth tightly.

After complete the filling work clean batching area and

prepration for next lot

Hydro extractor

After receiving the dyed fibre carrier open the lid, Change the

hanging from old one to new carrier



extractor, close the lid and lock of hydroRun the hydro according to type of fibre and instructions of

supervisor ( Machine Cycle time)( Parallel operator performs

other activity)


After completetion of hydro (stop the M/C) open lock and lid

and take out the extracted fibre cake into trolley



Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water

Clean the carrier drum with chemical dipped cloth and water ________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS NO: FD/W/04





Helper


11 1 1 4.00 4.00

12 1 1 10.00 10.00

A 836.36

B 14

C 953.45

D 450E 70.63%

Dry the cloth by putting in the Hydroextractor


Remarks:





________________________________________________________________________________________






Department

Section


Designation Proposed Manpower - - - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

A

1

2 3 4.81 28.86

2

1 3 1.00 3.00

31 3 4.41 13.23

41 3 2.28 6.84

51 3 5.13 15.39

6 1 3 2.32 6.96

7

1 3 6.34 19.02

8 1 3 3.63 10.88

91 3 10.00 30.00

B 0.00

1

1 6 2.14 12.84

2 1 6 2.14 12.84

31 6 3.56 21.36

4

5 1 6 1.52 9.12

61 6 4.03 24.18

7

2 6 2.00 24.00

8 1 6 3.00 18.00


Move the trolley with fibre & paste the slip of

information about lot and keep aside


Run the hydro according to type of fibre and instructions

of supervisor ( Machine Cycle time)( Paralley operator

performs other activity)

After completetion of hydro (stop the M/C) open lock and

lid and take out the extracted fibre cake into trolley



extractor,close the lid and lock of hydro

Place the bottom Carrier plate inside the carrier,Turn the

stemping machine & start


fibre properly during filling (Machine Stemping)




After full loading, close the lid and filter cloth tightly.



Stemping 320 kg

Hydroextractor&Stempi

Hydro extractor

After receiving the dyed fibre carrier open the lid and

filter cloth,Change the hanging from old one to new

carrier

Helper


See the Noted prog. from prog. register and take

instructions from supervisor to fill fibre in dyeing carrier

,Bring the fibre and Weight according to program (check

denier and bale number)



Clean the filter cloth and set into dyeing carrier as per

shade color (dark or light)

Stemping - 320 Kg Batch - Mechanical Stemping

WLS No: FD/W/05



________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

Stemping 320 kg

Hydroextractor&Stempi

Helper


WLS No: FD/W/05



9 1 1 2.10 2.10

10 2 1 11.00 22.00

11 1 1 4.00 4.00

12 1 1 10.00 10.00

A 160.44

B 13

C 181.30

D 450

E 40.29%

Remarks:

Clean the Carrier plates with chemcial cloth and water






Clean the carrier lid with chemcial dipped cloth and water

Clean the carrier drum with chemcial dipped cloth and

Dry the cloth by putting in the hydroextractor

________________________________________________________________________________________






Department

Section


Designation Proposed Manpower - - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

A

1

2 3 5.84 35.01

22 3 1.00 6.00

32 3 7.00 42.00

42 3 4.18 25.08

52 3 7.50 45.00

6 2 3 2.01 12.06

72 3 10.15 60.90

8 2 3 3.01 18.06

92 3 5.00 30.00

B 0.00

12 6 2.68 32.16

2 1 6 2.14 12.84

31 6 3.56 21.36

4

6 0.00

5 1 6 1.52 9.12

6

2 6 5.15 61.80

72 6 2.00 24.00

8 1 6 3.00 18.00

9 1 1 2.10 2.10





fibre properly during filling (Machine Stemping)After full loading, close the lid and filter cloth tightly.



Move the trolley with fibre & paste the slip of

information about lot and keep aside

Run the hydro according to type of fibre and instructions

of supervisor ( Machine Cycle time)( Parallel operator







register in Front of lot no.Clean the filter cloth and set into dyeing carrier as per

shade color (dark or light)




lid and take out the extracted fibre cake & put in the

trolley

WLS No: FD/W/06


Fibre DyeingShifts A B C

Hydroextractor&StempiG

Helper





Stemping 700Kg

Place the bottom Carrier plate inside the carrier, Turn the


Hydro extractor

After receiving the dyed fibre carrier open the lid ,Change




________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: FD/W/06



Hydroextractor&StempiG

Helper


Stemping 700Kg

102 1 15.00 30.00

11 1 1 5.00 5.00

12 1 1 10.00 10.00

A 226.38

B 13C 255.81

D 450

E 28.42%





Remarks:



Clean the carrier drum with chemical dipped cloth and

water

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

A

1

2 5 3.00 30.00

2 1 5 1.00 5.00

31 5 3.72 18.60

4 1 5 2.28 11.40

5

2 5 6.00 60.00

6 2 5 2.75 27.50

7 2 5 3.05 30.508 2 5 4.30 43.00

91 5 5.00 25.00

B

11 10 2.68 26.80

2 1 10 2.14 21.40

31 10 3.80 38.00

4

1 0.00

5 1 10 1.52 15.20

61 10 2.00 20.00

72 10 2.00 40.00

8 1 10 3.00 30.00

9 1 1 2.10 2.10


supervisor ( Machine Cycle time)( Parallel operator





Fill the fiber after hand open as per the programme( 1

person manually stemping) & wet fibre properly during

filling

After half loading of bale, put a plate into carrier

Fill the 2nd half of bale into the carrierAfter bale loading, close the lid and filter cloth tightly




Stemping - 120 Kg Batch - Manual Stemping

B C

After completetion of hydro (stop the M/C) open lock , lid

and take out the extracted fibre cake





WLS NO: FD/W/07


Fibre DyeingShifts A G


FD





Fibre denier and bale number write down into programregister in Front of lot no.

Hydro extractor

After receiving the dyed fibre carrier- open the lid ,Change


Hydroextractor &

Stemping

Helper




________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

B C

WLS NO: FD/W/07



FDHydroextractor &

Stemping

Helper


102 1 11.00 22.00

11 1 1 4.00 4.00

12 1 1 10.00 10.00

C

1

2 3 4.81 28.86

21 3 1.00 3.00

31 3 4.41 13.23

4 1 3 2.28 6.84

5 2 3 7.21 43.26

6 2 3 1.73 10.38

72 3 5.37 32.22

8 2 3 3.63 21.75

91 3 10.00 30.00

D

1 1 6 2.68 16.08

2 1 6 2.14 12.84

31 6 4.00 24.00

4

1 6

5 1 6 1.52 9.12

6 1 6 4.03 24.18


fibre properly during filling (Manual Stemping)







After completetion of hydro (stop the M/C) open lock andlid and take out the extracted fibre cake into trolley




Fill the fiber after hand open as per the programme & wetfibre properly during filling (Manual Stemping)






Hydro extractor

After receiving the dyed fibre carrier open the lid, Changethe hanging from old one to new carrier




See the Noted prog. from prog. register and takeinstructions from supervisor to fill fibre in dyeing carrier



Stemping -280 Kg Batch - Manual Stemping


water


________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

B C

WLS NO: FD/W/07



FDHydroextractor &

Stemping

Helper


72 6 2.00 24.00

8 1 6 3.00 18.00

9 1 1 2.10 2.10

102 1 11.00 22.00

11 1 1 4.00 4.00

12 1 1 10.00 10.00

E

1

2 3 4.81 28.86

21 3 1.00 3.00

31 3 4.41 13.23

41 3 2.28 6.84

51 3 5.13 15.39

6 1 3 2.32 6.96

71 3 6.34 19.02

8 1 3 3.63 10.88

91 3 10.00 30.00

F

11 6 2.14 12.84

2 1 6 2.14 12.84

3

1 6 3.56 21.36




register in Front of lot no.Clean the filter cloth and set into dyeing carrier as per shade








fibre properly during filling (Machine Stemping)After full loading, close the lid and filter cloth tightly.



Hydro extractor


waterClean the carrier lid with chemical dipped cloth and water



After receiving the dyed fibre carrier open the lid and filter

cloth, Change the hanging from old one to new carrier










________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

B C

WLS NO: FD/W/07



FDHydroextractor &

Stemping

Helper


4

5 1 6 1.52 9.12

61 6 4.03 24.18

72 6 2.00 24.00

81 6 3.00 18.00

9 1 1 2.10 2.10

102 1 11.00 22.00

11 1 1 4.00 4.00

12 1 1 10.00 10.00

G 0.00

1

2 3 5.84 35.01

22 3 1.00 6.00

3

2 3 7.00 42.00

42 3 4.18 25.08

52 3 7.50 45.00

6 2 3 2.01 12.06

72 3 10.15 60.90

8 2 3 3.01 18.06

92 3 5.00 30.00


























lid and take out the extracted fibre cake into trolley






water


________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

B C

WLS NO: FD/W/07



FDHydroextractor &

Stemping

Helper


H 0.00

12 6 2.68 32.16

2 1 6 2.14 12.84

31 6 3.56 21.36

4

6 0.00

5 1 6 1.52 9.12

62 6 5.15 61.80

72 6 2.00 24.00

8 1 6 3.00 18.009 1 1 2.10 2.10

102 1 15.00 30.00

11 1 1 5.00 5.00

12 1 1 10.00 10.00

A 1631.47

B 14

C 1859.87D 450

E 68.88%

F 5

G 82.66%








lid and take out the extracted fibre cake & put in the trolley



Clean hydro extracting area with water and broom stick Clean the Carrier plates with chemical cloth and water

After receiving the dyed fibre carrier open the lid ,Change






water

Hydro extractor


Remarks:






________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

A

1

2 15 3.00 90.00

2 2 15 1.10 33.00

3 2 15 0.60 18.004

1 15 1.00 15.00

5 1 4400 0.055 242.00

6 198.00

7 1 15 0.91 13.70

81 4400 0.06 242.00

91 180 0.62 111.60

101 15 3.00 45.00

A 810.30

B 14

C 1121.74

D 450

E 62.32%

F 3

G 83.09%

Helper


For polyester batch, the materials are directly fed into R/F drier belt conveyor.

Waiting between the loading(Due to machine speed limit)

For Polyester Fibre in R/F Drier


Total Workload ( in man minutes ) ( 923.74+198 = 1121.74 mins)


Take trolley, weigh on weighing balance and write down

on slips gross weight and trolley weight as per priority of

drying based on fibre type co-ordination with supervisor

Move the trolley from weighing machine to R/F drier area

WLS No: FD/W/08



R/F Drier-Polyester

Batch

B C GDrier

Note: As per discussion with the management personnel, only R/F drier going to be used. So they

workload sheet prepared only for the R/F drier operation.


Remarks:

Average weight of batch/ trolley - 300 Kg

Target per operator /shift - 1100 Kg * 4 operator = 4400/300 = 15 trolleys (Polyester batch)

Load the Fibre(S.No 5 ) is the actual workload of the operator. Because of belt speed , the operator

has to wait in between loading activity for few seconds/minutes which is called as unavoidable

delay. But operator presence is required. So, the total cycle time = 242 +198 =440 mins/shift. But

Relaxation allowance only provided to activity.

R/F drier capacity(Polyester batch) - 600 kg/hr.


Move the trolley near the R/F drier inlet point

Tie the bag with information card/tag as per lot qty

( 25 kg/ bag = 4400/25=180 Bags)

Move the empty trolley back to respective place



Take instructions from supervisor to dry the lot and set

the speed of conveyer belt according to moisture

Fill fiber in bags after drying (Take the bag, fill &keep

aside)

Load the fibre from trolley to belt conveyor of drier ( kg)

Clean the spillage area around the machine after one

batch dried.

________________________________________________________________________________________






Department

Section

Work Centr Present Manpower 3* 3 3 -

Designation Proposed Manpower 2* 2 2 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

12 4 6.10 48.80

2 1 4 0.07 0.28

31 4 0.07 0.28

41 4 1.95 7.80

51 4 1.00 4.00

6 1 1100 0.070 77.00

7 1 363.00

8 1 4 0.91 3.65

91 1100 0.06 60.50

10 1 44 0.62 27.28

111 4 3.00 12.00

A 547.43

B 14

C 624.07

D 450

E 46.23%

F 2

G 69.34%

Average weight of batch/ trolley - 300 Kg,R/F drier capacity(Viscose batch) - 150 kg/hr.

Target per operate/shift - 1100 Kg for 3 operators = 1100/300 = 4 trolleys (Viscose batch)

Waiting between the loading(Due to machine speed

Move the empty trolley back to respective place


( 25 kg/ bag = 4400/25=180 Bags)


For Viscose batch, the fibre is first passed through Viscose opener and then fed into belt conveyor.

The moisture content for the viscose batch is in the range of 60-70%

Load the Fibre(S.No 6 ) is the actual workload of the operator. Because of belt speed , the operator

has to wait in between loading activity for few seconds/minutes which is called as unavoidable

delay. But operator presence is required. So, the total cycle time = 77+363=440 mins/shift.







Discuss with the shift incharge, weigh the trolley to be

dried and move to R/F drier area

Collect the opened fibre from viscose opener outlet and

keep aside(load it on the R/F drier belt conveyor)

Take instructions from supervisor to dry the lot and set

the speed of conveyer belt according to moisture

Load the fibre from viscose opener outlet to belt

Clean the spillage around the trolley and move the empty

trolley back to Weigh machine area

Viscose Fibre in R/F Drier


WLS No: FD/W/08 A



Drier

* There is no separate manpower for Viscose batch R/F drier. The above workload sheet is

prepared to show the utilisation of drying operator ,when they perform viscose batch drying.

Viscose Opener

B C G


Clean the spillage area around the machine after one

batch is over

Open the Viscose fibre and put on the viscose opener

R/F Drier-Viscose Batch

Helper

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 5.00 5.00

2 1 17 3.00 51.00

3 1 17 2.50 42.50

4 1 17 1.00 17.00

5 1 1 3.00 3.00

6

a 1 2 1.51 3.02

b 1 2 3.18 6.36

c 1 2 0.97 1.94

d 1 2 2.73 5.46

e 1 2 1.06 2.12

7 1 1/5 5.00 1.00

8 1 1 30.00 30.00

9 1 1 20.00 20.00

10 1 1/30 420.00 14.00

A 202.40

B 12

C 226.69

D 450

E 50.38%

F 1

G 50.38%

Colour&Chemical Store

Helper


Check stock availability in stock register

WLS No: FD/W/09



Store room

Physical stock verification

Take the empty trolley to store from fibre dyeing

Discussion with the storepersonnel,Load the

materials(Cans,bags,etc) in the trolley as per slip

Tie the thread around the trolley after loading

unload the materials from trolley to storeroom

Weigh the chemicals as per drug slip given by

supervisor(considered 3 chemicals per batch)

Take samples for washing fastness checking to SPH lab

& bring testing report ( Only in A or B Shift)

End of shift note down the color & chemical consumed

in their shift in the register

After completion of work, clean the Colour & Chemical

rooms. Clean the cans surface and chemical spillage

around the cans

Weigh the colors as per drug slip given by

supervisor(considered 3 colours per batch)

After weighing color less that particular dyes and

chemicals in register and upto date the stock

Bring the color & Chemical from store as instructed in

issue slip(Only in A or B shift) **






Remarks:

if any dyes have change the lot no. inform to supervisor

for lab testing and handover samples to the lab



Move the trolley back to fibre dyeing section store

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

Colour&Chemical Store

Helper


WLS No: FD/W/09



Store room

Total - 17 batch/shift

** Shifting of colurs & chemicals from stores, floor cleaner in the fibre dyeing dept assist the store

personnel. So crew size for shifting activity is two. Same practice is recommended.

In view of low utilisation of storeman in B shift and C shift (Only 32.32% Activities from 1-

5),personnel is being recommended keeping in mind the follwing: As the operator has to wait every

time for the supervisor before weighinh chemicals and colours,which is impratical. As the

supervisor is already engaged in other activity. The weighment operational is critical and store

personnel is fully responsible.

HTHP 2,3,4 & 5 - 12 batch/shift

HTHP 1- 5 batch /Shift

Number of Batch

________________________________________________________________________________________






Department

Section

Work Centre Present Manpower 1 1 - -

Designation Proposed Manpower 1 1 - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 1.07 1.07

2 1 1 5.00 5.00

3 1 1 10.00 10.00

4 1 1 2.83 2.83

51 21 1.00 21.00

1 21 0.08 1.68

1 21 0.42 8.82

6

1 21 2.85 59.85

7

1 21 2.91 61.11

1 1 1.67 1.67

1 21 0.60 12.60

1 1 9.50 9.50

1 21 0.56 11.76

1 1 1.77 1.778

1 21 1.49 31.29

9

1 21 0.73 15.39

1 1 0.30 0.30

1 1 6.44 6.44

WLS No: FD/W/10



FD

Pilot Plant

Operator


Clean the machine after one shade is over

Breaker & Finisher

Collect the output sliver and cut into pieces

Cheese Winding Machine

Make the cheese cone from the R/F bobbins in the

sample cheese winding machine

Put the carding sliver in machine, pass through the

breaker, collect the breaker sliver output, cut into

pieces again pass through the machine. Collect the

finisher sliver and put it in the cover

Put the finisher silver in the speed frame and make

the s/f roving, Clean the speed frame.

Reach the texmaco ring frame in the unit-2

Insert the rovings in the ring frame and make the

R/F bobbins(2 R/F bobbins per roving)

Machine cycle time

TFO

Take the cheese cone and empty paper cone, reach

the TFO, Put the cones in the respective count

machine

Remove the R/F bobbins from the machine and

clean the machine

Come back to yard development room

Speed frame

Check the machine

Machine cycle time ( In the mean time come toYarn developmental room, select the sample card

from the cupboard)

Collect fibre sample from shift incharge and keep

on lab

Keep the sample in the oven

Take the dried sample from oven, put in cover and

write identification slip

Come from fibre dyeing to pilot plant

Carding MachinePut the samples at the inlet of carding machine

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: FD/W/10



FD

Pilot Plant

Operator


1 1 2.16 2.16

10

1 21 1.28 26.88

11 1 21 0.18 3.76

12 1 1 2.83 2.8313 1 21 0.17 3.65

141 21 1.51 31.73

151 21 1.26 26.46

A 359.54

B 12

C 402.68

D 450

E 89.48%

F 1

G 89.48%

Come to TFO section and remove the TFO cone

from the machine

Come back to yard development room and put the

cones in the warp machine and make sample yarn (

batch wise)

Clean the R/F bobbins

Come back to fibre dyeing machine

HTHP 1 - 5 batch/shift * 3 Shift = 15 Batch

HTHP 2-4 - 3 batch/shift * 3 Shift * 3 Machine = 27 batch

Total = 42 batch/ day







So per shift - 21 batch / shift


Remarks:

From the past record , 518 batches was prepared in the HTHP and number of tickets made 515

Nos.

The above workload sheet, was calculated

Cut the blue card to prepare ticket

Paste the yarn prepared in the blue card to prepare

the ticket

Check the ticket in the machine, take the printout

and staple the report

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 8.00 8.00

2 1 1 53.33 53.33

31 1 14.80 14.80

4 1 1 15.83 15.83

5

1 72 138.00 138.00

61 1 6.00 6.00

71 36 11.88 11.88

81 36 11.88 11.88

91 1 10.08 10.08

101 1 15.00 15.00

11 1 36 4.68 4.68

13

1 1 29.20 29.20

14 1 1 2.40 2.40

151 1 6.32 6.32

16 1 1 4.32 4.32

A 331.72

B 13

C 374.85

D 450

E 83.30%

F 1G 83.30%Proposed Utilisation(%)

Remarks:







Hand over charge to next shift

Hydro extraction of received dyed filament lot

Rewinding the dyed & grey filament according tosupervisor instruction(72 cones means 6 doffs and the

helper's time attending the m/c is 40% of m/c time for 6

doffs)

During rewind of dyed filament check the conning oil in

every spindle

Check the weight and length of every rewind grey cone

and write into the register and set into rack

Checking every rewind dyed filament cone (shade

varriation and rewinding quality )

Write down the production grey and dyed filament in

production register

Taking cones to SQC for quality checking and write

down sqc register

Put packing slip on each dyed filament cone

Packing the dyed filament cones in cartons with slip(

assuming 1 carton carries 18 cones , so timings are for 5

cartons)

After complete the work of winding clean the winding

area

Check weight of every packed carton and write down onpacking slip

WINDING

Do the cleaning of M/C as per check list

Checking the weight of received grey filament and write

down into grey received register

SSM WINDING

HELPER


Take charge at shift start

WLS No: FD/W/11


FIBRE DYEINGShifts A B C G

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 2 91.52 91.52

2 1 100 42.00 42.00

31

200

bags226.00 226.00

4 1 2 18.90 18.90

A 378.42

B 13

C 427.61

D 450

E 95.03%

F 1

G 95.03%

Assist the store man in bringing the required material








Remarks:

FIBRE DYEING

Cleaning of empty bags

Stitching Of dyed fiber filled bags

FIBRE DYEING

FLOOR CLEANER


Floor cleaning with swab

WLS No: FD/W/12


FIBRE DYEINGShifts A B C G

________________________________________________________________________________________






Department

Section

Work Centre Present Manpower - - -


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

1 1 1 25.00

2 1 1 25.00

3 1 1 20.00

4 1 1 20.00

5 1 11 15.00

6 1 11 15.00

7 1 1 10.008 1 11 77.00

9 1 1 5.00

A

B

C

D

E

F

G


Feeding Daily Production in excel


Confirm pending lots in sap


Remarks:

Maintain dyeing Cards

Make Production Order in sap for dyeing fibre


B




Make Card For Dyeing

Daily mail for filament dispatch and transfer it into sap

FIBRE DYEING OFFICE

SAP OPERATOR


C

Match Sap production to actual production

FIBRE DYEING OFFICE

Transfer Daily Fibre to Btm & Elg in sap

Make Ready Daily Advice Slips

WLS No:


FIBRE DYEINGShifts A

________________________________________________________________________________________






1

1

Total

Time

(Mins)

25.00

25.00

20.00

20.00

15.00

15.00

10.0077.00

5.00

212.00

13

239.56

450

53.24%

1

53.24%

G

D/W/13

________________________________________________________________________________________






Department

Section

Work Centre Present Manpower - - 1 2

Designation Proposed Manpower - - 1 2

Sl.

No

Crew

Size

Total

Time

(man

mins)

1

1.1 2 86.54

1.2 2 44.77

1.3 2 63.46

1.4 2 80.77

1.5 2 112.151.6 2 111.35

1.7 2 16.73

1.8 2 48.92

1.9 2 32.77

2 2 36.15

A 633.61

B 15

C 728.65D 384

E 94.88%

F 2

G 94.88%

1/26

Freq/ Shift

1/26

1/26

1/26

One person in the night shift is provided based on discussion with the incumbent and detailed

discussion with the maintenance personnel. The personnel mainly provided to attend the running

problems occurred in the night shift.It is provided based on the allocation.

1/26

1/26

1/26

1/26




SSM Winding Machine - 1 no

Monga Hydro - 1 no

Wet Opener - 2 nos

Remarks:

Hydro Extractor - 5 nos

1/26

HTHP Dyeing Vessel - 5 nos

Electric Hoist - 5 nos


Steam Drier - 2 nos

Net Available man-mins per shiftTotal Workload

85 KW RF Drier - 1 no

G

FD&YD

Fitter/Helper


Preventive Maintenance

Stamping Machine - 5 nos

Breakdown


WLS No: FD/MECH/01



Electrical

________________________________________________________________________________________






5 B YARN DEVELOPMENT

________________________________________________________________________________________






5.0 B5.1


13 kg Sample Dyeing M/C &

Fibro MixerHelper 1 1 - - 2 1 1 - - 2

2 Beaker Dyeing M/C's Helper 1 1 - - 2 1 1 - - 2

3 Yardage Sample MakingWeaver/sider/

Winder2 2 2 - 6 2 2 2 - 6

4 Handloom Sample MakingWeaver/winde

r/sider2 2 - - 4 2 2 - - 4

5 Checker Monitor - - - 1 1 - - - 1 1

6Dope Dyed & Yarn

CheckingHelper - - - 1 1 - - - 1 1

6 6 2 2 16 6 6 2 2 16Total

YARN DEVELOPMENTManpower Deployment


Remarks

_______________________________________________________________________________________________________ __________________________







5.0 B

5.2

1

YARN DEVELOPMENT



________________________________________________________________________________________






5.0 B

5.2

S.No Area of work1

3 kg Sample Dyeing M/C & Fibro

Mixer

2 Beaker Dyeing M/C's

3 Yardage Sample Making

4 Checker -Monitor

5 Dope Dyed & Yarn Checking -Helper YD/W/05

YD/W/03 & A

YD/W/04

YARN DEVELOPMENT


WLS NumberYD/W/01

YD/W/02

________________________________________________________________________________________






Department

Section


DesignationProposed

Man ower1 1 - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 15.00 15.00

21 3 60.00 60.00

3

1 3 30.00 30.00

A 105.00

B 13

C 118.65

D 450

E 26.37%

F 1G 26.37%


Remarks:






HTHP DYEING VESSEL

3KGHELPER-CONTRACT

EMPLOYEE



Weighing grey fibre, dye & chemical as per 3kg dyeing

program

Hyrdro extracting of dyed material to remove excess waterthen dry the fibre on RF dryer, put in bags add tags having

info about lot no., shade no., qty. & fineness

WLS No: YD/W/01


YDDShifts A B C G

YARN DEV. LAB

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 10.50 10.50

21 2.5 93.75 93.75

3

1 2 90.00 90.00

4 1 1 20.00 20.00

51 12.00

61 1 15.00 15.00

7 1 1 90.00 90.00

A 331.25

B 13

C 374.31

D 450

E 83.18%

F 1

G 83.18%

**Taking an average of twice in a month

Remarks:







Bring the dope dyed fibre from godown for mixing

Dyeing 50gm filament yarn sample on multiprecise-TC

sample dyeing m/c **

Weighment of the fibre for 100gm to make yarn sample

cone.

Drying of fibre in hot air oven


BEAKER DYEING

DYEING VESSEL

3KG)


Taking charge at the starting of the shift

According to mixing & matching color soln. m pippete

color as per recipes, weighment of fibre & start dyeing.

Open beaker dyeing m/c , drying fibre samples, stick the

fibre sample in record register & mention mixing details

from mixing register.

WLS No: YD/W/02


YARN DEV. DEPT.Shifts A B C G

YARN DEV. LAB

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 10.00 10.00

21 1 15.00 15.00

3 1 1 10.00 10.004

1 1 15.00 15.00

5 1 1 45.00 45.00

7 1 1 30.00 30.00

81 1 5.00 5.00

A 130.00B 13

C 146.90

D 450

E 32.64%

F 1

G 32.64%

Running 15 kgs of lap sample on LR C 1/3 CardThree passages at drawframe, sliver received from

carding.

Run Drawframe sliver on speed frame to form roving

Remarks:

The above workload is the operator's manual workload. But the operator has to wait during the

machine cycle time.





B C




Running the R/F machine till the doff is due

To give the charge at the end of the shift to reliever to

proceed working in next shift.

Receiving 15 kgs of lap from blowroom dept & bringing

it to pilot plant

GYARDAGE SAMPLE

DRAWFRAME,

SPEEDFRAME,RING

FRAME

WEAVER/SIDER


WLS No: YD/W/03


YDDShifts A

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 10.00 10.00

2 1 1 10.00 10.00

3 1 1 45.00 45.00

41 1 15.00 15.00

51 1 45.00 45.00

6 1 1 15.00 15.00

71 1 5.00 5.00

A 145.00

B 13

C 163.85

D 450

E 36.41%

F 1

G 36.41%

Remarks:

The above workload is the operator's manual workload. But the operator has to wait during the

machine cycle time.







Look after the 24 drums TFO m/c which will be

running throughout the shift

Run the new material on TFO before discharging his

duties

Carrying the final yarn from pilot plant to packing

To give the charge at the end of shift to reliever to

proceed working in next shift.


SAVIO, CHEESE

WINDING,TFO

WEAVER/SIDER



Take out the doff and make cones at winding

Simultaneously make cheeses of the winded cones

WLS No: YD/W/03 A


YDDShifts A B C G

YARDAGE SAMPL

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 4.72 4.72

21 1 40.00 40.00

3 1 1 12.00 12.00

41 1 35.00 35.00

51 1 30.00 30.00

6 1 1 20.00 20.00

7 1 1 15.00 15.00

81 5.00

A 161.72

B13

C 182.74

D 480

E 38.07%

F 1


Remarks:







Checking wrapping at R/F stage & provide final yarn

sample to SQC for quality checking.

Send final yarn to packing dept. yarn sample of each lot

made in pilot plant to ydd lab for shade checking.

Keep 1/2 kg of new shade in library

Random checking of m/c's parameter as per requirement

Sending material for conditioning if required.

YARDAGE SAMPLE

MONITOR


To check lap weight coming from blow room line.

To change gauge of card, set drawframe wrapping &

speed frame according to count.

To set the R/F program according to count

WLS No: YD/W/04


YDDShifts A B C G

PILOT PLANT

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11

15

cones45.00 45.00

2 1 1 90.00 90.00

31

15

cards75.00 75.00

41 1 36.00 36.00

5

1 1 100.00 100.00

6 1 1 8.00 8.00

7 1 1 45.00 45.00

A 399.00

B 13

C 450.87

D 480

E 93.93%

F 1

G 93.93%

Remarks:







Preparation of yarn shade ticket of each & every finalyarn lot & out sourced yarn for export quality to check

data values through CCMS(5-6 outside yarn avg.)

Making tuffts of dope dyed viscose & polyster to check

delta values through CCMS & keep record in sample

register (8-10 tuffts)

House keeping of dark room

Filling the shade consistency card after shade checking


SHADE CHECKING

HELPER


Bring the yarn sample cones from BTM for shade

checking

Noting down mixing details of Elegant and BTM.

Preparation of shade consistency card for shade

checking.

WLS No: YD/W/05


YDDShifts A B C G

YD LAB

________________________________________________________________________________________






6. WEAVING - PREPARATORY

_________________________________________________________________________ _______________







6.06.1


1 Warping Warper 5 5 5 - 15 5 5 5 - 15

Creel Boy 5 5 5 - 15 3 3 3 - 9

Fitter 1 1 1 - 3 - - - 1 1

Rewinder 6 6 6 - 18 5 5 5 - 15

Cleaner 1 1 1 - 3 1 1 1 - 3

Loose Packer 2 2 - - 4 1 1 - - 2

Godown Man 2 2 - - 4 2 2 - - 4

2 Drawing Reed man - - - 1 1 - - - - -

Cleaner - - - 1 1 - - - - -

Pinner 4 4 4 - 12 2 2 2 - 6

Drawer & Reacher 16 10 6 5 37 10 10 10 - 30

Beam Colie 3 3 3 - 9 2 2 2 - 6Total 45 39 31 7 122 31 31 28 1 91

WEAVING - PREPARATORYManpower Deployment


Remarks

__________________________________________________________________________________________________________ _______________________







6.0

6.2

6.2.1

a)

b)

c)

d)

e)

f)

g)

h)

i)

WEAVING - PREPARATORY


A deployment of 5 personnel in the rewinding section is recommended instead of the

present deployment of 6 per shift. For the 4 personnel recommended in the viscose areathe utilization works out to be 50.72 % per person per shift and for the one person

recommended in the polyester area, the utilization works out to be 82 % per shift. The

5 member crew has to manage the rewinding machines. The personnel may interchange

positions so that the workload evens out for all the personnel.

Proposed Changes

One maintenance fitter per shift is not being recommended. Instead one Fitter in the

general shift is being recommended. This is subject to certain activities to be performed

by the production personnel.

Deploy three creel boys per shift instead of the present deployment of 5 per shift. Two

creel boys are for machines 1,2 and 3 and two creel boys are for machines 4,5.

Beam colie- deploy two personnel in general shift instead of the present deployment of

three, based on workload

Position of Reed man in the general shift is not being recommended. These activities

may in the future be performed by the shift cleaner. The combined workload is detailed

in the workload sheet WGP/08

Position of cleaner in the general shift for the drawing area is not being recommended.

These activities may in the future be performed by the shift cleaner. The combined

workload is detailed in the workload sheet WGP/08

For pinning 8000 ends per shift a crew of two personnel is sufficient. Utilization for

each person works out to be 21.45 % per shift.

Drawer & Reacher - Deploy 10 personnel per shift for the processing of 5 beams,

based on workload

Deploy one loose packer per shift instead of the present deployment of two per shift

based on workload.

_________________________________________________________________________ _______________







6.0

6.3

S.No

12

3

4

5

6

7

8

9

10

11

1213

14

15

Drawer and Reacher WGP/14

Beam Colie WGP/15


WLS NumberArea of work

Loose packer WGP/09

Godown man WGP/10

Rewinders - polyester WGP/07

Shift Cleaner WGP/08

Shift fitter WGP/05

WGP/06

Pinner WGP/13

Reed man WGP/11

General shift cleaner WGP/12

WEAVING - PREPARATORY

Rewinders - viscose

Warper - machine 1,2,3 WGP/01Warper - machine 4,5 WGP/02

Creel Boy - machine 1,2,3 WGP/03

Creel Boy - machine 4,5 WGP/04

_________________________________________________________________________ _______________







Present Manpower 3 3 3 -

Proposed Manpower 3 3 3 -

S.

No

Crew

Size

Freq/

beam

Basic

Time

(mins)

Total

Time

(min)

1

2 1/1 20.35 20.35

22 1/1 8.41 8.41

32 1/1 6.48 6.48

4 2 1/1 1.08 1.08

51 1/1 1.27 1.27

6 1 1/1 1.67 1.67

7

1 29/1 0.96 27.82

8 1 1/1 1.64 1.64

9

1 1/1 5.49 5.49

10

2 1/1 13.64 13.64

11

- 1/1 2.00

WLS No:WGP/01


Department WeavingShifts A B C G

Section

Pass thread from V-reed to be tied them to the Roller

Preparatory

Work Centre Warping

Designation Warper

Set the Count,warp length and No of ends in the electronic

display

Make Long rope to insert Leese in the sections required

Tie the combined ends(after passing them through V-reed) to

the drum and insert leesing;same step being repeated forevery section


Manual Element

Take the cone out of the packet and load on to the creel(iron

bars) i.e. 148 cones

Take the cone out of the packet and load on the other side of

the creel(for selvedge purpose)

Setting stop motion pin and check tension in the threads and

tie them upto the leese reed

Attend to thread cuts(1 per 29 sections)

Make adjustments i.e. tie bolts ,adjust drums,unhook all

sections onto the iron bar ,place them onto the beam and tie

the ends onto the beam

Take out remaining cones as the full beam has been

prepared and place them in a bag;Both from creel and

selvedge

Machine Elements

Rotate @550 meters/min(actual 450 meters/min)i.e for 1

section of 1020 meters

_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

beam

Basic

Time

(mins)

Total

Time

(min)

WLS No:WGP/01



Section Preparatory

Work Centre Warping

Designation Warper


12- 1/1 10.33

A 87.85B 6

C 527.10

D 13

E 595.62

F 1350

G 44.12%

H 3

I 44.12%

Roll onto the beam@100 meters/min;Total warping

length=1020 metres

Basic Workload per Beam ( in man minutes)Frequency per Shift;No of beams to make




Remarks:1) Number of beams to make has been taken as per data provided by the management i.e.

30000 mtrs of the fabric is to be warped per day or 2000 mtrs per m/c.In one time average 1000

mtrs being warped on an average therefore warping is being done 2 times per m/c per shift


Total Workload per Shift( in man minutes )

Net Available man-mins per shift


_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

beam

Basic

Time

Total Time

(min)

1 2 1/1 16.47 16.47

22 1/1 8.83 8.83

32 1/1 4.81 4.81

4 2 1/1 1.99 1.9951 1/1 1.26 1.26

61 1/1 0.87 0.87

7

1 44/1 39.23 39.23

8 1 1/1 1.04 1.04

9

1 1/1 7.73 7.73

10

2 1/1 11.61 11.61

11

- 1/1 1.84

12- 1/1 8.29

A 93.82B 4

C 375.30

D 13

E 424.09

F 900

G 47.12%

H 2

I 47.12%

WLS No:WGP/02



Section


Preparatory

Work Centre Warping

Designation Warper

Set the Count,warp length and No of ends in the

electronic display

Make Long rope to insert Leese in the sections

required

Tie the combined ends(after passing them through V-

reed) to the drum and insert leesing;same step being

repeated for every section


Manual Element

Take the cone out of the packet and load on the other

side of the creel(for selvedge purpose)

Setting stop motion pin and check tension in the

threads and tie them upto the leese reed

Roll onto the beam@100 meters/min;Total warping

length=829 metres

Basic Workload per Beam ( in man minutes)Frequency per Shift;No of beams to make


Attend to thread cuts(1 per 44 sections)

Make adjustments i.e. tie bolts ,adjust drums,unhook

all sections onto the iron bar ,place them onto the

beam and tie the ends onto the beam



selvedge

Machine Elements

Rotate @550 meters/min(actual 450 meters/min)i.e

for 1 section of 829 meters







_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

beam

Basic

Time

Total

Time

(mins)

1

2 1/1 20.34 20.34

22 1/1 8.41 8.41

32 1/1 6.48 6.48

4 2 1/1 1.08 1.08

5 1 1/1 5.34 5.34

62 1/1 9.44 9.44

7 1 1/1 28.00 28.00

8 1 1/1 6.34 6.34

A 85.43

B 6

C 90

D 602.55

E 13

F 680.88

G 1350

H 50.44%

I 2

J 75.65%

WLS No:WGP/03



Section


Manual Element

Take the cone out of the packet and load on to the creel(iron

bars) i.e. 148 cones

Take the cone out of the packet and load on the other side of

the creel(for selvedge purpose)

Setting stop motion pin and check tension in the threads and

tie them upto the leese reed

Preparatory

Work Centre Warping

Designation Creel Boy

Put oil in the m/c oiling tank from storage tank

Basic Workload per Beam ( in man minutes)

Frequency per Shift;No of beams to make

Relieve Warper for lunch


Bring empty beam from empty beam space and fit bolts

Take out remaining cones as the full beam has been prepared

and place them in a bag;Both from creel and selvedge

Airing of workplace with air-pipe




Remarks:





_________________________________________________________________________ _______________









S. NoCrew

Size

Freq/

beam

Basic

Time

Total

Time

(mins)

1

2 1/1 16.47 16.47

22 1/1 8.83 8.83

32 1/1 4.81 4.81

4 2 1/1 1.99 1.99

5 1 1/1 5.51 5.51

6

2 1/1 11.61 11.61

7 1 1/1 28.00 28.00

8 1 1/1 6.23 6.23

A 83.43

B 4

C 60

D 393.73

E 13

F 444.91

G 900

H 49.43%

I 1

J 98.87%

WLS No:WGP/04



Section


Manual Element

Take the cone out of the packet and load on to the

creel(iron bars) i.e. 120 cones

Take the cone out of the packet and load on the other

side of the creel(for selvedge purpose)

Setting stop motion pin and check tension in the threads

and tie them upto the leese reed

Preparatory

Work Centre Warping

Designation Creel boy

Put oil in the m/c oiling tank from storage tank

Basic Workload per Beam ( in man minutes)

Frequency per Shift;No of beams to make

Relieve Warper for lunch ( in man minutes)


Bring empty beam from empty beam space and fit bolts



selvedge

Airing of workplace with air-pipe




Remarks:





_________________________________________________________________________ _______________








Proposed Manpower - - - 1

S. NoCrew

Size

Freq/

Shift

Basic

Time

(mins)

Total

Time

(mins)

1 1 10 2.00 20.00

21 4 0.50 2.00

3

3.1 1 1/3 5.00 1.67

3.2 1 1/3 10.00 3.33

3.31 1 3.75 3.75

41 5 0.69 3.47

51 5 2.00 10.00

61 1/18 424.78 23.60

7 1 15.00 15.00

A 82.82B 13

C 93.58

D 450

E 20.80%

F 1

G 19.50%

Oil lubrication (rewinding - 20 spindles / shift)


Attend to the breakdowns in the various machines

Set the beam flange after warping

Start the idle spindle running on the rewinding machine

Check the tightness of the bolts in the individual beams,

tighten if required

Unload the beam after warping from the warping

machine

Perform preventive maintenance of the machines in the

presence of the supervisor

Perform the oiling and greasing for all the warping

machines and the rewinding machines

Oil lubrication (warping )

GSection

Greasing (warping machines)

Preparatory

Work Warping and Rewinding

Designation Fitter

Proposed Manpower per day


WLS No:WGP/05


Department WeavingShifts A B C

3. Keeping the above points in mind, this position is being recommended to be manned only in the

general shift.

4. Some of the rewinders will have to be trained in the performance of the activity 2 in the shifts B

and C respectively.

1 It is observed that the utilization per shift is only 20 %. Activities 1,3 and 5 may be shifted to the

warper / warper helper as these do not require any complex routines to be performed.

2. No data regarding the breakown attendance and the preventive maintenace performed has been

furnished. The details provided here are based on discussions with the Maintenace In Charge and theFitter. During my study for a shift no breakdown attendance has been observed.



Remarks:



_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

BasicTime

(mins)

man

mins

Total

Time

(mins)

14 733.91 733.91

2

3

4

5

6

7

8

9

10

11 60.00 60.00

A 793.91

B 15

C 913.00

D 450

E 50.72%

F 4

G 50.72%

Remarks:

1. The rewinding section is to be manned by a crew of 5 personnel. During the shift itself the

personnel may interchange positions to even out the workloads for the individuals.






Place the unused cones in the storage area and back



Others - discussions with the supervisors etc

Place the big poly bag aside and back

Attend to problems such as thread cuts, changing the small

input rolls etc.,

Pull the big poly bag from near to the weighing machine tothe working area

Place cones from the big poly bag onto the machine

Connect the thread to the empty cone, wind and start the

cones

Place the completed big rolls into a big poly bag

WLS No:WGP/06


Department WeavingShifts A B

PreparatoryC G

Section

Place completed roll in the poly cover and place the same on

the machine top

Prepare slips and paste on the inside of the cone

Get cones, place cones on the machine


Designation Rewinders viscose


_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

Basic

Time

(mins)

man

mins

Total

Time

(mins)

12 305.99 305.99

2

3

4

5

6

7

8

9

10

1115.00 15.00

A 320.99

B 15

C 369.14

D 450

E 41.02%

F 1

G 82.03%




1. The rewinding section is to be manned by a crew of 5 personnel. During the shift itself the

personnel may interchange positions to even out the workloads for the individuals.




Remarks:

Connect the thread to the empty cone, wind and start the

cones

Place the completed big rolls into a big poly bag

Place the big poly bag aside and back

Attend to problems such as thread cuts, changing the small

input rolls etc.,

Others - discussions with the supervisors etc


Place completed roll in the poly cover and place the same

on the machine top

Prepare slips and paste on the inside of the cone

Get cones, place cones on the machine

Place the unused cones in the storage area and back

Pull the big poly bag from near to the weighing machine to

the working area

Place cones from the big poly bag onto the machine

Preparatory


Designatio

n

Rewinder - polyester


WLS No:WGP/07


Departmen WeavingShifts A B C G

Section

_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

BasicTime

(mins)

man

mins

Total

Time

(mins)

1

2

3

4 1 99.20 99.20

51 115.70 115.70

A 577.51

B 13

C 652.58

D 450E 48.34%

F 3

G 48.34%


Net Available man-mins per day

362.61 362.61


General shift cleaning works


1


B Shift : (362.61/3 + 99.20/2 + 115.70/2) * 1.13 = 258 minutes and utilization = 57.33 %

C Shift : (362.61 /3)*1.13= 137 minutes and utilization = 30.35 %

Remarks:

1. The utilization for this position holder in the three shifts will be as follows:


A shift : (362.61/3 + 99.20/2 + 115.70/2) * 1.13 = 258 minutes and utilization = 57.33 %


Clean the warping area (collect waste, collect the creel

covers, waste cones etc., collect in a poly cover and

dispose in the disposal area). Clean by both the broom

stick and the long handled broom

Clean rewinding area by broomstick, collect wastes in the

polycover and dispose in the disposal area

Reed man activities

Clean godown area by broomstick, collect wastes in the

polycover and dispose in the disposal area

Preparatory


Designation Cleaner


WLS No:WGP/08



Section

_________________________________________________________________________ _______________







Weaving

Preparatory

Preparatory Present Manpower 2 2 - -

Loose Packer Proposed Manpower 1 1 - -

Sl. No CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1 5 18.07 90.33

2 1 5 0.85 4.24

31 5 0.53 2.65

4 1 1 5.21 5.21

5 1 1 2.11 2.11

6 1 1 4.31 4.31

7 1 1 2.21 2.21

8

1 20 2.61 52.27

9 1 20 1.78 35.51

10 1 20 0.83 16.66

11 1 20 0.46 9.23

12 1 20 0.28 5.56

131 2 0.95 1.91

14 1 2 0.35 0.71

15

1 20 0.88 17.59

16 1 1 0.35 0.35

A 250.85

B 13C 283.47

D 900

E 31.50%

F 1

G 62.99%

Section


Packing empty cones coming from Loom Shed and

shift to godown

Shift 400 empty cones in a separate bag coming from the

Loom Shed;segregation is done according to color of the

cones

Department

WLS No:WGP/09


Shifts A B C G

Shift the bags after weighing to be sent for reuse

Load 10 bags on trolley

Carry 5 bags upto yarn godown entry and unload

Return with empty trolley

For transferring extra bags to upwrad godown for

external sales and use

Open the stitch of the bags

Transfer cones from 1 bag to another(28 cones)

Prepare,stitch and put a sample cone outside the bag

Put details on the bag viz lot no and number of cones with

a marker

Bring trolley to load bags for transfer

Load 5 bags on to the trolley


Remarks:




Work Centre

Designation


Carry upto weighing m/c

Weigh the bags (deduce 200 gm of bag wt and 350 gms

of card board of cone and note in the register) and put

aside

Return for next set


Stitich the new bag and put sample cone outside new bag

Note the count lot,no and shade no in register

Put new count no on the register

_________________________________________________________________________ _______________







Present Manpower 2 2 - -

Proposed Manpower 2 2 - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 7 1.26 17.64

2 2 7 2.31 32.36

3 2 6 1.01 12.11

4 2 5 1.31 13.12

5 2 5 2.16 21.58

6 2 5 0.35 3.55

7 2 5 1.07 10.65

8 2 5 0.35 3.53

9 2 4 1.62 12.99

10 2 2 1.23 4.92

11 2 2 5.81 23.23

12 2 2 2.74 10.96

13 1 5 3.87 19.36

14 1 5 0.97 4.85

15 1 5 0.54 2.72

16 1 2 1.17 2.35

17 1 1 0.75 0.75


Arrange the yarn on warping m/c

Destack and load 6 bags(at a time) of 64 kg each on two

trolley

Designation

WLS No:WGP/10


Shifts A B C G

Unload all 3 bags to the place

Return and carrying the bags to Weft godown 2(for

another set of 70 looms)

Unload all 3 bags to the place

Return with empty trolley for next load

Carrying upto warping m/c and dump

Return with empty trolley for next load

Put the yarn from main godown to weft godownDestack and load 6 bags(at a time) of 64 kg each on

trolley

Carrying the bags to Weft godown 1(for 1 set of 70

looms)

Carry bag to yarn godown or rewinding

Return empty handed for next bag

From Weft Godown to Loose Section

Loading 6 bags(containing semi used cones) on to the

trolley

Carrying the trolley upto rewinding and place after

weighing

Return to take next load

Packing cones left after Warping to be transferred

either to rewinding or to godown

Shifting cones from 1 bag(48 cones in 1 bag) to another

according to their destination

Prepare and stitch the bag

Write lot no,count and no of cones on the bag

Weaving

Preparatory

Preparatory

Godown Man

Department

SectionWork

Centre

_________________________________________________________________________ _______________








Proposed Manpower 2 2 - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)


Designation

WLS No:WGP/10


Shifts A B C GWeaving

Preparatory

Preparatory

Godown Man

Department

SectionWork

Centre

18 1 1 95.84 95.84

A 292.51

B 13

C 330.53

D 900E 36.73%

F 2


Remarks:Since 6000 mtrs have to be given to warping m/c i.e. per shift 31.2 bags.Since at a time 6

bags can be taken to warping by two persons therefore they will deliver all the bags in 7 trips

Check the loose yarn available for next day program






_________________________________________________________________________ _______________







Present Manpower - - - 1

Proposed Manpower - - - -

S. NoCrew

Size

Freq/

Shift

BasicTime

(mins)

TotalTime

(mins)

1

1 1 5 5

2

2.1 1 7 0.27 1.89

2.2 1 14 0.71 9.98

2.3 1 7 1.57 10.99

2.4 1 14 3.05 42.63

2.5 1 7 2.02 14.12

2.6 1 14 0.25 3.52

2.7 1 14 0.16 2.26

3

3.1 1 1 0.42 0.42

3.2 1 2 0.83 1.65

3.3 1 2 1.05 2.10

3.4 1 2 0.47 0.93

3.5 1 2 0.11 0.23

4

4.14.2

4.3

A 115.70

B 13

C 130.75

D 480

E 27.24%F -

G -

Stack reed

Clean the reed using the cotton waste





Cut damaged reeds to smaller sizes, using a saw

Clean the reed using the polishing piece

Adjust the gap in the reed using the plier

Place reed on the work table, clean with compressed air

Clean reed with wire brush

Clean reed with cotton waste

Other miscellaneous works

Pick reed, place on the work table, clean using the wire

Clean the reed using emery paper -both sides


Remarks:

20

In case the reeds are damaged, provide the information to

the supervisor who will make the necessary entries in the

computer

Go the machine area, using the plier adjust the reed gap

At the beginning of the shift - switch on the bulb, adjust,

clean the work area, collect tools and place on the work

table

Sultex, Dornier reeds

Transport reeds from the ground floor to the first floor



Preparatory

Work Drawing

Designation Reed Man

1. The position of the Reed man is not being recommended and this activity is shifted to shift cleaner

Keep the reed in the rack and back to workplace

Airjet

Walk to the airjet area


WLS No:WGP/11



Section

_________________________________________________________________________ _______________







Present

Manpower- - - 1

Proposed - - - -

S. NoCrew

Size

Freq/

Shift

Basic

Time

(mins)

man mins

Total

Time

(mins)

1

1.1 1 1 3.57 3.57

1.2 1 1 73.51 83.84

1.3 1 1 1.79 1.79

1.4 1 1 10.00 10.00

A 99.20

B 13

C 112.10

D 450

E 24.91%

F -

G -

Remarks:

1. The position of the general shift cleaner in the drawing area is not being recommended and this

activity is shifted to shift cleaner

Office

Collect the wastes in the poly cover and dispose







Clean



Weft godown

Drawing work area

WLS No:WGP/12



Section Preparatory

Work Centre Warping and Rewinding

Designation Cleaner

_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

Basic

Time

(mins)

man mins

Total

Time

(mins)

1 2 2 2.48 9.90

2 1 2 1.32 2.64

3

3.11 2 0.68 1.35

3.2 1 2 0.45 0.90

3.3 1 2 0.30 0.60

3.4 2 2 0.89 3.54

3.5 1 2 1.58 3.15

3.6 1 2 0.79 1.58

4 2 8000 0.01 128.99

5

1 2 1.39 2.78

61 2 4.36 8.71

7 1 2 0.45 0.90

A 165.03

B 17

C 193.09

D 450

E 21.45%

F 2

G 21.45%



Check, segregate sections

Make preparation for the pinning

Perform pinning


Remarks:

1. For pinning 8000 ends one crew of two personnel is sufficient.





Work Centre Warping and Rewinding

Designation Pinner


Position 2 rods, adjust

WLS No:WGP/13


Department WeavingShifts

Bring 6 non serrated rods to the machine

Bring 2 small reeds, gunny bag to sit on, gunny bag to put

on the loom

Place the gunny bags on the loom

A B C GSection

Keep the extra pins in the storage area

Insert 6 serrated rods into the pins stack, remove the non

serrated rods

Bring pins along with the serrated rods - 6 numbers

Fix the 6 non serrated rods to the 2 small reeds

Set tightness of gear

After pinning, clean up, collect the dropped pins, check for

the missing pins in the work performed and insert

whereever required

Preparatory

_________________________________________________________________________ _______________







Department

Work Centr Present Manpower 16 10 6 5


Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1 2 1 43.05 86.10

2 1 1 5.04 5.04

3 1 1 2.57 2.57

4 2 1 1.29 2.57

5 1 1 2.47 2.47

6 1 1 5.48 5.48

7 1 1 3.47 3.47

8 1 1 4.48 4.48

9 1 1 3.87 3.87

10 2 1 8.64 17.28

11 2 1 386.50 400.00

A 533.33

B 13

C 602.67

D 900

E 66.96%

F 2

G 66.96%

Process

Make drawing and reaching process for making

monograms and tape(212 ends for both start and end of

the beam)

Drawing and reaching process for rest of the ends;4000

ends in this case




Remarks:Assumed that per shift 5 beams goes for gaiting so per shift 10 persons can do the required

work





Setting the frame on drawn beam and adjust heald wire

Take 9 rods and insert in b/w frames

Tie all frames with threads and adjust iron rods

Take out the sheet cover from the beam and adjust the

beam ;Take all the knots on an iron bar and put the bar

above frame so that it suspends before frame

Tie reed on one side of the frame

Adjust threads on other side of the frame

Preparatory

Drawer & Reacher


Preparatory Activities

Prepare and adjust old frames coming from loom sheds to

be used for drawing and reaching purpose;10 frames+2

selvedge frames

Carrying the frame upto the drawn beam

Return for next frame

WLS No:WGP/14


WeavingShifts A B C G

PreparatorySection

_________________________________________________________________________ _______________







Department

Work Cent Present Manpower 3 3 3 -


Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1 1 5 1.14 5.71

2 1 5 1.01 5.05

3 1 5 1.80 8.98

4 1 5 0.72 3.58

5 2 5 5.61 56.09

6 2 5 4.75 47.50

7 2 5 3.59 35.90

8 1 8 0.37 2.95

9 1 8 2.19 17.49

10 1 5 2.04 10.20

11 1 5 2.27 11.36

12 1 5 2.10 10.52

13 2 10 2.22 44.40

A 259.71B 13

C 293.48

D 1350

E 21.74%

F 2

G 32.61%






Remarks:

Knotting Beam from Warping Section to Loom

Shed

Take out the beam after knotting and load the beam on

to the Beam Loader

Carry the knotted beam to the respective section in

Loom Shed

Return to warping section for next transfer

Placing the warp beam in its proper place


Return to warping section for next transfer

Beam transfer from Drawing Section to Loom ShedSetting Drawn Beam m/c on the drawn beam,setting

lever to insert beam and take out the beam loaded on

m/c

Carry the Drawn Beam m/c to the Loom Shed and

place at the required position

Return with another emptied Drawn Beam m/c to load

next beam from Drawing section

Empty beam from Loom Shed to Warping Section

Load empty beam on to the trolley

Carry the beam to empty beam section near Warping

Preparatory

Beam Colie


Beam transfer from Warping Section to Drawing

Unhook the beam after warping and take out the beam

Adjust the Beam Loader m/c beneath the beam and lift

the beam

Carry the beam to the Drawing section and release the

beam at its proper place

WLS No:WGP/15



PreparatorySection

_________________________________________________________________________ _______________







7. WEAVING - LOOMSHED

_________________________________________________________________________ _______________







7.0

7.2

7.2.1

a)

b)

c)

d) Deploy 4 waste pickers instead of 6 waste pickers in the general shift, based on worklaod

WEAVING - LOOMSHED


Combine the positions of the two fancy jobbers (one in khata 1 and the other in khata 2).

The combined utilization will be 75.38 %. Deployment of one fancy jobber per day is

recommended.

Proposed Changes

Deploy one roll doffer per khata instead of the present deployment of 3 for two khatas.

The workload for the two roll doffers per shift is 84.22 %.

Deploy one Charkhi man for both the khatas and in general shift. The utilization is 48 %

for this position holder in each shift.

_________________________________________________________________________ _______________







7.0

7.3

S.No

12

3

4

5

6

7

8

9

10

11

1213

14

15

WEAVING - LOOMSHED

Weaver Helper


WLS Number

Fitter WGL/04

Area of work

Weaver WGL/01

WGL/03

Roll Doffer WGL/06

Charkhi Man WGL/07

Weaver WGL/02

Jobber WGL/05

Beam Gator - Airjet WGL/10

Beam Gator - Sultex WGL/11

Fancy Jobber - 1 WGL/08

Fancy Jobber - 2 WGL/09

Waste Picker WGL/14

Cleaner WGL/15

Beam Gator - Dornier WGL/12Weft Distributor WGL/13

_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

BasicTime

(mins)

TotalTime

(mins)

A

11 1 2.11 2.11

2 1 90 1.31 117.90

3 1 120 1.08 130.08

41 55 0.58 32.08

5 1 2 5.28 10.55

6

1 27.93 27.93

71 10.00 10.00

A 330.65

B 17

C 386.86D 450

E 85.97%

F 1

G 85.97%

To check the fabric of all 10 looms for quality, every twohours


At the time of shift starting put sign on all 10 looms

fabric. Indicating the shift change and date.

To attend (mend) filling (weft breakage).

Designation Weaver

WLS No:WGL/01


Department WeavingShifts

Work Centre Khata 1

A B C GWeaving


To attend (mend) broken warp end

Dornier

Patrolling behind the looms to see if there is any crossing

or entanglement at the beam, and do the correction if

required.

Report any abnormality in terms of quality or working to

the supervisor

Section

To change weft cones when finished.and tie the tails of

the reserve cone



Remarks:





_________________________________________________________________________ _______________







Present

Manpower1* 1 1 -

ProposedManpower

1 1 1 -

*

1

2N F X 1-X

Number of

machines

Factor derived

from finite

queuing tables8 0.975 0.052 0.948

9 0.969 0.052 0.948

10 0.963 0.052 0.948

11 0.957 0.052 0.948

12 0.95 0.052 0.948

13 0.941 0.052 0.948

14 0.932 0.052 0.948

2.1

a

b

c

0.69

0.41

0.45

0.50

0.55

C G

One weaver for every 10 looms

0.60

0.64

Work Centre Khata 1

Designation Weaver

Operator

workload

0.92

WLS No:WGL/02



Section Weaving

0.92

0.91

0.91

0.91

0.90

0.89

ME

Machine

efficiency

For the computation of the number of machines to be allocated to each weaver, we have

analyzed the machine efficiency and operator workload for different machine assignments.

The same is depicted in the table below:

Looms

Calculation for X value:

Time study was carried out to determine quantum of time spent on mending broken warp,

broken weft and other activities carried out in the shift by the weaver. For the mending of the

broken warp the weaver takes 1.31 minutes (including walking time) and for mending weftbreakages the weaver takes 1.08 minutes (including walking and taking 25 % breakage before

the thread enters the accumulator and 75 % after the thread has passed through the

accumulator).

OW

Multiplying these values with the respective frequencies per shift (90 per 10 machines per

shift for warp breakages and 120 per 10 machines per shift for weft breakages) we obtain the

total external work to be carried out by the weaver. This is determined to be 247.98 minutes

per 10 machines per shift. Per machine it is 24.80 minutes per shift. That is for getting output

from the machine for 480-24.80 = 455.20 minutes per shift, the machine has to be serviced

for 24.80 minutes, giving a value of X = 24.80/480 = 0.052

For X = 0.052 the different values of the machine efficiency and operator workload has beencomputed and they are depicted in the table above. Based on the formulae provided in the

finite queuing tables the values of the machine efficiency and the operator workload are

derived. The same are plotted in a graph and it is observed that for N=10 machines we reach

a ideal combination of the machine efficiency and the operator workload.

_________________________________________________________________________ _______________







Present

Manpower1* 1 1 -

ProposedManpower

1 1 1 -

C G

Work Centre Khata 1

Designation Weaver

WLS No:WGL/02



Section Weaving

d The ideal combination is to allot 11 machines to each weaver, but as the layout is such that

there are 10 machines in one line, we recommend that the same to be continued.

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.87

0.88

0.89

0.90

0.91

0.92

0.93

1 2 3 4 5 6 7

ME Machine efficiency

OW Operator workload

_________________________________________________________________________ _______________








Proposed Manpower 1 1 1

S.

No

Crew

Size

Freq/

Shift

BasicTime

(mins)

man

mins

Total

Time

(mins)

1

2 1 5.6 4.00 22.40

31 135.00 135.00

41 6 5.28 31.66

5 1 5/6 25.64 21.28

61 10.00 10.00

71 10.00 10.00

A 230.34

B 17C 269.50

D 450

E 59.89%

F 1

G 59.89%



Remarks:

1 This activity is alrady performed by the Weaver himself, hence this need not be performed again

by the Weaver Helper also. Hence no time has been allocated for this activity here.







To help in passing the knotting of newly knotted beams

To attend to machine whenever there is multiple breaks or

smash

Report any abnormality in terms of quality or working to

the supervisor

To check the fabric of all looms of his lines (2 lines in

sultex and dornier & 3 lines in airjet) for quality at

resumption *1

To change catch selvedge spool, when finished

To relieve the weaver for lunch (30 min) and tea (15 min)

of three lines in loomshed *2

To take quality round of his respective lines twice a shift

and sign

GSection Weaving

Work Centre Khata 1

Designation Weaver Helper

2. The workload has been computed based on the sum of the activities 2,3,4 and 6 detailed in the

weaver workload sheet. These are the activities that the weaver helper is supposed to perform when

he is relieving the weavers. This works out to be 86.62 min3. One weaver helper for three lines in the loomshed is recommended. As seen in the workload sheet,

the workload per shift for any of the weaver helpers is 59.89 %.

WLS No:WGL/03



_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

BasicTime

(mins)

TotalTime

(mins)

11 3 10.00 30.00

2

3

41 3 20.00 60.00

51 1 6.26 6.26

6 1 1 6.09 6.09

71 1 9.34 9.34

A 231.69

B 15

C 266.44

D 450

E 59.21%

F 1G 59.21%

To remove the heald frames,empty beam & droppins of

finished beam.

To take the round for selvedge,oil leakage,abnormal sound

or any abnormality related to machine.

At the time of beam gaiting adjust the reed space according

to fabric width.

To do the oiling & greasing of new gaited or knottedlooms.


120.00

To do the oiling of cutter scissor & rapier head.

To attend the weft breakage & selvedge problem.1 1


Remarks:

120.00





To take the reading of (warp breakage, weft breakage &

efficiency) at the time of shift end.



Weaving

Work Centre Khata 1 & 2

Designation Fitter

WLS No:WGL/04



Section

_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

BasicTime

(man

mins)

Total

Time

(mins)

11 1 15.00 15.00

2

1 1 35.00 35.00

31 2.43 30.00 72.90

41 15.00 15.00

5

1 15.00 15.00

6 1 15.00 15.00

7

A 167.90B 15

C 193.09

D 450

E 42.91%

F 1

G 42.91%

Remarks:



Net Available man-mins per day





To allocate workmen in the department, if any shortage

then he has to arrange workers accordingly.

To take round of the department to ascertain the number

of beam gaiting expected in the shift and plan the man

power accordingly.

To start the new beam with the shift incharge.

To attend the machines for warp & weft breakages,

selvedge problems etc.

To report and attend (help to attend) any abnormal

machine in terms of quality or productivity to the

concerned shift incharge.

To attend minor breakdowns

To organise for warp or weft shortage if any

GSection Weaving

Work Centre Khata 1

Designation Jobber

1. Activity 4 and 5 are primarily the responsibility of the weaver and weaver helper.

2. This role is a Team Leader role wherein the position holder is a link between the workmen and the

first level of management.

WLS No:WGL/05



_________________________________________________________________________ _______________









S. NoCrew

Size

Freq/

Shift

BasicTime

(mins)

TotalTime

(mins)

1

1.11 120 0.63 75.08

1.2 1 120 0.48 57.84

1.3 1 120 0.29 34.78

1.4 1 120 1.39 167.14

1.5

1 120 2.39 286.20

2

1 3 0.80 2.39

3 1 1 30.00 30.00

3.1

3.2

3.3

A 653.43B 16

C 757.97

D 450

E 56.15%

F 2

G 84.22%

Load empty spindle, lock, roll some fabric

Write details on completed roll by chalk

Transport completed roll to grey checking area

To cut the first one meter fabric from every new

gaited or knotted looms & keep that fabric in the

bucket for checking.

Others

Roll doffing



Remarks:





To fix one small sample of the newly started quality

on loom for reference.

Discussion with operator, supervisor etc.,

B


G

Load empty spindle onto trolley, return back to the

weaving section, check machine panel, unload empty

near machine


Weaving


Designation Roll Doffer

C

Tear cloth, load completed roll onto trolley, keep

trolley aside

Section

To wrap the light shade qualities in polythene.

WLS No:WGL/06


Department WeavingShifts A

_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

Basic

Time

(mins)

man mins

Total

Time

(mins)

1 1 20.00 20.00

2

2.11 10 0.69 6.93

2.2 1 10 0.38 3.802.3 1 10 12.23 122.27

2.4 1 10 0.24 2.41

2.5 1 10 0.41 4.12

2.6 1 4 1.16 4.64

3

3.11 2 0.69 1.39

3.2 1 2 0.38 0.76

3.3 1 2 7.00 14.00

3.4 1 2 0.24 0.48

3.5 1 2 0.41 0.82

3.6 1 2 1.16 2.32

41 1 5.03 5.03

51 1 2.55 2.55

A 191.51

B 13

C 216.41D 450

E 48.09%

F 1

G 48.09%

Lock the machine and adjust

Remarks:

1. As the utilization of this position holder is 48 %, possibility of deploying only one person in the

general shift has to be explored. The recommended manpower is one in the general shift.





Wind new thread

Remove lock and keep completed spool in rack

Place new thread roll, connect



Pass through the pins, reeds and connect


Lock the machine and adjustWind new thread

Pass through the pins, reeds and connect

Go to yarn godown, search for materials, get thread

spools, place them in the stand

Cut the selvedge (20 threads), knot, go to stand and

connect for monogram threads

Prepare the spools for monogram bobbin

Pick new spool, place in machine, remove old thread

and dispose into the dust bin

Remove lock and keep completed spool in rack

Place new thread roll, connect


Pick new spool, place in machine, remove old thread

and dispose into the dust bin

Weaving


Designation Charkhi Man

To collect all the empty bobbins from the looms.

Prepare the spools for catch selvedge waste for

Dornier, Sultex and Picanol.

WLS No:WGL/07



Section

_________________________________________________________________________ _______________









S.

No

Crew

Size

Freq/

Shift

BasicTime

(mins)

TotalTime

(mins)

1

1.1

1 6 10.00 60.00

1.2

1 6 6.00 36.00

1.3 1 6 1.00 6.00

2

2.11 3 22.25 66.75

2.21 2/25 66.75 5.34

2.2

1 3 11.36 34.08

2.3 1 3 1.00 3.00

A 211.17

B 13

C 238.62

D 450

E 53.03%

F 1

G 53.03%


Monogram

Punch holes of the required pattern on the sheet (done by

copying the existing pattern on the pattern being created)

Cut sheet to size, check visually, paste by fevibond and

scrape by emery, using a rod remove the glue from the

holes

Go to the loomshed and hang in the hanger





Punch holes of the required pattern on the sheet (partly

punching done manually, major portion done by copying the

existing pattern on the pattern being created)

Cut sheet to size, check visually, paste by fevibond and

scrape by emery, using a rod remove the glue from the

holes

Go to the loomshed and hang in the hanger




Remarks:

Weaving

Work Centre Khata 1

Designation Fancy Jobber

Punch holes of the required pattern on the sheet (done by

manual punching)

Body

WLS No:WGL/08



Section

_________________________________________________________________________ _______________








Proposed Manpower - - - -

S.

No

Crew

Size

Freq/

Shift

BasicTime

(mins)

TotalTime

(mins)

1

1 1 16.36 16.36

21 5 15.00 75.00

31 13/100 105.17 14.02

A 89.02

B 13

C 100.59

D 450

E 22.35%

F 1

G 22.35%

Remarks:

1. The utilization of this incumbent is 22.35 %. One person may be deployed for the Fancy Jobber

activity for both the khatas.





Take a round of the dornier section and check for the

quality of the monograms. Incase of any non-conformity

found then correct the same

Prepare the monogram for the jacquard machines in the

dornier section

Perform preventive maintenance works on jacquard in

the dornier section




Weaving

Work Centre Khata 1

Designation Fancy Jobber


WLS No:WGL/09



Section

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1 1.28 10.25 13.12

2 1 1.28 7.34

3 1 1.28 6.22

4

2 1.28 9.34 23.91

51 1.28 1.68 2.15

6 1 1.28 8.54 10.93

7

2 1.28 34.67 88.76

8 2 1.28 18.21 46.62

91 1.28 5.35 6.85

102 2 57.50 230.00

A 422.33

B 13

C 477.24

D 900

E 53.03%F 2

G 53.03%

C GWeaving

Airjet looms

Beam Gaitor



To remove the heald frames,empty beam & droppins of

finished beam

WLS No:WGL/10


WeavingShifts A B

To change the leno bobbin in airjet at the time of beam

Fitting and passing threads through the reed (Work is

done on both side i.e. on one side tyeing the ends of

previous beam to the new beam,fixing the reed and on the

other side adjusting bolts,run contrast patti to check for

weaving damages ,placing roller

Final adjustment and make 1 meter fresh fabric of new

gaited loom & rectify all cross ends.

Call the shift incharge for final,checking and hand over

the machine for production.

To get the machine clean with the help of loom cleaner.

To get the machines lubricated with the help of Fitters

Gait the new beam on loom.

Arrange and adjust the beam carrying m/c on to the Airjet

m/cPut the correct weft yarn as per design on the loom card,

and run the machine with fresh fabric.

Remarks:




To pass the knots of knotted beam either of warping

knotting or loom knotting.




_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1 1.71 13.41 22.93

21 1.71 8.19

31 1.71 7.22

4

2 1.71 21.56 73.74

51 1.71 1.68 2.87

6

2 1.71 41.44 141.72

7

2 1.71 25.78 88.17

81 1.71 12.45 21.29

92 2 57.50 230.00

A 580.72

B 13

C 656.21

D 900E 72.91%

F 2

G 72.91%

WLS No:WGL/11


WeavingShifts A B G

Weaving



To get the machine clean with the help of loom

cleaner.

To get the machines lubricated with the help of

Fitters


Arrange and adjust the beam carrying m/c on to the

Sultex m/c

Put the correct weft yarn as per design on the loom

card, and run the machine with fresh fabric.

Sultex looms

Beam Gaitor


Fitting and passing threads through the reed (Work

is done on both side i.e. on one side tyeing the ends

of previous beam to the new beam,fixing the reed

and on the other side adjusting bolts,run contrast

patti to check for weaving damages ,placing roller

Drawing the ends in correct order and finaladjustment and make 1 meter fresh fabric of new


Call the shift incharge for final,checking and hand

over the machine for production.



C


To remove the heald frames,empty beam &

droppins of finished beam

Remarks:





_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1 1.71 21.11 36.10

21 1.71 11.12

31 1.71 6.47

4

2 1.71 16.46 56.29

51 1.71 1.82 3.11

6

2 1.71 75.22 257.25

7

2 1.71 32.43 110.91

81 1.71 19.45 33.26

92 2 57.50 230.00

A 726.93

B 13

C 821.43

D 900

E 91.27%

F 2

G 91.27%

Dornier looms

Beam Gaitor



To remove the heald frames,empty beam & droppins

of finished beam

WLS No:WGL/12


WeavingShifts A B




Remarks:

C GWeaving

Fitting and passing threads through the reed and fix

the correct Dobby card on the machine(Work is done

on both side and i.e.on one side tyeing the ends of

previous beam to the new beam,fixing the reed and

on the other side adjusting bolts,run contrast patti to

check for weaving damages ,placing roller etc)

Drawing the ends in correct order and final

adjustment and make 1 meter fresh fabric of new








To get the machine clean with the help of loom

cleaner.

To get the machines lubricated with the help of

Fitters


Arrange and adjust the beam carrying m/c on to the

Dornier m/c

Put the correct weft yarn as per design on the loom

card, and run the machine with fresh fabric.

Call the shift incharge for final,checking and hand

over the machine for production.

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1 21 4.72 99.12

2

1 4 20.68 82.72

3

1 21 13.28 278.88

4

1 21 7.10 149.08

5 1 21 2.18 45.68

61 2 31.32 62.64

71 2 9.60 19.20

8 1 2 2.74 5.48A 742.81

B 13

C 839.37

D 900

E 93.26%

F 2

G 93.26%


Open the bags and put the yarn in the racks as per

loom no wise(for 1 bag of 64 kg carrying 32 cones on

an average)

WLS No:WGL/13



Weaving


From Weft Godown to Loom shed

Inspecting and checking the requirements for each

m/c(total 140 m/c) and note on the paper

Fill the trolley (65-70 kg in a trolley) according to

requirement i.e as per beam ticket count, shade , lot

number

Carry the trolley to the respective m/cs and place in

the respective boxes(1 trolley can fulfil the

requirement of 3 m/cs )


Loomshed

Weft Distributor


From Looms shed to Weft Godown

Collecting semi used cones into trolley from 140 m/c

Carrying the trolley to weft godown and place in bags

to be taken to rewinding m/c



Remarks:30000 mtr=10000 kgs; by 60/40 rule,60 percent will go to warping and 40 percent to the

weft godown.So 4000 mtrs i.e.21 bags will be transferred to the weft godown and same will be

distributed in the loom per shift





_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

11 6 108.54 651.24

2 1 3 105.76 317.28

31 3 75.45 226.35

41 3 72.58 217.74

5 1 1 90.54 90.54A 1503.15

B 13

C 1698.56

D 2880

E 58.98%

F 4

G 88.47%

WLS No:WGL/14



Weaving

Clean the m/c with the help of cleaner

Collect waste(empty bags,polythene waste,gatta) from

each m/c and pack it separately

To segregate all types of yarn waste,length wise and

pack it

To segregate all types of fabric waste and pack it

Loom Shed

Waste Picker


Collect empty polythene,paper cones and plastic cones

in 3 separate bags




Remarks:





_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 2 2 2 2

Designation Proposed Manpower 2 2 2 2

Sl.

No

Crew

Size

Freq/

Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1 9 22.89 206.01

2 1 6 66.78 400.68

3

1 3 31.11 93.33

4 1 3 4.34 13.02

51 3 14.67 44.01

6 1 9 24.33 218.97

71 6 25.44 152.64

A 1128.66

B 13

C 1275.39

D 1860E 68.57%

F 4

G 70.85%


To remove the catch selvedge waste from waste box with

work divided among 3 workmen each having 40(sultex and

picanol),48(Donear) and 40(Airjet) m/c

WLS No:WGL/15



AirJet/sultex/ dornier


To clean the running machines with air pressure .

Help the fitter in removing the old heald frame set, drop

pins and reed from the machines where the beam has

finished.

Take the old set of drop pins, reed and frames to thedrawing in section carefully

To do the thorough cleaning of new gaited looms with air

pressure & cloth.

Loom Shed

Cleaner


To keep the loom shed neat & clean.

To collect the paper cones & polyethene, and transfer it to

bardana godown


Remarks:

The above worload sheets reflects the activity of two personnel in general shift and two personnel in

shift




_________________________________________________________________________ _______________







8 A. WEAVING MAINTENANCE - MECHANICAL

MAINTENANCE

_________________________________________________________________________ _______________







8 A

8.1 A


1 AIRJET FITTER - - - 1 1 - - - 2 2

2 DORNIER FITTER - - - 2 2 - - - 2 2

3 SULTEX FITTER - - - 2 2 - - - 2 2

Total 0 0 0 5 5 0 0 0 6 6

Man ower De lo ment

WEAVING MAINTENANCE - MECHANICAL MAINTENANCE

Proposed ManpowerRemarksS. No Section / Work area Designation

Present Manpower

__________________________________________________________________________________________________________ _______________________







8 A

8.2 A

8.2.1 A

a)

8.2.2

a)

b)

c)

-

-

-

-d)

Two fitters in each area are being proposed keeping in mind the importance of

getting the equipment up and running in the least possible time and to increase

the production output. The utilization for the two fitters in the sultex section

works out to be 77 % whereas in the dornier and the airjet sections the

utilization is 42.82 % and 38.56 %, after allowing for a loading factor of 80 %.

Observations

Technically if we proceed only as per workload, it is possible to combine both

the airjet and the dornier sections and a common crew of two fitters may man

the combined sections. However analyzing the data of breakdown maintenance

for a period of two months it is observed that in the span of two months there

has been one occurence of a simultaneous occurence in the airjet and the

dornier areas. There has also been two breakdowns in the airjet area on one day

and in the dornier areas for two days. Keeping in mind the possibility of

simultaneous occurence of breakdowns inside the sections and between the

sections, two seperate crews are being recommended for each of the above

mentioned areas. It is furthur recommeded that the company analyze the

occurence of the breakdowns in the two sections for a period of 2-3 years toobtain a reasonable estimate of the simultaneous occurences. If the

simultaneous occurences are not many then a common crew of two fitters may

be deployed to take care of both the sections.

WEAVING MAINTENANCE - MECHANICAL


Deploy two fitters in the general shift in the airjet area instead of the present

deployment of one in the general shift

Proposed Changes

The following need improvements to make the maintenance function more

effective

Records keeping

The start and end times for both the preventive maintenance and the breakdown

maintenance to be maintained. This would help in the analysis of the

breakdowns and in maintenance planning

The manpower has been computed with a loading factor of 80 % for the

maintenance personnel. The 80 % loading has been considered to take into

account the following

Variation in machine availability

Collection & deposit of tools, dress change

Effort variation

Getting consumables from the sub store etc,

_________________________________________________________________________ _______________







8 A

8.2 A



8.2.2

Use of standard operating procedures

Observations

For the preventive maintenance activities the personnel should use SOP's which

will also detail the time element of the activities to be carried out. Presently

checklists are used, but SOP's will reduce the variations and also act as

benchmarks

Effective supervision

It is observed that the breaks (tea and lunch) taken by the maintenance

personnel are not synchronized and the allowed time / more than the allowed

time for the same is utilized. The maintenance personnel to be trained and

educated that during the preventive maintenance / breakdown maintenance the

times for the breaks can be kept at minimum so that the crew is able to focus

better on the maintenance aspects

Coordination

Coordination between the mechanical and electrical maintenance sections is

poor leading to less effective maintenance levels. On two of the days when the

preventive maintenance activities in the mechanical section were studied it has

been observed that the electrical section did not perform the electrical side of

the preventive maintenance activities. Stopping a particular equipment again

only for electrical maintenance would lead to loss of time and effort

_________________________________________________________________________ _______________







8 A

8.3 A

S.No

1

2

3 AIRJET WGM/MECH/03


DORNIER

SULTEX ANDPICANOL

WGM/MECH/01

WGM/MECH/02



_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Year

BasicTime

(Hrs) -

man

hrs

Total

Time

(Hrs)

1

1.1 2 1040 1.87 1943.26

1.2 2 40 2.22 88.70

1.3 370.59

2

1.1 2 72 2.46 177.32

1.2 2 6 4.63 27.76

A 2607.63

B 15

C 2943.18

D 3840

E 76.65%

F 2

G 76.65%


1. Available man hours per year has been calculated @ 25 working days per month

Yearly maintenance

Net Available man-hrs per year



B C GMechanical

Sultex (number of machines - 40)


Total Workload ( in man hours per year)

WLS No: WGM/MECH/01


Weaving MaintenanceShifts A

Half yearly maintenance

Sultex and Picanol

Fitter

Remarks:


Breakdown maintenance

2. The crew size for breakdown maintenance is as per the requirement. We have only considered the

man hrs required for the performance of the activity

Picanol (number of machines - 6)

Monthly maintenance

Yearly maintenance


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Year

BasicTime

(Hrs) -

man

hrs

Total

Time

(Hrs)

1

1.1 2 48 11.68 560.56

1.2 2 999.79

A 1560.35

B 15C 1644.43

D 3840

E 42.82%

F 2

G 42.82%






Remarks:


Rest & Relaxation Allowances ( % )Total Workload ( in man hours per year)



Yearly maintenance


Dornier

Fitter


Dornier (number of machines - 48)

WLS No: WGM/MECH/02


Weaving MaintenanceShifts A B C G

Mechanical

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Year

BasicTime

(Hrs) -

TotalTime

(Hrs)

1

1.1 1 52 4.73 245.98

1.2 2 80 4.97 397.83

1.3 2 40 10.05 402.09

1.4 277.86

A 1323.76

B 15

C 1480.64

D 1920

E 77.12%

F 2

G 38.56%


Weekly greasing






Remarks:




Airjet

Fitter


Airjet (number of machines - 40)


Half Yearly maintenance

Yearly maintenance


WLS No: WGM/MECH/03



Mechanical

_________________________________________________________________________ _______________







8 B. WEAVING MAINTENANCE - ELECTRICAL

MAINTENANCE

_________________________________________________________________________ _______________







8.0 B

8.1 B


1 Shift maintenance Electrician 1 1 1 - 3 1 1 1 - 3

2

General shift

maintenance - attending

to major breakdowns and

preventive maintenance

Electrician - - - 3 3 - - - 2 2

3 Humidity plant Humidity attendant 1 1 1 - 3 1 1 1 - 3

4 Engineering Workshop Fitter / Turner - - - 2 2 - - - 1 1


6 Motor winding Motor winder - - - 1 1 - - - 1 1

7Lighting and outside

worksWireman - - - 2 2 - - - 2 2

8

Cleaning of return air

grills, ducts and RA wire

mesh

Cleaners - - - 3 3 1 1 1 - 3

Total 2 2 2 12 18 3 3 3 7 16


Man ower De lo ment

WEAVING MAINTENANCE - ELECTRICAL MAINTENANCE


__________________________________________________________________________________________________________ _______________________







8 B

8.2 B

8.2.1 B

a)

b)

8.2.2 B


maintenance to be maintained. This would help in the analysis of the breakdowns and

in maintenance planning


For the preventive maintenance activities the personnel should use SOP's which will

also detail the time element of the activities to be carried out. Presently checklists are

used, but SOP's will reduce the variations and also act as benchmarks. It has also been

observed that the crew use the mobile torch during the maintenance activities which is

not a healthy practice.


It is observed that the breaks (tea and lunch) taken by the maintenance personnel are

not synchronized and the allowed time / more than the allowed time for the same is

utilized. The maintenance personnel to be trained and educated that during the

preventive maintenance / breakdown maintenance the times for the breaks can be kept

at minimum so that the crew is able to focus better on the maintenance aspects

Coordination

Coordination between the mechanical and electrical maintenance sections is poorleading to less effective maintenance levels. On two of the days when the preventive

maintenance activities in the mechanical section were studied it has been observed that

the electrical section did not perform the electrical side of the preventive maintenance

activities. Stopping a particular equipment again only for electrical maintenance would

lead to loss of time and effort

WEAVING MAINTENANCE - ELECTRICAL


Deploy two electricians in the general shift for the attending of the preventive

maintenance and breakdown maintenance works instead of the present deployment of

three personnel in the general shift. The utilization is 48 % at 80 % loading factor.

Proposed Changes

Records keeping

Observations

Deploy one person in the workshop instead of the present deployment of two

personnel.

_________________________________________________________________________ _______________







8 B

8.2 B

WEAVING MAINTENANCE - ELECTRICAL


8.2.2 B

The activities to be so planned and peformed that the time taken is minimized.

Activites that can be carried out in parallel have to be planned. For example, when the

production personnel are shutting down the machine and handing over for production,

the maintenance personnel can start their activities such as keeping the grease gun

ready, bring all the tools, arrange in the workplace, bring the bearings and other

consumables which are likely to be changed and keep ready in the workplace. It is

observed that the personnel keep making rounds to the workshop often to get tools,

bearings etc,.

Planning

Observations

_________________________________________________________________________ _______________







8 B

8.3 B

S.No

12

3

4

5

6

7

8


Humidity plant operator WGM/ELE/08

Workshop fitter and turner WGM/ELE/07

Cleaners WGM/ELE/05

Lighting electricians WGM/ELE/06

Motor Fitter WGM/ELE/03

Motor winder WGM/ELE/04

WEAVING MAINTENANCE

General shift electriciansShift Electricians WGM/ELE/01

WGM/ELE/02


_________________________________________________________________________ _______________







Department

Section



12

Date Total time

1-Dec 345

2-Dec 525

3-Dec 445

4-Dec 490

5-Dec 300

6-Dec 395

7-Dec 495

2995

3

4

5

6

λ/μ = 0.2976 ~ 0.30

For λ/μ = 0.30 we find that the utilization of the shift electrician is 30 % only per shift.

Hence it is recommended that the deployment of one per shift may be continued and

additional works as deemed fit may be allocated to the incumbent whenever required

The average time to resolve a complaint works out to be 50 minutes and as per the time

distribution also the modal value is 45 minutes.

9

7

8

11

Number of complaints

7

Loomshed

Electrician

Data provided for the period december 1-7 (7 days)Number of complaints attended on each day and the total time spent for the same is

60

The average arrival rate λ is 60/7 = 8.57 per day and the average servicing rate μ =

24*60/50 = 28.8 per day

9

9

WLS No: WGM/ELE/01



Electrical

_________________________________________________________________________ _______________







Department

Section



1

2

3

4

5

PF CE PH CH

SULTEX 75.8 221.0 0.0 1.2 PF

CE

AIR JET 67.8 247.8 0.0 2.2 PH

CH

DORNIER 44.0 140.0 48.0 24.0

PICNOL 126.0 258.0 0.0 0.0

WARPING 27.0 224.0 0.0 17.0

H PLANT 120 * 0.0 0.0 360**

STABILIZER 3.2 9.0 0.0 0.0

TRANSFORMER 1.6 4.0 0.0 0.5

COMPRESSOR 153.5 36.5 0.0 307 **

BREAKDOWNMAINTENANCE

128.0 702.0 0.0 38.5

TOTAL 506.9 1842.3 48.0 82.2

*

**

Loomshed

Electrician

Contract

Electrician

Permanent

The yearly workload section wise is detailed below:

The preventive maintenance data was collected for all the category of machines. Check studieson a sample basis were carried out to ascertain the process being followed for the preventive

maintenance.

Detailed discussions were held with the incumbents and the supervisory personnel.

Breakdown maintenance data has been obtained for a period of two months and the same has

been extrapolated for a year.

The sum of the preventive maintenance and the breakdown maintenance workload for the year

gives us the total workload for the general shift electricians. The works performed by the

Motor Fitter, humidity plant operator and the cleaning personnel are refle

WLS No: WGM/ELE/02


Weaving MaintenancShifts A B C G

Electrical

Section

Included in the Motor Fitter workload and given in the separate workload

The cleaning personnel workload sheet detailes these activities. Hence the

total not considered here

Yearly Workload of Crew Category Involved (In hrs)

Permanent

Contract

_________________________________________________________________________ _______________







Department

Section



Loomshed

Electrician

WLS No: WGM/ELE/02


Weaving MaintenancShifts A B C G

Electrical

6

-

-

-

-

Collection & deposit of tools, dress change

Effort variation

For the two personnel recommended, the workload percentage appears to be 48 %. Two

personnel are recommended as the base crew size for this kind of maintenance activity is

two personnel

The yearly workload for the personnel works out to be 1842.3 hrs.The manpower has been computed with a loading factor of 80 % for the maintenance

personnel. The 80 % loading has been considered to take into account the following

Variation in machine availability


_________________________________________________________________________ _______________







Department

Section



1

2

3

4

5

S.No

1

2

6

WLS No: WGM/ELE/03



Electrical

Breakdown maintenance data has been obtained for a period of two months and the same has

been extrapolated for a year.

The sum of the preventive maintenance and the breakdown maintenance workload for the year

gives us the total workload for the general shift electricians. The works performed by the Motor

Fitter are reflected in this worklaod sheet.

The yearly workload for the Motor Fitter, section wise is detailed below:

Loomshed

Motor Fitter

The preventive maintenance data was collected for all the category of machines. Check studieson a sample basis were carried out to ascertain the process being followed for the preventive

maintenance.


Description

For the one person recommended, the workload percentage appears to be 53.48 % (at 80 %

loading)

Workload peryear (Hrs)

The yearly workload for the personnel works out to be 1026.9 hrs.

626.9Preventive and breakdown maintenance

Check all the motors in the loomshed, clean,

check earthing points, leakage etc.,

Total workload per year

400

1026.9

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Year

BasicTime -

man

hrs

TotalTime

(Hrs)

1

1 40 2.0 80.00

1 4 4.0 16.00

1 28 12.0 336.00

A 432.00

B 15

C 496.80

D 2400

E 20.70%

F 1

G 20.70%


Rewind the motors of the following categories, check its

performance

WLS No: WGM/ELE/04



Electrical


1 HP and Less

Between 1 HP to 7.5 HP

Above 7.5 HP

Motor Rewinding

Motor Rewinder

1. Man hours per year has been calculated @ 25 working days per month




2. The number of the motors serviced and rewinded have been obtained from the present

incumbent.

3. The utilization per year is 20.70 %. As this position has been filled recently, the company willhave to decide the continuity of this position based on the work which will be performed by this

position holder in the next one year. Also the pros and cons of sending the motors for outside

servicing and the advantages of an in house facility for this activity will have to be taken into

consideration by the company.




Remarks:

_________________________________________________________________________ _______________







Department

Section


Designation ProposedManpower1 1 1 -

Sl.

No C r e w S i z e

F r e q / Y e a r

B a s i c T i m e -

m a n m i n s

T o t a l T i m e

( H r s )

1

a)

1 300 22.10 110.50

b) 1 1095 22.95 418.84

c) 1 300 3.83 19.13

d)1 1095 38.25 698.06

e) 1 1095 2.55 46.54

f)1 300 17.14 85.72

g) 1 300 14.03 70.13

h) 2 1095 25.50 930.75

i)2 1095 51.00 1861.50

j) 1 1095 14.80 270.10

k)1 1095 26.40 481.80

2 307 **

3 360**

4 82.17

A 5075.23

B 14

C 5785.76

D 8760

E 66.05%

F 1

G 66.05%

Half Trenches inside the loomshed (two numbers - sultexand picanol area)

Galleries and rooms (3 numbers) above warping

Galleries and rooms (2 numbers) near the electrical

manager's room

Compressors (three numbers)

H plant

Trenches inside the loomshed (two numbers - dornier

area)








Battery room (inside grey checking)

Preventive and breakdown maintenance

Main Trenches below the weaving loomshed (7 channels)

Transfer the waste to the waste yard

Weaving power house by broomstick, equipments and

control panel by weaving waste

Work shop

Loomshed

Helpers


Clean the

Manager's room, steps in the department, weft godown,

humidity room near warping, electrical panel room in

warping, yarn godown no 2, collect waste in poly cover

and dispose in the dust binHumidity room adjacent to the sultex area

WLS No: WGM/ELE/05



Electrical

_________________________________________________________________________ _______________







Department

Section


Designation ProposedManpower1 1 1 -

Sl.

No C r e w S i z e

F r e q / Y e a r

B a s i c T i m e -

m a n m i n s

T o t a l T i m e

( H r s )

Loomshed

Helpers


WLS No: WGM/ELE/05



Electrical


2. Presently three personnel are working in the general shift, but discussions with the manager has

revealed that they would be deployed in the shifts after the training period

3. The time taken for the activities will be less than what is reflected here as the cleaning will be

taking place in all the shifts and not in general shift as at present. This will impact activites g,h,i,j,k

Remarks:

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Day

BasicTime -

man

mins

TotalTime

(mins)

1 1 1 30.00 30.00

2 1 1 60.00 60.00

3 2 5 48.00 480.00

A 510.00

B 15

C 586.50

D 960

E 61.09%

F 2

G 61.09%

WLS No: WGM/ELE/06



Electrical



Daily check the tubelights in mending, loom shed,warping

and drawing * 2

Attend to complaints in the various departments

Loomshed & outside

Electricians


KWH meter reading

3. This crew has attended 31 complaints in 7 days (29th dec - jan 4th), the data for which was

provided. The average number of complaints handled is ranging between 4 -5 per day with an

average handling time of 48 minutes.


Remarks:


2. During the studies in the various departments this activity by the electrical staff has not been

observed regularly and this actiivty does not add value. Hence this activity time is not included in

the total. Whenever there is a complaint then the same may be resolved by the deployed crew.

Total Workload ( in man hours per day)

Net Available man-hrs per day



_________________________________________________________________________ _______________







Department

Section



1

2

3

4

5

During the observations carried out, it has been observed that the primary work is performed

by the personnel who need the work to be carried out (various maintenance departments). The

workshop personnel only perform secondary works such as providing technical assistance in

the completion of the works.

The works being carried out in this department is not very complex and the equipment is very

old and not very high precision type.

Keeping in mind the above points, it is recommended that the workshop be manned by one

person.

Workshop

Fitter / Turner

The following equipment are present in the workshop: 2 lathes, 1 shaper, 1 planer, and 1power hacksaw. All the equipment are very old and the planer in fact is 1899 make model.


WLS No: WGM/ELE/07



Electrical

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

BasicTime -

man

mins

TotalTime

(mins)

1 1 1 30.00 30.00

2

a) 1 1 15.00 15.00

b) 1 1 30.00 30.00

c) 1 1 90.00 90.00d) 1 1 10.00 10.00

e) 1 1/18 90.00 5.00

f) 1 1/60 300.00 5.00

3 1 4 10.00 40.00

4

1 2/3 45.00 30.00

A 255.00

B 15

C 293.25

D 450

E 65.17%

F 1

G 65.17%

Once in two hours record readings from the 6

thermometers

Operate valves, perform back wash

Operate the softner plantPerform flashing

Operate the RO plant

Clean plant premises



Remarks:


Nozzle cleaning (performed only during the A and B

Clean the nozzles: during summer one hour spent on this

activity (about 4 in sultex and 3 in others) and during

winter 30 minutes spent on this activity (about 2 in sultex

and 2 in others). Hence taken 50 % @ 1 hour and 50 % @

30 minutes



Humidity plant

H plant operator


Check all the supply air fans ( 19 numbers) and return air

fans (13 numbers) and pumps (12 numbers) for the 7

plants daily



Clean the 6 filters in RO plant once in a week

Change salt every 20 days (70 Kg)

WLS No: WGM/ELE/08



Electrical

_________________________________________________________________________ _______________







9. WEAVING - QA

_________________________________________________________________________ _______________







9.09.1


1 Greige fabric checking Investigator / Checker - - - 1 1 - - - 1 1

Helper - - - 1 1 - - - 1 1

2 Weaving QA Investigator 1 1 1* - 2 1 1 - - 2

* Staff category and

the rest are contract

employees

3 QA - Process Lab Investigator 1 1 1 - 3 1 1 1 - 3

Total 2 2 1 2 7 2 2 1 2 7


Manpower DeploymentWEAVING - QA


__________________________________________________________________________________________________________ _______________________







9.0

9.2

9.2.1

a)

WEAVING - QA


Proposed Changes


_________________________________________________________________________ _______________







9.0

9.3

S.No

1

2

3

WEAVING - QA

Quality rounds and report preparation

Process lab WGQA/03

Checking of fabric received from theoutside vendors

WGQA/01

WGQA/02



_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

12 14 0.64 18.02

2 1 18 7.12 128.16

31 18 0.63 11.25

4 1 36 0.48 17.28

5 2 18 0.27 9.60

6 1 18 0.27 4.807 1 9 0.45 4.05

82 4 7.32 58.56

9 2 4 3.30 26.40

102 4 1.71 13.65

112 1 30.00 60.00

12 1 4 8.20 32.80

13 1 18 1.50 27.00

A 411.58

B 17

C 481.54

D 960

E 50.16%

F 2

G 50.16%

2. The inspection will be carried out in cycles of 20 minutes followed by a break of 17 % X 20minutes = 3.4 minutes. The two personnel will be carrying out the inspection in turns. When one

person avails tea break, the other can continue the inspection .

Write details of completed roll in the record, open new page,

write details of the new roll, set counter to zero

Entry of greige fabric checking in SAP

Remarks:




Checking of Ends & Picks of the all inspected fabric pieces

Collect the rolls to be processed from the respective storage

areas, weigh and stack near the machine

Transport completed rolls to the big batching machine

Others such as discussion with the superiors, getting

instructions etc,.

Write quality details on the fabric - twice

Untie knots, keep the completed roll in the designated area

Load new empty spindle, roll certain length of clothCut cloth piece at the end

1. The average length is considered as 100 meters





Place new roll on the stand, pull some cloth, tie two ends to

the previous fabric

Inspect fabric till the fabric roll is completed

Greige Fabric Checking

Investigator, Helper


Load new roll in the machine, pass through the rollers, pull

fabric till the inspection table

WLS No: WGQA/01



Quality Assurance

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 1 1 1* -


Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1.11 1 70.71 70.71

1.21 3 3.00 9.00

1.31 3 1.00 3.00

1.41 4 5.00 20.00

2 1 1 25.00 25.00

A 127.71

B 15

C 146.86

D 450

E 32.64%

F 1G 32.64%

* - Staff category


Ascertain the defects being noticed in the grey checkingmachines, note down the quality number and the defect

meters



Remarks:

WLS No: WGQA/02


WeavingShifts A


Quality Assurance

Investigator


Quality round of the loom shed - 134 looms

B C GQuality Assurance


Input data into the computer, file documents

Check for the quality of the fabric being woven in the

looms, mark defects by chalk

In case of non conformities, discuss with the production

supevisor

Prepare slips for the non-conformity observed and place

one slip in the roll being processed


_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1

1.1 1 1 26.32 26.32

1.2 1 3 10.23 30.70

1.31 1 105.26 105.26

1.41 1 21.93 21.93

1.5

1 1 31.14 31.14

1.6 1 1 24.92 24.92

1.7 1 1 62.30 62.30

1.8 1 1 5.00 5.00

2

2.11 1 42.10 42.10

2.2 1 3 10.23 30.70

2.3

1 1 31.14 31.14

2.41 1 62.30 62.30

2.51 1 5.00 5.00

2.61 1/9 60.00 6.67

2.71 1/6 60.00 10.00

Samples submission to despatch department, bills

collection from HOD office and forwarding to accounts

Yarn testing (Blend % & Colour fastness to washing) - 8

samples (1 reading)

Fabric sample collection from Process House - 14 samples

Development fabric testing (Width, GSM, Colour fastness

to washing, water & rubbing, Blend composition & Pilling)

- 5 samples (1 reading)

Outsourced fabric testing-bulk (Colour fastness to washing

& rubbing & Pilling) - 10 samples (1 reading)

Folding of the roll strips for grouping and returning back to

folding department - 60 strips

Material collection from stores (Chemical & stationary for

lab use)

Fibres testing (Colour fastness to washing) - 20 samples

(1 reading)

Sample preparation for CSV checking - 18 samples

(1 reading)

Shift B

Development fabric testing (Width, GSM, Colour fastness

to washing, water & rubbing, Blend composition & Pilling)

- 5 samples (1 reading)

Outsourced fabric testing-preshipment (Width, GSM,

Colour fastness to washing & rubbing, Blend composition,

Pilling) - 4 samples (1 reading)

Outsourced fabric testing-bulk (Colour fastness to washing

& rubbing & Pilling) - 10 samples (1 reading)

Folding of the roll strips for grouping and returning back to

folding department - 60 strips

Process lab

Investigator


Shift A

Instrument & Lab Cleaning

Fabric sample collection from Process House - 14 samples

WLS No: WGQA/03



Quality Assurance

_________________________________________________________________________ _______________







Department

Section



Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

Process lab

Investigator


WLS No: WGQA/03



Quality Assurance

3

3.1 1 3 10.23 30.70

3.2

1 1 18.69 18.69

3.3

1 1 124.60 124.60

A 669.47

B 14

C 763.20

D 1350

E 56.53%

F 3

G 56.53%

Fabric sample collection from Process House

Shift C

Bulk fabric sample testing-Domestic fabric (Width, Colour

fastness to washing & rubbing & Pilling) - 20 samples (1reading)

Remarks:







Basic Workload per day ( in man minutes)

Bulk fabric sample testing-RMG fabric (Width, GSM,

Colour fastness to washing, water & rubbing, Blend

composition & Pilling, CSV stitching) - 3 samples (1

reading)

_________________________________________________________________________ _______________







10. CHECKING, MENDING AND FINISHING

_________________________________________________________________________ _______________







10.010.1


1 Grey checking Checker 4 4 3 - 11 4 4 3 - 11

Loader 6 6 4 - 16 4 4 3 - 11

Segregator cum

Loader2 3 - - 5 - - - - -

2 Mending Damage reporter - - - 1 1 - - - 1 1

Menders - - - 45 45 - - - 28 28

Mended fabric

checker- - - 3 3 - - - 4 4

Loaders - - - 3 3 - - - - -

Cleaner - - - 1 1 - - - 1 1

Computer operator 2 - - 1 3 2 - - 1 3

3 Kitty mending Kitty Menders - - - 17 17 - - - 8 8

Totally 20 are there,

17 are in mending

and 3 in finish folding

4 Finish folding Finish Checker - - - 1 1 - - - 1 1

5 Perching Checker 4 4 4 - 12 2 2 2 - 6

6 Fold machine Operator - - - 3 3 - - - 2 2

Helper - - - 3 3 - - - 2 2

7 Grading section Monitor - - - 1 1 - - - 1 1

Sample man - - - 2 2 - - - 2 2

Loader - - - 2 2 - - - 2 2

Grader - - - 25 25 - - - 18 18

THAN loader - - - 2 2 - - - 2 2


Manpower DeploymentCHECKING, MENDING AND FINISHING


__________________________________________________________________________________________________________ _______________________







10.010.1



Manpower DeploymentCHECKING, MENDING AND FINISHING


Cut piece grader - - - 9 9 - - - 7 7

Kitty Menders - - - 3 3 - - - 2 2

8 THAN packingBar code sticker

operator- - - 1 1 - - - 1 1

Manpower

deployment given per

Helper - - - 3 3 - - - 3 3

THAN folder - - - 2 2 - - - 2 2 Per line

THAN screening - - - 1 1 - - - 1 1 Per line

THAN stamper - - - 1 1 - - - 1 1 Per line

Wrapper man - - - 1 1 - - - 1 1 Per line

Poly bag man - - - 1 1 - - - 1 1 Per line

THAN segregator - - - 3 3 - - - 3 3

9 PL Packing section PL Packers - - - 16 16 - - - 16 16

FRC Sorter - - - 2 2 - - - 1 1

10 B & R Inspection Finish Checker - - - 1 1 - - - 1 1Inspector 8 8 8 - 24 7 7 7 - 21

Packers 6 6 4 - 16 4 4 4 - 12

Sample man - - - 1 1 - - - 1 1

11 Finish folding Helper - - - 4 4 - - - 4 4

Computer operator - - - 2 2 - - - 2 2

Cleaner - - - 2 2 - - - 1 1

Total 32 31 23 163 249 23 21 19 121 184

__________________________________________________________________________________________________________ _______________________







10.0

10.2

10.2.1

a)

b)

c)

d)

e)

f)

g)

h)

i)

j)

k)

l)

Fold machines - operate two machines per day to fulfill the production requirements of

26500 per day, hence deploy 4 personnel instead of the present deployment of 6

personnel

THAN grader - deploy eighteen personnel instead of the present deployment of twenty

five per day based on workload

CP grader - deploy seven personnel instead of the present deployment of nine per day

based on workload

Kitty mender in grading - Deploy 2 personnel instead of the present deployment of 3personnel, based on workload. The graders may be trained in this activity also so that

this position may be eliminated in the long run.

FRC sorter - Deploy 1 person instead of the present deployment of 2 personnel, based

on workload.

CHECKING, MENDING AND FINISHING


Proposed Changes

Mending checker helper - Deploy none as mender helper inspead of the present

deployment os one along with each checker. The utilization amounts to 14.69 % and

these activities may be performed by the mender who takes his fabric for re-inspection.

Kitty mender - Deploy 8 personnel instead of the present deployment of 17 personnel,

based on workload.Perching - deploy two operators per shift instead of the present deployment of 4 per

shift. The organization needs to operate only two machines per shift

Deploy one personnel for two machine as loaders in the grey checking area instead of the present deployment of three personnel for two machines. The workload works out to

be 15.28 % per shift per machine. Also the activities of the segregator cum loader are

also to be performed by these loaders. During the inspection of the rolls adequate time

is available to carry out the segregator cum loaders's activities also. At the outset it is

recommended that one person per machine be deployed and thereafter this may be

rationalized to the above staffing pattern after some period of working.

Segregator cum loader - deploy none per shift instead of the present deployment of 2 in

A shift and 3 in the B shift. The activiites will henceforth be performed by the grey

checking loaders. The utilization per shift is 10.29 % for each of the two personnel

deployed.

Menders - Deploy 28 menders in general shift instead of the present deployment of 45

in general shift. An allowance of 17 % has been provided and the personnel may avail

these allowances after the time specified in the workload sheets.

Mender checkers - Deploy 4 personnel in general shift inatead of the present

deployment of three personnel, if all the 9000 meters have to be checked.

_________________________________________________________________________ _______________







10.0

10.2

10.2.1



Proposed Changes

m)

n)

o)

B & R inspection - packers - deploy 4 personnel per shift instead of the present

deployment of 6 personnel. The breakup of the activities are explained in detail in the

workload sheet

Finish folding - cleaner - deploy one person in the general shift instead of the present

deployment of two per day based on workload

Rolling cum inspection - Checkers - Operate 7 machines per shift instead of the presentoperation of eight machines, hence deploy 7 personnel as checkers instead of the

present deployment of 8 personnel per shift

_________________________________________________________________________ _______________







10.0

10.3

S.No

1

23

4

5

6

7

8

9

10

11

12

1314

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

Cleaner - finish folding

Monitor

Finish checker - B & R section

Bale helpers

Sample man - B & R section

Bar code operator - B & R section

Computer operator - B & R section

THAN segregator

PL packer - bar code operator

PL packer - screening

FRC sorters

Rolling machine inspection B & R

section

Packers - B & R section

Alignment helper

THAN folder

Screening

Stamping

Wrapper man

Poly bag man

THAN grader

Cut piece grader

THAN loader

Kitty mender in grading

Perching checker

Finish fold operator and helper

Sample man

Finish folding loader

Bar code operator

Mender checker helper

Kitty mender

CMF/38

CMF/30

CMF/31

CMF/32

CMF/33

CMF/26

CMF/27

CMF/39

CMF/40

CMF/41

CMF/34

CMF/35

CMF/36

CMF/37

CMF/28

CMF/29

CMF/22

CMF/23

CMF/24

CMF/25

CMF/16

CMF/17

CMF/18

CMF/19

CMF/20

CMF/21

CMF/12

Computer operator - mending

CMF/10


CMF/14

CMF/15

CMF/08


CMF/09

Damage Reporter

CMF/13


Grey checking loader

Cleaner - mending

CMF/11

Finish Checker - finish folding

Segregator cum loader CMF/03

Mender CMF/04

CMF/07

Mender checker CMF/05

CMF/06

Grey Checker CMF/01

CMF/02



_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 20 10.67 213.40

2 1 20 0.63 12.60

3 1 40 0.48 19.20

4 1 1 25.64 25.64

A 270.84B 17

C 316.88

D 440

E 72.02%

F 1

G 72.02%



Others such as discussion with the superiors, getting

instructions etc,.

Remarks:






Inspect fabric till the fabric roll is completed

Write details of completed roll in the record, open new

page, write details of the new roll, set counter to zero

Write quality details on the fabric - twice

Grey Checking

Checker


2. The inspection will be carried out in cycles of 24.52 minutes followed by a break of 17 % X 24.52

minutes = 4.2 minutes. There can be 14 cycles of inspection in the shift, after accounting for 30

minutes of discussions and a tea time of 14.2 minutes. One of the breaks has to be combined with the

time of ten minutes provided to make a tea time of 14.2 minutes. 14 cycles has been calculated based

on 410 minutes ( 450-10 minutes tea - 30 minutes discussions). In each cycle 300 meters of fabric

can be processed

WLS No: CMF/01


Checking, Mending

& finishing Shifts A B C G

Grey Checking

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 16 0.46 14.72

2 2 20 0.27 10.67

3 1 20 0.12 2.40

4 1 20 0.27 5.33

5 2 20 0.32 12.98

6 2 4 1.71 13.68

A 59.78

B 15

C 68.75

D 450

E 15.28%

F 4

G 15.28%

Remarks:


Keep the empty roll in the designated area








Grey Checking

Loader


Place new roll on the stand, pull some cloth, tie two ends to

the previous fabric

Load new roll in the machine, pass through the rollers, pull

fabric till the inspection table

Untie knots, keep the completed roll in the designated area

Load new empty spindle, roll certain length of cloth

Collect the rolls to be processed from the respective

storage areas, weigh and stack near the machine

2. The utilization being 15.28 % for one person, one loader should be able to handle all four

machines, but keeping in mind the interference it is recommended that one loader may be allocated

two machines each. The checker will assist the loader in activities wherein the crew size is two

personnel.In the initial stage one person per machine is recommended,later one person per two

machine could be reached

WLS No: CMF/02


Checking, Mending &

finishing Shifts A B C G

Grey Checking

_________________________________________________________________________ _______________







Department

Section


Designation Proposed Manpowe - - - -

Sl.No

CrewSize

Freq/ Shift

BasicTime

(Mins)

TotalTime

(Mins)

1 2 5 0.69 6.86

2 2 67 0.51 68.34

3 1 5 0.44 2.20

4

5 1 1 10.00 10.00

A 87.40B 13

C 98.76

D 960

E 10.29%

F -

G -

Remarks:

1. For stacking the rolls the present norm is 4000 meters per person. Since 5 personnel are deployed

per day, 20000 meters has been considered per day. The average roll length is 150 meters, hence

giving us about 134 rolls to be processed per day. Converting this on a per shift basis we get 67 rolls

to be processed per shift.

2. This position is not being recommended. It is suggested that this activity be performed by the

machine loaders.

In case of any problem, reconsile






Grey Checking

Segregator cum Loader


Transport rolls from the grey checking machines to work

area


Stack the rolls as per the sequence, note details in the

register

Move the empty trolley back to grey checking area

Send recorded figure in the register to the computer

WLS No: CMF/03


Checking, Mending &Shifts A B C G

Grey Checking

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

(meters)

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 9000 1.00 9000.00

21 60 3.49 209.23

31 60 1.00 60.00

4 1 9000 0.18 1620.00

51 60 1.04 62

A 10951.63

B 17

C 12813.41

D 480

E 59.32%

F 28G 95.34%

Time in minutes per

meter

Weight

ed

average

0.16 0.04

0.36 0.09

0.963 0.24

2.52 0.63

1.00






Category


1

Weight

25%


Remarks:

1. The time of one minute per meter of fabric has been arrived at after studying the various categories

of the fabric being mended and based on the time taken for each of these categories. Based on the

discussions with the various personnel it was decided to allocate 25 % weightage to each of the four

categories. The weighted average time per meter is 60 seconds ~ 1 minute. If the weights are going to

change in the future then the weighted average time also will be changing.

2

3

4

25%

25%

25%

Mending

Mender


Put the piece on the mending table for mending, rectify

the defects if found on the mending table, put flag on

unmendable defects

Weighted average time in minutes per meter

Collect fabric in trolley, transport trolley to the rerolling

machine / mending checker and back to work place

Transport the 'to be processed material' near the work

place and reposition trollies after completionCheck the fabric along with the mended fabric checker

Reposition trollies, tie knots to the fabric and push

fabric in the bin

WLS No: CMF/04


Checking, Mending &

finishing Shifts A B C GMending

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

(meters)

Basic

Time

(Mins)

Total

Time

(Mins)

1

2

A 1593.00

B 17

C 1863.81

D 480

E 129.43%

F 4

G 97.07%


Remarks:

1. The time of one minute per meter of fabric has been arrived at after studying the various categories

of the fabric being mended and based on the time taken for each of these categories.





1 9000


0.18


1593

Mending

Mender Checker


Check the fabric along with the mender, get mendable

defects corrected by the mender

Record the details of the fabric checked and send to the

computer operator

WLS No: CMF/05


Checking, Mending

& finishing Shifts A B C GMending

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 60 1.04 62

A 62.40

B 13

C 70.51

D 480E 14.69%

F -

G -


Remarks:

1. This activity may be performed by the mender who brings his fabric for checking. This is being

shifted to the corresponding workload sheet.




Mending

Mender Helepr


Reposition trollies, tie knots to the fabric and push

fabric in the bin



WLS No: CMF/06


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 23 0.97 44.62

22 1020 2.59 2641.80

A 2686.42

B 17

C 3143.11D 480

E 38.52%

F 8

G 81.85%

Time in man-minutes

per meter

Weighte

d

average

0.67 0.17

1.95 0.49

2.46 0.62

5.28 1.32

2.59

2 25%

Weighted average time in minutes per meter

2. Four groups of two personnel each are being recommended.

3 25%

4 25%


Remarks:

1. The time of one minute per meter of fabric has been arrived at after studying the various

categories of the fabric being kitty mended and based on the time taken for each of these categories.

Based on the discussions with the various personnel it was decided to allocate 25 % weightage to

each of the four categorie. The weighted average time per meter is 2.59 man-minutes per meter. If the

weights are going to change in the future then the weighted average time also will be changing.

Category Weight

1 25%






Check and remove the superficial defects in the fabric

after observing the singeing and finish fabrics

Kitty Mending

Kitty Mender


Load new fabric roll, reposition trollies

WLS No: CMF/07


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 30.00 30.00

21 1 60.00 60.00

3

1 1 60.00 60.00

4

1 1 15.00 15.00

A 165.00

B 15

C 189.75

D 480

E 39.53%

F 1

G 39.53%



Based on the feedback of the menders, inspect the piece,

call the concerned supervisor of weaving, discuss with

him enter details in the register


Remarks:





Mending

Damage Reporter


Distribute the fabric after grey checking and make

entries in the allocation register

Enter details mender-wise in the mender's production

register

Based on the feedback of the menders, inspect the piece,

call the concerned supervisor of spinning, discuss with

him enter details in the register

WLS No: CMF/08


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 17.54 17.54

2 1 1 39.47 39.47

3 1 1 26.32 26.32

4 1 1 13.16 13.16

5 1 1 13.16 13.16

6 1 1/2 13.16 6.58

7 1 1 19.74 19.74

8 1 1 26.32 26.32

9 1 1 10.00 10.00

Calculate 'upto date' and 'daily' production for loomshed

in SAP and export data to excel to prepare 'khata wise

daily grey checking report'

Calculate the stock pending in the mending from SAP

and convert to excel

Perform loom out after the completion of the grey

checking, mending and mending checking

Make entry from the menders production register to

excel sheet and once in 15 days calcualte the quantum of

work completed using calculator and record the same inregister

Manually enter the number of personnel present after

checking, in a printed format, check with the deposited

cards, & for people who are on OT make entry in the

OT register. Prepare OT list, send to time office. Get the

'daily present employee list for the date' every 2-3 days

from the time office and verify with manually entered

data in OT register. In case of any deviations in the list,

go to the time office and clarify. Get sign of the section

head and the departmental head on the 'daily present

employee list for the date' and submit to time office

Enter leave details in the register and submit the forms

to time office

Mending

Computer operator


Mark attendance for all workmen (77 in mending and 24

in grey checking)

For material going out for mending, prepare challan sub-

contractor wise. Compute the total per day per worker

employed and check whether it matches with 4000

meters

Prepare loomwise major damage report

WLS No: CMF/09


Checking, Mending &


Mending

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

Mending

Computer operator


WLS No: CMF/09


Checking, Mending &


Mending

10 1 1/7 120.00 17.14

A 189.42

B 15

C 217.84

D 480

E 45.38%

F 1

G 45.38%



Remarks:






Prepare special reports as per the instructions of the

HOD

_________________________________________________________________________ _______________







Department

Section

Work Centre Present Manpower 1 - - -

Designation Proposed Manpower 1 - - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 276 0.31 84.64

2 1 1 13.50 13.50

3 1 1 15.00 15.00

4 1 1 13.16 13.16

5 1 1 13.50 13.50

6 1 1 10.00 10.00

7 1 1/7 120.00 17.14

A 166.94

B 13

C 188.64

D 450

E 41.92%

F 1

G 41.92%

Prepare special reports as per the instructions of the HOD




Remarks:





Mending

Computer operator


Enter grey checking report in SAP for all 3 shifts (276 per

day) (quality, meter and weight)

Make entries of the checkers in SAP

Input piece number and code number of menders in SAP from

the allocation register and after completion of works, enter

details in SAP

Input piece number and code number for material being sent

out for mending in SAP

Prepare loom damage report from grey checking report

When the mended material returns from the sub-contractor,

make necessary entries in SAP

WLS No: CMF/10


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 276 0.46 126.91

2 1 1 40.00 40.00

3 1 1 15.00 15.00

4 1 1 15.00 15.00

5 1 1/7 120.00 17.14

A 214.06

B 13

C 241.88

D 480

E 50.39%

F 1

G 50.39%

1. For both the compter operators put together the utilization is 90 %. Once computer operator is

recommended in the general shift.






Prepare 'summary of non-compliance pieces from

01.01.2012 onwards', in excel

For a particular quality number, if the defects are more then

take out the particular grey checking report, based on the

instructions of the superiors

Receive 'off standard card' from weaving production, enter

the piece number and meters and hand over to quality


Remarks:

Mending

Computer operator


Enter grey checking report in SAP for all 3 shifts (276 per

day) (defects details)

Prepare special reports as per the instructions of the HOD


WLS No: CMF/11


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section


Designation Proposed Manpower 1 - - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 85.03 85.03

2 1 1 81.40 81.40

3 1 1 3.00 3.00

A 169.43

B 13

C 191.46

D 450

E 42.55%

F 1

G 42.55%

WLS No: CMF/12


Checking, Mending &

finishing Shifts A

Cleaner


Clean with broom stick the mending and grey checking

area

B

Collect dust and waste in the polythene covers and

tranfer to the waste yard



Mending


C GMending

Remarks:





Clean with mop the mending and the grey checking

areas

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 45.00 45.00

a)

b)

c)

2 1 1 30.00 30.00

3 1 1 10.00 10.00

4 1 1 60.00 60.00

5 1 1 15.00 15.00

A 160.00B 15

C 184.00

D 480

E 38.33%

F 1

G 38.33%



Remarks:





Measure the cut pieces cut by graders

Reverse fold (place yellow strip inside)

Direct fold (green slip)

Reject slip

Match the samples with the process house materials

Finish Folding

Finish Checker


Check the process batch card for QC approval. If

approved, then make entries in the register for

qualititeswhich are to be sent for

In the direct fold machine check the length and in case

of any problem, get it rectified by the fitter

Enter details of the data written in the register into excel

sheet. Take out printout. Send the data regarding the

pieces packed to marketing department who in turn

provide information regarding the assortment to be

carried out.

WLS No: CMF/13


Checking, Mending

& finishing Shifts A B C GFinish Folding

_________________________________________________________________________ _______________







Department

Section


Designation Proposed Manpower 2 2 2 -Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 60 1.08 64.64

2 1 60 0.29 17.28

3 1 60 7.35 441.00

4 1 6 2.32 13.92

5 1 10 0.80 8.00

6 1 10 1.60 16.00

A 560.84

B 17

C 656.18

D 440

E 37.28%

F 2G 74.57%





2. For a production of 6000 meters per shift, two machines need to be operated and hence two

operators per shift are being recommended

3. The inspection will be carried out in cycles of 17.44 minutes followed by a break of 17 % X 17.44

minutes = 3.0 minutes. There can be 20 cycles of inspection in the shift, after accounting for 15

minutes of discussions and a tea time of 13.0 minutes. One of the breaks has to be combined with the

time of ten minutes provided to make a tea time of 13.0 minutes. 20 cycles has been calculated based

on 425 minutes ( 450-10 minutes tea - 15 minutes discussions). Each cycle 200 meters of fabric canbe processed.


Remarks:

1. Each roll is 100 meters and the processing is 6000 meters per shift



Transport empty horse to the process house, check

materials on new horse, and transport the new horse to

the perching machineInsert new tag cartridge

Transport completed trolley to the next work station

and bring back empty trolley and position

Perching

Perching Checker


Tag at four places and affect changeover

Reset meter and start new page

Perform checking, insert tag whereever required, note

details in the register

WLS No: CMF/14


Checking, Mending &


Finish Folding

_________________________________________________________________________ _______________







Department

Section


Designation Proposed Manpower 4 4 4 -Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 27 0.99 53.64

2 1 27 0.20 5.40

3 1 27 1.59 42.84

4 1 265 2.09 553.85

5

6

7 1 265 1.48 392.20

8 1 265 0.48 125.889 1 265 0.21 56.31

A 1396.89

B 14

C 1592.46

D 480

E 331.76%

F 4

G 82.94%

Pull fabric from the fold machine onto work table

Perform counting

2 265 0.31

Position trolley, load fabric onto it



2. Two machines per shift need to be operated to fulfill the production requirements of 26500 meters

per day.





Remarks:

1. Folding time and checking time is for 100 meters

C G

Finish Folding

166.77


Scrutinize papers

Pull fabric into the machine, adjust

Start folding

Push completed onto work table and tear fabric

Write details on fabric, paper

Finish folding

Operator


Position perching trolley

WLS No: CMF/15


Checking, Mending &

finishing Shifts A B

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 200 0.82 164.00

2 1 200 0.25 50.00

3 1 200 0.99 197.50

4 1 200 0.56 112.00

5 1 200 0.75 150.00

6 1 30.00 30.00A 703.50

B 14

C 801.99

D 480

E 83.54%

F 2

G 83.54%

Grading

Sample man


Cut sample cloth, write number on cloth, keep aside,

arrange, compare with assorted grey card

WLS No: CMF/16


Checking, Mending &

finishing Shifts A B C GFinish Folding




Clarify shade number to the next section personnel

Paste the sample fabric in the sample book

Print out bar code stickers, stick and tag

Deliver sample fabric to warehouse

Maintain sample book of production, marketing and

ware house seperately

Remarks:





_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 265 0.21 56.31

2 1 150 1.91 285.75

A 342.06

B 14

C 389.95D 480

E 40.62%

F 1

G 81.24%

C GFinish Folding

Grading

Loader


Assist folding helper to load fabric to the trolley

WLS No: CMF/17


Checking, Mending &



Shift double folded fabric to the graders, write piece

number, quality number and graders name in the note

book

Remarks:







_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2

3

4

5

6

7

8

9

10 1 1 270.00 270.00

11 1 200 0.31 62.00

A 6955.33B 17

C 8137.74

D 480

E 67.81%

F 18

G 94.19%

90.00

2. The present practice of each person grading 1000 meters each has been aggregated for the 25

graders as 25000 meters per shift

Remarks:

1. Point 1-7, the frequency is mentioned in meters

Unload the folded fabric near to the work table


WLS No: CMF/18


Checking, Mending &


Grading

THAN Grader


1Cleaning the grading table before starting the grading.

Put folded piece on the table for grading.

Check the piece throughly .

Take out the fresh THAN , Safari ,Suit length , PL

,Cut and FRC to avoid the defects.

Recording the THAN, PL,and FRC in the grading

inspection sheet.

Send back the fabric for rectification which is having

stain, crease, seinging line.Wrapper mark, width

variation to process house

0.26 6533.33







Discuss with Incharge, get clarifications etc,.

90.00

Put the damage fabric on the damage table for showing

the defects the concerned departmental Head.

Put the PL/Cut Length / and FRC in the specified area.

Put the stamp of category wise on PL/CL/ and FRC.

25000

11

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2

3

4

5

6

7

8 1 1 175 175

9 1 58 0.31 17.98

A 2743.48

B 17

C 3209.87

D 480

E 74.30%

F 7G 95.53%

2515.5

35

Unload the folded fabric near to the work table


Discuss with Incharge, get clarifications etc,.

1 5850 0.43

1 1

1. Point 1-5, the frequency is mentioned in meters





35Put the stamp of category wise on PL/CL/ and FRC.

Put the PL/Cut Length / and FRC in the specified area.

Remarks:

GFinish Folding

2. The present practice of each person grading 650 meters each has been aggregated for the 9 graders

as 5850 meters per shift

Cleaning the grading table before starting the grading.

Put folded fabric piece on the table for grading.

Check the piece throughly .

Take out the fresh , Safari ,Suit length , PL ,Cut and

FRC to avoid the defects.

Recording the PL,and FRC in the grading inspection

sheet.


Grading

Cut piece Grader


WLS No: CMF/19


Checking, Mending &

finishing Shifts A B C

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 19 8.10 307.80

2 2 19 4.14 157.32

A 465.12

B 14

C 530.24

D 480

E 55.23%

F 2

G 55.23%

Remarks:

1. As per data provided, 15000 meters ie., 1500 thans have to be transported daily. Out of this 50

% has been considered as transporting upto the work table and which involves no unloading and 50

% has been considerd as transporting to the concerned area and unloading in that area. Also in each

trip on an average 40 thans are transported, hence there is a need to make 38 trips per shift. 19 trips

are for option 1 and 19 trips are for option 2.







Lift THAN from the grading sheet and shift to the

patti for folding and unload in the concerned area


Grading

Loader


Lift THAN from the grading sheet and shift to the

patti for folding

WLS No: CMF/20


Checking, Mending


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 15000 0.03 480.00

A 480.00

B 17

C 561.60

D 480

E 39.00%

F 2

G 58.50%





3. Keeping in mind the random nature of occurrence of these events, a manpower of two personnel

is recommended and the utilization level is 58.5 % each per shift.


Remarks:

1. As per data provided, 10 % of the thans require to be kitty mended every day. Daily 1500 thans

are produced, hence 150 thans may require kitty mending.

2. In the 216 meters graded, kitty mending was performed 5 times and time spent was 6.95

minutes. Extrapolating this to 15000 meters we obtain the time thans may require kitty mending in

a shift.



Grading

Kitty Mender


Based on the calls of the individual graders, go to the

concerned table and rectify the defects.

WLS No: CMF/21


Checking, Mending


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 550 0.30 165.00

2 1 550 0.27 147.40

A 312.40B 14

C 356.14

D 480

E 74.20%

F 1

G 74.20%



Remarks:





Grading

Bar code Sticker

Operator


Pick thans from the trolley, input meters into SAP,

take printout of the bar code sticker and place in the

than bundle. Write details in the register.

Affix one sticker onto the fabric, the other onto the

tag, attach tag using tag gun, forward to than folder


WLS No: CMF/22


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 990 0.27 267.30

2 1 30.00 30.00

3 1 10.00 10.00

4

A 297.30

B 14

C 338.92

D 480

E 70.61%

F 1

G 70.61%

Remarks:







Grading

Helper


Check alignment and cut end of piece

Provide raw material for packing


Bring water bucket for washing the stamps

Assist in joining the wrappers in case of graviera

Finish Folding

WLS No: CMF/23


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2

A 366.85

B 15

C 421.88

D 480

E 87.89%

F 1

G 87.89%





Remarks:

1. 275 thans per day has been considered based on the data provided. Based on the field study

conducted, the time provided is for a than with an average length of 11.6 meters.

1 275 1.334 366.85



B C

Grading

THAN Folder


Check the than length, wrap the fabric on the stra board

patti, transfer the than to the screening work station

G

Finish Folding


Show the defective piece to the officer, and return back

to the grader for rectification of the same

WLS No: CMF/24


Checking, Mending &

finishing Shifts A

_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 550 0.62 341

A 341.00

B 15

C 392.15

D 480

E 81.70%F 1


Remarks:

1. 550 thans per day has been considered based on the data provided.






Grading

Screener


Transfer the print screening on the than and forward

the than to stamping

WLS No: CMF/25


Checking, Mending


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 550 0.46 253

A 253.00

B 15

C 290.95

D 480

E 60.61%F 1

G 60.61%



Remarks:





Grading

Stamper


Stamp the quality number, shade number, meters and

forward the than to the next work station


WLS No: CMF/26


Checking, Mending


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 550 0.47 258.5

A 258.50

B 14

C 294.69

D 480

E 61.39%F 1

G 61.39%



Remarks:





Grading

Wrapper Man


Stamp the quality number, shade number, meters and

forward the than to the next work station


WLS No: CMF/27


Checking, Mending


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 550 0.462 254.1

A 254.10

B 14

C 289.67

D 480

E 60.35%F 1

G 60.35%



Remarks:





Grading

Poly Bag Man


Put the than in the specified poly bag, close mouth with

cello tape and place in patti


WLS No: CMF/28


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1100 0.29 319

A 319.00

B 14

C 363.66

D 480

E 75.76%F 1

G 75.76%



Remarks:

1. 550 thans per day has been considered based on the data provided. One person mans two lines

presently. As the utilization per line is 76 %, the present manning pattern may be continued




Grading

Than Segregator


Put the than in the specified poly bag, close mouth

with cello tape and place in patti


WLS No: CMF/29


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 600 0.25 151.07

2 1 600 0.07 41.4

3 1 1 3.95 3.945

3.1

3.1

4 1 600 0.14 86.3

A 282.72

B 14

C 322.30

D 480

E 67.14%

F 1

G 67.14%

Remarks:1. 600 pieces per day has been considered based on the data provided.

Arrange for packing

Take trolley, go to the storage, get pattis, unload and

arrange in work place

Get poly baks from storage

Pack the PL using the pattis, poly covers



PL packing

Bar code operator cum

packer


Count, generate bar code for the PL, affix two numbers

on each, arrange bundle and keep in the prescribed place



Sign on sticker




WLS No: CMF/30


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 2400 0.14 336.8

A 336.80

B 14

C 383.95

D 480

E 79.99%

F 1

G 79.99%

Remarks:

1. 2400 pieces per day has been considered based on the data provided.







PL packing

Screener


Transfer the print screening on the PL

WLS No: CMF/31


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 400 0.13 104

A 104.00

B 14

C 118.56

D 480E 12.35%

F 1

G 24.70%



Remarks:

1. 10000 kg to be segregated per month which works out to be 400 kg per day.

2. One person recommended for this activity.




PL packing

FRC Sorter


Segregate the fabric grade-wise, unit wise, pack in the

bag and keep aside


WLS No: CMF/32


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 35.00 35

2 1 80 2.55 204

3 1 8000 0.25 1990.4

4 1 2 4.64 9.28

5 1 1 105.00 105.00

A 2343.68

B 17

C 2742.11

D 440E 77.90%

F 7




Discussion with superiors

Remarks:

1. For an inspection of 8000 meters per day, 7 machines need to be operated per day.


Carry out inspection, put flag where defect is sighted,enter details in the inspection register

Transport empty horse to the process house, check

materials on new horse, and transport the new horse to

the rolling inspection machine



Rolling cum inspection

Inspector


Clean machine before starting inspection

Change output rolls - Remove the completed roll and

place on adjacent rollers, insert cardboard roll & roll

some fabric onto it, cut piece and throw in dust bin, cut

one sample piece and keep aside, tag the completed roll,

write details on the completed r

WLS No: CMF/33


Checking, Mending &


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 133 1.31 348.46

2 2 133 0.36 95.228

3 1 133 0.25 33.25

4 2 133 0.66 175.0285 1 33.25 1.18 39.24

6 1 133 0.36 47.88

A 739.08

B 14

C 842.55

D 450

E 31.21%

F 4

G 46.81%

B


Packers

Wrap rolls with poly cover, put cello tape

Stack roll in the designated place and back

WLS No: CMF/34


Checking, Mending &

finishing Shifts A

Write the details of rolls being packed in a register


B & R Inspection

Remarks:


b) One person for writing the details in the register and generating bar code

C G

Finish Folding




Pick rolls from the trolley, place on table, put poly covers,

cut extra threads, attach two stickers ('face side' and 'fabric

once cut cannot be claimed') and push rolls to the next

work station


Generate bar code, affix stickers on the rolls

c) One person for stacking the rolls and acting as an online reliever for the two personnel mentioned in

a)

1. For processing of 8000 meters per day, 133 rolls need to be processed @ 60 meters per roll.

Transport rolls from the rolling inspection to work place

2. Instead of the six personnel per shift a manning of four is recommended:

a) Two personnel for performance of activities 1,2 and 4


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 160 1.68 538.24

2 1 480 0.68 327.36

A 865.60

B 14

C 986.78

D 480

E 51.40%

F 4

G 51.40%

WLS No: CMF/35


Checking, Mending &


Finish Folding




Segregate shade wise and stack

B & R Inspection

Bale Helpers


Open bales of outsourced fabric, cut sample piece

Remarks:

1. Presently 40 bales per person per day are processed ie., for 4 personnel it amounts to 160 bales per

day.

2. In each bale there are three sets of fabric, hence for activity 2, 480 numbers of sets have been

considered.





_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1.1 1 67 0.11 8.23

1.2

1.3

2

2.1 1 20 2.86 57.2

2.2 1 20 1.74 34.78

2.3 1 1 2.00 2.00

A 132.36

B 15

C 152.22

D 480

E 31.71%

F 1

G 31.71%

WLS No: CMF/36


Checking, Mending &


Finish Folding

As per the list provided by the marketing department,

arrange roll cutting as per serial number, and handover to

the sample department.

Affix stickers


30.15

B & R Inspection

Sample Man


Sample Preparation


Pack it in polythene cover and handover to marketing

department peon

Grading

Inspect fabric, cut sample pieces as per requirement,

affix marks, put in poly cover and pack.

Prepare challan

1 67 0.45

Handover the hanger material in the sample room


Remarks:

1. Activity 1 - 200 samples per three days considered





_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 550 0.33 181.50

A 181.50

B 14

C 206.91

D 480

E 43.11%

F 1

G 43.11%

WLS No: CMF/37


Checking, Mending &


Remarks:

1. The walk time is distributed to three thans.








C G

Finish Folding

Input meters into SAP, take printout of the bar code

sticker and affix.

B & R Inspection

Bar code StickerOperator


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 120.00 100.00

2 1 1 30.00 30.00

3 1 1 20.00 20.00

4 1 1 20.00 20.00

5 1 1 20.00 20.00

6 1 1 30.00 30.00

7 1 1 20.00 20.00

8 1 1 15.00 15.00

A 255.00B 14

C 290.70

D 480

E 60.56%

F 1

G 60.56%

B & R Inspection

Computer operator


Receive '4-point' inspection report from finish folding

inspection, compute fresh and damage, input details in

excel and in SAP

WLS No: CMF/38


Checking, Mending &


Finish Folding




Input details of the loom wise defects into the excel sheet



Remarks:

Input in excel the details of the roll number, date, meters,

points, grader, beam number

Calculate the fresh point / 100 square meter and total

points / 100 square meters and input into excel sheet

Find out the spinning lot number from SAP and input into

spinning value loss report

Prepare daily quality wise report

Prepare main damage report for damages

Maintain excel sheet detailing the meters of fabric given

to process house and received from process house


_________________________________________________________________________ _______________







Department

Section


Designation Proposed Manpower - - - 1Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 3 44.00 132.00

2 1 3 44.00 132.00

3 1 1 3.00 3.00

A 267.00

B 13

C 301.71

D 450

E 33.52%

F 1

G 67.05%

WLS No: CMF/39


Checking, Mending &


Finish Folding

Clean with mop the finish folding, B & R inspection and

grading area

Collect dust and waste in the polythene covers and

tranfer to the waste yard



Finish Folding

Cleaner


Clean with broom stick the finish folding, B & R

inspection and grading area


Remarks:





_________________________________________________________________________ _______________







Department

Section



No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 30.00 30.00

2 1 1 10.00 10.00

3 1 80 1.00 80.00

4 1 1 30.00 30.00

5 1 1 30.00 30.00

6 1 1 40.00 40.00

7 1 1 30.00 30.00

8 1 1 10.00 10.00

A 260.00

B 15

C 299.00

D 480

E 62.29%

F 1

G 62.29%




Remarks:





Ensure proper tagging, stickering and in case the

personnel face any problems, resolve the same

Attend inter-departmental meeting daily at 3.30 pm

Periodically check whether the production targets are

being achieved by the graders

Show the damaged pieces to the superior and explain the

defects

Provide stationery to the personnel as per requirements

Finish Folding

Monitor


Check the position of materials in process house, compare

with the mail already received from PPC, and decide on

the number of personnel to deploy for THAN and cut

piece

In the direct fold machine check the length and in case of

any problem, get it rectified by the fitter

Give instructions to the graders and ensure that the

production is completed as per schedule and on time

WLS No: CMF/40


Checking, Mending &


Finish Folding

_________________________________________________________________________ _______________







Department

Section



No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 30.00 30.00

2 1 1 45.00 45.00

3a)

b) 1 1 30.00 30.00

c) 1 1 90.00 90.00

4 1 1 30.00 30.00

5 1 1 15.00 15.00

A 240.00

B 15

C 276.00

D 480

E 57.50%

F 1

G 57.50%




Remarks:





10 meter sample has been cut from each quality

Party's requirement of rolls is intimated to all the

individual workmen

20 cm is cut from each roll which is completed

Scrutinize the fabric roll shade and csv report received

In case of customer complaints, collect information,

investigate and inform superiors

B & R Inspection

Finish Checker


Receive hand written list from the process house

regarding the materials which will be handed over by

the process house along with the approval slips of QC,

schedule the material on the machines

Check finish of fabrics in process house by feel, note in

register, write details on card, and place card in the

horse

Ensure that

WLS No: CMF/41


Checking, Mending

& finishing Shifts A B C G

Finish Folding

_________________________________________________________________________ _______________







11. PROCESS HOUSE - PRODUCTION

________________________________________________________________________________________






11.011.1


1 Grey Seggreation 2 2 3 - 7 2 2 2 - 6

2Sample Card

Preparation- - - 1 1 - - - 1 1

3 Grey Plaiting 1 1 - - 2 1 1 - - 24 Grey Batching 3 3 3 - 9 2 2 2 - 6

5Job fabric computer

data entr- - - 1 1 - - - 1 1

6 Grey incharge - - - 1 1 - - - 1 1

7 Grey Rolling 4 4 - - 8 3 3 - - 6

8Batch Card and Report

preparation2 1 - - 3 2 2 - - 4

9 Relax scouring Range 8 8 8 - 24 6 6 6 - 18

10 Weight reduction 6 6 6 - 18 4 4 4 - 12

11 Dolly Winch 2 2 - - 4 2 2 - - 4

12 Jumbo Jigger 2 2 2 - 6 2 2 2 - 6

13 Hydro Extraction 1 1 1 - 3 2 2 2 - 6

14 Jet Dyeing 8 8 8 - 24 6 6 6 - 18

15 Auto Jigger 3 3 3 - 9 3 3 3 - 916 Stores -1 1 1 1 - 3 1 1 1 - 3

17 Singeing 3 3 - - 6 3 3 - - 6

18 Stenter 12 12 12 - 36 12 12 12 - 36

19 Kier decatising 2 2 2 - 6 2 2 2 - 6

20 MD 2 2 2 - 6 2 2 2 - 6

21 Super Finish 2 2 2 - 6 2 2 2 - 6

22 Shrinking Range 2 2 2 - 6 2 2 2 - 6

PROCESS HOUSE - PRODUCTION


SPH

Present Manpower

Manpower Deployment

_______________________________________________________________________________________________________ __________________________







11.011.1




Present Manpower

Manpower Deployment

23 Calendar 2 2 2 - 6 2 2 2 - 6

24 Checker 1 1 - - 2 1 1 - - 2

25 Press 1 1 - - 2 1 1 - - 2

26 Sample Process 1 1 - - 2 1 1 - - 2

27 Gun spotting 1 1 - - 2 1 1 - - 2

28 Jobber 1 - - - 1 1 - - - 1

29 Sweeper 1 - - 4 5 1 - - 3 4

30 Trolley movement 1 1 1 - 3 1 1 1 - 3

31 Stitching 1 1 - - 2 1 1 - - 2

32 Computer operator - - - 1 1 - - - 1 1

33 Hand spotting - - - 2 2 - - - 2 2

34 Machine cleaning 1 1 - - 2 1 1 - - 2

35 Stores -2 - - - 1 1 - - - 1 1Total 77 74 58 11 220 70 68 51 10 199

SPH

The average engagement of manpower in this department has been 175 (without considering over time).

_______________________________________________________________________________________________________ __________________________







11.0

11.2

11.2.1

a)

b)

c)

d)

e)

f)

g)

h)

Batch card and report preparation - deploy 2 personnel in shifts A and

B instead of the present deployment of 2 in A shift and 1 in B shift

based on workload

Relax scouring - deploy 6 personnel for two machines instead of the

present deployment of 8 personnel for two machines

Hydro extraction - deploy 2 personnel per shift instead of the present

deployment of 1 per shift based on workload

Jet Dyeing - deploy 6 personnel - one operator for each machine and

two helpers for 4 machines, instead of the present deployment of 8personnel for 4 machines

Sweepers - deploy 4 sweepers per day instead of the present

deployment of 5 per day



Proposed Changes

Grey Batching - deploy 2 personnel per shift instead of the present

deployment of 3 per shift based on worklaod

Grey Rolling - deploy 3 personnel per shift instead of the present

deployment of 4 per shift based on worklaod and the work pattern

Weight reduction - deploy 4 personnel for three machines instead of the present deployment of 6 personnel. One operator is assigned for

each machine and one common helper for all three machines

________________________________________________________________________________________






11.0

11.3

S.No1

2

3

4

5

6

7

8

9

1011

12

13

14

15

16

17

18

19

2021

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

Machine cleaning PHP/35

Stores - 2 PHP/36

Stitching PHP/32

Computer operator PHP/33

Hand spotting PHP/34

Jobber PHP/29

Sweeper PHP/30

Trolley movement PHP/31

Press PHP/26

Sample processing PHP/27

Gun spotting PHP/28

Shrinking range PHP/23

Calendar PHP/24

Checker PHP/25

KD Lycra PHP/20Multi Decatising PHP/21

Super finish PHP/22

Singeing PHP/17

Stenter PHP/18

KD Domestic PHP/19

Jet Dyeing PHP/14

Auto jigger PHP/15

Stores - 1 PHP/16

Dolly winch PHP/11

Jumbo jigger PHP/12

Hydro extractor PHP/13

Batch Card and Report preparation PHP/08

Relax Scouring PHP/09

Weight reduction machine PHP/10

Job fabric computer entry PHP/05

Grey Incharge PHP/06

Grey rolling PHP/07

Sample card preparation PHP/02

Grey Plaiting PHP/03

Grey batching PHP/04



Area of work WLS NumberGrey segregation PHP/01

________________________________________________________________________________________






Department

Section Grey Seggregation


Designation Proposed Manpow 2 2 2 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 10.21 10.21

2

2 200 1.60 640.00

32 17 2.34 79.63

4 2 17 1.41 48.08

A 777.91

B 13

C 879.04

D 900

E 97.67%

F 2

G 97.67%




Remarks:25000 mtrs to be transferred to the batching m/c per shift(average 120 mtrs in each

roll.Therefore 200 rolls taken as the frequency





Shift rolls to batching m/c area

Take out the required rolls to be transferred to the

batching m/c and place them vertically

Carry and load rolls on to the trolley (12 rolls on 1

trolley)

Unload all the rolls on the ground near batching m/c

Seggregation

Gey Seggreation


Take the programe from grey incharge

WLS No: PHP/01


GShifts A B CPHP

________________________________________________________________________________________






Department

Section Grey Seggreation



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 10.11 10.11

21 7 6.77 47.39

31 7 30.03 210.21

41 7 0.77 5.41

51 1 30.14 30.14

A 303.26

B 13

C 342.68

D 480

E 71.39%

F 1G 71.39%

WLS No: PHP/02


GShifts A B

Mark the attendance of all the workers in grey

seggrigation




PHP

Sample Card Preparation

Sample Card Preparator






C

Remarks:

take the strips of all the batches of domestic made by the

grey batching operator

Cut the samples and staple the same on sample cards and

prepare three sets of cards

Put the quality no batch no and shade no against each

cutting

Deliver one set of cards to folding dept.,one set to process

house and the third set to marking

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 5.44 5.44

21 3 8.44 25.32

3 1 46 0.92 42.24

4

1 3 49.20

5 1 3 1.42 4.26

6 1 3 1.74 5.23

71 3 10.72 32.17

81 3 6.54 19.62

9

1 3 3.45 10.35

A 144.63

B 13

C 163.43

D 450

E 36.32%

F 1

G 36.32%



Remarks: Production per machine per shift has been taken as 5500 mtrs.Average 120 mtrs in each

roll.One trolley contains 2000 mtrs of fabric after being plaited






Carry the trolley to place near batch m/c

Load 1 roll for plaiting (tie with old running cloth)

Opening rolls kept near the machine by grey

seggrigator on plaiting machine in the trollies or

table(2000 mtr on one table) (machine element)

Locate the empty trolly or table in proces house and

take it to the plaiting machine

Adjust the plaits on the table

Plaiting

-


Prepare and stitch all the pieces together(in 2000

mtr,16 stitches for 17 pieces are to be made)

Take the batch card from batchcard printer and tie

the same with the end piece of the trolly

Carry the trolly in the process house according to theinstruction written on the Batch processing card or

according to the process house shift supervisor'

instruction

Get the programe for the machine from the shift

Supervisor

WLS No: PHP/03


GShifts A B CPHP

________________________________________________________________________________________






Department

Section Grey Seggreation



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 4.55 4.55

2

1 1 15.11 15.11

3

1 46 5.56 255.76

41 138 0.26 36.39

5 1 138 0.25 34.22

6

1 7 98.00

7 1 138 0.66 91.38

8 1 7 1.54 10.77

9

1 7 2.24 15.68

A 463.86

B 13

C 524.16

D 1350

E 38.83%

F 2

G 58.24%

WLS No: PHP/04


GShifts A B CPHP

Locate the empty rolls in proces house and take it to

the Batching machine and aligned the same with

machine batching device

Load roll on one of the two loading points

Grey Batching

-




Remarks:1. Production per machine per shift has been taken as 16500 mtrs.Average 120 mtrs in

each roll




Opening time of 1 batch of 2500 mtr (average length)

in fabric accumulator with the help of machine

(machine element)

Writing no on rolls at the time of rolls being delivered

by grey segregation persons (3 rolls at a time) and

note down all the pc details on a format and give it tobatch card printer ,take the batch card from batchcard

printer and tie the same with the end piece of the

Giving 1 roll at a time to the grey batching handling

person


After opening of one roll,write batch no on new rolland stitch with previous roll

Remove the completed roll

Deliver the roll in the process house according to the

instruction written on the Batch processing card or

according to the process house shift supervisor'


________________________________________________________________________________________






Department

Section Gey Seggreation



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 6.67 6.67

21 1 65.56 65.56

3

1 1 90.66 90.66

41 1 45.34 45.34

51 1 37.65 37.65

6

1 1 34.65 34.65

A 280.53

B 13

C 317.00

D 480

E 66.04%

F 1

G 66.04%

WLS No: PHP/05


GShifts A B CPHP

After varification of goods received from job weaving

against challan the job fabric entry operator takes all the

challans from grey incharge

Prepare the challan of all the pcs and give it to the logistic

dept. for the dispatch of the same

After entering all the pcs whether received from Job

weaving or sent for job processing he hand over all the

challans to grey incharge for filing

Job fabric computer data ent

Operator


Find out all the PO and line item and write it down on the

challan against which the goods has received from the

Receive all the pcs in the system and book the yarn

consumption against the line item recieved and if the yarn

stock is not in the system then he contact to the job weaving

person and get it changed in the PO

In case of goods to be sent to job processing he is entering

all the pcs and transfer it to job vendor location in the




Remarks:





________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 15.78 15.78

21 1 20.45 20.45

3

1 25 5.65 141.25

41 3 15.56 46.68

51 1 30.00 30.00

61 1 36.87 36.87

A 291.03

B 13

C 328.86

D 480

E 68.51%

F 1

G 68.51%

WLS No: PHP/06


GShifts A B CPHP

Take the daily grey issue programme from PPC dept.

Maintain the record of the goods coming from job

weaving and sent for job processing

Grey incharge

Grey incharge


Show this prog. to process head and take the approval

from him for issuing the same

In case of B&R goods prepare the shade continuity card

and show the same along with previous supply to

process head for getting the clearance for grey issue

According to the stock reoprt and the grey issuance prog

give instruction to grey seggregator, plaiter, grey batcher

Co-ordinates with PPC, process head and Mending dept.

for different issues related to grey seggregation




Remarks:





________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 10.55 10.55

2

1 46 0.94083 43.28

31 46 2.60

4 1 46 0.21 9.73

52 46 0.08 6.93

6 1 46 0.28 12.90

7 1 46 0.22 9.95

81 46 0.26 12.01

92 46 0.09 8.60

10 1 46 0.25 11.40

11 1 45 0.14 6.33

122 35 2.45 171.50

132 35 0.08 5.33

14 1 35 0.23 8.15

15 1 34 0.19 6.30

16 1 35 0.29 9.98

A 332.95

B 13

C 376.24

D 1800

E 20.90%

F 3

G 27.87%

Tally against the challan the incoming material

Carry the rolls to stack

Return for next roll

If the Mending goods come from outside they tally it

against the challan and put them in the trollies.

Place on trolley after rolling



Note in register the details of the rolls transferred to the

stack

Shifting the rolls to Grey Plaiting

Destack and load the rolls on shoulder

Carry the rolls to the plaiting m/c




Remarks:1. Production per machine per shift has been taken as 5500 mtrs.Average 120 mtrs in each

roll.Average 5 lakh metres comes from outside per month.Therefore 70 rolls comes in two shifts





From Job weaving(outside) to stacking in grey

Destack and load the rolls on to the shoulder

Rolling

-


Carry the rolls to stack

Shifting the rolls to Stack from rolling (Loom wise)

Destack and load the rolls on to the shoulder

Take all the pcs from mending(after final checking) and

job weaving in lump form and bring one trolley near the

m/c and adjust (tie with old fabric and note the details

in the register)

Make individual rolls of all the pcs on rolling

machine(120-130 mtr average) (machine element)

2. Three personnel are recommended with a utilization of 28 % because of the simultaneous

occurance of activities

WLS No: PHP/07WORK LOAD DETAILS SHEET

GShifts A B CPHP


Bring iron rods for rolling purpose

________________________________________________________________________________________






Department


Work Centr Present Manpower 2 1 - -


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 12.78 12.78

21 1 98.87 98.87

3

1 1 87.78 87.78

41 1 25.88 25.88

51 1 4.77 4.77

6 1 1 66.78 66.78

71 20 15.54 310.8

8

1 20 1.43 28.6

A 636.26

B 13

C 718.97

D 900

E 79.89%

F 2

G 79.89%

Book the consumption of all the pcs production order wise

in the system and take out the batch processing card

Hand over the batch processing card to grey batcher or the

paiter for attatching the same with the material

Prepare the summary of grey activities and hand it over to

PPC dept. and process house MIS dept.

Batch Card and Report

preparation

Batch Card and Report prep


Take the pc wise detail of each batch from grey plaiter and

grey batcher


WLS No: PHP/08


GShifts A B CPHP

Make the production order of process house

Remarks:





Take the report of grey reciept from mending and the job

weaving on the previous day

Prepare the grey issue report of previous day(tallying

outside and inside cloth and note category wise production)

Prepare the stock report of grey dept.((Job mending

out+previous day stock)-export delivery of previous day))



________________________________________________________________________________________






Department

Section


Machine Name Proposed Manpower 6 6 6 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

4 1/3 109.8 146.4

2 1 1 5.43 5.4

3 1 1 7.21 7.24

2 6 7.84 94.0

5

1 1 433.33

6

1 2 7.91 15.8

71 4 1.87 7.5

81 3 43.66 131.0

9

2 6 5.43 65.2

101 3 30.00 90.0

A 562.52

B 1125.04

C 13

D 1271.30

E 3600

F 35.31%

G 6

H 47.09%

locate the goods to be run on the machinestitch the end of the material with previous material and

ensure all cloth ends are tied together.Rectify the same if

found to be broken and start the machine

set the machine parameter on the screen and ensure its

occurance(average speed of the m/c =30 mtr/min)

(machine element)

get the chemical issue slip from the shift supervisor and

give the issue slip to chemical substore and get the

chemical from there for the machine


Basic Workload per Shift ( in man minutes) of two relax scouring machines


Remarks: 1. Production per machine per shift has been taken as 13000 mtrs.Average 2500 mtrs in

each trolley and average speed of the m/c =30 mtr/min).

Dissolve the chemical in the bucket and dose the same in

the machine

Cleaning of all the chambers of scouring as well as

drying zone with air and water pressure

after reciving the goods at delivery end put the tag of

next process on the trolly and deliver it to the designated

place of next process and cover the trolly with HDPE

trolly cover

Relieve the three operators at loading,relaxing and drying

areas and manages the work of all the three operators





CPHP

Relax scouring Range

Relax scouring range


clean the filter of the washing cambers,clean the filter of

the dryer and cleaning of all the chambers of scouring as

well as drying zone and full cleaning of the m/c

get the programe for the machine from the shift

Scouring area


2. Six personnel are recommended for 2 machines

WLS No: PHP/09


GShifts A B

________________________________________________________________________________________






Department

Section Scouring area



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 5.61 5.6

22 1 3.12 6.2

3

2 1 4.56 9.1

42 4 6.17 49.4

52 4 5.30 42.4

61 1 1.67 1.7

7

1 1 9.50 9.5

8

1 1 101.00

91 1 14.00

101 1 51.00

11 1 1 14.00

121 1 30.00

13 1 1 14.00

14

1 1 60.00

15 1 1 14.00


Supervisor

Take the temperature of the water in the m/c to 90

degree celcius and dissolve the chemical (caustic

+solite) in the dosing tank and dose the same in the

machine, hold water at 90 degree celcius and allow the

temp to drop down from 90 degree celcius to 70

degree celcius (machine element)

give the issue slip to chemical substore and get the

chemicals from there for the machine(caustic,solide

plus,soda ash,oxolic acid,acitic acid and vita foam in

case foam is being formed)

Drain water and load new water (machine element)

Load the fabric rope wise in the machine

Cleaning the windows of the m/c

Locate the goods to be run on the machine no 2 (1200

mtrs processed i.e. 2 beams of 600-650 mtr ) and clean

remaining chemicalsLoad the fabric(1200 mtr and 300 mtr in one window)

in windows and note in the register

Stitch (12 stitches for 1200 mtr) both the ends of the

fabric loaded in windows


WLS No: PHP/10


GShifts A

set the machine parameter or program number on the

screen and ensure its occurance of the same

Weight reduction

Weight reduction


B CPHP

Drain water and load new water(2800 lts in this case)

(machine element)



degree celcius and do hot wash (machine element)


degree celcius and dissolve the chemical (acitic acid

+auxilic acid) in the dosing tank a,hold water at 90degree celcius (machine element)

Take the temperature of the water in the m/c to 90degree celcius and and dissolve soda ash in the dosing

tank hold water at 90 degree celcius (machine

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: PHP/10


GShifts A

Weight reduction

Weight reduction


B CPHP

16 1 1 30.00

17 1 1 14.00

181 1 30.00

19 1 1 14.00

20 1 1 20.00

212 1 4.21 8.4

22 2 1 14.90 29.8

23 1 1 2.68 2.7

24 1 1 5.66 5.7

25

1 1 4.12 4.1

26 1 1 14.23 14.2

27

1 1 4.36 4.4

281 1 5.21 5.2

A 198.38

595.14

B 13

C 672.51D 2700

E 24.91%

F 4

G 37.36%

Basic Workload per Shift ( in man minutes); 3 machines of the same kind



Perform cool wash (machine element)



degree celcius and do hot wash (machine element)



Bring on more trolley and place polythene sheets into

Unload the material in trolley

Tearing apart the stitched material

Take the trolley to reopenor

1 For each of the weight reduction machines one operator and one helper who will help all the

three operators and also act as an online reliever.

Tie the fabric with the old fabric already hung and run

the m/c till it passes to the other side of the reopenor

where it is coming after being reopened

Start reopening

after reciving the goods at delivery end put the tag of

dry for next process on the trolly and deliver it to the

designated place of drying process and cover the trolly

with polythene sheet



Remarks:


Locate the empty trolly in the process house for next

fabric



Wash at 90 degree celcius (machine element)

________________________________________________________________________________________






Department



Machine Name Proposed Manpower 2 2 - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 5.32 5.3

22 10 6.54 130.8

32 10 1.11 22.2

41 10 0.90 9.0

51 1 2.63 2.6

6

1 1 5.75 5.8

71 1 1.42 1.4

8 1 1 34.16

9

1 1 79.63

10

1 1 70.43

11 1 1 18.45

B CPHP

Load the fabric rope wise in the machine (total 10

nozzles and 100 mtrs to be loaded in each nozzle)

Dolly Winch

Dolly Winch



Supervisor

WLS No: PHP/11


GShifts A

Dissolve the chemical(DTC:800 gms) in the dosing

tank and dose the same in the machine

Fill water in the m/c, perform cold washing anddrain the water (machine element)

Fill new water, pass chemical (DTC:500 gms),

increase the temperature upto 50 degree celcius,

hold at 50 degree celcius and drain the water

(machine element)

Fill new water in the m/c,increase the temperature

upto 50 degree celcius and perform two hot wash

(machine element)

Stitch the ends of all the ropes to make them

endless rope of the fabric

Note all the piece detail rope wise and process

parameter in the register in a given format

Set the machine parameter or program number on

the screen and ensure its occurance of the same

Get the chemical issue slip from the shift supervisor

and give the issue slip to chemical substore and get

the chemical from there for the machine

Drain water and fill new water (machine element)

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

B CPHP

Dolly Winch

Dolly Winch


WLS No: PHP/11


GShifts A

12

1 1 70.00

13

1 1 54.00

14

1 1 54.00

151 1 33.00

16 1 1 9.00

172 1 59.64 119.3

18 1 1 4.24 4.2

191 1 14.43 14.4

20

1 1 4.65 4.7

A 319.72

B 13

C 361.28

D 900

E 40.14%

F 2

G 40.14%

Drain water and fill new water and do cold wash

(machine element)


Fill new water in the m/c,increase the temperature

upto 50 degree celcius,hold at 50 degree celcius and

drain the water (machine element)Fill new water in the m/c,increase the temperature

upto 50 degree celcius,hold at 50 degree celcius and

drain the water (machine element)


Locate the empty trolly with hole and unload the


Remarks:

Drain out the water


After reciving the goods at delivery end put the tag

of dry for next process on the trolly and deliver it to

the designated place of drying process and cover the

trolly with polythene sheet





Open the fabric rope with the help of ropeopener in

an trolly with polythene sheet

Dissolve the chemical (DTC:300 gms) in the

dosing tank and dose the same in the

machine,increase the temperature upto 50 degree

celcius, hold at 50 degree celcius and drain the

Take the material in rope form to the rope openerand stitch the end with the previous cloth

________________________________________________________________________________________






Department

Section Scouring Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 4.59 4.59

21 2 4.83 9.66

32 2 45.23 180.92

41 2 2.57 5.14

5 1 2 8.77

6

1 2 9.50 19

7 1 6 25.008 1 2 15.76

9 1 6 25.00

10 1 2 15.76

111 2 26.14 52.28

122 2 44.65 178.6

13

2 2 4.65 18.6

14 2 2 8.92 35.68

A 504.47

B 13

C 570.05

D 900

E 63.34%

F 2

G 63.34%


Locate the empty trolly with hole and unload the

material in it

After unloading the goods put the tag of dry for next

process on the trolly and deliver it to the designated

place of drying process and cover the trolly with

polythene sheet

Clean the machine filter before starting of any batch

Roll from one roll to another (machine element)



Roll from one roll to another (machine element)


Jumbo Jigger




Supervisor

Locate the goods to be run on the machine (2500 mtr

at a time)


B


Shifts

Fill water in the m/c (4000-5000 ltr) (machine

Jumbo Jigger

Stitch leader cloth with the main fabric and load the

material on the machine

Get the chemical issue slip from the shift supervisor

and give the issue slip to chemical substore and get the

chemicals(hydro,caustic,soda ,catsol and BTC) from

there for the machine and dissolve the chemical in the

dosing tank and dose the same in the machine

Set the machine parameter or program number on the

screen and ensure its occurance of the same

Remarks:

WLS No: PHP/12


GC


Take chemical (acid) and add, roll from one roll to

another for one round

PHP


A

________________________________________________________________________________________






Department

Section Scouring Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 5.27 5.27

2 1 1 3.27 3.27

3

2 11 9.81 215.82

4 2 11 0.83 18.26

51 11 45.00

62 11 10.21 224.62

7 1 11 2.12 23.32

81 11 5.72 62.92

9

1 11 1.03 11.33

10 1 11 3.55

11

1 11 3.21 35.31

121 1 3.85 3.85

A 603.97B 13

C 682.49

D 450

E 151.66%

F 2

G 75.83%


After complition of the cycle take out the goods from

the machine in a cleaned trolly

Remarks:

Start the m/c and do hydro extraction (machine

element)

After reciving the goods at delivery end put the tag





fabric

Tie the fabric with the old fabric already hung and

run the m/c till it passes to the other side of the

reopenor where it is coming after being reopened

Start reopening (machine element)



C




Hydro Extraction

Hydro Extractor


Bring on more trolley and place polythene sheets into

it


Supervisor

Locate the goods to be run on the machine

PHP

Close the cover of the m/c and note the details intheregister


Load the goods in piled form in Hydro extractor as

per the program given (300 mtr at a time) (machine

element)

WLS No: PHP/13


GShifts A B

________________________________________________________________________________________






Department

Section Dyeing section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 5.12 5.12

21 4 4.08 16.32

3 1 4 3.00

42 4 25.32 202.56

5

1 4 22.87 91.48

61 4 6.76

71 4 14.57

81 4 17.34

9

1 4 52.32

10 1 4 30.00

11

1 4 22.67

121 4 3.00

131 4 18.00

14

1 4 15.77 63.08

15 1 4 1.11 4.44

161 4 4.79 19.16

17

1 4 1.19 4.76

WLS No: PHP/14


GShifts A B CPHP

Dyeing section

Jet Dyeing


Go the temperature up to 80 degree celcius and tuck

in 1 kg air at the same temperature (machine

Add chemical to m/c at 60 degree celcius (machine

element)

Load the goods in the machine as per the program

given(includes stitching both the ends to one

Add color and hold at the same temperature

(machine element)

Fill water in m/c(350 ltr) (machine element)


Supervisor


at a time)

Bring on more trolley and place polythene sheets

into it

Get the colors and chemicals from the stores as per

the chemicals issue slip.(acitic acid,DFT ) and make

color

Open the valve and allow the temperature to come

down to 80 degree celcius and sent out air at the

same temperature (machine element)

3.5 degree celcius steam will be blown for prog 5

and 1 degree celcius steam for prog no 8 and reach

the temp in both cases to 130 degree celcius

(machine element)


Hold at the same temperature (machine element)

Drain the water at 70 degree celcius (machine

element)Fill water in m/c(350 ltr) and perform cold wash

(machine element)

When temperature decreases to 30 degree

celcius,make hold of whatever stitch they get cut

sample,dry it and send to supervisor

Tie the fabric with the old fabric already hung and

run the m/c till it passes to the other side of the

reopenor where it is coming after being reopened

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: PHP/14


GShifts A B CPHP

Dyeing section

Jet Dyeing


18 1 4 4.14

19

1 4 3.82 15.28

202 4 10.22 81.76

A 503.96

2015.84

B 13

C 2277.90

D 3600

E 63.27%

F 6

G 84.37%



1. Four operators for 4 machines and two helpers are recommended

Hand over the thoroughly cleaned machine to next

shift operator





after reciving the goods at delivery end put the tag




Remarks:

Basic Workload per Shift ( in man minutes); 4 m/cs


Start reopening (machine element)

________________________________________________________________________________________






Department

Section Dyeing Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 5.43 5.43

21 1 4.83 4.83

31 1 51.24 51.24

4 1 1 32.50

5

1 1 24.56 24.56

6 1 1 5.00

71 2 10.12

81 1 10.00

9

1 4 13.33

10

1 2 42.09 84.18

111 2 10.00

12 1 1 5.00Drain water,fill new water (machine element)

Cut a sample from the fabric while in dyeing

solution and show the sample to the shift officer for

the shade matching and if approved complete the

further dyeing cycle. If the shade does not match

,then take the required addition of the color as

suggested by shift officer and run again till the shadeRun from one roll to another in same color for

cooling (machine element)

Drain water,fill new water (machine element)

Add the other half color in tank and run from one

roll to another and add 500 gms hydro in each round

(10 minutes - machine element)


Supervisor


at a time i.e. two beams of 350 mtrs)

Add chemicals in tanks and run from one roll to

another (machine element)

Fill water(800 ltrs) and perform two rounds of hotwash at 60 degree celcius (machine element)

Add half color in tank and run from one roll to

another (machine element)

Load from trolley and do stitching(6 stitches for two

beams)

Get the colors and chemicals from the stores as per

the chemicals issue slip(Hydro,caustic,hydrogen

peroxide,acitic acid,soda ash,soap and make color

according to the requirement)

B CPHP

Auto Jigger

Jigger Dyeing


WLS No: PHP/15


GShifts A

________________________________________________________________________________________






Department

Section Dyeing Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

B CPHP

Auto Jigger

Jigger Dyeing


WLS No: PHP/15


GShifts A

13 1 2 20.00

141 1 5.52

15 1 3 10.00

161 2 10.46

171 1 6.45

18 1 4 10.00

19 1 1 5.00

201 2 10.00

211 1 15.00

221 1 6.35

23 1 2 10.00

241 1 4.79 4.79

25 1 1 18.18 18.18

26 1 1 3.22 3.22

A 196.43

589.29

B 13

C 665.90D 1350

E 49.33%

F 3

G 49.33%

Drain water,fill new water and add hydrogen

peroxide to it (machine element)

Perform washing in new water (machine element)

Send to next section



Unload the fabric in the trolley

Basic Workload per Shift ( in man minutes);Three m/cs of Auto Jigger

Run from one roll to another (machine element)


Run from one roll to another in hot temperature

(machine element)

Bring on more trolley and place polythene sheets

into it

Add acitic acid and run from one roll to another

(machine element)



Remarks:





Drain water,fill new water,add soda ash and soap

(machine element)

Drain water,fill new water (machine element)

Drain water,fill new water and run from one roll to

another in cold temperature (machine element)

Drain water,fill new water and add acitic acid

(machine element)

________________________________________________________________________________________






Department

Section Stores



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 35 6.66 233.1

21 1/3 60.65 20 2/9

3

1 1 70.77 70.77

A 324.09

B 13

C 366.22

D 450

E 81.38%

F 1

G 81.38%

WLS No: PHP/16


GShifts A B

Fill the receipt form and fill the details in the

register


-

Stores


According to the issue slip issued by the

Supervisor he issues the chemicals to different

operators



CPHP

Remarks:





He get the chemical issued from Main stores as

per the expected consumption for two days

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 3.89 3.89

2

2 1 68.92 137.84

3 1 12 5.67 68.04

4

2 12 2.54 60.96

5

2 12 27.77

6

2 12 3.34 80.16

A 350.89

B 13

C 396.51

D 1350

E 29.37%

F 3

G 29.37%

WLS No: PHP/17


GShifts A B CPHP

Clean the machine rollers and gas burners before

starting the machine and clean the water scruber and

fill fresh water in it

After getting the goods in the trolly remove the trolly

from delivery end and take the trolly out of the

singeing room

Stitch the main fabric with leading cloth and run the

fabric on the machine with the given parameters onthe batch processing card

Locate the goods to be run on the machine

Ensure the crease free enrty of the goos in the

machine otherwise no singe portion will come and run

till trolley gets empty (machine element)

Singeing machine

Singeing machine






Remarks:1. Production per machine per shift has been taken as 29000 mtrs.Average 2500 mtrs in






________________________________________________________________________________________






Department

Section Wet finishing sectio

Work Centre Present Man ower 12 12 12 -


Sl.

No

Crew

Size

Freq/

Shift

BasicTime

(Mins)

TotalTime

(Mins)

11 1 5.12 5.12

21 9 5.63 50.67

3

1 3 24.41 73.23

41 9 12.73 114.57

5

1 1 6.56 6.56

61 9 50.66

71 8 14.56 116.48

8

1 9 6.34 57.06

91 9 3.12 28.08

101 3 30.00 90

A 541.77

1625.31

B 13

C 1836.60

D 5400

E 34.01%

F 12

G 34.01%


fabric

Basic Workload per Shift ( in man minutes);Three m/cs


Stitch the material with the the leading cloth and give

signal to the feeder man to operate the machine

Relieve the three operators for lunch,report damage if in

case it happens






Proposed Utilisation(%)Remarks:1. Production per machine per shift has been taken as 17000 mtrs.Average 2500 mtrs in


-

Stenter machine


Plaiter man check all the material deliver at delivery end

(average 650 mtrs of one quality),note down the process

parameter and batch details of all the batches run on the

machine. After reciving the goods at delivery end put the

tag of dry for next process on the trolly and deliver it to




Supervisor

Locate the goods to be run on the machine(1800-2000

mtrs average)

Feeder man set all the parameter of the machine

according to the instruction given by the supervisor and

ensures the proper feeding of the fabric in the machine at

desired parameter (machine element)

Cleans the filter of the machine after every hour in

running condition of the machine

Take the chemical issue slip from the supervisor and

bring the chemicals from the substore.Make the finishing

chemical solution in the dosing tank and make the

required voume

The machine starts running (average speed of m/c=37.5

meters per minute) (machine element)

WLS No: PHP/18


GShifts A B CPHP

________________________________________________________________________________________






Department

Section Dry finish section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 5.61 5.61

2 1 5 4.56 22.8

31 1 30.00 30

4

2 21 3.73 156.66

5

1 21 10.16

6 1 21 20.12

7

1 21 5.61 117.81

81 21 0.91 19.1275

9

1 5 2.89 14.45

A 366.46

B 13

C 414.10

D 900

E 46.01%

F 2

G 46.01%

Machine operator feed all the details of batch run on

the machine with prog. No. in a format register

Machine helper will locate the empty tables from out

side the folding dept. and clean the same before taking

the goods on it and does the plaiting of all the material

coming out of the machine at delivery end and during

plaiting the helper will check all the material


After getting the goods on trolly put the trolly in line

designated for the ready for fold material with the

batch processing card

Send the rolled fabric for steaming (machine element)

Clean with air pressure and check the machine input

parameter like steam pr., air pr. etc.

Load the material as per the programe given by the

shift supervisor and load it upto wrapper of the m/c

and make a cut


Remarks: Production per machine per shift has been taken as 9400 mtrs.Average 2000 mtrs in each

trolley and 450 mtrs can be loaded at a time.Speed of m/c is 60 mtrs per minute






-

Kier decatising


Running Domestic


Supervisor

Locate the goods to be run on the machine (2000

M/C runs upto first fabric's end(i.e. average 100

mtrs).Adjusts the stitches,cut extra cloth for domestic

fabric and start the m/c again (avg speedof m/c =60

mtrs per minute) (machine element)

WLS No: PHP/19


GCShifts A BPHP

___________________________________________________________________________ _____________







Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 5.61 5.61

21 21 4.56 95.76

31 1 30.00 30

4

2 21 3.73 156.66

5

1 21 5.58

6 1 21 20.12

7

1 21 5.43 114.03

81 21 0.91 19.1275

9

1 21 2.89 60.69

A 481.88

B 13C 544.52

D 900

E 60.50%

F 2

G 60.50%

Send the rolled fabric for steaming (machine element)

Clean with air pressure and check the machine input

parameter like steam pr., air pr. etc.

WLS No: PHP/20


GCShifts A BPHP

Machine operator feed all the details of batch run on

the machine with prog. No. in a format register


shift supervisor and load it upto wrapper of the m/c

and make a cut with hands (Here,besides cutting,they

have to write details of the fabric on each piece

viz.mtrs,quality)

after getting the goods on trolly put the trolly in line

designated for the ready for fold material with the


-

Kier decatising



side the folding dept. and clean the same before

taking the goods on it

Running Lycra


Supervisor

Locate the goods to be run on the machine (150 mtrs

average)

M/C runs.Adjusts the stitches,cut extra cloth for lycra

fabric and start the m/c again(avg speedof m/c =40

mtrs per minute) (machine element)



Remarks: Production per machine per shift has been taken as 3200-3400 mtrs.Average 100-150

mtrs loaded each time.Speed of m/c is 40 mtrs per minute






________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 4.76 4.76

21 6 3.89 23.34

32 1 30.00 60

4 2 6 8.82 105.84

5

1 6 6.53 39.18

6

1 6 56.21

71 6 3.85 23.1

A 256.22

B 13

C 289.53

D 900

E 32.17%

F 2

G 32.17%

Clean the m/c with cloth and air pressure and belt

cleaning

WLS No: PHP/21


GShifts A B CPHP



Remarks: Production per machine per shift has been taken as 7000 mtrs.Average 1000-1500 mtrsloaded each time.Speed of m/c is 20-30 mtrs per minute

-

Multi decatising


After getting the goods on trolly put the trolly in linedesignated for the ready for fold material with the



Supervisor

Locate the goods to be run on the machine (1000-1500

mtrs average)



the goods on it


load the material as per the proograme given by theshift supervisor





Machine operator runs the m/c(average speed=25

metres per minute) and feed all the details of batch run

on the machine with prog. No. in a format register

(machine element 50 minutes) (machine element)

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 5.03 5.03

21 4 4.12 16.48

32 1 30.00 60

4 2 1 25.76 51.52

52 4 6.61 52.88

6

1 4 66.66

7

1 4 4.51 18.04

81 4 0.90 3.617333

9

1 4 2.13 8.52

A 216.09

B 13

C 244.18

D 900

E 27.13%F 2

G 27.13%




Load the material as per the programe given by the shift

supervisor



after getting the goods on trolly put the trolly in line

designated for the ready for fold material with the batch

processing card



the goods on it

Remarks:Production per machine per shift has been taken as 8000 mtrs.Average 2000 mtrs loaded

each time.Speed of m/c is 30 mtrs per minute

-

Superfinish machine


Machine operator feed all the details of batch run on the

machine with prog. No. in a format register


Supervisor


average)

Start the m/c and check the machine input parameter

like steam pr., air pr. Etc.(average speed=30 mtrs per

minute) (machine element)

Clean the m/c with cloth and air pressure and silicon

belt cleaning


Add waste cloth and take temperature to 130-140 degreecelcius

WLS No: PHP/22


GCShifts A BPHP

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 4.78 4.78

21 6 3.82 22.92

32 1 10.24 20.48

41 6 18.33

52 6 7.63 91.56

6

1 6 76.66

7

1 6 3.71 22.26

81 6 0.94 5.64

A 167.64

B 13

C 189.43

D 900

E 21.05%

F 2

G 21.05%

Carry the processed goods to the designated place for

further process after covering the goods and attaching

the batch process card with the goods.

Add waste cloth old running m/c and pass through them/c and raise the tmeperature of the m/c upto 130

degree celcius to start the function (machine element)

WLS No: PHP/23


GShifts A B CPHP

-

Shrinking Range.



Supervisor

Locate the goods to be run on the machine (2000-

2500 mtrs average)


like steam pr., air pr. Etc.(average speed=30 mtrs per

minute) (machine element)

Clean the m/c with cloth and air pressure and silicon

belt cleaning

Remarks: Production per machine per shift has been taken as 12000 mtrs.Average 2000-2500 mtrs

loaded each time.Speed of m/c is 30 mtrs per minute



shift supervisor







Keep a record of the goods processed with all the

details.

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 4.44 4.44

21 5 5.69 28.45

32 1 18.82 37.64

4 2 5 7.62 76.2

5

1 5 53.10

61 5 5.12 25.6

71 5 0.95 4.75

8 1 5 4.21 21.05

A 198.13

B 13

C 223.89

D 900

E 24.88%

F 2

G 24.88%

A B C


PHP

-

Calender


Shifts

Remarks: Production per machine per shift has been taken as 9000 mtrs.Average 1800 mtrs loadedeach time.Speed of m/c is 30 mtrs per minute

Carry the processed goods to the designated place forfurther process after covering the goods and attaching

the batch process card with the goods.







WLS No: PHP/24


G

Keep a record of the goods processed with all the

details.


Supervisor


average)


like temp(average speed=30 mtrs per minute)

(machine element)

Clean the m/c with cloth and air pressure and take

temperature to 70 degree celcius

Arrange for the empty trolley or table as per the

requirement for delivery end.

Load the material as per the programe given by theshift supervisor

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 3.81 3.81

2

1 3 15.27 45.81

3 1 3 6.51 19.53

41 8 1.19 9.52

51 5 5.38 26.9

61 1 5.82 5.82

7

1 5 48.92 244.6

81 5 3.18 15.9

91 5 3.88 19.4

A 391.29

B 13

C 442.16

D 450

E 98.26%F 1

G 98.26%





Go to the finish folding deptt. to lift the defective

goods for reprocessing



Arrange the reprocess goods process wise and open

them on the plaiter and prepare small batches process

wise

Remarks:

Checker

Checker


Take the batches for the respective processes and

inform to shift officer.

Takes the program from shift officer for the goods to

be checked.

Checks all the goods of Piece Dyeing and Top Dyed

as per instructions given and in case of any damage ,

informs to the shift officer for corrective action to be

taken

Get the program for the treatment of reprocess goods

from the shift officer

Attach the tags with every batch with details of batch

No. and the process to be done.

Takes the O.K.goods to the designated place forfurther process.

Cut the cuttings of defective goods if any and give

them for the treatment in the lab.

WLS No: PHP/25


GCShifts A BPHPSpotting

________________________________________________________________________________________






Department

Section Dry finish sectio



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 45 3.32 149.4

2

1 3 3.32 9.96

3

1 45 4.51 202.95

41 3 3.12 9.36

A 371.67

B 13

C 419.99

D 450

E 93.33%

F 1

G 93.33%



Remarks:






Returns the ironed pcs. to the respective graders in

finish folding.

WLS No: PHP/26


Press

Ironing

Shifts A B CPHP

G

Collects the than lengths or PL which are having

superficial creases and need not to be

reprocessed.(12 to 50 mtrs average length)

Does the steam Ironing to the fabric having creases

and ensures that the creases are totally removed

without disturbing its fold.


Coordinates with all the graders in finish folding.

________________________________________________________________________________________






Department

Section Sample processing



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 2 6.54 13.08

2

1 1 5.64 5.64

3 1 10 5.31 53.1

4

1 10 10.21 102.1

51 10 2.22 22.2

61 10 8.87 88.7

7

1 10 8.74 87.4

8 1 2 7.65 15.3

A 387.52

B 13

C 437.90

D 450

E 97.31%F 1

G 97.31%


Present Utilisation(%)Proposed Manpower per day



Checks all the samples received for any defect or stains

at the grey stage.



Remarks:

Sample processing

Sample processing


Recieves the samples from Design development for

processing along with the instructions slip.(average 10-

12 samples)

Shows the samples and the instructions to the

concerned officer and gets instructions for processing

of different samples.

Deliver the samples at the respective m/cs and follow

each and every process personally.

Deliver the samples to the finish folding deptt.

Checks the initial parameters like GSM ,width etc.andenters in his records

After going through 8-10 m/cs ,cut half meter of each

sample ,take it to lab and make entry i.e. for which GR

testing is to be done

Seggregates the different samples as per the suggested

process routes take these samples to lab and cut in

required shapes and note in the register,come back

again cut in required shape and paste in the continuity

card

WLS No: PHP/27


GShifts A B CPHP

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 1 4.18 4.18

21 1 22.38 22.38

31 1 221.66 221.66

41 1 3.91 3.91

A 252.13

B 13

C 284.91

D 450

E 63.31%

F 1

G 63.31%

CSpotting

Takes program from shift officer for the goods to

be done spotting

Shifts A B

After removing the stains hands over the goods tothe shift officer for further processes.

WLS No: PHP/28


Spotting

Gun Spotting

PHPG

Takes the goods to his machine and load on to the

m/c (1500-2000 mtrs in one trolley)

Remove the stains with Gun spotting

machine(average speed of m/c =15 mtrs per





Remarks:





________________________________________________________________________________________






Department

Section


Machine Name Proposed Manpower 1 - - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 115.87 115.87

21 1 145.11 145.11

3

1 1 9.17 9.17

41 1 12.76 12.76

51 3 5.12 15.363

6

1 3 14.33 42.99

71 1 4.00 4

A 345.26

B 13

C 390.15

D 450

E 86.70%

F 1

G 86.70%

WLS No: PHP/29


GShifts A B CPHPJobber

-

Jobber


Arranges for thr opening of China goods from the

rolls.

Prepares the position of goods lying for Finish

folding and Seggregates the O.K. goods and

undertesting goods and prepares separate position for

Maintains good house keeping in the ready goods

section and ensures that all the trollies are well

covered and labelled.

Gives the samples(40 cms) of RMG goods for testing

in the lab after final mechanical process.

Checks the goods in folding deptt. which are to be

taken back for reprocessing.

Coordinates with the concerned Folding person and

offers him the O.K. goods for folding and grading.

Gets approval on the batchcards of all the

undertesting goods after the complete testing.




Remarks:





________________________________________________________________________________________






Department

Section

Work Centre Present Manpower 1 - - 4

Machine Name Proposed Manpower 1 - - 3

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 3 91.11 273.33

2

1 3 96.23 288.69

3 1 3 25.31 75.93

41 3 28.78 86.34

5 1 1/4 52.45 13.1125

6

1 4 30.11 120.44

7 1 3 15.11 45.33

8 1 2 62.10 124.29

1 2 65.87 131.74

10

1 2 90.84 181.68

11 1 1 24.81 24.81

12 1 1/4 44.98 11.245

13 1 1 34.12 34.12

A 1410.97

B 13

C 1594.39

D 2370

E 67.27%

F 3

G 84.36%






Remarks:

Cleaning of all the walls of the deptt

Clean the m/c

Sweeping the segregation deptt


Cleaning of all the walls of the deptt

Cleaning of all the toilets.


Cleaning of all the drain pipes and sewer lines of the deptt.

-

Sweeper


Removes unwanted dust and dirt from the deptt

and throws the same in the waste yard out side

the deptt.

For Scouring Section,Dyeing section,Wet

finishing section

Sweeps the the floor of whole deptt.and keeps it

neat and clean.

For Dry finish section

Sweeps the the floor of whole deptt.and keeps it

neat and clean.

Removes unwanted dust and dirt from the deptt

and throws the same in the waste yard out side

the deptt.

Cleaning of all the drain pipes and sewer lines of

the deptt.

Cleaning of all the toilets.

Segregation Deptt

Fill the bags with waste cuts(big cuts being torn

apart into smaller cuts) and send them out

WLS No: PHP/30


GShifts A B CPHPSweeper

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1/3 21.73 7.24

2 1 1/3 32.60 10.87

3 1 1/3 98.54 32.85

4 1 4 18.11 72.44

5 1 12 9.06 108.66

6 1 3/7 9.06 3.88

7 1 1/3 23.54 7.858 1 2/5 97.76 39.10

9 1 5 22.64 113.19

A 396.08

B 13

C 447.57

D 450

E 99.46%

F 1

G 99.46%

WLS No: PHP/32


GShifts A B CPHPStitching



-

Stitching


Stitching for fabric coming from Calender

Stitching for fabric coming from Seinging

Stitching for fabric coming from LR

Stitching for fabric coming from Relax Scouring

Stitching for fabric coming from Kitty Mending

Stitching for fabric coming from KD


Stitching for fabric coming from outside(China)



Remarks:

Stitching for fabric coming from Than

Reject from folding



________________________________________________________________________________________






Department

Section Computer Operator


Machine Name Proposed Manpower - - - 1

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 170.76 170.76

2 1 3 28.87 86.61

3 1 1 62.19 62.19

41 1 45.71 45.71

5 1 1 8.16 8.157

A 373.43

B 13

C 421.97

D 450

E 93.77%

F 1

G 93.77%

WLS No: PHP/33


GShifts A B CPHP

Does the confirmation of all the prodn. Orders.

Generates all the MIS reports at the month end.

Does the chemical issue reservation on daily basis.

Feeds the routing of all the new shades in case of P.D.

fabrics

-

Computer Operator


Prepares the daily position of the deptt.




Remarks:





________________________________________________________________________________________






Department

Section


Position Name Proposed Manpower - - - 2

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

12 1 5.61 11.22

2 2 1 5.91 11.82

3 2 1 4.42 8.84

42 1 204.22 408.44

52 1 3.91 7.82

A 448.14

B 13

C 506.40

D 960

E 52.75%

F 2

G 52.75%

After removing the stains hand over the goods toshift officer for further processing




Remarks:





-

Spotting


Takes program from shift officer for the goods to

be done spotting

Gets chemicals from the color room from store

Removes the stains with help of chemical and

rubbing the same with brush

Take the trolley to the spotting table

WLS No: PHP/34


GShifts A B CPHPSpotting

________________________________________________________________________________________






Department




Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 4 81.83 327.32

A 327.32

B 13

C 369.87

D 450

E 82.19%F 1

G 82.19%

Press

Ironing


He cleans all the machines from outside with the used

cloth or by using air pressure wherever required.

G

WLS No: PHP/35


Shifts A B CPHP



Remarks:





________________________________________________________________________________________






Department

Section


Machine Name Proposed Manpower - - - 1

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 2 46.77 93.54

2

1 2 55.65 111.3

31 1/3 33.74 11.24667

41 2 32.65 65.3

A 281.39

B 13

C 317.97

D 450

E 70.66%

F 1

G 70.66%

WLS No: PHP/01


GShifts A B CPHPStores

Maintains cleanliness in the color room and ensures

that all the containers containing chemicals and dyes

are properly covered.

Loading and unloding of all the chemicals coming

from Main storePours the chemicals from big containers into the

smaller ones as and when required.



-

Stores


Cleans all the containers containing chemicals for

any spill over etc.


Remarks:





________________________________________________________________________________________






12. PROCESS HOUSE - MAINTENANCE

________________________________________________________________________________________






12

12.1


1 Shift maintenance Electrician 1 1 1 - 3 1 1 1 - 3

2

General shift maintenance -attending to major

breakdowns and


Electrician - - - 2 2 - - - 2 2

3Water softener operator

cum boiler helperSoftener operator 1 1 1 - 3 - - - - -

4 Shift maintenance Fitter 1 1 1 - 3 1 1 1 - 3

Fitter and Welder - - - 5 5 - - - 5 5

Helper - - - 3 3 - - - 3 3

Oilman - - - 1 1 - - - 1 1

6 SAP input and computeroperation

Computer operator - - - 1 1 - - - 1 1


8Lighting of mill and

outsideElectrician - - - 1 1 - - - 1 1

Helper - - - 1 1 - - - 1 1

Total 3 3 3 16 25 2 2 2 16 22

PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING)


Present Manpower

General shift maintenance -

attending to major

breakdowns and


5

Manpower Deployment

_______________________________________________________________________________________________________ __________________________







12

12.2

12.2.1

a)

12.2.2

a)

b)

--

-

-

c)

As per utilization a crew of three fitters are sufficicient for the performance of the

maintenance activities in the general shift. Since the data provided does notprovide any information about the simultaneous occurance of the preventive

maintenance activities and the breakdown maintenance activities and

simultaneous occurance of the breakdowns itself, a crew of five fitters is

proposed to be continued. But the data regarding the simultaneous occurance has

to be studied and only thereafter the strength can be rationalized to three fitters.In

the workload sheet, the utilization level for the crew of three fitters is displayed.

The manpower has been computed with a loading factor of 80 % for the

maintenance personnel. The 80 % loading has been considered to take into

Variation in machine availabilityCollection & deposit of tools, dress change

Effort variation

The following need improvements to make the maintenance function more

effectiveRecords keeping


maintenance to be maintained. This would help in the analysis of the breakdowns

and in maintenance planning


PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING


Deploy none as Water softener operator. The utilizationof this position holder is

38 % and if the water softening duties are removed then the utilization works out

to be 20 %. The water softening plant may be operated by the Humidity operator

and remaining activities stand shifted to the Boiler attendant

Proposed Changes


Observations

For the preventive maintenance activities the personnel should use SOP's which

will also detail the time element of the activities to be carried out. Presently

checklists are used, but SOP's will reduce the variations and also act as

benchmarks


It is observed that the breaks (tea and lunch) taken by the maintenance personnel

are not synchronized and the allowed time / more than the allowed time for the

same is utilized. The maintenance personnel to be trained and educated that

during the preventive maintenance / breakdown maintenance the times for thebreaks can be kept at minimum so that the crew is able to focus better on the

maintenance aspects

________________________________________________________________________________________






12

12.2

PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING


12.2.2

Planning

The activities to be so planned and peformed that the time taken is minimized.

Activites that can be carried out in parallel have to be planned. For example,

when the production personnel are shutting down the machine and handing over

for production, the maintenance personnel can start their activities such as

keeping the grease gun ready, bring all the tools, arrange in the workplace, bring

the bearings and other consumables which are likely to be changed and keep

ready in the workplace. It is observed that the personnel keep making rounds to

the workshop often to get tools, bearings etc,. Also when the capacity of thegrease gun is known then why not have more than one grease gun for the

Observations

________________________________________________________________________________________






12

12.3

S.No1

2

3

4

5

6

7

8

9

10 Computer operator

PHM/MECH/08

PHM/MECH/09

PHM/MECH/10

Electrician - general shift

Hleper - general shift

Motor Fitter

Shift Fitter

PHM/MECH/04

PHM/MECH/05

PHM/MECH/06

PHM/MECH/07

Shift Electrician

Softener operator

Oilman PHM/MECH/03

PROCESS HOUSE - MAINTENANCE (SPH ENGINEERING)

Hleper - general shift

Fitter - general shift PHM/MECH/01

PHM/MECH/02



________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Year

Basic

Time

(Hrs) -

man hrs

Total

Time

(Hrs)

1 2702.78 2702.78

2 1773.91 1773.91

3 223.83

A 4700.52B 15

C 5405.60

D 1920

E 56.31%

F 3

G 93.85%


B C G

Mechanical

Preventive maintenance works

Breakdown maintenance works

Process House

Fitter


3. As per utilization a crew of three fitters are sufficicient for the performance of the maintenance

activities. Since the data provided does not provide ant information about the simultaneous

occurance of the preventive maintenance activities and the breakdown maintenance activities and

simultaneous occurance of the breakdowns itself, a crew of five fitters is proposed to be continued.

But the data regarding the simultaneous occurance has to be studied and thereafter the strength can

be rationalized to three fitters.

Remarks:




WLS No: PHM/MECH/01


Process House

Maintenance Shifts A



2. The crew size for breakdown maintenance is as per the requirement. We have only considered

the man hrs required for the performance of the activity



________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Year

Basic

Time

(Hrs) -

man hrs

Total

Time

(Hrs)

1 2456.13 2456.13

2 1339.36 1339.36

3 189.77

A 3985.26B 15

C 4583.05

D 1920

E 79.57%

F 3

G 79.57%








Remarks:



Process House

Helper





WLS No: PHM/MECH/02


Process House

Maintenance Shifts A B C G

Mechanical

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Year

Basic

Time

(Hrs) -

man hrs

Total

Time

(Hrs)

1 805.29 805.29

2 450.00 450.00

3 62.76

A 1318.05B 15

C 1515.76

D 1920

E 78.95%

F 1

G 78.95%



Daily routine works










Process House

Oilman



Remarks:

WLS No: PHM/MECH/03


Process House


Mechanical

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Year

Basic

Time

(Hrs) -

man hrs

Total

Time

(Hrs)

1 353.52 353.52

2 761.79 761.79

3 55.77

A 1171.08B 15

C 1346.74

D 1920

E 35.07%

F 2

G 35.07%


WLS No: PHM/MECH/04


Process House


Electrical




Process House

Electrician







3. There are two electricians working in the general shift and two personnel looking after the

lighting of plant and outside. This is the total workload for the two crews (1 Electrician and 1

Helper composition). The workload for the helper category personnel are detailed in the next

workload sheet.




Remarks:

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Year

Basic

Time

(Hrs) -

man hrs

Total

Time

(Hrs)

1 312.17 312.17

2 472.42 472.42

3 39.23

A 823.82B 15

C 947.39

D 1920

E 24.67%

F 2

G 24.67%

WLS No: PHM/MECH/05


Process House


Electrical




Process House

Helper








Remarks:





________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Year

Basic

Time

(Hrs) -

man hrs

Total

Time

(Hrs)

1 1166.96 1166.96

2 380.87 380.87

3 77.39

A 1625.22B 15

C 1869.00

D 1920

E 48.67%

F 2

G 48.67%






Remarks:





Process House

Motor Fitter



WLS No: PHM/MECH/06


Process House


Electrical

________________________________________________________________________________________






Department

Section



1

2

Date Total time

20-Dec 650

21-Dec 585

22-Dec 67023-Dec 595

24-Dec 690

25-Dec 750

26-Dec 570

27-Dec 645

28-Dec 540

29-Dec 750

30-Dec 870

31-Dec 735

8050

3

4

5

6

λ/μ = 0.47

For λ/μ = 0.47 we find that the utilization of the shift electrician is 47 % per shift. Hence it

is recommended that the deployment of one per shift may be continued.

10

11

10

12

Data provided for the period december 20-31 December 2011

Number of complaints attended on each day and the total time spent for the same is

14

11

11


24*60/60 = 24 per day

WLS No: PHM/MECH/07


Process House

Maintenance Shifts A

135

12


Process House

B C G

Electrical

The average time to resolve a complaint works out to be 60 minutes

11

1111

11

Fitter

________________________________________________________________________________________






Department

Section



1

2

Date Total time

20-Dec 405

21-Dec 290

22-Dec 390

23-Dec 450

24-Dec 475

25-Dec 515

26-Dec 385

27-Dec 260

28-Dec 340

29-Dec 620

30-Dec 535

31-Dec 600

5265

3

4

5

6

10

10

For λ/μ = 0.30 we find that the utilization of the shift electrician is 30 % per shift. Hence it

is recommended that the deployment of one per shift may be continued.

131

The average time to resolve a complaint works out to be 40 minutes


24*60/40 = 36 per day

λ/μ = 0..30

10

11

10

9

11

15

Process House

Electrician

Data provided for the period december 20-31 December 2011

Number of complaints attended on each day and the total time spent for the same is


12

10

13

10

WLS No: PHM/MECH/08


Process House


Electrical

________________________________________________________________________________________






Department

Section


Designation Proposed Manpowe - - - -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time -

man

mins

Total

Time

(mins)

1 1 30.00 30.00

2

a)b) 1 1 30.00 30.00

c) 1 1 10.00 10.00

d) 1 1 20.00 20.00

e) 1 1 10.00 10.00

3 1 4 10.00 40.00

4

a) 1 1/15 120.00 8.00

A 148.00

B 15

C 170.20

D 450E 37.82%

F 1

G 37.82%





1. The water softener plant is operated by the Humidity operator also (from electrical maintenance -

Loomshed). Hence having one more person in the shift to perform the same operation is not

required. The overall utilization is 38 %, but if the softener plant operation is removed then it

becomes 20 %.

2. Activity 1 and 4 may be shifted to the boiler attendants. Activity 4 is not a regular activity.




Remarks:

Operate push buttons to operate pumpsOperate valves, perform back wash

Operate valves to transfer salt water to tank

Charge 14 bags of salt to the salt water tank

Give water samples to laboratory for testing

3. This position is not being recommended

Check performance of the pumps in the diggy pump

house

Boiler monitoring (This is operated only during the

shutdown of the turbine which occurs six times in a

year for a duration of 10 days on one occasion and 1-2days on others)

Check the fire performance, water level, steam meter,

gas emission and charge chemical whenever required.

Process House

Water Softener

Operator


Monitor the overflow from the hold tank, in case of

overflow, switch off pump in the nearby area

Operate the softener plant

WLS No: PHM/MECH/09


Process HouseShifts A B C G

Electrical

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Day

Basic

Time -

man

mins

Total

Time

(mins)

1 1 1 30.00 30.00

2 1 1 15.00 15.00

3 1 1 15.00 15.00

4 1 1 10.00 10.00

5 1 1/6 30.00 5.00

6 1 1/6 120.00 20.00

6.1

6.2

A 95.00

B 15

C 109.25

D 450

E 24.28%

F 1

G 24.28%

1. The utilization is 25 % for this position holder

2. This position is being recommended for the present

3. This position may be reviewed to ascertain whether it is possible to shift the activities

performed to the supervisory personnel of the department.







Others

Give material samples to purchase department

Prepare reports based on the instructions of the HOD


Remarks:

Check the status of the release of the indents in SAP and

inform the HOD about the same

Prepare new indents

Go to purchase department, get bills of the serviceproviders, make entry in SAP and return the bills to the

purchase department

Process House

Computer Operator


Collect the register from the weaving and SPH, with the

values of the TPP compute the values and input into

SAP. Take out the print out of the daily power

consumption report - ZPP

Collect the RO water consumption, coal consumption

from thermopack, enter into SAP, take print out of the

daily utility report

WLS No: PHM/MECH/10


Process HouseShifts A B C G

Electrical

________________________________________________________________________________________






13. LOGISTICS

________________________________________________________________________________________






13.013.1


Rack Monitor - - - 9 9 - - - 6 6

Sample Maker (B&R) - - - 7 7 - - - 5 5

Sample Dispatch - - - 3 3 - - - 2 2

Return /Purchase Goods - - - 4 4 - - - 4 4Invoicing - - - 6 6 - - - 3 3

Workmen - - - 6 6 - - - 4 4

Packers and Checkers - - - 14 14 - - - 10 10

Packing Section for Loose - - - 7 7 - - - 4 4

Bag Stitching - - - 8 8 - - - 8 8

Loader / Marker - - - 15 15 - - - 8 8

RMG - - - 8 8 - - - 6 6

Sample (Domestic) - - - 16 16 - - - 16 16

Loose Opening Section - - - 17 17 - - - 10 10

Combo Packing - - - 24 24 - - - 10 10

Suit Length / Safari - - - 12 12 - - - 8 8

PL Packing - - - 16 16 - - - 9 9

Good Cut / FRC - - - 6 6 - - - 4 4

Packers and Checkers - - - 24 24 - - - 18 18Loader / Checker - - - 16 16 - - - 10 10

Regrading / General - - - 12 12 - - - 9 9

Total 0 0 0 230 230 0 0 0 154 154

DesignationPresent Manpower

Manpower DeploymentLOGISTICS


OLD WAREHOUSE

NEW WAREHOUSE

S. No Section / Work area

1

2

_______________________________________________________________________________________________________ __________________________







13.0

13.2

13.2.1

I

a)

b)

c)

d)

e)

f)

g)

h)

IIa)

b)

c)

d)

e)

f)

Rack monitor - Deploy six personnel in general shift instead of the present

deployment of 9 personnel based on workload

Sample maker - Deploy five personnel in general shift instead of the present

deployment of 7 personnel based on workload

Sample dispatch - Deploy two personnel in the general shift instead of the present

deployment of three in the general shift. The combined workload is 26.08 % and

two personnel are recommended because of the crew size limitations.

Invoicing - Deploy 3 personnel in general shift instead of the present deployment of

6 personnel based on workload

LOGISTICS


Proposed Changes

Old ware house

Loader / Marker - Deploy 8 personnel instead of the present deployment of 15

personnel in general shift based on workload

New WarehouseWorkmen - RMG godown - Deploy 6 personnel instead of the present deployment

of 8 based on workload

Workmen - Deploy 4 personnel instead of the present deployment of 6 personnel

based on workload and simultaneous requirements

Packers and checkers - Deploy 10 personnel instead of the present deployment of

14 personnel based on workload and simultaneous requirements

Packers Loose - Deploy 4 personnel instead of the present deployment of 7

personnel, based on workload, crew size and simultaneous requirements

Good cut / FRC - Deploy 4 personnel instead of the present deployment of 6personnel based on workload

Loose opening - Deploy 10 personnel instead of the present deployment of 17

based on workload

Combo packing - Deploy 10 personnel instead of the present deployment of 24

personnel based on workload

Suit length / safari - Deploy 8 personnel instead of the present deployment of 12

personnel based on workload

PL packing - Deploy 9 personnel instead of the present deployment of 16 personnel

________________________________________________________________________________________






13.0

13.2

13.2.1

LOGISTICS


Proposed Changes

IIg)

h)

i) Regrading / General - Deploy 9 personnel instead of the present deployment of 12

personnel

Packers and checkers - Deploy 18 personnel instead of the present deployment of

24 personnel based on workload and simultaneous requirements

Loader / Marker - Deploy 10 personnel instead of the present deployment of 16

personnel based on worklaod

New Warehouse

________________________________________________________________________________________






13.0

13.3

S.No1

2

3

4

5

6

7

8

9

1011

12

13

14

15

16

17

18

19

20

LOGISTICS



Sample dsipatch - old WH LOG/03

Return purchase goods - old WH LOG/04

Rack monitor - old WH LOG/01

Sample maker - old WH LOG/02

Packers and Checkers LOG/07

Packing loose LOG/08

Invoicing LOG/05

Workmen LOG/06

Workmen - RMG godown LOG/11

Sample maker - domestic LOG/12

Bag stitching LOG/09

Loader LOG/10

Loose opening LOG/13

LOG/14

LOG/15

Combo Packing

Suit Length / Safari

Regrading / General

PL Packing

Good Cut / FRC

Packers and Checkers

Loader / Checker

LOG/20

LOG/16

LOG/17

LOG/18

LOG/19

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

3 25 0.68 51.15

23 25 2.58 193.13

3 3 25 1.14 85.65

42 25 5.46 273.13

52 25 0.53 26.40

6

2 24 0.58 28.00

72 24 2.29 109.88

8 2 24 0.86 41.49

91 24 32.51 780.15

10 1 24 0.29 6.88

11

3 26 0.56 43.71

12 3 26 1.37 106.47

13 3 26 0.85 66.12

14 2 26 3.91 203.42

Carry thr rolls to the warehouse

Load the rolls on to the trolley(18 on one trolley)

Shift rolls from final packing section to the oldwarehouse

Take trolley to respective positions in the finish section

Take to packing section and place aside

Take the trolley to the scanning section

Take the trolley to the scanning section

Scan the pieces one by one and transfer on to the other

trolley

Scan the pieces one by one and transfer on to the other

trolley

Take the trolley to the loose packing section and leave

the trolley there

Shift PL from PL section to the old warehouse

Take trolley to respective positions in the PL section

GReceipt Section

Shift fresh from final packing section to the old

warehouse

Take trolley to respective positions in the finish section

Load the pieces(average 70-80 pieces being loaded in one

trolley) on to the trolley

Old Warehouse

Rack Monitor


Scan and transfer to other trolley

WLS No:LOG/01


LogisticsShifts A

Load the pieces(average 65-70 pieces,11 PL in one

piece) on to the trolley

B C

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GReceipt Section

Old Warehouse

Rack Monitor


WLS No:LOG/01


LogisticsShifts A B C

15 2 26 3.83 198.90

A 2214.47

B 13C 2502.35

D 4320

E 57.92%

F 6

G 86.89%

Stack the rolls for packing to transferring outside

Remarks:Fresh has average 10-12 mtrs and Roll has average 40-50 mtrs.One PL has average 1.2-1.3

mtrs.Frequency has been taken on the basis of past data (for resh,rolls and PL)







________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 150.66 150.66

21 2 75.76 151.52

3

1 1 45.65 45.65

4

1 3 5.54 16.62

5 1 3 27.65 82.95

6 1 3 4.32 12.96

71 3 3.88 11.64

8

1 3 28.77 86.31

91 3 1.56 4.68

10

1 3 5.65 16.95

11

1 3 162.66 487.98

12 1 3 50.32 150.96

Sample preparation of PL

Note down quality/shades on to the paper (18 quality's

average12 shades in this case)

Find the required quality's shades(whichever is

available,average 12 shades per quality) and cut shades

Press the pieces and bring to m/c

WLS No:LOG/02


LogisticsShifts A B C G

Sample

Old Warehouse

Sample Maker (B&R)


Monitoring and sample sticker preparation as per packing

slip and as required for record. Handing over of all

stickers required in sampling to concerned workmen. Co-

ordination with store and indentor for desired packing

material for sample preparation. Coordination with sales

and logistic team for preparation of samples as desired.

Maintenance of racks of sample fabric as per quality and

shade


Bring and adjust the material required for sample making

like glue,samle boards pins and other materials

Press the piece and bring to m/c

Take the piece to the m/c and cut it according to the

requirement

Bring covers,paste sticker and write quality nos on

them.Place the cut pieces on to the covers and put staplerand adjust

Take the final sample to the sample dispatch and put there

for dispatch

Sample preparation of fent

Take the print out of the email and note down quality on

to the paper from the email sent for the requisitedemands(18 quality's average 2-3 shades in this case)

Find the required quality and cut piece

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No:LOG/02



Sample

Old Warehouse

Sample Maker (B&R)


131 3 5.62 16.86

14

1 3 93.78 281.34

15

1 3 1.26 3.78

16

1 3 4.97 14.91

17

1 3 28.43 85.29

18 1 3 4.59 13.77

191 3 5.65 16.95

20

1 3 43.20 129.6

211 3 1.18 3.54

22

1 3 5.82 17.46

23

1 3 25.27 75.81

24 1 3 4.42 13.26

251 3 1.76 5.28

Sample preparation of Hanger


average 2-3 shades in this case)


available,average 2-3 shades per quality) and cut shades


Take the pieces to the m/c and cut them according to the

requirements

Sample preparation of Card


average 3 shades to be pasted in this case)





requirements

Bring covers,paste big sample as base and small samples

at the bottom of the card and adjust,paste stickers on the

card and write quality details


for dispatch


requirements

Bring covers,paste sticker and write quality nos on

them.Place the big cut pieces on to the right side of the

covers and put 12 shades on left side,staple


for dispatch

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No:LOG/02



Sample

Old Warehouse

Sample Maker (B&R)


26

1 3 16.76 50.28

271 3 1.15 3.45

A 1950.46B 13

C 2204.02

D 3360

E 65.60%

F 5

G 91.83%

Bring covers,staple big sample as base of the hanger and

small samples at the bottom of the hanger and

adjust,paste stickers on the hanger and write quality

details


for dispatch



Remarks:





________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 350 0.27 95.20

2

2 23 1.09 50.14

3

2 23 0.74 33.85

4 2 23 0.34 15.76

5

1 23 0.95 21.74

61 23 0.21 4.85

A 221.54

B 13

C 250.34

D 1440

E 17.38%

F 2

G 26.08%





GSample Dispatch




C

Remarks:

Old Warehouse

Dispatcher


WLS No:LOG/03


LogisticsShifts A B

For Dispatching

Segregate the samples according to delivery sheet and

paste on each sample ,sticker generatd by computer

Again scan for dispatch

Segregate according to party requirements and paste

address on each packet(average 5-10 samples in each

packet)

Take the packet to dispatch and take back LR number

which is to be entered into the system

Samples made last evevning,transferred to the dispatch

section the next morning are segregated (for

grasim,graviera and esp) and placed

For receiving

Receipt by scanning each sample ,tie for each category

and place at its respective position

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 96.87 96.87

2

2 3 1.56 9.36

31 3 45.87 137.61

4

1 3 34.65 103.95

5

1 3 15.55 46.65

6

2 5 1.34 13.40

7

1 5 7.46 37.30

Take pieces one by one,open each piece and remove old

board ,tag and cut worn out pieces and repack it again

with new board and place asidePack the remaining 15 pieces after placing new bar code

and new length parameter and pack them in plastic and

place aside

Goods coming from parties(fresh and EP)

Take the jute bag ,open and take out the pieces(average 10

pieces comes in 1 bag)

Open the bags adjust the fabric neatly ,place new tag and

repack

Intimation recvd from marketing / outsource purchaser

alongwith documents to release the goods from

transporter. The person then goes to transporters to

release the returned/puchased goods by handing over the

LR and by shifting of same to the mill by arranging the

vehicle / loaders. Handing over of goods to concerned

authority. In case of return goods, the matching of recvd

stock with return sale order and its verification. The

difference if any is informed to concerned for

rectification. The co-ordination with accounts department

for to pay freight and carriage charges for return /

purchased goods and reconcilliation of same.

Measure each piece and place it shadewise while

noting(average 15 pieces come in 1 bag)

Old Warehouse

Workmen


Goods coming from showroom(used fresh)

Take the jute bag ,open and take out the pieces

WLS No:LOG/04



Return /Purchase Goods

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

Old Warehouse

Workmen


WLS No:LOG/04



Return /Purchase Goods

8

2 4 1.59 12.72

91 4 17.89 71.56

10

2 3 1.33 7.98

11

2 3 47.82 286.92

12

1 45 10.87 489.15

A 1313.47

B 13

C 1484.22

D 1920

E 77.30%

F 4

G 77.30%

Barcode stickers:- On return goods PL's sticker genration

and pasting on Fabric (Both Small and big size)


repack


repack

Goods coming from parties(PL/DPL)


pieces,where 10 sub pieces in each piece in a bag)

Goods coming from parties(Safari and suit length)


pieces comes in 1 bag)

Remarks:








________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 203.37 203.37

2

1 1 183.35 183.35

3

2 1 334.95 669.90

4

1 1 58.22 58.22

A 1114.84

B 13

C 1259.77

D 2880

E 43.74%

F 3

G 87.48%

The generation of delivery sheet and printing of invoice

and delivery sheet for outsource job fabric and handingover of same to transporter. The reaching date of goods is

fed into SAP for transporter evaluation. The print out of

same is attached with with transporter bill.

GInvoicing

Printing of bills of 5 copy each (average 450 bills per day),

remove the carbon papers, segregating the bills

transportwise/agentwise/customerwise/extracopy/office

copy. Tearing of same sheetwise and making the bundles

separate as said above. The customerwise / agentwise

segregated bundle is handed over to courier dispatch

section. Extracopy and office copy is kept for further doing

the needful.

The extracopy of bill is attached with respective LR(350

LR average per day)and fed into the SAP for generation of

schedule. The schedule is then printed and segregated

partywise after removing the carbons.The schedule, LR

Copy and extra invoice copy is attached and further

checked. Then stamping of same is done brandwise e.g.

grasim / graviera and signed. The bunch thus prepared is

sent to courier dispatch section for its onward courier.

Monitoring of pending LR's and ensuring that all LR's are

received and fed into system timely.

Old Warehouse

Workmen


The dispatch details of previous day is collected by the

person from domestic warehouse. Then the transportwise

segregated bills are carried over to respective transporters

and LR copy of previous day dispatch is collected from

them.

WLS No:LOG/05



Remarks:








_______________________________________________________________________ _________________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 30 3.21 96.30

2 1 4 35.65 142.60

3 1 2 132.87 265.74

4

1 10 6.43 64.30

5

1 332 0.25 82.06

6

1 1 67.73 67.73

71 356 0.26 93.21

8

1 490 0.73 357.86

A 1169.81

B 13

C 1321.88D 2880

E 45.90%

F 4

G 68.85%

Putting Shipping Marka on case at the time of dispatch

Sticker pasting on case and suit length polythene mouth

closed at the time of dispatch,physical Stock taking for

loose

Time of Loading of loose / packed cases in any vehicle

prepare record and will maintain as per instruction


Broken Cases - Opening of broken cases and arranging in

racks quality and shade wise

Sorting of packing slips and sent to sample, sales and

maintaining the record and Peon work of old warehouse

Checking the invoice case no’s during dispatch the

invoiced cases

Chindi shorting -FRC, making / Packing

House keeping / Cleaning of department



WLS No:LOG/06


LogisticsShifts A B

Old Warehouse

Workmen

C GOld Warehouse

Remarks:





Reprocess for sample cutting and any work in folding as

inspection, convert in thans and refinish etc

work,sampling Cutting as per instruction by reprocess

and sticker generation


________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 60 8.65 519.00

2

3 392 0.29 337.90

3

2 392 0.23 181.37

4

2 392 0.42 330.46

5 2 392 0.52 405.85

6

1 392 0.77 303.08

7 2 392 0.08 62.07

8 1 10 6.75 67.50

A 2207.22

B 13

C 2494.16

D 6720

E 37.12%

F 10

G 51.96%

Shifting cases to packing.Weighing and scanning of fabric

for case preparation at packing station and generation of packing slip. Shifting of fabric on table alongwith packing

slip

Checking of packed case thru reading out details on

stamping of than and comparing it thru packing slip. The

signing of packing slip by checker if details are correct. One

copy of packing slip will kept alongwith loose case and rest

3 copies will be kept at checkers end for Sampling /

Marketing and Self Record. If details are not correct, will

take up with higher authority.

WLS No:LOG/07


LogisticsShifts A B


Old Warehouse

Packers n Checkers


Segregation of Fabric from racks for case preparation as per

assortment and marketing advise and shifting it to packing

station. Attend the Byers, case making, than fancy doing

&keeping back to racks

Take PP rolls to pack from stitching place

Packing of prepared case in cartons / bags and stitching of

bag after putting packing slip in the bag's pocket

Put excise sealing onto each roll

Marking of case thru packing slip kept in pocket of bag (e.g.

case no. / quality no./no. of piece / gross weight / net weight

etc

Keeping the rolls at designated place


Remarks:

C GPacking Section






________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

11 490 1.43 700.70

22 45 0.58 52.53

32 333 0.31 207.24

41 333 0.47 156.62

5 1 333 0.29 97.79

64 17 0.74 50.32

71 5 5.45 27.25

A 1292.45

B 13

C 1460.47

D 3360

E 43.47%

F 4

G 76.07%

Prepare and loose stitch the jute bags

Sort and tie the waste carrying bags and place aside(16-17

bags comes on an average )

Bring empty jute bags from raw material section

GPacking Section for Loose

Adjust the trolley placed by rack monitor near the loose

section

Take than and load into jute bags (9 pieces in each jute

bag)

Old Warehouse

Packers

B

WLS No:LOG/08


LogisticsShifts A

Take the jute bags and place aside and mark the number on

the bag

C


Taping the mouth of loose fabric of Safari / PL / Suitlength



Remarks:






________________________________________________________________________________________






Department

Section



Sl.

No

Cre

w

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2 1/3 20.43 13.62

2 1 1/3 7.86 2.62

31 81 6.64 537.84

41 6 5.87 35.22

51 401 0.40 159.66

62 401 0.70 561.80

7 2 401 0.53 421.99

8

4 1/9 47.84 21.26

91 47 5.56 261.32

10 1 46 3.49 160.72

11

1 25 2.17 54.35

121 369 1.07 395.20

A 2625.61

B 13

C 2966.94

D 3840

E 77.26%

F 8

G 77.26%




Prepare and stitch pocket on the rolls/cartons

Cut plastic to be inserted inside the bags(for 15 bags at a

time)

Take jute and plastic ,stitch them on the m/c together and

place aside

Prepare and stitch the sheet of polythene to make it in a

roll/carton form

For making packing bags for loose (Hessian)

Preparation of issue pass for issuance of packing material

from the store and collection of packing material and

taking them to its workstation

Unlock the jute strips and take out the rolls and give for

stitching

Cut jute for bag formation(for 8 bags at a time)





WLS No:LOG/09



Bag Stitching

Unlock the PP strips and take out the big roll

Cut pieces (for 5 bags at a time) according to the required

measurements and give inside for stitching

Cut pocket for pocket formation(70-80 pockets at a time)

Segregate and place aside

Old Warehouse

Workmen


For making packing bags for rolls and carton (HDPE's

/ LDPE's)

Preparation of issue pass for issuance of packing material

from the store and collection of packing material and

taking them to its workstation

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 18 3.21 57.86

2 1 18 1.88 33.83

3 2 18 2.51 90.36

4 1 17 1.63 27.67

5

2 332 0.04 28.11

6 1 332 0.15 49.08

7 1 331 0.13 42.20

8

2 332 0.04 25.79

91 332 0.06 18.43

101 331 0.05 15.83

11

1 354 2.55 902.70

122 20 10.50 420.00

13 1 20 1.55 31.00

14 1 20 2.54 50.80

15 1 19 1.33 25.27

16

2 354 0.04 28.67

17 1 354 0.09 32.80

From stack to tuck door

Destacking/loading bags on the back/shoulders of the

workmen


C) Loading rolls in truck

Obtaining invoice from dispatch officer and marking

(billwise/transportwise/partywise) on invoiced cases as

advised by dispatch officer.

B) Loading of loose packed goods for shifting them to

domestic warehouse


workmen

Carry the bags upto truck door

From truck door to inside

Loading the bags on the back/shoulders of the workmen

Carrying inside the truck and dump


D) From stacks to place near truck to load

Load rolls onto the trolley(17 -19 rolls being loaded)

Carry the rolls near the truck

GLoading/Unloading

Carry the rolls outside the warehouse

Returning with empty trolley for next load

Old Warehouse

Loader / Marker


A) Shifting the packer rolls outside the warehouse


Unload all the rolls and stack/adjust the rolls

WLS No:LOG/10






________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GLoading/Unloading

Old Warehouse

Loader / Marker


WLS No:LOG/10



18 1 353 0.08 28.00

19

2 354 0.04 29.97

20 1 354 0.06 22.60

21 1 353 0.05 16.30

22

1 2 3.67 7.35

23 1 2 1.38 2.76

24 2 2 2.61 10.44

251 2 1.21 2.42

26

1 10 11.83 118.30

27 1 10 1.45 14.50

28 2 10 2.66 53.20

291 9 1.32 11.88

A 2198.12

B 26C 2769.63

D 7200

E 38.47%

F 8

G 72.13%


F) Shifting the rolls from one place to anotherLoad rolls onto the trolley(17 -19 rolls being loaded)

Carry the rolls to the desired place



Carrying inside the truck and dump


E) Shifting broken cases to packing section


Carry the rolls to the packing section




From truck door to inside

Loading the bags on the back/shoulders of the workmen


Remarks:





________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2 50 4.45 445

2

2 50 17.84 1784

3

1 1 119.87 119.87

A 2348.87

B 13

C 2654.22

D 3840

E 69.12%

F 6

G 92.16%

Remarks:








WLS No:LOG/11



RMG Godown

Sorting and picking of ordered material from the rakes

is done. Picked item is packed into cartons by scanning

the article, same is checked thru packing slip and put

into bag, stripped and weighed for accuracy. The final

weight is updated in SAP. Packing slip is kept in pocket

of bag and marking of details happen on the bag e.g.

case no. /weight / qualtiy / pcs etc. Packed cases are then

kept at designated place for onward dispatch.(24 pieces

in 1 carton)

Printing of invoice copy - invoice copies are printed

after invoicing by sales, two copies are handed over to

transporter, one copy is handed over to invoice section

for LR updation, one copy is handed over to sales and

one copy is kept for record purpose

Printing of delivery sheet and getting it signed by

respective authority and arrange its availability at gate

before physical dispatch of goods.

New Warehouse

Workmen


The RMG goods dispatched by vendor is Tallied as per

documents at time of receipt, the cartons are opened,

tally and segregate it quality / shade wise, inwarding of

same by scanning each article

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 156.77 156.77

21 2 83.l6 166.32

3

1 1 45.65 45.65

4

1 18 13.33 239.94

5

1 18 135.55 2439.9

61 18 41.66 749.88

71 18 5.43 97.74

8 1 18 9.55 171.9

9

1 18 9.82 176.76

101 18 3.21 57.78

Press the pieces(12 shades) and bring to m/c


requirements

Place the small shades on base shades

Collecting packs,covers and glue to fix the folder and paste

the shades with glue,insert sticker on small samples and

write transport no and quality no

Final adjustment and place aside the final folder

GSample

Sample preparation of window sample

Prepare and note down quality/shades(15 qualities' average

12 shades) on to the paper the folder for sample

making(pasting small windows on folders for inserting

shades)



New Warehouse

Sample Maker (Domestic)


Monitoring and sample sticker preparation as per packing

slip and as required for record. Handing over of all stickers

required in sampling to concerned workmen. Co-ordination

with store and indentor for desired packing material for

sample preparation.Co-ordination with sales and logistic

team for preparation of samples as desired.

Maintenance of racks of sample fabric as per quality and

shade


Bring and adjust the material required for sample making

like glue,samle boards pins and other materials

WLS No:LOG/12



________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GSample

New Warehouse



WLS No:LOG/12



11

1 18 5.64 101.52

12

1 18 23.69 426.42

13 1 18 3.82 68.76

14

1 18 1.68 30.24

151 18 36.44 655.92

16 1 18 4.11 73.98

17

1 18 5.73 103.14

18

1 18 21.05 378.9

19 1 18 11.05 198.9

20

1 18 3.87 69.66

21

1 18 13.96 251.28

22 1 18 3.76 67.68

Sample preparation of Card


average 3 shades to be pasted in this case)



Bring covers,staple big sample as base of the hanger and

small samples at the bottom of the hanger and adjust,paste

stickers on the hanger and write quality details



Sample preparation of Hanger


average 2-3 shades in this case)


available,average 2-3 shades per quality) and cut shades



requirements


requirements

Bring covers,paste big sample as base and small samples atthe bottom of the card and adjust,paste stickers on the card

and write quality details


________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GSample

New Warehouse



WLS No:LOG/12



23

1 2 24.65 49.3

A 6778.34

B 13

C 7659.52

D 7680

E 99.73%

F 16

G 99.73%



The bundles of record samples are made and kept to be

picked up by desired person and in case of case samples,

preparation of gate pass getting it signed by concerned

authority and taking them to sample dispatch section at oldwarehouse for their further dispatch






________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2 349 3.21 2243.26

21 349 0.28 97.55

3 1 348 0.07 26.044 1 349 0.61 212.19

51 47 7.03 330.54

61 47 8.11 381.30

7 1 46 0.52 24.00

8

1 46 8.13 374.12

9

1 6 7.01 42.05

10 1 6 0.51 3.08

11 1 5 0.29 1.45

12 1 1 134.44 134.44

A 3870.01

B 13

C 4373.11

D 8160

E 53.59%

F 10G 91.11%




Remarks:




WLS No:LOG/13



Loose Opening Section

Take out all the packets(average 9 in each pack) from the

jute bags and place nearby

Return to open next jute bag

New Warehouse

Workman


Opening of loose bags and arrange nearby in stack

Opening of loose bag once unloaded by loaders

Housekeep of section

Return to take the next load

Arrange all the pieces shade wise

Shifting of made cases upto packing station.

Loading pieces into the trolley(65-70 in one trolley)

Carrying the pieces upto scanning section

From stack to placing in racks

Loading pieces into the trolley(65-70 in one trolley)

Carry the pieces upto the rack and place the pieces quality

wise and shade wise

Attending of buyers, showing them the desired fabric,

keeping the goods back in rakes and making of case as

advised by buyers. In case of assortment, making the case

as per packing instruction recvd from sales / LE. Keeping

the residual fabric in rakes.Keeping of fabric in

qualitywise /shadewise in rakes and ensuring proper

upkeep and tracing of same as and when required.

Maintaining agewise fabric in rakes and retrievel of same

when required.

Retun to take the next lot

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 1 197.66 197.66

2

1 39 13.55 528.45

31 39 44.34 1729.377

4

1 39 8.87 345.93

5 1 39 18.14 707.265

6

1 39 2.51 98.0785

7

1 1 220.22 220.22

8

1 1 90.44 90.44

A 3917.42

B 13

C 4426.69

D 11520

E 38.43%

F 10

G 92.22%


Opening of shirting, matching it with documents and

stamping of each piece brandwise and cut wise and

then keeping it in rakes sizewise and shade wise.


The PL stickers is then removed by maker and

generate new combo sticker in SAP and paste it on

fabric.

Insert shirting and PL in primary pack

Write the details on the sticker ,bring big box and load

average 13 primary packs in the box ,paster sticker

and place aside

Preparatory time(for bringing laces ,gum,cartons and

other material) and proper maintenance and upkeep of

Combo packing section.)

Co-ordination with sales team / logistics for order

processing and packing material respectively.

B C GCombo Packing



Bring shirting and PL from the respective sections(for

making one big bag in which average 4-6 sub packswill come.In each sub pack a combination of 12

shirting,12 PL or 14 shirting,14 PL is being done)

Pack shirting and PL in compact form and tie lace

New Warehouse

Workmen

Remarks:





WLS No:LOG/14


LogisticsShifts A

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 34 16.43 558.57

2 1 34 5.89 200.42

3 1 34 39.98 1359.43

4 1 34 18.27 621.18

5 1 1 240.55 240.55

6 1 3 90.00 270.00

A 3250.16

B 13

C 3672.68

D 5760

E 63.76%

F 8

G 95.64%




Remarks:





WLS No:LOG/15



Suit Length / Safari

Packing starts by scanning each piece and generating

packing slip and checking of same for correctness and

putting the polythene bag in primary box of safari which

is made by folding the edges of raw primary box and

keeping of primary box in secondary outers alongwith

packing slip and leaving at designated place to be carried

away for final packing by packing team





Safari / suit length section.)

Arrange the pieces on table

Wrapping of fabric onto 15x7 patti and keeping it in one

polythene bag and closing the mouth of same

New Warehouse

Workmen


Carrying (50 bundles at a time with 5 pieces in each) and

opening of master pack of safari / suitlength and keeping

them at designated place qualitywise, shadewise and

cutwise.

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 12 9.1595 109.914

2

2 46 9.33 858.36

3

1 46 3.46 159.16

4

1 304 5.45 1656.8

52 1 250.44 500.88


Carrying and opening of master pack of PL and keeping

them at designated place qualitywise, shadewise and

cutwise.(40 PL packs where 8 PL pieces in each pack at a

time)

GPL Packing

New Warehouse

Workmen

WLS No:LOG/16



Scanning of bar code of each piece occurs in SAP and

generation and printing of packing slip and making of PL

case(80 PL pieces in one bag in an average) starts by

keeping the pieces of different quality / shade together in

one case

The generated case no. is written on summary card and

take away the generated cases at designated place for

fancying and packing of PL case(80 PL pieces)

There are two types of packing 2 fold or 3 fold. In case of

2 fold, the fabric is wrapped on 14x8 patti, one poster is

kept onto it and inserted into one 9.5x15.5 polyhthene

thaili. 10 pcs of each are then tied with ribbon and

inserted in one 14x22 thaili. The packed cases are kept at

desginated place to be carried away for final packing. In

case of 3 fold packing, fabric is wrapped on 10x8 gatta

and tied with ribbon, poster of 3 fold is kept onto it and

inserted in 9.5x15.5 thaili. The thaili's are then kept into 5ply outer and kept at designated place to be carried away

for final packing by packing team



________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)


GPL Packing

New Warehouse

Workmen

WLS No:LOG/16



6

1 3 90.00 270

A 3555.11

B 13

C 4017.28

D 7680

E 52.31%

F 9

G 92.99%





Remarks:





PL section)


________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 6 43.65 261.90

2

1 6 2.22 13.32

3

1 12 45.55 546.60

4

1 12 2.57 30.84

5

2 1 218.98 437.96

6

1 3 90.00 270.00

A 1560.62

B 13

C 1763.50

D 2880

E 61.23%

F 4G 91.85%


Pack Good cut

Segregate all the pieces rangewise / cutwise /

qualitywise and brandwise .The lengths of the pieces

include 91 cms,95 cms,1 mtr,1.05 mtr,1.10mtr and 1.14

mtrs

GGood Cut / FRC

New Warehouse

Workmen



WLS No:LOG/17



The sorted pieces cut wise and qualitywise are kept on

one gatta of 30x8 and then inserted into one thaili of

17x35 (90 pieces being packed in each bag) alongwith

one the summary card having details of packed pieces

and kept at designated place to be carried away for final

packing

Pack FRC

In case of Fent and Rags, opening of packet / bag and

sorting the fabric rangewise / cutwise / qualitywise andbrandwise.The lengths of the pieces include 120 cms,95

cms(chindi),21-44 cms(rag) and 45-90 cms(fant)

Remarks:




The packed pieces are kept in one thaili alongwith

summary card to be taken away for final packing. In

case of chindi, stuffing of chindies in bags in according

to their size and kept at designated place to be carried

away for final packing.


processing and packing material



FRC section.)


_________________________________________________________________________ _______________







Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2 342 0.46 313.04

2

2 342 0.46 313.84

3

2 342 0.78 535.57

4

2 342 0.92 628.71

5

1 342 0.80 273.09

6

1 342 0.78 268.01

72 342 0.07 47.99

A 2380.26

B 13

C 2689.70

D 11520

E 23.35%

F 18G 31.13%

Stripping on the packed case manually / thru machine and

mentioning final gross weight on case and keeping it atdesignated place

Remarks:





Place the jute bags on stack and write the weight on bags

Packing Section




New Warehouse

Packers n Checkers


Weighing and scanning of fabric(11-12 pieces) in case of

than packing at packing station and generation of packing

slip. Shifting of fabric on table alongwith packing slip.

Corner Making of packed case thru stitching for

compactness and better handling at time of loading /

unloading.

Marking of case thru packing slip kept in pocket of bag

(e.g. case no. / quality no./no. of piece / gross weight / net

weight etc

Checking of packed case thru reading out details on

stamping of than and comparing it thru packing slip. The

signing of packing slip by checker if details are correct.

One copy of packing slip will kept alongwith loose case

and rest 3 copies will be kept at checkers end for Sampling

/ Marketing and Self Record. If details are not correct, will

take up with higher authority.

Packing of prepared case in cartons / bags(11-12 pieces in

one bag) and stitching of bag after putting packing slip in

the bag's pocket

WLS No:LOG/18



________________________________________________________________________________________






Department

Section

Work Centre Present Manpower - - - 16Designation Proposed Manpower - - - 10

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2 342 0.04 27.93

21 342 0.39 132.35

3 1 341 0.366333 124.92

4 1 342 0.25 84.13

5

2 203 0.04 17.19

6 1 203 0.06 11.60

7 1 202 0.05 9.70

8 1 203 0.13 25.92

9 1 202 0.11 22.02

10

2 203 0.04 15.77

11 1 203 0.05 10.89

12 1 202 0.05 9.70

13 1 203 0.10 21.08

14 1 202 0.09 18.62

152 203 0.04 14.21

16 1 203 0.09 17.66

17 1 202 0.08 16.43

B) Unloading of loose packed goods and place them

in the lower godown(Graviera) entry


workmen


C) Unloading of loose packed goods and place them

in the upper godown(Grasim) entry


workmen




Carry the bags from truck door to inside godown

Carry the packed cases to be placed inside the godown

Stack/adjust the packed cases

New WarehouseLoader / Marker


A) Shifting the packed cases inside the warehouse

Destacking/loading packed cases on the back/shoulders

of the workmen


WLS No:LOG/19


Logistics

Shifts A B C G

Loading/Unloading

Carry the bags from lift to stack nearby


Carry the bags from truck door to lift


Upstation(Grasim)



________________________________________________________________________________________






Department

Section


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)



WLS No:LOG/19


Logistics

Shifts A B C G

Loading/Unloading

18

2 114 2.12 483.36

19

2 57 0.04 4.62

20 1 57 0.10 5.90

21 1 56 0.09 5.16

22

2 57 0.04 4.43

23 1 57 0.16 9.28

24 1 56 0.14 8.07

25

2 57 0.04 4.58

26 1 57 0.31 17.82

271 56 0.29 16.39

28

2 114 0.04 8.44


Carry the bags to lift

E) Shift packed cases from upwards(Grasim) to be

send for dispatch


workmen

D)Loading marked cases for dispatch

Printing of delivery sheet, case marka report and

transportwise case report.Case marka report will

handed over to marker to mark the dispatchable case

for the day.The checker will check the cases at bay andpermanent marka will be put before the loading of

cases into the vehicle

Carry the bags from lift to be placed for dispatch


F) Shift packed cases from downwards(Graviera) to

be send for dispatchDestacking/loading bags on the back/shoulders of the

workmen

Carry the bags outside the warehouse and place

Downstation


workmen


G) Load cheched and assembled cases into vehicle


workmen

________________________________________________________________________________________






Department

Section


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)



WLS No:LOG/19


Logistics

Shifts A B C G

Loading/Unloading

29 1 114 0.09 10.72

30 1 113 0.08 9.19

31

2 114 0.04 8.09

32 1 114 0.05 5.93

33 1 113 0.05 5.44

A 1187.53

B 26

C 1496.29

D 7680

E 19.48%

F 10

G 31.17%

Return for next case

Return for next case

Remarks:








From door to inside vehicle

Destacking/loading bags on the back/shoulders of theworkmen

Carry the bags inside vehicle and place

Carry the bags upto vehicle and place

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 3 22.41 67.23

21 3 7.58 22.74

3 1 3 179.55 538.65

4 1 3 32.50 97.5

5 1 3 9.97 29.91

6 1 3 131.62 394.86

7 1 3 14.48 43.44

8

1 3 20.98 62.94

9 1 3 7.64 22.92

10 1 3 93.03 279.09

11 1 3 162.50 487.5

12 1 3 10.21 30.63

131 3 112.10 336.3

14

2 1 240.54 481.08

15

1 1 206.97 206.97

16

1 1 248.76 248.76

C GRegrading / General

New Warehouse

Workmen


Cut and pack fresh into PL

Load(60-70)fresh pieces on to the trolley and carry upto the

scanning section,scan each piece and carry upto the FRC

section

WLS No:LOG/20


LogisticsShifts A B

Fold the suit length in compact form

Cut the pieces into 4 suit lengths

Pack the suit lengths in poly bag with laces on both sides

and paste sticker on them

Packing material keeping with systematic way and deliver

to respective user by one hand on daily basis

Unload the pieces on the table in FRC section

Cut the pieces into 10 PLs

Unload the pieces on the table in FRC section

Packing Slip sort out and give to concern department and

other all peon work will do as per concer officer

Monitor for Supervision of Graviear & Grasim Warehouse

as inspection the work and making the requirment of

packing material and monitior the store / Purchase work for

avoide the any shortage of packing material.

Paste stamp on the PLs

Cut and pack fresh into Suit Length/Safari

Load(60-70)fresh pieces on to the trolley and carry upto the

scanning section,scan each piece and carry upto the FRC

section

Bring new SAP generated sticker from the computer

Paste stickers on the PLs

Tie 30 pieces together and send to PL.

Bring new SAP generated sticker from the computer

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

C GRegrading / General

New Warehouse

Workmen


WLS No:LOG/20


LogisticsShifts A B

17

1 3 90.00 270

A 3620.52

B 13C 4091.19

D 5760

E 71.03%

F 9

G 94.70%

Remarks:







Preparatory time(for bringing laces ,gum,cartons and other

material) and proper maintenance and upkeep of FRC

section.)

________________________________________________________________________________________





________________________________________________________________________________________Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani

14. THERMAL POWER PLANT

________________________________________________________________________________________





___________________________________________________________________________________________________________________________________Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani

14.014.1


1TPP ( Turbine

Operation)Operator 1 1 1 - 3 1 1 1 - 3

2TPP (Boiler Fuel

Feeders)Operator 2 2 2 - 6 2 2 2 - 6

When Pet coke is

used

3

TPP (Boiler Fuel

Feeders)-PA Hopper

Poking

Operator 1 1 1 - 3 1 1 1 - 3

4TPP (ESP & ASH

Handling)Operator 1 1 1 - 3 1 1 1 - 3

5TPP (Coal Handling

Plant)Operator 7 7 7 - 21 7 7 7 - 21

When Indian Coal

is used

6 TPP (Maintenance) Fitter / Asst. Fitter - - - 2 2 - - - 2 2

7 TPP (Maintenance) Helper - - - 5 5 - - - 5 5

8 TPP (Maintenance) Welder - - - 1 1 - - - 1 1

9TPP (DM Plant

Operation)Fitter - - - 2 2 - - - 1 1

10TPP (DM Plant

Operation)Helper - - - 2 2 - - - 2 2

11TPP (DM Plant

Operation)Chemist 1 1 1 - 3 1 1 1 - 3

Man ower De lo mentTHERMAL POWER PLANT


Present Manpower

_______________________________________________________________________________________________________ __________________________






___________________________________________________________________________________________________________________________________Study on Manpower Assessment at M/s Grasim Bhiwani Textiles Ltd,Bhiwani

14.014.1


Man ower De lo mentTHERMAL POWER PLANT


Present Manpower

12TPP (DM Plant

Operation)Operator 1 1 1 - 3 1 1 1 - 3

13 TPP (House Keeping) Helper - - - 2 2 - - - 2 2

14 TPP/WartsilaGardener &

Sweeper- - - 2 2 - - - 2 2

15 Wartsila (Operation) Operator 1 1 1 - 3 1 1 1 - 3

16 ETP (Operation) Operator / Helper 2 2 2 - 6 2 2 2 - 6

17

TPP ( Electrical

maintenance+Elect.

B/D)

Electrician / Asst.

Foreman1 1 1 - 3 1 1 1 - 3

18 18 18 16 70 18 18 18 15 69Total

_______________________________________________________________________________________________________ __________________________







14.0

14.2

14.2.1

I

a)

14.2.2

I

a)

b)

c)

II

a)

b)

III

a)

THERMAL POWER PLANT


Proposed Changes

DM Plant-Mechanical Maintenance

In view of low utilisation (37.62 %) it is recommended to deploy one fitter for DM

plant maintenance activities instead of the present two personnel.

In TPP-Temporary stores, where the materials like bed materials, lime stone which

comes in bags was teared and spilled all around the entrance. It increases the

workload of coal handling personnel as the materials has to be shifted from ground

instead of bags.

Observations

TPP-Coal Handling

It is observed that the coal handling areas like Vibratory screen area, magnetic

separator, Crusher and belt conveyor walking pathways was not cleaned at regular

intervals and causing threat to walk in that area for the mechanical checkups. It is

recommended to maintain checklist to monitor the cleanliness in critical area for easy

access to maintenance.

In the belt conveyor pathways which is slide in nature and spilled materials are round

in nature causes safety issues.

In general, overall Coal handling plant and belt conveyor area to be improved in

safety point of view like providing cross bars to prevent accidents, near magnetic

separator(where magnetic separator operator works) adequate safety precautions to

be provided.

DM Plant -Mechanical Maintenance

TPP

Presently, open end small trolley is being used by DM plant mechanical helpers to

shift salt bags from temporary stores to salt tank and to shift HCL chemical from

storage tank to cooling tower. As the trolley is open (no boundary), two person is

deployed during shifting of HCL chemical(one person front side and another person

backside) and also causes spillage (if can falls). It is recommended to provide big

trolley and recommended to tie the cans while moving.

It also helps in reducing number of trips required to shift salt bags from stores to salt

tank. Presently only 4 bags is shifted per shift.

________________________________________________________________________________________






14.0

14.3

S.No Area of work1 TPP ( Turbine Operation)

2 TPP (Boiler Fuel Feeders)

3 TPP (Boiler Fuel Feeders)

4 TPP (ESP & ASH Handling)

5 TPP (Coal Handling Plant)

6 TPP (Maintenance)-

Fitter/Asst.Fitter

7 TPP (Maintenance)-Welder

8 TPP (DM Plant Operation)-Fitter

9 TPP (DM Plant Operation)-Helper

10 TPP (DM Plant Operation)-

Chemist

11 TPP (DM Plant Operation)-

Operator

12 TPP (House Keeping)-Helper

13 TPP/Wartsila -Gardener&sweeper

14 Wartsila (Operation)-operator

15 ETP (Operation)-operator

16 TPP ( Electrical

maintenance+Elect. B/D)

TPP/W/06

TPP/W/07

TPP/W/08

TPP/W/09

TPP/W/10

TPP/ELEC/01

TPP/W/05

TPP/DM-MECH/02

TPP/DM-MECH/01

TPP/MECH/02

TPP/MECH/01

TPP/W/05

THERMAL POWER PLANT

TPP/W/01

TPP/W/02


WLS Number

TPP/W/04

TPP/W/03

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

a

b

c

d

2 1 8 3.00 24.00

3 1 1 20.00 20.00

4 1 1/10 30.00 3.00

5 1 1 15.00 15.00

61 1/30 60.00 2.00

7 1 1/90 60.00 0.67

8 1 1

A 79.67B 12

C 89.23

D 450

E 19.83%

F 1

G 19.83%



Cooling Tower fan checking

Centrifuge operation checking

Log Book Record

Turbine Start Up and Normal Shut Down

CW pump Suction strainer cleaning (Only in A Shift)

Daily Check List Monitoring (Only in B Shift)

ACW pump Suction strainer cleaning (Only in A Shift)

Lube Oil and Control Oil Filter Checking



* As the activity is observatory & monitoring in nature, not considered for calculating utilisation.

Lube Oil and Control Oil Filter Cleaning

(Only in A Shift)



Remarks:

Presently operator is being relieved by the shift incharge for the Tea break, Lunch break & personal

needs during the shift hours.

A shift person Utilisation comes to 16.09 %, B shift personal utilisation- 13.61%, C shift it is9.87 %

Monitoring of Turbine through DCS *

Cooling Water pump -CW & ACW Pumps Checking

WLS No: TPP/W/01


EngineeringShifts A B C

1 1

GTPP

Control Room

Turbine Operator


Turbine field parameter checking

15 15

________________________________________________________________________________________






Department

Section

Work Centre Present Manpower 2* 2 2 -

Designation Proposed Manpow 2* 2 2 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

a2 5 1/3 1.49 15.91

a 2 5 1/3 3.80 40.49

b 1 5 1/3 1.29 6.90

c1 5 1/3 0.37 1.97

2

a 1 37 0.98 36.26

b 1 37 0.95 35.22

c 1 37 0.52 19.31

d1 37 10.63 393.16

e 2 37 0.58 43.17

f 2 37 0.40 29.60

3 1 1 60.00 60.00

A 681.98

B 14

C 777.45

D 450

E 86.38%

F 2

G 86.38%

Move the empty trolley back to drain pipe area




House keeping ground floor (area 900 sq meter bybroom)

Load the bags in the tractor

Bed material screening is being carried out only when pet coke is used as fuel.

When indian coal is used as a fuel, it is recommended to deploy one person per shift instead of two

personnel. The utilisation of single personnel deployed would be around 54.73%.

B


TPPG

* Recommended manpower is for petcoke feeding

Bed Ash drain:( 37 Trolley/Shift)


Remarks:




Waiting for the operator to open the next pipe in

computer

Hit the pipe with the hammer & Collect ash

Move the filled trolley to dumping yard and dump

Screen the bed material through portable screen(2

level screening)

Put the screened materials in the bags and tie

Waiting for the ash to fill in the trolley

Move the filled trolley to dumping yard for cooling

Move the empty trolley back to drain pipe area

WLS No: TPP/W/02


EngineeringShifts A

PA Line drain:( Once in a day- 16 Pipes)

C

Boiler Fuel Feed

Helpers

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 4 6.11 24.44

21 4 5.00 20.00

3

1 1 15.00 15.00

41 1 45.00 45.00

51 0.00

A 104.44

B 12

C 116.97

D 450E 25.99%

F 1

G 25.99%

House keeping Boiler furnace area (area 900 sq

meter by broom) (Only in A Shift)

Monitor the Pocket fuel feeder operation and poke

if feed get jammed






Remarks:



WLS No: TPP/W/03


EngineeringShifts A B C G

TPP

Boiler Fuel Feed

Helpers


PA mixing line, Fuel Feeding lines and vertical

chute check & poke(if required).PA injector

checking and hammering

Monitor Bunker fuel Level by visual inspection

once in a while

Cleaning of Auxiliary & Equipments(Only in A

shift)

________________________________________________________________________________________






Department

Section



Sl.

No

Cre

w

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 4 3.30 13.20

21 1 15.69 15.69

3 1 4 2.19 8.76

41 4 3.00 12.00

51 4 2.50 10.00

6

a1 4 4.00 16.00

b1 4 2.07 8.28

c 1 4 2.00 8.00d 1 4 4.00 16.00

e 1 4 1.00 4.00

7 1 1 10.00 10.00

81 1 30.00 30.00

91 1 15.00 15.00

101 1/2 150.00 75.00

A 241.93

B 13

C 273.38

D 450

E 60.75%

F 1

G 60.75%


Present Utilisation(%) ( S.No 1-10)


Proposed Utilisation(%)(S.No 1 -17)

Remarks:

The following data was collected from past record:

Clean the ESP&Ash handling area ( Once in a day-A & B

shift)

Oct'2011- Dec'2011 - 207 Tractors, Oct'2011-Dec'2011 - 98 Trucks




Bring down the chute to place properly on the truck,

Switch on

Ash Sample Collection and Sending to Lab

Monitor the Daily Check List parameter and fill the

list(Only in B shift)

Check the gearbox oil level and pumps, motors in ESP &

Ash handling section

Operator


Check the ESP and Ash handling plant during its

operation, Check the compressor readings like pressure etc

Clean the Compressor Suction Filter(2 Atlas + 2 Ingersoll

rand)

Fill the ash in truck from silo

GTPP

C

Help in placing the truck in properly and note down the

truck number in log book

Switch on the air blower and switch off

Observe the ash fillingHit the sides of the ash silo with hammer for proper flow

Switch on the TR set room switches(once in every twohours)

Switch off the TR set room switches(once in every two

hours)

Log book record keeping(once in every two hours)

ESP&Ash Handling

WLS No: TPP/W/04


EngineeringShifts A B

________________________________________________________________________________________






Department

Section

Work Centre Present Manpower 7* 7* - -


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

a4 31 2.53 313.41

b4 31 3.32 411.68

c4 10 1.34 53.50

d4 10 4.51 180.50

e2 1 9.45 18.90

f 2 1 9.45 18.90

2

a4 15 2.53

b4 15 3.32

c2 2 7.88

d 2 1 9.45

3

1 1 240.00 240*

41 1 240.00 240*

Indian Coal(90%) + Cow dung ( 10 %)

Waiting for the tractor to dump next load, in between

pokingPoke the grizzly screen after cow dung dumped by the

tractor


poking

Shift the Bed material from store to JCB (40 kg

/bag)(30 bags/ JCB trip)

Open the bed material bag and dump in the grizzly

hopper(30 bags)

Poke the grizzly screen after pet coke dumped by the

tractor


poking

One operator @ Grizzly hopper Bottom -While

loading

Shift the Limestone from store to JCB (60 kg/bag * 25

bags/JCB trip)

Pet Coke(95%) + Lime Stone ( 5 %)

Open the lime stone bag and dump in the grizzly

One operator @ Bunker Floor -While loading

Poke the grizzly screen after coal dumped by the tractor

Four operator @ Grizzly hopper Poking -While

loading

WLS No: TPP/W/05


EngineeringShifts A

Remove the unwanted materials from the coal(running

belt conveyor) near the magnetic separator

Open the hopper outlet door manually to control the

flow of the materials in the belt conveyor ( to avoid

overflow & underflow in belt conveyor)

One operator @ Magnetic Separator -While loading

B C GTPP

Coal Handling

Helpers


________________________________________________________________________________________






Department

Section

Work Centre Present Manpower 7* 7* - -


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

WLS No: TPP/W/05



TPP

Coal Handling

Helpers


5

1 1 240.00 240*

61 1 30.00 30.00

72 1 120.00 240.00

8 2 1 45.00 90.00

9

1 1525 0.40 610.00

10 1 1 60.00 60.00

A 2026.89B 16

C 2351.19

D 450

E 74.64%

F 7

G 74.64%

To get the workload, when petcoke is used as fuel, add S.No 2 a,b,c & d

* Seven personnel per shift is deployed When indian coal is used as fuel. Six personnel per shift is

deployed if petcoke is used as fuel. The study was done for indian coal feeding.

Cow dung is used along only with indian coal.


Clean the Coal Crusher, Screen, Belt BC-2, BC-3 andCoal Plant House Cleaning.

Clean the Bunker BC4 Belt and Bunker floor

Fuel spillage recovering from ground floor all over coal

plant, put it on the JCB and transfer& house Keeping. (

Total Area-3050 sq meter. A shift - 3050/2 =1525

sq.mt)

Water spraying to ground floor area in coal yard area


Clean the Grizzly hopper and feeding area ,area

opposite coke storage

Seven operator is recommended because simultaneously seven operators are involved (during

loading)

Monitor the bunker level manually and inform the

Control room for belt diverting once the level

reached(like Bunker 1 to 2 or 2-3,etc)

After loading over, all helpers clean the areas as group



Remarks:

Lime stone is used along only with pet coke.




________________________________________________________________________________________






Department

Section

Work Centre Present Manpower - - -2 Fitter +5

HelperDesignation Proposed Manpower - - -

2 Fitter +5

Helper

Fitter Helper

1 63.18 63.18

2

a 3.50 3.50

b 5.17

c 16.80

3 80.00 240.00

4 40.00 40.00

5 36.40

6 17.67 40.33

7 20.00 58.00

8 9.30 36.00

9 6.67 20.0010 18.67 37.33

A 258.98 596.72

B 14 14

C 295.24 680.26

D 166 166

E 88.71% 81.76%

F 2 5

G 88.71% 81.76%

WLS No: TPP/MECH/01


EngineeringShifts A C G

TPP & DM


Total Workload ( in man hours )

Daily Works-Routine Checkup *

Lubrication Works*

Big Gear Box Oil Change ( 1 Fitter + 1 Helper)

Mechanical

Welder

Small Gear Box Oil Change ( 2 Helpers)

Small Breaing Greasing ( 1 Helper)

Repair Work

Roller Repair

Basic Workload per month ( in man hours)

B

TPP Annual Shutdown works

Kaizen Works-TPP


Assist Welder in carryout his activities (minor problems)

Abnormalities-TPP

Breakdown-TPP

Wartsila Yearly Maintenance

Breakdown maintenance,abnormalities,Kaizen works, Wartsila yearly Mt and TPP annual

shutdown works data has been obtained for a period of two months and the same has been

extrapolated for a month.

The preventive maintenance data was collected for all the category of machines. Check studies on

a sample basis were carried out to ascertain the process being followed for the preventive

maintenance. The data gathered during check studies has been applied to the remaining preventive

maintenance activities in that section.

Net Available man-hours per month ( 26*8 *80% = 166 )


Total Time(Hours)

/Month

Proposed Manpower


Sl.

No

Remarks:

* For details See WLS-TPP/MECH/01 A & B

________________________________________________________________________________________






Department

Section

Work Centre Present Manpower - - -2 Fitter +5

HelperDesignation Proposed Manpower - - -

2 Fitter +5

Helper

WLS No: TPP/MECH/01



TPP & DM

Mechanical

Welder

B

Repair work- The activity perform to resolve the running problems identified during daily check

up. The timings was estimated based on the data collected from the past records & discussion with

the workmen.

The manpower has been computed with a loading factor of 80 % for the maintenance personnel.The 80 % loading has been considered to take into account the following:


Prepare attendance

Roller Repair- The time spent in rectifying & replacing the damaged rollers in the belt conveyors.

The timings was estimated based on the data collected from the past records & discussion with the

workmen.

Unavoidable delay. EX:New activity cannot start after 4.30 pm as only 30 mins left for that day

Change dress

Write logbook






________________________________________________________________________________________






Department

Section

Work Centre Present Manpower - - -


Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2

3

4

5

6

7

8

9

10 1 1 25.00 25.00

111 1 60.00 60.00

A 146.20

B 2.44

Check belt conveyor rollers(BC1,3&4)

1 1 61.20

CW pump,ACW pump coupling, sound checking

Vibratory screen,V belt, Crusher checking

CT fan gearbox oil level checking

HP Dosing pump and LP dosing pump checking

Check the bunker floor belt conveyor motor

Check the DEB floor

WLS No: TPP/MECH/01 A


EngineeringShifts A

Basic Workload per Shift ( in man hours)


ETP pump gland and compressor oil, sound level

checking

Check belt conveyor rollers(BC2)

B C GTPP

Check Pocket feeder floor and check oil level

TPP

Mechanical


Drag chain feeder, gearbox oil, nut & bolt checking

61

________________________________________________________________________________________






Department

Section

Work Centre - - -

Designation - - -

Sl.

No

Crew

Size

Numbe

r of

parts

Freq/

Month

Basic

Time

(Hour)

Total

Time

(Hour)

1

1 F+1 H 4 1/12 2.00 0.67

1 F+1 H 2 1/12 2.00 0.33

1 F+1 H 2 1/12 2.00 0.33

1 F+1 H 4 1/12 2.00 0.67

1 F+1 H 1 1/12 2.00 0.17

1 F+1 H 1 1/12 2.00 0.171 F+1 H 1 1/12 2.00 0.17

1 F+1 H 1 1/12 2.00 0.17

1 F+1 H 4 1/12 2.00 0.67

1 F+1 H 1 1/12 2.00 0.17

3.50

2

2 8 1/6 0.50 1.33

2 4 1/6 0.50 0.672 4 1/6 0.50 0.67

2 2 1/6 0.50 0.33

2 1 1/6 0.50 0.17

2 1 1/6 0.50 0.17

2 1 1/6 0.50 0.17

2 1 1/6 0.50 0.17

2 1 1/6 0.50 0.17

2 8 1/6 0.50 1.33

5.17

3

1 2 1 0.15 0.30

1 2 1 0.15 0.30

1 2 1 0.15 0.30

1 8 1 0.15 1.20

1 4 1 0.15 0.60

1 4 1 0.15 0.60

1 3 1 0.15 0.45

1 3 1 0.15 0.45

WLS No: TPP/MECH/01 B


EngineeringB C G

TPPA

TPP

Mechanical


BC - 4 - 1 No.

Gearbox oil change (Small)

Pocket feeder gearbox - 8 Nos.

Drag chain gearbox - 4 Nos.

Lub oil changing - 1 No.

Total Workload per month

Gearbox oil change (big)

PA fan bearing greasing - 2 Nos.

ID Fan bearing greasing - 2 Nos.

FD fan bearing greasing - 2 Nos.

Pocket feeder bearing greasing - 8 Nos.

C.W Pump motor bearing greasing - 3 Nos.

Motor Bearing & Plumber Block

Bearing and all bearing greasing

C T Fan Gearbox - 4 Nos.

HMDC Gear Box - 2 Nos.

Ash Silo Air blower - 2 Nos.

ETP Air blower - 4 Nos.

BC - 1 - 1 No.

BC - 2 - 1 No.

BF - 1 - 1 No.


Shifts

Present Manpower

Proposed Manpower

Lime stone feeder gearbox - 4 Nos.

BF - 2 - 1 No.

RBF - 1 - 1 No.

BC - 3 - 1 No.

Collecting rapping gearbox - 4 Nos.

Rotor feeder gearbox - 2 Nos.

Drag chain feeder bearing greasing - 4 Nos.

Lime stone feeder greasing - 4 Nos.

CT fan motor bearing greasing - 3 Nos.

RBF - 2 - 1 No.

ETP Plant gearbox - 8 Nos.

RBF - 3 - 1 No.

________________________________________________________________________________________






Department

Section

Work Centre - - -

Designation - - -

Sl.

No

Crew

Size

Numbe

r of

parts

Freq/

Month

Basic

Time

(Hour)

Total

Time

(Hour)

WLS No: TPP/MECH/01 B


EngineeringB C G

TPPA

TPP

Mechanical


Shifts

Present Manpower

Proposed Manpower

1 2 1 0.15 0.30

1 1 1 0.15 0.15

1 4 1 0.15 0.60

1 4 1 0.15 0.60

1 2 1 0.15 0.30

1 4 1 0.15 0.601 2 1 0.15 0.30

1 1 1 0.15 0.15

1 1 1 0.15 0.15

1 1 1 0.15 0.15

1 1 1 0.15 0.15

1 4 1 0.15 0.60

1 9 1 0.15 1.35

1 9 1 0.15 1.351 3 1 0.15 0.45

1 4 1 0.15 0.60

1 30 1 0.15 4.50

1 2 1 0.15 0.30

16.80

Rotary feeder motor gearing - 2 Nos.

BC-1 Motor - 1 No.

BC-2 Motor - 1 No.

BC-3 Motor - 1 No.

BF-2. RBF-1, RBF-2, RBF-3 Motor-4 Nos.

Screen arm bearing - 4 Nos.

Screen small bearing - 30 Nos.

Crusher bearing greasing - 2 Nos.


BF-1 Motor - 1 No.

F- Fitter , H - Helper

BC tail pulley bearing greasing - 9 Nos.

BC head pulley bearing greasing - 9 Nos.BC counter belt bearing-3 Nos.

A.C.W Pump motor bearing greasing-2Nos.

G.D motor bearing greasing - 1 No.

Emmiting rapping motor - 4 Nos.

Collecting rapping motor - 4 Nos.

HMDC Motor greasing - 2 Nos.

Air blower motor greasing - 4 Nos.

________________________________________________________________________________________






Department

Section



No

Total

Time(hours)

/Month

1 6.67

2 2.67

3 8.00

4 22.66

5 3.66

6 4.677 36.40

A 84.72

B 14

C 96.58

D 166

E 58.04%

F 1

G 58.04%

Proposed Manpower

C



Remarks:

The activities performed under abnormalities, breakdown and Kaizen works was collected from the

past record and workload per month was arrived.

Minor Problems attended daily


Abnormalities Attended-TPP

The past data of minor activities was collected from the past records. The data gathered during

check studies has been applied to the remaining preventive maintenance activities.



Net Available man-hours


GTPP & DM

Mechanical

Welder

TPP Annual Shutdown

Abnormalities Attended - DM

Breakdown Activities - TPP

Kaizen Works-TPP

Kaizen Works-DM

WLS No: TPP/MECH/02


EngineeringShifts A B

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Month

Basic

Time

(hours)

Total

Time

(hours)/

Month

1

21.00

31.00

4 2.67

5 8.006 6.00

7 79.04

A 110.71

B 14

C 126.21

D 166

E 37.92%

F 1G 75.84%

Breakdown maintenance,abnormalities,Kaizen works data has been obtained for a period of two

months and the same has been extrapolated for a month.

Running maintenance data has been collected by detailed discussions with the incumbents and

the supervisory personnel and compared with check studies and estimated.

Check the raw water tank pump, Trail run the standby


Net Available man-hours


Proposed Manpower

The preventive maintenance data was collected for all the category of machines. Check studies on

a sample basis were carried out to ascertain the process being followed for the preventive

maintenance. The data gathered during check studies has been applied to the remaining

Abnormalities Attended

WLS No: TPP/DM-MECH/01



TPP

Breakdown Activities

Check PAC tanks,hypodosing tank and refill oil

B

131 26 0.5

DM Plant

Fitter


Check polyelectrolyte tank agitator motor and refill the

oil

Lubrication Works- Gear box oil change Small (6 Nos)

Check the degassing tank pump

Apply grease in clarifier chain link

Check the clarifier motor and its oil level

Check RO&softener feed tank pumps

Check the DMF pump

The manpower has been computed with a loading factor of 80 % for the maintenance personnel.

The 80 % loading has been considered to take into account the following:

Pump motor bearing greasing( Raw Water-2 nos,

Jockey Pump-2 nos, Fire pump-2 nos)

Kaizen Works




Remarks:


________________________________________________________________________________________






Department

Section






TPPB

DM Plant

FitterBring tools/materials from store Ex: oil,grease,waste cloth, new parts

Prepare attendance

Unavoidable delay. EX:New activity cannot start after 4.30 pm as only 30 mins left for that day

Dress change

Write logbook






________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

BasicTime

(Mins)

TotalTime

(Mins)

11 1 60.00 60.00

2 1 1 30.00 30.00

3

a 2 7 2.03 28.42

b 2 28 0.33 18.48

c 2 7 2.51 35.09

d 2 28 1.12 62.77

4

a 1 5 1.00 5.00

b 1 5 3.37 16.85

c 2 3 5.40 32.40

52 1 5.00 10.00

6 2 1/3 120.00 80.00

7 2 1 5.00 10.00

82 1 5.00 10.00

92 1 10.00 20.00

10

a 2.31

b 21.54

c 36.92d 21.53

e 165.85

A 667.16

B 14

C 760.57

D 480

E 79.23%

F 2


Remarks:

As the helpers have routine works, other than maintenance, 480 min is taken as available time.








Abnormalities Attended

Move the filled can to cooling tower & come back

Shift chlorine from Dm plant to cooling tower

(2 cans/day- 2 cans/trip)

Breakdown Activities

Clean the salt preparation tank 1 & 2

Shift hypo chemical from mechanical room to nearthe tank ( 100 kg/day-40 kg/can- 3 can per trip)

Lubrication Works & Gear box oil change Small

Bring the empty can to sulphuric acid tank

Fill the acid in can from the tank

Move the loaded trolley back to salt tank

Place the bag from trolley to salt tank top

Shift PAC bag from mechanical room to near the

tank (50kg/day- 25 kg/bag- 2 bags/trip)

Kaizen Works

Shift the caustic to near the tank & mix

(100kg/day-50kg/bag-2 bags/trip)

Assist the fitter in the repair work in DM plant

Sulphuric Acid can shifting (250 Kg/ day - 50 Kg per can- 2 cans per trip)

DM Plant

Mechanical Helper


Clean the DM plant (under the shed area) (office,DM

plant,mechanical office)

Place the bag on the trolley from the floor

TPP

Clean the outside area of the DM plant

Shift the salt bag from store to salt mixing tank ( 1100 Kg/Day- 40 Kg per bag- 4

bags per trip)

Move the empty trolley to the store area




________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 17.83 17.83

2 1 1 7.17 7.17

3 1 1 10.00 10.00

4 1 1 9.50 9.50

5 1 1 9.50 9.50

6 1 1 8.00 8.00

7 1 1 45.00 45.008 1 1 50.83 50.83

9 1 1 50.83 50.83

10 1 1 35.00 35.00

11 1 1 40.00 40.00

12 1 1 20.00 20.00

13 1 1 45.00 45.00

A 348.67

B 13C 393.99

D 450

E 87.55%

F 1

G 87.55%

WLS No: TPP/W/05


ENGINEERINGShifts A B C G

THERMAL POWER PL

DM PLANT, RO PLAN

CONTRACT CHEMIST


Sample collection from Boiler

Sample collection from cooling Tower

sample collection from softener

Sample collection from DM Plant

Sample collection from Mix bed

Sample collection from R.O.Plant

All sample testingFuel feeder fuel Testing

Eco.APH, Bed and Ash silo ash sample testing

Chemical solution Preparation

Test report preparation and pass it Shift in charge

Log book maintaining

Chemical dosing in cooling tower,LP and HP tanks


Remarks:






________________________________________________________________________________________






Department

Section

Work Centre Present Manpower 1 1 1 1

Designation Proposed Manpowe 1 1 1

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 1 50.83 50.83

2 2 1 20.00 20.00

3 2 1 20.00 20.00

42 1 30.00 30.00

5 2 1 8.60 8.60

6 2 1 40.00 40.007 2

1 60.00 60.00

8 2 1 45.00 45.00

9 2 1 30.00 30.00

10 2 1 25.00 25.00

A 329.43

B 13

C 372.26D 450

E 82.72%

F 1

G 82.72%

WLS No: TPP/W/06



DM PLANT

TECHNICIAN JOB

CONTRACT OPERAT


DM plant operation through PLC

Boiler chemical preparation &charging

cooling water chemical preparation & dosing


All dosing point clarifier, R.O. DM Plant chemical

preparation and dosing in points

clarifier sludge draining

DMF Back washDM PlantRegenration/Softener

Regeneration/R.O.Cleaning

System update

Logbook Record keeping




Remarks:

* General shift operator position is not required

Check list monitoring




________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 2100.83 100.83

21 1 55.83 55.83

31 1 70.00 70.00

4 1 1 30.00 30.00

5 1 135.00 35.00

6 1 3 45.00 45.00

7 2 1 54.00 54.00

8 2 1 22.50 22.50

9 2 1 7.50 7.50

A 420.67

B 13

C 475.35

D 480

E 99.03%

F 2

G 99.03%

WLS No: TPP/W/07



THERMAL POWER PL

TPP, WARTSILA,ETP

HELPER(Houeskeeping)


House keeping work in TPP and Wartsila ( cleaning

area3840 sq meter by broom and water)

TPP control room cleaning (area 112 sq meter by water

and broom)

TPP 4.0M,12 Mand 8M level cleaning . (1980 SQ meter

by broom)Water spraying on all TPP area

Unwanted scrap materials removing from TPP and

shifting.

Tee and water arrangement for staff.

Machine cleaning of Turbine,ejector,and cooling tower

Control room and office cleaning in TPP

Dust removing from dust bin


Remarks:







________________________________________________________________________________________






Department

Section


Designation Proposed Manpow - - - 2

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 2 180.83 80.83

2 1 1 84.17 84.17

3 1 1 65.00 65.00

4 1 1 20.00 20.00

5 1 1 5.33 5.33

A 255.33

B 13

C 288.53

D 480

E 60.11%

F 2

G 60.11%

WLS No: TPP/W/08



THERMAL POWER PL


TPP

Sweeper &Gardener


House keeping work on Road in TPP Wartsila. And

ETP plant. (Area 4000 sq meter by broom)

Handling of garden in TPP.

Toilet cleaning in TPP WTP area.





Remarks:

Water spraying on all Green area.

Unwanted grass removing from green area.



________________________________________________________________________________________






Department

Section


Designation Proposed Manpowe 1 1 1 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 40.00 40.00

2 1 1 15.33 15.33

31 1 12.00 12.00

41 1 25.00 25.00

5 11 20.00 20.00

6 1 1 8.00 8.00

7 1

8 1

9 1 1 7.00 7.00

10 1 1 10.00 10.00

11 1 1 8.36 8.36

12 1 1 10.00 10.00

A 207.69

B 13

C 234.69

D 450

E 52.15%

F 1

G 52.15%

WLS No: TPP/W/09



WARTSILA

WARTSILA

OPERATOR


Engine aux,skid cleaning.

All parameter checking of aux. skid.

Water supply checking of cooling tower and fiber

dying

HFO and LO separator start and cleaning done

steam line checking ,steam traps checking from

TPP and fiber dying

Log book parameter records.

Wartsila start and stop activity done.1 52.00 52.00

Wartsila trial taken every day.

Lube oil cleaning and taken in line.

HFO and LO truck unloading.

HFO sludge removing.

Air filter cleaning.



Remarks:






________________________________________________________________________________________






Department

Section


Designation Proposed Manpow 1 1 1 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 9.52 9.52

22

14

trips35.00 35.00

32

14

trips44.80 44.80

4 2 4 40.00 40.005 1 22.50

6 1 1 43.33 43.33

7 2 2 30.00 30.00

8 1 5.00

9 1 1 3.45 3.45

10 1 4 12.00 12.00

11 2 1 20.00 20.00

12 1 1 5.00 5.00

13 1 1 5.00 5.0014 1 2 10.00 10.00

15 1 8 0.96 0.96

A 286.56

B 13

C 323.82

D 450

E 71.96%

F 1G 71.96%

WLS No: TPP/W/10



THERMAL POWER PL

ETP

OPERATOR


Sample testing in lab.

Pre treatment dosing.

Chemical shifting.

Chemical preparation every two hrs.water pump and tank level monitoring.

All drain cleaning

House keeping in ETParea

Chemical line cleaning

Air blower operation.

Tube settler draining

Drain sludge taken in decanter/filter

Treated water sending to TPP CT and garden

ETP R.O plant operation.Back of ACF and MGF

RO plant flushing.



Remarks:






________________________________________________________________________________________






Department

Section


DesignationProposed

Manpower1 1 1 -

Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1 1 1 20.00 20.00

2 1 1/7 17.14 17.14

3 1 1 20.83 20.83

4 1 1 30.00 30.00

5 1 1 12.00 12.006 1 1 12.50 12.50

7 1 1 30.00 30.00

8 1 1/7 21.43 21.43

9 1 1/7 8.57 8.57

10 1 1/7 8.57 8.57

11 1 1 10.00 10.00

12 1 1/7 2.86 2.86

13 1 1/7 2.14 2.14

14 1 1

motor 30.00 30.00

15 1 1 8.00 8.00

A 234.05

B 13

C 264.47

D 360

E 73.46%

F 1

G 73.46%

WLS No: TPP/ELEC/01


TPPShifts A B C G

ENGINEERING

TPP,WARTSILA,ETP,

WTP

ELECTRICIAN/ASST.

FOREMAN


All energy meter reading.

Cleaning of electrical panels.

All electrical equipments monitoring.

Load checking in all motor

Log book parameter records.TPP synchronization with grid and Wartsila.

All lighting work.

Filter cleaning of all AC total 16 nos.

Checking all connection of all motor and panels.

Checking water levels in batteries.

Check Transformer oil level and temp.

Check condition of Battery charger.

start and stop of 1250 kv DG set. And fire pump

Keep ready of all stand by motor, drives for emergency.

Control the aux. cons. in TPP


Remarks:




Net Available man-mins(450*80%)



________________________________________________________________________________________






15. YARN GODOWN

________________________________________________________________________________________






15.015.1

I II III G OR T I II III G OR T

1 BTM GODOWN - - - 8 - 8 - - - 4 - 4

2ELEGANT

GODOWN

- - - 8 - 8 - - - 4 - 4

3 FIBRE GODOWN - - - 8 - 8 - - - 8 - 8

4OUTSIDE YARN

GODOWN- - - 11 - 11 - - - 6 - 6

Total 0 0 0 35 0 35 0 0 0 22 0 22

YARN GODOWN


YARN GODOWN


Manpower Deployment

_______________________________________________________________________________________________________ __________________________







15.0

15.2

15.2.1

a)

b)

c)

YARN GODOWN


Proposed Changes

BTM godown - Deploy 4 personnel instead of the present deployment of 8 personnel based

on workload and simultaneous requirement

ELEGANT godown - Deploy 4 personnel instead of the present deployment of 8 personnel

based on workload and simultaneous requirement

Outside yarn godown - Deploy 6 personnel instead of the present deployment of 11 based

on workload and simultaneous requirements

________________________________________________________________________________________






15.0

15.3

S.No1

2

3

4

YARN GODOWN



Fibre godown YAG/03

Outside yarn godown YAG/04

BTM godown YAG/01

Elegant godown YAG/02

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

2 122 0.04 9.39

2 1 122 0.13 16.02

3 1 121 0.12 13.96

4 1 5 1.56 7.80

51 122 0.04 4.43

6 1 122 0.19 23.71

7 1 121 0.18 21.70

8 1 122 0.08 9.239 1 4 1.56 6.24

10

2 55 0.04 3.87

11 1 55 0.18 9.82

12 1 54 0.16 8.89

13 1 3 1.21 3.63

142 55 0.03 3.81

15 1 55 0.11 6.07

16 1 54 0.10 5.26

17 1 2 1.21 2.42

182 55 0.04 4.07

19 1 55 0.12 6.81

20 1 54 0.10 5.51

Return for the next load

From dump to truck

De-stack and load the bags on head or shoulder

Auto driver return for next transfer

Carry the bags upto the door of the truck

Return for next load


From auto to godown

Destack and load the bags on head or shoulder

Auto driver shifted to godown

Auto driver shifted to Open compound

From auto to dump


Carry the bags and dump to the ground

Stacking/adjusting the bags inside the godown

B) To move the yarn from Godown to open

compound and then loading the yarn for job

weaving / sale.


Carry the bags upto the auto and dump on it

Carry the bags inside the godown and dump



A) Yarn Shifting from packing to godown.



BTM

Loaders/Unloaders



WLS No:YAG/01


BTM Yarn GodownsShifts A B C G

Packing Section

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

BTM

Loaders/Unloaders


WLS No:YAG/01



Packing Section

212 55 0.06 6.11

221 54 0.05 2.68

23

2 70 0.04 5.65

24 1 70 0.20 14.13

25 1 69 0.16 11.35

26 1 3 3.87 11.61

27

2 70 0.04 5.02

28 1 70 0.16 11.15

29 1 69 0.14 9.95

30 1 2 3.87 7.74

31

2 50 0.04 3.90

32 1 50 0.17 8.43

33 1 49 0.15 7.24

34 1 50 0.09 4.72

35

1 1 62.87 62.87


From auto to place inside the Weaving deptt



D) To shift yarn bags from one place to another

place in same godown.




E) Lot wise and shade wise stock taking in different

godowns.

To verify lot no and shade no of bags and note verified

bag in stock register

Auto driver shifted to Weaving Deptt

Carry the bags inside godown and dump

Carry the bags to a place inside the same godown



C) To deliver yarn bags from godown to weaving.


Carry the bags from the door of the truck to inside the

truck and adjust


________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

BTM

Loaders/Unloaders


WLS No:YAG/01



Packing Section

36

1 192 3.86 741.12

A 1086.30

B 26

C 1368.74

D 3840

E 35.64%

F 4

G 71.29%

F) For Marking on yarn bags.

To note and verify bag no and lot no of packed yarn

from packing report and to note and verify bag no and

lot no of yarn to be issued or to be despatched

Remarks:








________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

12 124 0.04 8.85

2 1 124 0.15 18.33

3 1 123 0.13 16.24

4 1 5 1.87 9.35

51 124 0.04 4.67

6 1 124 0.20 24.53

7 1 123 0.18 22.18

8 1 124 0.08 9.42

9 1 4 1.87 7.48

10

2 62 0.04 4.46

11 1 62 0.16 10.16

12 1 61 0.15 8.88

13 1 3 1.65 4.95

142 62 0.04 4.98

15 1 62 0.11 6.88

161 61 0.10 5.86

171 2 1.65 3.30

182 62 0.04 5.04

19 1 62 0.11 7.05

20 1 61 0.09 5.74


From dump to truck






From auto to godown

Destack and load the bags on head or shoulder

Auto driver shifted to godown


From auto to dump




B) To move the yarn from Godown to open compound

and then loading the yarn for job weaving / sale.



Carry the bags inside the godown and dump



A) Yarn Shifting from packing to godown.



Elegant Spinning

Loaders/Unloaders



WLS No:YAG/02


Elegant Spinning GodownShifts A B C G

Packing Section

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

Elegant Spinning

Loaders/Unloaders


WLS No:YAG/02



Packing Section

212 62 0.06 8.00

22 1 61 0.05 3.03

23

1 60 0.03 2.08

24 1 60 0.16 9.87

251 59 0.15 8.57

261 3 3.87 11.61

27

2 60 0.04 4.44

28 1 60 0.16 9.76

29 1 59 0.14 8.48

30 1 2 3.87 7.74

31

2 50 0.04 3.87

32 1 50 0.17 8.43

33 1 49 0.16 7.88

34 1 50 0.09 4.63

35

1 1 60.66 60.66


D) To shift yarn bags from one place to another place in

same godown.







C) To deliver yarn bags from godown to weaving.


Carry the bags to a place inside the same godown



E) Lot wise and shade wise stock taking in different

godowns.

To verify lot no and shade no of bags and note verified bag

in stock register




Carry the bags from the door of the truck to inside the truck

and adjust

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

Elegant Spinning

Loaders/Unloaders


WLS No:YAG/02



Packing Section

36

1 184 4.87 896.08

A 1243.47B 26

C 1566.78

D 3840

E 40.80%

F 4

G 81.60%

For Marking on yarn bags.

To note and verify bag no and lot no of packed yarn from

packing report and to note and verify bag no and lot no of

yarn to be issued or to be despatched

Remarks:







________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

4 46 2.16 398.11

2 3 23 0.65 45.09

31 23 0.96 22.09

4 1 22 0.56 12.26

5

1 10 1.26 12.61

6 1 10 1.83 18.30

7 1 9 1.66 14.94

83 20 0.74 44.56

92 20 1.56 62.44

10 2 19 1.18 44.75

11

3 20 2.12 127.20

122 20 1.50 59.85

13 2 19 1.21 46.09

14

1 20 1.26 25.18

151 20 1.84 36.76

C) Issue of Fibre Bales from Go down to BTM

Carry from back and load the bale on trolley

Carry the bale and place inside upto the processing point

Return for next transfer

D) Issue of Fibre Bales from Go down to Fibre Dyeing

Load two bales on forklift

Carry the bales to the fibre dyeong entry pt. and dump



From elegant entry to the process point

Load the bale on trolley

Carry the bale and place inside upto the processing point


Carry the bales to the elegant entry pt. and dump

B) Issue of Fibre Bales from Go down to Elegant

Load two bales on forklift

GPacking Section

Pull and make pair of bales

Carry the bales inside the godown with forklift and adjust

Yarn Bags Movement

Loaders/Unloaders


A) Unloading of Polyester / Viscose / Wool Fibre Bales

to Go downDestack unloading the bales and place on the ground

Work Centre

Designation

WLS No:YAG/03


Fibre GodownsShifts A B C

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GPacking Section

Yarn Bags Movement

Loaders/Unloaders


Work Centre

Designation

WLS No:YAG/03



16 1 19 1.14 21.67

17

3 20 0.65 39.10

18 2 20 0.38 15.22

19 2 19 0.20 7.42

20

2 90 0.21 38.49

21 1 90 0.09 8.33

22 2 90 0.06 9.99

23 1 90 0.15 13.31

24 1 89 0.13 11.51

25

2 45 0.06 5.00

26 1 45 0.25 11.21

27 1 45 0.13 5.9128

4 5 8.79 175.80

292 45 0.04 3.48

30 1 45 0.09 4.25

31 1 44 0.08 3.49

32 4 4 5.65 90.40

332 45 0.04 3.65


Carry the fibre bag and place at the required position

Note down the weight and other details in register

G) Issue of Fibre Bags from Dye House to BTM deptt.Destack/load bags on head/shoulder


E) Shifting of dyed fibre bags to Go down from Dye

House

Take the bag upto the weighing m/c,weigh

Return trolley for next transfer


Trolley transfer to Elegant deptt.

Tie knot on the bags and carry the trolley to elegant deptt.

Load the bag on head/shoulder

F) Issue of Fibre Bags from Dye House to Elegant

deptt.

Destack/load bags on head/shoulder

Carry the bags and load on to the trolley


Unload the bags inside the deptt



Carry and dump at the required place

From fibre dyeing entry pt to place stackwise nearby

Load the bale on trolley

Carry and stack nearby

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GPacking Section

Yarn Bags Movement

Loaders/Unloaders


Work Centre

Designation

WLS No:YAG/03



34 1 45 0.25 11.42

35 1 44 0.15 6.50

36

4 5 4.01 80.24

372 45 0.04 3.66

38 1 45 0.13 5.83

39 1 44 0.09 3.98

40 4 5 3.04 60.85

41

1 20 18.87 377.40

422 8 0.95 15.14

43 6 8 4.34 208.32

44 1 7 0.43 2.99

45

4 10 2.22 88.80

46 3 5 0.71 10.61

471 5 0.98 4.90

48 1 4 0.58 2.31

49

2 55 0.04 4.46

J) Loading & Unloading Job Fibre A/c

Destack unloading the bales and place on the ground

Pull and make shadewise bunch of Bales.

Carry the bales inside the godown with forklift and adjust


K) Shifting of dyed fibre bags to Shade wise stackling

in the depttDestack/load the bags on head/shoulder



Trolley transfer to BTM deptt.

Tie knot on the bags and carry the trolley to elegant deptt.

Unload the bags inside the deptt


Carry and dump at the required place


Carry the bags and load on to the trolley

Return trolley for next transfer

H) Handling & Packing of Fibre Waste / Empty Bags

and delivered to as per direction of deptt.

I) Loading of Fibre waste Sale

Put waste bales putting on trolly for loading.

Moving the bales through Trolly to the truck.

________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GPacking Section

Yarn Bags Movement

Loaders/Unloaders


Work Centre

Designation

WLS No:YAG/03



50 1 55 0.19 10.28

51 1 54 0.16 8.88

52 1 55 0.09 5.07

531 27 1.45 39.15

A 2389.23

B 26

C 3010.43

D 3840

E 78.40%

F 8G 78.40%

Carry the bags to the nearby place and dump

L) Arranging fibre samples to dye house for testing

Stack/adjust the bags


Remarks:







________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

1

1 115 0.21 24.36

22 115 0.03 7.97

3 1 115 0.06 7.44

4 1 114 0.05 5.28

51 115 0.30 34.62

6 1 114 0.26 30.04

7 1 115 0.09 10.83

8

2 60 0.03 4.10

9 1 60 0.28 16.69

10 1 60 0.22 13.23

11 1 3 0.76 2.29

122 60 0.04 4.42

13 1 60 0.13 7.56

141 60 0.10 5.81

15 1 2 0.76 1.53

162 60 0.04 4.46

17 1 60 0.11 6.74

18 1 59 0.10 5.77


From auto to dump




From dump to truck


Auto driver return for next load



B) To move the yarn from Godown to opencompound and then loading the yarn for job weaving

/ sale.






godown

GPacking Section



Yarn Bags Movement

Loaders/Unloaders


A) Unloading the outside yarn without weighment.

Checking of bag lot and shade wise from challan .

WLS No:YAG/04


Outside Yarn GodownsShifts A B C



________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GPacking Section

Yarn Bags Movement

Loaders/Unloaders


WLS No:YAG/04



192 60 0.06 6.64

20 1 59 0.05 2.84

21

2 62 0.04 4.57

22 1 62 0.26 16.08

231 61 0.26 15.68

241 3 4.87 14.62

25

2 62 0.04 4.77

26 1 62 0.15 9.52

27 1 61 0.14 8.77

28 1 2 4.87 9.74

29

2 10 0.03 0.69

30 1 10 0.27 2.75

31 1 9 0.26 2.31

32 1 1 2.46 2.46

33 2 10 0.04 0.72

34 1 10 0.21 2.1235 1 9 0.18 1.65


To deliver the yarn from godown to BTM Spinning/

Packing/ Fibre Dyeing & shifting back to godown.De-stack and load the bags on head or shoulder


Auto driver shifted to Respective godown


Carry the bags inside the godown and dumpReturn for the next load



C) To deliver yarn bags from godowns to weaving.





truck and adjust


Auto driver return for next load




________________________________________________________________________________________






Department

Section



Sl.

No

Crew

Size

Freq/

Shift

Basic

Time

(Mins)

Total

Time

(Mins)

GPacking Section

Yarn Bags Movement

Loaders/Unloaders


WLS No:YAG/04



Mnapower Report

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