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Summary

The current study had been undertaken with the object of analyzing different factors that

contributed and hindered the productivity level of textile fabric industry in past three years

and devising methods that could achieve targeted productivity in future.

Huge monetary amounts are invested in fabric preparation steps like desizing, scouring,

bleaching, singeing and mercerizing that are employed to remove impurities from grey

fabrics so that effects of ensuing dyeing and finishing treatments can be feasibly produced on

them. However due to inappropriate implementation of scientific and technological methods,

and inadequate maintenance activities, productivity level was far much lower in textile

industry than was expected. This was contributed to the fact that company had not pursued

TPM (Total Productive Maintenance) in their fabric processing machines like jigger, stenter,

squeezing machine and calendar machine which are primarily used in textile industry to

transform grey fabric into calendared one.TPM involves activities pertaining to planned,

breakdown and recurrent maintenance that presumably helps in taking several measurements

for calculating OEE (Overall Equipment Efficiency) of machines

As regards Dyeing industry one of the major shortfalls is a low OEE which can be due to the

loss in availability or blackout of equipment that in turn pave the way for downtime loss.

Downtime loss results when unsatisfactory maintenance of machines causes stoppages in

production line. This directly affects production speed and product quality and hence the

product failure is inevitable. Low productivity that arises from these production line

complications can be evaded by curtailing downtime losses. Several mathematical models

used for measuring OEE can be effective in putting TM into practice.

Existing disorganized framework gave low productivity and quality levels which was due to

unsatisfactory maintenance conditions, ineffective plant layout, insufficient resources and

inappropriate allocation of worker. Measurement of OEE was then thought to be a

prerequisite for the analysis of production line so that application of technological procedures

can lead to improved productivity and quality. A systematized framework will serve this

purpose by devising improved maintenance policies which can cope with the production

losses of machinery that were reported in the preceding years. Allocation of manpower in

different industrial activities before and after the implementation of TPM was helpful in

productivity measurement because improved contribution of manpower after the framework

was put into effect had a pronounced effect on improvement of machinery system.

Structured and methodical based framework to improve productivity is TPM which is used in

textile fabric industry. It includes steps

Collection of data about machinery in existing textile industry. This data is then analyzed for the productivity performance measurement of

machineries and quality performance measurement

Quality performance measurement yields data about the conditions in compliancewith the requirements and customer satisfaction level

Results of both performance measurements then are then evaluated prior to theimplementation of TPM

These evaluated results are then compared with the past performance consideringworld class OEE as the standard

Gaps between prevalent and targeted performance is then scrutinized with theobjective of setting goals and designs

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TPM methodology is then made functional for analyzing existing conditions andplans for the improvement of productivity.

Planned Maintenance executed by Maintenance department is aimed at restraining

breakdown chances of machinery and reduce such downtime losses. It comprises conjoint

systems of Time Based, Corrective and Breakdown maintenance.

Production variables and support variables such as planned production time, operating time

and quantity of accepted goods were then optimized.

In Total productivity model, Total productivity of firm TPF was found out by calculating

1. Total Productivity of Product in terms of its partial productivities which wasdetermined by evaluating

Partial productivity of product with respect to some input factor(PP) current input and output values of that product Fraction of input factor with respect to sum of all inputs used to produce that

product

2. Total Productivity of a firm as a function of Total Productivities of individualproducts can be determined using

Total Productivity of Product Total Number of products manufactured(N) Total number of factors(m) involved, where Input Factors are probably

Human(H),material(M),capital(C), energy(E), and other inputs(X)

fraction of total output for a specific product with respect to total of all suchinputs combined for the N products manufactured in the firm.(W)

3. Total productivity of firm as a function of partial productivities hence can becalculated by formula

TPF = 1/m (WHPPH+ WMPPM+ WCPPC+ WEPPE+ WXPPX)

Implementation of TPM model increased average OEE of all fabric machines which was

being calculated on a daily basis. Increase in OEE was favoured by an improvement in

production parameters like decreased fabric rejection, reduced downtimes, increased

production of machines per minute. Hence OEE factors namely machine availability,

performance and quality when compared with world class standards showed an increase

which in turn caused productivity of the plant to increase. Consequently, the benefits of such

planned maintenance can lead to effective and efficient utilization of machines to give

increased profits

A number of areas for further analysis are suggested from the observation made in the course

of this paper Alternative ways of increasing production should be viewed so that

counteractive measures could be taken in times of unexpected reductions in production

In a nutshell, analysis of shortfalls in OEE factors, and proper implementation of TPM can

result in increased productivity.