PROJECT 12:

MANUFACTURING COST ANALYSES

We developed manufacturing cost analyses pc-programs in one of the spinning mill in Türkiye. Our cost analyses quite differ from the existing analyses in many ways. It starts from raw material to winding at each stage of processing. It is not only the actual costs but predicted costs calculations are obtained through machine data parameters. Therefore, the ways could be found to minimize these costs. The figure shows us that actual % of main cost items. This graph gives us two main ideas. First, what are the main expenditures and secondly how we could reduce and make savings within a shortest time and right at the first time.

Graphic 2: Main Cost Items

12.1 Main Cost Items

It is clear from the graph that main cost part is the raw material and secondly general manufacturing costs and thirdly direct labour. These cost analyses also give information about the general structure of the mill. Therefore, in the first instance having look at the analyses at macro levels then going into details for each stage of processing. Therefore, our pc-programs can able to reduce manufacturing costs within a systematic manner. This also proves that the importance of Optimum Quality / Minimum Manufacturing Cost conception.

Cotton fibers take the primary importance in short staple spinning. There are mainly two handicaps in spinning mills in terms of evaluating cotton fibers. One of them is subjective judgement such as hand staple the second is not to use measuring instruments effectively. Most of the cotton cost is not calculated according to spinning performance and yarn quality. Therefore, actual cost price could be much higher or not suitable one could be chosen. In order to avoid these handicaps we have developed FIBER-MIX SELECTION.

Fiber Mix selection: Selection of fiber mix according to required spinning data (yarn count, process and twist)

Bale Management: Category system blending for maximum spinning and weaving performance and minimum RKM CV% in relation to loom stress-strain curves. Bale Management runs in accordance with our fabric Setting Pc-program so that optimum bale mix is achieved. It is clear from our experience that especially with weaving yarns raw material costs could be reduced more than as expected.

Fiber Data: Projected end breaks, yield performance and quality data.

However, it is also clear that also other pc-programs are necessary to reduce raw material costs. In order to achieve minimum difference between projected and actual spinning performance and at each stage of processing- reducing stoppages- reducing waste- manufacturing yarn with zero defects. On the other hand these pc-programs also assist to achieve these targets such as since Bale Management Pc-programs has been designed to minimize yarn strength variation and strength it minimizes the drafting waves and end-breaks therefore achieving optimum draft Organization.

The second point is to reduce manufacturing cost with Process Management pc-programs to improve material yield performance. For these purposes following pc-programs have been developed:

• Yield Performance Control
• Spinning Mill Data Bank
• Process / Quality Control
• Process Management

Our pc-programs have reduced the material costs in spinning mills. With respect to cost factor is general manufacturing costs in order to lower these costs following points should be considered

• Maximum gram/spindle hour
• Knowledge Based Mill Management and job descriptions

Spinning Mill Data Bank based upon machine card index, lot number and machine check lists and maintenance procedures to maintain minimum spare parts consumption. It is clear that all our pc-programs have been developed to achieve these targets.

Third main cost is direct labour, which could be reduced by reducing the H.O.K (operative hours necessary to produce 100 kg of yarn). H.O.K could be reduced by

• Increasing production levels
• Minimizing stoppages
• Training and motivating of employees

For efficient working of employees we have developed time studies-work load assignment and PRODUCTIVITY ANALYSES pc-programs, which include workers data bank by which it becomes possible to evaluate the direct labour and increase the productivity.

Therefore, it is clear that higher the number of styles changes higher the manufacturing costs. The other factors efficiency end-breaks per 1000 spindle hour. Knowledge Based Mill Control systems have been developed to minimum levels and it has pronounced effects actual in mill practice than as expected.

 Knowledge Based Quality Systems             Proses Optimization and R&D Projects for Textile Mills