Study on Productivity Development Status of a Jute Mill in

International Journal of Scientific Research and Engineering Development-– Volume 3 - Issue 4, July - Aug 2020

Available at www.ijsred.com

ISSN : 2581-7175 ©IJSRED: All Rights are Reserved Page 1177

Study on Productivity Development Status of a Jute Mill in

West Bengal, India

Dr.Satya Narayan Bag

Principal AMS College of Polytechnic.

Rangapur, Barrackpur, 24 Pgs( N ) , West Bengal, India.

Abstract :In weaving department , strong positive significant correlation ship exist between loom efficiency and loom

production of Kgs/loom/shift. Positive correlation ship present between spinning frame efficiency and per winder

production/shift. Strong positive correlation exists between Hemming and Herackle monthly production. CV% of

Actual production/frame/shift and per winder production /shift in kgs and Actual efficiency of frame is comparatively

less in case of fine side spinning frame compare to the coarse side production. Skilled competent machine operator,

training of learners at workplace with proper guidance,, quality of yarn, etc. are important areas for improvement of

weaving efficiency. Sizing process parameters, e.g., quality of beam, steam pressure and temperature, sizing

ingredients composition are taken into consideration.

Key words :Efficiency, Correlation, Production, Weaving, Spinning

Introduction :

Agarpara jute Mills Ltd. Is a pioneer Jute Industry in West Bengal, India. Various types of Hessian, Sacking Jute Bags

,fine fabrics, Cultured yarn and fabric are manufacturing in this unit. Demand of jute products are now increasing in

domestic and international market. The unit is gradually modernized to manufacture fine good quality, fault free cloths.

As a result, Top management are installing various modern weaving and preparatory machineries to meet the

Customer’s requirement. The Management is now trying to manufacture in right time, right quality and right quantity

too. Present study is observing the productively status of finished and semi-finished products and possible measures for

future development .Statistical analysis is done based on the data obtained from day wise, monthly productivity report

of the unit for observing the relationship of efficiency ,productivity parameters in different stages of production

process.

Research Methodology:

Productivity parameters of day wise, monthly of various stages of manufacturing process are studied, collected and

analyzed for finding out the statistical relationship of production process relating to efficiency, productivity of various

departments. Based on the studied productivity status and statistical analysis, suitable corrective actions are finding out

.This analysis will give a guideline to the management to find out the present productivity status of the unit and

possible improvement criteria for future development.

Study Area :Productivity has been studied OF THE Jute Industry Agarpara Jute Mills Ltd (. AJML).Kamarhati ,

Kolkata . The unit is ISO 9001: 2015 certified organization. Round the year of 2018-19 and 2019-2020 periods

RESEARCH ARTICLE OPEN ACCESS




production report has been collected, studied and analyzed for further development of the unit., Various departments

has been selected for study . Thereafter a study has been carried out for finding out the status of productivity of the

unit.

Literature Review:

Mahabubuzzaman A. K. M 1

,et.al., explained in their research findings that ,it is necessary to select proper flyer speed

for the production of yarn of particular linear density (tex). It was also observed that the number of breakages increased

with the increase of flyer speed. At 2900-rpm flyer speed, the yarn breakage was 0.8/ spindle-hr and at 4850 rpm the

yarn breakages is 3.5/spindle-hr. forproducing 241 tex jute yarn. Almost all jute mills of Bangladesh have been slip

draft spinning machine. Using proper flyer speed, whichwas found from the experiment, can use the machine in

production of medium count jute yarn. The produced yarn can replace the synthetic/manmade fibre in the world textile

market.

MD. Mohiuddin2

explained in his research findings that Bangladesh’s jute sector started to face a critical time since

1990s, as jute started to face increasing competitive pressure from synthetic substitutes, failure to follow modern

marketing procedure and international trade practices, lack of significant efforts and required investment towards

product development and diversification, inability to undertake the technological transformation undermined jutes

prospects as fiber. All these had adverse impact on production & marketing.

HabeeburRahman. T 3

explained in his research findings that Absenteeism is one of major human problem of Indian

textiles industries. Absenteeism is the term generally used to refer to unscheduled employee absences from the

workplace. It is a habitual pattern of absence from a duty or obligation. Absenteeism is a big barrier for any kind of

organization because its effect on organization growth. This research shows how absenteeism is a big barrier for retail

sector and how it’s give the inverse effect on organization growth and development.

Results and Discussion: Productivity has been studied in Agarpara Jute Mills Ltd, Agarpara, Kolkata. The data are

tabulated in the Table 1 and 2. From the table 1, it is found that efficiency at fine side spinning is much lower than

standard norms. The average of one month data is summarized in the table 1 and 2.Actual production in MT per day is

much lower than the target MT /day. It is due to lower efficiency % of spinning frame, higher absenteeism of skilled

labors, sliver shortage and idle spindles.

Table 1 Study of productivity status of Fine side spinning area for the month of September

2019(AJML)

Date Target

production in

MT /day

Actual

production in

MT /day

Actual

production

/frame/day in

kgs

Production

/winder

In kgs

Actual

efficiency %

Average 48.12414 39.85138 253.2414 270.3793 66.13793

Maximum

Value 54.3 44.2 262 289 69.3

Min value 28.9 23.22 245 260 63.1

SD 6.93 6.07 4.32 5.89 1.69

CV% 14.4 % 15.08% 1.7 % 2.1 % 2.55 %

International Journal of Scientific Research and Engineering Development

ISSN : 2581-7175

Source : Day wise productivity report of the mill

Figure 1 represent the fine side production round the month of September 2019. Target and actual production graph

varies in the same pattern round the month of September 2019. High variation of graph i.e., cv% indicates that

September month has lot of pujas. As a r

MT values. Here wide difference observed in target and as well as actual values of the day wise production.

Management is trying to achieve such production with constant atten

Table 2 : Study of productivity status of Corse side spinning area for the month of September 2019

(AJML)

Date Target

production in

MT /day

Actual

production in

MT /day

Average 14.0069 10.5469

Maximum

Value 16.7 12.62

Min value 7.3 4.9

SD 2.40 1.96

CV% 17.1% 18.59%


Figure 2, represent the target and actual spinning production in coarse side. It is found that, target and actual graph

follows the same pattern round the month of September 19. CV% of actual day wise production was higher, 18.59%

compare to target production which is 17.1%.Top Management is trying to achieve such target production. The average

value of monthly production was 10.54 MT indicates that , Sacking warp was included in fine side production, whereas

sale and sacking weft were included in coarse si

Figure 1 : Comparative analysis of target and actual fine side spinning production of the month

September 19(AJML)

0

10

20

30

40

50

60production in MT

International Journal of Scientific Research and Engineering Development-– Volume 3 -


©IJSRED: All Rights are Reserved


the fine side production round the month of September 2019. Target and actual production graph


September month has lot of pujas. As a result, absenteeism of labors, staffs etc., are responsible for such high cv% of


Management is trying to achieve such production with constant attention at the department.

: Study of productivity status of Corse side spinning area for the month of September 2019

Actual

production in

/day

Actual

production

/frame/day in

kgs

Production

/winder

In kgs

Actual

efficiency %

10.5469 570.5172 263.7241 60.33103

12.62 613 281 67.3

4.9 521 240 54.8

1.96 23.2 10.4 2.97

18.59% 4.0% 3.9% 4.9%




ion which is 17.1%.Top Management is trying to achieve such target production. The average


sale and sacking weft were included in coarse side production. Management is trying to achieve the target production.


Target production in MT

Actual production in MT

date

- Issue 4, July - Aug 2020

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Page 1179

the fine side production round the month of September 2019. Target and actual production graph


esult, absenteeism of labors, staffs etc., are responsible for such high cv% of


: Study of productivity status of Corse side spinning area for the month of September 2019

Actual

efficiency %

60.33103

67.3

54.8

2.97

4.9%



ion which is 17.1%.Top Management is trying to achieve such target production. The average


de production. Management is trying to achieve the target production.





ISSN : 2581-7175

Figure 2 : Comparative analysis of target and actual coarse side

September 19(AJML)

Figure 3 represent the kgs/frame /shift of fine and coarse side. It is found that coarse side graph is running above than

fine side curve. Coarse side graph runs almost 600 kgs /f/s line, whereas

Due to heavier yarn count , the curv always present in upper position than fine side curve. Now cv% of kgs/f/s in

coarse side is 4 %, which is higher than fine side cv% of 1.7 %. Higher cv% is not desirabl

fluctuation / changing of yarn count round the month.

Figure 4, represent the comparative analysis of per winder production in kgs over the month of September 19. It is

found that, both the curve are present higher than 250 kgs li

production curve is higher than coarse side curve. Initially first and second week of September 19, both the curve are

superimposed. CV% value in coarse side is 3.9% was higher than fine side which exh

is not desirable. Management is now trying to reduce this by close monitoring of winders production, winder : spinning

frame allocation etc. Minimum value of per winder production in coarse side is 240 kgs, which is much

kgs of fine side production. Management is now trying to improve this area.

Figure 3 : Comparative analysis of kgs/frame/shift of fine and coarse side spinning production of the

month September 19 (AJML)

0

200

400

600

800

1.9

.…

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kgs/loom/shift

02468

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production inMT




Figure 2 : Comparative analysis of target and actual coarse side spinning production of the month


fine side curve. Coarse side graph runs almost 600 kgs /f/s line, whereas , fine side curve runs almost 250 kgs /f/s line .


coarse side is 4 %, which is higher than fine side cv% of 1.7 %. Higher cv% is not desirabl

fluctuation / changing of yarn count round the month.


found that, both the curve are present higher than 250 kgs line. At the end of the month of September 19,per winder


superimposed. CV% value in coarse side is 3.9% was higher than fine side which exhibits 2.1 %.Higher value of cv%

Management is now trying to reduce this by close monitoring of winders production, winder : spinning

frame allocation etc. Minimum value of per winder production in coarse side is 240 kgs, which is much

kgs of fine side production. Management is now trying to improve this area.


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kgs/frame/shift ,fine side

kgs/frame/shift ,coarse side

date

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date


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spinning production of the month


, fine side curve runs almost 250 kgs /f/s line .


coarse side is 4 %, which is higher than fine side cv% of 1.7 %. Higher cv% is not desirable, but this may be due to


ne. At the end of the month of September 19,per winder


ibits 2.1 %.Higher value of cv%

Management is now trying to reduce this by close monitoring of winders production, winder : spinning

frame allocation etc. Minimum value of per winder production in coarse side is 240 kgs, which is much lower than 260


29

.…

30

.…

kgs/frame/shift ,fine side

kgs/frame/shift ,coarse side

date






Figure 4 : Comparative analysis of production per winder in kgs of fine and coarse side spinning

production of the month September 19 (AJML)

Figure 5 : Comparative analysis of actual efficiency %of fine and coarse side spinning production of

the month September 19 (AJML)

Figure 5 explained the comparative analysis of efficiency % of spinning department of fine and coarse side. It is found

that fine side efficiency% is much higher than coarse side, round the month and it is always higher than 60%. Whereas

coarse side efficiency % curve runs almost 60% line. Slight fluctuation is observed in coarse side curve of efficiency

%. From table 1 and 2, it is found that cv% of coarse side is 4.9% which is higher than fine side spinning line, having

cv% of 2.55%. Higher variation in cv% of spinning efficiency% is not desirable. Management is trying for better batch

composition at coarse side and good monitoring at coarse side spinning line, maintenance of spinning machineries etc.

It is found that fine side spinning efficiency% is less than industry standard.

Table 3 explained the target and actual efficiency of various month of the year 2018-19. Both fine side and coarse side

from figure 6 and 7, foundthat, from November- December 2018 efficiency has been decreasinggradually up to

January 2019, thereafter it increased and reached maximum in the month of April-May 2019of efficiency more than

71% in fine side and 65% in coarse side. Per winder’s production of the month of November-December 2018 was

minimum due to various pujas and absenteeism of workmen, lot of machineries remained idle.

0

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250

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350

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production per winder in kgs

fine side

production per winder in kgs

coarse sidedate

per winder production in kgs

020406080

1.9

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2.9

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3.9

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efficiency % fine side

date

efficiency%




Table 3 :Efficiency of Spinning frame over different Months Period : August 18 to June 19

Months Per Winder

Production

(target 300

Kgs)

Efficiency fine Side Efficiency Coarse Side

Target Actual Target Actual

August 18 256 80 % 69.3 80 % 67.9

September 18 264 80 % 69.2 80 % 70.6

October 18 254 80 % 72.3 80 % 67.2

November 18 236 80 % 72.2 80 % 68.1

December 18 243 80 % 70.3 80 % 64.8

January 19 259 80 % 69.3 80 % 61.3

February 19 261 80 % 70.9 80 % 62.0

March 19 285 80 % 72.0 80 % 65.1

April 19 296 80 % 71.5 80 % 65.3

May 19 269 80 % 69.6 80 % 64.5

June 19 256 80 % 69.7 80 % 63.7

Source :Monthly productivity report

Figure 06 : Variation of Average Sinning Frame Efficiency % over different months

Figure 07 : Variation of Coarse side Spinning Efficiency % over Different Months

67686970717273 Efficiency fine Side (Actual)

Efficiency fine Side (Actual)

efficiency%

55

60

65

70

75 Efficiency Coarse Side

Efficiency Coarse Side (Coarse

Side )months

Efficiency%




Table 04 and figure 08,09,10 exhibit the productivity status of AJML over different months. From figure 08, it is found

that weaving bags production are comparatively higher in the months of Dec 18,Feb 19, and April 19.In May 2019, it

is found that bags production is comparatively lower than previous months. It is due to lower productivity at summer

session. Full utilization of resources on December 2018, Feb 19, and April 19 gives higher productivity on these

months. Figure 09 explained the variation of cutting production over different months. It is found that monthly cutting

production exhibits decreasing trend from April 19 to May 19, due to shortage of manpower at summer season. Figure

10 explained the variation of packed bales production over different months. It is found that packed bales production

was increasing trend from Aug 18 to October 18, but decreasing trend from Jan 19 to May 19. It is due to lower supply

of finished goods to domestic market. From June 19 to Aug. 19, it is found that both the total cutting of bags and no. of

packed bales wereincreased. Weaving bags production was increased in June to Aug. 19 periods. This was due to

enhancement of bags demand in domestic market.

Table 04 Productivity Status of Finishing department

Period : August 2018 to May 2019

Months Area Production

(Total)Weaving

Bags

Cutting in pieces No. of Bales Packed

August 18 Finishing Dept. 1265224 304400 3859

September 18 Finishing Dept 1270222 318200 4119

October 18 Finishing Dept 1249120 306400 4441

November 18 Finishing Dept 1193212 293600 3404

December 18 Finishing Dept 1362627 318400 3911

January 19 Finishing Dept 1141564 262200 3983

February 19 Finishing Dept 1295137 292600 3896

March 19 Finishing Dept 1164262 266000 3597

April 19 Finishing Dept 1337127 320200 3662

May 19 Finishing Dept 1010582 229000 3001

June 19 Finishing Dept 1099903 214200 2949

July19 Finishing Dept 1400250 309000 3901

August 19 Finishing Dept 1342067 345100 3814

Source : Monthly Productivity report

Figure 08 : Variation of total bags production over different months

0

500000

1000000

1500000Variation of Production (Total) Weaving Bags

over Different Months

Production (Total)Weaving

Bags

Months

No.of bags


ISSN : 2581-7175

Figure 09 : Variation of total cutting Production over different months

Figure 08 explained that monthly cutting production for bags has been increasing from May to Aug. 19 as the domestic

demand has been increased. In the month of May 19 , lower production of cutting is due to the summer season , less

machineries are running due to absenteeism

Figure 10 : Variation of No. of Bales Packed Over Different Months

Table 5 : Machine wise Productivity report

Months

Hemming

(Bags)

Herackle

(Bags)

August 18 3000 2250

September 18 2963 2217

October 18 2900 2120

November 18 2852 2112

December 18 2643 2180

January 19 2950 2185

February 19 2862 2110

March 19 2919 2127

April 19 2555 2164

May 19 2157 1675

0

100000

200000

300000

400000

Variation of Total Monthly Cutting

Production over Different Months Total Cutting

Production in

0

2000

4000

6000 Variation of No. of Bales Packed over Different No. of bales




: Variation of total cutting Production over different months

explained that monthly cutting production for bags has been increasing from May to Aug. 19 as the domestic


senteeism of labours.

: Variation of No. of Bales Packed Over Different Months

: Machine wise Productivity report

Production /mcs/day

Herackle

(Bags)

Hand sewing

(bags)

Lapping (yrds) Press

(no. of bales )

2250 8194 21700

2217 3245 20822

2120 4135 20925

2112 3311 20232

2180 3245 20021

2185 3416 19530

2110 3258 19902

2127 3247 15159

2164 3250 22785

1675 3021 16327

Variation of Total Monthly Cutting

Production over Different Months

Cutting Production

months

Variation of No. of Bales Packed over Different

Months

No. of Bales Packed

months


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Page 1184

explained that monthly cutting production for bags has been increasing from May to Aug. 19 as the domestic


Press Production

(no. of bales )

53

59

58

60

55

52

55

56

62

55

Cutting Production

months

No. of Bales Packed

months


ISSN : 2581-7175

June 19 2568 1980

July19 2684 2095

Aug 19 2796 2042

Source : monthly productivity report of the mill

From table 5, it was found that, Hemming production has been increasing from

of domestic demand. This was also reflecting as no of bales production mc/day of bale press m

also increasing from the period May 19 to Aug. 19

Figure 11 : Variation of Hemming and Herackle production/mc/day (Average ) over different months

Table 05 and figure 11 explained the variation of hemming and herackle/ machine production /day over different

months. It was found that hemming and herackle bags production/mcs/day

period. After May19, it was found that both the targ

Aug. 19 period .It was found that no. of bales production /day has been showing increasing trend from Jan 19 to Aug

19 period.

Figure 12 : variation of Press production /day over differen

Table 06, figure 13, explained the variation of actual efficiency % of Hessian loom over study period. It

target efficiency % was quite low in the month of December 18 and Jan 19

the lower number of machines running and less n

0

5000No. of bags stitches

45

50

55

60

65

Variation of Press production (no. of bales ) over

different months No. of bales




1980 3255 20275

2095 3249 23891

2042 3127 27034

Source : monthly productivity report of the mill

found that, Hemming production has been increasing from May 19 to Aug

also reflecting as no of bales production mc/day of bale press m

also increasing from the period May 19 to Aug. 19

: Variation of Hemming and Herackle production/mc/day (Average ) over different months

explained the variation of hemming and herackle/ machine production /day over different

found that hemming and herackle bags production/mcs/day was following the same trend of the given

found that both the target and actual no. of bags stitches has been increasing from June to

o. of bales production /day has been showing increasing trend from Jan 19 to Aug

: variation of Press production /day over different months

Table 06, figure 13, explained the variation of actual efficiency % of Hessian loom over study period. It

quite low in the month of December 18 and Jan 19 of 60% and 62 % respectively. It

of machines running and less number of man power involvement compare to other months of the

Hemming (Bags)

Herackle (Bags)

months


different months

Press (no. of bales )

months


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Page 1185

62

58

56

19 to August 19.due enhancement

also reflecting as no of bales production mc/day of bale press machine. Lapping in yards

: Variation of Hemming and Herackle production/mc/day (Average ) over different months

explained the variation of hemming and herackle/ machine production /day over different

following the same trend of the given

et and actual no. of bags stitches has been increasing from June to

o. of bales production /day has been showing increasing trend from Jan 19 to Aug

Table 06, figure 13, explained the variation of actual efficiency % of Hessian loom over study period. It was found that

60% and 62 % respectively. It was due to

of man power involvement compare to other months of the

Hemming (Bags)

Herackle (Bags)

months


Press (no. of bales )

months


ISSN : 2581-7175

study period. As a result actual efficiency % of the Hessian loom on those months

months of the study period. In the month of April, May 19, actual efficiency of Hessian loom

than other months due to summer season. At that time less number of weavers, weavers away from the workplace,

absenteeism of weavers were the main factors for lo

sacking loom are the function of actual efficiency %.

Table 06: Productivity report of weaving department over different months

MONTH HESSIAN

EFFICIENCY %

TARGET ACTUAL

August 18 65 54.1

September 18 65 52.7

October 18 65 50.2

November 18 65 55.4

December 18 60 49.3

January 19 62 50.3

February19 63 51.7

March19 65 50.2

April 19 65 43.6

May 19 65 41.9

June 19 65 42.4

July 19 65 46.2

Aug 19 65 51

Sept 19 65 52.4

Source : Monthly Productivity report of

Figure 13: Variation of Actual efficiency % in hessian loom over different months

0

50

100Efficiency %




study period. As a result actual efficiency % of the Hessian loom on those months was comparatively lower than other

riod. In the month of April, May 19, actual efficiency of Hessian loom


the main factors for lower efficiency%. It was found that kg/loom/shift for Hessian and

sacking loom are the function of actual efficiency %.

Productivity report of weaving department over different months

HESSIAN

SACKING

KG/LOOM/SHIFT

EFFICIENCY % KG/LOOM/SHIFT

TARGET ACTUAL TARGET ACTUAL TARGET

38.1 30.9 80 70.1 64.3

38.1 30.9 80 69.6 64.3

32.5 29.4 80 70.6 64.3

25.8 20.4 80 71.7 64.3

31.5 25.7 80 71.4 64.3

33.8 27.0 80 70.2 64.2

34.1 28 80 69.8 64.3

37.1 28 80 69.6 64.2

38.6 25.3 80 69.4 66.3

37.2 24.3 80 71.1 66.3

35.5 23.5 80 70.3 64.3

32.4 23.8 80 71.5 64.3

33.1 25.4 80 72.1 64.2

33.1 26.2 80 72.4 66.3

Source : Monthly Productivity report of Mill

Variation of Actual efficiency % in hessian loom over different months

EFFICIENCY % TARGET

EFFICIENCY % ACTUAL

months


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Page 1186

comparatively lower than other

riod. In the month of April, May 19, actual efficiency of Hessian loom was comparatively lower


found that kg/loom/shift for Hessian and

SACKING

KG/LOOM/SHIFT

TARGET ACTUAL

64.3 56.3

64.3 55.9

64.3 56.7

64.3 57.6

64.3 57.3

64.2 56.1

64.3 56.1

64.2 55.9

66.3 55.9

66.3 57.2

64.3 56.4

64.3 57.4

64.2 57.9

66.3 58.4

Variation of Actual efficiency % in hessian loom over different months

EFFICIENCY % TARGET

EFFICIENCY % ACTUAL


ISSN : 2581-7175

Figure 14 : Variation of Actual efficiency % of sacking loom over different months

From table 06 and figure 14, it is found that Sacking loom actual efficiency %

was due to the Eco loader mechanism and fabric construction. The Sacking loom efficiency

standard industry norms. The actual efficiency %

Table 07: Productivity report of Victor C loom over different months

MONTH

EFFICIENCY %

TARGET ACTUAL

August 18 70 41.3


October 18 70 45.4

November 18 70 44.7

December 18 70 42.0

January 19 68 42.3

February19 65 41.8

March19 66 43.6

April 19 59 42.2

May 19 60 43.0

June 19 59 37.2

July 19 61 35.2

Aug 19 59

Sept 19 70 37.6


Table 07 and figure 15, explained the variation of Victor loom efficiency% over study period. It was

differences were observed between target and actual efficiency. It was due to the higher warp yarn breakage rate ,

lower quality ratio of warp yarn, , variation of yarn quality ratio etc. were responsible Kg/loom/shift were the function

of actual efficiency % were proved here.

60

80efficiency%




Variation of Actual efficiency % of sacking loom over different months

From table 06 and figure 14, it is found that Sacking loom actual efficiency % was quite higher than Hessian loom. It

due to the Eco loader mechanism and fabric construction. The Sacking loom efficiency

actual efficiency % wasobserved round the 70 % on the study period.

ctor C loom over different months

Vector C loom


ACTUAL TARGET ACTUAL

41.3 84.3 50.9

44.6 85 52.6

45.4 88 55.8

44.7 89.2 56.6

42.0 91.9 54.8

42.3 83.6 55.1

41.8 77.4 51.3

43.6 77.5 51.5

42.2 77.1 53.7

43.0 79.9 55.6

37.2 77.1 47.9

35.2 79.9 45.5

35 80.7 45.4

37.6 53.7 49.1


Table 07 and figure 15, explained the variation of Victor loom efficiency% over study period. It was



EFFICIENCY %

TargetEFFICIENCY %

Actual

months


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Variation of Actual efficiency % of sacking loom over different months

quite higher than Hessian loom. It

due to the Eco loader mechanism and fabric construction. The Sacking loom efficiency % was following the

0 % on the study period.

ACTUAL

Table 07 and figure 15, explained the variation of Victor loom efficiency% over study period. It was found that wide



EFFICIENCY %

EFFICIENCY %


ISSN : 2581-7175

Figure 15 : Variation of Actual efficiency % of Vector looms over different months

Table 08: Productivity report of S4 loom

MONTH

EFFICIENCY %

TARGET ACTUAL

August 18 80 59.6


October 18 80 60.3

November 18 80 61.0

December 18 80 60.2

January 19 80 59.4

February19 80 58.2

March19 80 57.4

April 19 80 58.0

May 19 80 59.6

June 19 80 57.5

July 19 80 59.7

Aug 19 80 61.7

Sept 19 80 66.1


Table 08 , explained the variation of S4 loom efficiency % over study period. Wide difference observed between target

and actual efficiency %of S4 loom. It is due to the higher warp yarn breakage rate, faulty beaming, breakage of weft

yarn, poor quality of quality ratio of yarn poor quality parameters of the yarn. Kg/loom/shift is quite higher compare to

sacking loom. It is due to the fabric construction.

0

50

100efficiency%




Variation of Actual efficiency % of Vector looms over different months

S4 loom over different months

S4 loom


ACTUAL TARGET ACTUAL

59.6 110.1 82.2

59.3 110.1 82.2

60.3 110.1 83.5

61.0 110.1 84.6

60.2 110.1 83.1

59.4 110.1 82.0

58.2 110.1 80.2

57.4 110.1 79.1

58.0 110.1 80.0

59.6 110.1 81.1

57.5 110.1 79.5

59.7 110.1 82.3

61.7 110.1 85.2

66.1 110.1 91.1




quality ratio of yarn poor quality parameters of the yarn. Kg/loom/shift is quite higher compare to

It is due to the fabric construction.

EFFICIENCY %

Target

EFFICIENCY %

Actual

months


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Variation of Actual efficiency % of Vector looms over different months

ACTUAL



quality ratio of yarn poor quality parameters of the yarn. Kg/loom/shift is quite higher compare to

EFFICIENCY %

Target

EFFICIENCY %

Actual

months


ISSN : 2581-7175

Figure 16 . Variation of Actual efficiency % of S4 looms over different months


Figure 17 :Variation of actual kgs/loom/shift hessian loom over different months

Figure 17 is describing the variation of Kgs/loom/shift from June 19 to September 19 as the efficiency of the Hessian

loom has been increasing on the said period .It is found that curve of Kgs/loom/shift is running above the line of 20 kgs

of the same period.

Figure 18 :Variation of actual kgs/loom/shift sacking loom over different months

0

50

100efficiency%

0

10

20

30

40

june (19) July(19)

Kgs/loom/shift

50

55

60

65

70

june (19) July(19)

Kgs/loom/shift %




. Variation of Actual efficiency % of S4 looms over different months

Productivity report of Mill

Variation of actual kgs/loom/shift hessian loom over different months


n the said period .It is found that curve of Kgs/loom/shift is running above the line of 20 kgs

Variation of actual kgs/loom/shift sacking loom over different months

EFFICIENCY % Target

EFFICIENCY % Actual

months

July(19) Aug(19) sept(19)

target

kg/loom/shift

actual

kgs/loom/shift

months

July(19) Aug(19) sept(19)

target kgs/loom/shift

actual kgs/loom/shift

months


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Variation of actual kgs/loom/shift hessian loom over different months


n the said period .It is found that curve of Kgs/loom/shift is running above the line of 20 kgs

Variation of actual kgs/loom/shift sacking loom over different months

EFFICIENCY % Target

EFFICIENCY % Actual

target

kg/loom/shift

actual

kgs/loom/shift

months



ISSN : 2581-7175

Figure 18 explained that the Kgs/loom/shift has been

sacking loom has been increasing on the said period. It is found that the kgs/loom/shift is running above the line of 55

Kgs/loom/shift.

Figure 19 :Variation of actual kgs/loom/shift Vector

From the figure 19 , it is found that Kgs/loom/shift slightly increasing from the year June 19 to September 2019,as the

efficiency has been increasing on the said period. The kgs/loom/shift line has been present above the st

kgs/loom/shift.

Figure 20 :Variation of actual kgs/loom/shift s4 loom over different months

Figure 20 described the variation of kgs/loom/shift from June 19 to September 2019. It is found that Kgs/loom/shift has

been increasing from June to September 19 as the loom efficiency has been increasing on the same period.

Table 09 : Statistical Significance Test

Sl

No.

Department Subject under

testing

1 Weaving

Department

Relationship

between Loom

Efficiency and

Kgs/loom/shift

0

20

40

60

80

100

june(19) july(19)

Kgs/loom/shift

0

100

200

june(19)

Kgs/loom/shift%




Figure 18 explained that the Kgs/loom/shift has been increasing from June 19 to September 19,as the efficiency of the


Variation of actual kgs/loom/shift Vector C loom over different months


efficiency has been increasing on the said period. The kgs/loom/shift line has been present above the st

Variation of actual kgs/loom/shift s4 loom over different months


to September 19 as the loom efficiency has been increasing on the same period.

Statistical Significance Test

Pearson’s

correlation

coefficient

R

Coefficie

nt of

Determin

ation R2

Value of p Remarks

0.9927 0.9855 0.00001 Strong positive

correlation, p

value is <0.00001.

The result is

july(19) aug(19) sept(19)



months

july(19) aug(19) sept(19)



months


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Page 1190

increasing from June 19 to September 19,as the efficiency of the


C loom over different months


efficiency has been increasing on the said period. The kgs/loom/shift line has been present above the state line of 40


to September 19 as the loom efficiency has been increasing on the same period.

Remarks

Strong positive

correlation, p

value is <0.00001.

The result is



months



months




production for

S4 loom

significant at

p<0.05

2 Weaving

Department

Relationship

between Loom

Efficiency and

Kgs/loom/shift

production for

Victor loom

0.9043 0.8178 0.00001 Strong positive

correlation,p value

is <0.00001. The

result is significant

at p<0.05

3 Weaving

Department

Relationship

between Loom

Efficiency and

Kgs/loom/shift

production for

Hessian

shuttle loom

0.3449 0.119 0.227171 Positive

correlation, the

relationship

between two

variables is weak.

The result is not

significant t

p<0.05 and p<0.1

4 Weaving

Department

Relationship

between Loom

Efficiency and

Kgs/loom/shift

production for

Sacking

shuttle loom

0.9902 0.9805 0.00001 Strong positive

correlation ,p

value is <0.00001.

The result is

significant at

p<0.05

5 Spinning

Department

Relationship

between

Spinning

frame

efficiency %

and per

winder’s

production

0.0949 0.009 0.781359 Weak positive

correlation ship ,

but the result is not

significant as p

value is higher

than 0.05

6 Finishing

Department

Total number

of bags

production

/month and

total number

of bales press

production

/month

0.6289 0.3955 0.021302 Positive

correlation ship

between the two

variables. P value

is less than 0.05. It

is significant tat

95 % confidence

level.

7 Finishing

Department

Relationship

between

Hemming and

Herackle

production/mc

/day

0.8303 0.6894 0.000424 Strong positive

correlation ship

Exist between the

two variables. The

result is significant

at p<0.05




Table 9 described the Pearson’s correlation coefficient ‘R’ of different production process and their relationship. Here

Weaving, Spinning and Finishing, these three department are selected for analysis. In Weaving department ,Victor, S4

, Hessian and sacking shuttle loom efficiency% and Kgs/loom/shift are observing and it is found that strong positive

correlation exist between the production variables.In Spinning department, Spinning frame efficiency% and per winder

production /shift in Kgs has positive correlation, but not significant at 955 confidence level. In Finishing department

,total number of bags production /month and press production /month has strong positive correlation . Hemming and

Herackle ,production /mc/day has strong positive correlation .

Suggestive Measures for Improvement:

• Both fine side and coarse side actual spinning frame efficiency % are comparatively less than industry norms.

In such cases, efficiency of spinning frame are to be improved. Regarding this ,timely schedule maintenance of

spinning frames, quality of feed material ,proper speed of flyers, spinner’s efficiency, skilled manpower,

reduction of absentees of workmen etc. are areas for further improvement.

• Fluctuations of coarse side spinning frame efficiency are to be improved. Regarding this, feed material quality,

skilled manpower, better supervision, timely maintenance of machineries are to be taken in time.

• Both coarse side and fine side average monthly spinning efficiency data are to be improved. Regarding this

above mentioned points is to be taken in time.

• Regarding efficiency of victor and S4 loom, Management is trying for improvement. Skilled competent

machine operator, training of learners at workplace with proper guidance,, quality of yarn, etc. are important

areas for improvement of weaving efficiency. Sizing process parameters, e.g., quality of beam, steam pressure

and temperature ,sizing ingredients composition are taken into consideration.

Conclusions:

The study is based on the day to day study of productivity of machineries of various department of the unit. It also

indicates the present, efficiency status of the unit. The present study has identified the critical areas for development of

the unit. Jute products have higher demand in National and International market due to biodegradable nature. Under

this circumstances, productivity, efficiency of machineries along with skilled trained machine operators are now urgent

to fulfil the demand of customers.

Acknowledgement:

We are extremely thankful to the Senior Officers of Agarpara Jute Mills Ltd. , Kolkata for carrying out such

research work at their organization.

Reference :.

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Documents

Study on Productivity Development Status of a Jute Mill in