OUR Dream Company

Sameer Fabric Limited

Indian Institute of Technology,

Bombay

Presented By:
1. Raghvendr Omer (143190001)
2. Ashish Dubey (143190003)
3. Anshika Chaurasia (143190012)
1

TABLE OF CONTENTS:
1.

1. INTRODUCTION:
A terry towel is described as a textile product, which is made with loop
pile on one or both sides generally covering the entire surface or
forming strips, checks, or other patterns.

2. PRODUCT DETAILS:
A woven towel consists of five parts. These are the pile area, fringes,
beginning and end part, selvedge, border. The pile area is considered
the towelling part of the towel.

Product Specifications:
Product
Specifications
Length (cm)

Target

Ikea

Kohls

Walmart

140

140

140

140

Width (cm)

70

70

70

70

Pile Height (mm)

EPI

62

64

70

65

PPI

30

28

34

29

Ground Count (Ne 's)

2/24 KW

2/24 KW

2/24 KW

2/24 KW

Pile Count (Ne 's)

1/12 CW

1/12 CW

1/12 ZT

1/12 CW

Weft Count (Ne 's)

1/10 OE

1/10 OE

1/10 OE

1/10 OE

GSM

450

490

500

450

Fabric Weight

441

480

490

441

Terry Type

3 Pick

3 Pick

3 Pick

3 Pick

Ground Weave

2/2 Plain Weave 1/1 Plain Weave 2/1 Twill Weave 1/1 Plain Weave

3. PROCESS FLOW:
Cheese Winding

After- treatment

Winding process

Warping
process

Sizing process

Weaving process

Main mechanism in weaving

process

Weaving
machine

Dyeing
machine

4. PLANT LAYOUT:

14

Loom Section
(35 M/c)

Sizing Section
(1 M/c)
Warping Section
(2 M/cs)
TFO Section
(1 M/c)
Cheese Winding
(1 M/c)

Dyeing Section
(6 M/cs)

Humidity
Controllers

Finishing Section
(23 M/cs)

Carton Packing Area

Designing
MILL YARD
QA
Department
Yarn Warehouse

15

No. of Machines in Each Section:

Section

Weaving Preparatory

Weaving

Dyeing

Finishing

Machine Name

No. of Machines

Cheese Winding

TFO

Direct Warping

Sectional Warping

Sizing

Looms

35

Dyeing Machine

Hydroextractor

Rope Opener

Stenter

Length Cutting Machine

Length Hemming and Cross Hemming

Juki Machines

20

16

PLANT LOCATION:
Region Selected: Surat, Gujarat
Selection of Region:
Surat was considered for plant location due to the following reasons:
1. Supply of Raw Materials:
It is essential for our organization to get the raw materials supplied on- time, as our
company is a continuous manufacturing company working 24 * 7, thus requires, on- time
delivery of raw materials.
2. Proximity to Sea- Ports:
Ours company is dealing with foreign customers, thus it is required to serve them on time,
and so it is required that is closed to the sea- port.
3. Labor and Wages:
Skilled labor is easily available in that place.
4. Laws and Taxation:
Law and taxation rules of Gujarat State was quite flexible for setting the factory.

17

5. DEMAND FORECASTING:
Towel Demand Data

Month
1
2
3
4
5
6
7
8
9
10
11
12

Target
60000
55000
50000
49000
48000
58000
47000
46000
50000
61000
58000
59000

Ikea
120000
125000
115000
135000
115000
125000
106000
125000
110000
119000
124000
117000

Kohls
70000
74000
68000
75000
65000
72000
68000
62000
68000
65000
68000
71000

Walmart
150000
145000
155000
159000
144000
130000
160000
157000
162000
146000
139000
149000

Bathrobe Demand
Data
Walmart
59000
63000
60000
58000
62000
61000
59500
60500
57500
56500
59000
61500

18

Exponential Smoothing Forecast With Alpha = 0.3

Months

Towel Forcast

Bath Robe Forecast

Forecast Walmart Forecast Walmart Forecast

Target

Forecast

Ikea

Forecast

Kohls

60000

60000

120000

120000

70000

70000

150000

150000

59000

59000

55000

58500

125000

121500

74000

71200

145000

148500

63000

60200

50000

55950

115000

119550

68000

70240

155000

150450

60000

60140

49000

53865

135000

124185

75000

71668

159000

153015

58000

59498

48000

52105.5

115000 121429.5

65000

69667.6

144000 150310.5

62000

60248.6

58000

53873.85 125000 122500.7

72000

70367.32 130000 144217.4

61000

60474.02

47000

51811.7

106000 117550.5

68000

69657.12 160000 148952.1

59500

60181.81

46000

50068.19 125000 119785.3

62000

67359.99 157000 151366.5

60500

60277.27

50000

50047.73 110000 116849.7

68000

67551.99 162000 154556.6

57500

59444.09

10

61000

53333.41 119000 117494.8

65000

66786.39 146000 151989.6

56500

58560.86

11

58000

54733.39 124000 119446.4

68000

67150.48 139000 148092.7

59000

58692.6

12

59000

56013.37 117000 118712.5

71000

68305.33 149000 148364.9

61500

59534.82

Demand
Forecasted
for Next
Month

56013.37158

118712.455

68305.33283

148364.897

59534.82248

19

6. CALCULATIONS:
Maximum Capacity Calculation Per Day:
Number of looms = 35
Number of looms assigned for towel production = 25
Number of looms assigned for bathrobe production = 10
Towel Calculation:
Loom RPM = 550 rpm (on average)
Picks per inch = 34 (on average)
Length produced per shift per machine = Loom rpm * 60 * 8 *.75
39.37*PPI
= 550 * 60 *8 * .75 / (39.37*34)
= 147.92 mts
Length produced per day = 147.92 * 3 = 443.75 mts
Length produced in 30 days per 25 machines = 443.75 * 25 * 30 *.93(repair) = 309518 mts
Loom Width = 170 cm
Towel Length = 1.4 mts
Lines of towels produced per loom = 2
Thus, total length = 309518 * 2 = 619036 mts
Maximum number of towels produced with 75% efficiency per month = 619036 / 1.4 = 442168
20

Bathrobe Calculation:
Area required per bathrobe = 3 sq mts
Length produced in 30 days per 10 machines = 443.75 * 10 * 30 *.93(repair) = 123807 mts
Area produced per 30 days per 10 machines = 12807 * 1.6 = 198092 sq mts
Maximum number of bathrobes produced with 75% efficiency per month = 198092/3 = 66030
Dye Requirement Calculation:
Cost of dye = Rs. 2500 per 25 kg
% Shade depth requirement of towel on average = 2%
Requirement of dye for 1 month:
Customer
Target
Ikea
Kohls
Walmart
Walmart

Type
Towel
Towel
Towel
Towel
Bathrobe

Weight(g)
Demand
441
56013.3716
480
118712.455
490
68305.3328
441
148364.897
1200
59534.8225
Total Dyes Consumption

Total Weight (kgs)

24701.89687
56981.97839
33469.61309
65428.91958
71441.78697

2% Shade
494.0379373
1139.639568
669.3922617
1308.578392
1428.835739
5040.483898
21

7. MRP:
DyesCone
Cones
& Chemicals
ofofdifferent
differentyarn
yarncount
counts
count

22

Target
Terry Towel LT-

Gross Requirement

7
14007

Scheduled Receipts
Projected on Hand

4002

6003

8004

10005

12006

Net Requirements

2001

2001

2001

2001

2001

2001

Planned Order Receipts

2001

2001

2001

2001

2001

2001

2001

2001

2001

2001

2001

2001

100

100

100

100

100

100

Net Requirements

100

100

100

100

100

100

Planned Order Receipts

100

100

100

100

100

100

100

100

100

100

100

Planned Order Releases

1/24 KW

LT- 1 day

2001

Gross Requirement
Scheduled Receipts
Projected on Hand

Planned Order Releases

100

100

23

1/12 CW

LT- 1 day

214

214

214

214

214

214

Net Requirements

214

214

214

214

214

214

Planned Order Receipts

214

214

214

214

214

214

214

214

214

214

214

214

65

65

65

65

65

65

Net Requirements

65

65

65

65

65

65

Planned Order Receipts

65

65

65

65

65

65

65

65

65

65

65

Gross Requirement
Scheduled Receipts
Projected on Hand

Planned Order Releases

1/10 OE

LT- 1 day

214

Gross Requirement
Scheduled Receipts
Projected on Hand

Planned Order Releases

65

65

24

Dyes
Dyes LT- 1 Week

1 Week

Gross Requirement

2 Week

3 Week

4 Week

2245

2245

Net Requirements

2245

2245

Planned Order Receipts

2245

2245

Scheduled Receipts
Projected on Hand

Planned Order Releases

1122.5

2245

2245

25

8. SCHEDULING:
Total number of looms: 35 (Toyota Air Jet 170 cm)
Customer

Type

No. of looms assigned

Target

Terry Towel

IKEA

Terry Towel

Kohl's

Terry Towel

Wal-Mart

Terry Towel

10

Wal-Mart

Bathrobe

10

26

9. ECONOMIC ORDER QUANTITY

FOR DYES:

Total Monthly Demand (D)

5040 kgs

Ordering Cost (S)

Rs. 1000

Carrying Cost (I)

2% per unit cost per month

Dyes Cost per Kg (C)

100

Economic Order Quantity

2244.994432

Order Period

2 Weeks

Lead Time

1 Week

27

10. TPM:
TPM Policy Sameer Company is committed to achieve ZBAD (i.e.
Zero Breakdown, Zero Accident and Zero Defect) through the
elimination of all types of losses by adapting TPM Culture, with
enhanced people skill, company morale, asset life, productivity,
customer satisfaction & market capitalization in a Clean and Green
Environment.
All data related to the manufacturing is stored in SAP (System,
Applications and Products).

28

11. LEAN MANUFACTRING:

Lean is the process of eliminating waste with the goal of creating value.
We focus on lean manufacturing in our COMPANY by undertaking
some projects as listed below to reduce waste:
Areas of Waste
Generation

Waste

Projects Undertaken

Loom

False Selvedge

To decrease Loom Waste generation by

reduction in the false selvedge

Loom

Yarn

Loom

Downgrade Towels

Dyeing

Torn

Dyeing

Re Processing

Finishing
Finishing

To minimize the weft breakages to reduce

the wastage of yarn during pick insertion
To minimize the generation of downgrade
towels by ensuring the FD sensors are
working properly
To reduce the the generation of torn towels

To increase the RFT% of dyeing

To ensure proper setting on the Length
Length Selvedge Damage Cutting Machine during each loading of the
machine
Pile Pulling
To reduce the pile pulling generation
29

12. COSTING:
Fixed Assets
Land Cost
TFO
Direct BeamWarping Machine Cost
Cheese Winding and Sizing
Sectional Warping
Loom Cost
Dyeing and Finishing Machines
Construction Cost
Total Fixed Assets
Current Assets
Inventory
Cash
Account Receivable
Total Current Asset
Revenue
Target Towel
Ikea Towel
Kohls Towel
Walmart Towel
Bathrobe Towel
Total Revenue
Material Cost
Labor Cost
Overheads

INR
22500000
2000000
1500000
10000000
3000000
70000000
80000000
7500000
196500000
2000000
5000000
3000000
10000000
14003343
35613736
34152666
51927714
32744152
168441612
84220806
15500000
54220806

30

13. ROI:
Profit Margin
Assets
Income
Sales
Assets
Turn (16.8
Over
Sales
Cost
Fixed
Working
Employed
(8.6%)
(1.45
of
crore)
Crore)
Rate
(16.8
Capita
Material
Overheads
Current
crore)
Good
Capital
(0.81)
(20.65
crore)
(19.65
Sold
Liabilities
assets
Cost
(1
(5.4
crore)
(15.39
crore)
crore)
(8.4
(1crore)
crore)
crore)
(0)
crore)

31

14. PERFORMANCE EVALUATION:

Line Balancing
Work Station
Process Name

Winding Doubling Warping

Sizing

Weaving

Dyeing

Finishing

Process Time (hrs)

2.76

1.51

12

2.5

No. of Workers/ Mc

0.25

Process Efficiency

75%

80%

76%

70%

78%

80%

84%

Idle Time

25%

20%

24%

30%

22%

20%

16%

Idle Time (min)

41.4

18.12

43.2

126

26.4

144

24

32

REFERENCE:
1.

www.academia.edu/26966090/Production_and_Processing_of_Terry_Towe
ls
2. http://texinfo.files.wordpress.com/2011/10/terry-towel.pdf
3. www.alibaba.com
4. www.tridentindia.com
5. www.huntsman.com
6. www.search.fibre2fashion.com
7. Tirupur market rate- Tirupur yarn rate (www.tirrate.blogspot.in)
8. www.nptel.ac.in
9. Textile Mathematics by R.Sen.Gupta
10. Woven Fabric Part-II by NCUTE
11. Class notes of forecasting and MRP

33

THANK YOU FOR

YOUR VALUABLE
TIME
AND PATIENCE.

34