The Scope of the consultancy could cover one or several of the below mentioned areas as per mutual agreement.
1)NEW PROJECT MANAGEMENT
2)OPERATION PROCESSES AND PRODUCTIVITY ENHANCEMENT
3)QUALITY ASSURANCE
4)NEW PRODUCT DEVELOPMENT
5)VENDOR DEVELOPMENT(OUT SOURCED YARNS)
1. Assistance in planning production output, and machinery balancing with plant personnel and machinery suppliers.
2. Selection of machinery and finalizing layout for smooth material and men movement.
3. Co-Ordination with civil (structural), H plant and WCS suppliers, and machinery suppliers for technical specification finalization.
4. Complete Planning and erection of machines as per agreed upon time bound plan.
5. Successful commissioning and hand over of the plant.
6. Optimization of process parameters for achieving the required quality.
7. Assistance in requirement of workers and their training(optional at additional cost)
OPERATION PROCESSES AND PRODUCTIVITY ENHANCEMENT
1. Review of current productivity at all stages and suggestion to improve the same.
2. Review of manufacturing cost and help optimize the same.
3. To review machine utilization in all departments and suggestions to maximize the same.
4. Manpower allotment review and suggestions to right size the same.
5. Review of maintenance practices, replacement schedules, and maintenance cost.
6. Energy consumption study at various departments and suggestions for savings.
7. Review of process parameters at all stages of manufacture and optimization of the same based on the test results, and intermediate/yarn/fabric quality. These include production speeds, settings, and methods of operation.
8. Machinery Audit of all machines types in various departments
9. In depth study of process wastes and help minimize them. (Yarn Realization, Hard Wastes, Fabric Wastes).
QUALITY ASSURANCE
Raw Material:
1) Assisting in selection of cotton and optimization of mixings based on fibre properties and yarn quality required.
2) Continual review of cotton properties, based on requirement for optimum mixing cost.
3) Assisting in conducting various cotton mixing based trials to arrive at the most optimum cost of mixing
4) Suggestions to modify the machine sequence/process parameters to achieve the same.
Quality Systems:
1. Review of quality systems adopted, including various testing, audits and studies, their frequency, and points of observations.
2. Observations of various processes for proper working (for ex., Loom stop marks study, winding cuts study, etc).
3. Review of standards adopted for incoming materials (including packing materials), in-process intermediate products, and final products and customer’s requirement.
Fabric quality/Packing:
1) Improvement in fresh fabric quality through vigorous analysis of defects, review of process at the concerned affected departments, initiating necessary actions to over come the same.( Aim is to achieve 90% first quality fabrics)
2) Specific attention to be given to rope based denims, and new products.
Customer complaints resolution:
1) In depth analysis of customer complaints and help in resolving the same with active support to marketing.
2) Corrective and Preventive actions to ensure that the problems do not re-occur.
NEW PRODUCT DEVELOPMENT
1. Development of New products based on different fibers, spinning methods, and processes.
2. Process stabilization in all departments during commercial run of new products.
3. Feasibility study of the products in manufacturing, review of fabric properties as well as ability to produce the new products on continual basis with excellent fresh packing before launch.
4. Objective co-ordination with the Production as well as Marketing departments for launching of new products
VENDOR DEVELOPMENT
1) Third Party Audit of yarn suppliers to review the present condition of machines and Process parameters and mixing quality used.
2) Review and suggestions to improve the performance of their processes as well as yarn quality as per mill’s requirement.