With increasing consumer preferences for aesthetically improved designs, textures and colours the complexity for BCF yarns has been ever increasing. Other parameters which impacted productivity & downgrades were

 Multiple raw material inputs- PA6, PP and their unpredictable behaviour and the impact on yarn breakages

Master batches quality and impact of colour changes

Variation in planned activities-pack changes, winder changes etc

Planning & Shade Sequencing impacted downgrades & productivity

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How we helped

Developed OEE based ‘True Utilization’ metric and Utilisation reconciliation method

 Improved Quality Control of Master batches to reduce shade failures and strength changes (LDR%)

 Improved Winder reliability by implementing reliability based maintenance practices

Standardised all online & offline activities to optimize downtime Reduction in pack chocking instances, identification and correction of Master batches with risk of clogging