Operations Transformation for a Carpet Yarns(BCF Yarns) Manufacturer

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Our Impact

BCF Manufacturing Line Utilisation

2.5%

FDY Utilization Improvement

28%

Downgrade

Reduction

40%

LDR & Shade failures reduced

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

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

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91-22-22853816/ 91-9769070161