SMME Where science is converted into technology Prospective target research areas for Process Improvements in the Textile and affiliated Industry by Dr Shahid Ikramullah HoD Research NUST School of Mechanical & Manufacturing Engineering

SMME Where science is converted into technology Background  Pakistan is one of the largest manufacturers and exporters of textile goods, declining in the recent years.  Attempts have been made to investigate the challenges faced by the textile industry of Pakistan. A specific objective was to find out main reasons through qualitative and quantitative study and suggest solutions for further progress.

SMME Where science is converted into technology Background  The main challenges related to the process and productivity improvement are Efficient Energy Utilization, Production Cost, Quality Cost, Human Resource Development, Facility Layout, Supply Chain Management, Process Improvement Strategies, Production System Modeling, Lack of Modern Equipment and Machinery, Change Management, Lack of Research and Development (R&D) Institutions etc.  Although, some challenges are uncontrollable but several others can be resolved by well define scientific techniques and methods at our level.

SMME Where science is converted into technology Background  The aim of this presentation is to suggest techniques and areas which may support this sector to continue its journey thus further contributing towards the economy of the country.

SMME Where science is converted into technology Areas contributing towards Process Improvement of Textile Industry

SMME Where science is converted into technology Supporting Research Areas Performance Improvement of Textile Sector by Implementing Quality Six Sigma (QSS)  Six Sigma offers a proven management framework (including processes, techniques and training) which satisfy ISO 9001:2015 requirements.

SMME Where science is converted into technology Supporting Research Areas Expected Achievements due to Quality Six Sigma (QSS): Plant Maintenance & Reliability Production Efficiency Product Yield Increase Line Capacity Decrease Cycle Time Increase Throughput Reduce Variation in product tolerances Reduce Product Defects Decrease Changeover Time Reduce Shipping Delays

SMME Where science is converted into technology Supporting Research Areas Statistical Quality Improvement Tools for the Apparel & Textile Industries  Based on the Principle, “Trivial are many and Vital are Few”, training of basic quality tools to line workers and middle management is imperative to control defective product at initial level before value is added to the product.  Training of Basic Statistical Quality Tools can be provided for better control of product quality at different levels.  Online quality controls and inspection can also be provided where necessary in textile industry to electronically monitor processing weights, faults and running performance.

SMME Where science is converted into technology Supporting Research Areas Supply Chain Management (SCM)  Nearly all organizations face enormous inventories. Supply chains are extremely long and complex, and products are routinely stored, loaded and shipped many times during the production cycle. Warehouses represent a large part of the space and costs in the textile manufacturing process.  SCM will provide feasible solution from Factory to Customer thus reducing inventory as well as transportation costs.

SMME Where science is converted into technology Supporting Research Areas Ergonomics / Human Factor Engineering  Ergonomics is another important area which can provide considerable benefits to the textile sector at a small cost. Prospective benefits are:  Conducting Time and Motion study will result in correcting faulty movements, work station layout, line layout, improving line balancing and reducing line set-up time.  Methods study will help to modify the work methods to improve productivity during the process.

SMME Where science is converted into technology Supporting Research Areas Manufacturing System Modelling & Simulation Manufacturing System Modelling & Simulation  Complete manufacturing system can modeled using available Simulation Packages thus analyzing real time bottlenecks on the shop floor in the plant.  Such study will help in re-organizing facility layouts thus making optimum use of available space.

SMME Where science is converted into technology Supporting Research Areas Lean Manufacturing Lean Manufacturing  Lean manufacturing will help in making the system lean with small number of work-in- process inventories thus releasing capital block at different process stages.  Value Stream Mapping in combination with Simulation is applied to achieve the objective of reduced inventories.

SMME Where science is converted into technology Supporting Research Areas Energy Management Programs  These programs can be worked through Energy Efficiency Improvement opportunities in the Textile Industry including both opportunities for retrofit/process optimization as well as the complete replacement of the current machinery with state-of-the-art new technology.  Equipment Replacement Analysis (ERA) can be provided, including all the benefits received from the installation of the new technologies, such as water savings, material saving, less waste, less waste water, less redoing, higher product quality, etc. are taken into account.

SMME Where science is converted into technology Flow Chart for Energy Management Program

SMME Where science is converted into technology Supporting Research Areas HUMAN RESOURCE DEVELOPMENT  Development of Human Resource is considered as an asset for any industry because lesser number of skilled and trained employees are more beneficial for a company rather than number of un-skilled workers. Following could be offered:  Vocational training and skill development for Productivity and development based work culture.

SMME Where science is converted into technology Industrial & Research Projects

SMME Where science is converted into technology Process Improvement of Ceiling Fan Production Shop at Starco Fan Industry, Gujrat. Initial study for Production Improvement revealed following problems: a.Unnecessary cells at the production floor. b.Less efficient methods of working. c.Excessive Work in Process (WIP) d.Unbalanced lines e.Excessive rework. f.Poor Housekeeping.

SMME Where science is converted into technology Process Improvement of Ceiling Fan Production Shop at Starco Fan Industry, Gujrat. PROCESS IMPROVEMENT 1. OBEYA 3. Production Simulation 2. Value Stream Map 4. Layout Improvement of Factory

SMME Where science is converted into technology Obeya Implementation – A manual ERP system

SMME Where science is converted into technology Change in Work Environment

SMME Where science is converted into technology Process Improvement

SMME Where science is converted into technology Process Improvement

SMME Where science is converted into technology Research Projects (Completed) Syntronics Ltd. Implementation of Six Sigma approach (Extrusion, Weaving, Cutting & Stitching Departments)

SMME Where science is converted into technology Industrial Projects (Completed) Design and development of Mechanical Knee Joint (Collaboration MVRDE)

SMME Where science is converted into technology Industrial Projects (Completed) Various Project for Heavy Industries Taxila

SMME Where science is converted into technology Research Projects (Completed) 1.Implementation of Statistical Quality Control Tools at Refrigerator production line of Haier Industries to improve Quality and enhance Productivity. 2.Developed Methodology for Process Capability Enhancement & Rework Reduction in Fast Manufacturing Consumer Good (FMCG) (Powder Milk) Processing Plant using DMAIC approach. (Nestle) 3.Reduction in Welding Defects and Rejection Rates at Pakistan Welding Institute.

SMME Where science is converted into technology Industrial & Research Projects (In progress) 1.Development of Production Software to calculate production time of article stitching for ‘Service Shoes Industry’. 2.Implementing Six Sigma Technique using DMAIC approach at a shoe industry near Lahore. 3.Preparing a scheduling software for the job shop industry based on Genetic Algorithm.

SMME Where science is converted into technology Patent Patent on “Vision based Automatic mold positioning system in a sand casting process” is filed through Intellectual Property Office (IPO) NUST.

SMME Where science is converted into technology Vision based Automatic mold positioning system in a sand casting process.

SMME Where science is converted into technology EQUIPMENTS  Rapid prototyping facility ◦ Fused deposition Modeling System ◦ 3D Laser Scanner ◦ FARO Arm CMM  CNC Machining Centers ◦ CNC Turning and Milling machine  Computer Aided Design Lab ◦ Pro/Engineer CAD Modeling Software ◦ ANSYS FEM Analysis Software

SMME Where science is converted into technology THANK YOU