Major
uses of Textiles optimisation
of product-mix and simulation
are,
- Contribution
Maximization
- Setting
Production / Marketing Targets
- Prioritising
Capital Investment Decisions
- Managing orders and ensuring
timely deliveries
Studies of a number of textile
mills have shown that to ensure
profitability it is important
to keep a constant watch on
Product-mix based on contribution
analysis, Fixed Costs, Sales,
Raw Materials, Colours, Chemicals,
Packing Materials, Royalty,
Commission and Brokerage on
sales.
Textile Optimisation of Product-mix
and Simulation offers a formal
approach to optimise contribution
through a Mathematical Programming
System. This software is the
answer for problem to determine
the number of loom-shifts
or machine-shifts in various
departments, that should be
allocated to the production
of each fabric or yarn, so
that the total contribution
earned is maximum subject
to the constraints of machine
capacities, achievable production
rates and the upper and lower
marketing bounds specified
by the sales manager for each
product or class of products.
The optimised plan has to
be altered heuristically to
meet the committed deliveries
and / or orders cancelled
or rescheduled where possible.
Some important characteristics
of the textile products specifications,
which give rise to a multitude
of choices,
- What
is sold are an assortment
of fabrics rather than an
individual fabric.
- Each
fabric goes through machine
centres which can be classified
as - i) pre-loom ii) loom
and iii) post-loom machine
centres. The manufacturing
sequence is both serial
and parallel. Further, the
input/output ratio at different
machine centres differ and
so also the production rates.
- A composite
mill could sell - i) Yarn
or ii) Finished/Grey Cloth
or iii) Finished/Grey Cloth,
which uses Yarn Bought-out,
or iv) Bought-out cloth
processed in-house. These
options arise because capacities
of different machine centres
seldom 'balance' or even
if they do, the phenomenon
is short lived owing to
shifting market demands
and consequent production
changes.
- Export
orders are of bigger runs
and with very rigid delivery
schedules
- Domestic
buyers are becoming choosey
and specify more assortments
Benefits
/ Features
- TOPS
assists in data acquisition,
problem formulation and
interpretation of the solution.
- It is estimated that about
90% of the data preparation
the user of TOPS saves cost
and effort that is normally
needed in implementing a
scheduling or a linear programming
exercise.
- A very conservative estimate
of the increase in contribution
or avoidance of order cancellation
costs owing to delays that
is expected by the use of
this package is 5 to 10%.
The cost of implementing
this system can be offset
by the increase in contribution
achieved in a matter of
weeks.
- Implementation of TOPS
has also the advantage of
unifying the efforts of
different departments and
it frees a considerable
amount of managerial and
clerical time spent in production
plan preparation.
- Typical installation (i.e.
first run) of TOPS in a
textile mill requires 4
months - the time required
depends upon the level of
preparedness of the organisation
and also the receptivity
of department managers.
Subsequent runs can be made
within a FEW HOURS.
Product Category
Planning and Scheduling operations
in Textiles industry, Capacity
scheduling, Product-mix optimisation
Target Users
Textiles Industry - spinning,
weaving and composite textile
mills
Request for more
information: Enquiry
or email on info@sdindia.com
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