Production Stages and Data of Study are Analyzed as ...which includes factory buildings, utility buildings, stores, hangers, residential camps, customs yard, administration building,

Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020

© IEOM Society International

Production Stages and Data of Study are Analyzed as System Throughput Optimization

Ahmad Yame Doctor of Engineering in Manufacturing Systems (DEMS)

A. Leon Linton Department of Mechanical EngineeringLawrence Technological University

Southfield, MI 48075, USA [email protected]

Abstract

Textile production stages and data of the study are analyzed as system throughput optimization by collected data from Libyan textile companies to provide the required space of solutions to the research problem that has been formulated in the previous work by A. Yame. The analysis involves the system capacity to respond, utilization in the manufacture, and the stability of inventory along with the variables simulation, and experimentation. Data have been analyzed based on both operating time and operating costs for the experimentation using the standard data of the manufacturing systems.

Keywords Production Stages, textile data, Production plants

Statistics Interpretation

The Libyan Textile Company is one of the largest industrial fortresses in the spinning and weaving sector. The total area of factory premises is 477,225𝑚𝑚2 which includes factory buildings, utility buildings, stores, hangers, residential camps, customs yard, administration building, car workshop, central workshop, etc. The factory buys its raw wool directly from farmers and sheep projects that belong to the government. These projects are in the middle region of Libya, which Wool textile company is a part of, and can be considered as a rich source of wool compared with other parts of Libya. It is one of the few factories which is still operating today. It is the leading company in carpet manufacturing. The objective of the wool Textile Company is to meet the demand of the Libyan market of the carpet and floor covering and export the surplus. This aim is achieved by utilizing the Libyan raw wool in this industry. The products of wool Textile Company are very high quality, of classical and modern designs with very attractive colors which makes Wool Textile Company a very well-known name in Libya and the Baniwaild carpet is the pride of Libya.

Textile Production Stages

Textile manufacturing or production is a very complex process. The range of textile manufacturing is so long. It starts from fiber to finished products. The textile product in Baniwild Company is passed through many activities in each production unit; these units will present respectively: Flow chart of the Process flow diagram of the company is given below:

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Figure 1. Technical Specifications for Libya Wool Textile Company ( Bani Waild )

Technical Specifications The event data is automatically extracted by the Libyan Textile Company, based on specific instructions. Woven carpet; Produced by Rapier Loom-CRX83

1 •Wool sorting unit

2 •Wool washing unit

3 •Wool blending unit

4 •Wool Dye unit

5 •Wool spinning unit

6 •Drawing Stage

7 •Fine Spinning

8 •Twisting and Assembly Winding Stage

9 •Reeling and Winding Stage

10 •Textile Unit

11 •Final Preparation Unit

12 •Rolling

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Table. 1 Technical Specifications for Libya Wool Textile Company

Woven Carpet Specifications Technical Specifications

Pile MaterialYarn Count =100%VirginLibyanWool=Nm8/2

Pile Weight /Sq. Meter =2400 Grams

Pile Height =10 -11 mm=2/2

Weave structure =1770

Picks/Meter =350

Tufts/ Sq.Meter = 6 colours

Colour =74 Grams

Warp yarn Polycotton 20/5 =158 Grams

Warp yarn Polycotton 20/3 =469 Grams / Sq.Meter

Weft 100% jute yarn 4.8/2 = 200 Grams / Sq.Meter

Weft 100% jute yarn 6/2 = 60 Grams / Sq.Meter

Weight of dry latex =3,350 Grams/ Sq. Meter

Gross weight of carpet =Bematin 988

Moth prof -

Ends / Meter =315,000

To keep this goodwill and name in the market for ”Bani Waild Carpet” the wool textile company management in 2018 is planning to develop its technical specifications for products to satisfy all the consumers; now the work is going on implementing new production lines to diversify its products by adding new products such as shaggy carpet and hand tuft carpet in elegant designs and sophisticated dimensions for art galleries, conference rooms, etc. Production Plants This part will walk you through the production steps in Libya Textile Company – from wool sorting to final preparation unit – and give you an idea of the kind of production capacity, and plants installed on single shift operations that are used.

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Table. 2 Production plants for Libya Wool Textile Company

Production capacity Plants installed on single shift operation

Wool Sorting 12,000 Kg 1 Revolving + 3 Manual Bailing

Wool Scouring 3,360 Kg 1 Scouring range

Stock Dyeing 1,065 Kg 3+ other auxiliary machines

Hank Dyeing 1,350 Kg 8+ other auxiliary machines

Semi-worsted spinning Nm 4.8/2 1477 Kg Nm 4.8/2 1477 Kg Nm 4.8/2 1477 Kg

14 Ring spinning + Preparatory + post spinning machine

Tufting 3333𝑚𝑚2 3 loom + Mending machine

Printing 3000𝑚𝑚2 1 Range

Coating 3333𝑚𝑚2 1 Range

Weaving 700 𝑚𝑚2 16 Looms + Warping + Mending + Back cleaning + Cop winding

Woven finishing 1000 𝑚𝑚2 1 back sizing + 6 other finishing machines

knitting Flat, 333 pcs, 36 machines Circular, 1000 pcs, 03 machines

Garment making 34 machines

Quilt plant 133 Pcs, 02 Quilting machine 04 Edge Binding machine 04 Swing machine 04 Fancy sewing machine 02 Over lock machine

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Utility Plant

Figure 2. Utility plant Service Department

Figure 3. Service department

• Woven Carpets: Woven carpets are as per standard prescribed by IWS, the leading organization for wool

quality marking, and they have passed Wool Textile Company for heavy duty after testing. The highest production achievement of 324142𝑚𝑚2 has been in 2010 and the lowest of 106212𝑚𝑚2 in 2011 during the years, 2008 to 2019.

• Tufted Carpet: The highest production achievement of 1,774,929𝑚𝑚2 has been in 2009 and the lowest of 69425𝑚𝑚2 in 2017-2011 during the years, 2008 to 2019

• Knitwear Garments: The highest production achievement of 1,774,507 pcs has been in 2010 and the lowest of 1235 pcs in 2011 during the years, 2008 to 2019

• Spinning Yarn: The highest production achievement of 1018 ton has been in 2010-2008 and the lowest of

368 tons pcs in 2013 during the years, 2008 to 2019

• Needle Felt Carpets: As a part of project expansion and manufacturing cheaper carpets to suit every pocket, the needle felt plant has installed and commenced start up work on 26th April 2010 and completed over test runs on 18th July 2010. The Production capacity of the plant is 2,000,000𝑚𝑚2 per annum on a single shift operation. The highest production achievement of 2,792,486 𝑚𝑚2 has been in 2015 and the lowest of 202,185𝑚𝑚2 in 2017 during the years 2008 to 2019

Air conditionin

g

Water treatment and supply

Steam generators

Effluent treatment

plant

Air compressor

Fire Fighting Central Workshop

Quality Control

Store & Lnternal

TransportCar Workshop

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Textile Exports The textile segment is considered one of the best industrialized of the Libyan economic growth, as it represents the sixth-largest manufacturing sector after the oil and gas sectors. Libya is the fourth largest North Africa and the second largest Mediterranean exporter of carpet for best quality. The following is the share of the main Libyan textile markets (Figure 4.1).

Figure 4. The Libyan export capacity and their markets worldwide Source: EEPC1 (2018) The factory is located near the coast to facilitate export activities by sea into international markets. The factory makes different types of products for which wool is the main raw material. Amer and Sharif. The factory has a staff headcount of about 2270 as shown in Table 3.

Table 3. The Libyan export capacity and their markets

Number

310

720

1130 Nationality Foreign ( India, Turkey) Arab ( Tunisia,

Morocco, Syrian) Libyan

Quilts and Bedspreads As part of project expansion and to diversify the product range from carpet to quilt sand other varied similar products, quilt plant has installed and commenced start-up work on 26th Feb. 2017 and completed taking over test on 28th Feb. 2017. The production capacity of the plant is 70,000 Pcs per annum on the single-shift operation and is the most modern and latest designed plant. This plant is now working on a production order basis. Statement showing year-wise production achievement in all the main production departments right from wool sorting to carpet finishing, needle felt, knitwear garments, quilts is attached. Almost all the plants, excluding quilts, could maintain reasonably

Libyan 58%

Tunisia23%

South Korea10%

Egypt9%

Sales of Protective Textile

Libyan Tunisia South Korea Egypt

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satisfactory performance up to 2017. Production in all departments decreased due to various reason such as scarcity of raw materials and spare parts as well as due to flooded market and decreased demand of our products in the local market due to heavy inflow of imported carpets and garments of all verities a comparatively cheaper price, with an exception of our woven carpet and few verities of tufted and needle felt carpets having reasonably good demand. Repaid and productivity necessitates replacement or modernization by better and improved equipment, for meeting the requirement of current production, to cope with the increasing competition in the market, improving the quality of products, improving productivity, cost reduction and increased earnings.

• Prepayments: The net prepayments amounts to LD 1.106 million (Dr. 1.549 –Cr. 0.443) includes security of guarantee deposits which constitutes 6.3% of the total net current assets and 1.8% of the total net assets.

• Inventories: The net inventories amount LD 12.842 million (Gross 17.220 – rebate 4.378) comprised of stock of finished products worth LD 2.601 million, materials and spare parts worth LD 7.380 million and stock in process worth LD 2.861 million. Value for finished product stock devalued by 48% on the basis of current marketable price of our products, The value of stores decreased by 22% by deducting nonmoving spares worth LD 1.980 Million and nonmoving materials worth LD 0.042 million or of the total stores of LD 9.402 million. Inventory constitutes 73.7% of the current assets and 22% of total net assets.

• Trade Debtors: The net account receivable amount to LD 1.450 million (DR. 3.244- Cr. 1.1794) constitutes

8.3% of the current assets and 2.5% of total net assets. Gross trade debtors equal to 3.5 months sales, which reveals the actual velocity or debt collection is very slow and reflects badly on the liquidity of the firm.

• Bank Balance: As the fund is heavily tried up in current assets approximately LD 24 million (Gross) such

as in inventories LD 17.220 million, in trade debtors LD 3.244 million, in prepayments LD 1.549 million, in trade creditors LD 0.688 million and in loans and advance LD 0.344 million, Bank balance.

Figure 5. Net working capital

0.199

0.293

0.189

0.022

0.704

4.333

3.136

0.936

3.051

0.026

7.148

29.234

3.732

2.542

1.046

0

7.32

10.097

0 5 10 15 20 25 30 35

Statutory Liabilities

Trade Creditors

Provisions & Liabilities

H.O.& sisiter Concerns

Total Labilities

Net Working Capital

Series 3 Series 2 Series 1

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Current Liabilities It has been increased considerably by LD 6.161 million between 2012 - 2019 Statutory liabilities such as accrued taxes, employee insurance, etc constitutes approximately 51% of the total liabilities. Outstanding payments to suppliers constitute 34.7% and unpaid wages, leave salary dues, provisions for expenses etc constitutes 14.3% to the total liabilities. Working Capital Ratio This ratio measures the firm’s ability to promptly meet its short period of obligation. The firm’s gross ratio equal to 2.5 times indicates short-term creditors’ claims are safely been covered by current assets. Inventory Turn-Over Ratio This ratio firm’s effective utilization of its available resources by measuring the velocity of conversion of stock into sales. The firm’s very low average inventory turnover ratio of 0.6 times against the industrial standard of 9 times indicates the firm is not suing its fixed assets to its optimum capacity and there have been too heavy investments in fixed assets and hence sales need to be increased. Financial Cost & Profitability Analysis An average profit margin of 3% is very low. The high cost can be due to high depreciation charges due to excessive investment in fixed assets and a higher depreciation rate of plant and machinery and due to higher overhead expenses. Cost and profitability for the previous 17 years as a whole, 2002 to 2019 is analyzed below.

Figure 6. Sales revenue

95,471

55648

196,326

201073

206846

47.50%

47.50%

97.60%

100.00%

74%

0 50,000 100,000 150,000 200,000 250,000

Stores Consumotion

Wages, Salaries,etc

Cost of Production

Cost of Sales

Sales Revenue / Production Value

Cost Elements %age Millions LD

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Figure 7. Depreciation Charges

Figure 8. Adminstartation & Sales Overheads

5,773

6698

1,318

35905

35512

2.90%

12.00%

7.00%

17.80%

17.70%

0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000

Operating Profit

Non- Operating Expenses

Non- Operating Income

Cash Proft

Depreciation Charges


4,092

2521

3,082

4747

2.00%

1.20%

1.50%

2.40%

0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

Power & Electricity

Insurance Premium

Factory Overhead

Administration & Sales Overheads


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Conclusions The company built-in six factories: Woven carpet, Tufted carpet, Needlefelt carpet, Trico, and Matters. The analysis involves the system capacity to respond, utilization in the manufacture, and the stability of inventory along with the variables simulation, and experimentation. Data have been analyzed based on both operating time and operating costs for the experimentation using the standard data of the manufacturing systems. Waste elimination is one of the most effective ways to increase the profitability of any industry. walk you through the production steps in Libya Textile Company – from wool sorting to final preparation unit. References Khaled Amer Ali Amer, and Mohamed Alamen Sharif, The Supply Chain Management Implementation on Misurata Textile Factory (MTF), Sebha University, 2015 Yame, A., Ali, A., Jawad, B., Nasser, D.A.W.M. and Abro, S., 2016. Optimization of Lean Methodologies in the Textile Industry Using Design of Experiments. World Academy of Science, Engineering and Technology, International Journal of Social, Behavioral, Educational, Economic, Business and Industrial Engineering, 10(9), pp.3208-3212. Yame, A., Alwerfalli, D., Jawad, B., Ali, A., Abro, S. and Nasser, M., 2016. Applications of Lean methodologies and Quality improvement in the Industry (No. 2016-01-0343). SAE Technical Paper. Yame. A. Survey-based statistical data and totaling long columns of numbers on Lean Manufacturing; Case Study. Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020 Yame. A. Tufted Woven Carpet with Enhanced Machine Mechanism Properties Using Response Surface Design Analysis. Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020 Ahmad Yame,”System Throughput Optimization and its Interaction with Waste under Lean Manufacturing Considerations” Ph.D. dissertation, Doctor of Engineering in Manufacturing Systems (DEMS). Lawrence Technological University. 2020 Yame. A. Synthesis and Interaction with Waste in Trico Factory Layout and Cycle time analysis. Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020 Yame. A. Method for Producing advanced Carpeting Using a HTC factor. Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020 Yame. A. An implementation of the variance analysis (ANOVA) for Mattresse factory at Fisher Pairwise Comparisons Level. Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020 Yame. A. Heating and Cooling Loading Processes and Optimizes Material Properties for the Best Thermal Performances using CES. Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020 Ahmad Yame. Advances on design and materials of solar Trombe Wall. Thesis Master of Science (MSc), University Kebangsaan Malaysia, Bangi 2007

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Yame. A. Applications and Theoretical Research for Fabric Manufacturing and Influence of Descriptive Statistics. Proceedings of the International Conference on Industrial Engineering and Operations Management Dubai, UAE, March 10-12, 2020 Biography Dr. Ahmad Yame earned his Bachelor degree in Engineering Technology from the Lawrence Technological University in 2010, Mr. Yame has three master degree, the latest was in 2015 in Industrial Engineering from Lawrence Technological University, second MSc was in Engineering Management 2011 from the Lawrence Technological University and his first MSc was in Mechanical Engineering back in 2007 from the National University of Malaysia. He earned his Associate's degree in Mechanical Engineering 2004 from the Libyan Higher Professional Center for Comprehensive Professions. He primarily develops engineers but also has experience with software and testing. Dr.Yame has tested many enterprise applications for automotive MAHLE Laboratories in 2013, he working with Panasonic automotive in North America since 2016 to test vehicles for AHU/Sync and diagnostic functionalities of engine control systems. He has organized several simulations, in order to test the engine control software and the diagnostic functionality on a CANlog, respectively, through non-regression and diagnostic tests.

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Production Stages and Data of Study are Analyzed as ...which includes factory buildings, utility buildings, stores, hangers, residential camps, customs yard, administration building,