Small Rolls vs Big Rolls

8/8/2019 Small Rolls vs Big Rolls

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ADVANTAGES OF BIG ROLLS OVERADVANTAGES OF BIG ROLLS OVER

SMALL ROLLSSMALL ROLLS

PREPARED BY:PREPARED BY:

Mr. ASHISH VAIDYAMr. ASHISH VAIDYA


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OBJECTIVEOBJECTIVE

To Improve quality & to reduce damage.To Improve quality & to reduce damage.

Increase Accountability as needed byIncrease Accountability as needed by

Management.Management. Reduction in man power with Time Saving.Reduction in man power with Time Saving.

Omitting totally opening/stitching procedure.Omitting totally opening/stitching procedure.

Utilization of roll opening cum inspection cumUtilization of roll opening cum inspection cum

mending.mending.


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STUDYSTUDY

SMALL ROLL STUDYSMALL ROLL STUDY

BIG ROLL STUDYBIG ROLL STUDY


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SMALL ROLL STUDYSMALL ROLL STUDY

Small roll opening & delivering procedure.Small roll opening & delivering procedure.

Man power consumed.Man power consumed.

Time consumed.Time consumed. Transportation used.Transportation used.

Storage condition.Storage condition.

Cost study.Cost study.


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SMALL ROLLS OPENING & DELIVERINGSMALL ROLLS OPENING & DELIVERING

PROCEDUREPROCEDURE

Unloading Storage Rolls on m/cUnloading Storage Rolls on m/c

BatchingBatching StitchingStitching OpeningOpening

Delivery to BleachingDelivery to Bleaching


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MAN POWER CONSUMEDMAN POWER CONSUMED

Minimum 9Minimum 9--10 Persons required to unload10 Persons required to unload

the truck.the truck.

1 pair(2 persons) inside the truck until whole1 pair(2 persons) inside the truck until wholematerial is unloaded.material is unloaded.

2 pairs (4 persons) for carrying the rolls on2 pairs (4 persons) for carrying the rolls on

shoulders for continues unloading.shoulders for continues unloading.

3 persons on each roll opening cum batching3 persons on each roll opening cum batchingm/c.m/c.

2 supervisor for contracted workers2 supervisor for contracted workers .


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TIME CONSUMEDTIME CONSUMED

33--5 Mins consumed for storage (avg 4min).5 Mins consumed for storage (avg 4min).

Daily unloading quantity 2 lakh mtrs.Daily unloading quantity 2 lakh mtrs.

Average roll length 200 mtrs.Average roll length 200 mtrs. Approx: no of rolls per day to unload is 1000.Approx: no of rolls per day to unload is 1000.

Time consumed is approx: 4000 min or 66Time consumed is approx: 4000 min or 66

hrs.hrs.

Note : By Using Two persons for unloadingNote : By Using Two persons for unloading


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TRANSPORTIONTRANSPORTION

77--8 trucks are used for transportation (avg8 trucks are used for transportation (avg

7.5).7.5).

Each truck contains approx: 26666 mtrs.Each truck contains approx: 26666 mtrs.

Approx: 133.3 rolls per truckApprox: 133.3 rolls per truck

Consumed average 533.2 mins or 8.8 hrs toConsumed average 533.2 mins or 8.8 hrs to

unload a truckunload a truck


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COSTINGCOSTING

Cost of transportation from silvass to vapi=5500Rs/truckCost of transportation from silvass to vapi=5500Rs/truck

Roll loading/unloading cost = 3.5 Rs /rollRoll loading/unloading cost = 3.5 Rs /roll

No. of rolls/truck = 133 rolls (Avg)No. of rolls/truck = 133 rolls (Avg)

Cost of unloading = 133x3.5=465/truckCost of unloading = 133x3.5=465/truck

Cost/Truck = 5965Rs/truckCost/Truck = 5965Rs/truck

No. of truck/day = 7.5(Avg)No. of truck/day = 7.5(Avg)

TOTAL COST = 5965X7.5TOTAL COST = 5965X7.5

= 44737.5 Rs/day= 44737.5 Rs/day


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BIG ROLL STUDYBIG ROLL STUDY

Opening & delivery procedureOpening & delivery procedure

Man power consumedMan power consumed Time consumedTime consumed

TransportationTransportation

Cost studyCost study


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BIG ROLLS OPENING & DELIVERINGBIG ROLLS OPENING & DELIVERING

PROCEDUREPROCEDURE

Beam unloadBeam unload

StorageStorage

Direct delivery to BleachingDirect delivery to Bleaching


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MAN POWER CONSUMEDMAN POWER CONSUMED

1 Fork Lift operator1 Fork Lift operator 1 person in truck1 person in truck

1 supervisor1 supervisor


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TIME CONSUMED (Big roll)TIME CONSUMED (Big roll)


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TRANSPORTIONTRANSPORTION

Due to more circumference, big rollsDue to more circumference, big rolls

consume more space.consume more space.

Required 2Required 2--3 more trucks than as in small3 more trucks than as in smallrolls for transportation.rolls for transportation.

So need of special designed trucks forSo need of special designed trucks for

more space utilization inside truckmore space utilization inside truck.


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COSTINGCOSTING


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Comparison Difference B/W Small Roll vs Big RollsComparison Difference B/W Small Roll vs Big Rolls

Small rollSmall roll Time consumingTime consuming

CostlyCostly

Require more manRequire more man

powerpower Wastage (paperWastage (paper

cones, fabric fromcones, fabric fromends during stitching)ends during stitching)

Less accountablyLess accountably Less productiveLess productive

Big rollBig roll Less time consumingLess time consuming

Cost effectiveCost effective

Require very lessRequire very less

manpowermanpower Beam reusedBeam reused

Easy accountabilityEasy accountability

More productiveMore productive

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Small Rolls vs Big Rolls