A system study on the fabric knitting operation of Company ABC

• Main Authors: Camelon, Reeve Eric B., Diokno, Dionisio Ramon J., IV, Que, Malvin Lucas T.
• Format: text
• Language: English
• Published: Animo Repository 2019
• Subjects: Clothing trade—Production control; Knitwear; Operations Research, Systems Engineering and Industrial Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/18641
• Institution: De La Salle University

A system study was conducted on Fabric Knitting Company ABC, a company that produces knitted fabrics. The company has been established and has produced fabrics to their customers for more than two decades in the Philippines. The study focuses on the processes involved with the acquisition of yarns all the way to the delivery of knitted fabrics, with a study period of May 2018 to April 2019. Based on the company's objectives, the company was evaluated by determining their strengths, weaknesses, opportunities, and threats. Through WOT-SURG Analysis, it was determined that the greatest problem of the company is the reject rate of Double Jersey Finished Fabrics, with a deviation of 34,498 kilograms leading to P 1,882,381.21 cost of goods sold. This problem was further investigated by using a Why-Why Diagram to identify the root causes 'of the problem. There were nine root causes of the problem, namely: Presence of Yarn Unevenness, Variation in Yarn Tension, Presence of Yarn Hairiness, Yarn Feeder Misalignment, Improper Machine Cleaning, Use of Wrong Yarn, Presence of Neps in Yarn, Improper Machine Net Setup, and Dry Yarns. With this, the proposed system if for the company to Buy Optical Yarn Inspection Machine and Incorporate AQL Sampling, Upgrade from Analog to Digital Yarn Tension Meter, Implement Yarn Feeder Monitoring Policy and Place Markings to the Yarn Feeders, Implement SS, Printing Labels, Buying New Machine Nets and Installation of Curtain Rings with Hooks, and Installation of Ventilation System and Window Insulation. The effectivity and improvement by this proposal was supported using a simulation model from ARENA Simulation Software. Results of the simulation show that with the proposed system, the company would be able to reduce the reject rate all the way to the acceptable level. Moreover, the proposal was able to minimize customer unmet orders. The implementation of this proposed system led to an annual worth of approximately P 2,858,596.92, and a payback period of 0.167 years.