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Yarncom

Capacity Building for one of the world’s largest home textiles manufacturers

The significant steps taken during the course of the action plan were:

The project started with a detailed Gap Analysis that identified the potential gaps to be improved. Based on the results, a comprehensive action plan was charted to achieve the targets and deliverables. The major steps of the action plan included machinery setting corrections, re-engineering and process optimization, performance improvement monitoring systems, continuous performance and systems monitoring, and periodical review meetings such as KPI, Budgeting, and Quality assessments.

Adjustments were made to the machinery settings in order to optimize its performance and improve the accuracy of the output. These adjustments such as machine speed, temperature, pressure, and feed rate, among others are crucial parameters depending on the type of machinery and the process it is being used for. Performance improvement monitoring systems and mechanisms were implemented in order to support and monitor the recurring interventions, along with continuous performance and systems monitoring in order to develop sustenance. All these steps contributed to ensuring that the framework for capacity building was strengthened and accelerated to its highest level.

The project team worked tirelessly to implement the action plan and close the identified gaps. The performance improvement monitoring systems were instrumental in supporting and monitoring the interventions, and continuous performance and systems monitoring was carried out to develop sustenance.

This was followed by periodical review meetings such as KPI, Budgeting, and Quality assessments. These tests were pivotal in measuring and evaluating the performance in alignment with the objectives of the organization, creating a financial plan for a defined period of time outlining estimated expenses and revenues, allocating resources, and finally evaluating the quality of a product, service, or process, with the aim of identifying areas for improvement.

Main Block:

The key deliverables of the project - Production Improvement, Yarn Realization Improvement, Energy Conservation (UKG), and Overall Quality Improvement - were achieved through a well-planned and executed action plan. While production improvement had to do with general optimization in the production process, yarn realization had to do with the percentage conversion of raw material to finished yarn. The rest of the waste fibers with less value are compared to the weight of the produced yarn from a given weight of raw material.

Result:

The results of the project were outstanding. The production increased from 9100 to 11800 kgs/day, the 40s (converted) GPS improved from 95 to 107, yarn realization improved by 4%, UKG reduced from 6.6 to 6.0, and overall quality improved by 50%.

The project team's relentless efforts in implementing the action plan and continuously monitoring performance and systems resulted in a significant transformation. The success of this project has set a new benchmark for the client and serves as a source of inspiration for future capacity-building initiatives in the company.

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