Wednesday, May 22, 2013

Case Study of Y Knitting Mills Ltd.

Survey of Bangladesh Textile industry to Up-date Database/MIS and to Assess the Requirement of Textile Technologists at Different Levels


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Prepared by
Green University of Bangladesh



Introduction:
The case study of Y Knitting Mills Ltd. is situated at ValukaMymensing. In respect of technical point of views (machines, raw materials, production planning, sequence and operation, maintenance, utility service, store and inventory control, cost analysis), it is a very good graded Knit Dyeing Mill and a strong base of financial aspect and marketing activities, this Mill is 100% export oriented and running up to now with profit.


A brief description of X1 Weaving Mills Ltd:

1. Name of the Mill                            : Y Knitting Mills Ltd
2. Nature of the Ownership              : Private Limited Company
3. Year of Establishment                  : 2005
4. Authorized Capital                       : Tk: 39.07
5.  Paid-up Capital                            : Tk: ?
6. Land Area                                     : 5 Bighas
7. Physical Structure                          : Pucca + Pre-Fabricated
8. Type or Nature of Mill                 : Knitting
9. Machine and Equipments, Capacity and Capacity Utilization:

SlNo.
Name of the Machine
Origin and Year of Purchase
No. of Machine
Installed Capacity Kg/Day
Target Production Kg/Day
Capacity Utilization (%)
1
Circular Knitting
Mayer &Cie
Germany
24
10368
9331
90
2
Dyeing Machine
OrigioItally
20
8400
7560
90





10. Stock Position and Volume of Shortfall (July 2007-December 2007)

Types of Stock
Stock (Kg)
Value of Stock (Tk)
Yarn
45000
5,40,0000

There was no shortage of raw material in the mill during July 2007 to December 2007.









11. Last Three Years Production (in Kg)

Sl. No.
Product
2005-06
2006-07
2007 (July07-Dec 07)
1
Cotton Fabric
85,00,000 yds
95,00,000 yds
51,00,000 yds
2
Total
85,00,000 yds
95,00,000 yds
51,00,000 yds

Production history of last two years.

12. Production and Shortfall During July 2007-December 2007



SlNo.

Name of the Machine

No. of Machine

Installed Capacity
Yds/Day

Target Production
Yds/Day

CapacityUtilizatio
Yds/Day

Shortfall
1
Ball Warping
3
72000
65000
33000
49%
2
Dyeing Machine
1
72000
65000
33000
49%
3
Long Chain Beamer
8
72000
65000
33000
49%
4
Loom
100
65000
60000
33000
45%
5
Sizing
1
60000
58000
33000
43%

13. Calculation of Sale Price During July 2007-December 2007

Products
Cost of Production
Sale Price
Total Revenue
(Tk)
Profit
(Tk)
Woven Fabric
127.65 Tk/Yd
140.42 Tk/Yd
65,10,15,000
6,40,05,000

14. Reason of Production Shortfall During July 2007-December 2007

Sl. No.
Reason of Production
Shortfall During The Quarter
1
Electricity Failure
X
2
Shortage of Raw Material
X
3
Shortage of Working Capital
X
4
Lack of Proper Planning
X
5
Misleading Lead Time/Procurement Time
X
6
Lack f Spare and Accessories
X
7
Strike/Unrest
X
8
Natural Disaster
X
9
Shortage of Skilled Manpower

From the above table it is clear that shortfall of production is only for shortage of skilled manpower. It is assumed that huge 50% production shortfall occurs due to shortage of Textile Technologists.

15. Cost of Good Sold
CHART OF COST OF THE FACTORY


16. Number of Shifts, Working Hours and Days During July 2007-December 2007

No. of Shifts/Day
Total No. of Shifts During July 2007-December 2007
Total No. of Days During July 2007-December 2007
Total No. of Working Hours During the Quarter
2
312
156
2496

17. Raw Material/Input Used During July 2007-December 2007
      2808000 Kg


18. Wastages in terms of % (During the Quarter Ended Decmber 2007)

Yarn
Fabric
Total
0.5%
0.5%
1%

19. Investment:

Fixed Assets in Tk
Working Capital in Tk
Original Value
Present Depreciated Value
In Cost Price as on 31stDecember 2007
39.01 Cores

2.5 Cores


20. Wages and Salaries (Tk) as in December 2007

Period
Officers and Staffs
Labour
December 2007
13,50,000.00
16,50,000.00

21. Manpower as on 31st December 2007:

Level of Skill ness
Education
Requirement
Existing
Shortfall
Shortage (%)
Managerial Level
B. Sc/M.Sc./MBA
in Textile Engg.
1
0
0
100%
High Skill/Expertise Level
B. Sc in Textile Engineering
6
5
1
17%
Moderate Skill Level
Diploma in Textile Engineering
15
10
5
33%
Specialized Skill Level
Trade Course
25
15
10
40%
Skilled /Unskilled Labour
Skilled by Experience
390
410
20
(+5)%

From the above table we have a clear idea about the present condition of overall situation of different mills and we can simulate this case in real/practical fields forenginners and technicians in the following ways.
Figure: Requirement of Textile Engineers and Technologists at Different Level.
22. Product Diversification Matching with the Need of RMG Sector and Quality
      Improvement

Sub-Sector
Existing Supply/Yr of Products to RMG Sector
Scope of Additional Production and Supply to RMG Sector
Scope for Improvement of the Product
Products
Quantity
Yes/No
How?
Yes/No
How?
Weaving
Fabric
99,00,000Yds
Yes
By Increasing Skilled Manpower
Yes
By Increasing Skilled Manpower

23. Conclusion:
From the above study, it is clear that the reason of shortfall of product is only due to shortage of Textile Technologists/Engineers. We have seen that there is about 40% shortage of Textile Technologists/Engineers at different levels. It is possible to achieve 100% target production and also quality by recruiting Textile Technologists/Engineers. So it is essential to appoint Textile Technologists/Engineers at different levels in all the textile mills within short time to face the challenge of 21st century.




Wish You Good Luck..................................
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