SSRG International Journal of Industrial Engineering (SSRG-IJIE) – volume 2 Issue 3–May to June 2015
An Observed Study of Factors Affecting Productivity in Textile
Industries
Dr.S.Bankebihari#1, Gurbaksh #2
1
Professor, 2Sudent
Department of Industrial Engineering
Arunnai Engineering College, India
12
ABSTRACT- This paper is a challenge to discover the factors dependable for productivity of solapur based Textile SMEs’. A
survey work of 164 textile manufacturing SMEs was carried out. The composed data was analyzed with numerical tools and
appropriate software which shows that there are eight factors disturbing productivity of this sector. The paper is prepared as:
Review of literature on factors distressing productivity is approved out, recognition of research gap and objective of the work is
finalized, research methodology is given. Analysis of data, results and discussion are offered. Finally the conclusions are drawn
and scope for future work is written.
Keywords: Productivity, Factors, Terry Towel Manufacturing Textiles.
I.
INTRODUCTION
India is the second biggest producer of textiles and
garments in the world. The Indian textiles and clothes
industry is predictable to grow to a size of US$ 223
billion by 2021, according to a report by Technopak
Advisors. This industry accounts for almost 24% of
the world’s spindle capability and 8% of global rotor
capability. Plentiful accessibility of raw materials
such as cotton, wool, silk and jute as well as skilled
workforce have made the country a sourcing hub the
textiles industry has made a major involvement to the
national economy in terms of direct and indirect
employment generation and net foreign exchange
earnings. The sector contributes about 14% to
industrial production, 4% to the gross domestic
product (GDP), and 27% to the country's foreign
exchange inflows. It provides straight employment to
over 45 million people. The textiles sector is the
second biggest provider of employment after
agriculture. Thus the growth and all round expansion
of this industry has a shortest bearing on the
improvement of the India’s economy. The Indian
textiles industry is set for strong growth, buoyed by
strong domestic consumption as well as export
demand.
The major important change in the Indian textiles
industry has been the advent of man-made fibres
(MMF). India has effectively located its modern
range of MMF textiles in approximately all the
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countries across the globe. MMF manufacture
recorded an increase of 10% and filament yarn
production grew by 6% in the month of February
2014. MMF fabrication enlarged by about 4% during
the period April 2013–February 2014. Cotton yarn
production increased by about 10% throughout the
February 2014 and by about 10% during April 2013
to February 2014. Blended and 100% non-cotton
yarn production increased by 6% during February
2014 and by 8% during the period April 2013 to
February 2014. Cloth production by mill sector
registered a growth of 9 per cent in the month of
February 2014 and of 6 per cent during April 2013–
February 2014.
Cloth construction by power loom and hosiery
enlarged by 2 per cent and 9 per cent correspondingly
throughout February 2014. The total cloth invention
grew by 4 per cent during February 2014 and by 3
per cent during the period April 2013–February 2014.
Textiles exports stood at US$ 28.53 billion during
April 2013–January 2014 as compared to US$ 24.90
billion during the equivalent period of the previous
year, registering a growth of 14.58%. Garment
exports from India is probable to touch US$ 60
billion over the next three years, with the help of
government support said Dr A Sakthivel, Chairman,
Apparel Export Promotion Council (AEPC). The
textiles sector has witnessed a burst in speculation
during the last five years. The industry fascinated
foreign direct investment (FDI) worth Rs
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SSRG International Journal of Industrial Engineering (SSRG-IJIE) – volume 2 Issue 3–May to June 2015
6,710.94crore that is US$ 1.11 billion during April
2000 to February 2014.
II.
used. One is ground fabrication and another is loop
formation. The weaving concept has been shown in
the following images.
TERRY TOWEL MANUFACTURING
Terry Towel that is a pile fabric is known as towel
worldwide. In terry towel loop plenty are present on
one or both side of the fabric. The research indicates
that the terry towel was first developed in Turkey
first and later towel industrialized concept spreads
across the world. Manufacturing of a fundamental
terry towel has been discussed in the subsequent
paragraphs. Towels are classified according to its
weight, invention process, pile density and pile
presence on fabric surfaces, pile formation, pile
structure and finishing. Though some basic concept
of organization mentioned below under the categories
of by end uses, weave and terry loop formation.
Common terminologies used in export market are
mainly based on end uses. Commercially 3 pick terry
towel is viable for the all the aspects like quality
parameters, look and appearance.
Fig 1.Terry Loom
Top beam is dependable for loop formation by terry
loom’s beat-up mechanism. Commercially 3 pick
terry is most popular. 3 picks terry means after each 3
picks addition full beat-up is made and one loop pile
is formed of the fabric.
Terry Towel Manufacturing process:
Warping (Direct)
↓
Sizing
↓
Weaving
↓
Greige Fabric Inspection
↓
Wet Processing
↓
Inspection
↓
Stitching
↓
Final Inspection
↓
Packing & Cartooning
↓
Shipment
Fig 2. Pile formation
Manufacturing of Towels - It is one type of natural
fiber where during weaving of this fabric 2 beams are
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Pile of the towel plays important role for a towel for
its water absorbency and other properties. Loop
length is determined by the quality, weight etc. as per
requirements. Pile manufacturers use better
excellence yarn like combed, compact, hydro, zero
twisted yarns. Piles are made by dissimilar high value
fibers like superior qualities of cotton suvin, giza,
pima, bamboo, modal etc. to get better absorbency
and lint properties. For ground yarn, reasonably
coarser counts are used in OE and 2-ply option to
give better strength and compactness in ground
fabric. Both piles and ground yarns are equipped in
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SSRG International Journal of Industrial Engineering (SSRG-IJIE) – volume 2 Issue 3–May to June 2015
the same manner of warping, sizing, and drawingin. like other textile products shirting, suiting,
sheeting fabrics, towel making has the same process
sequences – desizing, bleaching, mercerizing, dyeing
and finishing.
Basic Parameters of a Quality Terry Towel:
Weight & GSM: Weight and GSM should be same as
essential by customer. All manufacturers has some
template or software (ERPs) where towel
manufacturers estimate everything likes pile’s height,
density of picks and ends to meet requirement. This
database or any software has been developed during
some basic calculation.
Softness or Hand feel: It depends on properties of the
yarn used in pile, ultimate chemicals and too some
extent on pile orientation.
Pile Orientation: Absolutely depends on process line.
Lint: Lint is basically protruding fibers current in a
completed towel. It is measured by weight of
accumulated fiber composed from washing machine
and tumble drying machine during testing.
Absorbency: Terry towel should be extremely water
absorbent.
Dimensional Stability: How a towel is behaving after
washing is fall under dimensional solidity properties.
Dimensional stability is considered by the residual
shrinkage in a finished towel. Other Parameters are
strength, color fastness etc.
III.
LITERATURE REVIEW
The
factors
influencing
effectiveness
for
manufacturing sector that is textiles are studied. Then
the factors explicit to textile manufacturing sector are
reviewed. The summary is presented below.
Thomas P. Triebs and Subal C. Kumbhakar (2012)
have studied the level of procedural change and level
of management practice. They have confidential the
supervision levels into groups. They found that
technical change is higher; the lesser is the level of
management practice. Technical change is maximum
for management practice level-2. Lower quality of
management correlates with more organization
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flexibility which in turn makes it easier to exploit
opportunities for technical change. Hector Salgado
Banda and Lorenzo Ernesto Bernal Verdugo (2011)
have analyzed determinants of efficiency growth for
Mexican manufacturing environment. They have
used the variables such as input use intensity like that
capital, electricity and transport, technology
adoption, human capital intensity, concentration, and
exports. They further concluded that technology
adoption and human capital promote productivity.
Mohamed Goaied and Rym Ben Ayed Mouelhi
(2000) have studied Tunisian textile clothes and
lather industry. They have done competence
measurement with unstable panel data. The inference
method is used to examine technical efficiency in
Tunisian textiles. The outcome advises that involved
variables method produce more correct estimates of
the unknown firm level technical efficiency. Erol
Taymaz and Golin Saatci (1997) have studied
technical change and efficiency in Turkish
manufacturing industries. They have listening
carefully on measuring and considerate the technical
progress and efficiency. They have acknowledged
sector specific factors influencing technical
efficiency of manufacturing plants. Chiranjib Neogi
and Buddhadeb Ghosh (1994) have studied
intertemporal effectiveness variation in Indian
manufacturing industries. They have used time
varying frontier production function approach with
both fixed and variable reading models in Indian
industries to test the hypothesis. They concluded that
skill, labor productivity and profit play significant
positive role in technical efficiency and Total Factor
Productivity (TFP).
Nicholas Bilalis, et al. (2006) have done an analysis
of European textile sector and found that key
performance indicator of the textile sector are quality,
flexibility, supply chain management, strategy
formulation or accomplishment and human resource
management. Nicholas Bilalis, et al. (2007) have
studied the benchmarking the competitiveness of
European textile firms using seven factors namely
formulation of strategy, suppliers, customer demand,
modern HRM practices, employee recognition
programmes and incentives and existence of
processes for presentation improvement initiatives.
Out of these seven factors three factors existence of
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SSRG International Journal of Industrial Engineering (SSRG-IJIE) – volume 2 Issue 3–May to June 2015
processes for routine improvement initiatives,
suppliers and modern HRM practices have been
recognized as more momentous as they have highest
Crombach
Alpha
coefficients.
Kongkiti
Phusavat(2008) has recommended guidelines for
measurement of productivity of manufacturing
industries in Thailand. He has analyzed the
parameters like quality, customer focus, delivery,
flexibility, continuation services and technical. The
analysis was done using descriptive statistics. The
paper concludes that delivery, quality and customer
focus are the priorities for deciding the operational
strategies for improving productivity.
IV.
6. Hector Salgedo Banda and Lorenzo Ernesto Bernel Verdago
(2011), ‘Multifactor productivity and its determinants: an empirical
analysis for Mexican manufacturing’, Journal of production
analysis, DOI 10.1007/s 11123-011-0218-2.
7. Mahdi H. Al-Salman (2008), ‘Measuring the technological
change and productivity in food, textile and chemical anufactur in
Kuwait (1992-2002)’, Telematics and Informatics, Vol. 25, pp.
237-245.
8. Mohamad Goaied and Rym Ben Ayed Mouelhi (2000),
‘Efficiency measurements with unbalanced panel data: evidence
from Tunisian textile, clothing and lather industries’, Journal of
production analysis, DOI 10.1023/a 1007875009531 dt.
01/05/2000.
9. Report of Base line survey of power looms conducted by
Solapur Zilla Yantramag Dharak Sangh, Solapur dated 16.09.2011.
10. Shu-Hwa Lin et al. (1994), ‘Productivity and Production in the
Apparel Industry’, International Journal of Clothing Science and
Technology, Vol. 6 No. 1, pp. 20-27.
CONCLUSION
As the understood from the previous sections, the
fiber content and construction of terry towel plus
every step of the production provide terry towel with
features that serves end use of performance. After
literature review, designing the questionnaire, There
are most important vital factors which can involve
the productivity of textile SMEs: synchronization of
management processes, TPM for weaving and
dyeing, input process quality, HR policies for textile
SMEs, process technology, labor behavior, use of
scientific tools and techniques and systems
deployment. The outcome of this empirical study can
form an important reference to continue the research
for investigating the relationship between output
variable and input factors.
REFERENCES
1. Anup Kumar Bhandari and Subhash C. Ray (2007), ‘Technical
Efficiency in the Indian Textile industry: A Nonparametric
Analysis of Firm-Level Data, Working Paper 2007-49.
2. Chiranjib Neogi and Buddhadeb Ghosh (1994), ‘Intertemporal
efficiency variation in Indian manufacturing industries’, Journal of
productivity analysis, Vol. 5 pp. 301-324.
3. E. Bhaskaran (2013), ‘The Productivity and Technical
Efficiency of Textile Industry Clusters in India’, Journal of The
Institution of Engineers (India): Series C, Volume 94, Issue 3, pp
245-251.
4. Erol Taymaz and Golin Saatci (1997), ‘Technical change and
efficiency in Turkish manufacturing industries’, Journal of
productivity analysis, Vol. 8 pp. 461-475.
5. Gokham H. Akay and Can Dogas (2012), ‘The effect of labor
supply changes on output: empirical evidence from U.S.
industries’, DOI 10.1007/s 11123-012-0-290-2.
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