Optimization of the Critical Production Process in a Textile Factory using AHP

Abstract

The process of converting raw materials, components, or parts into finished goods that meet customer’s expectations or specifications is called the production process. Manufacturing commonly uses a man-machine set up with division of labor in a large scale production. It includes a design to raw material collection to manufacturing to distribution towards its end of life, including disposal. The textile industry has prominence globally and locally. Also, it has a vast relation with RMG (Ready Made Garments) production in Bangladesh and other countries, which is earning a lot of foreign remittance for the economic development for the country. There are many segments and factors involve in the entire production process. Therefore, it will be effective and economical if key segments and factors could be identified for optimization. A standard textile production process comprises spinning, weaving, dyeing, printing, and finishing. In this study, to find out the most prominent segment of the textiles industry production process initially Ishikawa diagram, 5 why the method was used for brainstorming purpose. Then a questionnaire was developed based on the idea received from the brainstorming part. The questionnaire was sent to the experts. Data received from them were used to perform analysis using Analytical Hierarchy Process (AHP). The AHP analysis shows that yarns manufacturing is the most critical segment in the textiles production process. Later, 5s and statistical process control charts were used to improve selected parameters of the production process. Data collected shows that productivity increased by 0.88%, maintenance frequency decreased by 20%, the defective number decreased by 20%, and decreased injured number by 16.66 %.