OVERVIEW ON TEXTILE MACHINERY BUSINESS

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OVERVIEW ON TEXTILE MACHINERY BUSINESS NEED
OF AUTOMATION
Texcellence09 Ahmedabad-14th Nov09
ASHOK JUNEJA JAYESH SIVAN
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Contents

• Indian Textile Engineering Industry - Overview
• About Kirlosakar Toyoda Textile Machinery Pvt Ltd
  ( KTTM)
• Automation in Ring Spinning Technology

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The Indian Textile Engineering Industry An
Overview

• The Textile Engineering Industry ( TEI)
• Is one of the five key Engineering sector in
  India.
• Which is more than 50 years old.
• Consists of more than 1400 units, as surveyed by
  the Textile
• Committee , Mumbai
• Capacity is Rs. 8048 crore
• Provides direct/indirect employment to gt 250,000
  people

The TEI contributes in big way to the
competitiveness of the Indian textile industry
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Year-wise Production of Textile Machinery, Parts
Accessories
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Export Import of Textile Machinery,Parts
Accessories
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Demand v/s Supply of Textile Machinery, Parts
Accessories
7
Year wise production of Textile Machinery, Parts
Accessory(Indigenous)
Export Import of Textile Machinery, Parts
Accessory
Out of total textile machinery produced in India,
Spinning contributes 6065
Import of Textile Machinery contributes around
55.
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Capacity Utilization of the Indian Textile
Engineering Industry
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CAPABILITIES OF TEI

• Manufactures
• Complete range of spinning machinery, of
  state-of-the-art technology
• Medium and high tech weaving machinery
• Complete processing plants for processing 1 lack
  meters fabric per day and more
• There are more than 50 companies making either
  complete or part of the plant, of low, medium to
  high tech machinery.
• Technology is comparable with international
  standard for most of the products

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CAPABILITIES OF TEI ( Contd..)

• Manufactures
• High quality latest generation testing and
  monitoring equipments
• Complete range of state-of-the-art synthetic yarn
  and fabric machinery
• Almost all kinds of parts and accessories of high
  quality, except some critical items.
• TEI products are also well accepted in the
  international market

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GOVERNMENT SUPPORT REQUIRED

• Fiscal Corrections
• EXISTING LEVEL OF CUSTOMS DUTIES (7.5 5) ON
  COMPLETE TEXTILE MACHINERY TO BE MAINTAINED AS IT
  IS.
• ALL PARTS/COMPONENTS ACCESSORIES SHOULD HAVE
  ZERO CUSTOMS DUTY
• EXISTING LEVEL OF EXCISE DUTIES (8) ON COMPLETE
  MACHINERY TO BE MAINTAINED AS IT IS.
• ALL PARTS/COMPONENTS ACCESSORIES SHOULD HAVE
  4 DUTY ONLY.
• Policy corrections
• SECOND HAND MACHINES SHOULD NOT BE CONSIDERED
  UNDER TUFS .
• IMPORT OF SECONDHAND MACHINES OLDER THAN 7 YEARS
  SHOULD NOT BE ALLOWED.

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GOVERNMENT SUPPORT REQUIRED (Contd)

• Other supports
• Assistance to the domestic textile engineering
  industry needed either in the form of higher
  subsidy under the existing schemes or in any
  other form or manner as deem fit
• Uniform treatment to the domestic suppliers of
  machinery to epcg licence holders and 100 eou as
  both are deemed export.
• Support to the domestic textile engineering
  industry needed for modernization, infrastructure
  and research development
• 150 weighted income tax deduction for rd
  expenditure made by the textile engineering
  units.

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About KTTM
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• KIRLOSKAR TOYODA TEXTILE MACHINERY (P) LIMITED
• BANGALORE, INDIA

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KTTM Company Profile
Mr. Sakichi Toyoda
Mr. Laxman Rao Kirloskar
Open your mind and look at the great world
outside
Human Intellect and Individual ability gives us
our means to direct our talents towards
production work
The Spirit of Entrepreneurship and Innovation
of two great visionaries of different era and
countries resulted in the formation of
KTTM The first Company of TOYOTA Group in
Bangalore
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KTTM Company Profile
Basic Policy Touch the Heart, People
First
Operational Policy Speed up !
Change Challenge !
Zero defect !
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KTTM Company Profile
1. Establishment 14th August 1995
2 Started Operation 6th June 1997
3. Share Capital Rs.2,426 Million
4. Share Capital Ratio Toyota Industries Corporation 95.1Kirloskar Oil Engines 3.8Kirloskar Brothers 1.1
5. Location Jigani Industrial Area, Bangalore Dist,Karnataka State, India
6. Land 132,054 m2
7. Building 22,838 m2
8. Numbers of Employees (as on March 09) 700
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K.T.T.M - Business Activity
Sales by Segments
2nd largest producer in the country with over 40
upper market segment. Over 95 varieties totaling
to 1,34,000 pieces are exported to Japan
Textile Machinery Parts Exports
Transmission Parts
Over 31 varieties of parts totaling to 3,00,000
pieces are send to TKAP each month.
Turnover 62 Million US dollar
Sales Service of Toyota Material Handling
Equipment. 170 units sold in first year and to
grow to 2000 units sale by 2010.
Materials Handling Equipment
Job Work
KTTM is the only authorized surface treatment
facility approved by VOLVO, Sweden for parts
sourcing from India
Surface Treatment for Volvo ,GE, Others
Our strengths are the synergies of technologies
and markets of our diversified businesses.
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KTTM has received awards and appreciations for
Quality, Delivery Innovation
ALUCAST BEST FOUNDRY AWARD2006
IMTMA SEIMENS PRODUCTIVITY AWARD2007
QCFI GROUP KAIZEN AWARD2007
ALUCAST BEST FOUNDRY AWARD2005
IMTMA SEIMENS PRODUCTIVITY AWARD2006
TKMLZERO PPM AWARD 2004
TKML SUPPLIER OF THE YEAR GOLD AWARD 2007
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KTTM has received awards and appreciations for
Quality, Delivery Innovation
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KTTM SPINNING MACHINES IN INDIAN MARKET
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NEARLY 2.0 MILLION SPINDLES SPINNING THE PERFECT
YARN
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AVERAGE MARKET DEMAND IN INDIA 300,000 SPINDLES/
MONTH

• KTTM, BANGALORE

Production Capacity 27000 Spindles / month
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AUTOMATION IN KTTM RING SPINNING MACHINES
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Todays challenges in front of spinning mills

• Increasing raw material Cost

Scarcity in
labor and
increasing labor cost
Increasing power cost

• Solution for all above is with KTTM RXI 240 e
• Speed up to increase productivity
• Produce best quality of yarn and compete in
  global market

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NEED FOR AUTOMATION
Man Power

• Due to change in Job preferences, availability of
  manpower is scarce.
• Not keen to work in production. Migration of
  qualified man power towards lucrative areas like
  marketing, fashion design, garmenting etc. has
  created vacuum in supervisory staff of mills.
• Increase in man power cost.
• Since mill locations are remote, people dont
  prefer to travel.

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AUTO DOFFER SCD
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AUTO DOFFING in RXI 240e
Empties are being inserted on spindles
Sub conveyor
TBC
Doffing in Operation

• Doffing Time Just 1 minute 45 Seconds.
• More than 400 machines with Auto doffer with TBC

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KTTM Market trend for SCD Machines Spindleage
per machine.
Details 03-04 04-05 05-06 06-07 07-08
Auto Doffer (SCD) To save man power cost. High productivity. Price performance due to high productivity and reliability.
Spindles per Machine Price performance (Lesser cost per spindle) Saving in space.
Machines without Auto Doffer
Longer machine upto 1440
Machines With Auto Doffer (SCD)
48576 Spindles
6241008 Spindles
10561200 Spindles
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ELECTROLIFTLaunched in ITME 2000
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Automation- Improvement in Productivity - Lifting
1. CAM LIFT
ADVANTAGES

1. Cost effective.
2. Proven mechanism.

DISADVANTAGES

1. Too many elements involved(5 mechanisms Heart
   cam box, box worm cam drive, main lifting shaft,
   lever tilting and sub lifting assy).
2. Machine setting is a human skill and time
   dependent factor.
3. Transmission loss because of more moving parts.
4. More space required.
5. More inventory needed of all parts.
6. Wear and tear of parts.
7. Fine adjustment not possible.

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RXI240e - ELECTROLIFT PICTORIAL VIEW
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ELECTRODRAFTTo be launched shortly
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Automation in Ring Spinning Technology
Increasing fashion consciousness
Spin smaller lot size
Reduce count changing time
Electro Draft
Produce Multi twist yarn
Produce Multi Count Yarn
Produce Slub Yarns
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Electrodraft System
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Electrodraft System
GE
Front Roller LH)
OE
MdOE
Middle Roller (LH)
MdGE
Back Roller (LH)
Bk?GE
BkOE
Back Roller (RH)
Fr-OE
Middle Roller (RH)
Fr-GE
Front Roller (RH)
?No Change Gear? Yarn spec is adjusted through
key-in operation
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AUTOMATIC MATERIAL TRANSPORT SYSTEM WITHIN THE
DEPARTMENT
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Link Winder System
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Automatic Roving Transfer

• Automatic Transfer of Roving Bobbins from Roving
  Frame to Ring Frame.
• No deterioration in Roving quality due to storage
  and handling.
• Better yarn quality.

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COMPACT SYSTEMLaunched in ITME 2008
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RX240NEW-EST
Toyota Compact Ring Spinning Frame
Excellent Spinning Technology
TOYOTA INDUSTRIES CORPORATION
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Feature of compact yarn
High quality, highly value added yarn
Compact yarn
Conventional ring spun yarn
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• ADVANTAGES OF COMPACT
• Less USTER hairiness Less ZWIGEL S3
• Higher elongation Higher RKM.

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Machine conectivity to Computers
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Automation on Ring Frame
Automatic Data Acquisition

• All machines are connected to a Central Computer.
• Two way communication between the Computer and
  Machine can be established.
• Possible to change the speed parameters from the
  Computer.
• On line monitoring of the machine status.
• Data acquired can be converted to production
  report. No need to manually record the production
  information from the machine.

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Dream of Spinning industry
AUTOMATIC YARN PIECING AT RING FRAMES
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CONCLUSION - Overview of TEI

• The Indian Textile Engineering Industry is
  capable of producing the latest technology
  machineries .
• Technology of our spinning machinery is at par
  with international level but in weaving and
  processing we are far behind and depend upon
  imports of major machines
• TEI requires Government support to develop
  further.

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Thank you
FOR PROVIDING THIS OPPORTUNITY
KTTM TEAM Commitment
ONTIME DELIVERY ZERO DEFECT