Cotton determines about 60 to 70 per cent of yarn manufacturing cost, working performance and desired yarn quality. Cotton procurement system and cotton sampling and testing methods are an integral part of the manufacturing process. This article highlights the authors experience and challenges in setting right the cotton management in toto to achieve the objective improve yarn quality and productivity in a large spinning mill.
The unit had a culture of everyone is responsible but no one is accountable. KPIs were developed with standards for spindle point production, utilisation, quality, yarn realisation, power consumption per kilogram of yarn produced, man power employed per 1,000 spindles and manufacturing cost per kilogram of yarn. Every individual was assigned responsibility and held accountable, performance incentive linked to the results. After a year of close follow-up, the performance culture was set in.