CRITICAL ANALYSIS of a Spinning Mill

CRITICAL ANALYSIS OF PERFORMANCE IMPROVEMENT OF A
Spinning Mill with 32400 spindles working on 100% cotton combed yarns
The data given below will help us to understand the impact on overall contribution by
1. Utilisation of the plant 2. Selling price increase
3. Cheaper rawmaterial for coarse counts 4. selling price increase for coarse counts
5. Increased back process production 6. Increased spindleage
7. Increased grams per spindle 8. Working coarses counts
9. working finer counts 10.Raw material price
ASSUMPTIONS:
The selling prices is the actual net sales price for a reasonably good yarn produced in Indonesia.
Product mix is decided by Linear programming which satisfies all the constraints given below
Linear programming decides the maximum possible contribution meeting all the constraints.
contrubution = Net sales price - clean raw material cost - packing and forwarding cost
grams per
market constraints spindle
24sc should be less than 60 tons per month 240 utilisation 97%
20sc should be less than 510 tons per month 280 no of RFs 45
30sc should be less than 90 tons per month 170 no spls/RF 720
32sc should be less than 20 tons per month 155
36sc should be less than 20 tons per month 135
40sc should be less than 300 tons per month 120
Total no of ring frames should not be more than 45
utilised total avg
count 24sc 20sc 30sc 32sc 36sc 40sc rfs cotrbn count
usd
sell price 1.96 1.90 2.10 2.14 2.30 2.40
raw mat 1.30 1.30 1.30 1.30 1.30 1.30
packing 0.04 0.04 0.04 0.04 0.04 0.04
contrbn 0.62 0.56 0.76 0.8 0.96 1.06
12. 5 tons 20.5 0 90 20 20 225 44.3 354291 36.09
13.5 tons 60 22.9 77.5 0 20 225 45 366179 34.39
15 tons 60 137 7.99 0 20 225 45 377470 31.4
17 tons 0 303 0 0 0 207 45 389117 28.12
19 tons 0 408 0 0 0 162 45 400217 25.69
21 tons 3.39 510 0 0 0 117 45 411308 23.72
if the utilisation goes up by 1% I.e form 97% to 98%
15 tons 60 127 15.7 0 20 227 45 380179 31.68
17 tons 0 297 0 0 0 213 45 392156 28.36
19 tons 0 402 0 0 0 168 45 403256 25.9
if grams per spindle is increased by 5%
15 tons 60 88.6 45.6 0 20 236 45 390605 32.74
17 tons 60 171 90 0 20 169 45 399811 29.5
19 tons 60 276 90 0 20 124 45 410911 26.92
if the selling price goes up 5%
15 tons 60 137 7.99 0 20 225 45 426494 31.4
17 tons 0 303 0 0 0 207 45 442743 28.12
19 tons 0 408 0 0 0 162 45 458418 25.69
if the raw material price comes down by 3 cents
15 tons 60 137 7.99 0 20 225 45 390970 31.4
17 tons 0 303 0 0 0 207 45 404417 28.12
19 tons 0 408 0 0 0 162 45 417317 25.69
if the rawmaterial for 20s, 24s and 30s is cheaper by 3 cents compared to other counts
15 tons 60 137 7.99 0 20 225 45 383634 31.4
17 tons 60 250 0 0 0 200 45 398281 28.3
19 tons 60 355 0 0 0 155 45 412531 25.84
if grams per spindle comes down by 3% bec of cheaper raw mat for 20s,24s and 30s
15 tons 51.3 154 0 0 20 225 45 381512 31.15
17 tons 0 310 0 0 0 200 45 394824 27.84
19 tons 0 418 0 0 0 152 45 407902 25.35
if grams per spindle comes down by 10% bec of cheaper rawmat for 20s,24s and 30s
15 tons 0 212 0 0 19.8 218 45 375491 30.41
17 tons 0 326 0 0 20 164 45 385255 27.05
19 tons 0 441 0 0 20 109 45 395018 24.39
if 40sc can not be sold more than 180 tons per month
15 tons 60 92.1 90 7.91 20 180 45 373479 31.45
17 tons 60 243 7.14 0 20 180 45 386071 28.3
19 tons 0 408 0 0 0 162 45 400217 25.69
if 20sc can not be sold more than 300 tons per month
15 tons 60 137 7.99 0 20 225 45 377470 31.4
17 tons 3.39 300 0 0 0 207 45 389108 28.13
19 tons 60 300 90 0 20 97 45 395617 26.0
if 20sc can not be sold more than 150 tons per month
15 tons 60 137 7.99 0 20 225 45 377470 31.4
16 tons 60 150 90 0 20 161 45 379760 29.79
17 tons 60 150 90 0 20 161 45 379760 29.79
19 tons 60 150 90 0 20 161 45 379760 29.79
pleease note in this case it has not considerd more than 16 tons , even thought the option upto
19 tons is given to choose
if spindle installed is increased by 10%
15 tons 60 35.5 90 20 20 225 49 398660 33.76
17 tons 60 169 36.7 0 20 225 49.5 416621 30.62
19 tons 0 349 0 0 0 221 49.5 429693 27.75
if grams/spl goes up by 5% for 40sc
15 tons 60 109 25.3 0 20 236 45 386556 32.29
17 tons 0 284 0 0 0 226 45 398527 28.86
19 tons 0 393 0 0 0 177 45 407582 26.20
if grams/spl goes up by 5% for 20sc
15 tons 0 170 35.9 0 20 225 45 379457 31.49
17 tons 0 293 0 0 0 217 45 394340 28.53
19 tons 0 394 0 0 0 176 45 407251 26.18
PLEASE NOTE THAT WHATEVER CONCLUSIONS, STATEMENTS, OPINIONS ARRIVED AT BASED ON
THE ABOVE DATA IS APPLICABLE ONLY FOR THE SAME DATA. CONCLUSIONS, RESULTS MAY VARY
DEPENDING UPON THE PROUDCTIVITY OF DIFFERENT COUNTS, SELLING PRICE COMBINATIONS
FOR DIFFERENT COUNTS, OVERALL QUANTITY ETC
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