Operations

This article will explain how lean manufacturing came into existence and how the just-in-time system was started. The Toyota Company was the one that established these concepts in the Operations and Supply Chain of the Car manufacturing industry. Almost all companies are now using these concepts to deliver the desired outputs efficiently. One of the most outstanding companies in the world is Toyota. Additionally, Toyota is a firm that has practically every reason to fail, which is what makes it even more impressive. Japan had extremely few natural resources and a limited population because of its small size. Because of this, both labor and raw materials were quite expensive. Japan also frequently experiences natural disasters like earthquakes and tsunamis, which could destroy your factory in minutes. Thirdly, World War 2 broke out while Toyota was only two years old, and bombs fell from the sky. Furthermore, even surviving was a significant concern at the time, let alone doing business. Additionally, Japan’s economy was in utter disrepair following the bombing of Hiroshima and Nagasaki and World War 2. Finally, despite all the odds against them, they were in a direct rivalry with American industry behemoths like General Motors and Ford Motor. Despite these challenges, Toyota has become one of the world’s most prosperous automakers. In 2008, it even overtook Germany as the world’s top automaker. Toyota’s market capitalization surpassed that of Ford, General Motors, and Honda in 2016. This raises the question of how Toyota thrived in such challenging market conditions. What was their actual business plan? What, more importantly, can we take away from this excellent case study? This tale takes place in 1950 Japan, 13 years after Toyota’s founding, when that country was in total disarray following World War 2. Toyota nearly made it through the war by alternating between producing trucks and vehicles for the military. Even after 13 years of work, the company’s condition was so dismal that Toyota Motors built just 11,000 cars in the entire year. On the other hand, Ford Motor Company manufactured more than 1 million cars during the same period. And because of this stark difference in output, Toyota’s top manager EG Toyota and several of his engineers visited the Ford Rouge facility to observe how they improved their manufacturing procedures. However, following this trip, they concluded that replicating and enhancing the rouge system would not be effective in Japan. Why? Because Toyota’s financial situation was extremely precarious. Additionally, Japan was still recuperating from the negative impacts of the World War, which left the nation cash- and foreign exchange-starved. Toyota could not purchase the most recent Western production required to increase production and enhance production efficiency. Therefore, Toyota could not compete with American firms in the two most essential production components: capital and machinery. Any ordinary engineer would now quit at this point and claim that he could never compete with the Americans. However, EG Toyota founder Kiichiro Toyoda was not a typical engineer. Even though he knew the odds were stacked against him, he and his team continued to work tirelessly to figure out how to create a system that competes with American manufacturers. And it was at that point that they understood that, even though they could not compete with the Americans in terms of capital and apparatus, there was one critical area in which they could defeat them, and that area was efficiency. He, therefore, developed the concept of the LEAN PRODUCTION SYSTEM. To save money on the cost of machine parts and raw materials, EG Toyota realized that US manufacturers’ typical mode of operation was to first predict demand to a certain extent before placing bulk orders. The corporation will construct 200 red vehicles, 500 black cars, and 300 grey cars if three different car colors must be sold: red, black, and grey. These cars will be ready for delivery and kept in inventory until the order is placed. And they are taken out and delivered to the consumer right away once the customer placed the order. However, the Toyota team discovered a significant issue throughout this process, which in turn caused a string of four significant inefficiencies. And it was the elimination of these inefficiencies that propelled Toyota to billion-dollar status. It altered how the automobile industry operated and the global supply chain. What were these inefficiencies, and how were they resolved? Did the Toyota team resolve team discover that manufacturing always used to create more automobiles than was needed and never ran a deficit when demand forecasting took place in the United States? As a result, it frequently results in an over-allocation of resources. This resulted in the hiring of extra employees, the acquisition of more equipment, and the stockpiling of more supplies and goods. And as a result, the total cash costs increased without adding value. Second, extraneous personnel, machinery, and supplies inevitably result in overproduction. The third waste resulting from overproduction is an excessive stock of finished goods. In this instance, if there are 1000 different cars created, a significant quantity of land is being used, which raises maintenance, labour, and shipping expenses significantly. Finally, when all of these combined methods result in unnecessary capital investment, which is the fourth sort of waste, do you realize that, for instance, if a loan of $1 billion has been obtained and is used for overproduction, it will accrue an absurd amount of interest costs and result in extremely high prices with no return on investment? Additionally, this results in increased administrative expenses, depreciation charges, etc. Right now, it appears as though many things need to be adjusted at first. However, there was just one issue at hand when the Toyota team identified the source of this issue. Demand forecasting resulted in over-inventory, which in turn caused a chain reaction that produced the four forms of waste. So, do you know what Toyota decided to do away with two of the supply chain’s most essential components: inventory and demand forecasting? Toyota created a supply chain with

Menstruation Pad/ Sanitary Pad The menstrual pad is a very useful product today. Many still find it difficult to use such a sanitary napkin today, and it is very important to use the right kind of sanitary napkin. Let us understand everything with the help of the following content. What is meant by Menstruation or Menses? The standard physical process of discharging blood and related material from the uterus through the vagina as part of the menstrual cycle is menstruation or menses.  Menstruation officially begins when a girl experiences her first menstrual cycle or menarche. Why are sanitary napkins used? In women, after every 28 to 30 days, they get bleeding from the vagina, which is called the period, scientifically called the “Menstrual Cycle.” This process takes place every month. Some women may experience this for 3 to 5 days, and for some, it may take 7 to 9 days. It starts at the age of 13 and till 45 or 50. This means every woman has to face these periods at least 500 times in their life span. And for this bleeding, sanitary pads are used, which hygienically collect that blood and dispose of it. In short Sanitary napkin or sanitary pad is an absorbent personal care product worn by a woman. How the first sanitary napkins came into existence would surprise you all. Believe it or not, World War I led to the invention of disposable sanitary napkins. American nurses in France discovered that their bandages for the troops could double as very absorbent menstrual pads. This led the bandage company to introduce disposable sanitary napkins in 1921. Disposable hygienic pads were first effectively marketed in the United States in 1921 after being developed in 1896. Sanitary napkins are the most helpful product in today’s life. And the demand for napkins is more from the Indian public. In the early days, women used layers of cloth to absorb the blood, which was not absorbed correctly and could lead to stains. This was not hygienically safe and led to many diseases too. Today, sanitary napkins are the most demanding thing in the world, yet Indian women constitute only 20% to 30% who use or are affording to use. Sanitary napkin is the most demanding and has a growing business. The use of hygienic sanitary pads and spreading its awareness is essential to today’s youth in both rural and urban, as many women, even today, don’t know the uses and benefits of this product and fall prey to allergies and diseases. Spending very little money can save us from many problems and get the target of any severe health risks. Sanitary napkins are available in large numbers and wide varieties in the market, yet users are not educated enough about this. Today, Menstrual hygiene has been promoted by some governments and non-governmental organizations through health awareness campaigns and the free or discounted distribution of sanitary pads. Their quality, however, varies substantially.  Production of sanitary napkins is not much in India, and most of the napkins are imported from different countries. Materials used in Sanitary Pads. Various materials are used to make menstrual pads, and these materials vary by brand, style, and nation of origin. The primary components of disposable menstrual pads are often bleached rayon (cellulose generated from wood pulp), cotton, and polymers. However, manufacturers are typically unwilling to disclose the precise composition of their products. Antibacterial and aroma ingredients are other options. Backsheet and polymer powder, a more powerful absorbent (superabsorbent polymers), are made of plastic. When moistened, the polymer powder transforms into a gel. Raw materials used in Sanitary Napkins: Three layers are usually used to manufacture menstrual pads.  Most sanitary pads use the same basic construction: a cellulose-based absorbent core sandwiched between a top sheet with a fluid-permeable surface and a backing with a moisture-impermeable surface (backsheet). The function of Sanitary Napkins: The primary purpose is to retain and absorb menstrual flow.  The process of making of menstruation pad Given below are the seven stages of pad making process. This is the primary pad manufacturing process, and organic materials make a simple pad. Let’s get deeper to understand the process. Stage 1: Pulveriser Machine In this stage, the pine wood or cotton pulp is crushed and fibrated. De-fibration is the process of separating the pulp sheet into fibrous constituents. This crushed fibrous substance is called cellulose.  Stage 2: Pressing machine This cellulose is filled in pad shape carved hollow tray, and blocks of the same shape are placed on that filling as seen in the 2nd image below. This plate of trays is then placed under the pressing machine, where they get compressed, and a pulp cake is formed. Stage 3: Sealing and Embossing Raw materials are placed layer by layer, creating a sandwich in which the pulp cake is embossed and sealed. The image below shows that the first raw material identified is PE (Polyethylene) back sheet at the bottom. This sheet is breathable. 2nd layer is the pulp cake obtained in the previous stage, and then the non-woven fabric is placed on top. This fabric is also called artificial cloth. This 3-layer structure is then placed inside the machine where it gets sealed and embossed. Stage 4: Trimming The sealed and embossed pad is trimmed and shaped into a winged pad. A trimming machine is also called a pad-cutting machine. The steel or aluminium plate-like structure is placed on the pad which then goes through the machine. This machine presses and cuts the pad perfectly. Stage 5: Gumming liner and Silicon Release paper application This stage is essential. The sticker kind of paper available at the bottom side of the pad, which makes the pad stick on the underwear, is applied in this stage. In this stage, the complete usable pad is obtained. Stage 6: UV Sterilisation This is the most critical stage after manufacturing the pad. This machine is used to reduce the probability of Microbial contamination and infections. UV sterilization is necessary

COTTON TERMS Several terms are involved in converting cotton into yarn, which might be new to many of them. So, this article will help you to become familiar with unknown cotton-related terms, and the next time when you come across such terms, you won’t feel lost and unacquainted. Cotton Fibre Cotton fiber is a thin cotton hair or strands of cotton which make up the yarn. It is a thread-like structure and is very light in weight. These natural void fibers are also known as absorbent and breathable fibers. Boll A cotton boll is a round protective case or shell-like structure. It is called the fruit of the cotton crop, which holds the cotton seeds and fiber. During harvest time, it is matured and gets opened. Yarn Yarn is a continuous, long, rope-like structure of interlocking fibers of cotton with twists. Yarn is the raw material used in the textile industry for manufacturing fabrics that are used to create a variety of clothes and garments. This yarn is produced from cotton fibers after making it go through many processes. Different types of yarns are based on their material, appearance, application, and sizes.• Spun and Filament Yarns• Single-ply and Multi-ply Yarns• Flat and Textured Yarns• Zero-twist to High twist yarn• Ring and Open-end Yarns• Novelty Yarns• Bouclé Yarn• Slub Yarn• Nub, Knot, or Spot Yarn A yarn’s count, determined by its mass per unit length, determines how thick it is. The standard unit of measurement, known as “Tex,” is the number of grams per kilometre of yarn. Bales Cotton bales are the compressed cotton fiber packed in a bundle of uniform size and weight obtained after ginning. Ginning is the procedure of removing cotton seeds, stems, leaves, and other foreign matter from the cotton directly brought from the farm. The standard bale size in India is 170 Kg. Lint Lint is the term used for the tiny fluffy clean cotton fiber obtained after cleaning the cotton. The ginned cotton is called lint. Laps Laps of cotton are reduced to a flat, uniform layer of cotton fiber after opening and mixing the compressed cotton bales in the blow room of the spinning process. Sliver Sliver is the untwisted loose rope obtained after the process of carding. This sliver is a long, uniform weighted bundle of fiber used to spin yarn. Neps Cotton The knots formed between a group of fibers are called neps. Single neps contain around 15-20 strands of fiber. Roving Roving is similar to yarn; the only difference is that it is not yet spun into yarn. The long thin rope-like fiber before spinning into yarn is the roving fiber. Spinning mills generate this roving. Bobbin A bobbin is a cylindrical hollow tube-like structure around which yarn or thread is rolled. Bobbin is derived from the French word “Bobine,” meaning mini-instrument used in sewing. I hope this article was useful.

INDEX How is Cotton fibre converted into Yarn? Yarn Manufacturing Cotton Journey Steps (Yarn Processing) Hand plucked Ginning Spinning 1. Blow room 2. Carding 3. Draw frame 4. Comber 5. Speed frame/ Roving Ring frame Conclusion How is Cotton fibre converted into Yarn? Let us first understand what is a cotton crop, from where it is originated and which countries and states in India are the biggest producers of cotton Cotton is a Kharif crop, and its origin belongs to India from 3000 B.C. in the Indus River Valley (Present day – Pakistan). The cotton plant has been cultivated widely in over 90 countries for its fiber and seeds. Cotton is an essential commercial crop cultivated in India and constitutes 25% of global cotton production. It plays a magnificent role in maintaining the livelihood of an estimated 6 million cotton farmers in India. Around 45 – 50% of the million people are occupied in related activities such as cotton production, processing, and trade. The other name for cotton is “White-Gold” due to its economic importance in India. As of 2022, the top five countries in the world in cotton production are India, China, the USA, Brazil, and Pakistan. Nearly 22% of the world’s cotton production is produced in India, the third-largest exporter. India also stands 1st in the world in cotton acreage with around 120.70 Lakh Hectares area under cotton cultivation. India’s cotton is grown in two types of places – rain-fed areas and irrigated areas. The majority of the cotton production in India comes from 3 zones: The northern zone, the Central Zone, and the Southern zone, which includes ten states of India. Northern Zone: Punjab, Rajasthan, and Haryana Central Zone: Gujarat, Madhya Pradesh, and Maharashtra Southern Zone: Telangana, Tamil Nādu, Andhra Pradesh, and Karnataka Gujarat and Maharashtra are the top two leaders in producing cotton as the climate of both states is moist and well-suited for the cultivation of crops. Gujarat’s estimated cotton production for 2021-22 is around 92 lakh bales, and Maharashtra’s estimate is around 85 lakh bales released by the CAI (Cotton Association of India), according to the latest crop estimates. Bharuch, Panchmahal, Vadodara, Ahmedabad, Mehsana, and Surendemagar are the major cotton-producing cities in Gujarat. Yarn Manufacturing Now, after knowing the basics of the cotton crop and its producers, we will now tear into the manufacturing process of the same into yarn. A series of processes in yarn manufacturing transforms unprocessed and raw cotton fibers into yarn that may be used in various end products. The clean, robust, and homogeneous threads needed for current textile markets require several techniques, which will be explained in detail below. Cotton is a soft, fluffy, whitish-yellow flower that grows in a shell called a boll. The Cotton seed is sown in the spring from March-May, grown over summer, and plucked in autumn. Before the 18th century, cotton fiber was processed traditionally by hand. The first automated processing machine was invented in the early 18th century in 1794 by American-born inventor Eli Whitney, who revolutionized cotton production by accelerating the removal of seeds from cotton fiber. Gradually, other processes were also invented. Cotton Journey Cotton is generally used in the textile industry, and cotton fabric entails every type of clothing, from shirts to jackets to trousers. Cotton uses are also extensively seen in the Medical field, sanitary pads, diapers, bed sheets, and pillows. Here we will understand how unprocessed cotton is converted into yarn widely used in many end products. Flow chart: From cotton field to final output of Yarn factory Steps (Yarn Processing) Hand Plucked Ginning Spinning – Blow room, Carding, Draw frame, Comber, Speed frame/ Roving Ring Frame Let’s dive into each stage. Hand plucked Cotton is a Kharif crop that requires almost eight months to cultivate. After sowing the seed into the soil takes 50-60 days for a flower to grow. The cotton is produced in a protective case called a boll around the seeds of the cotton plant. When the boll matures, it breaks, and we can find cotton popping out. This cotton is then harvested or hand-plucked and taken to the nearby gins. Ginning Gin is a facility or a type of plant where cotton ginning occurs. Ginning is the process of removing seeds and scrap from the cotton. In modern ginning, the cotton is first dried in dryers to reduce the moisture content and then is passed through a stage where they are cleaned thoroughly to remove unwanted foreign matters such as stems, seeds, debris, and leaves. The ginned cotton is called lint. This lint is converted into cotton blocks called bales and is sent to the spinning process. (Note: The seed separated from the cotton fiber during ginning process is used in making cottonseed oil which is used in many household activities especially cooking.) Spinning Spinning is the process of producing yarn from the cotton extracted. Spinning involves many sub-processes, crucial in forming thread at the output. 1. Blow room The bales from the ginning factory are brought to the blow room. These compressed bales of filers are opened and mixed. In this process of mixing, dirt, dust, seed particles, broken leaves, and foreign impurities are removed. This cleaned cotton fiber is converted into a sheet of definite width and uniform weight per unit length called lap, and the leftover cotton fiber is sent for recycling. This lap is rolled into a cylindrical shape around a lap pin and is sent to the carding process. 2. Carding Carding is the second sub-process of the yarn manufacturing industry in conventional spinning lines. It is called the heart of spinning. The primary function of carding is to resolve any locks and clumps in the fiber received from the blow room. The fibers are made parallel and straight by opening and blending them through the machine, where short fibers are removed in the process, and the long cotton fibers are converted into a rope-like thread called Sliver, which is uniform in weight per unit length. 3.