Need BOM related solution for Textile Industry (Weaving proces)

Question

HIi,
Made to Order Strategy:
Every times customer sends the specification of product. Specification format as given below:
Ex. 80x100/154x80*3-118u201D 4/1 Twill
Details of specifications:
     80: Count of EPI (Ends Per Inch)
     100: Count of PPI (Picks Per Inch)
     154: EPI
     80: PPI
     3: Insertation
     118u201D u2013 Width in Inch
     4/1 Twill : Design of Fabric
Operations Details:
1 Warping
2. Sizing
3. Weaving
4. Quality Inspection
5. Packing
As Is Business Process:
There are mainly four production lines viz. Warping, Sizing, Weaving and Quality Inspection. For all the production lines the individual machine work centers will be as listed below with brief description:
1.     Sectional Warping:
A kind of Warping specially used to prepare fabrics for shirting. In sectional warping dyed yarns are used to prepare warping beam. The end constraint of sectional warping is 720 ends at a time. The actual capacity of Sectional warping is 800 MTR/min.  This activity is job work for DEESAN group.
2.     Direct warping:
Direct warping process is used to prepare warping beam. The end constraint of warping is 1088 ends per beam. Machine width of the beam in 2200 mm, speed of warping varying from 300 MTR to 1200 MTR per minute depending upon the construction required. It has backup procedure for next round. Uploading speed   for single yarn is 8 yarn / min / person.
3.      Sizing:
Sizing process is used to prepare specific number of EPI/ beam as per the requirement of construction. A calculated no of warp beam used to prepare a single sizing beam. Speed of sizing 45 to 55 MTR / minute depending on the requirement of fabric.     
4.     Preparation of Drawing:
This process is used to preparation of new drawing for the loom machine. Drawing includes frame & reed. It will take 12 hr for 2 persons to prepare a single drawing i.e. 8000 ends per shift. This activity given as job work to some group of people.      
5.     Weaving:
Two types of weaving machines used are CAM and DOBBY. Fabric to fabric PPI is varying, the capacity of loom machine depends upon the PPI so the capacity of loom machines varying with the type of fabric. CAM is used specially for plain fabrics.
6.     Quality Inspection:
The beams of fabrics coming from looming machine are inspected on Inspection machine. 100% fabrics are inspected on QA machine for further grading, which is then bifurcated in Export, Local and chindi type.
7.     Rolling:
Rolling machine is used for rolling of inspected fabric on card board rolls according to the quality of fabric. A roll contain of maximum 350 MTR of fabric. Which are then packed with LDPE followed by HDPE with appropriate coding on rolls.
Material Requirement:
For ex. 80x100/154x90*3-118u201D 4/1 Twill
Order Qty.: 20000 M
Currently they are using single level BOM.
Formulas for calculate raw material requirements as given below:
Warp wt / mtr = (EPIWidthCrimp) /(1693*Count of EPI)
          = (154 * 118 * 1.025)/(1693 * 80)
          = 0.137524
          = 0.138 Kg/Mtr
Weft wt / mtr  = (PPIInsertationWidth * Crimp) /(1693*Count of PPI)
          = (9031181.025)/(1693100)
          = 0.192891
          = 0.193 Kg/Mtr
Total Qty req:
Warp = 0.138 * 20000 + add 5% loss
     = 2898 KG
Weft = 0.193 * 20000 + add 4% loss
     = 4014 KG
Packaging material requirement :
1. Paper tube = Total order qty / approximately for 300 m 1 paper tube required + 5% loss
          = 20000 / 300 *1.05
          = 70
2. HDPE sheet = No. of paper tube * 0.4 KG
      = 70 * 0.4
     = 28 KG
3. LDPE sheet = No. of paper tubes * 0.15 KG
          = 70 * 0.15
          = 10.5 KG
Chemical consumption in terms of yarn on KG basis. Its combination of 4-6 chemicals depends on construction to construction also material availability.
Note: We will consume chemicals against cost center.
Production planning at execution time:
Sizing and warping calculation:
1.     Sizing :
EPI per inch = 154
On loom will be = 154 * 1.025
           = 157.85
Total no of ends for 118u201D width = 157.85 * 118
                    = 18626
Add one more ends per 1000 ends = 18626 / 1000
                    = 19 ends
Total no of ends  = 18626 + 19
          = 18645 for  sizing
Warping :
Warping m/c capacity of output is 1088 Ends per set/beam.
Speed of machine 300-1200 MPM.
So for sizing we need 18645 ends. Now we want to calculate no warp set required for sizing & no. of ends per warp set.
Ends required per set = 18645 / 18 = 1036
     i.e. 18 * 1036 = 1 Sizing set
We need total yarn on KG basis
Issue related to BOM:
1.     How We can feet below 2 issues in BOM
a.     we want to calculate RM(Yarn) material requirement in Unit of  u201CENDu201D
NOTE: Procurement of Raw material Unit- KG as well as it depends no. of ends required for warp set / beam. i.e. its multiple of yarn cone required for 1 warp set.
As per Bom of Raw Martial Unit- Ends (EA)
b.     Also we want to calculate no of warp set required for sizing and no of ends required for warping process.

Answer 1

Hi Pankaj,
Hope you might have completed the project for Textile industry. I need to know implementation in Textile and some specific process. If you can share some documentation for Textile industry would be very helpful for me. My id k.anamika06 at gmail
Thanks a lot
Anamika