In 2012, SILA was asked to propose a solution to maintain a few of Alok Industries’ manufacturing units in Silvassa. Focus was to implement an efficient solution and upgrade the maintenance levels at their factories. After SILA’s success case at Alok Industries, we have grown to service other companies in the Textile Industry across Gujarat, Maharashtra & Karnataka – Bhilosa Industries, The Creative Group, Sanathan Textiles, Color Lines to name a few.
Based on our learnings & experience, we have listed the five most important points to keep in mind when maintaining Textile Factories.
1. Use the Right Machines, Equipment, Chemicals
Most textile facilities that we come across use local detergents such as phenyl, washing powders, household brooms to clean their Factories. Times have changed drastically. Using high grade chemicals with the technology & machines has allowed us to make the maintenance process more efficient, reducing the dependence on Labor.
2. Tailored Processes
After experimenting with different processes, maintenance techniques, chemicals & equipment, we arrived at a set of best-practices that are required to maintain Textile plants. For example, our processes for Cotton units are very different than Polyester Manufacturing Units. It is imperative to implement an efficient cleaning & maintenance process.
3. Educating the Labor that is Working at the Plant
It is important to hold training & awareness sessions for the labor working at the plants. For example, awareness about hygiene & spitting (paan/guthka) is very important. We have been successful in implementing techniques similar to the ones we implement in Pharmaceutical plants – creating spitting zones, installing spittoons, awareness training about hygiene levels, incentives for labour at the cleanest plant/shed in the complex etc.
4. Mindset of the Plant Managers – ‘do more with less people’
It is important that the plant in-charge has an open mindset. We have noticed that some engineers are more concerned with physically seeing people cleaning more vs assessing how clean the area is. It is important for the senior management at companies to drive the need for mechanization over manual work.
5. Be Statutory Compliant & Audit the Contractor
Some textile factories that we have come across use innovative ways to ‘beat’ the system. The myth is that it is the cleaning or maintenance contractor’s responsibility to pay his staff & statutory compliances. However, we have come across many cases where the maintenance staff working at the plants have not being given their dues. This severely hampers output & demotivates staff to follow basic processes.
Keeping in mind these five ways while maintaining a textile factory will help you improve the efficiency and maintenance standards of the factory.