A Novel Approach for Optimum Planning of Bobbin Boilers in Textile Industry

Abstract

As in all sectors, fierce competition across the world deeply affects the textile industry. With the addition of new players to the market day by day, the competition is getting more and more intense. In today's world, where the price is determined by the customer, not by the manufacturer, it is an inevitable necessity for companies to reduce their costs in order to survive by maintaining their profitability. This only depends on the efficient use of resources. In this article, a productivity study has been carried out for the bobbin (package) dyeing process, which is one of the important elements of the textile industry. In this study, which was carried out practically in Bursalı Tekstil LTD. ŞTİ, the problem of sequencing the batches waiting to be dyed in dye boilers is discussed. It is necessary to wash the boilers between batches of different colors that are dyed consecutively within certain constraints. In addition, the due dates of these yarn batches must be respected. With the solution methods presented, it is aimed to sequence the batches in a way that requires the least washing and minimizes the total tardiness. Developed integer linear model and iterative greedy based heuristics were first tested with randomly generated test problems. In addition, it has been tested with six months of actual data of the bobbin dyeing department of the relevant company. According to the manual sorting, 17% improvement has been achieved in terms of the number of boiler washes and 13% in terms of total tardiness.