Thesis Details

Thesis Title: A methodology to measure the cost of complexity in a weaving plant
Thesis Author: Michael Batson
Abstract: Complexity is a relatively new phenomenon for many textile plants that are experiencing greater product mix variety and change. Any operating condition of manufacturing, especially if unfamiliar or unmeasured, is difficult if not impossible to manage. As the American textile industry looses market share in commodity fabrics to lower cost imports, textile plants are increasingly challenged to reposition or expand their product mix into more profitable areas. This increased product mix diversification across the plant has led to higher manufacturing cost due to an irregular increase in the consumption of resources such as labor and supplies. This research determined the resource consumption patterns within a weaving plant based upon different theoretical levels of manufacturing complexity. Resource consumption was then tied to expected productivity in terms of cost per 100,000 yards of filling inserted. Manufacturing complexity was defined in terms of the number of different weave styles produced within the plant coupled with the amount of style change incurred over a fixed time interval.