Here is how SILA helped a textile production unit achieve better cleaning outcomes while simultaneously reducing the effort required.
Problem statement
Alok Industries Ltd is a textile manufacturing company, with integration in both streams – cotton as well as the polyester value chain. The company has faced significant challenges within its spinning unit, due to the persistent accumulation of extremely light particles on the factory floor, beneath machines and in the trenches.
Manual cleaning processes proved highly inefficient due to the considerable effort required to gather, collect, and dispose of these particles. This inefficiency not only increased operational costs but also compromised facility hygiene standards.
Solutions
In response to these challenges, SILA Real Estate partnered with Alok Industries in 2022 to implement an innovative solution – mechanized cleaning. The tailored approach included the following key components:
Scooter mop for supervisors: SILA introduced scooter mop machines equipped with high-efficiency cleaning mechanisms for the supervisors. These scooters enabled supervisors to quickly and effectively address localised particle accumulation, reducing the need for manual labor.
Industrial high suction vacuum cleaners: To tackle the issue of particles in the trenches, SILA deployed industrial high suction vacuum cleaners. These specialised machines efficiently extracted particles from the often hard-to-reach trench areas, ensuring a cleaner and safer working environment.
Ride-on scrubber for floors: SILA implemented ride-on scrubber machines for comprehensive floor cleaning. These machines significantly improved the speed and efficiency of floor cleaning, while also enhancing overall facility hygiene.
Results
The introduction of mechanised cleaning at Alok Industries’ spinning unit yielded impressive results:
Manpower reduction: SILA’s innovative approach has led to a 40% reduction in required manpower for cleaning operations. The shift from manual cleaning to mechanised solutions allowed for a more streamlined and efficient workforce.
Cost reduction: Alok Industries has benefitted from an overall cost reduction of 20% in facility management expenses. This reduction was achieved through both manpower savings and enhanced cleaning efficiency.
Increased cleaning frequency: The facility’s cleaning frequency increased by 100%. Instead of cleaning trenches once a week, they were now cleaned every alternate day, requiring significantly fewer resources. Moreover, the entire factory floor, which used to be cleaned twice a day manually, is now maintained 4-6 times a day using machines.
End goals
Reduced costs: By optimizing manpower and enhancing cleaning efficiency, Alok Industries realised a substantial reduction in operational costs, contributing to improved profitability.
Improved facility hygiene: The facility hygiene standards were elevated to new heights. Frequent and thorough cleaning with mechanized equipment ensured a cleaner and safer working environment for employees.
Highest audit scores: Alok Industries consistently achieved the highest audit scores from regulatory authorities and clients. The enhanced facility cleanliness and adherence to hygiene standards played a pivotal role in these accomplishments.
Overall improvement in output: Lesser forced shutdowns due to cleanliness-related issues resulted in improved production output and minimised operational disruptions.