improve the productivity with help of industrial engineering...

International Journal on Textile Engineering and Processes, ISSN: 2395-3578 Vol 1, Issue 4,

October 2015

Copyright@CTF- MPSTME Page 35

Improve the Productivity with help of Industrial Engineering Techniques Pranjali Chandurkar, Madhuri Kakde, Abhishek Bhadane

Centre for Textile Functions,

MPSTME, SVKM’S NMIMS, Shirpur -425405, Dist. Dhule, Maharashtra, India.

[email protected]

Abstract:

The scope of “To improve productivity with help of industrial engineering in Garment Manufacturing”

designs the improvement and install work system (integrated system of men, machine &material) have

broadened & encompass all the activities in factories, irrespective of propose or size of the organization. To

improve all work process to meet the demands of changing environment.

Keywords: work study, time study, man, material, method

1. Introduction

In this project trials were conducted for increasing productivity in garment manufacturing while lowering costs is

to make sure that you are giving the best achievement for any company.

This project is key to apparel industry to improve their work nature & the methods, the apparel industries is

identify as buyer driven or costumer driven industry, so the apparel production has become more intensified by

global competition. To survive in this comparative world the industry should work more efficient. The concept

which are outlined here are the most important factors to improve the productivity & efficiency of the industry

the application of industrial engineering methods like method engineering, work study, capacity study, line plan

& other operation management system are ultimately lead the industry to timely delivery of goods, high profit &

develop the working environment as a happy place.

II. Literature Review

Industrial Engineering

Industrial Engineering concerned with the design, improvement & installation of integrated system of man,

machine & equipment’s drawing upon specialized knowledge & skill in the technical, economics & human

science, either with the principles or methods of engineering analysis & design to specify predict & valuate the

result be obtained such system.

Responsibilities of Industrial Engineers

1) Capacity study

2) Work study

3) Time study

4) Operator performance

5) Follow-ups

6) Work in Progress (W.I.P)

7) Line balancing

1) Work study

Work study is the analysis of the operation required to produce a style. Effective work study requires both

method analysis & work measurement. Method is studied, analyzed, & the elements of the method measured in

terms of time consumed. Data are collected, analyzed & used to support decisions on rates and methods. Work

study is also important to ergonomic decisions, job design and work station development. Decisions must be

based on extensive study & documentation that is developed with work measurement procedures. Unsubstantial

opinions are not sufficient justification for change.

Definition: “work study is a generic term for those techniques, method study and work measurement which are

use in the examination of human work in its entire context. And which laid systematically to the investigation of

all the factors which affect the efficiency and economy of the situation being reviewed, in order to effect

improvement.”

Objectives of work study

1. Improvement of process and procedures.

2. Improvement in design of plant equipment.

3. Improvement of plant layout.

4. Improvement in the use of man, materials & machines.

5. Efficient material handling.

6. Improvement in the flow of production & process.

7. Economy in human effort & the reduction of unnecessary fatigue.

8. Method standardization.

9. Improvement in safety standards.

10. Development of a better physical working environment.

Procedure for work study

1. Select the work to be studied.

2. Record all the relevant facts about the present method by direct observation.

3. Examine those facts criticality and in an ordered sequence, using the techniques best suited to the

purpose.


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Work study

Method study (the search for best

method)

Record to compare Seek best method

Work measurement (how long should a job

take)

Time study Synthetics

4. Develop the most practical, economic and effective method, having due regard to all contingent

circumstance.

5. Define the new method so that it can always be identified.

6. Install the methods as standard practice.

7. Maintain that standard practice by regular routine checks.

These are the above seven essential stages in the application of method study; none can be excluded. Strict

adherence to their sequence, as well as to their content, is essential for the success of an investigation.

Work study can be best expressed in the following manner:

Figure-1: work study

Method study

Method study is the systematic recording & critical examination of existing & proposed way of doing work as a

means of developing & applying easier & more reducing cost.

The procedure which need to do follow while doing method study are given as follows there are seven steps to

be followed by industrial engineer to do method study they are:

1. Select the work to be studied.

2. Define the objectives.

3. Record the relevant information & data.

4. Examine information & data.

5. Develop the improved method.

6. Install improved method.

7. Maintain improve method.

8. Work measurement.

Work Measurement

It is used to determine:

Time required to complete one element of operation or

Amount of work that can be performed by one operator in a specific segment of time.

Work measurement techniques are:

1. Time study

2. Judgment or past experience of the engineer / production manager

3. Pre-determined time systems

4. Standard data

5. Operator reporting

6. Work sampling

Factors affecting working conditions:

The set of elements constituting the working conditions vector preliminarily consist of the following:

1. Occupational safety &health elements

2. Fire prevention & protection elements

3. Layout & housekeeping elements

4. Lighting 7 ventilation elements

5. Noise & vibration elements

6. Ergonomics elements

7. Arrangement of working time

2) Line balancing

Line balancing is the leveling the work load across all process in a cell or value stream to remove bottle necks &

excess capacity. A constraint slows the process down & results in waiting & absorption of fixed cost.

Objectives of line balancing:

1. Match the production rate after all wastages have been removed to the talk time at each

2. Process of the value stream.

3. Regular material flow.

4. Minimum usage of man power & machine capacity.


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Copyright@CTF- MPSTME 7

5. Minimum process time.

6. Minimizing stock section.

7. Minimizing the work station.

8. Minimum output at the desired time.

9. Quality maintenance of the garment.

10. Reduced the production cost.

Importance of line balancing:

1. Line balancing is help to know about new machine required for new style.

2. It becomes possible to deliver goods at right time at he agreed quality for list cost.

3. Good line balancing increase the rate of production.

4. Line balancing helps to compare the required machinery with the existing one compare balance.

5. It also helps in the determination of labor requirement.

6. Good balancing reduced production time.

7. Proper line balancing ensured optimum production at the agreed quality.

8. It reduces faults in the finished product.

Limitations of line balancing

Production lines where designed so that conveyor belts paced the speed of the employees work. This

arrangement wasn’t appreciate by the employees. Inevitable changes lead to production lines being out

of balance.

Rebalancing causes description to production.

III] Material and Method

Material

Table No.1 Style Description

Method

The initial observation is done by observing sewing line no7 directly. In this direct observation, it is found that

the line efficiency and output are having red color in the performance board which means poor. In order to review

how poor the efficiency of this line, a data of sewing efficiency of 10 days are collected.

First one I collected the time study of whole line. From that time study I have get the result which indicates the

hard operation or more time consuming operation. I give this operation to other operator & compare the results &

that result was significant. It means the problem has not been solved. At this point, I started to identify the actual

problem. The objective of this research was also stated in this point.

In order to solve the problem, literature study must be conducted prior to data collection and calculation. The

study was focused about time study and line balancing. Since the proposed line has not been applied, it has to be

evaluated by doing simulation.

According to literature study that has been done, there was some data that must be gathered;

(1) Kaizen Data,

(2) Operation process chart,

(3) Sewing method,

(4) Cell balancing sheet,

(5) work allowance,

(6) Minimum regional salary and overtime wage.

Style Description

Style No MD summer checks PJ (T- Shirt).

Buyer Cortefiel

Product T-Shirt

Brand WS

PO No. 32241414

SO No. 3022042458

Color Navy solid

Target 640

Fabric specification

Fabric single jersey knitted fabric

GSM 160

Yarn specifications

Count 60s

Ply of yarn 3 ply yarn.


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Besides that, there was several data that must be observed; cycle time for each operation and performance of

operators. Then, those data were tabulated and calculated. Less accuracy of standard time and poor work

arrangement were proven as the root cause of having low line efficiency.

Then, redesigning the work arrangement through line balancing had to be done. Some methods can be used to do

line balancing but only the method which results to the best work arrangement was chosen to be the proposed line.

The evaluation of proposed line was compared to the actual line. Thus the improvements in this research could be

measured. Last, the conclusion and recommendation are delivered. Conclusion is affirm whether the result of

analysis and development achieve the objectives or not. After having the conclusion, some recommendations for

company are stated.

Figure-2: Sleeve

IV] Results & Discussion In following chart shows study about the time required for each and every operation. From this study we also able

to calculate the targets per hour and per shift. This table used for identifies the hard operations (more time

consuming operation) & line balancing. Here yellow line is indicates the same operations in the line.

Table-2: Table of Time Study


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1) Standard operating procedure (SOP): This format is use for compare the operating procedure of

operator to standard operating system. This format is helpful to identify unnecessary movement of

operator and minimize that movement from operation. In this study ‘stitching’ movement is come about

9 times and that is more than required. So, we have to minimize this movement of operator that we found

here.

Table-3: Table of standard operating procedure for sleeve attach (Before)

Table-4: Table of standard operating procedure for sleeve attach (After)


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Figure 3 - Result of standard operating procedure.

This fig.3 shows that operation time reduced up to 22.91 seconds. That can be done because of only minimizing

the stoppages between the stitching operations. Before the change in operator’s procedure, he required 86.4

seconds for sleeve attach. But when I minimize his stoppages during sewing movement then he requires 63.49

seconds by proper a lining with less stoppage during sewing operation.

2) Two handed process flow chart of operation In this chart we know about each & every movement of the operator with his hand movement. This chart is

helps to compare number of movements in two operations or same operation. From that comparison we are

minimize the difference between this two operations.

In this case before changes in movement of operator he does the 14 movement. But after changes in the

movement that goes on 9.

Table- 6: Table of sleeve attach operation before any changes in operation

Table- 4: Table of sleeve attach operation after changes in operation

0

10

20

30

40

50

60

70

80

90

100

Before After

Tim

e in

Se

con

ds

Operation Sleeve Attach

Results of standardoperating system


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Figure 5: Result of two handed process flow chart of operation

Above in figure-4, comparison of the number of movements of operator before changes and after change in

operation before the changes that required 14 moves but when I minimize the stoppages in stitching movement

then he requires only 9 moves to complete his work.

VI] Conclusion This concept of Industrial Engineering is a key to apparel industry to improve their work nature and the

methods. The apparel industry is identified as a buyer-driven or customer driven industry, so the apparel

production has become more intensified by global competition. To survive in this competitive world the

industry should work more efficient. The concepts which are outlined here are the most important factors to

improve the productivity and efficiency of the industry. The application of industrial engineering method like

method engineering, work study, capacity study, line plan and other operations management systems are

ultimately leads the industry to timely delivery of goods, high profit and develop the working environment as a

happy place. In this project we reduced operation time by 22.91 seconds and increase operation efficiency.

VII] Acknowledgement

I wish to give my sincere gratitude to Alok Industries Limited plant situated at Silvasa( Garment Unit) for giving

me a golden opportunity for this research work, The undersigned is thankful to Centre for Textile Functions,

MPSTME, Shirpur, for their invaluable guidance and support throughout the project

VIII] References

1. Industrial engineering and engineering management in Australia by Professor John W H Price PhD,

FIEAust Mechanical Engineering Department, Monash University, Australia. Mst. Murshida Khatun.

2. Industrial-engineering- lecture-02 ppt,

3. Zeleny, M.: The Innovation Factory: On the Relationship between Management Systems, Knowledge

Management and Production of Innovations. Innovations 2005, Zilina 2005.

4. Guidelines for Industrial Engineering, KSA Technopak.

5. Method of analyzing the actual status 4-Time Study Chapter two (page E-1, E-10) and Chapter three

Production Design

6. http://www.lcmibd.com/industrialengineering.html.

7. http://wiki.answers.com/Q/Industrial_engineering_work_study_in_garments.

8. http://www.onlineclothingstudy.com/2012/09/-how-to-calculate-efficiency-of.html.

9. Dr. KC. Jain, Production planning, control & Industrial management.

0

2

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14

16

Before After

No.

of

Movem

en

t

Operation Sleeve Attach

Results of twohanded processflow chart ofoperation

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