Industrial Engineering In Garment

Manufacturing

By,

Aravin Prince Periyasamy M.Tech (Textiles)

Industrial Engineering In Garment Manufacturing

DEFINITION: Industrial Engineering is concerned with the design,

improvement and installation of integrated systems of people, materials,

equipments and energy.

Most important aspect of Industrial Engineering is PRODUCTIVITY.

PRODUCTIVITY= INPUT

OUTPUT

Input refers to the resources like men, machinery, money and material

used to produce the output.

Output is the quantity of goods and services produced.

Industrial Engineering Techniques In

Apparel Industry

• One major technique of Industrial Engineering followed

in the Apparel Industry is the WORK STUDY.

• Work Study investigates the work done in the most

effective way of using the resources and with the

minimum time as possible.

• The phases of Work Study which are also the

techniques of Industrial Engineering used in the

Apparel Industry are-

1) METHOD STUDY

2) WORK MEASUREMENT

Method Study

• Method Study is the systematic recording and criticalexamination of existing and proposed ways of doing work as ameans of developing and applying easier and more effectivemethods and reducing costs.

OBJECTIVES OF METHOD STUDY:

• To eliminate wastage of time and labour.

• To reduce fatigue and boredom of work by avoidingunnecessary movements.

• To find the best way of doing a job.

• To have more effective utilisation of resources.• To improve the design of work place layout.

• To train the worker in its practice as per the standard.

Procedure Of Method Study

• SELECT - Selection of the job or process to be studied.

• RECORD - Recording from direct observation everything thathappens using the most suitable methods like process charts,diagrams, models, motion and film analysis, etc.

• EXAMINE - Examination of the recorded facts critically.

• DEVELOP - Development of the most economic method.

• MEASURE - Measurement of the quantity of work andcalculate the standard time.

• DEFINE - Definition of the new method and the related time.

• INSTALL - Installation of the new method as the newstandard practice.

• MAINTAIN - Maintenance of the new standard practice byproper control procedures.

Method Study• Method study is the first part of work study.

• It is the methodology of determining the best way to carry out anyjob. It is not achieved by merely studying what has happened in thepast but also by examining how existing methods may be improvedand devise new methods.

• The investigation can be done through the following techniques ofmethod study.

• Flow charts – symbols

• Flow-process chart – comparison of the proposed method with thepresent one with time and operation sequence using symbols

• Multiple Activity Chart – two or more activities

• String Diagram – Workplace represented with a pin, movement ofworker represented using a thread or string of cotton.

• Two handed process chart – Both the hand movements recordedsimultaneously with respect to time.

There are a few other techniques also like simo chart, micromotionstudy, therbligs,etc

Purpose Of Method Study

• To determine the optimum working method.

• To standardize the work.

• To train the workers.

• To manage the work.

• LEVELS OF ANALYSIS OF METHOD STUDY

• WORK PROCESS LEVEL – Eg: Sew the front tuck.

• WORK COMPONENT LEVEL – Eg: Take the garment body,

fold the tuck,allign the needle entry point, reverse stitch.

• MOTION COMPONENT LEVEL – Eg: Extend the hand to

the garment, grasp the garment body, bring the garment

body to the table, place the garment body on the table.

Work Measurement• Work Measurement is the application of

techniques designed to establish the time fora qualified worker to carry out a specified jobat a defined level of performance.

• OBJECTIVES OF WORK MEASUREMENT:

1) Raise the production efficiency with littleadditional cost.

2) Work improvement through worksimplification.

3) Setting up of standards of performance.

4) Indication if material control andmaintenance are not functioning properly.

Procedure Of Work Study• SELECT - Selection of the work to be studied.

• RECORD - Recording the relevant data relating to thecircumstances in which the work is being done and also themethods and elements of activity in them.

• EXAMINE - Examination of the recorded data and the detailedbreakdown critically to ensure that the most effective method andmotions are being used.

• MEASURE - Measurement of the quantity of the work involvedin each element in terms of time.

• COMPILE - Compilation of the standard time for operation.

• DEFINE - Definition of the series of activities and method ofoperation for which the time has been compiled.

Time Study• Time Study is the art of observing and

recording the time required to do each detailedelement of an industrial operation.

• A Time Study consists of the following:-

1) Dividing a certain item into minute workcomponents.

2) Recording the time required to finish the workusing the appropriate time measuring device.

3) Specifying the standard time and making workimprovements based on the results obtained.

Establishing Standard Time

Select,record,examine and measure quantity of work performed using the technique

WORK SAMPLING

STOP WATCH TIME STUDY

PREDETEMINED TIME STANDARS

Compile with allowance to get standard time of operations

Compile to get standard time of operations

Techniques Of Establishing Standard Time

• WORK SAMPLING: It is the method of finding thepercentage occurrence of a certain activity bystatistical sampling and random observations.

• STOP WATCH TIME STUDY: It is the method ofrecording the times and rates of working for theelements of a specified job carried out under specificconditions and for analysing the data.

• PREDETERMINED TIME STANDARDS: They arethe advanced techniques which aim at defined thetime needed for the performance of variousoperations by derivation from pre-set time standardsfor various motions.

Plant Layout• Plant layout is defined as a technique of locating different machines and

plant services within the factory so that the greatest possible output ofhigh quality at lowest possible total cost can be available.

MAIN OBJECTIVES OF A PLANT LAYOUT:

1) Maximum utilisation of the floor space.

2) Lighting and ventilation of areas.

3) Fewer accidents

4) Minimizing production delays

5) Space for future expansion.

DIFFERENT TYPES OF LAYOUT

• Line or Product Layout – operational sequence.

• Functional or Process Layout – assembling of similar operations

• Fixed or Position Layout – product materials are too heavy to movearound;tools carried(eg.aircrafts)‏

• Combination Layout – products manufactured and assembled.

Production Systems• A production system is defined as a framework of activities within

which the creation of value can occur.It can be of two types for aproduct:-

Continuous System – item being processed is not storedproperly.(e.g..lap transferred through the chute system)‏

Intermittent System – item being processed is stored temporarily instorage areas.(e.g..lap transferred through trolleys)‏

CLASSIFICATION OF PRODUCTION SYSTEMS

Whole Garment Production System

Complete Whole Garment Production System

Departmental Whole Garment Production System

Section Production System

Sub Assembly Line System

(i) Unit Flow System

(ii) Multiple Flow system

Progressive Bundle System

(i) Garment Bundle

(ii) Job Bundle

Types Of Production Systems

• Complete Whole Garment Production System – entiregarment from cutting to final completion;expensive;production islow.

• Departmental Whole Garment Production System – workdone with respect to the various departments;all component partsmove together from department to department;production is high.

• Sub Assembly Line System – two or more operations made onthe same garment;two or more assembly lines merge.

• Unit Flow System – each garment part moves to the nextworkstation after the work is completed.

• Multiple Flow System – two or more of the same parts beingprocessed move to the next workstation at the same time in agroup or bundle.

• Garment Bundle – bundle contains all parts of a garment carriedby conveyors between workstations.

• Job Bundle – bundle contains pieces on which two or moreoperations may be performed.

Line Balancing• Line balancing is defined as distributing tasks evenly over the

workstations so that the idle time of men and machine is reduced.

• It aims at grouping the tasks and workers in an efficient pattern I order to obtain the optimum or most promising balance and also flow of production.

METHODS OF LINE BALANCING

Largest Candidate Rule Method – Work elements listed along with the time taken in the order they are done;listed in descending order of the time taken;workstations assigned by summing up the time taken and keepin in mind not to exceed cycle time.

Kilbridge and Webster’s Method – Work elements listed and divided into columns with the respective time taken;assign workstations summing up the time taken and not exceed cycle time.

Ranked Positional Weights – rank positional weight for each element is calculated;elements listed with the largest RPW value at the top;assign workstations not exceeding cycle time.

Ergonomics• Ergonomics Is Defined As The Scientific Study Of The

Relationship Between Man And His Working Environment.It IsThe Combined Activity To Solve Problems At The Interface OfPeople And Machine.Such A Combined Integration Goes ALong Way To Evaluate The Effects Of Interactory Factors On“Productivity”.

• Main Functions Analysed By Ergonomists Are- Body Motion,Fatigue, Accommodation To Fit,stress,comfort And Force.

Objectives Of Ergonomics:

1) Optimise The Integration Of Men And Machine In Order ToIncrease Work Rate And Accuracy.

2) To Provide The Worker With A Workplace Befitting The NeedsAnd Requirements.

3) Equipment,machinery And Controls Should Be Such ThatMinimal Mental And Physical Strain Is Given To The WorkerThereby Increasing Efficiency.

4) A Conductive Environment For Executing The Task Effectively.

Material Handling• Material Handling is concerned with moving the right quantity of materials-raw

materials,machinery spares,work-in-progress and finished goods at the right timein a given space.

• The movement of materials can be vertical;horizontal;in batches or in a single unit.

• Material handling increases only the cost of the product and not the value of theitem.

• Material Handling Equipments are of 2 types-Fixed Path equipments(e.g..Conveyors) and Variable Path Equipments(e.g..Forklifts)‏

• PRINCIPLES OF MATERIAL HANDLING

1) Minimise the movements involved in production operation.

2) Moving optimum number of pieces in one unit.

3) Minimise the distances moved by adopting the shortest routes.

4) Employ mechanical aids in place of manual labour in order to speed up thematerial movements.

5) Utilise gravity for assisting material movements.

6) Safe,standard and efficient material handling equipment must be chosen.

7) Material handling equipments must be resorted to periodic check ups,repairs andmaintenance.

Result Of Using The Industrial

Engineering Techniques

WORK STUDY

METHOD STUDY WORK MEASURMENT TIME STUDY

HIGHER PRODUCTIVITY