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Presentation On : Application of IE in garments capacity study and line balancing

Name IDMd. Asaduzzaman Roni 120103028

Rofikul Islam 120103022

Md .Abu Sayeed 120103020

Md .Murad Hossain 120103041

CONTENT Introduction Definition Objectives IE JOB Profile Industrial Engineering Tools Work study Characteristic of work study engineer Capacity sheet Capacity graph Total Time SMV(Standard Minute Value) Best Achieve Before balance and after balance line Result

Project Goals• To improve productivity and efficiency of existing layout and

new layout

• To meet unpredictable demand

• To improve labor and machine (sewing) productivity of this product

What is work-study?

It is a scientific method which ensures measurement of work content of a job & takes recourse to better method of doing it & thus realizes the best utilization of human, machinery & other resources of an organization. In a nutshell this is a science of setting up .Standard time of a job & discovering the best and the easiest way of performing the job.

Objectives

• To establish methods for improving the operations and controlling the production costs.

• To develop programmers for reducing costs.

IE JOB Profile

• Knowledge about various sewing production systems

• Operation break down

• Preparation of OB (Operation bulletin)

• SAM Calculation

• Line Balancing

• Motion analysis of the operations

Industrial Engineering Tools

• Lean Manufacturing

• 5S

• JIT (Just In Time).

Lean Manufacturing 

Lean Manufacturing, also called Lean Production, is a set of tools and methodologies that aims for the continuous elimination of all waste in the production process.

• Cycle Times• Inventory levels• Labor productivity • Utilization of equipment and space• Output

5S

1.Sort-All unneeded tools, parts and supplies are removed from the area

2. Set in Order-A place for everything and everything is in its place

3. Shine-The area is cleaned as the work is performed

4.Standardize-Cleaning and identification methods are consistently applied

5. Sustain-5S is a habit and is continually improved

JIT (Just In Time) 

• JIT philosophy means getting the right quantity of goods at the right place and the right time.

• Produce only the products the customer wants.

• Produce with perfect quality.

• Produce with minimum lead time

Work study

Ensure the highest productivity by the optimum use of man power, equipment and material.

Characteristic of work study engineer

• Sincerity and Honest

• Diplomacy

• Good Appearance

• Self-Confidence

Function of Work Study

• Work Measurement

• General Sewing Data(GSD)

• Breakdown and Layout

• Calculation

• Consumption

Capacity study

In Apparel Manufacturing, “Production capacity” is one of the most important criteria used for vendor selection by the buyers

Before experiment capacity sheet

After experiment capacity sheet

Capacity graph

Front P

art m

ark

Front p

art sc

issorin

g

Slv jo

in with fr

ont part

Bk & fr

ont part

join

Collar sc

issorin

g acc.

to meas

uremen

t

Collar m

ark fo

r join

Pollar jo

in with

Zipper

Collar jo

in with

body

Zipper

side c

ut

Zipper

join one side w

ith body

zipper

join another

side

collar c

olse sid

e psn

Tap att

with

zipper

one side

Tap att

with

zipper

another

side

Excess

tap fo

ld stitch

after

tap att

Coller clo

se

Size lb

l att with

body

Trim &ch

eck aft

er nk t

s

Trim & ch

eck aft

er co

llar ta

ck

Side s

eam

Side b

tm ta

ck

Cuff serve

cing

Trim & ch

eck aft

er btm

piping

trimming a

fter slv

piping

Stitch

open

Trimming a

fter tac

k

Btm re

-stitch

113

214214

455

129

200

129

259

200174

288259

375

169203200

149

500

161

278

139

227193176

238242221217205194

124

190217

166174149

223178

126

200

259

155195

142

231211200

86

209

131

200

147178

99

Chart Title

Line layout

Work often flows from the back of the layout to the front and

from workstation to work station until the garment is completed.

Line layout is most efficient with long runs (high volume of identical products) when the sequence of operations and equipment does not have to be changed frequently .

Cycle time

Total time taken to do all works to complete one operation. Time from pick up part of first piece to next pick up of the next piece.

Cycle times are taken 3 or 5 times for correct time. For Example Required time for collar close is 70, 75,78,65,70.This is the

5 cycle time. Cycle time measured in second.

Total Time

Average time

Different worker do the same work in different time and same worker done the same work in different time. To identify the capacity of a worker need to find out the average time.

SMV(Standard minute Value)

The amount of time required to complete a specific job or operation under existing condition.

Best Achieve

Line Balancing

Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity.

Objective of line balancing

• Regular material flow.

• Maximum uses of man power and machine capacity.

• Minimum process time.

• Minimizing workstation.

• Reduce production cost

Breakdown Process of Basic Shirt

Process breakdown

Upper Placket Rolling

Lower Placket Rolling

Gamble

Tuck and Cut

Sleeve Placket Join

Placket Iron

Pocket Iron

Pocket edge cutting

Back yoke join

Solder join

Sleeve join

Care label attach with body

Collar join Side sessaring

Side seam

Cuff join

Body ,Cuff Button hole

Body , Cuff Button Hole mark

Body , cuff Button attach

Bottom hem

Table: Before balance and after balance line

Before balance and after balance line

Before Balance After BalanceSL Process M/c Achieve Process M/c Achieve1 Slv join with front part

2 229 Slv join with front part

1 129

2 Bk & front part join

1 130 Bk & front part join

1 130

3 Tap join with collar upper side

2 559 Tap join with collar upper side

1 259

4 Zipper tack

1 174 Zipper tack

1 174

5 Pollar join with Zipper

1 375 Pollar join with Zipper

1 375

6 Collar join with body

1 203 Collar join with body

1 203

7 Zipper lower side join with body

1 200 Zipper lower side join with body

1 200

8 Zipper join one side with body

2 161 Zipper join one side with body

2 161

9 zipper join another side

2 239 zipper join another side

1 135

10 collar close

4 162 collar close

3 124

11 Care lbl att with body

1 190 Care lbl att with body

1 190

12 Size lbl att with body

1 217 Size lbl att with body

1 217

13 Neck top stitch 2 166 Neck top stitch 2 166

14 Side seam 3 187 Side seam 2 126

15 Bottom servicing 1 155 Bottom servecing 1 155

116 Btm piping 1 142 Btm piping 1 142

17 Sleeve piping 1 211 Sleeve piping 1 211

18 Sleeve cuff & bottom tack

2 147 Sleeve cuff & bottom tack

2 147

19 Bottom re-stitch 2 178 Bottom re-stitch 2 178

Result

We find out that the main target of our project is to minimize the SMV.

And we can do that, before line balancing the total operator is 80 and line SMV is 52.072 and after balanced total operator is 71 and line SMV is 46.236.

Limitations of Line Balancing 

• Inevitable changes lead to production lines being out of balance.

• Rebalancing causes disruptions to production 

CONCLUSIONCONCLUSION

• Line Balancing brings a new dimension to management philosophy and provides an adopted within a wide variety of organizations and settings; it appears that organizations using line balancing has determined that it can help them achieve a number of management objectives, including continuous improvement. The key outcome of this paper was the reduction in cycle time for single model assembly line, efficiency increases by reducing non value added activities, other outcomes were that assembly line balanced by recommending new layout. This study has identified the most pressing needs. Yet as already noted with sufficient interest, effort, and resources applied to basic production techniques and managerial disciplines, factories have great potential to increase productivity. Improvements in productivity of 20-25 % can be achieved with the right attitude and climate. A systematic program to introduce modern management concepts, including industrial engineering, production engineering, systems and controls is therefore of the highest priority

Thank You