1. PRESENTED BY:
MD. SHAIF UDDIN
DEPARTMENT OF LEATHER
PRODUCTS ENGINEERING
EXAM ROLL: 118
REGISTRATION NO:3466
ILET,DU
2. TITLE OF MY PROJECT
WORK
STUDIES ON THE IMPROVEMENT
OF PRODUCTIVITY THROUGH
REDUCTION OF WORK CONTENT
IN CLOSING DEPARTMENT
3. AIMS OF THE PROJECT
•Reducing work content.
•Productivity Improvement.
• Better utilization of manpower, material,
plant and equipment.
•Improved working method.
•Reducing ineffective time.
•Increasing efficiency.
5. 1. Cutting all leather, lining & reinforcement materials
2. Splitting
3. Skiving
4. Inspection & Numbering
5. Marking
6. Edge coloring & Buffing
7. Zipper Cutting
8. Stamping/ Embossing
9. Gluing on leather, PVC, Rabose & EVA attaching on
leather
10. Two pieces of front & back part leather stitching face to
face with single and double needle flat bed sewing
machine & hammering and threads trimming.
Flow Diagram of Sequential Operations
6. 11. Foam attaching to front & back part leather by
applying adhesive
12. Folding top edge of front part
13. Folding the top edge of back part keeping two sides
raw edge
14. Attaching #5 no. metal zipper with runner on top
edge of back part by applying adhesive
15. Attaching one edge of back zipper pocket lining on
lower edge of zipper with folded top edge of back part
by applying adhesive
16. Stitching top edge of back part with zipper and one
edge of back zipper pocket lining & thread trimming
17. Folding two sides of back top Patti & hammering
18. Attaching back top Patti with zipper and raw edge
of back part by applying adhesive
19. Attaching another edge of back zipper pocket lining
on top edge of zipper with folded back top Patti by
applying adhesive
7. 20. Stitching back top Patti with zipper , raw edge of
back part and another edge of zipper pocket lining &
thread trimming
21. Stitching two opened edge of back zipper pocket
lining & thread trimming
22. Attaching EVA with two gusset
23. Folding top edge of two gusset & hammering
24. Gluing on two parts of ring loop and attaching with
hammering
25. Stitching ring loop with square ring at marking
position on gusset & threads trimming
26. Belt folding 6mm from edge with glue
27. Attaching both part of belt & hammering
28. Belt stitching 2.5 mm from edge & threads trimming
29. Attaching rabose with bottom
8. 30. Folding two edge of bottom & hammering
31. Attaching two gusset with bottom by applying
adhesive
32. Stitching two gusset with bottom & thread trimming
33. Stitching front & back part with stitched gusset and
bottom part & thread trimming
34. Square ring, belt loop & buckle fitting with belt
35. Stitching belt with gusset of bag & threads trimming
36. Attaching foam with flap upper by applying
adhesive
37. Attaching PVC on the attached foam of flap upper by
applying adhesive
38. Folding the round of flap upper & hammering
39. Attaching EVA sheet with two counter flap side
strap
40. Folding two counter flap side strap & hammering
9. 41. Attaching two counter flap side strap with counter
flap by applying adhesive
42. Stitching two counter flap side strap with counter
flap & thread trimming
43. Attaching EVA with counter flap bottom strap
44. Folding counter flap bottom strap & hammering
45. Attaching counter flap bottom strap with counter
flap by applying adhesive
46. Stitching counter flap bottom strap with counter flap
& thread trimming
47. Attaching flap upper & counter flap by applying
adhesive
48. Stitching flap upper & counter flap with double
needle sewing machine & thread trimming
49. Fixing top part of magnet on the flap
50. Stitching flap with back top Patti by double needle
sewing machine & thread trimming
10. 51. Fixing bottom part of magnet on front part of bag
52. Preparation of Handy pocket
53. Stitching Handy pocket with front part inner lining
& threads trimming
60. Double face adhesive tape applying on the edge of
inner lining & folding
59. Stitching two inner gusset lining with front and back
part inner lining & threads trimming
58. Stitching two sides of inner zipper pocket lining &
threads trimming
57. Stitching inner zipper pocket lining with 3 No. nylon
zipper & threads trimming
56. Attaching inner zipper pocket lining with 3 No.
nylon zipper
55. Attaching #3 no. nylon zipper with runner & puller
at folded zipper portion of back part inner lining
54. Folding four edges of zipper cut portion of back part
inner lining
11. 64. Puller edge stitching 2.5mm around & threads
trimming
63. Puller edge folding with glue
62. Inner lining stitching with body 2.5mm top edge &
threads trimming
61. Edge of folded inner lining attached with the edge of
bag body
65. Puller setting with zipper runner by fitting o-ring of
metal zipper
66. Final stitch inspection
67. Cleaning and dressing
68. Stuffing
69. Inserting Bur code, Internet level, Price tag & safety
label
70. Final checking and finishing
71. Packing of Bag
12. Work content
Work content means the amount of work "Contained in" a given product or process
measured in man-hour or machine hour. The basic work content is the time the
product would take to manufacture on the operation to perform, if the design or
specification was perfect, if the process of method of manufacture or operation was
perfectly carried out, and if there was no loss of working time from any cause
whatever during the period of the operation.
The basic work content is the irreducible minimum time theoretically required to
produce one unit of output.
Total Work Content = Basic Work Content + Added Work Content
13. PRODUCTIVITY
A general definition of productivity is
the relationship between the output
generated by production and the input
provided to create this output.
Out put
Productivity = -----------------
In put
14. From the definition of productivity, it is
apparent that a higher total productivity may
result, if-
• More output is produced with the same on lesser input.
• The Same output is produced with lesser input, and
• More output is produced with more input; the
proportional increase in output being more that the increase in
input.
17. Work Measurement technique
Time study.
Synthesis.
Predetermined Motion Time System (PMTS).
Analytical Estimate.
Work Sampling.
18. Basic Time Study Equipment
Stopwatch
A study board
Time study form
Small calculator
Measuring instruments such as a measuring
tape, steel rule, spring balance etc.
19. Critical Examination:
(Basic Analysis)
Every activity should be subjected to the following
question asked one after the other in their proper
sequence. The answers of these questions wilt from the
basis for the development of the improved method:
1.Purpose?
2. Place?
3. Sequence?
4.Person?
5.Method?
20. 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Cutting all leather, lining & reinforcement materials
Splitting
Skiving
Inspection & Numbering
Marking
Edge coloring & Buffing
Zipper Cutting
Stamping/ Embossing
Gluing on leather, PVC, Rabose & EVA attaching on leather
Two pieces of front & back part leather stitching face to face with single and double needle flat bed sewing machine & hammering and threads trimming.
Foam attaching to front & back part leather by applying adhesive
Folding top edge of front part
Folding the top edge of back part keeping two sides raw edge
Attaching #5 no. metal zipper with runner on top edge of back part by applying adhesive
Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top edge of back part by applying adhesive
Stitching top edge of back part with zipper and one edge of back zipper pocket lining & thread trimming
Folding two sides of back top Patti & hammering
Attaching back top Patti with zipper and raw edge of back part by applying adhesive
Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top Patti by applying adhesive
Stitching back top Patti with zipper , raw edge of back part and another edge of zipper pocket lining & thread trimming
Stitching two opened edge of back zipper pocket lining & thread trimming
Attaching EVA with two gusset
Folding top edge of two gusset & hammering
Gluing on two parts of ring loop and attaching with hammering
Stitching ring loop with square ring at marking position on gusset & threads trimming
Belt folding 6mm from edge with glue
Attaching both part of belt & hammering
Belt stitching 2.5 mm from edge & threads trimming
Attaching rabose with bottom
Folding two edge of bottom & hammering
Attaching two gusset with bottom by applying adhesive
Stitching two gusset with bottom & thread trimming
Stitching front & back part with stitched gusset and bottom part & thread trimming
Square ring, belt loop & buckle fitting with belt
Stitching belt with gusset of bag & threads trimming
Attaching foam with flap upper by applying adhesive
Attaching PVC on the attached foam of flap upper by applying adhesive
Folding the round of flap upper & hammering
Attaching EVA sheet with two counter flap side strap
Folding two counter flap side strap & hammering
Attaching two counter flap side strap with counter flap by applying adhesive
Stitching two counter flap side strap with counter flap & thread trimming
Attaching EVA with counter flap bottom strap
Folding counter flap bottom strap & hammering
Attaching counter flap bottom strap with counter flap by applying adhesive
Stitching counter flap bottom strap with counter flap & thread trimming
Attaching flap upper & counter flap by applying adhesive
Stitching flap upper & counter flap with double needle sewing machine & thread trimming
Fixing top part of magnet on the flap
Stitching flap with back top Patti by double needle sewing machine & thread trimming
Fixing bottom part of magnet on front part of bag
Preparation of Handy pocket
Stitching Handy pocket with front part inner lining & threads trimming
Folding four edges of zipper cut portion of back part inner lining
Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner lining
Attaching inner zipper pocket lining with 3 No. nylon zipper
Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimming
Stitching two sides of inner zipper pocket lining & threads trimming
Stitching two inner gusset lining with front and back part inner lining & threads trimming
Double face adhesive tape applying on the edge of inner lining & folding
Edge of folded inner lining attached with the edge of bag body
Inner lining stitching with body 2.5mm top edge & threads trimming
Puller edge folding with glue
Puller edge stitching 2.5mm around & threads trimming
Puller setting with zipper runner by fitting o-ring of metal zipper
Final stitch inspection
Cleaning and dressing
Stuffing
Inserting Bur code, Internet level, Price tag & safety label
Final checking and finishing
Packing of Bag
21. 0 200 400 600 800 1000 1200 1400 1600 1800 2000
Cutting all leather, lining & reinforcement materials
Splitting
Skiving
Inspection & Numbering
Marking
Edge coloring & Buffing
Zipper Cutting & Stamping/ Embossing
Gluing on leather, PVC, Rabose & EVA attaching on leather
Two pieces of front & back part leather stitching face to face with single and double needle flat bed sewing machine & hammering and threads trimming.
Foam attaching to front & back part leather by applying adhesive
Folding top edge of front part & Folding the top edge of back part keeping two sides raw edge
Attaching #5 no. metal zipper with runner on top edge of back part by applying adhesive
Attaching one edge of back zipper pocket lining on lower edge of zipper with folded top edge of back part by applying adhesive
Stitching top edge of back part with zipper and one edge of back zipper pocket lining & thread trimming
Folding two sides of back top Patti & hammering
Attaching back top Patti with zipper and raw edge of back part by applying adhesive
Attaching another edge of back zipper pocket lining on top edge of zipper with folded back top Patti by applying adhesive
Stitching back top Patti with zipper , raw edge of back part and another edge of zipper pocket lining & thread trimming & Stitching two opened edge of back zipper pocket lining &…
Attaching EVA with two gusset & Folding top edge of two gusset & hammering
Gluing on two parts of ring loop and attaching with hammering
Stitching ring loop with square ring at marking position on gusset & threads trimming
Belt folding 6mm from edge with glue
Attaching both part of belt & hammering
Belt stitching 2.5 mm from edge & threads trimming
Attaching rabose with bottom
Folding two edge of bottom & hammering
Attaching two gusset with bottom by applying adhesive
Stitching two gusset with bottom & thread trimming
Stitching front & back part with stitched gusset and bottom part & thread trimming
Square ring, belt loop & buckle fitting with belt
Stitching belt with gusset of bag & threads trimming
Attaching foam with flap upper by applying adhesive
Attaching PVC on the attached foam of flap upper by applying adhesive
Folding the round of flap upper & hammering
Attaching EVA sheet with two counter flap side strap
Folding two counter flap side strap & hammering
Attaching two counter flap side strap with counter flap by applying adhesive
Stitching two counter flap side strap with counter flap & thread trimming
Attaching EVA with counter flap bottom strap
Folding counter flap bottom strap & hammering
Attaching counter flap bottom strap with counter flap by applying adhesive
Stitching counter flap bottom strap with counter flap & thread trimming
Attaching flap upper & counter flap by applying adhesive
Stitching flap upper & counter flap with double needle sewing machine & thread trimming
Fixing top part of magnet on the flap & Fixing bottom part of magnet on front part of bag
Stitching flap with back top Patti by double needle sewing machine & thread trimming
Preparation of Handy pocket
Stitching Handy pocket with front part inner lining & threads trimming
Folding four edges of zipper cut portion of back part inner lining and Attaching #3 no. nylon zipper with runner & puller at folded zipper portion of back part inner lining
Attaching inner zipper pocket lining with 3 No. nylon zipper
Stitching inner zipper pocket lining with 3 No. nylon zipper & threads trimming
Stitching two sides of inner zipper pocket lining & threads trimming
Stitching two inner gusset lining with front and back part inner lining & threads trimming
Double face adhesive tape applying on the edge of inner lining & folding
Edge of folded inner lining attached with the edge of bag body
Inner lining stitching with body 2.5mm top edge & threads trimming
Puller edge folding with glue
Puller edge stitching 2.5mm around & threads trimming
Puller setting with zipper runner by fitting o-ring of metal zipper
Final stitch inspection
Cleaning and dressing
Stuffing
Inserting Bur code, Internet level, Price tag & safety label
Final checking and finishing
Packing of Bag
22. According to table-1
The existing production of the closing line-1 was 250 pieces Bag per day.
Standard output of the line-1 (at 100% capacity) was 509 pieces per day.
Total no of worker was 80.
Work content (Minutes) per bag was 75.45
So the efficiency of the existing line was 49.12%
According to table -2 & table -3
Standard output of the modified closing line -1 (at 100% capacity) could be 561
Pieces Bag per day.
Work content (Minutes) of proposed line is 68.37 minutes.
So productivity increasing 10.21% by using same labour.
Work content reduction is 7.08 minutes.
23. 1. Line layout should be balanced according to sequence of operation.
2. Show board may be made for every article to ensure correct specification
3. Less order may be avoided.
4. Supervisor and worker need training.
5. Attitude towards work should be positive.
6. A preventive maintenance schedule should be strictly followed.
7. Incentives may be introduced to skill enhancement.
8. The sewing operator may be trained to keep hand away from balance wheel.
9. Skilled operators must be appointed for critical operations.
10. Line balancing and workers distribution may be done using standard times.
11. A regular training program (Non-Technical and Technical) on transactional analysis, Motivation,
quality concept, productivity etc. could be organized.
12. Workers should be encouraged to point out any inconstancies.
13. Efficiency calculation should be done on monthly basis.
14. Workers rating could be introduced according to the performance so that it acts as a guide for
improvement.
15. The wage difference of machine operator and manual operator is very less; therefore there is little
motivation for skill enhancement. Wages difference should be more.
16. After critical operation, there should be stage inspection.
17. During production, rework may not be done which need to change thread.
