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Welcome To Our Presentation
Presentation On : Application of IE in garments capacity
study and line balancing
Name ID
Md. 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
113
214214
455
129
200
129
259
200
174
288
259
375
169
203200
149
500
161
278
139
227
193
176
238242
221217205194
124
190
217
166174
149
223
178
126
200
259
155
195
142
231
211200
86
209
131
200
147
178
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 Balance
SL Process M/c Achieve Process M/c Achieve
1 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
CONCLUSION
CONCLUSION
• 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

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project-presentation

  • 1. Welcome To Our Presentation Presentation On : Application of IE in garments capacity study and line balancing Name ID Md. Asaduzzaman Roni 120103028 Rofikul Islam 120103022 Md .Abu Sayeed 120103020 Md .Murad Hossain 120103041
  • 2. 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
  • 3. 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
  • 4. 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.
  • 5. Objectives • To establish methods for improving the operations and controlling the production costs. • To develop programmers for reducing costs.
  • 6. 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
  • 7. Industrial Engineering Tools • Lean Manufacturing • 5S • JIT (Just In Time).
  • 8. 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
  • 9. 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
  • 10. 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
  • 11. Work study Ensure the highest productivity by the optimum use of man power, equipment and material.
  • 12. Characteristic of work study engineer • Sincerity and Honest • Diplomacy • Good Appearance • Self-Confidence
  • 13. Function of Work Study • Work Measurement • General Sewing Data(GSD) • Breakdown and Layout • Calculation • Consumption
  • 14. Capacity study In Apparel Manufacturing, “Production capacity” is one of the most important criteria used for vendor selection by the buyers
  • 16.
  • 18.
  • 21. 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 .
  • 22. 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.
  • 24. 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.
  • 25. SMV(Standard minute Value) The amount of time required to complete a specific job or operation under existing condition.
  • 27. Line Balancing Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity.
  • 28. Objective of line balancing • Regular material flow. • Maximum uses of man power and machine capacity. • Minimum process time. • Minimizing workstation. • Reduce production cost
  • 29. Breakdown Process of Basic Shirt
  • 30. Process breakdown Upper Placket Rolling Lower Placket Rolling Gamble Tuck and Cut Sleeve Placket Join
  • 31. Placket Iron Pocket Iron Pocket edge cutting Back yoke join Solder join Sleeve join
  • 32. Care label attach with body Collar join Side sessaring Side seam Cuff join
  • 33. Body ,Cuff Button hole Body , Cuff Button Hole mark Body , cuff Button attach Bottom hem
  • 34. Table: Before balance and after balance line Before balance and after balance line Before Balance After Balance SL Process M/c Achieve Process M/c Achieve 1 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
  • 35. 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
  • 36. 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.
  • 37. Limitations of Line Balancing • Inevitable changes lead to production lines being out of balance. • Rebalancing causes disruptions to production
  • 38. CONCLUSION CONCLUSION • 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