The document discusses the application of work study concepts in apparel manufacturing at Bombay Rayon Fashions Limited. It aims to optimize workplace utilization and productivity through analyzing existing plant layouts and workflows using process charts. Specific areas covered include redesigning the cutting, sewing and finishing sections layouts which improved space utilization and increased production output. Workstation designs and implementation of work study charts helped enhance efficiency.

1. RESEARCH TITLE : APPLICATION OF WORK STUDY CONCEPTS IN APPAREL MANUFACTURING RESEARCH ASSOCIATES IQBAL AHMED – BS in Industrial Engineering NIRANJAN K. H – BS in Industrial Engineering Dr. Ambedkar Institute of Technology Bangalore University BALAJI B JAGANNATH Head Of Industrial Engineering Bombay Rayon Fashion Limited CONDUCTED AT BOMBAY RAYON FASHIONS LIMITED(UNIT-1) BANGALORE

2. OBJECTIVE OF THE PROJECT WORK TO IMPLEMENT WORKSTUDY CHARTS TO OBTAIN MAXIMUM UTILIZATION OF THE RESOURCES(MAN, MACHINE AND MATERIALS) AND TO OPTIMIZE WORKPLACE BY CHANGING THE PLANT LAYOUT AND WORKSTATION, USING THE PROCESS CHARTS.

3. ROLE OF INDUSTRIAL ENGINEERING DEPARTMENT IN APPAREL INDUSTRY. Importance of Industrial Engineering (IE) tools that can be used to improve upon the productivity of their factories and thus enhance the profits ! Very few companies have been operating with a full-fledged industrial engineering department and even those which boast of an Industrial Engineering Department (IED) in their factories are not allowing ample freedom and scope to function to its full capabilities. The role of IED is important for the garment industry for the following two reasons: It’s a highly labor-intensive industry. Effective planning is emerging as one of the key factors for the garment manufacturing industry.

4. ABOUT THE COMPANY-BRFL: is one of the leading garment manufacturer in India, currently operating with 7 units in Bangalore.

5. GARMENT MANUFACTURING – BLOCK DIAGRAM Fabric from stores Cutting section Sewing section Finishing section Finished garment to warehouse

6. TOPICS COVERED DURING THE PROJECT WORK Plant Layout And Work Station Design Work Study Concepts

7. PLANT LAYOUT & WORKSTATION DESIGN

8. CUTTING SECTION

9. CUTTING SECTION – EXISTING LAYOUT

10. CUTTING SECTION – PROPOSED LAYOUT

11. CALCULATION – CUTTING SECTION FORMULA USED: PRODUCTION O/P = TOTAL TABLE * PRODUCTION PER DAY LENGTH CONSTANT -------------------------------------------------------------------------- EXISTING PROPOSED No. of tables 4 6 Total Table length 22*2+10*1+17*1 20*4+17*1+10*1 = 71mts = 107mts Production o/p 71 * 60 107 * 60 per day = 4260 = 6420 % increase in production = 6420 -4260 ------------- * 100 = 33.64 % 6420

12. COMPARISION B/W EXISTING & PROPOSED CUTTING SECTION LAYOUT EXISTING Lesser space utilization Operations not arranged in sequence. Bottle-necks occurs Production is less Too much of material movement & handling PROPOSED Maximum space utilization Operations are arranged in sequence. Bottle-necks avoided Higher production achieved Minimized material movement & handling

13. SEWING SECTION LAYOUT

14. SEWING SECTION LINE

15. FINISHING SECTION LAYOUT

16. FINISHING SECTION – EXISTING LAYOUT

17. FINISHING SECTION – PROPOSED LAYOUT

18. FINISHED SECTION: EXISTING LAYOUT V/S PROPOSED LAYOUT EXISTING Operations are not arranged in sequence Intersection of material flow occurs Material movement is more Material handling is more PROPOSED Operations are arranged in sequence Intersection of material flow avoide d Material movement is minimized Material handling is minimized

19. WORKSTATION DESIGN The work station design affects the production rate, efficiency and the accuracy with which an operation can be performed. A work station not only needs space for the workers and the machine, there are plenty of other items which also need accommodation. Space requirements and a few more factors governing a good work station design are described below: Space requirements Consideration of the space required, for the movement of material handling equipments. Easy access to safety stops in case of emergency. Easy access to machine for inspection, lubrication, maintenance and repair. Convenience of making foundations and machine installations. Aisle space between one machine and the next. Appropriate ventilating, lighting and safety arrangements.

20. WORKSTATION AT SEWING BATCH- EXISTING

21. WORKSTATION- Proposed/Implemented

22. COMPARISION OF EXISTING Vs PROPOSED 57 cm 18 minutes With out disturbing Barrier does not exists 63 cm 20 minutes Disturbing the operator Restricted by the barrier to a limit Needle distance from center table edge Time required to manufacture one garment from one batch Enter of performance card Movement of the operator towards the center table Proposed work station Existing work station Description

23. COMPARISION OF EXISTING Vs PROPOSED Calculation % Efficiency = 3168 – 2884 × 100 = 9 % 3168 20 operations 18mins 3.33*20 = 66 garments/hr 66*8 = 528 garments/day 528*6 = 3168 garments/day 20 operations 20mins 3*20 = 60 garments/hr 60*8 = 480 garments/day 480*6= 2884 garments/day No. of operations /batch To manufacture 1 garment Hourly production per batch Daily production per batch Daily production from sewing section Proposed Existing Description

24. WORK STUDY

25. IMPORTANCE OF WORK STUDY Improving the planning of work. Improving Methods of production. Effective Worker Selection Processes. Improving Worker Effectiveness. Providing Workers with Adequate Training. Improving Worker Morale. Rewarding worker Morale. Improving worker attendance levels. Reducing worker labor turnover. Effective Communications.

26. IMPLEMENTING WORK STUDY CHARTS IN APPAREL MANUFACTURING Objective : To record the movements of man, machine & materials in a layout, study the distance covered, time involved, interaction between them, identify the area for improvement, and suggest a better way to overcome these problems.

27. WORK STUDY- DEFINITION Work study is a generic term for those techniques, particularly method study& work measurement, which are used in the examination of human work in all its context, & which lead systematically to all the factors which affect the efficiency & economy of the situation being reviewed, in order to effect improvement.

28. METHOD STUDY WORK MEASUREMENT HIGHER PRODUCTIVITY WORK STUDY

29. PROCESS CHART SYMBOLS - OPERATION - STORAGE - DELAY - TRANSPORT - INSPECTION

30. OUT LINE PROCESS CHART: An out line process chart is a process chart giving an over all picture by recording in sequence only the main operation and inspection. Fabric inspecn sewing sec final check cutting sec finishing sec

31. Out line process chart: for apparel manufacturing Fabric insp front prep buttoning 1.5 1.25 Laying front back attch in line trim 0.15 1.0 0.6 Marking checking pressing 0.45 1.75 Cutting part atch final check 1.80 2.45 Panel check final check stain remove 2.0 Recut msrmnt check 1.5 Sorting prsnt check 1.5 tagging 0.65 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 18

32. FLOW PROCESS CHART The flow process chart as a process chart setting out the frequency of the flow of a product or procedure by recording all event under review using the process chart symbols. MAN TYPE MATERIAL TYPE EQUIPMENT TYPE

33. MAN TYPE – FLOW PROCESS CHART A FLOW PROCESS CHART WHICH RECORDS WHAT THE WORKER DOES

34. Flow Process Chart – Man type Feeding helper in Sewing Section. Click to Download File Flow Process Chart – Man Type Present Click to Download File Flow Process Chart – Man Type Proposed Improvement 4.08(8%) 51.5 55.58 Time (Min) 98 (41%) 136 235 Distance (Mtrs) 2 2 - - 1 13 10 - 2 1 15 12 - 2 - Operation Transport Delay Inspection Storage Savings Proposed Present Activity SUMMARY Subject Charted : Feeding Helper in Sewing Section Activity: Feeding of all parts and trims to assembly line Location: Sewing Section – Unit – 1 - BRFL Charted by: IQBAL & NIRANJAN Approved by: Date:5-03-07

35. MATERIAL TYPE – FLOW PROCESS CHART A FLOW PROCESS CHART WHICH RECORDS THE MOVEMENT OF MATERIALS, I.E. THE CHANGES THE MATERIAL UNDERGOES IN LOCATION. IN BUNDLE FORM , WAITING FINISHED APPAREL TO GET PICKED UP WAITING TO GET DISPATCHED MATERIALS IN-PROCESS

36. Flow Process Chart – Material Type Stitched Garments In Finishing Section Click to Download File Flow Process Chart – Material Type Present Click to Download File Flow Process Chart – Material Type Proposed Improvement 1.9(35%) 3.4 5.3 Time (Mins) 94 (35%) 171 265 Distance (Mtrs) - - - - - 16 21 2 - 3 16 21 2 - 3 Operation Transport Delay Inspection Storage Savings Proposed Present Activity SUMMARY Subject Charted: Stitched Garment in Finishing section Activity: Buttoning, Inline Trimming, Pressing, Inspection & Dispatch Location: Finishing Section – Unit – 1 – BRFL Charted by: IQBAL & NIRANJAN Approved by: Date:05-03-07

37. EQUIPMENT TYPE – FLOW PROCESS CHART A FLOW PROCESS CHART WHICH RECORDS THE MANNER IN WHICH EQUIPMENT IS USED. STAIN REMOVER – WAITING TO GET PICKED UP HAND KNIFE - UNDER WORKING

38. TWO- HANDED PROCESS CHART The two-handed process chart is a process chart in which activities of a workers hands(or limbs) are recorded in their relationship to the other.

39. MULTIPLE ACTIVITY CHART Is useful recording tool for situations where the work involves interactions of different subjects. One or more workers looking after different machines or a group of workers working on loading materials at one point.

40. MAN-MACHINE CHART FOR PLACKET TRIM & JOINT OPERATION Existing condition: The operations, placket trim and placket joint were carried on by 2 different operators at different places for a single batch. Proposed condition: A single operator to perform both the operations on two machines placed front & back of the operator , providing with a rotating chair.

41. MAN-MACHINE CHART FOR PLACKET TRIM & JOINT OPERATION 0 3 4 5 Idle Placket trim operation on m/c 1 Working 6 7 Working Placket joint operation on m/c 2 Idle 7.5 (placket joint machine) (trimming machine) (mins) Machine 2 Operator 1 Machine 1 Time Date: 06/04/2007 Approved by: Charted by: Iqbal and Niranjan Charted on: Placket trim & Placket joint operations for a bundle of 10 pieces MAN MACHINE CHART : 2 M/C 1 OPERATOR

42. NUMBER OF OPERATORS WORKING ON SINGLE MACHINE

43. CONCLUSION WITH THE APPLICATION OF WORK STUDY CHARTS IN APPAREL MANUFACTURING, THE EFFECTIVE UTILIZATION OF RESOURCES ( MAN, MATERIAL & MACHINES) CAN BE ACHIEVED. THE COST INVOLVED IN USING THESE CHARTS ARE VERY MINIMUM AND A SOLUTION CAN BE DERIVED IN A SHORT PERIOD OF TIME.

44. THANK YOU -----------------