Executive summary of production and productivity

1. Submitted by: Submitted to:
Azizur Rahman (191-036-111) Engr. FARUK AHMED
Hasibul Hasan (191-033-111) Assistant Professor, IE, BUFT
Tanvir Hasan (191-024-111) M. Eng. in AEM, IPE, BUET
Sarfaraj Hossain (191-034-111) MBA in OPM, IBA, DU
Fazla Rabbi (191-022-111) BSC Engineering in ME, BUET
Tayeeba Akhter (191-050-111) E-mail: faruk@buft.edu.bd
Contact: 01928371876
Apparel Production and Management
A Term paper on: Productionand Productivity.

2. Executive summary of production and productivity: In earlier
days clothing was only a basic necessity, used to cover the body
and to protect from the climatic changes. Over the time people
became concerned about the comfort of wearing and also the
durability of the product. Now a day’s garments are situational
wears. Need for a garment has become endless. In a day, one
needs different wears at different times. As a result, man started
thinking of the modernization, engineering tools and techniques
used for garment manufacturing for increasing the
productivity. Garment manufacturers have to focus on “Cost
effective production” to sustain. This is possible only when the
basic resources for garment manufacturing are being utilized
effectively. The level of productivity, in the production,
determines the profitability, efficiency and performance of the
enterprise, the higher the productivity of the firm the greater will
be the earning capacity. It aims at determining the relationship
between the input and output, in a particular production process.
In short, it is nothing but attaining the highest possible outcome,
while consuming minimum factors of production.
Aims and objectives of the study:
Objectives:
 Eliminate waste of waste of time;materials;space;
movement; effort.
 Minimize the number of setups
 Use standard components where possible

3.  Balance changeover costs with inventory costs
 Produce maximum good using minimum resource.
 Increase productivity
 To balance a number of factors in pursuit of organizational
goals.
 To use best way for production
Aims of the study:
-Product the right goods;
- of the right quality;
- at the right time;
- in the right place; and
- at the right price.
Theoretical Background:
Definition of Production:
Production is the method of turning raw materials or inputs into
finished goods or products in a manufacturing process. In other
words, it means the creation of something from basic inputs.
Definition of Productivity:
Productivity may be defined as the ratio between output of wealth
and input of resources of production. Output means the quantity
produced and inputs are the various resources employed,
Example., land, building, machinery, materials and labour.
Productivity refers to the efficiency of the production system. It
is an indicator of how well the factors of production (land, capital,
labour and energy) are utilized.
Productivity = Output /input

4. Types of Productivity:
 Labour Productivity.
 Capital Productivity.
 Material Productivity.
 Energy Productivity.
 Machinery Productivity.
Productivity formula's:
1. Labour Productivity = Total Output / Labour Input
2. Capital Productivity = Total Output / Capital Input
3. Material Productivity = Total Output / Total raw material
used
4. Energy Productivity = Total Output / Total energy used
5. Machinery Productivity = Total Output / Total machine hour
used
Example: Suppose a sewing line has produced 400 pieces by 35
workers in a day.
Productivity (labour productivity) = 400/35 = 11.42 pieces per
labour per shift.
Concept of Production & Productivity:
The concept of production and productivity are totally different.
Production refers to absolute output whereas productivity is a
relative term where in the output is always expressed in term of
inputs. Increase in production may or may not be an indicator of
increase in productivity. If the production is increased for the
same input, then there is an increase in productivity.

5. If viewed in quantitative terms, production is the quantity of
output produced, while productivity is the ratio of the output
produced to the input used.
Productivity = Production / Resources employed
Productivity is said to be increased, when
 The production increases without increase in inputs.
 The production remains same with decrease in inputs.
 The output increases more as compared to input.
Benefits from Increased Productivity:
Higher productivity results in higher volume of production and
hence increased sales, lower cost and higher profit. It is
beneficial to all concerns as stated below:
(a) Benefits to the management:
1. More profit.
2. Higher productivity ensures stability of the organization.
3. Higher productivity and higher volume of sales provide
opportunity for expansion of the concern and wide spread
market.
4. It provides overall prosperity and reputation of the
organization.

6. (b) Benefits to workers:
1. Higher wages.
2. More wages permits better standard of living of workers.
3. Better working conditions.
4. Job security and satisfaction.
(c) Benefits to the consumers:
1. More productivity ensures better quality of product.
2. It also enables reduction in prices.
3. More satisfaction to consumers.
(d) Benefits to nation:
1. It provides greater national wealth.
2. It increases per capita income.
3. It helps expansion of international market with the help of
standardizes and good quality products.
4. It improves standard of living.
5. It helps better utilization of resources of the nation.

7. Factors Affecting Productivity:
(a) Factors affecting national productivity
1. Human resources
2. Technology and capital investment
3. Government regulation
(b) Factors affecting productivity in manufacturing and services
1. Product or system design
2. Machinery and equipment
3. The skill and effectiveness of the worker
4. Production volume
Now some points are highlighted of above these investment
Human Resources:
1. The general level of education.
2. Use of computers and other sophisticated equipment by
employees.
3. Employees need to be motivated to be productive.
4. Technology and capital investment.
5. New technology depends on R & D.
6. Every industry and services put new technology into use,
they must invest in new machinery and equipment.
7. Computer aided design (CAD).

8. Government Regulation:
An excessive amount of government regulation may have a
detrimental effect on productivity.
Ways to Improve Productivity:
 Product development.
 Specialisation and Standardisation
 Market, consumer & product research.
 Value analysis
 Process Planning and research.
 Method study.
 Safety.
 Operators training.
 Production Planning and control.

9. Garment Manufacturing flow chart:

10. Production Flow chart (Wet Processing for Woven fabric) :

11. Difference between Production & Productivity:
No Production Productivity
1 Production is a
function of an
organisation which
is associated with
the conversion of
range of inputs into
desired output
Productivity is a
measure of how
efficiently
resources are
combined and
utilized in the firm,
for achieving the
desired outcome.
2 It is the measure of
produced Goods
It is the measure of
efficiency.
3 It is the actual
process of
conversion
It is the utilization
of resources to
from goods
4 Determine value of
output
Determine
efficiency of
factors of
production.

12. Production and Productivity Method and materials:
The concepts of production and productivity are totally
different. Production refers to absolute output where as
productivity is a relative term where in the output is always
expressed in term of inputs. Increase in production may or may
not be an indicator of increase in productivity. If the production
is increased for the same input, then there is an increase in
productivity.
If viewed in quantitative terms, production is the quantity of
output produced, while productivity is the ratio of the output
produced to the input used.
Productivity = Production / Resources employed
Productivity is said to be increased, when
The production increases without increase in inputs.
The production remains same with decrease in inputs.
The output increases more as compared to input.
Classification of Productivity:
Labour productivity=output/No of labour xw.hX W.d
M/C productivity=output/ No of m/cX W.hX W.d
Material productivity= output/ materials input
Energy productivity= Out Put/ Energy Input

13. Machinery: Machinery is the back bone of every industry. In
the textile industry machine are working 24 hours so it is
important that its efficiency would be excellent. Let’s look at the
comparison between the old and new machine. In Azad Textile
Mills we analyzed that, “why new machine are better than old
machine?” In the simplex department they have erected 10
frames and in which one of them is the old one. If we compare
the old machine with the new machine in production point of
view then, it is clear that new machines are better than old ones.
We got some experimental results, from the new frame with the
speed of 725 rpm the production is 45 bags/day while with the
old machine with the same speed production is 35 bags /days
because many factors involved in it like sliver and roving
breakages, machine adjustments and stoppages. If we compare
these machines in energy point of view then old machine
consumes more energy than the new ones. From the above
discussion it is clear that the machine matters if we talk about
productivity.
Garments Production System:
Garments assembly is a basic requirement of clothing and fashion
design which involves a conversion of raw materials into a
stitched and wearable piece of clothing. To make a complete
garment assembling is required for different parts of a garment.
The front and the back body, yoke, sleeve, collar, cuff, placket,
and pocket need to be assembled together in order to make a basic
shirt.

14. Production systems are needed to enable companies to produce
the largest number of products effectively and efficiently for the
lowest cost but at the required quality. Garments production
system is an integration of materials handling, production
processes, personnel, and equipment’s that direct workflow and
generate finished products. Simply, it is a way how the two-
dimensional fabric is being converted into a three-dimensional
garment in a manufacturing system. Garments can be made by
applying different types of system. The garment production
system used by an individual or in small tailor shops is different
from the system actions used in the factories

15. Result:
Productivity is one of the main concerns of business
management and engineering. Many companies have formal
programs for continuously improving productivity, such as
a production assurance program. Whether they have a formal
program or not, companies are constantly looking for ways to
improve quality, reduce downtime and inputs of labor, materials,
energy and purchased services. Often simple changes to
operating methods or processes increase productivity, but the
biggest gains are normally from adopting new technologies,
which may require capital expenditures for new equipment,
computers or software. Modern productivity science owes much
to formal investigations that are associated with scientific
management. Although from an individual management
perspective, employees may be doing their jobs well and with
high levels of individual productivity, from an organizational
perspective their productivity may in fact be zero or effectively
negative if they are dedicated to redundant or value destroying
activities.[11]
In office buildings and service-centered companies,
productivity is largely influenced and affected by operational
byproducts - meetings.[33]
The past few years have seen a
positive uptick in the number of software solutions focused on
improving office productivity such as Microsoft Office. In truth,
proper planning and procedures are more likely to help than
anything else.

16. Discussion:
The choice of best apparel production system will depend on the
product and policies of the company and on the capacities of
manpower. Where style changes are frequent and lot sizes small,
it may be advantageous to use skilled labor who can make whole
garment and use one of the whole garment systems. As the lot size
increases it is advisable to use section production system.
One of the aims of any production system is to make total
production time as minimum as possible. This automatically
reduces inventory cost to a minimum. Sub-assembly system
provides many opportunities to economies on temporary storage
and transportation space and time. No definite answer can be
given as to which is the best, as it depends on garment style,
specifications, machinery and manpower and manufacturing
policies.

17. Limitation of the study:
1) Standards cannotbe established by this techniqueon jobs which
are not well defined.
2) In situations where it is difficult to define quality precisely
standards and production incentives may cause deterioration in
quality levels.
3) It is not possible to maintain standards where piece rate system
of wage payment exists.
4) Labour unions may oppose the application of time study where
they are strong.
5) Time study is applicable only where the work is visible. So, it
can be applied only in manual job and for thinking portions of the
job.
6) Only specific type of jobs which have identifiable starting and
ending points can be timed accurately.
Recommendation:
Global buyers’ expectations—from audit requirements to
deadline pressures—shape the actions and decisions of other
actors in the value chain. This, in turn, has real implications for
workers, especially the women who are often found in the lowest-
paid, lower-skilled positions. While brands are not the only
actors, through their policies, practices, and influence, they can

18. drive change both within factories and in the broader operating
environment. Most brands are aware of the human rights
challenges affecting supply chain workers and understand that
they have a responsibility to identify, address, and mitigate
adverse human rights impacts with which they may be involved
through their business relationships. Most companies already
have policies, protocols, and procedures in place to communicate
and enforce these expectations across their sourcing countries.
The recommendations that follow are designed to go beyond
these basic expectations and focus on what companies can do to
help women in SSA achieve their full economic potential. This
section provides recommendations for global brands/buyers to
advance women’s economic empowerment through their
relationships with suppliers in SSA, and through engagement
with other actors and governments. Our recommendations are
focused on SSA country operations but are also relevant for
global corporate strategy. We use the Act, Enable, Influence
framework illustrated here to describe the different levers
companies can use to drive change. We have prioritized the levers
and recommendations where companies have the greatest
opportunity for positive impact. Given that women play such a
key role as factory owners and workers in global supply chains,
the recommendations focus on steps brands can take to advance
empowerment of these women. When we refer to women in the
supply chain, we include indirect suppliers to factories, such as
providers of catering, cleaning, or security services. We did not
include upstream cotton and fabric production in the scope of this
project, so women working in these areas of the supply chain are
not included.

19. As the old adage goes, time is money. The more production you
can squeeze out in a period of time, the more money you make,
right? But if you've been struggling with improving production or
even if everything is going fine. there are several things you can
do to increase throughput without sacrificing quality from
removing obstacles to reorganizing the way you work.
1 - Review Your Existing Workflow You won't know what can
be changed until you know how everything works now. Three
areas contain critical information to help you identify needed
changes. Before you make any changes, understand how
everything works now. There is still value in the saying, it isn’t
broke, don't fix it." Unless you can identify a financial or safety
reason for making a change. think long and hard about the value
of the expected outcome.
2 - Update Processes and Technology Automation is a powerful
tool for increasing efficiency and reducing error. New software
solutions can help with scheduling, inventory, and monitoring
workflow. improvements in equipment can improve production
speed and quality.
3 - Commit to Scheduled Maintenance Train all operators in
regular maintenance and troubleshooting procedures. Schedule
preventive maintenance at regular intervals. identify the best time
for maintenance by using information from the floor and your
workflow processes. Don’t delay maintenance.
4 - Train and Educate Employees Schedule training sessions for
all operators when new equipment is installed. Keep accurate
records of training and schedule refreshers if needed. Offer

20. educational opportunities for employees who wish to advance or
obtain new skills.
Don't limit training and education to equipment. Your
manufacturing facility will run more smoothly if everyone
understands your policies on workplace harassment and proper
communications.
5 - Organize the Workspace Reducing movement and clutter
saves time. Reduce movement for optimal task efficiency. Create
the optimal layout of tools and materials for the job or process.
Remove unneeded or unused tools and materials from the
workspace. Create organized storage to reduce time to find
materials, documents, and equipment. Layout the manufacturing
floor to maximize efficiency.
6 - Maintain Optimal Inventory Use software to track inventory
and create automatic notifications of shortages. You may be able
to allow vendors direct access to your inventory counts and
automatically fulfill needed supplies. Create favored vendor
relationships to gain accountability for the quality of parts and
timeliness of deliveries. Make predictions about the impact of
particular shortages and put processes in place to mitigate
production delays

21. References:
1. https://textilelearner.blogspot.com
2. https://benchpartner.com
3. https://myaccuntingcourse.com
4. https://www.differencebetween.info
5. https://keydifferences.com
6. https://www.bsr.org/reports
7. https://www.engineeringenotes.com
8. https://textilestudycenter.com/garment-
production-system/
9. https://fashion2apparel.blogspot.com/
10. https://indiantextilejournal.com/