In this modern world, fashion & styles are changing frequently. The emergence of fast changes in fashion has given rise to shorten production cycle time in the garment industry. To meet the dynamic customer demands of momentous quantities in shorten lead time, assembly line production systems are used, where the garment components are assembled into a finished garment through a sub-assembly process. So in the era of product customization, the optimal usage of resources especially the available facilities & operators who are adding the value of product is important. Therefore the assembly line has to be planned in much more flexible way. This paper deals with the maximum utilization of manpower in labor intensive assembly lines. The objective is to accurately delegate workers to the various operations required to complete the product based on their skill & experience so as to achieve the highest level of productivity and delivery as per planned target. The experimental result showed meaningful improvement in productivity as compared to the existing system
Analysis of sewing section efficiency by using time study technique in Appare...Khairul Bashar
This document discusses using time study techniques to analyze sewing section efficiency in the apparel industry. It begins with introducing industrial engineering and activities like work study and time study. It then discusses how time studies are conducted including setting objectives, using tools like stopwatches, breaking jobs into elements, and calculating basic and standard times. The document presents methodology for conducting a time study on a sewing section, results showing production increased to 220 pieces per hour after analysis, and concludes that time studies are important for improving production efficiency in garment industries.
This document provides an overview of quality control systems in the garments industry. It defines key quality terms like defects, defective pieces, DHU, and percentage defective. It describes the quality control process flow from fabric inspection to final inspection. It also discusses critical defects, major/minor defects, and acceptable quality levels. Key performance indicators for quality like customer complaints, percentage defective, and DHU are presented. The document outlines how to improve quality through communication, clean workplaces, proper tools and training, and corrective measures.
1. The document outlines a 44-point inspection system used to evaluate fabrics based on defect size and significance, with penalties ranging from 1 to 4 points.
2. It describes random sampling methods for inspections and specifies that 10-20% of shipment quantities should be sampled.
3. A multi-stage inspection process is defined involving quantity checks, pattern/color verification, measurements, appearance evaluation, and shade matching.
This document provides a training manual for trim quality checkers. It outlines the module code, entry requirements, duration, course content, objectives, inspection procedures, and check points for various trims and accessories. The key points are:
- The course is 120 hours and aims to train candidates to inspect trims, compare to standards and customer requirements, and approve or disapprove items.
- Course content covers familiarization with tools, trim types, specifications, defect reporting, and safety guidelines.
- Inspection procedures follow a 1.5AQL sampling system based on lot size, with acceptance levels defined.
- Detailed check points are provided for sewing thread, zippers, buttons, elastics
The Purpose of this presentation is to give knowledge about, how the different style garments should be inspected.
Prepared By Abdul Latif
Asst. Manager.QA
MTM Faisalabad Pakistan
The details quality control system of woven garments with pictures. Some cased you need to add or ignore some checking points based on styling. Shirt, pant, top, bottom.
Presentation on time study of apparel industryTanmoy Antu
This document discusses the importance of time studies for improving productivity in the garments industry in Bangladesh. It provides an overview of a garments company called KB Apparels Ltd and describes how they implemented time studies on the processes for making T-shirts and athletic shirts. The time studies identified bottlenecks in the processes and areas where line speeds needed to be balanced. Recommendations included assigning more skilled operators to bottleneck areas and quick responses from workers to meet production targets.
Analysis of sewing section efficiency by using time study technique in Appare...Khairul Bashar
This document discusses using time study techniques to analyze sewing section efficiency in the apparel industry. It begins with introducing industrial engineering and activities like work study and time study. It then discusses how time studies are conducted including setting objectives, using tools like stopwatches, breaking jobs into elements, and calculating basic and standard times. The document presents methodology for conducting a time study on a sewing section, results showing production increased to 220 pieces per hour after analysis, and concludes that time studies are important for improving production efficiency in garment industries.
This document provides an overview of quality control systems in the garments industry. It defines key quality terms like defects, defective pieces, DHU, and percentage defective. It describes the quality control process flow from fabric inspection to final inspection. It also discusses critical defects, major/minor defects, and acceptable quality levels. Key performance indicators for quality like customer complaints, percentage defective, and DHU are presented. The document outlines how to improve quality through communication, clean workplaces, proper tools and training, and corrective measures.
1. The document outlines a 44-point inspection system used to evaluate fabrics based on defect size and significance, with penalties ranging from 1 to 4 points.
2. It describes random sampling methods for inspections and specifies that 10-20% of shipment quantities should be sampled.
3. A multi-stage inspection process is defined involving quantity checks, pattern/color verification, measurements, appearance evaluation, and shade matching.
This document provides a training manual for trim quality checkers. It outlines the module code, entry requirements, duration, course content, objectives, inspection procedures, and check points for various trims and accessories. The key points are:
- The course is 120 hours and aims to train candidates to inspect trims, compare to standards and customer requirements, and approve or disapprove items.
- Course content covers familiarization with tools, trim types, specifications, defect reporting, and safety guidelines.
- Inspection procedures follow a 1.5AQL sampling system based on lot size, with acceptance levels defined.
- Detailed check points are provided for sewing thread, zippers, buttons, elastics
The Purpose of this presentation is to give knowledge about, how the different style garments should be inspected.
Prepared By Abdul Latif
Asst. Manager.QA
MTM Faisalabad Pakistan
The details quality control system of woven garments with pictures. Some cased you need to add or ignore some checking points based on styling. Shirt, pant, top, bottom.
Presentation on time study of apparel industryTanmoy Antu
This document discusses the importance of time studies for improving productivity in the garments industry in Bangladesh. It provides an overview of a garments company called KB Apparels Ltd and describes how they implemented time studies on the processes for making T-shirts and athletic shirts. The time studies identified bottlenecks in the processes and areas where line speeds needed to be balanced. Recommendations included assigning more skilled operators to bottleneck areas and quick responses from workers to meet production targets.
Traffic Light System is a visual quality control tool used in garment manufacturing to reduce defects at their source. It works by randomly inspecting operators' workstations and placing colored cards - green for meeting quality standards, yellow for minor faults, and red for not meeting standards. This alerts operators to quality issues and allows immediate corrective action. Studies show the system can increase production capacity by 5% and lower rework rates from 2.14% to 1.01% by motivating operators and catching defects earlier. It is an effective yet easy to implement system that can improve quality, costs, lead times and supply chain performance for apparel companies.
Inline inspection in the garment industry involves checking product quality during the production process rather than after completion. This allows defects to be identified and addressed earlier. There are several methods of inline inspection, including checking at fixed checkpoints within the production line and roving checks by quality inspectors. The goals of inline inspection are to stop defects from occurring, improve productivity by reducing rework, provide early feedback to other departments, and lessen the workload of final inspectors. It is particularly important for complex garments with many production steps.
At present Industrial Engineering (IE) is one of the important department for each garments or textile factory. Today’s maximum factory is run by industrial engineers, where they have to follow a process flow chart. By which they can easily control the whole garments production processes....
This document provides information about line balancing for a textile production process. It begins with an introduction to line balancing and definitions. It then discusses specific methods for balancing a production line, including determining the number of operators needed, work-in-process inventory levels, and standard minute values. The document provides examples of time studies, production data collection, and calculating key metrics like pitch time and bottleneck processes. The goal is to design an optimized production flow to improve throughput and reduce costs.
The document discusses various formulas used in the garment industry for tasks like setting production targets, measuring individual and line efficiencies, tracking work-in-process, and calculating costs. It also provides examples of how industrial engineering concepts are applied through tasks like time studies, standard setting, production planning, and performance analysis to improve factory processes and operations. Key roles of industrial engineers include work measurement, standard setting, planning, analysis, improvement projects, and ensuring efficient use of resources.
This document is a presentation by Md. Shamsuzzaman on garment production and productivity. It discusses key topics like the definitions of production and productivity, benefits of increased productivity, factors affecting productivity, ways to improve productivity in garment production, and key factors that can decrease garment production. It also provides an example calculation of garment production output and outlines steps that should and should not be taken to measure and improve productivity. The overall presentation aims to educate about optimizing garment manufacturing processes and outputs.
The document discusses the roles and responsibilities of different positions in a garment factory's production, store, commercial, accounts, merchandising, and HR departments. It describes 18 positions in production including operators, helpers, supervisors, quality inspectors, quality controllers, finishing supervisors, cutting masters, and production managers. It also outlines responsibilities for store managers and keepers, commercial officers, accounts officers, merchandising managers and assistants, and HR in-charges and officers. Finally, it discusses quality control considerations for procurement, knitting, batching, and dyeing processes.
There are three main categories of garment defects: 1) Fabric defects related to the material itself, 2) Workmanship and handling defects caused during the production process such as cutting and sewing, and 3) Defects related to trims, accessories, and embellishments like colors, sizing, and placement. Defects are further classified as critical, major, or minor depending on their severity, with critical defects not being shipped and major defects limited to 3% or less depending on buyer requirements. Typical defects include seam puckering, shading variations, open or broken seams, dropped stitches, wavy stitching, loose threads, sizing issues, ironing problems, misaligned buttons/holes, and issues with
Process flow of knit industry for a basic t-shirtMohin Mahmud
The document discusses the history and growth of Bangladesh's knitwear industry since the 1970s. It outlines the key steps in knit composite manufacturing including knitting, dyeing, cutting, printing, sewing, washing, finishing and packing. Knitting turns yarn into fabric using interconnected loops and has advantages over woven fabrics like flexibility and ability to create smaller pieces. The knitwear industry has lower costs and requires less space than woven composites. It has become the largest export sector in Bangladesh, surpassing woven garments. The objectives of the study are to evaluate each stage of the knit composite process flow and understand how it functions as a whole.
Garment manufacturing process from fabric to poductKarthika M Dev
This was one of my internship project which i done in SIYARAM'S in Gujarat. This is all about the process wch going in the factory from raw materials to the finished goods After a conformed order. Hope this will be helpful.
Standard minute value( SMV) in garments, calculation and importanceMazharul Islam
This document discusses the calculation and importance of standard minute value (SMV) in the apparel industry. It defines SMV as the basic time plus allocated allowances needed to produce a garment. Basic time is calculated as the observed time multiplied by a rating factor and represents the likely minimum time required. Observed time is the recorded time taken under close observation. Rating factors adjust for worker speed. SMV is important for costing, setting targets, measuring efficiency, and planning factory production. Formulas are provided for calculating basic time and SMV from observed cycle times under different conditions.
The document discusses various topics related to industrial engineering processes in garment manufacturing, including:
1. How to calculate the Standard Allowed Minute (SAM) value for a garment, which is used to measure work content and for cost estimation.
2. The different types of garment production systems and how factors like machinery and labor affect the system type.
3. How to calculate key metrics like production targets, line efficiency, garment cost, and operator efficiency that are important for production management and cost control.
4. Process flow charts that illustrate the sequence of operations to make basic garments and show how raw materials are transformed through cutting, sewing, finishing and packaging processes.
This document discusses different types of garment defects categorized into 3 groups: 1) fabric defects found in the material itself, 2) workmanship and handling defects caused during production, and 3) defects related to trims, accessories, and embellishments. Workmanship defects include seam puckering, shading variations, open or broken seams, broken stitches, dropped stitches, wavy stitching, and loose threads. Defects are further classified as critical, major, or minor depending on their severity. Typical defects from each category are provided as examples.
We took two quality control problems from the apparel/textile industry and used 2 classical QC tools to solve one of them, i.e., fishbone diagram and flowchart for the open seam defect, and 2 new QC tools to solve the other one, i.e., tree diagram and affinity diagram for the shade variation defect. We presented a report on the same.
Defects of garment(print, fabric & sewing)Rupak Barua,
This document discusses various types of defects that can occur in fabric, printing, dyeing, sewing, and other stages of apparel production. It begins by defining defects and classifying them based on their severity. Section 1 then lists and describes common fabric defects such as loose warp, double ends, broken warp, and oil spots. Section 2 covers dyeing, printing and finishing faults. Section 3 examines sewing problems like slipped stitches, seam pucker, and variable stitch density. Section 4 lists other defects from sizing, ironing, trims and accessories. The document emphasizes that defects can lead to lower prices or seconds goods, creating significant value loss. It stresses the importance of quality control and remedial measures to minimize defects
The document describes a Traffic Light System (TLS) implemented at a garment factory to monitor quality and identify problems at production lines. The TLS involves:
1. An in-line auditor inspecting random samples from each operation daily and assigning color codes (green, yellow, red) based on defects found.
2. Actions like stopping production for red lights to address issues. Top defect-making operations are discussed at meetings.
3. End-line inspection also identifies defect-making operations. Data is captured on forms and charts to track performance over time, with the goal of reducing defects and achieving Right First Time production.
The document discusses maintenance of textile machinery. It defines different types of maintenance including reactive, preventive, predictive, and capital replacement. It then provides details on maintenance needs and procedures for specific textile processes like singeing, desizing, scouring, bleaching, dyeing, and finishing. Checklists are also included for yearly, half-yearly, and monthly maintenance of machinery. The goal of maintenance is to keep equipment functioning properly to maximize productivity and minimize downtime.
Quality costing and reporting of garments and textile industry of BangladeshTAREK MAHMUD
Quality costing is an important measurement tool for assessing the quality of product and service. Quality costing help to detect prevention, appraisal and internal & external failure cost of the product and service.
This document discusses fabric inspection systems used in the garments industry. It describes four main inspection systems: the 4-point system, 10-point system, Graniteville "78" system, and Dallas system. Each system involves identifying fabric defects and assigning penalty points based on defect length and severity. The 10-point system separately inspects warp and weft directions. The goal of inspection is to detect defects early to avoid wasting time and money on defective garments. Inspection occurs at various stages of production from pre-production to final product. Both textile suppliers and garment manufacturers are responsible for ensuring fabrics meet buyer standards through inspection.
SOP of Seven Zero System or Traffic Light System । TLSRabiul Hasan
Standard of Operating Procedure of sewing Traffic Light System or Seven Zero System. Traffic Light System in Garments also known as TLS. Basically it's a Quality tool to improve garments product quality from sewing line. Traffic light system is the most effective inspection tool to reduce defect generation at source. It is a random inspection system. Traffic Light System is a visual control for highlighting quality issues in sewing line. Traffic light quality system works in a similar fashion the transportation traffic light system works. Three different colour cards are placed in each operators place. Green indicates that Quality meets the customers Standard. Yellow indicates that a minor fault has been found and caution is required. Red indicates that the Quality Standard does not meet the customers standard requirement.
This document summarizes the agenda and content covered in a skills matrix tutorial session. The session focused on helping students develop strong skills matrix stories using the STAR-L method and providing feedback to each other. Key points included how to analyze job postings by identifying required skills, industry terms, needed qualities, and relevant experiences. Students were assigned to research job postings and complete their skills matrices due the following week.
A new technology based on nano bubbles developed and patented by a Spanish company, Jeanologia, is known as e-flow. The e-flow ‘breaks up’ the surface of the garment, achieving soft hand feel and controlling shrinkage. A minimal quantity of water is needed and there is zero discharge from the process. Air from the atmosphere is introduced into an electro flow reactor and subjected to an electromechanical shock creating nano bubbles and a flow of wet air. The nano bubble mix is then transported into a rotating tumbler containing the denim garments, and when it comes into contact with them produces a soft and natural hand feel. The garments are then dried in the same tumbler. When treating indigo dyed garments with this technology, some indigo cross contamination may occur that can be eliminated by a dry ozone treatment.
Traffic Light System is a visual quality control tool used in garment manufacturing to reduce defects at their source. It works by randomly inspecting operators' workstations and placing colored cards - green for meeting quality standards, yellow for minor faults, and red for not meeting standards. This alerts operators to quality issues and allows immediate corrective action. Studies show the system can increase production capacity by 5% and lower rework rates from 2.14% to 1.01% by motivating operators and catching defects earlier. It is an effective yet easy to implement system that can improve quality, costs, lead times and supply chain performance for apparel companies.
Inline inspection in the garment industry involves checking product quality during the production process rather than after completion. This allows defects to be identified and addressed earlier. There are several methods of inline inspection, including checking at fixed checkpoints within the production line and roving checks by quality inspectors. The goals of inline inspection are to stop defects from occurring, improve productivity by reducing rework, provide early feedback to other departments, and lessen the workload of final inspectors. It is particularly important for complex garments with many production steps.
At present Industrial Engineering (IE) is one of the important department for each garments or textile factory. Today’s maximum factory is run by industrial engineers, where they have to follow a process flow chart. By which they can easily control the whole garments production processes....
This document provides information about line balancing for a textile production process. It begins with an introduction to line balancing and definitions. It then discusses specific methods for balancing a production line, including determining the number of operators needed, work-in-process inventory levels, and standard minute values. The document provides examples of time studies, production data collection, and calculating key metrics like pitch time and bottleneck processes. The goal is to design an optimized production flow to improve throughput and reduce costs.
The document discusses various formulas used in the garment industry for tasks like setting production targets, measuring individual and line efficiencies, tracking work-in-process, and calculating costs. It also provides examples of how industrial engineering concepts are applied through tasks like time studies, standard setting, production planning, and performance analysis to improve factory processes and operations. Key roles of industrial engineers include work measurement, standard setting, planning, analysis, improvement projects, and ensuring efficient use of resources.
This document is a presentation by Md. Shamsuzzaman on garment production and productivity. It discusses key topics like the definitions of production and productivity, benefits of increased productivity, factors affecting productivity, ways to improve productivity in garment production, and key factors that can decrease garment production. It also provides an example calculation of garment production output and outlines steps that should and should not be taken to measure and improve productivity. The overall presentation aims to educate about optimizing garment manufacturing processes and outputs.
The document discusses the roles and responsibilities of different positions in a garment factory's production, store, commercial, accounts, merchandising, and HR departments. It describes 18 positions in production including operators, helpers, supervisors, quality inspectors, quality controllers, finishing supervisors, cutting masters, and production managers. It also outlines responsibilities for store managers and keepers, commercial officers, accounts officers, merchandising managers and assistants, and HR in-charges and officers. Finally, it discusses quality control considerations for procurement, knitting, batching, and dyeing processes.
There are three main categories of garment defects: 1) Fabric defects related to the material itself, 2) Workmanship and handling defects caused during the production process such as cutting and sewing, and 3) Defects related to trims, accessories, and embellishments like colors, sizing, and placement. Defects are further classified as critical, major, or minor depending on their severity, with critical defects not being shipped and major defects limited to 3% or less depending on buyer requirements. Typical defects include seam puckering, shading variations, open or broken seams, dropped stitches, wavy stitching, loose threads, sizing issues, ironing problems, misaligned buttons/holes, and issues with
Process flow of knit industry for a basic t-shirtMohin Mahmud
The document discusses the history and growth of Bangladesh's knitwear industry since the 1970s. It outlines the key steps in knit composite manufacturing including knitting, dyeing, cutting, printing, sewing, washing, finishing and packing. Knitting turns yarn into fabric using interconnected loops and has advantages over woven fabrics like flexibility and ability to create smaller pieces. The knitwear industry has lower costs and requires less space than woven composites. It has become the largest export sector in Bangladesh, surpassing woven garments. The objectives of the study are to evaluate each stage of the knit composite process flow and understand how it functions as a whole.
Garment manufacturing process from fabric to poductKarthika M Dev
This was one of my internship project which i done in SIYARAM'S in Gujarat. This is all about the process wch going in the factory from raw materials to the finished goods After a conformed order. Hope this will be helpful.
Standard minute value( SMV) in garments, calculation and importanceMazharul Islam
This document discusses the calculation and importance of standard minute value (SMV) in the apparel industry. It defines SMV as the basic time plus allocated allowances needed to produce a garment. Basic time is calculated as the observed time multiplied by a rating factor and represents the likely minimum time required. Observed time is the recorded time taken under close observation. Rating factors adjust for worker speed. SMV is important for costing, setting targets, measuring efficiency, and planning factory production. Formulas are provided for calculating basic time and SMV from observed cycle times under different conditions.
The document discusses various topics related to industrial engineering processes in garment manufacturing, including:
1. How to calculate the Standard Allowed Minute (SAM) value for a garment, which is used to measure work content and for cost estimation.
2. The different types of garment production systems and how factors like machinery and labor affect the system type.
3. How to calculate key metrics like production targets, line efficiency, garment cost, and operator efficiency that are important for production management and cost control.
4. Process flow charts that illustrate the sequence of operations to make basic garments and show how raw materials are transformed through cutting, sewing, finishing and packaging processes.
This document discusses different types of garment defects categorized into 3 groups: 1) fabric defects found in the material itself, 2) workmanship and handling defects caused during production, and 3) defects related to trims, accessories, and embellishments. Workmanship defects include seam puckering, shading variations, open or broken seams, broken stitches, dropped stitches, wavy stitching, and loose threads. Defects are further classified as critical, major, or minor depending on their severity. Typical defects from each category are provided as examples.
We took two quality control problems from the apparel/textile industry and used 2 classical QC tools to solve one of them, i.e., fishbone diagram and flowchart for the open seam defect, and 2 new QC tools to solve the other one, i.e., tree diagram and affinity diagram for the shade variation defect. We presented a report on the same.
Defects of garment(print, fabric & sewing)Rupak Barua,
This document discusses various types of defects that can occur in fabric, printing, dyeing, sewing, and other stages of apparel production. It begins by defining defects and classifying them based on their severity. Section 1 then lists and describes common fabric defects such as loose warp, double ends, broken warp, and oil spots. Section 2 covers dyeing, printing and finishing faults. Section 3 examines sewing problems like slipped stitches, seam pucker, and variable stitch density. Section 4 lists other defects from sizing, ironing, trims and accessories. The document emphasizes that defects can lead to lower prices or seconds goods, creating significant value loss. It stresses the importance of quality control and remedial measures to minimize defects
The document describes a Traffic Light System (TLS) implemented at a garment factory to monitor quality and identify problems at production lines. The TLS involves:
1. An in-line auditor inspecting random samples from each operation daily and assigning color codes (green, yellow, red) based on defects found.
2. Actions like stopping production for red lights to address issues. Top defect-making operations are discussed at meetings.
3. End-line inspection also identifies defect-making operations. Data is captured on forms and charts to track performance over time, with the goal of reducing defects and achieving Right First Time production.
The document discusses maintenance of textile machinery. It defines different types of maintenance including reactive, preventive, predictive, and capital replacement. It then provides details on maintenance needs and procedures for specific textile processes like singeing, desizing, scouring, bleaching, dyeing, and finishing. Checklists are also included for yearly, half-yearly, and monthly maintenance of machinery. The goal of maintenance is to keep equipment functioning properly to maximize productivity and minimize downtime.
Quality costing and reporting of garments and textile industry of BangladeshTAREK MAHMUD
Quality costing is an important measurement tool for assessing the quality of product and service. Quality costing help to detect prevention, appraisal and internal & external failure cost of the product and service.
This document discusses fabric inspection systems used in the garments industry. It describes four main inspection systems: the 4-point system, 10-point system, Graniteville "78" system, and Dallas system. Each system involves identifying fabric defects and assigning penalty points based on defect length and severity. The 10-point system separately inspects warp and weft directions. The goal of inspection is to detect defects early to avoid wasting time and money on defective garments. Inspection occurs at various stages of production from pre-production to final product. Both textile suppliers and garment manufacturers are responsible for ensuring fabrics meet buyer standards through inspection.
SOP of Seven Zero System or Traffic Light System । TLSRabiul Hasan
Standard of Operating Procedure of sewing Traffic Light System or Seven Zero System. Traffic Light System in Garments also known as TLS. Basically it's a Quality tool to improve garments product quality from sewing line. Traffic light system is the most effective inspection tool to reduce defect generation at source. It is a random inspection system. Traffic Light System is a visual control for highlighting quality issues in sewing line. Traffic light quality system works in a similar fashion the transportation traffic light system works. Three different colour cards are placed in each operators place. Green indicates that Quality meets the customers Standard. Yellow indicates that a minor fault has been found and caution is required. Red indicates that the Quality Standard does not meet the customers standard requirement.
This document summarizes the agenda and content covered in a skills matrix tutorial session. The session focused on helping students develop strong skills matrix stories using the STAR-L method and providing feedback to each other. Key points included how to analyze job postings by identifying required skills, industry terms, needed qualities, and relevant experiences. Students were assigned to research job postings and complete their skills matrices due the following week.
A new technology based on nano bubbles developed and patented by a Spanish company, Jeanologia, is known as e-flow. The e-flow ‘breaks up’ the surface of the garment, achieving soft hand feel and controlling shrinkage. A minimal quantity of water is needed and there is zero discharge from the process. Air from the atmosphere is introduced into an electro flow reactor and subjected to an electromechanical shock creating nano bubbles and a flow of wet air. The nano bubble mix is then transported into a rotating tumbler containing the denim garments, and when it comes into contact with them produces a soft and natural hand feel. The garments are then dried in the same tumbler. When treating indigo dyed garments with this technology, some indigo cross contamination may occur that can be eliminated by a dry ozone treatment.
Using lean to reduce prototype lead time 2006Chris Baichoo
The document discusses Watlow Batavia's efforts to reduce lead times for custom heating part prototypes from 12 weeks to 6 weeks using Lean concepts. It outlines four Kaizen events from 2003-2006 that standardized processes, created dedicated prototype cells, and reduced waste. As a result, productivity increased 34% from 2003-2006, sales doubled, and lead times were cut in half, improving competitiveness and ensuring the division's survival.
Training needs analysis, skills auditing and training roi presentation 31 aug...Charles Cotter, PhD
This document discusses training needs analysis, skills auditing, and training return on investment. It provides an overview of the training process and cycle, including training needs analysis, skills auditing, workplace skills plans, and evaluating training return on investment. It describes a 6-step process for conducting a training needs analysis involving situational analysis, envisioning desired outcomes, identifying data collection methods, collecting data, sharing findings, and developing an implementation plan. Best practices for skills auditing are outlined, including using job analyses and developing performance standards. The skills auditing process involves determining skills requirements, auditing actual skills, and identifying development needs.
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
- Infosys has plans to expand its training facility in Mysore from accommodating 4,000 trainees to 10,000 trainees.
- Wipro Spectramind provides educational support called SEED to help talented employees pursue higher education so they are not lost to the business.
- LG Electronics requires its staff to complete two training modules per month with tests and provides prizes every three months to encourage learning.
PRODUCTIVITY IMPROVEMENT IN STITCHING SECTION OF A GARMENT MANUFACTURING COMPANYAM Publications
In this study one heuristic assembly line balancing technique known as the “Ranked Positional weight Technique”, developed by Helgeson and Birnie was applied to solve the problem of assembly line balancing in a garment manufacturing company for one model. Information about solution methods related to assembly line balancing problems is given. Operator reduction is achieved by line balancing. Layout was modified using the template method. The aim of this article is the usage of these techniques to improve the productivity in a clothing company.
1. The document discusses improving line efficiency in a garment manufacturing plant through line balancing and layout modification.
2. It analyzes the sewing line balancing problem using the Largest Candidate Rule Algorithm and Ranked Positional Weight Method to optimally assign tasks to workstations.
3. The goal is to evenly distribute work across stations to reduce work-in-progress, waiting times, production cycle times and costs which are currently problems in the plant due to unbalanced lines.
This document presents a mathematical model for analyzing a generic single channel, multi-phase production line. The model aims to minimize system costs by reducing idle machine times and work-in-process inventory levels between machines. The model accounts for machine cycle times and calculates the times at which products enter and exit each machine in the production line. It assumes deterministic arrival rates and develops equations to determine the optimal level of service to minimize the total expected costs of providing service and of waiting for service.
AN EXPERIMENTAL STUDY ON THE AUTOMOTIVE PRODUCTION LINE USING ASSEMBLY LINE B...IAEME Publication
The main aim of an assembly line is to group the different facilities and workers inan efficient manner in order to obtain effective utilization of man power and machine.This calls for uniform rate of production as well as decrease in the work in process
inventory. Hence, this paper attempts to achieve these in an assembly line of anautomotive manufacturing unit using three different techniques such as Largestcandidate rule (LCR), Kilbridge and wester column method (KWC) and Rank
positional weighted method (RPW). All the three methods show better efficiency and acomparison is also drawn amongst the three to determine the best suited techniquepertaining to the current research work
Balancing the line by using heuristic method based on cpm in salbp –a case studyeSAT Journals
Abstract
In mass production systems, line balancing plays a great role, but this is not easy even if it is a simple straight line. So, in order to
solve these problems Heuristic methods are very much desirable. It is also found that Heuristic methods play a great role in the
formation of metaheuristic methods.Therefore it is very much important to use more efficient heuristic methods. In this research
paper we presents a heuristic method that is based on critical path method for simple assembly line balancing. This research is
mainly concerned with objectives of minimizing the number of workstations, improvement of smoothness index, mean absolute
deviation (MAD) and increasing line efficiency.
Keywords-Heuristic methods,Assembly line balancing problem, Critical path method, Simple assembly line balancing.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The document presents an experimental design of a constraint satisfaction adaptive neural network (CSANN) for solving generalized job-shop scheduling problems. The CSANN is able to easily map the constraints of a scheduling problem into its architecture and remove any constraint violations during processing through adaptive adjustment of connection weights and biases. Simulation results show that the CSANN produces good solutions, often near-optimal, for various sized job-shop scheduling problems, from small problems with known optimal solutions to larger problems with hundreds of operations where optimal solutions are not known. The CSANN approach provides an effective means for solving complex job-shop scheduling problems in a manner that scales linearly with problem size.
Assembly Line Balancing to Improve Productivity using Work Sharing Method in ...ijtsrd
The garment factories are always trying to improve production and the quality of the garments to sustain in the enormous competitive market. This paper is about the productivity improvement by reducing cycle time with work sharing in garment factories. A garment factory manufactures different types of garments. In many types of garment productions, this paper is to improve productivity of lady pencil skirts production process. Overall efficiency of single model assembly line by reducing the non value added activities, cycle time and distribution of work load at each work station by line balancing. For that, the productivity improvement is shown by two ways. The first way is proper training and supervision for activities and the second is work sharing with same type of jobs and skills. Keywords Cycle Time, Line Balancing, Productivity, Training, Work Sharing. Khin Nann Yu Aung | Yin Yin Tun "Assembly Line Balancing to Improve Productivity using Work-Sharing Method in Garment Factories" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-5 , August 2019, URL: https://www.ijtsrd.com/papers/ijtsrd26656.pdfPaper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/26656/assembly-line-balancing-to-improve-productivity-using-work-sharing-method-in-garment-factories/khin-nann-yu-aung
IRJET- Basic Study of Assembly Line BalancingIRJET Journal
1) The document discusses assembly line balancing, which involves assigning tasks to workstations in a way that minimizes idle time while satisfying precedence constraints between tasks.
2) It provides an overview of different types of assembly lines, including single model lines, mixed model lines, multi-model lines, paced vs unpaced lines.
3) The objectives of assembly line balancing are outlined as minimizing the number of workstations, minimizing cycle time, maximizing workload smoothness, and maximizing work relatedness.
The document discusses improving the efficiency and productivity of a sewing section in an apparel factory by addressing low performing operators. It begins with an introduction describing the importance of the apparel industry in Bangladesh and the need for continuous improvements. It then reviews relevant literature on productivity, line layout, workstation layout, line balancing, time study, standard minute value, and the eight wastes of lean production. The methodology section describes analyzing data from a sewing line to identify seven low performing operators. The goal is to eliminate wastes and bottlenecks through tools and techniques to improve productivity.
The document discusses strategies for achieving labor flexibility in the garment industry. It presents a case study of a garment company that receives an order for 3000 military uniforms to be completed within 30 working days. The document proposes algorithms to determine the optimal number of workers and distribution of tasks among skill levels to minimize labor costs and production time without penalties. The goal is to apply numerical and functional labor flexibility strategies to find the most cost-effective solution.
Job Shop Layout Design Using Group TechnologyIJMER
This document summarizes a study that uses simulation to improve the performance of a job shop layout by reconfiguring the machines. 34 job elements that are processed on 6 machines were analyzed. The jobs were clustered into 4 part families using direct clustering. Similar machines were then grouped together. Computerized Relative Allocation of Facilities Technique (CRAFT) with computer graphics was used to design a new layout. The initial layout had a total material handling cost of 1738.75 units per period. The optimized layout designed using CRAFT reduced this cost to 1071.25 units, a significant improvement without additional investment.
Artificial Neural Networks can achieve high degree of computation rates by
employing a massive number of simple processing elements with a high degree of
connectivity between elements. In this paper an attempt is made to present a Constraint
Satisfaction Adaptive Neural Network (CSANN) to solve the generalized job-shop
scheduling problem and it shows how to map a difficult constraint satisfaction job-shop
scheduling problem onto a simple neural net, where the number of neural processors equals
the number of operations, and the number of interconnections grows linearly with the total
number of operations. The proposed neural network can be easily constructed and can adjust
its weights of connections based on the sequence and resource constraints of the job-shop
scheduling problem during its processing. Simulation studies have shown that the proposed
neural network produces better solutions to job-shop scheduling problem.
This document summarizes a study that used simulation to improve the layout of a job shop manufacturing facility using group technology concepts. 34 parts processed on 6 machines were analyzed. The parts were divided into 4 families using direct clustering. A new layout was designed with similar machines grouped together using the CRAFT algorithm. This resulted in a minimum material handling cost layout. The initial layout cost was 1738.75 units per period, while the optimized layout using group technology concepts and CRAFT algorithm cost 1071.25 units per period, a significant cost reduction.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Improving productivity of apparel manufacturing system using value stream map...eSAT Journals
Abstract Traditional printing works in maximum garment industries are facing different problems like low productivity, longer production lead time, high rework and rejection, low flexibility, lower quality product, high non-value added work etc. In this study these different problems were identified by using numerous effective production control tools like process analysis, layout of work station, motion and time study, work standardization etc. The encouraging results after implementing these tools give the way to go forward and thrust to reach at the end point. Some key benefits of this implementation are decrease in sample rejection level by 70%, reduction of work level for repairing works by 80%. Value stream mapping has been used to identify the most bottleneck process. Eliminating bottleneck process results in reduction of excess motion and non-value added works by 50%. As a result, total processing time for final output is decreased. After the implementation of these tools effectively, the result shows a significant improvement of the production than before. Index Terms: Value stream mapping, Production control tools, Process analysis, Motion study, Time study.
This paper presents an interactive decision support system called YFADI for production planning and scheduling in the textile industry. Textile production has complex characteristics like multi-phase processes with multiple machines per phase, different planning horizons and requirements for each phase. YFADI accounts for these characteristics and aims to optimize scheduling to minimize setup times across phases. The system architecture and algorithms for master production scheduling are described.
IRJET- A Review: Design, Analysis & Optimization of Drag Chain ConveyerIRJET Journal
This document summarizes a review of the design, analysis, and optimization of drag chain conveyors. It begins by describing how vibrations in chain conveyors can cause failures and reduce chain durability. It then discusses the development of a multi-body simulation model to analyze vibrations. The review aims to redesign the chain conveyor system to eliminate errors and reduce the power needed by the conveyor drive motor.
The team of ten members was tasked with designing a plant to manufacture and assemble hair dryers for use in regional peripheral warehouses, shopping malls, and shops. A well-equipped assembly area, a raw materials warehouse (RMW), a finished product warehouse (FPW), a semi-finished storage area, and service areas have all been available at the plant. Geometric and volumetric sizing, lines and/or cells and/or work departments, shelving, reception areas, shipping areas, picking areas, packaging areas, and finished product containment buildings were all the responsibility of each project team.
1) The study used value stream mapping to analyze the production process of PLC controllers at PALCO in Jordan. The current state map revealed long cycle times for preparing and wiring controllers.
2) Implementing lean principles and techniques, including purchasing an automated crimping machine and adding staff, reduced the wiring preparation time by 50 minutes. This decreased the production cycle time by 30% and increased output from 2 to 4 units per day.
3) The future state map proposed merging some processes, standardizing roles, and using a supermarket pull system to further improve flow and double production rates.
Similar to Line Balancing for Improving Apparel Production by Operator Skill Matrix (20)
The document summarizes the impacts of COVID-19 on the Bangladeshi economy. It discusses how the pandemic has disrupted livelihoods and reduced incomes. Key sectors like textiles have been affected. The government announced stimulus packages including loans, but the economy is still expected to decline by 3-4%. Challenges in implementing social distancing due to population density are also noted. International assistance is needed to help Bangladesh minimize the pandemic's impacts.
Aid, development and diplomacy: Need for an aid policy book review by elias ...Elias Khalil (ইলিয়াস খলিল)
The document summarizes a book review of the book "Aid, Development and Diplomacy: Need for an Aid Policy". The book discusses how Bangladesh's concept of development has expanded to include human development factors in addition to economic growth. It argues that Bangladesh needs to modify its aid policy and diplomacy to attract more aid from donors based on this expanded concept. The book also analyzes Bangladesh's aid scenario, issues with aid conditionalities and utilization, and case studies of successful and unsuccessful projects. While providing useful information, the reviewer critiques that the book could have analyzed issues like the relationship between aid and liberalization, and Bangladesh's development experience in comparison to other countries, in more depth.
Aid, Development and Diplomacy : Need for an Aid Policy Book Review by Elias ...Elias Khalil (ইলিয়াস খলিল)
The document summarizes a presentation on a book called "Aid, Development and Diplomacy: Need for an Aid Policy". It discusses the book's authors, topics covered including Bangladesh's aid scenario, case studies on development projects, the impact of aid on development, and the need for an aid policy. The presentation outlines the book's contents and provides analysis of its strengths and weaknesses.
Phase change materials or PCMs are compounds which store and release latent heat by changing chemical bonds through a phase alteration. These materials absorb energy during the heating and release energy to the surroundings through a reverse cooling process. The integration of PCM in textiles by coating, encapsulation or any other means has grown concentration to the scientist. In this paper; characteristics, classification, working principle of PCMs and its versatile application in textiles are mainly discussed.
Nowadays, fashion in clothing is unimaginable without denim garment with a numerous effect. Various types of dry and wet process are used to make these effect. In this article, 3D/crinkle effect by creating wrinkles on the denim garments preceded by resin application is discussed. This effect gives vintage look as well as add value to the garments though having possibility of decreasing tearing strength.
Investigation on physical properties of organic cotton t shirt by bio-scourin...Elias Khalil (ইলিয়াস খলিল)
Wet processing treatment plays an important role in the physico-mechanical properties of finished apparel products. This paper presents an investigated result of enzymatic scouring and eco-friendly remazol reactive dyes treatment on the physical properties of finished T-shirt product. 100 % organic cotton single jersey knitted grey fabric having 160 gsm was considered. To investigate the selected physical characteristics of the finished organic cotton T-shirt, the eco-friendly enzymatic scouring with Prima Green Eco scour, Prima Fast Gold RSL and remazol ultra RGBN series reactive dyed treatment were performed following standard recipe. Selected physical properties namely washing fastness, bursting strength, fabric drapability, color fastness to rubbing, perspiration and absorption have been investigated for the newly developed organic cotton T-shirt that showed better results in terms of quality. Hence, it can be concluded that by selecting eco-friendly materials like organic cotton and chemical processing treatment, it is possible to develop finished T-shirt products with improved physical properties.
Investigation on physico chemical properties of 100% cotton woven fabric trea...Elias Khalil (ইলিয়াস খলিল)
This paper represents an approach to observe the physic-chemical effects of titanium dioxide (TiO2) applied on 100% cotton woven fabric. Cotton fabric was treated with TiO2 by exhaustion method and followed by necessary curing and washing pro-cesses. The treated fabrics were then analyzed by Scanning Electron Microscope (SEM) and the tensile strength, pH and ab-sorbency of the treated and untreated fabrics were examined. It was found that titanium dioxide impairs the hand feel and absorbency of 100% cotton woven fabrics, wetting time of all treated fabrics increased gradually than untreated fabrics. The treatment increases the tensile strength of 100% cotton woven fabrics. The treatment with titanium dioxide also kept the pH of the fabric in acidic medium.
Effect of gauge variation of circular knitting machine on physical and mechan...Elias Khalil (ইলিয়াস খলিল)
This paper deals with the results of an investigation of various gauges of circular knitting machines with a view to producing same single jersey fabric with different parameters. All parameters including machine diameter, stitch length, yarn count, yarn lot, yarn tension etc. but gauges are used for this work is different. Even dyeing has been done at the same time on the same machine by stitching one with other, finishing parameters and processes are also same and done at same time as well to minimize the effects of other variable which can be responsible for changing the physical and mechanical properties like finished width of the fabric, finished GSM (Grams per Square Meter), shrinkage, spirality, bursting strength etc. This is done for finding only the effects which actually affects the fabric properties. Finally the findings or results are as expected with some variations with the results that are thought theoretically.
Investigation on effluent characteristics of organic cotton fabric dyeing wit...Elias Khalil (ইলিয়াস খলিল)
Environmental sustainability is the major concern in the age of modern world. For textile and apparel sector, this has been a burning issue for many related concerned bodies. The pretreatment and dyeing process of greige fabrics results in large volume of effluents that has harmful effect on environment. In this study, the ecological parameters of the effluents obtained from scouring and dyeing of 100% organic cotton single jersey knitted fabrics with environmentally low impact Remazol series reactive dyes adopting exhaust dyeing method was investigated. The effluents collected for investigating the ecological parameters include chemical oxygen demand (COD), biological oxygen demand (BOD), total dissolved solids (TDS), total suspended solids (TSS), dissolved oxygen (DO) and alkalinity. The results show that the use of the low impact reactive dyes has greater ecological advantages as it reduces the COD, BOD, TDS, TSS, pH values and increases the DO values of effluents. Organic cotton itself being eco-friendly along with Remazol series sustainable dyes provides the better ecological results. Hence, the results indicated that wet processing of organic cotton knitted fabric with eco-friendly and low impact reactive dyes provide better ecological advantages.
Efficiency losses calculation and identify causes of losses of circular knitt...Elias Khalil (ইলিয়াস খলিল)
This thesis deals with a major problem of production loss of a knitting industry. The knitting machine has to stop when defects occurred and then faults are corrected, which results in time loss and efficiency loss. Not only that the knitted fabric may be rejected if quality requirements are not met. An effective monitoring is required to avoid defects and to avoid productivity and quality losses. The study identifies two main categories of defects (average time required for correcting defects and machine down time) are responsible for reducing productivity. The thesis reflects that due to yarn breakage machine stopped for seen minutes per days, for maintaining machine stopped for two hours per month, for needle breakage six minutes per day and for technical problem machine stopped for several times.
Influence of enzyme and silicone wash on the physico mechanical properties of...Elias Khalil (ইলিয়াস খলিল)
Garments washing is one of the most important finishing treatments applied on apparels which have vital use to create special outlooks and improving the fashion. Technologically washing is one of the most important fashion elements for clothing industry and production of washed garments depends on the machine quality. In order to achieve an optimum effect of washing process, on the woven fabric in different washing time, Enzyme Wash and then Silicone wash were carried out for cotton fabric. However, there are some of the comments that when the garments have longer washing time, use of the chemical on the washing procedure will affect the physical and mechanical performance. The aim of this study is to determine the effects of industrial enzyme silicone wash combined with silicone wash. For this study currently fashionable regular Non- denim (100% cotton with twill 3/1 weave construction) trouser was chosen. The selected Non-denim trouser has been processed by enzyme and then silicone wash. In order to evaluate the washing effects on Non-denim trouser, changes of fabric handle, fabric specification (ends/inch, picks/inch, surface density, warp & weft yarn linear density), fabric strength has been determined during and after washing
The use of enzymes in the textile chemical processing is rapidly gaining globally recognition because
of their non-toxic and eco-friendly characteristics with the increasingly important requirements for textile
manufactures to reduce pollution in textile production. Furthermore, the use of enzymes results in reduced
process times, energy and water savings, improved product quality and potential process integration. Variation
of knit fabric and enzyme concentration is taken to do this project. The aim is to know the effect of enzyme
concentration on the physical properties of knit garments of various constructions. In this project 0.4 g/l and 0.5
g/l enzyme concentration is taken to wash Single Jersey and Rib fabric. Then to see the effect of enzyme
concentration on the physical properties of Single Jersey and Rib fabric some tests like GSM, Bursting strength,
Dimensional Stability and Pilling are done. The results of before and after enzyme wash is compared to know
the effect of concentration of enzyme on the physical properties of Single Jersey and Rib fabric. After enzyme
wash GSM of the fabric increases, Dimensional Stability and Bursting strength decreases and pilling formation
on the fabric surface also decreases.
Evaluation of physico mechanical properties of 1×1 interlock cotton knitted f...Elias Khalil (ইলিয়াস খলিল)
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Effect of stitch length on physical and mechanical properties of single jerse...Elias Khalil (ইলিয়াস খলিল)
The physical and mechanical properties of knitted fabric can be changed due to use of various count of yarn, type of yarn
(ring, rotor, and compact), quality of yarn, stitch length / loop length, structural geometry, fiber composition of yarn etc. This study
focused on the various stitch length effect of grey single jersey. With an increase in stitch length, the dimensional properties like CPI,
WPI, GSM, thickness & tightness factor will be decreased for all the structures; while comfort properties like air permeability & water
absorbency will be increased. Again shrinkage & spirality will be decreased with increased stitch length at grey stage. Other properties
such as bursting strength, abrasion resistance & pilling resistance improved with increased stitch length. Though all the tests for fabric
properties were carried out for grey stage, there properties can considerably vary after further finishing of the fabrics. As finishing is
mandatory for fabric production, so now-a-days, these kinds of tests are carried out after finishing stage & proper controlling is done
according to desired quality. Sometimes, controlling of some properties of finished fabrics are beyond our trial. In that case, analysis of
fabric properties at grey stage can help us to take various control & corrective actions when necessary.
Effect of titanium dioxide treatment on the properties of 100% cotton knitted...Elias Khalil (ইলিয়াস খলিল)
Titanium dioxide (TiO2) is a white, water insoluble pigment. It is used in paints, plastics, foods, pharmaceuticals and cosmetics. Its main application on textile materials as an ultraviolet ray protecting agents. Titanium dioxide can reflect, scatter or absorb ultraviolet ray. Besides Titanium dioxide also modify the properties of fabrics. In previous research, titanium dioxide was applied mainly by padding mangle method. This paper presents an approach to observe the effect of titanium dioxide treatment 100% cotton knitted (plain jersey) fabric applied by exhaustion method followed by curing and washing. The treated fabrics were then analyzed by Scanning Electron Microscope (SEM) and the tensile strength, pH value and absorbency of the treated and untreated fabrics were checked. It is found that titanium dioxide impairs the better hand feel and absorbency (wetting time) of all treated fabrics increased gradually than untreated fabrics. The treatment increases the strength and keeps the pH of the fabric in acidic medium.
Effect of hardness of water on fixation and total wash off percentage of reac...Elias Khalil (ইলিয়াস খলিল)
Dye-house water quality is the most important parameter to be confirmed before dyeing; precisely the presence of metal content i.e. Hardness. This research will investigate & analyses the impact of separate hardness (i.e. Calcium, Magnesium & Iron) on particular „Turquoise‟ (C.I. Reactive Blue 21) & a „High Exhaustion‟ class (C.I. HE Red 120, C.I. HE Yellow 84) of Reactive dye on cotton knitted-fabric. From evaluation of dyed fabric the range of metal content is sorted out where the quality starts to fluctuate as distinctive visible & spectral change of shade & fixation rate of the dye molecules has been found. The result of the work will help for further projection about water quality degradation in upcoming years & its effect on dyeing behavior, also the sustainability of present dyeing process to cope with the ever degrading quality of water.
Effect of industrial bleach wash and softening on the physical, mechanical an...Elias Khalil (ইলিয়াস খলিল)
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ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Optimizing Gradle Builds - Gradle DPE Tour Berlin 2024Sinan KOZAK
Sinan from the Delivery Hero mobile infrastructure engineering team shares a deep dive into performance acceleration with Gradle build cache optimizations. Sinan shares their journey into solving complex build-cache problems that affect Gradle builds. By understanding the challenges and solutions found in our journey, we aim to demonstrate the possibilities for faster builds. The case study reveals how overlapping outputs and cache misconfigurations led to significant increases in build times, especially as the project scaled up with numerous modules using Paparazzi tests. The journey from diagnosing to defeating cache issues offers invaluable lessons on maintaining cache integrity without sacrificing functionality.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEMHODECEDSIET
Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
1. **Time Slots Allocation**: The core principle of TDM is to assign distinct time slots to each signal. During each time slot, the respective signal is transmitted, and then the process repeats cyclically. For example, if there are four signals to be transmitted, the TDM cycle will divide time into four slots, each assigned to one signal.
2. **Synchronization**: Synchronization is crucial in TDM systems to ensure that the signals are correctly aligned with their respective time slots. Both the transmitter and receiver must be synchronized to avoid any overlap or loss of data. This synchronization is typically maintained by a clock signal that ensures time slots are accurately aligned.
3. **Frame Structure**: TDM data is organized into frames, where each frame consists of a set of time slots. Each frame is repeated at regular intervals, ensuring continuous transmission of data streams. The frame structure helps in managing the data streams and maintaining the synchronization between the transmitter and receiver.
4. **Multiplexer and Demultiplexer**: At the transmitting end, a multiplexer combines multiple input signals into a single composite signal by assigning each signal to a specific time slot. At the receiving end, a demultiplexer separates the composite signal back into individual signals based on their respective time slots.
### Types of TDM
1. **Synchronous TDM**: In synchronous TDM, time slots are pre-assigned to each signal, regardless of whether the signal has data to transmit or not. This can lead to inefficiencies if some time slots remain empty due to the absence of data.
2. **Asynchronous TDM (or Statistical TDM)**: Asynchronous TDM addresses the inefficiencies of synchronous TDM by allocating time slots dynamically based on the presence of data. Time slots are assigned only when there is data to transmit, which optimizes the use of the communication channel.
### Applications of TDM
- **Telecommunications**: TDM is extensively used in telecommunication systems, such as in T1 and E1 lines, where multiple telephone calls are transmitted over a single line by assigning each call to a specific time slot.
- **Digital Audio and Video Broadcasting**: TDM is used in broadcasting systems to transmit multiple audio or video streams over a single channel, ensuring efficient use of bandwidth.
- **Computer Networks**: TDM is used in network protocols and systems to manage the transmission of data from multiple sources over a single network medium.
### Advantages of TDM
- **Efficient Use of Bandwidth**: TDM all
Literature Review Basics and Understanding Reference Management.pptxDr Ramhari Poudyal
Three-day training on academic research focuses on analytical tools at United Technical College, supported by the University Grant Commission, Nepal. 24-26 May 2024
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
The Python for beginners. This is an advance computer language.
Line Balancing for Improving Apparel Production by Operator Skill Matrix
1. International Journal of Science, Technology and Society
2015; 3(4): 101-106
Published online May 29, 2015 (http://www.sciencepublishinggroup.com/j/ijsts)
doi: 10.11648/j.ijsts.20150304.11
ISSN: 2330-7412 (Print); ISSN: 2330-7420 (Online)
Line Balancing for Improving Apparel Production by
Operator Skill Matrix
Md. Mazharul Islam1, *
, Md. Tanjim Hossain1
, Mohammad Abdul Jalil2
, Elias Khalil3
1
Department of Textile Engineering, Northern University of Bangladesh, Dhaka, Bangladesh
2
Department of Textile Engineering, Mawlana Bhashani Science and Technology University, Tangail, Bangladesh
3
Department of Textile Engineering, World University of Bangladesh, Dhaka, Bangladesh
Email address:
mazh999@gmail.com (Md. M. Islam), tanjimseu@yahoo.com (Md. T. Hossain), jalil.mbstu@gmail.com (M. A. Jalil),
eliaskhalil52@gmail.com (E. Khalil)
To cite this article:
Md. Mazharul Islam, Md. Tanjim Hossain, Mohammad Abdul Jalil, Elias Khalil. Line Balancing for Improving Apparel Production by
Operator Skill Matrix. International Journal of Science, Technology and Society. Vol. 3, No. 4, 2015, pp. 101-106.
doi: 10.11648/j.ijsts.20150304.11
Abstract: In this modern world, fashion & styles are changing frequently. The emergence of fast changes in fashion has given
rise to shorten production cycle time in the garment industry. To meet the dynamic customer demands of momentous quantities in
shorten lead time, assembly line production systems are used, where the garment components are assembled into a finished
garment through a sub-assembly process. So in the era of product customization, the optimal usage of resources especially the
available facilities & operators who are adding the value of product is important. Therefore the assembly line has to be planned in
much more flexible way. This paper deals with the maximum utilization of manpower in labor intensive assembly lines. The
objective is to accurately delegate workers to the various operations required to complete the product based on their skill &
experience so as to achieve the highest level of productivity and delivery as per planned target. The experimental result showed
meaningful improvement in productivity as compared to the existing system.
Keywords: Line Balancing, Skill Matrix, Assembly Line, Apparel Production
1. Introduction
As a supply chain of textile industry, garment industry is
one of the major industries of the world. The production
process of garments is separated into four main phases:
designing/ clothing pattern generation, fabric spreading &
cutting, sewing and ironing & packing. The most critical
phase is sewing phase [1]. As the sewing is the heart of
apparel industry, we have to design the sewing line properly
so as to achieve the best output at maximum efficiency.
Apparel is a mass production system. Assembly line
production systems are developed to meet the requirements
of mankind, which continue to grow day by day [2]. The
demand for greater product variability and shorter life cycles
has caused traditional production methods to be replaced
with assembly lines [3]. Assembly line is an industrial
arrangement of machines, equipments and workers for
continuous flow of work pieces in mass production operation.
Manufacturing a product in an assembly line requires
partitioning the total amount of work into a set of elementary
operations called tasks [4]. Tasks are assigned to operators
depending on constrains of different labor skill levels. Finally,
several workstations in sequence are formed as a sewing line
[5]. The sewing process includes a set of work stations, at
each of which a specific task is carried out in a restricted
sequence, with hundreds of employees and thousands of
bundles of sub-assemblies producing different style
simultaneously [6]. Therefore this process is of critical
importance and needs to be planned more carefully [7]. As a
consequence, good line balancing with small stocks in the
sewing line has to be drawn up to increase the efficiency and
quality [7-9]. So the aim of assembly line balancing in
sewing line is to assign tasks to the workstations, so that the
machines of the workstation can perform the assigned task
with a balanced loading with different labor skill levels [5].
2. Literature Review
A line is defined as a group of operators under the control of
one production supervisor [10]. Balancing is the technique of
maintaining the same level of inventory at each and every
2. 102 Md. Mazharul Islam et al.: Line Balancing for Improving Apparel Production by Operator Skill Matrix
operation at any point of time to meet the production target and
to produce garments of acceptable quality [10]. Assembly line
balancing (ALB) is a managerial technique and can be applied
to balance production flow lines [11-12]. Line balancing is the
distribution of work on the line in such a way that everyone
gets the same amount of work in terms of time [13]. In practice,
a perfect balance could not be achieved but we can improve
the situation by using proper technique.
The assembly line balancing problem was first introduced
by Bryton in his graduate thesis. In his study, he accepted the
amount of workstations as constant, the workstation times as
equal for all stations and work tasks as moving among the
workstations [14]. The first article was published in 1955 by
Salveson [15]. He developed a 0-1 integer programming
model to solve the problem. This heuristic method was
developed by Helgeson and Birnie of the General Electric
Company in 1961 COMSOAL (Computer Method of
Sequencing Operations for Assembly Lines) was first used by
Arcus in 1966 as a solution approach to the assembly line
balancing problem [16,17]. Bartholdi (1993) was the first to
address the Two-sided Assembly Line Balancing Problem
with the objective of minimizing the number of stations by
applying a simple assignment rule. Liu & Chen (2002)
presented a Genetic Algorithm approach for assembly
planning involving various objectives, such as minimizing
cycle time, maximizing workload smoothness, minimizing
the frequency of tool change, minimizing the number of tools
and machines used and minimizing the complexity of
assembly sequences [18-19]. Helgeson ve Birnie (1961)
developed the “Ranked Positional Weight Technique” in
which operation having the largest ranged weight is assigned
to the first workstation, and other operations are assigned to
workstations in accordance with their ranked positional
weight value [16]. Abdolmajid Yolmeh et al. (2012) proposed
a hybrid genetic algorithm to solve the assembly line
balancing problem [20].
Operator's Skill Inventory is the database which maintains
the record of each operator, who can do what type of
operation and at what rating. It is very important to keep this
database updated as over the time, operator acquire skills for
most of the new operations as well as improve performance
in existing operations [21].With the use of skill matrix an
engineer's or line supervisors needs very list time to find out
and select most efficient operator for a particular operation
from the pull of operation. It helps the line supervisor for
balancing the line with particular skilled operators according
to the work content [21].
There are so many researches going on in the field of
assembly line balancing. Various methods are used for
balancing sewing lines which are discussed in the above
section. We use operator skill matrix for better allocation of
operator throughout the sewing line to get maximum output.
3. Materials and Methodology
In this experiment, 100% cotton Jacket was considered.
Total 30 sewing machines were used where number of plain,
over lock and flat lock machines was 13, 11, and 6
respectively.
In order to balance a production line in sewing floor a line
was chosen & necessary data was accumulated from the line.
First the garment was analyzed and operational bulletin or
breakdown was created with process sequence, operational
description & machine requirements (Table 1). Then workers
were placed to different work stations based on operation &
machine types and a standard minute for each job was given
to the operators (allocated SMV) (Table 1). After one day we
calculate the output & found that we didn’t get the desired
output. To found out the problem, we calculated individual
workers performed SMV by work study. After that workers
individual efficiency & output at individual efficiency was
calculated and then saw that efficiencies varies dramatically
due to unplanned layout (Table 1). So to balance the line we
have to rearrange the operators within the line. To do this,
first machine-wise breakdown (Table 2 to Table 7) was done
and workers are reallocated based on two assumptions: a)
operators are only be allocated depending on the machine
type that he/she can operate; b) allocation is also depend on
operation type that he/she can perform. After fulfilling above
two conditions we rearranged operators based on SMV.
Higher the SMV, higher should be the efficiency % as we
know where the workload is high, we need higher efficient
worker. After total rearrangement, we again calculated the
output (Table 8). We observed that productivity is increased
but not up to the theoretical productivity. In some process,
huge bottleneck was appeared. So to improve productivity
we introduced another worker to the bottleneck operation by
dividing the workload between two workers (Table 9).
Finally we got satisfactory productivity.
4. Experimental Data
Operational Bulletin of Jacket before and after
arrangement, Breakdown of different machines before and
after rearrangement along with comparison of productions
are shown below in different tables.
Table 1. Operational Bulletin of Jacket before arrangement.
SL Process Name Name M/c Type
Performed
SMV
Allocated
SMV
Output @
100% eff
Efficiency %
Output @
performed
efficiency %
1 Back part panel join Jarna O/L 0.64 0.62 96.77 96 93.26
2 Back panel ts tc Naher F/L 0.35 0.3 200.00 87 173.08
3 Left and right panel join Hasina O/L 1.72 0.62 96.77 36 34.95
4 Left and right panel join Eima O/L 1.28 0.62 96.77 48 46.88
5 Left and right panel ts and tc Mena F/L 0.62 0.55 109.09 89 97.30
3. International Journal of Science, Technology and Society 2015; 3(4): 101-106 103
SL Process Name Name M/c Type
Performed
SMV
Allocated
SMV
Output @
100% eff
Efficiency %
Output @
performed
efficiency %
6 Front part panel join & tc Ronju O/L 0.78 0.5 120.00 64 76.60
7 Front part panel ts & tc Monzilla L/S 0.53 0.3 200.00 57 113.92
8 Left & right panel join Amina O/L 0.82 0.62 96.77 76 73.47
9 Left and right panel join Sahina O/L 0.79 0.62 96.77 78 75.95
10 Left and right panel ts & tc Nurbanu F/L 0.53 0.55 109.09 103 112.50
11 Shoulder panel join Lima O/L 0.94 0.43 139.53 46 63.60
12 Shoulder panel ts Alima F/L 0.88 0.42 142.86 48 68.18
13 Shoulder join Rojina O/L 0.92 0.59 101.69 64 65.45
14 Sleeve panel make Morina O/L 0.64 0.45 133.33 70 93.26
15 Sleeve panel top stitch & tc Sokina F/L 0.47 0.49 122.45 104 126.76
16 Sleeve hem Momina F/L 0.42 0.3 200.00 71 141.73
17 Collar make Pervin L/S 0.79 0.63 95.24 80 75.95
18 Collar twill tape attach Rebeka L/S 0.26 0.22 272.73 85 230.77
19 Collar serving Roksana O/L 0.43 0.39 153.85 90 138.46
20 Zipper twill tape make Sabina L/S 0.88 0.42 142.86 48 68.44
21 Zipper twill tape attach Rojina L/S 0.87 0.5 120.00 57 68.97
22 Zipper holding tuck Bobita L/S 0.66 0.3 200.00 45 90.91
23 Zipper patch attach at bottom Shahanara L/S 0.45 0.57 105.26 127 133.33
24 Collar join Sabina L/S 1.77 0.78 76.92 44 33.90
25 Collar join Shahila L/S 1.99 0.78 76.92 39 30.15
26 Zipper tuck with body Naher L/S 0.36 0.42 142.86 118 168.22
27 Zipper join with left side Halima L/S 0.58 0.5 120.00 86 103.45
28 Zipper join right side Orchona L/S 0.76 0.69 86.96 90 78.60
29 Zipper facing join Beauty L/S 0.66 0.5 120.00 76 90.91
30 Zipper facing o/l Sharmin O/L 0.36 0.3 200.00 83 165.14
Max Theoretical output 76.92 practical output 30 pcs
Table 2. Breakdown of Plain machines before rearrangement.
SL Process Name Name M/c Type Performed SMV Efficiency
7 Front part panel ts & tc Monzilla L/S 0.53 57%
17 Collar make Pervin L/S 0.79 80%
18 Collar twill tape attach Rebeka L/S 0.26 85%
20 Zipper twill tape make Sabina L/S 0.88 48%
21 Zipper twill ta[e attach Rojina L/S 0.87 57%
22 Zipper holding tuck Bobita L/S 0.66 45%
23 Zipper patch attach at bottom Shahanara L/S 0.45 127%
24 Collar join Sabina L/S 1.77 44%
25 Collar join Shahila L/S 1.99 39%
26 Zipper tuck with body Naher L/S 0.36 118%
27 Zipper join with left side Halima L/S 0.58 86%
28 Zipper join right side Orchona L/S 0.76 90%
29 Zipper facing join Beauty L/S 0.66 76%
Table 3. Breakdown of Plain machines after rearrangement.
SL Process Name Name M/c Type Performed SMV Efficiency
18 Collar twill tape attach Shahila L/S 0.26 39%
26 Zipper tuck with body Sabina L/S 0.36 44%
23 Zipper patch attach at bottom Bobita L/S 0.45 45%
7 Front part panel ts & tc Sabina L/S 0.53 48%
27 Zipper join with left side Monzilla L/S 0.58 57%
22 Zipper holding tuck Rojina L/S 0.66 57%
29 Zipper facing join Beauty L/S 0.66 76%
28 Zipper join right side Pervin L/S 0.76 80%
17 Collar make Rebeka L/S 0.79 85%
21 Zipper twill tape attach Halima L/S 0.87 86%
20 Zipper twill tape make Orchona L/S 0.88 90%
24 Collar join Naher L/S 1.77 118%
25 Collar join Shahanara L/S 1.99 127%
4. 104 Md. Mazharul Islam et al.: Line Balancing for Improving Apparel Production by Operator Skill Matrix
Table 4. Breakdown of Overlock machines before rearrangement.
SN Process Name Name M/c Type Performed SMV Efficiency
1 Back part panel join Jarna O/L 0.64 96%
3 Left and right panel join Hasina O/L 1.72 36%
4 Left and right panel join Eima O/L 1.28 48%
6 Front part panel join & tc Ronju O/L 0.78 64%
8 Left & right panel join Amina O/L 0.82 76%
9 Left and right panel join Sahina O/L 0.79 78%
11 Shoulder panel join Lima O/L 0.94 46%
13 Shoulder join Rojina O/L 0.92 64%
14 Sleeve panel make Morina O/L 0.64 70%
19 Collar serving Roksana O/L 0.43 90%
30 Zipper facing o/l Sharmin O/L 0.36 83%
Table 5. Breakdown of Overlock machines after rearrangement.
SN Process Name Name M/c Type Performed SMV Efficiency
30 Zipper facing o/l Hasina O/L 0.36 36%
19 Collar serving Lima O/L 0.43 46%
14 Sleeve panel make Eima O/L 0.64 48%
1 Back part panel join Ronju O/L 0.64 64%
6 Front part panel join & tc Rojina O/L 0.78 64%
9 Left and right panel join Morina O/L 0.79 70%
8 Left & right panel join Amina O/L 0.82 76%
13 Shoulder join Sahina O/L 0.92 78%
11 Shoulder panel join Sharmin O/L 0.94 83%
4 Left and right panel join Roksana O/L 1.28 90%
3 Left and right panel join Jarna O/L 1.72 96%
Table 6. Breakdown of Flat lock machines before rearrangement.
SN Process Name Name M/c Type Performed SMV Efficiency
2 Back panel ts tc Naher F/L 0.35 87%
5 Left and right panel ts and tc Mena F/L 0.62 89%
10 Left and right panel ts & tc Nurbanu F/L 0.53 103%
12 Shoulder panel ts Alima F/L 0.88 48%
15 Sleeve panel top stitch & tc Sokina F/L 0.47 104%
16 Sleeve hem Momina F/L 0.42 71%
Table 7. Breakdown of Flat lock machines after rearrangement.
SN Process Name Name m/c Performed SMV Efficiency
2 Back panel ts tc Alima F/L 0.35 48%
16 Sleeve hem Momina F/L 0.42 71%
15 Sleeve panel top stitch & tc Naher F/L 0.47 87%
10 Left and right panel ts & tc Mena F/L 0.53 89%
5 Left and right panel ts and tc Nurbanu F/L 0.62 103%
12 Shoulder panel ts Sokina F/L 0.88 104%
Table 8. Operational Bulletin of Jacket after rearrangement.
SN Process Name Name M/c Type Performed SMV Efficiency % Output @ performed efficiency
1 Back part panel join Ronju O/L 0.64 48 46.45
2 Back panel ts tc Alima F/L 0.35 48 96.00
3 Left and right panel join Jarna O/L 1.72 96 92.90
4 Left and right panel join Roksana O/L 1.28 90 87.10
5 Left and right panel ts and tc Nurbanu F/L 0.62 71 77.45
6 Front part panel join & tc Rojina O/L 0.78 64 76.80
7 Front part panel ts & tc Sabina L/S 0.53 44 88.00
8 Left & right panel join Amina O/L 0.82 76 73.55
9 Left and right panel join Morina O/L 0.79 70 67.74
10 Left and right panel ts & tc Mena F/L 0.53 87 94.91
11 Shoulder panel join Sharmin O/L 0.94 83 115.81
5. International Journal of Science, Technology and Society 2015; 3(4): 101-106 105
SN Process Name Name M/c Type Performed SMV Efficiency % Output @ performed efficiency
12 Shoulder panel ts Sokina F/L 0.88 89 127.14
13 Shoulder join Sahina O/L 0.92 78 79.32
14 Sleeve panel make Eima O/L 0.64 64 85.33
15 Sleeve panel top stitch & tc Naher F/L 0.47 103 126.12
16 Sleeve hem Momina F/L 0.42 104 208.00
17 Collar make Rebeka L/S 0.79 86 81.90
18 Collar twill tape attach Shahila L/S 0.26 39 106.36
19 Collar serving Lima O/L 0.43 46 70.77
20 Zipper twill tape make Orchona L/S 0.88 48 68.57
21 Zipper twill tape attach Halima L/S 0.87 57 68.40
22 Zipper holding tuck Rojina L/S 0.66 45 90.00
23 Zipper patch attach at bottom Bobita L/S 0.45 85 89.47
24 Collar join Naher L/S 1.77 118 90.77
25 Collar join Shahanara L/S 1.99 127 97.69
26 Zipper tuck with body Sabina L/S 0.36 57 81.43
27 Zipper join with left side Monzilla L/S 0.58 76 91.20
28 Zipper join right side Pervin L/S 0.76 90 78.26
29 Zipper facing join Beauty L/S 0.66 80 96.00
30 Zipper facing o/l Hasina O/L 0.36 36 72.00
Practical output after rearrangement
Table 9. Final Practical output after sharing of work.
SN Process Name Name M/c Type Performed SMV Efficiency % Output @ performed efficiency
1 Back part panel join Raju O/L 0.64 48 46.45
1 Back part panel join Ronju O/L 0.64 48 46.45
2 Back panel ts tc Alima F/L 0.35 48 96.00
3 Left and right panel join Jarna O/L 1.72 96 92.90
4 Left and right panel join Roksana O/L 1.28 90 87.10
5 Left and right panel ts and tc Nurbanu F/L 0.62 71 77.45
6 Front part panel join & tc Rojina O/L 0.78 64 76.80
7 Front part panel ts & tc Sabina L/S 0.53 44 88.00
8 Left & right panel join Amina O/L 0.82 76 73.55
9 Left and right panel join Morina O/L 0.79 70 67.74
10 Left and right panel ts & tc Mena F/L 0.53 87 94.91
11 Shoulder panel join Sharmin O/L 0.94 83 115.81
12 Shoulder panel ts Sokina F/L 0.88 89 127.14
13 Shoulder join Sahina O/L 0.92 78 79.32
14 Sleeve panel make Eima O/L 0.64 64 85.33
15 Sleeve panel top stitch & tc Naher F/L 0.47 103 126.12
16 Sleeve hem Momina F/L 0.42 104 208.00
17 Collar make Rebeka L/S 0.79 86 81.90
18 Collar twill tape attach Shahila L/S 0.26 39 106.36
19 Collar serving Lima O/L 0.43 46 70.77
20 Zipper twill tape make Orchona L/S 0.88 48 68.57
21 Zipper twill tape attach Halima L/S 0.87 57 68.40
22 Zipper holding tuck Rojina L/S 0.66 45 90.00
23 Zipper patch attach at bottom Bobita L/S 0.45 85 89.47
24 Collar join Naher L/S 1.77 118 90.77
25 Collar join Shahanara L/S 1.99 127 97.69
26 Zipper tuck with body Sabina L/S 0.36 57 81.43
27 Zipper join with left side Monzilla L/S 0.58 76 91.20
28 Zipper join right side Pervin L/S 0.76 90 78.26
29 Zipper facing join Beauty L/S 0.66 80 96.00
30 Zipper facing o/l Hasina O/L 0.36 36 72.00
Final Practical output (after sharing of work)
Table 10. Comparison of production before & after study.
Parameter Before Rearrangement After Rearrangement After sharing of work
No of m/c 30 30 31
No of manpower 30 30 31
Output per hr 30 46 68
6. 106 Md. Mazharul Islam et al.: Line Balancing for Improving Apparel Production by Operator Skill Matrix
5. Results & Discussion
Changing from traditional layout to balanced layout model
by proper allocation of workers, there are considerable
improvements have moved towards us. With final scenario,
the best performance results were obtained as summarized in
table 10. The average hourly output of the system increased
from 30 to 68 pieces. With reference to scenario, it can be said
that the balance of sewing line seems appropriate for all
performance measures.
6. Conclusion
Skill matrix helps in allocating right person for the right job
which helps in achieving desired performance level. It keeps
record of all operations an operator had done in the past and
efficiency level in each operation. Engineers / line supervisors
need minimum time to find and select most efficient operators
for an operation from the pull of operators. For line balancing,
operators can be selected according to work content. When
someone is absent, supervisor can easily find suitable person
from the skill matrix table and replace. To analyses the skill
availability and distribution throughout the factory. This can
be compared with the skill requirement for a particular time
period and shortage/excess skill availability to achieve at the
training requirement. So productivity can be achieved by
allocating skill & semi-skilled workers to the right place and
unskilled operator should be trained properly.
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