effect of work study & time study on production and quality

Our Project Title On:

Effect of work study & time study on production and quality.

Southeast University

Name : MAZADUL HASAN SHESHIRID: 2010000400008Batch: 13th Batch (Session 2009-2013)Department: Wet Processing Technology Email: [email protected]: www. Textilelab.blogspot.com Southeast UniversityDepartment of Textile Engineering

PREPARED BY ©right

Objectives of project work:

To implement of work study charts to obtain maximum utilization of the resources( Man, Machine & Materials) and to optimize workplace by changing. The plant layout & workstation, using the process charts.


Role of industrial engineering department in apparel industry:

Importance of industrial engineering (IE) tools that can be used to improve upon the productivity of their factories and thus enhance the profits. Very few companies have been operating with a full fledged industrial engineering department and even those which boast of as an industrial engineering department(IED) in their factories are not allowing freedom and scope to function to its full capabilities. The role of IED is important for the garments

industry for the following two reasons:It’s highly labor –intensive industry. Effective planning is emerging as one of the key factors for the garments manufacturing industry.


Garments manufacturing diagram:

Fabric from stores

Cutting section

Sewing section

Finishing section

Finished garments to warehouse


Topics covered during the project work:

• Plant layout & workstation design.• work study & time study concepts on production and quality.


Workstation Design:

Workstation Design are described below-

1. Space requirements.

2. Consideration of the space requirement for the movement of material handling equipment.

3. Easy access to safety stops in case of emergency.

4. Easy access to machine for inspection and lubrication, maintenance and repair.

5. Space between one machine to another machine.

6. Appropriate ventilation, lighting & safety.


Cutting Section


Work Study

Method Study Work Measurement

What is work study?

Work study is mainly concerned with the examination of human work.There are two parts of work study:


• To eliminate wastage of time and labor.• To reduce fatigue and boredom of work by avoiding unnecessary

movements.• To find a best way of doing a job.• To have more utilization of materials, machines and workers.• To improve the design of work place layout.• To standardize the method, obtained after conducting the motion

study.• To train the individual operator in its practice as per standardized

methods.

Why work study?Southeast University

• Set target• Manpower allocation• Calculate efficiency• Production planning and control• Determine cost• Incentive schemes

Why Work Measurement is Important?


Work Measurement Techniques

Time Study: Directly observing an operator.

Pre-Determined Motion Time Study System: Analyzing the motions used to carry out the activity.

Analysis of Past Records: Using previous records/ Studies available in the factory.


Time Study

To determine the time it should take for a qualified worker to perform a specific task using a specified method by directly observing an operator.


Time Study Sheet of IE Department:Southeast University

Observed time X

1. Compute the basic time

Basic Time =

2. Compute the standard minute value

SMV = Basic Time + Allowance

Standard rating

How it Works?

Observed rating


GSD layout of IE:Southeast University

SL Operation Observed time Standard time

1 Seam right shoulder 15” 10”

2 Bind neck 16” 10”

3 Seam left shoulder 14” 11”

4 Bind sleeve openings 14” 12”

5 Seam sleeves 14” 12”

6 Attach sleeves 36” 30”

7 Cut & fold label 7” 4”

8 Attach label 16” 12”

9 Bartack shoulder & neck 10” 6”

10 Hem bottom 16” 12”

Total time 158” 119”

Practically process following in the sewing floor:

List of processes to produce T-shirts:


SI Operator Process Observed time Rating Basic time Allowance time Standard time

1 Rahima Stay sewing 9” 80% 7.2” 20% 8.6”

2 Nazma Collar

fitting

3” 75% 2.25” 20% 2.7”

3 Moyna Collar

sewing

30’ 85% 25.5” 20% 30.6”

Time measurement table:


For this process operation is 2, but making time taking around 10 min.seam joining uneven, seam, broken stitch, puckering needle hole and down grade quality etc defects are coming more which clearly indicate that garment piece handling by the operator are not proper, they need to trained how to handle the fabric or the proper method of stitching the garment.

Practically process following in the sewing floor:


In this case, we need to follow PDCA process improvement chart which can give us a solution.

PDCA

Figure : The Shewhart Cycle is a fundamental idea for continuous process improvement.


Benefits of TQM: The benefits of TQM can be classified into the following two categories:1. Customer satisfaction oriented benefits.2. Economic improvements oriented benefits. 1. Customer satisfaction oriented benefits: The benefits under this category are listed below:(a) Improvement in product quality.(b) Improvement in product design.(c) Improvement in production flow.(d) Improvement in employee morale and quality consciousness.(e) Improvement of product service.(f) Improvement in market place acceptance. 2. Economic improvements oriented benefits: The benefits under this category are as follows: (a) Reductions in operating costs.(b) Reductions in operating losses.(c) Reductions in field service costs.(d) Reductions in liability exposure.

Time Study Exercise

Process Name = Side Seam

Observed Time = 35.27 SecObserved Rating = 92%Allowance = 25%

Basic Time = (35.27 X 0.92) Sec= 32.45 Sec

SMV = 32.45 + (32.45 X 0.25) Sec= 40.56 Sec

Capacity = (3600 ÷ 40.56) Pcs/ Hour= 88 Pcs/ Hour

Some suggestions:

Existing Proposed

Operation are not arranged in sequence,

Intersection of material flows occur.

Material movement is more.

Material handling is more.

Operation are arranged in sequence,

Intersection of material flows avoided.

Material movement is minimized.

Material handling is minimized.


Conclusion

WITH THE APPLICATION OF WORK STUDY CHARTS IN APPAREL MANUFACTURING, THE EFFECTIVE UTILIZATION OF RESOURCES ( MAN, MATERIAL & MACHINES) CAN BE ACHIEVED.

THE COST INVOLVED IN USING THESE CHARTS ARE VERY MINIMUM AND A SOLUTION CAN BE DERIVED IN A SHORT PERIOD OF TIME.


THANKS EVERYBODY