Witness Project PDF

University of Mauritius
Faculty of Engineering
Mechanical and Production Department
Optimization of the
Production System at Tara
Knitwear LTD
By
RADHA Yashvan
Submitted as a partial fulfillment for the degree of
B.Eng. (Hons) Manufacturing Engineering
March 2012
UNIVERSITY OF MAURITIUS
PROJECT/DISSERTATION DECLARATION FORM
Name: RADHA Yashvan
Student ID: 0711623
Programme of Studies: BEng (Hons) Manufacturing Engineering
Module Code/Name: MECH 4000Y
Title of Project/Dissertation:
Optimisation of the Production System at Tara Knitwear LTD
Name of Supervisor(s): Dr. DK Hurreeram
Declaration:
In accordance with the appropriate regulations, I hereby submit the above dissertation for
examination and I declare that:
(i) I have read and understood the sections on Plagiarism and Fabrication and
Falsification of Results found in the University‟s “General Information to Students”
Handbook (20…./20….) and certify that the dissertation embodies the results of my own
work.
(ii) I have adhered to the „Harvard system of referencing‟ or a system acceptable as per “The
University of Mauritius Referencing Guide” for referencing, quotations and citations in my
dissertation. Each contribution to, and quotation in my dissertation from the work of other
people has been attributed, and has been cited and referenced.
(iii) I have not allowed and will not allow, anyone to copy my work with the intention of
passing it off as his or her own work.
(iv) I am aware that I may have to forfeit the certificate/diploma/degree in the event that
plagiarism has been detected after the award.
(v) Notwithstanding the supervision provided to me by the University of Mauritius, I warrant

that any alleged act(s) of plagiarism during my stay as registered student of the University of
Mauritius is entirely my own responsibility and the University of Mauritius and/or its
employees shall under no circumstances whatsoever be under any liability of any kind in
respect of the aforesaid act(s) of plagiarism.
Signature: Y.R Date: 30. March 2012

Table of Contents
Chapter 1: Introduction
List of abbreviation ............................................................................................................ i
Table of figure..................................................................................................................iii
Acknowledgement ............................................................................................................ v
Abstract ............................................................................................................................ vi
1.1 Export Processing Zone .......................................................................................... 1
1.2 Company profile ..................................................................................................... 1
1.3 Problem statement ................................................................................................... 2
1.4 Objectives of the project ......................................................................................... 2
1.5 Overview of chapters .............................................................................................. 3
Chapter 2: Literature Review

2.1 Productivity ............................................................................................................. 5
2.1.1 Job Shop Production ........................................................................................ 6
2.1.2 Batch Production .............................................................................................. 6
2.1.3 Mass Production............................................................................................... 6
2.1.4 Productivity ...................................................................................................... 7
2.1.4.1 Factors affecting productivity ................................................................... 7
2.1.4.2 Type of productivity ................................................................................. 9
2.2 Work study ............................................................................................................ 10
2.2.1 The basic procedure of work study ................................................................ 11
2.2.2 Work measurement ........................................................................................ 11
2.2.3 Time study ..................................................................................................... 12
2.2.3.1 Main steps in making a time study ......................................................... 12
2.2.3.2 Elements .................................................................................................. 13
2.2.3.3 Timing each element ............................................................................... 14
2.2.3.4 Rating ...................................................................................................... 14
2.2.3.5 Allowances .............................................................................................. 15
2.2.3.6 Standard allowed minutes (S.A.M) ......................................................... 16
2.3 Line Balancing ...................................................................................................... 16
2.3.1 Six basic steps in line balancing procedures .................................................. 17
2.4 Simulation ............................................................................................................. 18
2.4.1 Definition of Simulation ................................................................................ 18
2.4.2 Advantages and disadvantages of using simulation....................................... 18
2.4.3 WITNESS Simulation .................................................................................... 19
2.4.3.1 Application of the WITNESS simulation software ................................ 20
2.4.4 Steps in developing a simulation model ........................................................ 20
Chapter 3: ERP
3.1 Advantages and disadvantages of using ERP software ........................................ 22
3.2 MSC Apparel ERP solution .................................................................................. 23
3.3 Problem background ............................................................................................. 23
3.4 Objectives ............................................................................................................. 23
3.5 The analysis .......................................................................................................... 23
3.6 Proposed solution .................................................................................................. 25
Chapter 4: Methodology
4.1 Description of the production flow ....................................................................... 26
4.1.1 The process .................................................................................................... 26
4.1.2 Make-up section ............................................................................................. 26
4.1.3 The loading process ....................................................................................... 27
4.1.4 The operation ................................................................................................. 27
4.1.5 The production line ........................................................................................ 27
4.1.6 Cycle time ...................................................................................................... 27
4.1 Model of Shirt to be studied.................................................................................. 28
4.2 Data collection ...................................................................................................... 30
4.3 Simulation model .................................................................................................. 31
4.4 Experimentation .................................................................................................... 32
Chapter 5: Data Collection

5.1 Standard Allowed Minutes (S.A.M) ..................................................................... 33
5.2 Breakdown ............................................................................................................ 35
5.3 Inter arrival time ................................................................................................... 35
5.4 Timing a batch of 15 units .................................................................................... 36
5.5 Analysis................................................................................................................. 37
5.6 Problems noticed during study.............................................................................. 37
Chapter 6: Model Construction

6.1 Structuring the model ............................................................................................ 39
6.1.1 The assembly line .......................................................................................... 39
6.1.2 Line balancing ................................................................................................ 40
6.1.3 Indentifying WITNESS elements .................................................................. 42
6.2 Building the model ................................................................................................ 43
6.2.1 Defining elements .......................................................................................... 43
6.2.2 Displaying elements ....................................................................................... 44
6.2.3 Detailing elements ......................................................................................... 44
6.3 Detailing WITNESS elements .............................................................................. 44
6.3.1 shirt ................................................................................................................ 45
6.3.2 rail1 ................................................................................................................ 47
6.3.3 Sewing machine ............................................................................................. 48
6.3.4 Rail ................................................................................................................. 51
6.3.5 Shift ................................................................................................................ 53
6.4 Assumption made.................................................................................................. 54
6.5 running the model ................................................................................................. 55
6.6 Generating reports ................................................................................................. 55
6.7 Testing and evaluating of results .......................................................................... 56
Chapter 7: Experimentation
7.1 Objectives of the experiment ................................................................................ 58
7.2 Design of experiment (DOE) ................................................................................ 58
7.2.1 Identification of factors .................................................................................. 59
7.2.2 Defining the level of each factor .................................................................... 60
7.2.3 Selecting the Orthogonal Array (OA) ............................................................ 61
7.3 Conducting the experiment ................................................................................... 61
7.3.1 Selecting the sample size ............................................................................... 62
7.4 Summary of results ............................................................................................... 62
7.4.1 Signal to noise ratio ....................................................................................... 63
7.4.2 Analysis of mean (ANOM) ............................................................................ 64
7.4.3 Analysis of variance (ANOVA)..................................................................... 67
Chapter 8: Conclusion and Further Works

8.1 Conclusion ............................................................................................................ 70
8.1 Further works ........................................................................................................ 71
Referencing ..................................................................................................................... 72
Appendices
A.0 Simulatiom ........................................................................................................... 74
B.1 Time study, breakdown and inter arrival time sheet ............................................ 87
C.1 Detailing of Model Elements ............................................................................. 116
D.O DOE, ANOV and ANOVA ............................................................................... 127
E.1 Witness simulation results .................................................................................. 140
F.0 F-Table ................................................................................................................ 196
List of abbreviation
ANOM - Analysis of Mean

ANOVA - Analysis of variance
Avg. time -average time
Avg. WIP - average work-in-progress
C - Cycle time
d.f - degree of freedom
DOE - Design of experiment
ERP - Enterprise Resource Planning
LP - Labour factour productivity
m - Mean of signal to noise ratios
M/C - machine
MFT - Multiple factor productivity
MTBF - Mean time between failures
MTTR - Mean time to repair
N - number of workstation
OA - Orthogonal array
PFP - Partial factor productivity
Prn - pseudo random number
s.d - Standard deviation
S /N - signal to noise ratio
SAM - Standard allow minutes
SFP - Single factor productivity
SS - sum of squares
SSA - sum of square due to A
SSe - sum of square due to error
SST - Total sum of squares
T - time
VA - variance due to factor A
i
Ve - variance due to error
WIP - work-in-progress
α - risk
η - Signal to noise ratio
ii
List of figures
Figure 2.1 Production system ........................................................................................... 5

Figure 2.2 Work study .................................................................................................... 10
Figure 2.3 Standard time ................................................................................................ 16
Figure 6.1 Material flow ................................................................................................. 40
Figure 6.2 Actual production layout ............................................................................... 42
Figure 6.3 Detail dialog box of part ............................................................................... 46
Figure 6.4 Detail dialog box of machine ........................................................................ 49
Figure 6.5 Detail dialog box of machine breakdown ..................................................... 49
Figure 6.6 Detail dialog box of buffer (rail2) ................................................................. 52
Figure 6.7 Detail dialog box of shift .............................................................................. 53
Figure 7.3 signal to noise ratio ....................................................................................... 64
Figure 7.4 signal to noise ratio ....................................................................................... 65
Figure 7.5 Factor effect for the output ............................................................................ 65
Figure 7.6 Factor effect of work-in-progress ................................................................. 66
Figure 7.1 Graph of average η by factor levels (db) for the output ................................ 66
Figure 7.2 Graph of average η by factor levels (db) for the W.I.P ................................. 67
Figure D.1 Proposed line balancing ............................................................................. 128
Figure D.2 Levels of cycle time ................................................................................... 129
Figure D.1 L9 array ...................................................................................................... 130
Figure D.3 reduced L9 array ........................................................................................ 131
Figure D.4 signal to noise ratio .................................................................................... 133
iii
List of tables
Table 4.1 Operation Breakdown ..................................................................................... 29

Table 5.1 S.A.M for each operation ............................................................................... 34
Table 5.2 MTBF & MTTR for each machine type ........................................................ 35
Table 5.3 Inter arrival time ............................................................................................. 36
Table 5.4 Operating time of a batch of 15 units ............................................................. 36
Table 5.5 Efficiencies of theoretical & actual ................................................................ 37
Table 6.1 Operation breakdown ..................................................................................... 41
Table 6.2 WITNESS element used ................................................................................. 43
Table 6.3 Detailing of part.............................................................................................. 46
Table 6.4 Detailing of machine ...................................................................................... 50
Table 6.5 Detailing of machine breakdowns .................................................................. 50
Table 6.6 Detailing of buffer .......................................................................................... 52
Table 6.7 Detailing of buffer .......................................................................................... 54
Table 6.8 Report for part at each replication .................................................................. 56
Table 6.9 Extract from buffer report .............................................................................. 56
Table 6.10 Extract from machine report......................................................................... 57
Table 7.1 Factors and level to be tested ......................................................................... 61
Table 7.2 Results of simulation ...................................................................................... 63
Table 7.7 Analysis of variance for the output ................................................................ 68
Table 7.8 Analysis of variance for the work-in-progress ............................................... 68
Table 7.9 Analysis of experiment relative to the first one.............................................. 69
Table D.5 Orthogonal array L9 .................................................................................... 135
iv
Acknowledgement
I would like to thank my supervisor, Mr HURREERAM D.K. for having being

of a tremendous help right from the very beginning in providing me good guidelines
which have help me in completing this dissertation.
I would also thanks Mr. RAMASAWMY H. for his lectures on WITNESS

simulation software.
I would like to give an especial thanks to Mr. Caunhye Asraf who has given me
the opportunity to conduct my final year product at TARA Knitwear where he is the
assistant manager. I would also like to extend my sincere thanks to all the people of
TARA Knitwear who have help me in overcome all the difficulties occurred during my
time at the company.
Thanks to:
Mme Collette – for helping me understanding the ERP software
Mr. Rengen – for giving me the required information on the production floor at
Nouvelle France Branch
Mme Hema & Allet – for providing me information on the problem of the
software
Mme Anjanee & Antish – for helping me in conducting my studies
Moreover, this dissertation has been made possible by the ceaseless and
unlimited support of my parents. My special thanks to Bhavna, who, above all, has
encouraged and supported me since the beginning and for having been there with me
and correcting my writing language. Furthermore, I would like to thank all my class-
friends (Gunnoo, Tisha, Manveer, Ravi, Girish, Riteish, Aza and Muazin) who in a way
or another shared my difficulties throughout this dissertation.
I am also grateful to the University of Mauritius Library for having provided me

with the necessary materials needed for this dissertation.
v
Abstract
In local and foreign industries, it is common practice to operate a production system
with inherent and random sources of variations since it is often believed that these
variations do not affect the system, that is, a system cannot operate at 100% efficient.
But still, with a correct method and good planning, these variation can be further
reduced and increase the system efficiency. Similarly, this project has the objective to
analyse the actual system of production and to develop a new system which would
increase the productivity and the efficiency.
The study has been undertaken at Tara Knitwear LTD to optimize the productivity of a
production line. The study was conducted in 2 phase:
 Data collection and analysis of the system.
 Simulation for an optimal solution of improvement of productivity.
The first phase involves in conducting a time study to get the required data about the
actual system of production. The data is then computed and compared to the theoretical
efficiencies of the company to locate the actual production level to what was intended to
be.
The second stage is to simulate a model under different conditions to find an optimal
combination of set parameters to increase productivity. WITNESS simulation software
was used to construct and run the model based on the actual system. So, the data
collected from the time study was used. Then, the Taguchi design of experiment was
used to provide combination of experiments for 3 factors at 3 levels according to a
defined orthogonal array. The results were then analyse by the concepts ANOM and
ANOVA to provide the best combination of the factors for the improvement of
productivity.
vi
Chapter 1:
Introduction
1.1 Export Processing Zone
„The textile industry is one of the main pillars of the Mauritian economy. In order to
fight unemployment, which was rampant, the government created the Export Processing
Zone (EPZ) in 1971. It has undergone many changes in its almost thirty years of
existence. Equipped with a high skilled labour force and efficient management
practices, Mauritius manufactures products of excellence for export towards the EU and
USA. Great emphasis is laid on quality control.‟
The definition can be found at http://www.mauritius-embassy.de/industry.php
1.2 Company profile
Tara Knitwear LTD is a garment making company, forming part in the EPZ, involved in
producing mainly shirts and pullovers according to its customer‟s orders and
specifications. The company consists of 2 production plants situated at Riviere du
Rempart and Nouvelle France and a Head office is situated at Plaine Lauzun. At the
Head office, most of the departments can found such as Marketing, Maintenance,
Planning, Administrative and Store and the Production department is found at both
production plant. Most of its products are exported to the European countries, especially
France. Its workforce is composed of about 90% of expatriate labour from China and
Bangladesh and the rest are Mauritians.
The Riviere du Rempart production plant operates only in manufacturing shirt. The
main production department is found there. All the necessary production planning,
operation breakdown list and line balancing are conducted at this plant.
At Nouvelle France production plant, there are 2 floors of production. One floor, ground
floor, is dedicated to manufacture only pullovers. The floor is designed in such a way
1
that there is no backflows from sections unless the scrapped pullovers need to reprocess.
The 1st floor is dedicated for the manufacturing of only shirts. Similarly, this floor is
also designed not to have backflows.
1.3 Problem statement
Since the garment sector is a very competitive one, the company came up with ERP
(Enterprise Resources Planning) software to minimize wasting time. The ERP software
provides a co-relationship between departments which help in decision making.
However, they do not make the maximum use of the software. Also, some entry
mistakes were noted which leads to wrong decision making and wrong calculation on
the material usage. Thus, the company wants to achieve a maximum use of the software
in order to reduce these kinds of errors. Furthermore, the company wants to increase its
productivity using some performance indicators generated by the software.
The main problems identified at the company were:
1. Line balancing was found to be wrongly designed which leads to a high level of
work-in-progress in the production line.
2. The ERP software is not being used for all its available modules.
1.4 Objectives of the project
The main objective of the project is to optimise the production line at the company in
order to improve the productivity by making the maximum use of the ERP software.
The objectives are:
1. To study the actual production system.
2
2. To identify the modules of the software not being use.

3. To generate performance indicators to assess the production.
4. To increase productivity through the software.
5. To minimize work-in-progress and idleness.
6. To design an ideal line balancing and line of production.
1.5 Overview of chapters
Chapter 2 – Literature review. This chapter describes some definitions concerning the
project and the tools used during the study and its procedures.
Chapter 3 – Enterprise Resource Planning (ERP) software. This chapter discusses

the integration of the ERP software in the company and the its lack of usage.
Chapter 4 – Methodology. This chapter explains the methods used and procedures to
conduct the study to attain the mentioned objectives.
Chapter 5 – Data collection and analysis. This chapter discusses the data collection
process for the production line and the analysis made to compare the actual system to
the theoretical system.
Chapter 6 – Model construction. This chapter explained the steps how the simulation
model was constructed on the WITNESS software
Chapter 7 – Experimentation. This chapter describes the methods used to evaluate the
model on different conditions to find an optimal solution through analysis of mean and
variance.
3
Chapter 8 – Conclusion and further works. This chapter concludes the entire project
and discusses any solution that can be implemented to provide a better production
system.
4
Chapter 2:
Literature Review
Chapter2: Literature Review
2.1 Productivity
A production system can be defined as the processes needed and methods employed to
transform tangible and intangible inputs into some desired outputs of products or
services. In other words, a production system is the process of adding value to products
or services.
Tangible inputs are elements such as raw materials, sub-assemblies and semi-finished
goods and intangible inputs are elements such as ideas, knowledge and information.
Figure 2.1 Production system

The figure 2.1 is available at http://www.machine-information-
systems.com/Production_Process.html
Feedbacks can be used, at any stage, in order to keep track on the performance of the
transformation process and readjust according to the desired outcome at the stage.
There are 3 main types of production systems:

1. Job Shop
2. Batch
3. Mass
5
2.1.1 Job Shop Production
Job Shop production system is also known as a One-Off or Jobbing involves the
production of a single type of product for a specific customer. This type of product is
usually a customised product to meet the customer specifications and the amount of
production is normally very low. The cost of producing a single product of this type is
very high compared to other types of production system since highly skilled labour is
needed and dedicated equipment are used. Also, wastage is higher depending on the
type of product needed.
2.1.2 Batch Production
Batch production usually involves producing products or semi-finished products in a bit

larger quantity compared to Job Shop. It is the production of an amount of product
according to the customer specifications and once the production is over, the templates
and equipment that cannot be used for other different production are kept aside for a
future production of the same kind, that is, they are used for repeat customer orders.
2.1.3 Mass Production
Mass production is also known as Flow production and involves manufacturing large
amount of products, normally standardised products, in a common production line. In
other words, it is continuous production flow where there are several labours in a
production line and each labour is doing a single operation but in a repetitive manner
and the products have to pass through each labour for the product to finish.
6
2.1.4 Productivity
In the manufacturing sector, productivity is defined as the ratio of what is produced to

what is required to produce it. Or, it can simply be defined as the ratio of output to
input.
Equation 1.1
2.1.4.1 Factors affecting productivity
The factors affecting productivity can be classified into 2 main categories:

 Internal (controllable)
Hard factors
Soft factors
 External (uncontrollable)
Structural changes in society
Natural resources
Government resources
Some of the internal hard factors are listed below.
 Product – variations in the product specification will lead to changes in the

production line which eventually affects the productivity. It is also about how
customers perceive the product and how much they are ready to pay.
 Plant and equipment – the type of machine and equipment and their arrangement
will prove how economical and efficient the productivity is.
7
 Technology – lack of up-to-date technologies will tend to lower the productivity.

Automation can be used to increase productivity through improving material
handling
 Material and energy – the raw material being used and the amount of energy
needed to transform the raw material into product is a major factor of
productivity.
Some of the internal soft factors are listed below.

 People – the way labours work has a direct impact on the productivity. A
motivated worker will give up to 100% of his/her ability for the firm.
 Organisation and system – organisation needs to be dynamically operated and
also needs to be flexible and to have the ability to response to market change.
 Management styles – management is responsible for the effective use of all
resources under the enterprise control.
 Work methods – the improper use of the techniques such as work study, method
study will lead to an unreliable and false results on the evolution of productivity.
Some of the external soft factors are listed below.

 Structural changes in society – the change influence national and enterprise
productivity independently of enterprise management.
 Natural resources – the resources such as land, manpower are crucially
important for the productivity and it would improve the productivity if the
nation can generate, mobilise and use these resources.
 Government aspects – the rules and regulation abided by the government might
prevent a firm to attain its maximum productivity.
(Y.R. Surnam, 2008)
Some management techniques for improving productivity are
 Travel chart, proper plant layout, good production planning.
8
 Statistical process control (SPC) to reduce scraps on finished products.

 Method study to improve the layout and eliminate unnecessary material
movement.
 Work measurement to set up a standard of performance.
 Proper maintenance schedule to reduce breakdowns
 Motivation of workers to reduce absenteeism, lateness, careless working and
idleness, giving the sense of belonging to the workers.
 Choosing the perfect machines and equipment for a maximum return on
investment.
2.1.4.2 Type of productivity
Productivity can be expressed in many ways such as partial-factor productivity, single-

factor productivity, multi-factor, labour productivity.
Partial-factor productivity (PFP) measures productivity with respect to a specific

resource.
Equation 1.2
Single-factor productivity (SFP) measures ratio of a specific output to a single input.

Equation 1.3
Multi-factor productivity (MFP) measures ratio of output to a set of key resources.

Equation 1.4
9
Labour productivity (LP) measures ratio of the physical units of production to the
available labour time.
Equation 1.5
(H. Noori, R. Radford, 1995)
2.2 Work study
Work study is the systematic examination of the methods of carrying out activities so as
to improve the effective use of resources and to set up standards of performance for the
activities carried out.
Figure 2.2 Work study

(Y.R. Surnam, 2008)
As shown in the figure above, work study leads to a higher productivity and an
improved planning of a firm. There are two major techniques of work study namely
method study and work measurement.
10
2.2.1 The basic procedure of work study
There are 8 basic steps in conducting a work study.

1. Select the job or process to be studied.
2. Record from direct observation everything that happens.
3. Examine the recorded facts critically and challenge everything.
4. Develop the most economical method.
5. Measure the quantity of work and calculate standard time.
6. Define the new method and the related time.
7. Install the new method
8. Maintain the new standard practice by proper control procedures.
2.2.2 Work measurement
Work measurement is the application of time and motion study and activity sampling
techniques to determine the time for a qualified worker to complete a specific job at a
defined level of performance.
The principal techniques by which work measurement is carried out are listed below:
1. Work sampling
2. Time study
3. Structured estimating
4. Pre-determined time standards
However, this project will deal with only time study.
11
2.2.3 Time study
Time study is a work measurement technique for recording the times and rates of
working for the elements of a specified job carried out under specified conditions, and
for analysing the data so as to obtain the time necessary for carrying out the job at a
defined level of performance.
(Y.R. Surnam, 2008)
2.2.3.1 Main steps in making a time study
The main steps in making a time study are as follows.
Choosing the job to be studied

Assessing all the necessary information about the job like information about the
operator, product being processed, machine, tools and the surrounding
environment.
Recording a complete description of the method, breaking down the operation
into „elements‟.
Examine the detailed breakdown to ensure that the most effective method and
motions are being used.
Measuring with a timing device and recording time taken by the operator to
perform each „element‟ of the operation and at the same time, the time of each
element is rated according to the speed, skill and effort made by the operator.
Computing the basic times of the operator by multiplying the time of each
element by its corresponding rating.
Determining the allowances to be added to the basic time for the operation.
Obtaining the standard time (S.A.M) by adding the allowance to the basic time.
12
The Time study equipments are:

A stopwatch
A study board
Pencils
Time study forms
2.2.3.2 Elements
An element is a portion of an operation to facilitate the study of the time taken for the
whole operation to complete. The time duration of an element must neither be too short
nor too long unless a given action which cannot be broken down has long time duration.
Elements must be easily identifiable with definite beginnings and endings.
Eight types of elements are listed below.

Repetitive element - an element which occurs in every cycle of the job.
Occasional element - an element which does not occur in every work cycle of
the job, but which may occur at regular or irregular intervals.
A constant element - an element for which the basic time remains constant
whenever it is performed.
A variable element - an element for which the basic time varies in relation to
some characteristics of the product, equipment or process.
A manual element - an element performed by a worker.
A machine element - An element automatically performed by power driven
machine.
Governing element - An element occupying a longer time than any other
element which is being performed concurrently.
Foreign element - An element observed during a study which, after analysis, is
not found to be necessary part of the job.
13
2.2.3.3 Timing each element
There are two main methods of timing elements:

1. Cumulative timing
2. Flyback timing
Cumulative timing
The watch runs continuously throughout the study. It is started at the beginning of the
first element and is not stopped until the whole cycle is completed. At the end of each
element the watch reading is recorded. The individual element times are obtained by
successive subtractions after the study is completed. The purpose of this procedure is to
ensure that all the time during which the job is observed is recorded in this study.
Flyback timing
The hands of the stopwatch is returned to zero at the end of each element and are
allowed to start immediately, the time of each element is obtained directly. The
mechanism of the stopwatch is never stopped.
2.2.3.4 Rating
Rating is the assessment of the effective speed of working of an operation relative to the
observer‟s concept of the rate corresponding to standard rating. In other words, rating is
a comparison of the rate of working of an operator compared to the average rate of work
that the study man perceives a qualified worker would be able to do at a normal pace
under normal conditions.
Rating is mostly used as a worker cannot work at the same pace with the same
motivation under the same condition for the whole day or the whole week. Any
fluctuation in the recorded time is upon the changes in the factors that affect the
14
operator to work consistently. By rating the operator, the study man ensures that all
these factors are taken into consideration.
Standard performance is the rate of output which qualified workers will naturally
achieve without over-exertion as an average over the working day or shift provided they
know and adhere to the specified method and provided they are motivated to apply
themselves to their work.
This performance is denoted by 100 on the standard rating and performance scales.
(Y.R. Surnam, 2008)
2.2.3.5 Allowances
Allowance is the time added to the basic time in order to cater for several unproductive
actions made by the operator for his/her own ease and personal needs. There are
different types of allowances such as contingency and relaxation.
Contingency allowance is a small allowance of time which may be included in the

standard time to meet legitimate and expected items of work or delays, the precise
measurement of which is uneconomical because of their frequent or irregular
occurrence.
Relaxation allowance is an allowance which is intended to allow the worker to recover

from the physiological and psychological effects of carrying out specified work under
specified conditions and allow attention to personal needs. The amount of allowance
will depend on the nature of the job.
(G. Kanawaty, 1992, pg 331&333)
15
2.2.3.6 Standard allowed minutes (S.A.M)
The S.A.M, also known as standard time, of an operation consists of all the time the
elements making the operation multiply by its corresponding rating and adding the
required allowance for the operation. The S.A.M can be represented graphically as
follows:
Figure 2.3 Standard time

(Y.R. Surnam, 2008)
2.3 Line Balancing
Line balancing can be defined as the process of assigning tasks to workstations in a

product layout in order to achieve a desired output and balance the workload among
stations, thus, gaining a high utilisation of labour and equipment and therefore,
minimise idle time.
(J.G. Monks, 1987, pg 349)
16
Assembly-line balancing is associated with product layout in which material moves

continuously and uniformly through a sequence of operations (work centers) until the
work is completed, thus forming a line of continuous product flow. A designated
number of work elements are performed at each center. The times to perform work
elements are derived from work measurement studies. The period allowed to complete
operations at each station is determined by the speed at the assembly line; all work
stations share the same allowed cycle time. Idle or float time is created for a station
when the work assigned to it takes less time than the set cycle time. The objective of
line balancing is to minimise idle time and work-in-progress while assigning operations
to work stations according to a predetermined technological sequence. A perfect
balance, from a theoretical viewpoint is obtained when the assignments provide no idle
time and no work-in-progress.
(J. L. Riggs, 1987, pg404-405)
2.3.1 Six basic steps in line balancing procedures
The six basic steps in line balancing procedures are listed below,
Step 1: Identifying tasks and their immediate predecessors

Step2: Determining output rate
Step 3: Determining cycle time
Step 4: computing the theoretical minimum number of stations
Step 5: Assign tasks to workstations (balance the line)
Step 6: Compute efficiency, idle time and balance delay
([R.D. Reid, 2010, pg 349-354)
Additional notes and the equations to calculate the parameters are discuss in Appendix
A
17
2.4 Simulation
It is not hard to conceive that if a computer can be programmed to execute the steps of a
mathematical algorithm, which is in essence a transformation of numbers, characters,
etc organised into datatypes, it can also be directed to mimic transformations and
movements of material in the real world and in particular the real world of
manufacturing.
(N. Thomson, 1995)
Today, in many industries, many companies tend to select computer simulation and
modeling softwares for the planning and decision-making. These softwares help
companies attaining a better quality product or service on a more cost-effective basis
while trying to reduce significantly the production or service lead time.
2.4.1 Definition of Simulation
Simulation can be said to imitate a real life situation. Simulation can be defined as
developing a computer model based on a real life situation and conduct experiments on
it and analyse the behavior over a given period of time. Thus, from the result, it can
easily improve the system if there is room for it.
2.4.2 Advantages and disadvantages of using simulation
The advantages and disadvantages of simulation are discussed below.

Advantages
1. Simulation can be jumped to events, thus, eliminates unnecessary time.
2. Different scenarios can be conducted to evaluate according to changes in real-
life situation.
3. Simulation can be done for a longer period of time in a shorter actual time.
18
4. Simulation does not interrupt the actual on-going events in a real-life situation.
Disadvantages
1. With great time and effort spent on developing the model, there is no guarantee
that the model would match the real life situation at 100%.
2. Simulation is only limited to imitate the real-life situation. It does not provide
any optimal solution, thus, the user needs to do the necessary analysis to
evaluate the model.
2.4.3 WITNESS Simulation
The literatures onwards are taken for „WITNESS Release 9, Tutorial Manual‟.
Due to the availability of WITNESS software at the University of Mauritius, this

software has been used for the simulation of the production line.
WITNESS simulation forms part of the Lanner Group‟s simulation software package. It
is the culmination of more than a decade‟s development experience with computer-
based simulation. This experience has led to the evolution of a visual, interactive and
interpretative approach to simulation without the need for complication.
The benefits of the WITNESS approach are that:
 People can gain commitment by working together as a team on creating and

using WITNESS models.
 Models can be built and tested in small incremental stages, which greatly
simplifies model-building, provides the ability to identify errors in the logic and
makes the model more reliable.
 The model can be changed at any time during the run. Changes are incorporated
immediately leading to faster model building.
19
2.4.3.1 Application of the WITNESS simulation software
The software can be applied for:

 The evaluation of capital projects.
 Running models regularly for testing production schedules.
 The evaluation of alternative proposals.
 The improvement of existing facilities
 The management of changes.
The environments where it can be applied are:

 The automotive industry
 The textile industry
 The chemical industry
 Electronics
 Aerospace
 Engineering
 Food
 Paper
 Banking and finance
 Government
 Transport
2.4.4 Steps in developing a simulation model
Projects which involve simulation have several unique aspects which must be managed
particularly carefully to ensure their success. Several steps, in sequence, have been
developed to ensure a good and reliable model construction according to the real-life
situation analysing through a systematic flow of actions. The steps are as follows:
1. Establishing objectives
20
2. Deciding the scope and level of details in the model

3. Collecting data
4. Structuring the model
5. Building the model
6. Generating reports
7. Testing the model
8. Experimenting the model
9. Presenting the results and implementing them
The description of the above mentioned steps are discussed in Appendix A
21
Chapter 3:
ERP
Chapter 3: ERP
The enterprise resource planning (ERP) system is an integrated set of programs that
provides support for core organizational activities such as manufacturing and logistics,
finance and accounting, sales and marketing, and human resources. An ERP system
helps the different parts of the organization share data and knowledge, reduce costs, and
improve management of business processes.
(A.L. Aladwani, 2001)
3.1 Advantages and disadvantages of using ERP software
Implementing the ERP software benefits the company to a great extent but, it also
brings some difficulties.
The advantages of ERP are:

1. It provides a better co-relation between departments, thus facilitate the decision
making.
2. It quickens the information flow between departments.
3. It keeps track of every transaction made in the software over a long period of
time.
4. It easily tracks the inventory level at any point in time.
5. Similar entries do not need to be done. It keeps all information of the customers,
suppliers, product description. So, for any new order, the required information is
imported.
The disadvantages of ERP are:

1. It takes very long to successfully implement the software.
2. End-users must be trained to a high level.
3. It is associated to a huge investment cost.
22
Chapter 3: ERP
3.2 MSC Apparel ERP solution
The ERP software, the computer actually implemented is named MSC Apparel ERP
solution. It consists of 7 integrated modules and 45 sub-modules. It was especially
developed for a garment making company. The software was implemented in 2007 and
can be run in 2 modes which are in live mode and in offline mode. The company was
running the software in the offline mode for almost a year due to the adaptation of the
users with it.
3.3 Problem background
As it is a powerful tool to interact between departments and provide a better decision

making, it takes time to successfully use the software. But, after so much time, still the
company do not used the software to the maximum. It was found that some of the
available module was not fully utilised such as the packing instruction and packing list.
The person concerned is still using the old manual system.
3.4 Objectives
The objective of this study was:

1. To analyse the ERP software to identify the exact reason for the lack of usage
2. To make the maximum use of the software.
3. To assess and increase the productivity through the software.
3.5 The analysis
After a few weeks working on the software, it was found that out of the 45 sub-module
available, only 29 are being used and 4 of the remaining are as important. 2 more are
23
Chapter 3: ERP
found to be slightly important and the rest are either not much important or not
applicable for the company.
The 4 important modules not being used are:

1. Packing instruction – it provides the packing specifications. It simulates the
specifications according to the customer‟s prescription and returns the total
number of shirts to be packed together of which size and colour combination.
2. Packing list – it provides a list of the packing order to easily identify what type
of shirt there are in what packing.
3. Critical path – it shows the path which is the most significant.
4. Alert message – it returns alerts for any delays occur in production schedule and
orders that are not yet scheduled.
The 2 modules that are slightly important are:

1. Shipping schedule
2. Material transfer
A survey was conducted with various end-users to find the reasons for the lack of the
software usage.
It was found that many of the users are not fully at ease with the software. They make
several wrong entries, but most of them are not too significant on the productivity.
Sometimes, the inventory is not updated in the software and manual cross-check needs
to be done to ensure that materials are available for production.
Also, the person concerned for the packing was interviewed. The person reflects that the
software was not adaptable, he better use the manual system to perform the packing
instruction and packing list.
24
Chapter 3: ERP
3.6 Proposed solution
After conducting the analysis, the required solution to increase the use of the software
was found to be:
1. To provide adequate training session for the users to improve their
understanding of the software.
The other objective set was to assess and increase the productivity. After a deep
analysis on the functionality of each module and software as a whole, it was found that
this could not be attained. The software does not generate the data of the performance
indicators that could have been used in assessing the productivity. However, there are
factors associated with the software that can lead to loss of production like entries are
modify and the floor manager did not receive the changes, but there are no such factors
that can directly assess the productivity. This problem has lead to change the approach
of optimizing the productivity. Thus, simulation was used to attain the objectives set.
25
Chapter 4:
Methodology
4.1 Description of the production flow
When the research started at the company, a nearly three week period was dedicated for
the understanding of the processes and the plant activities. The sequence of the
processes was identified and analysed.
4.1.1 The process
The process of the production line begins at the cutting section. The panels are stacked
manually on a table and on top, a sheet of paper is placed which has been marked the
outline of each component to be cut. The marking is made through templates, designed
manually, by arranging them in such a way to minimize waste. The templates are kept
since they might be used for other order having much of the same specifications. An
electric cutter is then used to cut each panel and sorted according to their size, for
example, all small size sleeves are attached in bundles. Then all bundles are moved to
the make-up section.
4.1.2 Make-up section
In this section, all the bundles are worked according to their requirements. For example,
the half moon is attach to the back panel of the shirt, so, only the half moon pieces and
the back panel bundles are brought to the all the station where this preparation is made.
Else, those bundles which don‟t need preparation processes are brought directly to the
loading station and wait for all the necessary part are arrived.
26
4.1.3 The loading process
The operator is always standby at the loading station waiting all the necessary parts to
arrive. The parts arrive in lot size not necessary the same amount of the bundles size
and are loaded on the line using a batch hanger which slides on a rail. The loaded
amount is, very often, the same as the lot size of part arrived. When all the necessary
parts are loaded, the batch is push immediately to the first operator.
4.1.4 The operation
On receiving the batch, the operator does the necessary adjustments, if any, before
starting the operation. He/she takes one shirt at a time to process it and places it back on
the batch hanger. Some operators remove the entire batch and keep them aside, and then
each shirt completed is placed back on the hanger. Others, do not remove any shirt, they
work directly from the hanger as it is slides close to the sewing machine.
4.1.5 The production line
The production floor consists of 6 lines of production (rails), each having 20 stations
(sewing machines). The machines are fixed on tables which can be moved anywhere
and when there are not many orders, some of the machines are put aside to provide free
spaces. The production line is in a straight line.
4.1.6 Cycle time
A cycle time of the operation consists of the operator takes a shirt on the hanger, adjusts
it on the table, processes it in the machine and places it back on the hanger.
27
4.1 Model of Shirt to be studied
The shirt selected to be studied was a polo shirt with a box placket at the chest and
having slit on both sides of the shirt.
This polo shirt was chosen because:

- It consists of all the operations required.
- This order was on the production line for a longer period compared to the
other orders.
- It was the easiest model to study as the process was sequential.
The shirt consists of the following parts:
 Front and back panel

 1 pair of sleeve (right and left)
 Placket (in 2 pieces)
 Neck and collar
 1 Half moon
 Buttons
Throughout the project, a shirt is referred to all the parts mentioned above combined
together whether they are sewed together or not.
The operation breakdown list is shown in the table 4.1.
28
Ref: P/Order No: SCR 1100394 N.F

Customer Ref No 3Y2C CUSTOMER : ORVIS
Style No: ST10000360
Description:
Order Quantity 1157 Head count = 47 Line target/hr = 150
No. Operation Description SAM/min Target/hr No of M/c M/c type Cycle Time
1 attach cuff to sleeve 0.70 86 2 OL 0.35
2 top stitch on cuff 0.47 128 1 INT 0.47
3 fuse placket 0.47 127 1M 0.47
4 iron placket 0.45 133 1M 0.45
5 marking front 0.33 182 1M 0.33
6 run & stitch placket 1.31 46 3 SN 0.44
7 iron half moon 0.49 122 1M 0.49
8 attach half moon 1.18 51 3 SN 0.39
9 bottom hem (open) 0.68 88 2 INT 0.34
10 loading 0.47 128 1M 0.47
11 join shoulder seam 0.47 128 1 OL 0.47
12 top stitch on shoulder 0.47 128 1 INT 0.47
13 attach collar 1.00 60 3 SN 0.33
14 binding on neck (all round) 0.47 128 1 INT 0.47
15 make placket + placket box 3.25 18 7 SN 0.46
16 top stitch on binding + label 1.10 55 3 SN 0.37
17 attach sleeves 0.92 65 2 OL 0.46
18 top stitch on armhole 0.70 86 2 INT 0.35
19 side seam + OL placket end 1.15 52 1 OL 1.15
20 tacking cuff (t/s) 0.55 109 1 SN 0.55
21 make slit + tacking side seam 2.48 24 4 SN 0.62
22 marking button hole 0.20 300 1M 0.20
23 button hole *3 0.55 109 1 B/H 0.55
24 marking button attach 0.20 300 1M 0.20
25 attach button (3 + 1 spare) 0.70 86 2 B/A 0.35
Total sewing SAM 20.76
Table 4.1 Operation Breakdown
From theoretical calculations by the company, the efficiencies are found to be:
Head count (operator) : 60
Line target pcs/hr : 150
Expected line efficiency : 71.30%
29
Balancing efficiency : 70.80%

The equations for the calculations are further discuss in chapter 5
The main objective is to compare these efficiencies to the actual ones on the shop floor.
For this, a time study has been conducted to find out the time for each operation and to
assess the production line.
4.2 Data collection
Data collection consists of undertaking various methods in order to get the required
information for further analysis. For this project, data collection was important for the
calculation of efficiencies and for simulating a model to assess the performance of the
production. The steps for collecting data are described below.
1. Number of shirts arrived on the line
The data for the number of shirts arriving on the production is noted to get an average
of the lot size since the number varies. This data is important for the simulation process
to imitate the actual system and to provide reliable results
2. The inter arrival time of the shirts
The shirts are not always present at the loading station. So, the inter arrival time of the
shirt is noted using watch. The time at which a batch arrived at the loading is recorded
and the difference in time between two successive batches is computed to get the time
between arrivals. Then, the mean is calculated for all the interval computed.
30
3. The cycle times of each machine used

A time study was conducted to determine the cycle time for each operation in the
production line. Cycle time includes the time for a quick set up of the machine, the time
the operator takes the shirt on the rail, the actual processing and placing back the shirt
on the rail.
4. The time between failures and time to repair

Whenever a failure occurs, it slows the production flow and the system remains
unproductive for that duration of failure. So, a special time study sheet was prepared to
note the time at which breakdown occurs and also the duration of each breakdown. The
number of breakdown is then counted for a particular machine and the MTBF is
calculated by the time period of the study divided by the number of breakdown between
that time period.
5. Timing a batch
From the study conducted at the start, it was found that a batch takes too long to
complete all the operations. A batch of 15 units was selected to evaluate the time it
takes for the batch to complete all the operation on the production line.
4.3 Simulation model
In relation to the objectives, computer simulation software is used in order to the best
solution to improve productivity. As described in previous chapter, there are different
incremental steps in constructing an efficient simulation model that can imitate the
actual production system.
31
4.4 Experimentation
Experimentation consists of testing the model under a various combination of factors in

order to improve productivity. The factors that are found to have high influence in the
productivity are selected to vary in different levels. Combinations are made between
each factors and its level by conducting Taguchi design of experiment. The results are
then analyse by the analysis of mean and variance in order to get the best combination
of the factors which would indicates the optimal solution for the production system.
32
Chapter 5:
Data Collection
Data collection is the process of recording some data about a process in order to analyse
for improvement. Data collection was conducted in order to get the required data of the
process which are further used in the simulation of a computer model constructed
according to the actual system. The data to be collected consists of the time taken of
each operation in the production line.
The polo shirt to be studied consists of 25 operations out of which 13 are the main ones
which are processed on the production line. The other operations are the preparation
processes before the shirt is loaded on the line and some addition processes after the
shirt is unloaded.
The data collection consists of a time study which records the time taken by each
operator to perform their assigned task. A stopwatch was used to take the time as lapped
time for each cycle for an operation and noted in a time study sheet. A rating is then
given to the operator for each cycle. A set of 20 values was recorded for each operation
with its corresponding rating and is shown in Appendix A. the basic time is then
calculated by multiplying the recorded time by its corresponding rating.
For the time study, most of the operations were not broken into elements due to the
short duration of the cycle time.
5.1 Standard Allowed Minutes (S.A.M)
In order to get the standard time of each operation, allowance must be added to the
basic time.
According to International Standards, the percentage allowances to be used are:

Personal needs : 3 to 5 %
Fatigue : 3 to 5 %
33
Unavoidable delays : 3 to 5 %
Thus, an allowance from 9 to 15 % can be used. However, for this project, an allowance
of 15% is being used.
The results of the time study conducted for each operation are shown in table 5.1. It also
shows the number of machines actually placed for each operation.
Operation description SAM/min No of machine cycle time

1 Attach cuff to sleeve 0.386 1 0.386
2 Top stitch on cuff 0.213 1 0.213
3 Fuse placket 0.471 1 0.471
4 Iron placket 0.462 2 0.231
5 Marking front 0.571 1 0.571
6 Run & stitch placket 1.62 3 0.540
7 Iron half moon 1.034 2 0.517
8 Attach half moon 1.26 2 0.631
9 Bottom hem (open) 0.593 1 0.593
10 Loading 0.479 1 0.479
11 Join shoulder seam 0.477 1 0.477
12 Top stitch on shoulder 0.555 1 0.555
13 Attach collar 1.85 2 0.925
14 Binding on neck (all round) 0.759 1 0.759
15 Make placket + placket box 3.26 4 0.816
16 Top stitch on binding + label (loop) 0.818 1 0.818
17 Attach sleeves 0.575 1 0.575
18 Top stitch on armhole 0.780 1 0.780
19 Side seam + OL placket end 1.25 4 0.313
20 Tacking cuff (t/s) 0.765 1 0.765
21 Make slit (double fold) + tacking side seam 1.80 2 0.900
22 Marking button jole 0.392 1 0.392
23 Button hole *3 0.440 1 0.440
24 Marking button attach 0.448 1 0.448
25 Attach button (3 + 1 spare) 0.605 1 0.605
Total 21.870 38 14.199
Table 5.1 S.A.M for each operation
All the time study sheets can be found in Appendix B.
34
5.2 Breakdown
No major breakdown was to be noticed on the machines during the time study. On a
yearly basis, the more frequent breakdown was breakage of thread and needle.
However, there is no record for these failures. When analysing the behaviour of the
breakdown, it was found that, on a single machine, the occurrence of failures was only 0
to 5 for thread breakage and 0 to 2 for needle breakage. So, a 3-day failure study of the
system was conducted and the data recorded was calculated for each machine and is
shown in the table 5.2.
Thread Needle
No. Operation No. of breakage MTBF MTTR No. of breakage MTBF MTTR
1 Loading 0 0 1.81 0 0 0
2 Join shoulder seam 8 190 1.81 1 1520 3.12
3 Top stitch on shoulder 8 190 1.81 1 1520 3.12
4 Attach collar 4 380 1.81 0 0 0
5 Binding on neck (all round) 4 380 1.81 1 1520 3.12
6 Make placket + placket box 9 169 1.81 0 0 0
7 Top stitch on binding + label 8 190 1.81 2 760 3.12
8 Attach sleeve 9 169 1.81 1 1520 3.12
9 Top stitch on armhole 12 127 1.81 1 1520 3.12
10 Bottom hem 2 760 1.81 1 1520 3.12
11 Side seam + Ol placket end 8 190 1.81 1 1520 3.12
12 Tacking cuff 3 507 1.81 0 0 0
13 Make slit + tacking side seam 16 95 1.81 2 760 3.12
Table 5.2 MTBF & MTTR for each machine type
5.3 Inter arrival time
A study for the inter arrival time was also conducted on a single day. The mean of the
inter arrival time and the lot size are calculated and are shown in table 5.3.
Inter arrival time /min Lot size

35
Mean 11.86 17
s.d 3.18 5
Table 5.3 Inter arrival time
5.4 Timing a batch of 15 units
A batch of 15 units was timed to get an evaluation of the actual time taken for that batch
to complete all operations. The batch was timed; it started from the loading process to
end at the make slit (double fold) + tacking side seam process since, the other
operations are done by having a large quantity of parts available at the station and are
moved all together.
Time for batch of 15 / min

Operations
Waiting time Start End Operation time
Loading 0.00 0.00 8.37 8.37
Join shoulder seam 0.23 8.60 29.55 20.95
Top stitch on shoulder 7.70 37.25 51.80 14.55
Attach collar 11.02 62.82 87.30 24.48
Binding on neck (all round) 44.03 131.33 145.51 14.18
Make placket + placket box 41.83 187.34 260.26 72.92
Top stitch on binding + label 39.20 299.46 335.81 36.35
Attach sleeve 26.62 362.43 371.36 8.93
Top stitch on armhole 18.52 389.88 401.18 11.30
Bottom hem 0.00 401.18 409.60 8.42
Side seam + Ol placket end 33.48 443.08 460.46 17.38
Tacking cuff 13.57 474.03 484.35 10.32
Make slit + tacking side seam 35.63 519.98 546.80 26.82
Table 5.4 Operating time of a batch of 15 units
As is shown in table 5.3, the time of the batch selected to complete all operations on the
production line is 557.93 minutes, that is, 9.30 hours, which exceeds a day‟s working
hours. The time the batch has to wait for the next operation shows the amount of work-
in-progress that there was at that operation.
36
5.5 Analysis
The actual efficiencies were calculated according to the company‟s calculating

equations and are shown in table 5.5.
Factors Theoretical Actual

Head count (operators) 60 38
Line target pcs/hr 150 104
Expected line efficiency 71.30% 62.37%
Balance efficiency 70.80% 40.40%
Table 5.5 Efficiencies of theoretical & actual
Where,
5.6 Problems noticed during study
When the study was conducted, several problems were noted.
1. The operation breakdown list was not sequential compared to the actual line of
production.
2. Operation described was not implemented on the shop floor.
37
3. There was too much work-in-progress.

The actual time taken for a batch of 15 shirts to complete was much greater compared to
time it should take.
38
Chapter 6:
Model Construction
After the data was collected and analysed, a simulation model is built in the WITNESS
simulation software to simulate the given results. All the necessary information on the
shop floor was assessed so that the model can imitate the real-life situation.
The main objectives of the simulation are to find the optimal possible solution for the
line balancing efficiency and to reduce the work-in-progress.
Simulation was used because

1. Several what-if scenarios can be chosen for simulation to cater for any possible
changes in the real-life situation.
2. The model can be repeated at any time and stop and continue in between the
simulation process as the wish of the user.
3. Simulation can be performed for a much longer time period in a shorter actual
time without interrupting the actual production system.
For the model construction, only the operations from the loading to the make slit +
tacking side seam, which eventually unloaded at this stations, are considered since the
same batch passes through all these operations.
6.1 Structuring the model
Structuring consist of a plan of the model and listing all the required elements which
will be needed in the model.
6.1.1 The assembly line
The assembly line consists of 13 operations in sequence and the material flow is shown
in the figure 6.1.
39
start A
Loading Attach sleeves
Top stitch on
Join shoulder seam
armhole
Top stitch on
Bottom hem
shoulder
Side seam + OL
Attach collar
placket end
Binding on neck (all

Tacking cuff
round)
Make placket + Make slit + tacking

placket box side seam
Top stitch on binding Start

+ label
Figure 6.1 Material flow
6.1.2 Line balancing
Initially, the actual assembly line was considered for the model construction and the
summary of the operation breakdown is shown in table 6.1.
40
Operation S.A.M M/C No. of M/C Cycle time Expected output

1 Loading 0.479 M 1 0.479 1127
2 join shoulder seam 0.477 OL 1 0.477 1132
3 top stitch on shoulder 0.555 INT 1 0.555 973
4 attach collar 1.85 SN 2 0.925 584
5 binding on neck (all round) 0.759 INT 1 0.759 711
6 make placket + placket box 3.26 SN 4 0.815 663
7 top stitch on binding + label 0.818 SN 1 0.818 660
8 attach sleeve 0.575 OL 1 0.575 939
9 top stitch on armhole 0.78 INT 1 0.780 692
10 bottom hem 0.593 INT 1 0.593 911
11 side seam + Ol placket end 1.25 OL 4 0.313 1728
12 tacking cuff 0.765 SN 1 0.765 706
13 make slit + tacking side seam 1.8 SN 2 0.900 600
Total 13.961 21 8.7535
Table 6.1 Operation breakdown
Production time available = 540hr/day
Pieces
The schematic diagram of the actual layout of the production line is shown in the figure
6.2.
41
Make slit(2) Make slit(1)
Tacking cuff Bottom hem
Side seam + OL Top stitch on

placket end (2) armhole
Side seam + OL Side seam + OL

Attach sleeves
placket end (4) placket end (1)
Side seam + OL Top stitch on

placket end (3) binding
Make placket(4) Make placket(2)
Make placket(3) Make placket(1)
Material flow
Binding on neck
Attach collar(2)
Attach collar(1)
Top stitch on
shoulder
Join shoulder
seam
loading
Figure 6.2 Actual production layout
6.1.3 Indentifying WITNESS elements
In a real situation, product is produced by a number of processes which requires

different physical entities. WITNESS elements are the representative of those entities in
42
the software. So, the elements must be defined according to the real situation. On the
shop, the main entities to produce a shirt were identified and the corresponding
WITNESS elements used are shown in table 6.2.
Assembly line element WITNESS element used

Panels Part
Rail Buffer
Sewing machine + operator Machine
Bin Buffer
Table 6.2 WITNESS element used
A shift schedule was also used to make the model more real. The working hours and
also the break time of the company was recorded on the shop floor and incorporated in
the shift schedule.
6.2 Building the model
Building the model is concerned of placing all elements identified previously in the
model and assigned to them the necessary conditions and rules for them to work
according to the real-life situation. The model is constructed according to the
arrangement of all machines shown in figure 6.2 and the elements are assigned the
valued recorded in the time study shown in table 6.1. The building process consists of
three main steps, defining, displaying and detailing.
6.2.1 Defining elements
43
Defining element refers to adding the elements needed for the model on the simulation
screen by simply clicking on the element icon and click on the screen. An element has
its own default details, some of which will remain as it is and others are detailed further.
6.2.2 Displaying elements
Displaying of elements refers to the way the user wants the elements to look graphically
on the screen. Changes like adding note, text, colour of text can be brought to the
elements. However, I have chosen the default display setting.
6.2.3 Detailing elements
Detailing of elements refer to assign values to the parameters available in the dialog box
of an element for it to behave similar to real-life situation. Each element has its own
detail dialog box. Rules are added in order for an element to combine with other
elements and to control its input and output.
Input and output rules

After defining and displaying the elements, they are linked together through some rules
to imitate the real-life situation. This is done using input and output.
The basic rule for input and output is PULL and PUSH rule respectively. The PULL
rule will cause the element to pull parts upon available from the previous element and
the PUSH rule will cause the element to push parts to the next machine upon free.
6.3 Detailing WITNESS elements
44
Detailing element is the process of adding the required information to the element for
the model to run to attain the set objectives
6.3.1 shirt
The group of a shirt‟s component is defined as PART. A part can be detailed as:
1. Passive – parts are readily available in the system from infinite supply.
2. Active – parts are not readily available but are arrived after an interval of time.
The time interval and the lot size can be fixed or varied.
3. Active with profile – arriving in the system according to a set, repeating pattern
The part defined was detailed to be an active part as the part arrived in a varied lot size
and in a varied time interval.
The factors that are detailed for the part in the model are:
 Maximum part that can be arrived.
 The simulation time at which the first part arrives
 The inter arrival time of parts.
 The lot size of parts when arrived.
 The output rule.
45
Figure 6.3 Detail dialog box of part
The detailed element part is summarised in the table 6.3.
Detailing of part-shirt
Name Shirt
Type Active
Maximum arrival 1155
First arrival at 0.0
Inter arrival time NORMAL(28,4,1)
Lot size NORMAL(23,5.19,1)
Shift Shift
Output rule PUSH to rail1
Table 6.3 Detailing of part
46
The maximum number to be arrived was chosen to be 1155 parts as it is the order
quantity.
The first arrival was chosen to be at 0.0 min since the study was started when parts
already arrived at the loading station.
The values of the inter arrival time and the lot size were taken upon the study conducted
previously as shown in table 5.3 in chapter 5. Normal distribution was chosen because
from the same study, the data was found to follow that distribution.
The normal distribution is detailed in the format NORMAL (m, s.d, psn)
Where m = mean; real number
s= standard deviation; real number
psn= pseudo random number; integer
The push rule represent that, upon the condition stated the detailing of the part, it is
pushed to the next element in the sequence which is the buffer rail1.
A shift of 540 working minutes plus 60 minutes rest time was also added in the detail so
as parts would arrive only on working time.
6.3.2 rail1
The buffer rail1 acts as storage of parts arriving. It provides a real condition for the
actual production system. If there was not that rail1, the part should be push to the first
operation which is loading as this operation cannot pull from an active part. However,
when loading operation is busy and parts are available, they would be pushed to the
operation. But, being busy, the loading operation will not be able to take the parts, so,
they would be declared as rejected.
47
6.3.3 Sewing machine
Sewing machines are declared as machine elements in the WITNESS simulation

software. A machine has its own cycle time of processing an operation that can be
defined. A machine can be of type:
1. Single
2. Batch
3. Assembly
4. Production
5. General
6. Multiple cycle
7. Multiple station
The machine defined was detailed to be a batch type as a batch of shirt passes through
all the operations. Therefore, one operation of the machine would consist of processing
all the lot size of that batch. In actual situation, the loaded batch size varies and the
same batch passes through all operation. But, in the simulation model, it was too
difficult to include this condition, so, a batch of 15 units was selected.
The factors that are detailed for the machine in the model are:
 Cycle time.
 Batch min and max
 Breakdown
o mode of breakdown
o time between failures
o repair time
 Input and output rules
48
Figure 6.4 Detail dialog box of machine
Figure 6.5 Detail dialog box of machine breakdown
The detailed element machine is summarised in table 6.4.
49
Detailing of machine-sewing machine

Name Joinshoulderseam
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Cycle time NORMAL(0.503*15,0.023,1)
From PULL from rail2
To PUSH to rail3
Setup None
shift shift1
Table 6.4 Detailing of machine
The detailed breakdowns is summarised in table 6.5.

Breakdown Mode Time between failures /min Repair time /min
thread breakage Busy time NEGEXP(190,1) NORMAL(1.81,0.33,1)
needle breakage Busy time NEGEXP(1520,1) NORMAL(3.12,0.30,1)
Table 6.5 Detailing of machine breakdowns
The batch min and max refer to the range of lot size the machine can hold while on
operation.
Priority refers to which machine should assign the work first. It has a priority over the
other similar machine. For this type of machine, there is only one so, the priority will
not have any effect on the system. Thus, the priority remains lowest, as the default
setting.
The cycle time is set to NORMAL (0.503*15, 0.023, 1) having a mean of 0.503 min for
a shirt with a standard deviation of 0.023 min and prn of 1. However, the machine is
50
declared as a batch type which processes an amount of 15 units for 1 operation so, the
mean is multiplied by the batch size.
The input and output rules are set to PULL from the previous element which is a buffer
(rail2) and PUSH to the next element which is also a buffer (rail3).
Actually, there was no major setup to make for the machine. The common setup was to
adjust the shirt on the table and this is included in the cycle time.
Two types of breakdown were also assigned to the machine namely thread breakage and
needle breakage. Both breakdowns were notice to follow a negative exponential
distribution and are given in the form NEGEXP (m, prn) where m represents the mean
and prn represents the pseudo random number.
From the data collected, the repair time was found to follow a normal distribution and is
represented in the form NORMAL (m, s, prn).
The shift1 is also incorporated in the machine detail so that it operates only on the
working hours.
6.3.4 Rail
The arrangement of the rail and the sewing machines are such that the first batch moves
to the station. If the first batch is not yet processed upon the arrival of the next batch,
the second batch waits behind the first one. So, from this arrangement, the buffer will
operate on the first-in-first-out manner.
51
Figure 6.6 Detail dialog box of buffer (rail2)
The detailed element buffer is summarised in the table 6.6.
Detailing of buffer-rail2
Name Rail2
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Table 6.6 Detailing of buffer
The quantity of the buffer is set to 1 since on the actual system, the parts move on a
single rail except when there is multiple machine for an operation but still, the parts
wait on a single rail then the operator comes and pick a batch.
52
The capacity remains on 1000 since it is the default setting and if the value was changed
to a lower value, parts might be rejected if the capacity was surpassed. On the actual
system, there is no reject on this condition and parts are allowed to accumulate on the
rail.
The input option allows the coming part to enter at a specific place. Similarly, the
output allows the part to leave at a specific place in the search from option. Since the
production line is a sequence flow, rear entry is chosen for the input option and front for
search from option. As mentioned above, the output is set to first out so that the buffer
will respect the first-in-first-out condition.
6.3.5 Shift
In order to simulate the model according to the real-life situation, a shift must be
incorporated in the system.
Figure 6.7 Detail dialog box of shift
53
No. Period Duration /min Start time End time

1 Working time 120 07:30 09:30
2 Rest time 10 09:30 09:40
3 Working time 140 09:40 12:00
4 Rest time 40 12:00 12:40
5 Working time 140 12:40 15:00
6 Rest time 10 15:00 15:10
7 Working time 140 15:10 17:30
Table 6.7 Detailing of buffer
As it has been discuss previously on the detailing of buffer (rail) and machine (sewing
machine), the other buffers and machines are detailed similarly using their respective
data and rules and are shown in Appendix B.
6.4 Assumption made
A simulation model has the ability to imitate a real-life situation very closely, but still
there are some factors that such as the human behavior and random variations in the
environment cannot be controlled. So, assumptions have to be made to cater for these
factors.
 All the parts associated to make up a shirt are assumed to be a single WITNESS
part that passes through all operations.
 Parts are assumed to remain as it is although changes occur while processing the
part such as sleeves attached to the panel makes a new part.
 Parts are always arrived at the specified time interval.
 The operator and the sewing machine are assumed to be as a single WITNESS
element machine.
54
 Where there are multiple machines in a single operation, the different operators
are assumed to work similarly under common conditions with the same
motivation and having the same skills and abilities.
 The operators are always available in the working time. There were no urgencies
for operator to leave the machines.
 The reparation for thread and needle breakage are assumed to be done by the
operator and the spare needles are available at the station.
 No overtime was schedule for that production order.
6.5 running the model
This step in the model construction is only to see the behavior of the elements while
running it through a period of time. The model runs interactively to facilitate the
understanding of the system.
The model was run for a period of 1100 minutes including a warm-up period of 100
minutes for the machines to reach a steady state. The model was run again with
different replication conditions. Each replica has its own different random number
stream. Through this change in random number stream, the model would generate result
purely at random and thus, provide a robust model. Observation was then made by
generating reports to compare the model to the actual production system.
6.6 Generating reports
The statistics reports of the WITNESS simulation software provide enough data so that
the model can easily analysed.
The report generated for the simulation at different replication is shown in Appendix C.
55
Summary of the report for part element simulated for 1100min is shown in table 6.8
No. No. No. No. Sigma

Replica entered shipped scrapped rejected WIP Avg. WIP Avg. time rating
1 721 330 0 0 391 274.4 167.456 6
2 779 330 0 0 449 337.768 190.781 6
3 730 330 0 0 400 300.784 181.295 6
Table 6.8 Report for part at each replication
Thus, the mean output of the shirt completed is units
6.7 Testing and evaluating of results
Referring to the Appendix C, the first experiment is chosen for evaluation.
Buffer statistics
Name Total in Total out Now in Max Min Avg size Avg time
rail1 702 675 27 29 0 17.169 24.457
rail2 675 675 0 15 0 0.062 0.092
rail3 675 675 0 15 0 0.451 0.669
rail4 690 690 0 30 0 0.772 1.119
Table 6.9 Extract from buffer report
As it can be seen in the table 6.9, at rail4, that is, the cycle time of the operation attach
collar, is higher compared to the other operations. This creates a bottleneck at that
operation and a proper setup need to be made to overcome this problem.
56
Machine statistics
Name No. of Operation % Idle % Block % Busy % Setup% Setup wait labour
% Broken
attachcollar03 15 14.41 0.00 85.20 0.00 0.00 0.39
makeplacket05 6 40.48 0.00 58.63 0.00 0.00 0.88
makeplacket06 7 35.44 0.00 62.02 0.00 0.00 2.54
makeplacket07 6 38.00 0.00 60.73 0.00 0.00 1.27
topstitchonbinding02 14 64.21 0.00 34.95 0.00 0.00 0.84
Table 6.10 Extract from machine report
From the table 6.10 it can be noticed that some of the machines has a high level of idle
time. This shows that the operator has to wait long for the previous operation to finish.
Thus, the work-in-progress at the previous operation is high. So, a good planning would
reduce the idleness of these operators.
57
Chapter 7:
Experimentation
After the model is built, run and tested, it is then evaluated for an optimal solution to
increase the production line by simulating under different what-if scenarios. So,
experimentation refers to the testing of the model constructed through a change in the
factors that affect the production line the most. Then, the experimental results are
analysed to provide the optimal solution. So, for the experiments, the Design of
Experiments (DOE) based on the Taguchi Methods was used to identify the minimum
combination of factors for testing.
7.1 Objectives of the experiment
The objectives of the experiment are:
- To track the factors which have greater influence in the output.

- Select the best combination of factors to increase the productivity
- To reduce WIP.
7.2 Design of experiment (DOE)
Information on the DOE can be found in Appendix C.
The main objective of the DOE is to find out the best combination of the factors level in
order to increase the productivity.
Basic steps in conducting a DOE are:

1. Identifying the factors to be evaluated.
2. Defining the levels of the factors to be tested.
3. Creating an array of experimental combinations.
4. Conducting the experiments under the prescribed conditions.
58
5. Evaluating the results and conclusion.
7.2.1 Identification of factors
Factors are the parameters that can be varied in order to assess the changes in the
system.
From the study conducted, it was found that there are several factors which have great
influence on the productivity. From a brainstorming process among the concerned
persons, the following 3 factors were considered for the experimentation:
1. Batch size.
The batch size usually makes the operation to fatigue quickly since he/she needs to
continue the cycle to complete the batch and move it to the next operator. The larger the
batch, the slower it would flow which leads to high WIP. The smaller the batch, the
quicker it will pass through operation but it will provide idleness at some operation.
2. Line balancing
The right amount of machines must be selected for each operation so that each
operation has nearly the same cycle time which leads to a fluid flow of shirts and
reducing the WIP.
3. Cycle time
Cycle time is the time taken for each operation to complete one cycle including the
allowances.
The other factors such as the inter arrival time and lot size of the shirts, the breakdowns
interval were kept constant.
59
7.2.2 Defining the level of each factor
The levels chosen for the batch size are 15, 10 and 1. Batch size of 15 was chosen due
to the initial study based on this amount. Batch size of 1 was chosen due to its constant
flow of the shirt on the production line. The batch size of 10 was chosen because higher
amount leads to high WIP in the production line and it was approved by the person
concerned.
The 3 levels of line balancing was chosen are:

1. The actual line balancing on the shop floor
2. A theoretical one described in the operation breakdown list (table 4.1 in chapter
4)
3. A proposed one developed from the actual data collected in the time study. The
developed line balancing is shown in table C.1 in Appendix C.
The 3 levels of cycle chosen for the experimentation are:

1. The actual S.A.M recorded in the time study
2. The theoretical S.A.M according to the operation breakdown list
3. An optimistic cycle time which is the same as the basic time calculated in the
time study. The basic time was selected since it was noticed that the operators
can work to this level and it was approved by the supervisor.
Further information is found in Appendix C
The factors and their corresponding level are summarised in table 7.1 below
60
Factors
Level A B C
Batch size Line balancing Cycle time
1 15 Actual Actual S.A.M
2 10 Proposed Theoretical S.A.M
3 1 Theoretical Optimistic
Table 7.1 Factors and level to be tested
7.2.3 Selecting the Orthogonal Array (OA)
For an appropriate selection of the OA, there are 2 factors to be considered:

1. The number of factor to be tested.
2. The number of level of each factor.
Since for the experimentation there are only 3 factors with 3 levels each, OA L9 is
chosen as it corresponds to the requirements. The OA L9 consists of 9 experiments
varying each factors 3 times. The OA L9 matrix used in the project is shown table C.3
in Appendix C.
7.3 Conducting the experiment
Once the factors, levels and OA size have been finalised, the experiment can be
conducted through various trials randomly. The trial test conditions are dedicated by the
rows of the orthogonal array.
Philip Ross stated that randomisation is needed for the treatments since it protects the
experimenter from any unknown and uncontrolled factors that may vary during the
entire experiment and which may influence the results (1985, p86).
61
To cater for this randomness, the Witness simulation software provides replications of
the simulated model with different random sequence. Random sequence refers to the
series of random numbers used to simulate the model to provide reliable results.
7.3.1 Selecting the sample size
A sample is a representative of a whole population. It reflects the behavior of a whole

system in a few trials. A larger number of trials would provide an accuracy of the
results close to the whole system however, it provides also too much analysis job to
perform. Thus, a sample of 3 trials was selected.
7.4 Summary of results
The model constructed was used to test the different experiments scenarios defined
previously. Each experiment was conducted on 3 trials to provide a sensitive result.
This was done by defining a situation with different replication scenarios.
Replication refers to a specific random number stream setting and the run length. It
allows estimating experimental error. The reliability of the sample statistics increases
with the increase of the number of replication. But too much increase of the replications
will lead to the need of excessive time and/or memory space of the experiment meaning
that experimental errors would increase, finally decreasing the reliability of the result.
Therefore, a balance between what is statistically desirable and what is practically
possible should be established.
The replications were chosen with a stream offset of 1, 5 and 10 for a total run length of
1100 minute including a 100 minutes of warm-up period.
62
The results obtained from the experimentation are shown in Appendix D and a
summary is shown in table 7.2 below.
Experiment Output Work-in-progress

No. Replica 1 Replica2 Replica 3 Replica 1 Replica 2 Replica 3
1 330 330 330 391 449 400
2 360 360 360 393 384 340
2 510 495 510 281 279 327
4 360 360 360 324 313 419
5 590 590 600 159 175 180
6 480 490 470 241 243 206
7 531 539 540 75 64 40
8 613 675 677 26 16 53
9 574 554 618 37 35 43
Table 7.2 Results of simulation
7.4.1 Signal to noise ratio
The signal to noise ratio of the experiments was then calculated for both the output and
the work-in-progress.
For example, for experiment 1, the S/N is given by
for output and
for work-in-progress
(H.Ramasawmy, 2007)
The results of the signal to noise ratio, η are calculated in Appendix C, section C.6.1
and are shown in the table 7.3 below.
63
Figure 7.3 signal to noise ratio
The overall mean value, of η is given by,
7.4.2 Analysis of mean (ANOM)
As described in Appendix C section C.7, to calculate the factor effect, the experiment
for which a factor varies at a given level must be identified.
Factor A varies at level 1 in the experiment number 1, 2 and 3 and is denoted by A1.
Similarly, factor A at level 2, denoted by A2, varies in experiment number 4, 5 and 6.
Therefore, for the other factors, the experiments in which these factors vary are shown
in table 7.4.
64
Levels
Factors
1 2 3
A 1,2,3 4,5,6 7,8,9
B 1,4,7 2,5,8 3,6,9
C 1,6,8 3,5,7 2,4,9
Figure 7.4 signal to noise ratio
An example in calculating the factor effect, for the factor A at level 1 is given by,
db for the output
The other factors are calculated for both the output and the work-in-progress and are
shown in the tables 7.5 and 7.6 below.
Levels
Factors
1 2 3
A-Batch size 51.85 53.40 55.39
B- Line balancing 52.03 54.30 54.32
C-Cycle time 53.43 52.51 54.71
Figure 7.5 Factor effect for the output
65
Levels
Factors
1 2 3
A-Batch size -51.07 -47.65 -32.81
B- Line balancing -46.37 -42.36 -42.80
C-Cycle time -43.52 -44.72 -43.30
Figure 7.6 Factor effect of work-in-progress
The average signal to noise ratios η in the tables 7.5 and 7.6 above are represented
graphically in tables 7.7 and 7.8 below respectively where optimum level for each
factor can be observed. The optimum levels are determined by the maximum signal to
noise ratio η and in tables 7.5 and 7.6 above the optimal values are underlined and
written in bold.
56
55
54
53 Series1
Series2
52
51
50
A1 A2 A3 B1 B2 B3 C1 C2 C3
Figure 7.1 Graph of average η by factor levels (db) for the output
Since the output follows the larger-the-better approach, the higher value represent the
best level for the specific factor. From the table, it can be deduced that the best
combination for a maximum output is:
- A batch of 1 unit
66
- The theoretical line balancing from the operation breakdown list

- The optimistic cycle.
Chart Title
0
A1 A2 A3 B1 B2 B3 C1 C2 C3
-10
-20
-30
-40
-50
-60
Figure 7.2 Graph of average η by factor levels (db) for the W.I.P
Similarly, for work-in-progress which follows the smaller-the-better approach, the

highest points for a given factor from figure 7.2 are the optimal solution to reduce the
work-in-progress of the system and it consists of
- A batch of 1 shirt
- The proposed line balancing
- The optimistic cycle time
7.4.3 Analysis of variance (ANOVA)
ANOVA is a statistical method analysing the variation in the experimental results by

calculating various statistical values. It constitutes of several steps.
Computation of sum of squares
Degree of freedom
67
Estimation of error variance
The sum of squares is calculated for each factor according to the signal to noise ratio
associated with the respective factors. Then, the percentage contribution for each factor
is determined. The error variance and degree of freedom for each factor are calculated
for and the degree of freedom was deduced to be 2 for each factor. The variance is
calculated from the sum of square and degree of freedom for each factor and the F-test
is done. More details of the calculation and results of the ANOVA are shown in
Appendix C, section C.8. The results of the degree of freedom, sum of squares,
variance, error variance and F-test are shown below in table 7.9 and 7.10 for both the
output and the work-in-progress.
Degree of Sum of Mean Calculated

% Contribution
Factor freedom squares squares F
A. Batch size 2 50.5 18.89 9.445 2.58
B. Line balancing 2 27.83 10.4 5.2 1.42
C. Cycle time 2 19.59 7.32* 3.66
Error 2 2.04 0.763
Total 8 37.373
Error 2 7.32 3.66
Table 7.7 Analysis of variance for the output
Degree of % Sum of Mean Calculate

Factor
freedom Contribution squares squares dF
A. Batch size 2 93.70 565.35 282.7 34.85
B. Line balancing 2 4.81 29.02* 14.51
C. Cycle time 2 0.57 3.45* 1.725
Error 2 0.92 5.53
Total 8 603.35
Error 4 32.45 8.11
Table 7.8 Analysis of variance for the work-in-progress
Taking the confidence level at 95%, the risk factor would equal 1-0.95=0.5
68
Referring to the F table available in Appendix E the F value is given by
F0.05, 2, 2 = 19.00 for the output result

F0.05, 2, 4 = 6.94 for the work-in-progress
7.4.4 Interpretation of results
Putting the first experiment as a reference since it consists of all the actual parameters,
the other experiments are analysed to see the variation of the results in relative to the
actual system. It can be deduced, in table 7.9, that all the other experiments have an
increase of output compared to the actual system especially experiment 8 which has
nearly twice the output.
Experiment 1 2 3 4 5 6 7 8 9
Avg output 330 360 505 360 593.33 480 536.06 655 582
Avg WIP 413.33 372.33 295.67 352 171.33 230 59.67 31.67 38.33
Ratio output 1.000 1.091 1.530 1.091 1.798 1.455 1.624 1.985 1.764
Ratio WIP 1.000 0.901 0.715 0.852 0.415 0.556 0.144 0.077 0.093
Table 7.9 Analysis of experiment relative to the first one
Similarly, the ratio of the work-in-progress reduces for the other experiment and the
experiment 7 is less than one fifth of the work-in-progress of the experiment 1 as shown
in table 7.9.
69
Chapter 8:
Conclusion and Further Works

8.1 Conclusion
It can be said that the project was successfully completed matching the objective of the
project except for the ERP software. The main aim of my project has been to optimise
production of a line at Tara Knitwear LTD. Using the ERP software to attain the
objective would have helped the company to successfully implementing the software.
However, there were limitations in the software such as it does not generate enough
performance indicators to assess and improve productivity. So, other method was
employed and it can be deduced that the time study conducted can indeed helps
improving production to a large extent. As detailed in this project, different
combinations of factors having the most influence were experimented in simulation
software. The experiments have proved to be very effective and the optimal solution
was chosen after conducting various analysis techniques.
However, the method that I have used also has certain restrictions and constraints. It is
more concerned with line of production. However, to increase productivity, other
methods could have been also used such as, method study. This is because optimisation
of production depends largely on many factors such as movement of material, labour
skill and quality of raw material
Moreover, many other alternatives can be used to ensure the smooth running of the
production process such as selecting a suitable material handling system to flow a single
part at a time through the operations to reduce the work-in-progress.
A company should be very careful while choosing the means of production and it
should choose processes which will ensure a maximum production.
70
8.1 Further works
Due to the limited time, further studies could not be carried out which would have
further increase the productivity. A list of further works is shown below.
 The optimal solution derived from the experiment can be implemented on the
shop floor to assess the efficiency compared to the simulated one.
 Other factors can be used in the simulation model to assess their contributions
on the overall efficiency f the production system.
A cost analysis can be performed to analysis the cost of changing the current system to
the optimal one.
71
Referencing
Referencing
Referencing
Moore F. G. (1958). Manufacturing Management. United State of America: Richard D.

Irwin, Inc.
Monks, J. G. (1987). Operations Management – Theory and Problems. United State of

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Muhlemann, A., Oakland, J. & Lockyer, K. (1992). Production and Operation

Management. London: Pitman Publishing.
Noori, H. & Radford, R. (1995). Production and Operations management: Total

Quality and Responsiveness. United State of America: McGraw-Hill, Inc.
Reid, R. D. & Sanders, N. R. (2010). Operations Management – An Integrated

Approach. Asia: John Wiley & Sons, Inc.
Riggs, J. L. (1987). Production Systems: Planning, Analysis, and Control. Asia: John
Wiley & Sons, Inc.
Ross, P. J. (1989). Taguchi techniques for quality engineering loss function, orthogonal
experiments, parameter and tolerance, New York: McGraw-Hill.
Stevenson, W. J. (2009). Operations Management. United State of America: McGraw-

Hill, Inc.
Thomson, N. (1995). Simulation in Manufacturing. England: Research Studies Press

LTD.
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Referencing
Webography
Hasan, R.H., Arif-Uz_zaman., K.A, Rahman. Productivity improvement th through linr

balancing in Apparel Industries[pdf]. Dhaka, Bangladesh, (2010).
Available at :
http://www.iieom.org/paper/133%20rezaul.pdf
[Accessed on 16/09/2011}
73
Appendix A:
Simulation
Appendix A:Ssimulation
A.0 Simulatiom
A.1 Six basic steps in line balancing procedures
Step 1: Identifying tasks and their immediate predecessors
The tasks or the work elements that must be performed in order to produce the product
must be well defined as well as the time taken to perform each task or work element.
The sequence of the tasks, that is, the task to follow each previous task must be also
defined.
Step2: Determining output rate
The number of units planned to produce over a specific period of time, normally a day,
is determined which is called the output rate.
Step 3: Determining cycle time
Cycle time is the maximum amount of time needed for each workstation to complete its
assigned tasks. Cycle time can show how frequent a product is completed.
Cycle time can be calculated by
Step 4: computing the theoretical minimum number of stations
The theoretical minimum number of stations can be calculated by
74
Where = sum of the task times needed to complete a unit.

= cycle time.
Step 5: Assign tasks to workstations (balance the line)
An initial layout is developed by assigning tasks to the workstations.
Step 6: Compute efficiency, idle time and balance delay
Efficiency is the ratio of total productive time divided by total time
Where = sum of the task times needed to complete a unit.

= number of workstations
= cycle time.
Or simply,
If possible, the layout can be further improved.

(R.D. Reid, 2010, pg 349-354)
A.2 Simulation
It is not hard to conceive that if a computer can be programmed to execute the steps of a
mathematical algorithm, which is in essence a transformation of numbers, characters,
etc organised into datatypes, it can also be directed to mimic transformations and
movements of material in the real world and in particular the real world of
manufacturing.
75
(N. Thomson, 1995)
Today, in many industries, many companies tend to select computer simulation and
modeling softwares for the planning and decision-making. These softwares help
companies attaining a better quality product or service on a more cost-effective basis
while trying to reduce significantly the production or service lead time.
A.2.1 Definition of Simulation
Simulation can be said to imitate a real life situation. Simulation can be defined as
developing a computer model based on a real life situation and conduct experiments on
it and analyse the behavior over a given period of time. Thus, from the result, it can
easily improve the system if there is room for it.
A.2.2 Advantages and disadvantages of using simulation
Advantages
5. Simulation can be jumped to events, thus, eliminates unnecessary time.
6. Different scenarios can be conducted to evaluate according to changes in real-
life situation.
7. Simulation can be done for a longer period of time in a shorter actual time.
8. Simulation does not interrupt the actual on-going events in a real-life situation.
Disadvantages
3. With great time and effort spent on developing the model, there is no guarantee
that the model would match the real life situation at 100%.
4. Simulation is only limited to imitate the real-life situation. It does not provide
any optimal solution, thus, the user needs to do the necessary analysis to
evaluate the model.
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A.2.3 WITNESS Simulation
The literatures onwards are taken for „WITNESS Release 9, Tutorial Manual‟.
Due to the availability of WITNESS software at the University of Mauritius, this

software has been used for the simulation of the production line.
WITNESS simulation forms part of the Lanner Group‟s simulation software package. It
is the culmination of more than a decade‟s development experience with computer-
based simulation. This experience has led to the evolution of a visual, interactive and
interpretative approach to simulation without the need for complication.
A.2.3.1 The benefits of the WITNESS approach are that:
 People can gain commitment by working together as a team on creating and

using WITNESS models.
 Models can be built and tested in small incremental stages, which greatly
simplifies model-building, provides the ability to identify errors in the logic and
makes the model more reliable.
 The model can be changed at any time during the run. Changes are incorporated
immediately leading to faster model building.
A.2.3.2 Application of the WITNESS simulation software
The software can be applied for:

 The evaluation of capital projects.
 Running models regularly for testing production schedules.
 The evaluation of alternative proposals.
 The improvement of existing facilities
 The management of changes.
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The environments where it can be applied are:

 The automotive industry
 The textile industry
 The chemical industry
 Electronics
 Aerospace
 Engineering
 Food
 Paper
 Banking and finance
 Government
 Transport
A.2.4 Steps in developing a simulation model
Projects which involve simulation have several unique aspects which must be managed
particularly carefully to ensure their success. Several steps, in sequence, have been
developed to ensure a good and reliable model construction according to the real-life
situation analysing through a systematic flow of actions. The steps are as follows:
10. Establishing objectives
11. Deciding the scope and level of details in the model
12. Collecting data
13. Structuring the model
14. Building the model
15. Generating reports
16. Testing the model
17. Experimenting the model
18. Presenting the results and implementing them
A.2.4.1 Establishing Objectives

78
This is the first and most important phase of any simulation project. The aim of any
simulation project should be to make a better decision. Thus, the decision should be
well understood as it is likely to have important implications for the content of the
simulation model.
A.2.4.2 Scope and level of model detail
The scope of a simulation model refers to where it begins and where it ends. It is
important to limit the scope of the model as far as possible. With regards to the level of
detail contained within a model, the golden rule is to model the minimum necessary in
order to achieve the model‟s objective.
At the beginning of the model-building process, small additions to the model lead to
large increases in its accuracy. As the model becomes more detailed, however, each
subsequent addition adds less to the model‟s accuracy. In fact, it could be argued that
the addition of necessary detail could lead to an eventual fall in the accuracy of the
model.
A.2.4.3 Data collection
There are different ways in getting the data needed for building a model and these ways
can be classified in three categories:
1. Available – data is ready available and it is in an appropriate format that the
model can use immediately.
2. Not available but collectable – data is either in an incorrect format or it has not
been collected before. A small work study can be performed in order to collect
this type of data.
3. Neither available nor collectable – data is not currently available and it is not
easily collectable.
79
Estimation must be made if data is neither available nor collectable and useful data
estimations can be obtained by using the manufacturer‟s data often included in their
promotional literature and machine specifications and sensitive analysis which involves
in replacing parameters by higher and lower values and comparing the results of the
entire simulation. Whenever estimations are used, they should be declared as
assumptions upon which the model is based. If the model later proves inadequate as a
representation of the real world situation, then it is possible to scrutinise the
assumptions upon which it was made.
A.2.4.4 Structuring the model
An important final step before building the simulation model is to structure it. This will
identify the most difficult areas for the model-building and highlight any additional data
requirements that may have been overlooked up to now, such as the transfer time for
parts between stations.
This plan typically takes the form of a sketch of the facility to be modeled. The plan
should identify which element is to be used to model each real-life process. It may also
contain information regarding the input and output rules to be used on key elements and
a summary of the actions language that needs to be included in the elements to give the
necessary degree of logic control.
A.2.4.5 Building the model
It is recommended to build the model incrementally and test each stage thoroughly
before the next stage is built. In this way, it is easier to track any possible problem that
might occur during the building process. The main steps in building a model are
creating elements (defining, displaying and detailing them), then linking them together
with rules.
80
A.2.4.6 Running the model
After building the model, it can be run immediately and then modified by adding,
changing or deleting elements. The impact of these changes can be assessed by running
the model again.
This ability to build a model incrementally, testing each section, is a powerful aid to
productivity and generates confidence in the validation of the model.
The model can be run in different modes, from step-by-step (with full screen display) to
a „batched‟ time in the future (with no screen display).
There are many features which can help in analysing the model including standard
report tables and graphs, meteor trails, elements flows and process views. Timeseries,
pie charts, histograms and customised report tables are also available.
A.2.4.7 Generating reports
After the model has been built and run, reports can be used to help choosing between
alternative modeling scenarios, for example:
 In order to increase the utilisation of machinery, the factor of the time that
machines spend in an idle state compared to the time they spend in a busy state
during a simulated shift can be considered.
 In order to reduce wastage, the most important factor might be to consider the
quantity of parts that were scrapped during the simulated period.
 In order to increase the throughput of an operation, the ideal factor to consider
can be the number of parts processed during a simulated day‟s operation.
A.2.4.8 Testing the model
81
The testing of a simulation model consists of verification and validation.
Verification ensures that the content of the model is consistent with what was expected.
For example, establishing that the parts are travelling along the correct routes between
elements and that any labour used is attending to the correct elements in the correct
priority order.
Validation (which usually follows verification) investigates the accuracy of the model
compared to the real world. A typical validation exercise might involve providing a
typical set of inputs (parts arrival and production schedule) and studying a set of model
outputs (the average level of work-in-progress for a part).
The verification and the validation stages of a simulation study are usually iterative in
that they involve re-visiting some of the stages already described. For example, the
model may require the addition of some processes not yet modeled, thus increasing the
model‟s scope.
A.2.4.9 Experimentation
A number of what-if scenarios can be investigated once the model constructed seems to
resemble the behaviour of the real-life situation. The scenarios should have been
defined within the original objectives of the simulation study.
Successful experimentation typically involves using a warm-up period or starting

conditions, deciding on a suitable run-length and running the model with more than one
random number stream.
A warm-up period allows the model to reach a steady state before any results are
collated. Another way to provide the warm-up period is to include some starting
conditions within the model. At time zero, parts are dispatched to various elements. The
82
number of parts and their destinations correspond to a typical work-in-progress

situation. There is no need for a warm-up period as the model is being run from a
typical real-life situation.
Although most simulation runs require warm-up periods or starting conditions, some
situations do not need either.
A.2.4.10 Documentation
It is a good idea to document the way the model is built, as if the model is to be
examined at a later stage, it would be easier to understand. Such documentation should
include the model structure diagram.
The sources of data used, the assumptions made and the results obtained should also
form part of the model documentation. If the project is documented as it proceeds then
the documentation will prove to be less onerous task. It is recommended that any
project documentation is completed before the presentation of results as there is often
less inclination to document a project which has been laid to rest.
A.2.4.11 Presentation of results and implementation
The method of presentation for results depends on the size of the simulation project and
the culture of the organisation.
An animated model provides an effective communication tool to support business

decisions, particularly if it is enhanced by graphical display.
A.2.5 Elements: the WITNESS building blocks
A WITNESS model uses the combination of parts, people, machines and other
simulation devices, called modeling elements, in order to simulate the operation being
studied.
83
There are four kinds of modeling elements: discrete, continuous, logical and graphical.
A.2.5.1 Discrete elements
These are displayed as dynamic icons and represent tangible entities in the real-life
situation being studied.
Parts
Parts flow through the model and can represent:
 Products (cars, engines, garments).
 Tiny electronic components or whole computer.
 People moving from a queue to a counter.
Parts can be:

 Displayed in different ways – as an icon or a text description.
 Characterised by a particular set of attributes (weight, length, colour), which can
be fixed (for every part of the same type) or variable (for each individual part of
the same type).
 Handled in different ways (batched, created singly or in lots, changed into other
parts, many parts can be combined into one part, or one part can be split into
several parts).
Buffers
These are places where parts can be held, for example:
 Parts waiting for the next operation while the machine or operator is busy.
 People in a queue.
Buffers can:
84
 Have parts arranged within them according to different ordering methods (for
example, first-in first-out or by priority)
 Be tied directly to machines (dedicated buffers)
 Hold parts for a specified minimum time.
 Hold parts for a specified maximum time.
Machines
These are powerful elements which are used to present anything that takes parts from
somewhere, processes them and sends them on to their next destination, for example:
 A machine tool, lathe or a press
 A complete shop or a supermarket checkout
 A counter at service provider
Machines can:
 Be one of seven types, handling parts in a variety of ways.
 Model such factors as, the time a machine takes to process a part, time between
breakdowns, multiple setups, multiple stations, multiple cycles, time to repair
breakdowns and to set a machine up, as well as labour for these events.
Labour
This is a resource which may be required by other elements for processing, setting up,
repair, cleaning and maintenance. Labour can be moved to other elements so that a
more important task can be completed instead of being idle at a specific element.
A.2.5.2 Logical elements

These represent the data and reporting aspects of the model (that is, control and
information). Data is handled easily, reports can be customised and more complex logic
can be built into WITNESS models.
Attributes
85
These are characteristics of a specific part or labour unit. Each attribute may hold an
integer or real number or a string or a reference to another WITNESS modeling
element.
Distributions
Distributions allow building variability into the model by including data which have
been collected from the real world. Distribution can:
 Be defined by the user
 Be one of the wide range of the integer and real distributions already provided
by WITNESS
 Be either continuous or discrete
Shifts
The shift element is used to simulate a shift pattern (or a series of shift patterns) which
is, in effect, a sequence of working and non-working periods. Shift patterns may be
applied to labour and other elements in order to simulate shift working.
86
Appendix B:
Time study, breakdown and inter

arrival time sheet
Appendix B: Time study, breakdown and inter arrival time sheet
B.1 Time study, breakdown and inter arrival time sheet
Time Study Sheet

Operation: Attach cuff to sleeve
Date: 21.Nov.2011 Study No. 1
Machine: Overlock Sheet No. 1 of 1
Theoretical S.A.M = 0.70 min Studied by: Y. RADHA
Recorded time
No. in sec in min Rating Basic time
1 15.21 0.254 1.20 0.304
2 18.35 0.306 1.10 0.336
3 14.78 0.246 1.20 0.296
4 21.11 0.352 1.00 0.352
5 22.15 0.369 1.00 0.369
6 16.75 0.279 1.20 0.335
7 19.81 0.330 1.05 0.347
8 17.62 0.294 1.10 0.323
9 20.57 0.343 1.00 0.343
10 16.82 0.280 1.20 0.336
11 20.37 0.340 1.00 0.340
12 18.16 0.303 1.10 0.333
13 17.67 0.295 1.10 0.324
14 21.02 0.350 1.00 0.350
15 18.91 0.315 1.10 0.347
16 16.70 0.278 1.20 0.334
17 19.62 0.327 1.05 0.343
18 20.73 0.346 1.00 0.346
19 15.86 0.264 1.20 0.317
20 17.95 0.299 1.15 0.344
Mean 0.336
Standard deviation 0.017
Allowance = 15% S.A.M 0.386
87
Time Study Sheet

Operation: Top stitch on cuff
Machine: Interlock Sheet No. 1 of 1
Recorded time
1 10.25 0.171 1.10 0.188
2 8.96 0.149 1.20 0.179
3 10.75 0.179 1.10 0.197
4 9.71 0.162 1.10 0.178
5 11.12 0.185 1.00 0.185
6 12.38 0.206 1.00 0.206
7 9.26 0.154 1.20 0.185
8 9.92 0.165 1.10 0.182
9 10.56 0.176 1.10 0.194
10 11.34 0.189 1.00 0.189
11 10.24 0.171 1.10 0.188
12 9.71 0.162 1.10 0.178
13 9.13 0.152 1.10 0.167
14 10.91 0.182 1.10 0.200
15 8.93 0.149 1.20 0.179
16 11.19 0.187 1.00 0.187
17 10.42 0.174 1.10 0.191
18 9.31 0.155 1.10 0.171
19 9.60 0.160 1.10 0.176
20 8.98 0.150 1.20 0.180
Mean 0.185
88
Time Study Sheet

Operation: Fuse placket
Machine: Manual Sheet No. 1 of 1
Recorded time
1 23.62 0.394 1.00 0.394
2 24.35 0.406 1.00 0.406
3 23.81 0.397 1.00 0.397
4 25.99 0.433 0.95 0.412
5 24.32 0.405 1.00 0.405
6 25.16 0.419 1.00 0.419
7 25.36 0.423 1.00 0.423
8 25.72 0.429 0.95 0.407
9 24.81 0.414 1.00 0.414
10 23.19 0.387 1.05 0.406
11 23.85 0.398 1.00 0.398
12 24.11 0.402 1.00 0.402
13 23.92 0.399 1.00 0.399
14 25.07 0.418 1.00 0.418
15 25.46 0.424 1.00 0.424
16 25.79 0.430 1.00 0.430
17 24.96 0.416 1.00 0.416
18 24.54 0.409 1.00 0.409
19 23.73 0.396 1.00 0.396
20 23.81 0.397 1.05 0.417
Mean 0.409
89
Time Study Sheet

Operation: Iron placket
Recorded time
1 28.02 0.467 0.90 0.420
2 21.90 0.365 1.05 0.383
3 28.09 0.468 0.90 0.421
4 26.00 0.433 0.95 0.412
5 25.43 0.424 0.95 0.403
6 24.13 0.402 1.00 0.402
7 27.16 0.453 0.90 0.407
8 22.92 0.382 1.00 0.382
9 22.45 0.374 1.05 0.393
10 26.85 0.448 0.90 0.403
11 24.61 0.410 1.00 0.410
12 25.93 0.432 0.95 0.411
13 24.72 0.412 1.00 0.412
14 23.53 0.392 1.00 0.392
15 22.88 0.381 1.00 0.381
16 23.79 0.397 1.00 0.397
17 24.64 0.411 0.95 0.390
18 27.05 0.451 0.90 0.406
19 25.38 0.423 0.95 0.402
20 8.98 0.150 1.00 0.150
Mean 0.389
90
Time Study Sheet

Operation: Marking front
Recorded time
1 29.84 0.497 1.00 0.497
2 35.37 0.590 0.90 0.531
3 32.02 0.534 0.95 0.507
4 28.52 0.475 1.00 0.475
5 27.61 0.460 1.05 0.483
6 29.75 0.496 1.00 0.496
7 30.16 0.503 1.00 0.503
8 34.73 0.579 0.90 0.521
9 32.56 0.543 0.95 0.516
10 29.76 0.496 1.00 0.496
11 26.57 0.443 1.05 0.465
12 28.37 0.473 1.00 0.473
13 28.84 0.481 1.00 0.481
14 30.81 0.514 1.00 0.514
15 32.64 0.544 0.95 0.517
16 31.26 0.521 0.95 0.495
17 30.89 0.515 1.00 0.515
18 29.21 0.487 1.00 0.487
19 28.43 0.474 1.00 0.474
20 29.16 0.486 1.00 0.486
Mean 0.496
91
Time Study Sheet

Operation: Run &stitch placket
Machine: Single needle Sheet No. 1 of 1
Recorded time
1 92.78 1.546 0.95 1.469
2 87.45 1.458 1.00 1.458
3 88.53 1.476 0.90 1.328
4 85.53 1.426 1.00 1.426
5 89.16 1.486 0.90 1.337
6 91.85 1.531 0.90 1.378
7 86.35 1.439 1.00 1.439
8 86.91 1.449 1.00 1.449
9 90.67 1.511 0.90 1.360
10 85.29 1.422 1.00 1.422
11 86.23 1.437 1.00 1.437
12 88.16 1.469 0.95 1.396
13 85.91 1.432 1.00 1.432
14 87.62 1.460 0.95 1.387
15 86.96 1.449 1.00 1.449
16 89.46 1.491 0.90 1.342
17 90.31 1.505 0.90 1.355
18 86.71 1.445 1.00 1.445
19 85.64 1.427 1.00 1.427
20 85.97 1.433 1.00 1.433
Mean 1.408
92
Time Study Sheet

Operation: Iron half moon
Date: 21.Nov Study No. 7
Theoretical S.A.M = 0.49 Studied by: Y. RADHA
Recorded time
1 57.31 0.955 0.95 0.907
2 88.69 1.478 0.65 0.961
3 60.47 1.008 0.85 0.857
4 50.13 0.836 1.00 0.836
5 51.84 0.864 1.00 0.864
6 61.72 1.029 0.80 0.823
7 51.54 0.859 1.00 0.859
8 53.60 0.893 0.95 0.849
9 64.54 1.076 0.85 0.914
10 64.49 1.075 0.85 0.914
11 50.31 0.839 1.00 0.839
12 53.72 0.895 0.95 0.851
13 57.36 0.956 0.90 0.860
14 60.71 1.012 0.85 0.860
15 58.76 0.979 0.90 0.881
16 52.69 0.878 1.00 0.878
17 56.08 0.935 0.90 0.841
18 60.12 1.002 0.85 0.852
19 63.76 1.063 0.85 0.903
20 59.92 0.999 0.90 0.899
Mean 0.872
93
Time Study Sheet

Operation: Attach half moon
Recorded time
1 62.62 1.044 1.05 1.096
2 67.08 1.118 1.00 1.118
3 65.17 1.086 1.00 1.086
4 50.93 0.849 1.20 1.019
5 67.62 1.127 1.00 1.127
6 63.85 1.064 1.05 1.117
7 68.25 1.138 0.95 1.081
8 64.32 1.072 1.00 1.072
9 59.84 0.997 1.10 1.097
10 62.13 1.036 1.05 1.087
11 65.23 1.087 1.00 1.087
12 66.13 1.102 1.00 1.102
13 60.16 1.003 1.05 1.053
14 61.45 1.024 1.05 1.075
15 67.46 1.124 1.00 1.124
16 68.43 1.141 0.95 1.083
17 65.35 1.089 1.00 1.089
18 64.92 1.082 1.00 1.082
19 63.76 1.063 1.05 1.116
20 65.82 1.097 1.00 1.097
Mean 1.090
94
Time Study Sheet

Operation: Bottom hem
Recorded time
1 23.24 0.387 1.15 0.445
2 36.99 0.617 0.95 0.586
3 31.54 0.526 1.00 0.526
4 28.19 0.470 1.05 0.493
5 25.83 0.431 1.10 0.474
6 30.40 0.507 1.00 0.507
7 31.23 0.521 1.00 0.521
8 24.78 0.413 1.10 0.454
9 28.13 0.469 1.10 0.516
10 30.81 0.514 1.00 0.514
11 29.53 0.492 1.00 0.492
12 28.13 0.469 1.05 0.492
13 30.54 0.509 1.00 0.509
14 25.74 0.429 1.10 0.472
15 28.67 0.478 1.05 0.502
16 24.37 0.406 1.10 0.447
17 30.91 0.515 1.00 0.515
18 31.03 0.517 1.00 0.517
19 28.30 0.472 1.05 0.495
20 30.96 0.516 1.00 0.516
Mean 0.500
95
Time Study Sheet

Operation: Loading
Machine: manual Sheet No. 1 of 1
Recorded time
1 25.75 0.429 1.00 0.429
2 27.53 0.459 0.95 0.436
3 23.47 0.391 1.05 0.411
4 27.42 0.457 0.95 0.434
5 23.69 0.395 1.05 0.415
6 26.61 0.444 1.00 0.444
7 25.46 0.424 1.00 0.424
8 26.91 0.449 1.00 0.449
9 24.03 0.401 1.05 0.421
10 28.35 0.473 0.95 0.449
11 25.32 0.422 1.00 0.422
12 24.28 0.405 1.05 0.425
13 27.49 0.458 0.95 0.435
14 25.79 0.430 1.00 0.430
15 24.16 0.403 1.05 0.423
16 25.05 0.418 1.00 0.418
17 28.14 0.469 0.90 0.422
18 26.88 0.448 1.00 0.448
19 25.70 0.428 1.00 0.428
20 24.97 0.416 1.00 0.416
Mean 0.429
96
Time Study Sheet

Operation: Join shoulder seam
Recorded time
1 26.00 0.433 1.00 0.433
2 33.27 0.555 0.90 0.499
3 29.63 0.494 0.95 0.469
4 24.85 0.414 1.00 0.414
5 20.84 0.347 1.20 0.417
6 26.30 0.438 1.00 0.438
7 25.85 0.431 1.00 0.431
8 28.64 0.477 0.95 0.453
9 26.29 0.438 1.00 0.438
10 22.95 0.383 1.10 0.421
11 27.71 0.462 1.00 0.462
12 28.52 0.475 0.95 0.452
13 24.92 0.415 1.00 0.415
14 29.23 0.487 0.90 0.438
15 28.15 0.469 0.95 0.446
16 25.30 0.422 1.00 0.422
17 30.19 0.503 0.90 0.453
18 24.68 0.411 1.00 0.411
19 23.95 0.399 1.05 0.419
20 26.22 0.437 0.95 0.415
Mean 0.437
97
Time Study Sheet

Operation: Top stitch on shoulder
Recorded time
1 27.95 0.466 1.00 0.466
2 28.45 0.474 1.00 0.474
3 33.43 0.557 0.90 0.501
4 27.59 0.460 1.00 0.460
5 33.54 0.559 0.90 0.503
6 31.25 0.521 0.95 0.495
7 28.68 0.478 1.00 0.478
8 34.14 0.569 0.90 0.512
9 36.60 0.610 0.90 0.549
10 30.30 0.505 0.95 0.480
11 30.12 0.502 0.95 0.477
12 29.79 0.497 1.00 0.497
13 31.59 0.527 0.95 0.500
14 28.59 0.477 1.00 0.477
15 33.02 0.550 0.90 0.495
16 29.45 0.491 1.00 0.491
17 32.71 0.545 0.90 0.491
18 31.64 0.527 0.95 0.501
19 29.87 0.498 1.00 0.498
20 30.48 0.508 0.95 0.483
Mean 0.491
98
Time Study Sheet

Operation: Attach collar
Recorded time
1 95.66 1.594 1.05 1.674
2 97.48 1.625 1.00 1.625
3 100.40 1.673 0.95 1.590
4 82.52 1.375 1.15 1.582
5 104.18 1.736 0.90 1.563
6 98.45 1.641 1.00 1.641
7 97.34 1.622 1.00 1.622
8 103.82 1.730 0.90 1.557
9 89.76 1.496 1.10 1.646
10 97.59 1.627 1.00 1.627
11 96.19 1.603 1.00 1.603
12 100.81 1.680 1.00 1.680
13 99.86 1.664 1.00 1.664
14 103.24 1.721 0.95 1.635
15 102.39 1.707 0.95 1.621
16 98.72 1.645 1.00 1.645
17 95.91 1.599 1.05 1.678
18 94.72 1.579 1.05 1.658
19 97.65 1.628 1.00 1.628
20 101.58 1.693 0.95 1.608
Mean 1.627
99
Time Study Sheet

Operation: Binding on neck
Recorded time
1 42.51 0.709 0.95 0.673
2 44.76 0.746 0.90 0.671
3 43.71 0.729 0.95 0.692
4 40.65 0.678 1.00 0.678
5 38.08 0.635 1.05 0.666
6 39.83 0.664 1.00 0.664
7 41.13 0.686 1.00 0.686
8 38.97 0.650 1.05 0.682
9 43.11 0.719 0.95 0.683
10 41.36 0.689 0.95 0.655
11 42.28 0.705 0.95 0.669
12 40.54 0.676 1.00 0.676
13 44.15 0.736 0.90 0.662
14 39.71 0.662 1.00 0.662
15 38.84 0.647 1.00 0.647
16 40.25 0.671 1.00 0.671
17 41.93 0.699 0.95 0.664
18 38.72 0.645 1.05 0.678
19 39.84 0.664 1.00 0.664
20 41.68 0.695 0.95 0.660
Mean 0.670
100
Time Study Sheet

Operation: Make placket
Recorded time
1 174.23 2.904 1.00 2.904
2 178.42 2.974 0.95 2.825
3 171.63 2.861 1.00 2.861
4 164.28 2.738 1.05 2.875
5 173.45 2.891 1.00 2.891
6 168.87 2.815 1.05 2.955
7 173.83 2.897 1.00 2.897
8 172.41 2.874 1.00 2.874
9 176.13 2.936 0.95 2.789
10 177.27 2.955 0.95 2.807
11 171.41 2.857 1.00 2.857
12 173.38 2.890 1.00 2.890
13 168.75 2.813 1.05 2.953
14 178.33 2.972 0.95 2.824
15 174.81 2.914 1.00 2.914
16 172.68 2.878 1.00 2.878
17 176.12 2.935 0.95 2.789
18 174.46 2.908 1.00 2.908
19 177.15 2.953 0.95 2.805
20 170.24 2.837 1.00 2.837
Mean 2.866
101
Time Study Sheet

Operation: Top stitch on binding +label
Recorded time
1 46.28 0.771 0.90 0.694
2 40.83 0.681 1.00 0.681
3 42.03 0.701 1.00 0.701
4 38.93 0.649 1.10 0.714
5 44.51 0.742 1.00 0.742
6 45.85 0.764 0.95 0.726
7 42.74 0.712 1.00 0.712
8 40.36 0.673 1.05 0.706
9 46.10 0.768 0.90 0.692
10 41.29 0.688 1.00 0.688
11 44.12 0.735 0.95 0.699
12 39.16 0.653 1.05 0.685
13 40.56 0.676 1.00 0.676
14 42.63 0.711 1.00 0.711
15 41.44 0.691 1.00 0.691
16 45.96 0.766 0.95 0.728
17 46.24 0.771 0.90 0.694
18 43.38 0.723 1.00 0.723
19 41.82 0.697 1.00 0.697
20 42.67 0.711 1.00 0.711
Mean 0.703
102
Time Study Sheet

Operation: Attach sleeve
Theoretical S.A.M =0.92 min Studied by: Y. RADHA
Recorded time
1 29.20 0.487 1.00 0.487
2 34.03 0.567 0.90 0.510
3 29.64 0.494 1.00 0.494
4 32.56 0.543 0.95 0.516
5 28.89 0.482 1.00 0.482
6 33.13 0.552 0.95 0.525
7 29.45 0.491 1.00 0.491
8 35.43 0.591 0.90 0.531
9 26.12 0.435 1.05 0.457
10 32.49 0.542 0.95 0.514
11 28.41 0.474 1.00 0.474
12 26.34 0.439 1.00 0.439
13 31.30 0.522 0.95 0.496
14 25.82 0.430 1.05 0.452
15 29.06 0.484 1.00 0.484
16 33.62 0.560 0.90 0.504
17 34.27 0.571 0.90 0.514
18 28.90 0.482 1.00 0.482
19 27.76 0.463 1.00 0.463
20 31.58 0.526 0.95 0.500
Mean 0.491
103
Time Study Sheet

Operation: Top stitch on armhole
Recorded time
1 40.37 0.673 1.00 0.673
2 45.21 0.754 0.90 0.678
3 40.13 0.669 1.00 0.669
4 41.88 0.698 1.00 0.698
5 44.57 0.743 0.90 0.669
6 42.33 0.706 0.95 0.670
7 45.18 0.753 0.90 0.678
8 41.20 0.687 1.00 0.687
9 43.76 0.729 0.95 0.693
10 44.63 0.744 0.90 0.669
11 41.59 0.693 1.00 0.693
12 43.28 0.721 0.95 0.685
13 40.16 0.669 1.00 0.669
14 39.82 0.664 1.05 0.697
15 44.05 0.734 0.90 0.661
16 43.41 0.724 0.95 0.687
17 41.74 0.696 1.00 0.696
18 40.68 0.678 1.00 0.678
19 44.72 0.745 0.90 0.671
20 45.19 0.753 0.90 0.678
Mean 0.680
104
Time Study Sheet

Operation: Side seam + OL placket end
Recorded time
1 63.18 1.053 1.00 1.053
2 59.23 0.987 1.05 1.037
3 63.87 1.065 1.00 1.065
4 56.47 0.941 1.05 0.988
5 63.93 1.066 1.00 1.066
6 73.13 1.219 0.85 1.036
7 79.55 1.326 0.80 1.061
8 64.73 1.079 1.00 1.079
9 60.42 1.007 1.05 1.057
10 61.95 1.033 1.05 1.084
11 63.42 1.057 1.00 1.057
12 67.15 1.119 0.95 1.063
13 64.81 1.080 1.00 1.080
14 70.30 1.172 0.90 1.055
15 65.82 1.097 0.95 1.042
16 61.76 1.029 1.00 1.029
17 58.69 0.978 1.05 1.027
18 64.23 1.071 0.95 1.017
19 65.72 1.095 0.95 1.041
20 68.84 1.147 0.95 1.090
Mean 1.051
105
Time Study Sheet

Operation: Tacking cuff
Recorded time
1 41.23 0.687 1.00 0.687
2 41.88 0.698 1.00 0.698
3 40.54 0.676 1.00 0.676
4 23.28 0.388 1.30 0.504
5 34.62 0.577 1.15 0.664
6 36.91 0.615 1.10 0.677
7 39.16 0.653 1.00 0.653
8 35.74 0.596 1.10 0.655
9 40.37 0.673 1.00 0.673
10 33.21 0.554 1.15 0.637
11 40.72 0.679 1.00 0.679
12 41.84 0.697 0.95 0.662
13 37.21 0.620 1.05 0.651
14 39.48 0.658 1.00 0.658
15 42.06 0.701 0.95 0.666
16 41.70 0.695 0.95 0.660
17 39.37 0.656 1.00 0.656
18 40.82 0.680 1.00 0.680
19 38.40 0.640 1.05 0.672
20 39.93 0.666 1.00 0.666
Mean 0.659
106
Time Study Sheet

Operation: Make slit (double fold) + tacking side seam
Recorded time
1 160.96 2.683 0.70 1.878
2 129.32 2.155 0.75 1.617
3 93.28 1.555 1.00 1.555
4 94.54 1.576 0.95 1.497
5 91.13 1.519 1.00 1.519
6 102.59 1.710 0.90 1.539
7 85.35 1.423 1.10 1.565
8 104.23 1.737 0.90 1.563
9 96.41 1.607 0.95 1.526
10 97.63 1.627 0.95 1.546
11 92.58 1.543 1.00 1.543
12 96.77 1.613 0.95 1.532
13 101.26 1.688 0.90 1.519
14 97.31 1.622 0.95 1.541
15 91.16 1.519 1.00 1.519
16 93.63 1.561 1.00 1.561
17 90.84 1.514 1.00 1.514
18 95.47 1.591 0.95 1.512
19 98.12 1.635 0.95 1.554
20 93.91 1.565 1.00 1.565
Mean 1.558
107
Time Study Sheet

Operation: Marking button hole
Recorded time
1 21.45 0.358 0.95 0.340
2 18.32 0.305 1.05 0.321
3 19.75 0.329 1.00 0.329
4 24.11 0.402 0.90 0.362
5 22.91 0.382 0.95 0.363
6 26.64 0.444 0.80 0.355
7 20.42 0.340 1.00 0.340
8 19.83 0.331 1.00 0.331
9 27.72 0.462 0.80 0.370
10 21.07 0.351 1.00 0.351
11 19.05 0.318 1.00 0.318
12 20.76 0.346 1.00 0.346
13 26.81 0.447 0.80 0.357
14 25.72 0.429 0.90 0.386
15 21.54 0.359 1.00 0.359
16 19.39 0.323 1.00 0.323
17 20.63 0.344 1.00 0.344
18 22.80 0.380 0.95 0.361
19 23.07 0.385 0.95 0.365
20 20.43 0.341 1.00 0.341
Mean 0.348
108
Time Study Sheet

Operation: Button hole *3
Machine: B/H Sheet No. 1 of 1
Recorded time
1 22.35 0.373 1.00 0.373
2 24.24 0.404 0.95 0.384
3 27.58 0.460 0.85 0.391
4 25.81 0.430 0.90 0.387
5 24.03 0.401 0.95 0.380
6 21.92 0.365 1.00 0.365
7 23.71 0.395 1.00 0.395
8 22.95 0.383 1.00 0.383
9 26.67 0.445 0.85 0.378
10 25.38 0.423 0.90 0.381
11 21.38 0.356 1.00 0.356
12 24.57 0.410 0.95 0.389
13 26.81 0.447 0.95 0.424
14 23.72 0.395 1.00 0.395
15 26.06 0.434 0.90 0.391
16 27.23 0.454 0.85 0.386
17 23.15 0.386 1.00 0.386
18 21.76 0.363 1.00 0.363
19 22.60 0.377 1.00 0.377
20 24.19 0.403 0.95 0.383
Mean 0.383
109
Time Study Sheet

Operation: Marking button attach
Recorded time
1 17.87 0.298 1.15 0.343
2 37.17 0.620 0.75 0.465
3 27.14 0.452 0.90 0.407
4 23.74 0.396 1.00 0.396
5 24.43 0.407 1.00 0.407
6 21.65 0.361 1.05 0.379
7 18.92 0.315 1.10 0.347
8 24.12 0.402 1.00 0.402
9 26.29 0.438 0.90 0.394
10 22.53 0.376 1.00 0.376
11 24.19 0.403 1.00 0.403
12 26.76 0.446 0.90 0.401
13 20.19 0.337 1.05 0.353
14 19.71 0.329 1.05 0.345
15 23.41 0.390 1.00 0.390
16 27.05 0.451 0.90 0.406
17 25.73 0.429 0.95 0.407
18 26.91 0.449 0.90 0.404
19 22.52 0.375 1.00 0.375
20 23.38 0.390 1.00 0.390
Mean 0.389
110
Time Study Sheet

Operation: Attach button (3 + 1 spare)
Machine: B/A Sheet No. 1 of 1
Recorded time
1 31.23 0.521 1.00 0.521
2 28.68 0.478 1.05 0.502
3 33.74 0.562 0.95 0.534
4 32.28 0.538 1.00 0.538
5 35.67 0.595 0.90 0.535
6 29.81 0.497 1.00 0.497
7 31.73 0.529 1.00 0.529
8 31.18 0.520 1.00 0.520
9 28.94 0.482 1.05 0.506
10 31.97 0.533 1.00 0.533
11 32.45 0.541 0.95 0.514
12 31.72 0.529 1.00 0.529
13 30.13 0.502 1.00 0.502
14 31.26 0.521 1.00 0.521
15 33.74 0.562 0.95 0.534
16 29.76 0.496 1.00 0.496
17 31.63 0.527 1.00 0.527
18 34.36 0.573 0.90 0.515
19 32.03 0.534 1.00 0.534
20 31.58 0.526 1.00 0.526
Mean 0.521
111
Inter arrival time study

Date: 25/11/2011 Sheet no. 1
Studied by: Y.RADHA Sheet 1 of 1
No. Time Interarrival time /min lot size
1 8:15 0 17
2 8:23 8 22
3 8:31 8 3
4 8:40 9 10
5 8:57 17 16
6 9:19 12 15
7 9:30 11 20
8 9:46 16 23
9 10:08 12 24
10 10:15 7 22
11 10:25 10 18
12 10:37 12 24
13 10:50 13 15
14 11:04 14 10
15 11:14 10 11
16 11:30 16 17
17 11:46 16 19
18 11:58 12 16
19 12:53 15 22
20 13:01 8 23
21 13:09 8 14
22 13:24 15 13
23 13:33 9 16
24 13:45 12 8
25 13:56 11 9
mean 11.86 17
s.d 3.18 5
112
Failure Study Sheet

Studied by: Y. RADHA Sheet No. 1 of 1
No. Time of failure Failure duration /sec Operation No. Machine
1 09:16 123 2 OL
2 09:27 93 9 INT
3 09:52 96 13 SN
4 10:27 94 6 SN
5 10:42 134 3 INT
6 11:10 114 2 OL
7 11:23 103 13 SN
8 11:48 132 9 INT
9 11:57 119 11 OL
10 12:48 86 4 SN
11 13:05 95 13 SN
12 13:28 126 6 SN
13 13:53 96 7 SN
14 14:12 118 11 OL
15 14:32 98 9 INT
16 14:44 135 8 OL
17 14:57 126 2 OL
18 15:11 96 13 SN
19 15:18 108 3 INT
20 15:49 116 11 OL
21 16:02 103 7 SN
22 16:29 94 9 INT
23 16:42 98 6 SN
24 16:48 106 13 SN
25 17:10 143 8 OL
26 17:21 104 4 SN
113
Failure Study Sheet

1 08:11 121 6 SN
2 08:16 85 3 INT
3 08:35 73 12 SN
4 08:59 75 9 INT
5 09:24 111 5 INT
6 09:52 109 3 INT
7 10:13 135 8 OL
8 10:26 73 2 OL
9 10:39 137 9 INT
10 10:51 118 7 SN
11 11:04 79 13 SN
12 11:23 132 6 SN
13 11:40 121 2 OL
14 11:54 80 13 SN
15 12:52 102 10 INT
16 13:21 115 6 SN
17 13:36 130 9 INT
18 13:51 133 8 OL
19 14:18 116 5 INT
20 14:30 109 13 SN
21 14:46 93 7 SN
22 14:54 85 3 INT
23 15:22 112 11 OL
24 15:49 134 2 OL
25 15:54 128 9 INT
26 16:00 145 3 INT
27 16:19 119 13 SN
28 16:27 124 9 INT
29 16:41 127 8 OL
30 16:57 92 6 SN
31 17:12 106 12 SN
32 17:25 110 11 SN
114
Failure Study Sheet

1 08:02 106 9 INT
2 08:13 110 13 SN
3 08:26 92 6 SN
4 08:52 92 7 SN
5 09:08 96 3 INT
6 09:22 102 13 SN
7 09:42 131 8 OL
8 10:10 128 11 OL
9 10:29 95 2 OL
10 10:41 93 9 INT
11 10:54 87 13 SN
12 11:08 98 4 SN
13 11:20 109 13 SN
14 11:37 98 8 OL
15 11:45 102 5 INT
16 12:43 110 7 SN
17 12:51 134 11 OL
18 13:21 95 8 OL
19 13:44 121 10 INT
20 14:16 96 13 SN
21 14:37 98 9 INT
22 14:46 103 3 INT
23 14:55 141 7 SN
24 15:18 86 5 INT
25 15:22 82 13 SN
26 15:20 136 12 SN
27 15:48 93 2 OL
28 16:05 116 8 OL
29 16:13 104 6 SN
30 16:30 133 13 SN
31 16:43 90 11 OL
32 17:02 96 7 SN
33 17:21 120 4 SN
115
Appendix C:
Detailing of Model Elements

Appendix C: Detailing of Model Elements
C.1 Detailing of Model Elements
Detailing of part
Detailing of part-shirt
Name shirt
Type Active
Maximum arrival 1155
First arrival at 0.0
Inter arrival time NORMAL(28,4,1)
Lot size NORMAL(23,5.19,1)
Shift shift
Table C-1 Detailing of shirt
Detailing of buffers
Name Rail1
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Table C-2 Detailing of rail1
Name Rail2
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
116
Name Rail3
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail4
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail5
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail6
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
117
Detailing of buffer-rail
Name Rail7
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail8
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail9
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail10
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
118
Name Rail11
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail12
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
Name Rail13
Quantity 1
Capacity 1000
Input Rear
Output First
Delay None
Search from Front
119
Detailing of machines
Detailing of machine-loadshirt
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Input rule PULL from rail1
Setup None
Shift shift1
Breakdowns None
Table C-15 Detailing of joinshoulderseam
Detailing of machine-joinshoulderseam
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
Busy time NEGEXP(190,1) NORMAL(1.8,0.3,1)
breakage
Needle
breakage
Table C-16 Detailing of joinshoulderseam
120
Detailing of machine-topstitchonshoulder
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-17 Detailing of topstitchonshoulder
Detailing of machine-attachcollar
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Table C-18 Detailing of attachcollar
121
Detailing of machine-bindingonneck
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-19 Detailing of bindingonneck
Detailing of machine-makeplacket
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Table C-20 Detailing of makeplacket
122
Detailing of machine-topstitchonbinding
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-21 Detailing of topstitchonbinding
Detailing of machine-attachsleeve
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-22 Detailing of attachsleeve
123
Detailing of machine-topstitchonarmhole
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-23 Detailing of topstitchonarmhole
Detailing of machine-bottomhem
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-24 Detailing of bottomhem
124
Detailing of machine-sideseam
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-25 Detailing of sideseam
Detailing of machine-tackingcuff
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Table C-26 Detailing of tackingcuff
125
Detailing of machine-makeslit
Type Batch
Batch min 15
Batch max Batch min
Quantity 1
Priority Lowest
Output rule PUSH to SHIP
Setup None
Shift shift1
Breakdowns
Time between
Mode Repair time
failures
Thread
breakage
Needle
breakage
Table C-27 Detailing of makeslit
126
Appendix D:
D.O DOE, ANOV and ANOVA

Appendix D:
D.O DOE, ANOV and ANOVA
D.1 Design of experiment (DOE)
Engineers cannot afford to continue experimenting in a trial-and-error manner,

changing one factor at a time. A more effective way to develop a sequence of
experiments is to apply a computer-enhanced, systematic approach to experimentation,
one that considers all factors simultaneously. That approach is known as design of
experiments.
DOE is a systematic approach to examine a system. A series of defined tests are

designed in which the parameters are varied to different levels according to plan
changes. The influences of these changes are assessed on the output.
D.2 Taguchi design of experiment
The Taguchi method, developed by Dr. Genichi Taguchi, involves reducing the
variation in a process through robust design of experiments. The method is used to
assess the variation occurs due to different parameters by analysing the mean and
variance. The experimental design proposed by Taguchi involves using orthogonal
arrays to define combination of the parameters affecting the process and the levels at
which they should be varies. This allows identifying the factors which affects the
system the most with a minimum amount of experiments, thus saving time and
resources. The Taguchi method is best used when there is an intermediate number of
variables (3 to 50), few interactions between variables, and when only a few variables
contribute significantly.
(S. Fraley, M. Oom, B. Terrien, J. Zalewski, 2007)
Basic steps in conducting a DOE are:

127
Appendix D:
6. Identifying the factors to be evaluated

7. Defining the levels of the factors to be tested
8. Creating an array of experimental combinations
9. Conducting the experiments under the prescribed conditions
10. Evaluating the results and conclusion
D.3 Proposed line balancing
A proposed line balancing was developed according to the amount of W.I.P noticed on
the shop floor. The line balancing is defined in the table D.1 below
M/ No. of Cycle Expected

Operation S.A.M C M/C time output
1 Loading 0.479 M 1 0.479 1127
2 Join shoulder seam 0.477 OL 1 0.477 1132
3 Top stitch on shoulder 0.555 INT 1 0.555 973
4 Attach collar 1.85 SN 4 0.463 1168
5 Binding on neck (all round) 0.759 INT 2 0.380 1423
6 Make placket + placket box 3.26 SN 6 0.543 994
7 Top stitch on binding + label 0.818 SN 2 0.409 1320
8 Attach sleeve 0.575 OL 1 0.575 939
9 Top stitch on armhole 0.78 INT 2 0.390 1385
1
0 Bottom hem 0.593 INT 1 0.593 911
1
1 Side seam + Ol placket end 1.25 OL 3 0.417 1296
1
2 Tacking cuff 0.765 SN 2 0.383 1412
1 Make slit + tacking side
3 seam 1.8 SN 4 0.450 1200
13.96
Total 1 30 6.1125
Figure D.1 Proposed line balancing
The number of machines at some of the operation was changed so that the operation
cycle time of all operations becomes nearly equal.
128
Appendix D:
The balancing efficiency was then calculated using equation described in chapter 6,
section 6.1.1.2 and is found to be 78.53%
Pieces
Thus, from the balancing efficiency, it can be said that this line balancing is much better
compared to the actual one.
D.4 Cycle time
The cycle times selected for the experimentation are shown in table D.2 below.
Cycle time /min

No. Operation Level 1 Level 2 Level 3
1 Loading 0.479 0.47 0.429
2 Join shoulder seam 0.477 0.47 0.437
3 Top stitch on shoulder 0.555 0.47 0.491
4 Attach collar 1.85 1.00 1.63
5 Binding on neck (all round) 0.759 0.47 0.670
6 Make placket + placket box 3.26 3.25 2.87
7 Top stitch on binding + label 0.818 1.10 0.703
8 Attach sleeve 0.575 0.92 0.491
9 Top stitch on armhole 0.78 0.70 0.680
10 Bottom hem 0.593 0.68 0.500
11 Side seam + Ol placket end 1.25 1.15 1.05
12 Tacking cuff 0.765 0.55 0.659
13 Make slit + tacking side seam 1.8 2.48 1.56
Figure D.2 Levels of cycle time
129
Appendix D:
D.5 Orthogonal array
Orthogonal array is a mathematical representation proposed by Taguchi for identifying

the number of experiments can be performed depending on the number of parameters to
be tested and the corresponding number of levels.
The selection of an OA depends on 2 items:
1. The number of factors

2. The number of levels
Knowing the two items mentioned above, the proper OA can be selected by looking on
a table designed by Taguchi. Where the two items coincides, the required OA is shown.
The table can be found in the website
https://controls.engin.umich.edu/wiki/index.php/Design_of_experiments_via_taguchi_
methods:_orthogonal_arrays.
For the experiment, 3 factors were defined at 3 levels. Looking at the table mentioned
above, the OA L9 was the proper to select. An example of the L9 array is shown in
figure D.1 below extracted from the site
https://controls.engin.umich.edu/wiki/images/d/db/L9_Array.jpg
Figure D.1 L9 array
130
Appendix D:
Due to the experiment is limited to only 3 factors, the array reduces as shown in table
D.2 below.
Experiment Factors
No. A B C
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 2
5 2 2 3
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2
Figure D.3 reduced L9 array
D.6 Analysis of results
After collecting all data from the each experiment, the results were analysed by 2 main
concepts, analysis of mean (ANOM) through signal to noise ratio (s/n) and analysis of
variance (ANOVA).
The objectives of these analyses are:

 To identify the contribution of each factor to the productivity.
 To find the optimal condition to improve the productivity.
D.6.1 Signal to noise ratio
Signal to noise ratio is the measure of the level of a desired signal to the level of
background noise and it give in the unit of decibels (db). Signal to noise ratio has 3
types of approaches. However, for the project only 2 approaches are used.
1. Smaller the better

This approach refers to the minimising the effect of a factors for a better quality
characteristics. The ratio can be calculated by,
131
Appendix D:
Where η = signal to noise ratio of an experiment

= result of trial ί of the experiment
2. Larger the better

This approach refers to the maximising the effect of a factors for a better quality
characteristics. The ratio can be calculated by,
(H.Ramasawmy, 2009)
D.6.2 Calculating signal to noise ratio for each experiment
Taking the data in Appendix D, the signal to noise ratio for the experiment 1 is
calculated as follows.
For the output
Since the output needs to maximise to increase the productivity, the 2nd approach listed
above is used to calculate to signal to noise ratio.
db
132
Appendix D:
For the work-in-progress
Since the work-in-progress needs to manimise to increase the productivity, the 1st
approach listed above is used to calculate to signal to noise ratio.
db
The signal to noise ratio of the other 8 eight experiment for both the output and the
work-in-progress are calculated similarly and the results are shown in the table D.4
below.
Experiment No. S/N of output /db S/N of work-in-progress /db

1 50.37 -52.34
2 51.13 -51.54
3 54.06 -49.44
4 51.13 -51.01
5 55.47 -44.69
6 53.62 -47.23
7 54.59 -35.77
8 56.30 -30.96
9 55.27 -31.71
Figure D.4 signal to noise ratio
D.7 Analysis of mean (ANOM)
133
Appendix D:
“The analysis of mean is a process of estimating the factor effects graphically”.

(H.Ramasawmy, 2007, p4). The amalysis of mean helps to identify the optimal level
for each factor experimented. The steps in conducting an ANOM start with the signal to
noise ratio the follows by the following steps.
Step 1: Calculating the overall mean value of S/N ratios by
where i represents the experiment number and represent the total number of
experiment.
STEP 2 – Estimation of factor effect

Mr. H.Ramasawmy stated that the effect of a factor level is defined as the deviation it
causes from overall mean. (2007, p3). Factor effect is estimated by averaging the S/N of
the experiment for which a factor varies within a given level. For example, considering
the orthogonal array L9 below on which four factors is varying under three levels, it can
be deduced that factor A at level one is varying in experiment 1, 2 and 3 and is termed
as A1. Similarly, the factor B at level 1, termed B2, can be monitored in experiment 1, 4
and 7 and so do factor D at level 2 termed D3, it can be monitored in experiment 2, 6,
and 7.
Expt No. A B C D
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 2 1 2 3
5 2 2 3 1
6 2 3 1 2
7 3 1 3 2
8 3 2 1 3
134
Appendix D:
9 3 3 2 1
Table D.5 Orthogonal array L9
The average of S/N factor D at level 2 is given by:
The same analogy is done for the other factors at various levels and the entire signal to
noise ratios is tabulated. The S/N ratio for each factor at various levels is plotted into a
graph of S/N ratio against their respective factors. H.Ramasawmy stated that the
optimum level for a factor is the level that gives the highest value of η in the
experimental region. (H.Ramasawmy, 2007, p5).
D.8 Analysis of variance technique (ANOVA)
Mr. P. Ross defined the analysis of variance technique as a statistically based decision
tool for detecting any differences in average performance of groups of items tested. As
stated by A. Voice, A. Wilkins, R. Parambi, I. Oraiqat (2007), Analysis of variance
(ANOVA) is the method used to compare continuous measurements to determine if the
measurements are sampled from the same or different distributions. “This technique
was developed in 1930‟s by Sir Ronald Fisher for the purpose of analyzing and
interpreting results obtained from agricultural experiments written” (P. Ross, 1988, p23-
24). Actually there exist several types of ANOVA analysis depending on the number of
parameters being controlled. The ANOVA technique is normally used to separate total
variation in an experiment in term of its constituents, which are as follows:
The variation of the average (mean) of all observations relative to zero
The variation due to factors (controlled parameters) effect
The variation of the interaction of the factors effect
135
Appendix D:
The variation is generally data points around the average. This source of
variation is generally termed as the experimental error.
(P.Ross, 1988)
D.8.1 Sum of squares
One of the steps in analyzing the variance is to compute the sum of squares of the signal
to noise ratios for each experiment. This step is also called the grand total sum of
squares and it is given by,
Grand total sum of squares =
where η is the signal to noise ratio of experiment

and is the number of experiment conducted.
H.Ramasawmy also stated that the grand total sum of square can be decomposed into
two parts – sum of squares due to mean and total sum of squares which are defined as
follows:
2
Sum of squares due to mean = (number of experiments) x
Total sum of squares
Where is the mean of the S/N ratio of all the experiments conducted.
The sum of squares due to a factor is equal to the total square deviation of the wave for
that factor from the overall mean line. Thus, the sum of squares of factor A, SSA is
given by,
(No. of experiments * m2)
An example, for the factor A for the output

136
Appendix D:
SSA = 3(MA1-M) 2 + 3(MA2-M) 2 + 3(MA3-m) 2
Where A1, A2 and A3 are the sum of the signal to noise ratio made under the first level,
second level and third level respectively.
Therefore, the sum of squares due to error is added to the sum of squares of each factor
to result in the total sum of squares (SST) which is given by
SST = SSA + SSB + SSC + SSe
Where SSe is the sum of squares due to error and is given by
(SSe) =
N= number of experiment
i = treatment n
(H.Ramasawmy, 2007, p7-8)
D.8.2 Degree of freedom
“The number of independent parameters associated with an entity like a matrix

experiment, or a factor, or a sum of squares is called its degree of freedom” (H,
Ramasawmy, 2007, p9). For instance a matrix experiment of 9 rows has to 9 degrees of
freedom so does the grand total sum of squares. For instance, a factor having 3 levels
would have 2 levels independent from the experiment being conducted, thus the degree
of freedom of that factor is 2. In other words, a factor has a degree of freedom one less
than the number of level the factor has.
Thus, the degree of freedom for the total sum of squares = (sum of the degrees of
freedom for the various factors) + (degree of freedom of the error)
(H, Ramasawmy, 2007, p9).
137
Appendix D:
Degree of freedom of factor A, dfA =KA-1

Where KA is the number of levels of factor A
Degree of freedom due to error, dfe = dfT – (dfA + dfB + dfC)
D.8.3 Variance Error
The variance for each factor is computed using the equation below:
VA = SSA/dfA
Where VA represents the variance due to factor a
SSA represents the sum of squares due to factor A
dfA represents the degree of freedom attached to factor A
and the variance due to error, Ve is given by SSe/dfe
D.8.4 The F-Test
The F-test is at the center of the ANOVA analysis. The F-test is simply a ratio of
sample variance. “The F-test was named after Sir Ronald Fisher, a British statistician
who invented the ANOVA method” (P. Ross, 1988, p43).
F=Vfactor/Ve
(P. Ross, 1988, p43)
Where V factor represents the variance at any factor effect, and Ve represents the variance
due to error. This value of the F-test obtained is generally compared to a predetermined
value of the F ratio which is available from F-value table. To be able to determine the F-
ratio from the tables, 3 pieces of information are needed and they are
The confidence level
138
Appendix D:
The degree of freedom of the factor/interaction effect Vfactor
The degree of freedom of the error effect Ve
(P Ross, 1988, p44)

The F-ratio is provided in tables in the form of
Fα, Vfactor, Ve
Where α is known as the risk and is evaluated as follows
Risk, α = 1 – confidence interval
(P.Ross, 1988, p44)
The factors which are found to have a greater F ratio from calculation compared to the F
ratio taken from the F-table distribution are believed to have higher influence on the
sample mean. Otherwise, the factors are less influence.
D.8.5 The Percentage contribution
The variation of a factor is significant over the total variation of the all experiment. So,
there is a need to track the percentage of contribution of a factor to the variation. P.Ross
defined the percentage contribution as a function of the sum of squares for each
significant (1988, p116) and is also a measure of the relative importance of the factor in
changing the value of S/N ratio. The percentage contribution can be calculated as
follows:
P = (SSA/SST) *100
Where P represents the percentage contribution
SSA is the sum of squares due to factor A
SST is the total sum of squares
139
Appendix E:
Witness simulation results

Appendix E: Experiment Results
E.1 Witness simulation results
Experiment :1 replication: 1 stream offset :1

Run length: 1100 minutes
Part statistics
Nam No. No. No. No. No. W.I Avg Avg Sigma
e Entered Shipped Scrapped Assemble Rejected .P W.I.P time rating
shirt 721 330 0 0 0 391 274.40 167.46 6
Buffer statistic
rail1 601 600 1 35 0 3.434 5.715
rail2 600 600 0 15 0 0.066 0.110
rail3 600 585 15 15 0 8.152 13.587
rail4 600 465 135 135 0 90.947 151.579
rail5 465 465 0 15 0 0.729 1.569
rail6 450 450 0 15 0 0.000 0.000
rail7 435 435 0 15 0 0.144 0.331
rail8 420 420 0 15 0 0.000 0.000
rail9 405 405 0 15 0 0.0153 0.038
rail10 405 405 0 15 0 0.000 0.000
rail11 390 390 0 15 0 0.000 0.000
rail12 375 375 0 15 0 0.035 0.093
rail13 360 360 0 15 0 0.613 1.702
Machine report
No. of % % % % % Setup
Name % Broken
Operation Idle Block Busy Setup wait labour
Loadshirt 40 33.69 0.00 66.31 0.00 0.00 0.00
Joinshoulderseam 39 32.32 0.00 67.24 0.00 0.00 0.44
topstitchonshoulder 39 23.44 0.00 75.42 0.00 0.00 1.14
attachcollar01 16 0.00 0.00 98.60 0.00 0.00 1.40
Bindingonneck 30 17.87 0.00 80.94 0.00 0.00 1.19
makeplacket01 8 13.64 0.00 85.68 0.00 0.00 0.68
Topstitchonbinding 28 20.72 0.00 77.90 0.00 0.00 1.38
Attachsleeve 27 45.56 0.00 53.79 0.00 0.00 0.66
Topstitchonarmhole 27 27.16 0.00 71.98 0.00 0.00 0.86
140
Bottomhem 26 48.37 0.00 50.92 0.00 0.00 0.71

sideseam01 8 66.41 0.00 32.92 0.00 0.00 0.68
Tackingcuff 24 37.38 0.00 62.32 0.00 0.00 0.29
makeslit01 11 26.48 0.00 71.27 0.00 0.00 2.25
makeslit02 11 29.99 0.00 68.46 0.00 0.00 1.54
sideseam02 6 73.03 0.00 26.61 0.00 0.00 0.37
sideseam03 6 74.81 0.00 24.74 0.00 0.00 0.45
sideseam04 5 79.38 0.00 20.62 0.00 0.00 0.00
makeplacket02 7 12.44 0.00 86.20 0.00 0.00 1.37
makeplacket03 7 14.18 0.00 84.07 0.00 0.00 1.75
makeplacket04 7 16.94 0.00 81.46 0.00 0.00 1.60
attachcollar02 15 0.00 0.00 98.86 0.00 0.00 1.14
141
Experiment: 1 replication: 2 stream offset: 5

Part statistics
No.
No. No. No. No. W. Avg Avg Sigma
Na Assembl
Entered Shipped Scrapped Rejected I.P W.I.P time rating
me e
44 337.7
779 330 0 0 0 190.78 6
shirt 9 7
Buffer statistic
rail1 659 645 14 25 0 10.152 15.406
rail2 645 645 0 15 0 0.161 0.250
rail3 660 660 0 15 0 1.984 3.006
rail4 675 480 195 210 0 149.361 221.276
rail5 480 480 0 15 0 0.253 0.528
rail6 465 465 0 15 0 0.000 0.000
rail7 435 435 0 15 0 0.153 0.353
rail8 420 420 0 15 0 0.000 0.000
rail9 420 420 0 15 0 0.030 0.073
rail10 405 405 0 15 0 0.001 0.002
rail11 390 390 0 15 0 0.000 0.000
rail12 375 375 0 15 0 0.054 0.143
rail13 360 360 0 15 0 0.442 1.228
Machine report
% Setup
No. of % % % %
% Idle wait
Operation Block Busy Setup Broken
Name labour
Loadshirt 43 29.02 0.00 70.98 0.00 0.00 0.00
joinshoulderseam 43 25.76 0.00 73.76 0.00 0.00 0.48
attachcollar01 16 0.00 0.00 99.68 0.00 0.00 0.32
Bindingonneck 31 17.58 0.00 82.05 0.00 0.00 0.37
makeplacket01 8 12.93 0.00 86.28 0.00 0.00 0.79
topstitchonbinding 28 20.08 0.00 79.27 0.00 0.00 0.65
Attachsleeve 28 45.85 0.00 53.83 0.00 0.00 0.32
topstitchonarmhole 27 25.99 0.00 72.97 0.00 0.00 1.04
142
Bottomhem 26 47.25 0.00 52.05 0.00 0.00 0.70

sideseam01 8 66.65 0.00 32.96 0.00 0.00 0.39
Tackingcuff 24 36.58 0.00 62.99 0.00 0.00 0.43
makeslit01 11 27.47 0.00 71.98 0.00 0.00 0.55
makeslit02 11 29.00 0.00 68.80 0.00 0.00 2.19
sideseam02 6 72.01 0.00 27.18 0.00 0.00 0.81
sideseam03 6 74.76 0.00 24.73 0.00 0.00 0.51
sideseam04 5 79.38 0.00 20.62 0.00 0.00 0.00
makeplacket02 7 10.46 0.00 87.72 0.00 0.00 1.82
makeplacket03 7 12.65 0.00 85.61 0.00 0.00 1.75
makeplacket04 7 15.79 0.00 83.01 0.00 0.00 1.20
attachcollar02 16 0.00 0.00 99.57 0.00 0.00 0.43
143
Experiment: 1 repitcation: 3 stream offset: 10

Part statistics
No.
Na Assembl
me e
40 300.7
730 330 0 0 0 181.29 6
shirt 0 8
Buffer statistic
rail1 610 600 10 32 0 7.983 13.088
rail2 600 600 0 15 0 0.080 0.133
rail3 600 600 0 15 0 0.677 1.128
rail4 630 480 150 150 0 111.788 177.441
rail5 480 465 15 15 0 7.789 16.227
rail6 450 450 0 15 0 0.000 0.000
rail7 435 435 0 15 0 0.214 0.492
rail8 420 420 0 15 0 0.000 0.000
rail9 420 420 0 15 0 0.000 0.000
rail10 405 405 0 15 0 0.000 0.000
rail11 390 390 0 15 0 0.000 0.000
rail12 375 375 0 15 0 0.031 0.083
rail13 360 360 0 15 0 0.790 2.194
Machine report
No. of % % % % % Setup %
Name
Operation Idle Block Busy Setup wait labour Broken
Loadshirt 40 33.48 0.00 66.52 0.00 0.00 0.00
attachcollar01 16 0.00 0.00 99.11 0.00 0.00 0.89
Bindingonneck 30 18.13 0.00 81.46 0.00 0.00 0.41
makeplacket01 8 12.91 0.00 85.74 0.00 0.00 1.35
Attachsleeve 28 45.79 0.00 53.78 0.00 0.00 0.42
Bottomhem 26 47.41 0.00 51.94 0.00 0.00 0.65
144
sideseam01 8 66.83 0.00 32.96 0.00 0.00 0.21

Tackingcuff 24 36.79 0.00 62.76 0.00 0.00 0.45
makeslit01 11 27.24 0.00 71.85 0.00 0.00 0.91
makeslit02 11 28.59 0.00 68.67 0.00 0.00 2.73
sideseam02 6 72.18 0.00 26.93 0.00 0.00 0.89
sideseam03 6 74.56 0.00 24.73 0.00 0.00 0.71
sideseam04 5 79.39 0.00 20.61 0.00 0.00 0.00
makeplacket02 7 11.24 0.00 87.04 0.00 0.00 1.72
makeplacket03 7 13.42 0.00 85.43 0.00 0.00 1.15
makeplacket04 7 16.44 0.00 82.14 0.00 0.00 1.42
attachcollar02 16 0.00 0.00 99.21 0.00 0.00 0.79
145

Part statistics
Sigm
No. No. No. No. No. W.I. Avg Avg
Nam a
Entered Shipped Scrapped Assemble Rejected P W.I.P time
e rating
shirt 753 360 0 0 0 393 318.53 186.13 6
Buffer statistic
rail1 618 618 0 26 0 3.095 5.008
rail2 630 630 0 15 0 0.079 0.126
rail3 645 645 0 15 0 0.305 0.472
rail4 645 645 0 15 0 0.000 0.000
rail5 630 630 0 15 0 0.000 0.000
rail6 630 630 0 15 0 0.019 0.030
rail7 630 630 0 15 0 0.513 0.815
rail8 615 450 165 165 0 112.119 182.308
rail9 435 435 0 15 0 0.000 0.000
rail10 435 435 0 15 0 0.000 0.000
rail11 420 420 0 15 0 0.000 0.000
rail12 405 405 0 15 0 0.000 0.000
rail13 390 390 0 15 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name Operation Idle Block Busy Setup wait labour Broken
64.4 35.5
10 0.00 0.00 0.00 0.00
attachcollar03 6 4
65.9 34.0
10 0.00 0.00 0.00 0.00
attachcollar04 3 7
65.0 33.6
21 0.00 0.00 0.00 1.28
bindingonneck2 7 4
19.7 77.6
7 0.00 0.00 0.00 2.65
makeplacket05 6 0
22.2 77.2
7 0.00 0.00 0.00 0.47
makeplacket06 9 4
22.2 77.3
21 0.00 0.00 0.00 0.39
topstitchonbinding01 3 7
Loadshirt 42 32.9 0.00 67.0 0.00 0.00 0.00
146
3 7
63.2 35.7
15 0.00 0.00 0.00 0.98
topstitchonarmhole01 4 8
30.5 68.1
43 0.00 0.00 0.00 1.30
joinshoulderseam 5 4
29.4 68.1
43 0.00 0.00 0.00 2.42
topstitchonshoulder 9 0
62.5 37.4
11 0.00 0.00 0.00 0.00
attachcollar01 2 8
65.7 34.2
21 0.00 0.00 0.00 0.00
bindingonneck1 8 2
21.6 76.9
7 0.00 0.00 0.00 1.41
makeplacket01 1 7
21.4 77.6
20 0.00 0.00 0.00 0.89
topstitchonbinding 7 4
93.8
29 2.57 0.00 0.00 0.00 3.53
Attachsleeve 9
65.8 33.4
14 0.00 0.00 0.00 0.75
topstitchonarmhole 4 1
33.3 65.9
28 0.00 0.00 0.00 0.74
Bottomhem 3 3
60.4 39.2
10 0.00 0.00 0.00 0.36
sideseam01 4 0
73.7 26.2
14 0.00 0.00 0.00 0.00
Tackingcuff 9 1
46.7 52.0
7 0.00 0.00 0.00 1.21
makeslit01 7 1
48.6 49.0
6 0.00 0.00 0.00 2.33
makeslit02 2 4
62.1 36.6
9 0.00 0.00 0.00 1.22
sideseam02 5 3
67.9 31.3
8 0.00 0.00 0.00 0.68
sideseam03 7 5
76.4 23.1
12 0.00 0.00 0.00 0.41
tackingcuff01 9 0
21.3 77.8
7 0.00 0.00 0.00 0.79
makeplacket02 5 7
21.1 78.1
7 0.00 0.00 0.00 0.77
makeplacket03 2 1
20.4 77.5
7 0.00 0.00 0.00 1.95
makeplacket04 8 7
62.5 37.4
11 0.00 0.00 0.00 0.00
attachcollar02 4 6
54.4 44.6
6 0.00 0.00 0.00 0.90
makeslit03 2 8
59.7 38.9
5 0.00 0.00 0.00 1.25
makeslit04 8 6
147
148

Part statistics
No.
Na Assembl
me e
38 290.3
744 360 0 0 0 171.71 6
shirt 4 5
Buffer statistic
rail1 609 609 0 39 0 3.758 6.171
rail2 615 615 0 15 0 0.002 0.003
rail3 615 615 0 15 0 0.147 0.239
rail4 615 615 0 15 0 0.000 0.000
rail5 600 600 0 15 0 0.000 0.000
rail6 600 600 0 15 0 0.027 0.045
rail7 570 570 0 15 0 0.130 0.228
rail8 570 465 105 105 0 72.529 127.244
rail9 450 450 0 15 0 0.000 0.000
rail10 435 435 0 15 0 0.035 0.080
rail11 435 435 0 15 0 0.000 0.000
rail12 405 405 0 15 0 0.000 0.000
rail13 405 405 0 15 0 0.000 0.000
Machine report
No. of % % % % Setup %
Name % Idle
Operation Block Busy Setup wait labour Broken
attachcollar03 10 65.90 0.00 34.10 0.00 0.00 0.00
attachcollar04 10 65.85 0.00 34.15 0.00 0.00 0.00
bindingonneck2 20 67.49 0.00 32.04 0.00 0.00 0.47
makeplacket05 6 27.69 0.00 70.46 0.00 0.00 1.85
makeplacket06 7 28.74 0.00 70.42 0.00 0.00 0.84
Loadshirt 41 34.52 0.00 65.48 0.00 0.00 0.00
topstitchonarmhole01 15 63.43 0.00 35.79 0.00 0.00 0.78
149
attachcollar01 10 63.39 0.00 36.61 0.00 0.00 0.00

bindingonneck1 20 67.64 0.00 32.36 0.00 0.00 0.00
makeplacket01 7 27.68 0.00 71.35 0.00 0.00 0.97
attachsleeve 30 2.56 0.00 96.06 0.00 0.00 1.38
bottomhem 29 30.90 0.00 68.26 0.00 0.00 0.83
sideseam01 10 59.50 0.00 39.22 0.00 0.00 1.27
tackingcuff 14 73.76 0.00 26.24 0.00 0.00 0.00
makeslit01 6 47.47 0.00 51.70 0.00 0.00 0.82
makeslit02 6 50.74 0.00 48.11 0.00 0.00 1.15
sideseam02 9 60.42 0.00 38.30 0.00 0.00 1.27
sideseam03 8 66.95 0.00 31.72 0.00 0.00 1.34
tackingcuff01 13 75.20 0.00 24.36 0.00 0.00 0.44
makeplacket02 6 27.67 0.00 71.47 0.00 0.00 0.86
makeplacket03 6 26.51 0.00 73.01 0.00 0.00 0.48
makeplacket04 6 25.80 0.00 71.62 0.00 0.00 2.58
attachcollar02 10 65.93 0.00 34.07 0.00 0.00 0.00
makeslit03 6 52.77 0.00 45.43 0.00 0.00 1.80
makeslit04 6 54.77 0.00 44.57 0.00 0.00 0.66
150

Part statistics
No.
Na Assembl
me e
34 270.9
700 360 0 0 0 170.29 6
shirt 0 2
Buffer statistic
rail1 565 555 10 29 0 8.437 14.933
rail2 555 555 0 15 0 0.031 0.055
rail3 570 570 0 15 0 0.027 0.047
rail4 570 570 0 15 0 0.000 0.000
rail5 555 555 0 15 0 0.000 0.000
rail6 555 555 0 15 0 0.000 0.000
rail7 555 555 0 15 0 0.239 0.431
rail8 540 465 75 75 0 52.811 97.799
rail9 450 450 0 15 0 0.000 0.000
rail10 435 435 0 15 0 0.026 0.060
rail11 420 420 0 15 0 0.000 0.000
rail12 405 405 0 15 0 0.000 0.000
rail13 390 390 0 15 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 9 69.31 0.00 30.69 0.00 0.00 0.00
attachcollar04 9 69.31 0.00 30.69 0.00 0.00 0.00
bindingonneck2 18 70.75 0.00 28.90 0.00 0.00 0.35
makeplacket05 6 32.01 0.00 66.53 0.00 0.00 1.45
makeplacket06 7 31.47 0.00 68.12 0.00 0.00 0.41
Loadshirt 37 40.08 0.00 59.92 0.00 0.00 0.00
151
attachcollar01 10 65.91 0.00 34.09 0.00 0.00 0.00

bindingonneck1 19 69.97 0.00 30.03 0.00 0.00 0.00
makeplacket01 6 28.87 0.00 70.56 0.00 0.00 0.57
attachsleeve 30 2.66 0.00 94.79 0.00 0.00 2.55
bottomhem 28 31.99 0.00 67.36 0.00 0.00 0.65
sideseam01 10 60.56 0.00 39.22 0.00 0.00 0.21
tackingcuff 14 73.83 0.00 26.17 0.00 0.00 0.00
makeslit01 7 47.04 0.00 52.06 0.00 0.00 0.90
makeslit02 6 50.89 0.00 47.57 0.00 0.00 1.54
sideseam02 9 61.26 0.00 37.53 0.00 0.00 1.21
sideseam03 8 68.24 0.00 31.38 0.00 0.00 0.38
tackingcuff01 12 75.59 0.00 23.93 0.00 0.00 0.47
makeplacket02 6 29.71 0.00 69.05 0.00 0.00 1.24
makeplacket03 6 28.50 0.00 70.70 0.00 0.00 0.80
makeplacket04 6 29.10 0.00 69.75 0.00 0.00 1.15
attachcollar02 9 68.74 0.00 31.26 0.00 0.00 0.00
makeslit03 6 54.43 0.00 44.72 0.00 0.00 0.85
makeslit04 5 55.68 0.00 43.11 0.00 0.00 1.21
152

Part statistics
No.
Na Assembl
me e
28 293.6
791 510 0 0 0 163.34 6
shirt 1 4
Buffer statistic
rail1 656 656 0 28 0 3.337 5.086
rail2 660 660 0 15 0 0.340 0.516
rail3 660 660 0 15 0 0.826 1.252
rail4 660 660 0 15 0 0.154 0.233
rail5 660 645 15 45 0 18.789 28.467
rail6 645 645 0 15 0 0.000 0.000
rail7 630 630 0 15 0 0.000 0.000
rail8 615 615 0 15 0 0.000 0.000
rail9 615 615 0 15 0 0.000 0.000
rail10 600 600 0 15 0 0.099 0.166
rail11 585 585 0 15 0 0.012 0.021
rail12 555 555 0 15 0 1.120 2.018
rail13 540 540 0 15 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 15 19.64 0.00 80.06 0.00 0.00 0.30
makeplacket05 6 39.88 0.00 58.61 0.00 0.00 1.51
makeplacket06 7 36.57 0.00 61.98 0.00 0.00 1.45
makeplacket07 6 38.25 0.00 60.63 0.00 0.00 1.12
Loadshirt 44 37.00 0.00 63.00 0.00 0.00 0.00
attachsleeve02 21 63.36 0.00 35.15 0.00 0.00 1.48
153

attachcollar01 14 18.24 0.00 81.41 0.00 0.00 0.35
bindingonneck 43 0.47 0.00 99.10 0.00 0.00 0.43
makeplacket01 6 36.23 0.00 61.66 0.00 0.00 2.10
attachsleeve01 20 65.95 0.00 33.50 0.00 0.00 0.56
bottomhem 39 32.32 0.00 66.97 0.00 0.00 0.71
sideseam01 19 29.18 0.00 68.61 0.00 0.00 2.21
tackingcuff 36 17.38 0.00 82.16 0.00 0.00 0.46
makeslit01 9 50.66 0.00 47.79 0.00 0.00 1.55
makeslit02 9 49.76 0.00 47.74 0.00 0.00 2.50
sideseam02 18 31.07 0.00 67.98 0.00 0.00 0.96
makeslit03 8 53.02 0.00 46.46 0.00 0.00 0.52
makeplacket02 6 37.99 0.00 59.52 0.00 0.00 2.49
makeplacket03 6 39.85 0.00 58.63 0.00 0.00 1.52
makeplacket04 5 42.31 0.00 56.91 0.00 0.00 0.78
attachcollar02 15 19.05 0.00 80.54 0.00 0.00 0.41
makeslit04 8 55.05 0.00 43.91 0.00 0.00 1.05
154

Part statistics
No. No.
No. No. No. W. Avg Avg Sigma
Nam Entere Assembl
Shipped Scrapped Rejected I.P W.I.P time rating
e d e
27 270.3
774 495 0 0 0 153.71 6
shirt 9 9
Buffer statistic
rail1 639 639 0 27 0 3.044 4.764
rail2 645 645 0 15 0 0.101 0.156
rail3 630 630 0 15 0 0.336 0.533
rail4 630 630 0 15 0 0.220 0.349
rail5 615 615 0 30 0 4.414 7.178
rail6 615 615 0 15 0 0.000 0.000
rail7 600 600 0 15 0 0.000 0.000
rail8 600 600 0 15 0 0.000 0.000
rail9 585 585 0 15 0 0.000 0.000
rail10 585 585 0 15 0 0.032 0.055
rail11 570 570 0 15 0 0.003 0.005
rail12 540 540 0 15 0 1.036 1.919
rail13 525 525 0 15 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 14 23.83 0.00 75.74 0.00 0.00 0.43
makeplacket05 6 39.78 0.00 58.59 0.00 0.00 1.63
makeplacket06 7 36.78 0.00 61.97 0.00 0.00 1.25
makeplacket07 6 42.91 0.00 55.99 0.00 0.00 1.10
Loadshirt 43 38.41 0.00 61.59 0.00 0.00 0.00
attachsleeve02 21 64.25 0.00 35.16 0.00 0.00 0.59
155

attachcollar01 13 21.99 0.00 77.64 0.00 0.00 0.37
bindingonneck 41 4.65 0.00 94.07 0.00 0.00 1.28
makeplacket01 6 40.66 0.00 58.17 0.00 0.00 1.16
attachsleeve01 18 68.15 0.00 31.47 0.00 0.00 0.38
bottomhem 38 34.45 0.00 64.85 0.00 0.00 0.70
sideseam01 18 31.72 0.00 67.39 0.00 0.00 0.89
tackingcuff 35 19.74 0.00 80.26 0.00 0.00 0.00
makeslit01 9 50.53 0.00 47.81 0.00 0.00 1.66
makeslit02 8 52.62 0.00 45.85 0.00 0.00 1.53
sideseam02 18 34.39 0.00 64.79 0.00 0.00 0.82
makeslit03 8 55.09 0.00 43.73 0.00 0.00 1.19
makeplacket02 5 41.10 0.00 58.21 0.00 0.00 0.69
makeplacket03 5 43.65 0.00 55.53 0.00 0.00 0.81
makeplacket04 5 47.15 0.00 52.46 0.00 0.00 0.39
attachcollar02 14 21.87 0.00 76.89 0.00 0.00 1.25
makeslit04 8 57.03 0.00 42.53 0.00 0.00 0.44
156

Part statistics
No.
Na Assembl
me e
32 298.2
837 510 0 0 0 156.79 6
shirt 7 5
Buffer statistic
rail1 702 675 27 29 0 17.169 24.457
rail2 675 675 0 15 0 0.062 0.092
rail3 675 675 0 15 0 0.451 0.669
rail4 690 690 0 30 0 0.772 1.119
rail5 675 645 30 60 0 26.257 38.899
rail6 645 645 0 15 0 0.000 0.000
rail7 630 630 0 15 0 0.000 0.000
rail8 615 615 0 15 0 0.000 0.000
rail9 615 615 0 15 0 0.000 0.000
rail10 600 600 0 15 0 0.079 0.132
rail11 585 585 0 15 0 0.011 0.019
rail12 555 555 0 15 0 1.593 2.871
rail13 540 540 0 15 0 0.000 0.000
Machine report
No. of % % % % Setup %
Name % Busy
Operation Idle Block Setup wait labour Broken
attachcollar03 15 14.41 0.00 85.20 0.00 0.00 0.39
makeplacket05 6 40.48 0.00 58.63 0.00 0.00 0.88
makeplacket06 7 35.44 0.00 62.02 0.00 0.00 2.54
makeplacket07 6 38.00 0.00 60.73 0.00 0.00 1.27
Loadshirt 45 34.99 0.00 65.01 0.00 0.00 0.00
attachsleeve02 21 64.38 0.00 35.19 0.00 0.00 0.42
157

attachcollar01 15 15.21 0.00 84.29 0.00 0.00 0.51
bindingonneck 43 0.46 0.00 99.19 0.00 0.00 0.36
makeplacket01 6 37.39 0.00 61.82 0.00 0.00 0.80
attachsleeve01 20 66.17 0.00 33.47 0.00 0.00 0.37
bottomhem 39 30.89 0.00 67.67 0.00 0.00 1.44
sideseam01 19 28.90 0.00 69.81 0.00 0.00 1.29
tackingcuff 36 17.27 0.00 82.36 0.00 0.00 0.36
makeslit01 9 50.45 0.00 47.87 0.00 0.00 1.68
makeslit02 9 51.00 0.00 47.82 0.00 0.00 1.19
sideseam02 18 31.11 0.00 67.94 0.00 0.00 0.94
makeslit03 8 52.98 0.00 46.11 0.00 0.00 0.91
makeplacket02 6 39.17 0.00 59.53 0.00 0.00 1.31
makeplacket03 6 40.60 0.00 58.61 0.00 0.00 0.79
makeplacket04 5 42.16 0.00 57.09 0.00 0.00 0.76
attachcollar02 15 18.05 0.00 81.16 0.00 0.00 0.79
makeslit04 8 55.05 0.00 43.84 0.00 0.00 1.10
158
Experiment: 4 repitcation: 1 stream offset: 1

Part statistics
No.
Na Assembl
me e
32 239.0
684 360 0 0 0 153.80 6
shirt 4 8
Buffer statistic
rail1 565 561 4 26 0 4.787 8.473
rail2 560 560 0 10 0 0.005 0.008
rail3 560 560 0 10 0 0.014 0.025
rail4 550 550 0 10 0 0.074 0.134
rail5 570 570 0 10 0 0.069 0.121
rail6 570 520 50 60 0 36.732 64.442
rail7 520 400 120 130 0 89.509 172.132
rail8 400 400 0 10 0 0.003 0.008
rail9 390 390 0 10 0 0.000 0.000
rail10 400 400 0 10 0 0.000 0.000
rail11 390 390 0 10 0 0.000 0.000
rail12 390 390 0 10 0 0.000 0.000
rail13 390 380 10 10 0 7.340 18.821
Machine report
% Setup
No. of % % % % %
Name wait
Operation Idle Block Busy Setup Broken
labour
Loadshirt 56 39.87 0.00 60.13 0.00 0.00 0.00
attachcollar01 29 35.99 0.00 63.68 0.00 0.00 0.32
bindingonneck 56 38.97 0.00 60.40 0.00 0.00 0.63
makeplacket01 13 2.40 0.00 96.79 0.00 0.00 0.81
attachsleeve 39 14.36 0.00 82.82 0.00 0.00 2.81
bottomhem 39 37.59 0.00 61.25 0.00 0.00 1.16
159
sideseam01 11 71.54 0.00 28.10 0.00 0.00 0.36

tackingcuff 39 51.23 0.00 48.77 0.00 0.00 0.00
makeslit01 18 5.93 0.00 91.85 0.00 0.00 2.22
makeslit02 18 7.69 0.00 89.20 0.00 0.00 3.10
sideseam02 10 71.22 0.00 27.56 0.00 0.00 1.22
sideseam03 9 75.79 0.00 23.53 0.00 0.00 0.68
sideseam04 9 76.49 0.00 23.51 0.00 0.00 0.00
makeplacket02 13 1.63 0.00 97.99 0.00 0.00 0.38
makeplacket03 13 3.87 0.00 94.51 0.00 0.00 1.62
makeplacket04 13 2.01 0.00 96.39 0.00 0.00 1.59
attachcollar02 28 36.11 0.00 63.48 0.00 0.00 0.42
160

Part statistics
No.
Na Assembl
me e
31 237.0
673 360 0 0 0 154.95 6
shirt 3 0
Buffer statistic
rail1 554 551 3 26 0 4.180 7.545
rail2 550 550 0 10 0 0.045 0.082
rail3 560 560 0 10 0 0.040 0.072
rail4 550 550 0 10 0 0.061 0.111
rail5 560 560 0 10 0 0.012 0.021
rail6 570 540 30 40 0 21.740 38.139
rail7 540 400 140 150 0 104.817 194.105
rail8 400 400 0 10 0 0.002 0.005
rail9 390 390 0 10 0 0.000 0.000
rail10 390 390 0 10 0 0.000 0.000
rail11 390 390 0 10 0 0.000 0.000
rail12 390 390 0 10 0 0.000 0.000
rail13 380 380 0 10 0 0.910 2.394
Machine report
% Setup
No. of % % % % %
Name wait
labour
Loadshirt 55 41.07 0.00 58.93 0.00 0.00 0.00
attachcollar01 28 36.77 0.00 62.59 0.00 0.00 0.64
Bindingonneck 56 39.42 0.00 59.82 0.00 0.00 0.76
makeplacket01 14 0.58 0.00 99.13 0.00 0.00 0.29
Attachsleeve 39 16.71 0.00 82.09 0.00 0.00 1.20
Bottomhem 39 38.05 0.00 61.11 0.00 0.00 0.83
161
sideseam01 11 71.53 0.00 28.08 0.00 0.00 0.39

Tackingcuff 38 52.34 0.00 47.66 0.00 0.00 0.00
makeslit01 18 5.68 0.00 92.28 0.00 0.00 2.04
makeslit02 18 7.63 0.00 90.11 0.00 0.00 2.26
sideseam02 10 72.69 0.00 26.46 0.00 0.00 0.85
sideseam03 9 75.58 0.00 23.53 0.00 0.00 0.89
sideseam04 9 76.50 0.00 23.50 0.00 0.00 0.00
makeplacket02 13 1.89 0.00 96.86 0.00 0.00 1.25
makeplacket03 13 0.89 0.00 96.96 0.00 0.00 2.15
makeplacket04 14 0.00 0.00 98.99 0.00 0.00 1.01
attachcollar02 28 36.13 0.00 63.45 0.00 0.00 0.42
162

Part statistics
No.
Na Assembl
me e
41 291.5
779 360 0 0 0 164.70 6
shirt 9 9
Buffer statistic
rail1 660 660 0 31 0 3.865 5.856
rail2 660 660 0 10 0 0.090 0.136
rail3 670 670 0 10 0 0.024 0.036
rail4 660 660 0 10 0 0.098 0.148
rail5 660 660 0 10 0 0.055 0.084
rail6 660 540 120 130 0 88.358 133.875
rail7 540 400 140 150 0 105.228 194.866
rail8 400 400 0 10 0 0.000 0.000
rail9 390 390 0 10 0 0.000 0.000
rail10 400 400 0 10 0 0.000 0.000
rail11 390 390 0 10 0 0.000 0.000
rail12 390 390 0 10 0 0.000 0.000
rail13 380 380 0 10 0 0.966 2.543
Machine report
% Setup
No. of % % % % %
Name wait
labour
Loadshirt 66 29.46 0.00 70.54 0.00 0.00 0.00
attachcollar01 33 25.16 0.00 74.46 0.00 0.00 0.38
Bindingonneck 65 28.80 0.00 70.22 0.00 0.00 0.98
makeplacket01 14 0.00 0.00 98.98 0.00 0.00 1.02
Attachsleeve 39 16.77 0.00 82.81 0.00 0.00 0.42
Bottomhem 39 37.25 0.00 61.20 0.00 0.00 1.55
163
sideseam01 11 70.89 0.00 28.09 0.00 0.00 1.02

Tackingcuff 38 51.56 0.00 48.44 0.00 0.00 0.00
makeslit01 18 5.42 0.00 93.26 0.00 0.00 1.32
makeslit02 18 7.92 0.00 90.49 0.00 0.00 1.59
sideseam02 10 72.40 0.00 27.20 0.00 0.00 0.40
sideseam03 9 76.10 0.00 23.52 0.00 0.00 0.38
sideseam04 9 76.48 0.00 23.52 0.00 0.00 0.00
makeplacket02 13 0.00 0.00 99.03 0.00 0.00 0.97
makeplacket03 13 0.59 0.00 97.95 0.00 0.00 1.45
makeplacket04 14 0.00 0.00 98.36 0.00 0.00 1.64
attachcollar02 33 23.78 0.00 75.41 0.00 0.00 0.80
164

Part statistics
No.
Na Assembl
me e
15 164.4
749 590 0 0 0 96.63 6
shirt 9 9
Buffer statistic
rail1 609 609 0 26 0 3.098 5.086
rail2 610 610 0 10 0 0.021 0.034
rail3 600 600 0 10 0 0.471 0.785
rail4 610 610 0 10 0 0.000 0.000
rail5 610 610 0 10 0 0.000 0.000
rail6 600 600 0 10 0 0.000 0.000
rail7 590 590 0 20 0 0.119 0.202
rail8 610 610 0 20 0 1.425 2.337
rail9 620 620 0 10 0 0.000 0.000
rail10 630 630 0 10 0 0.293 0.465
rail11 630 630 0 10 0 0.000 0.000
rail12 630 630 0 10 0 0.000 0.000
rail13 620 620 0 10 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 15 44.38 0.00 55.62 0.00 0.00 0.00
attachcollar04 15 43.27 0.00 56.43 0.00 0.00 0.30
bindingonneck2 31 52.56 0.00 46.74 0.00 0.00 0.70
makeplacket05 16 89.68 0.00 10.32 0.00 0.00 0.00
makeplacket06 8 49.12 0.00 50.52 0.00 0.00 0.36
loadshirt 61 40.70 0.00 59.30 0.00 0.00 0.00
165
attachcollar01 15 44.21 0.00 55.47 0.00 0.00 0.32

bindingonneck1 29 54.06 0.00 45.27 0.00 0.00 0.66
makeplacket01 8 46.29 0.00 53.25 0.00 0.00 0.47
attachsleeve 62 29.02 0.00 69.03 0.00 0.00 1.95
bottomhem 63 28.27 0.00 70.99 0.00 0.00 0.74
sideseam01 21 49.40 0.00 50.14 0.00 0.00 0.45
tackingcuff 31 53.57 0.00 46.43 0.00 0.00 0.00
makeslit01 15 45.60 0.00 53.18 0.00 0.00 1.22
makeslit02 15 44.00 0.00 54.89 0.00 0.00 1.11
sideseam02 22 46.84 0.00 52.27 0.00 0.00 0.90
sideseam03 20 50.14 0.00 48.95 0.00 0.00 0.91
tackingcuff01 31 52.67 0.00 46.95 0.00 0.00 0.38
makeplacket02 7 49.22 0.00 49.49 0.00 0.00 1.28
makeplacket03 7 54.36 0.00 45.64 0.00 0.00 0.00
makeplacket04 13 90.89 0.00 8.44 0.00 0.00 0.67
attachcollar02 16 43.95 0.00 56.05 0.00 0.00 0.00
makeslit03 15 45.63 0.00 53.03 0.00 0.00 1.35
makeslit04 14 46.86 0.00 52.66 0.00 0.00 0.47
166

Part statistics
No.
Na Assembl
me e
17 170.2
765 590 0 0 0 97.91 6
shirt 5 4
Buffer statistic
rail1 625 625 0 29 0 2.602 4.163
rail2 630 630 0 10 0 0.051 0.081
rail3 620 620 0 10 0 0.436 0.704
rail4 620 620 0 10 0 0.000 0.000
rail5 620 620 0 10 0 0.000 0.000
rail6 630 630 0 10 0 0.000 0.000
rail7 630 630 0 20 0 0.154 0.245
rail8 640 640 0 20 0 1.038 1.622
rail9 640 640 0 10 0 0.000 0.000
rail10 650 650 0 10 0 0.290 0.446
rail11 650 650 0 10 0 0.000 0.000
rail12 640 640 0 10 0 0.000 0.000
rail13 630 630 0 10 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 16 42.83 0.00 57.17 0.00 0.00 0.00
attachcollar04 15 41.11 0.00 58.04 0.00 0.00 0.85
bindingonneck2 32 50.91 0.00 48.21 0.00 0.00 0.88
makeplacket05 17 89.05 0.00 10.95 0.00 0.00 0.00
makeplacket06 9 44.37 0.00 54.68 0.00 0.00 0.95
Loadshirt 63 38.77 0.00 61.23 0.00 0.00 0.00
167
attachcollar01 15 42.40 0.00 56.98 0.00 0.00 0.62

bindingonneck1 31 52.08 0.00 47.20 0.00 0.00 0.72
makeplacket01 8 45.08 0.00 54.55 0.00 0.00 0.37
attachsleeve 64 26.45 0.00 72.16 0.00 0.00 1.39
bottomhem 65 25.52 0.00 73.22 0.00 0.00 1.26
sideseam01 21 48.41 0.00 50.63 0.00 0.00 0.95
tackingcuff 31 53.04 0.00 46.96 0.00 0.00 0.00
makeslit01 15 42.76 0.00 55.61 0.00 0.00 1.62
makeslit02 15 43.83 0.00 54.50 0.00 0.00 1.67
sideseam02 22 46.96 0.00 52.27 0.00 0.00 0.77
sideseam03 21 46.79 0.00 51.92 0.00 0.00 1.29
tackingcuff01 32 51.56 0.00 47.97 0.00 0.00 0.47
makeplacket02 8 47.09 0.00 52.12 0.00 0.00 0.79
makeplacket03 7 49.53 0.00 50.47 0.00 0.00 0.00
makeplacket04 14 90.09 0.00 9.14 0.00 0.00 0.77
attachcollar02 16 43.93 0.00 56.07 0.00 0.00 0.00
makeslit03 15 45.25 0.00 53.27 0.00 0.00 1.48
makeslit04 14 46.31 0.00 53.03 0.00 0.00 0.66
168

Part statistics
No.
Na Assembl
me e
18 171.4
780 600 0 0 0 96.70 6
shirt 0 2
Buffer statistic
rail1 640 630 10 28 0 7.792 12.175
rail2 630 630 0 10 0 0.040 0.063
rail3 630 630 0 10 0 0.456 0.724
rail4 630 630 0 10 0 0.000 0.000
rail5 640 640 0 10 0 0.000 0.000
rail6 640 640 0 10 0 0.000 0.000
rail7 640 630 10 10 0 5.115 7.993
rail8 630 630 0 20 0 0.931 1.478
rail9 640 640 0 10 0 0.000 0.000
rail10 650 650 0 10 0 0.192 0.296
rail11 650 650 0 10 0 0.000 0.000
rail12 640 640 0 10 0 0.000 0.000
rail13 630 630 0 10 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 16 39.85 0.00 60.15 0.00 0.00 0.00
attachcollar04 16 40.39 0.00 59.24 0.00 0.00 0.37
bindingonneck2 32 50.39 0.00 48.83 0.00 0.00 0.78
makeplacket05 16 89.72 0.00 10.28 0.00 0.00 0.00
makeplacket06 9 44.00 0.00 54.74 0.00 0.00 1.27
Loadshirt 63 38.75 0.00 61.25 0.00 0.00 0.00
169
attachcollar01 16 40.33 0.00 59.24 0.00 0.00 0.43

bindingonneck1 32 50.53 0.00 48.74 0.00 0.00 0.72
makeplacket01 9 40.88 0.00 58.62 0.00 0.00 0.49
attachsleeve 64 26.91 0.00 71.27 0.00 0.00 1.82
bottomhem 65 26.00 0.00 73.02 0.00 0.00 0.98
sideseam01 21 47.34 0.00 52.28 0.00 0.00 0.38
tackingcuff 31 52.74 0.00 47.26 0.00 0.00 0.00
makeslit01 15 44.28 0.00 55.23 0.00 0.00 0.49
makeslit02 16 42.04 0.00 56.75 0.00 0.00 1.20
sideseam02 22 47.00 0.00 52.30 0.00 0.00 0.70
sideseam03 21 49.08 0.00 50.51 0.00 0.00 0.40
tackingcuff01 32 51.73 0.00 47.86 0.00 0.00 0.41
makeplacket02 8 46.27 0.00 53.03 0.00 0.00 0.70
makeplacket03 8 47.66 0.00 52.14 0.00 0.00 0.19
makeplacket04 14 90.19 0.00 9.18 0.00 0.00 0.63
attachcollar02 16 43.92 0.00 56.08 0.00 0.00 0.00
makeslit03 15 45.24 0.00 53.51 0.00 0.00 1.25
makeslit04 14 45.73 0.00 52.75 0.00 0.00 1.52
170

Part statistics
No.
Na Assembl
me e
24 196.3
721 480 0 0 0 119.81 6
shirt 1 2
Buffer statistic
rail1 610 599 11 30 0 9.033 14.809
rail2 590 590 0 10 0 0.107 0.181
rail3 590 590 0 20 0 0.941 1.594
rail4 590 580 10 20 0 5.917 10.029
rail5 570 540 30 30 0 19.418 34.067
rail6 540 540 0 10 0 0.000 0.000
rail7 540 540 0 10 0 0.000 0.000
rail8 530 530 0 10 0 0.000 0.000
rail9 530 530 0 10 0 0.000 0.000
rail10 520 520 0 10 0 0.095 0.182
rail11 530 530 0 10 0 0.014 0.027
rail12 510 510 0 10 0 0.612 1.199
rail13 500 500 0 10 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 19 16.54 0.00 83.05 0.00 0.00 0.42
makeplacket05 7 38.78 0.00 59.39 0.00 0.00 1.83
makeplacket06 7 42.46 0.00 57.19 0.00 0.00 0.35
makeplacket07 8 43.05 0.00 55.44 0.00 0.00 1.51
Loadshirt 59 33.67 0.00 66.33 0.00 0.00 0.00
attachsleeve02 26 64.30 0.00 34.42 0.00 0.00 1.28
171
makeslit03 13 45.06 0.00 53.00 0.00 0.00 1.93

makeslit04 12 47.00 0.00 52.15 0.00 0.00 0.85
attachcollar01 19 17.68 0.00 81.62 0.00 0.00 0.70
bindingonneck 54 4.12 0.00 95.51 0.00 0.00 0.37
makeplacket01 8 43.40 0.00 55.71 0.00 0.00 0.89
attachsleeve01 27 66.13 0.00 33.55 0.00 0.00 0.32
bottomhem 53 30.45 0.00 68.37 0.00 0.00 1.18
sideseam01 26 27.84 0.00 71.71 0.00 0.00 0.45
tackingcuff01 50 12.97 0.00 86.58 0.00 0.00 0.44
makeslit01 12 50.14 0.00 48.98 0.00 0.00 0.88
makeslit02 11 53.57 0.00 45.32 0.00 0.00 1.11
sideseam02 25 28.57 0.00 70.70 0.00 0.00 0.73
makeplacket02 8 40.67 0.00 58.11 0.00 0.00 1.22
makeplacket03 8 40.05 0.00 59.52 0.00 0.00 0.42
makeplacket04 8 39.54 0.00 60.01 0.00 0.00 0.45
attachcollar02 19 19.64 0.00 79.94 0.00 0.00 0.42
172

Part statistics
No.
Na Assembl
me e
24 204.7
733 490 0 0 0 122.89 6
shirt 3 2
Buffer statistic
rail1 622 619 3 29 0 5.325 8.560
rail2 610 610 0 10 0 0.154 0.253
rail3 610 610 0 10 0 0.555 0.910
rail4 610 610 0 10 0 0.482 0.791
rail5 600 560 40 40 0 25.990 43.317
rail6 560 560 0 10 0 0.000 0.000
rail7 560 560 0 10 0 0.000 0.000
rail8 550 550 0 10 0 0.000 0.000
rail9 560 560 0 10 0 0.000 0.000
rail10 540 540 0 10 0 0.063 0.117
rail11 550 550 0 10 0 0.000 0.000
rail12 530 530 0 10 0 1.186 2.238
rail13 520 520 0 10 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 20 14.06 0.00 85.12 0.00 0.00 0.82
makeplacket05 8 37.44 0.00 61.36 0.00 0.00 1.21
makeplacket06 8 39.30 0.00 59.93 0.00 0.00 0.78
makeplacket07 8 38.89 0.00 59.06 0.00 0.00 2.04
Loadshirt 61 30.95 0.00 69.05 0.00 0.00 0.00
attachsleeve02 28 63.74 0.00 35.87 0.00 0.00 0.38
173
makeslit03 13 43.02 0.00 55.07 0.00 0.00 1.90

makeslit04 12 46.42 0.00 52.79 0.00 0.00 0.79
attachcollar01 20 13.81 0.00 85.44 0.00 0.00 0.75
bindingonneck 56 0.44 0.00 99.14 0.00 0.00 0.42
makeplacket01 8 40.10 0.00 59.40 0.00 0.00 0.50
attachsleeve01 28 64.45 0.00 34.85 0.00 0.00 0.70
bottomhem 55 27.81 0.00 70.98 0.00 0.00 1.21
sideseam01 27 24.14 0.00 74.60 0.00 0.00 1.26
tackingcuff01 52 9.81 0.00 89.80 0.00 0.00 0.39
makeslit01 12 49.83 0.00 49.34 0.00 0.00 0.83
makeslit02 12 50.02 0.00 48.75 0.00 0.00 1.23
sideseam02 26 25.40 0.00 73.28 0.00 0.00 1.32
makeplacket02 8 37.47 0.00 61.36 0.00 0.00 1.16
makeplacket03 8 40.14 0.00 59.53 0.00 0.00 0.33
makeplacket04 8 39.32 0.00 59.90 0.00 0.00 0.78
attachcollar02 20 13.79 0.00 85.45 0.00 0.00 0.76
174

Part statistics
No.
Na Assembl
me e
20 185.0
676 470 0 0 0 120.44 6
shirt 6 3
Buffer statistic
rail1 565 559 6 28 0 6.300 11.151
rail2 550 550 0 10 0 0.085 0.155
rail3 550 550 0 10 0 0.523 0.951
rail4 550 550 0 10 0 0.400 0.727
rail5 540 530 10 20 0 7.438 13.775
rail6 530 530 0 10 0 0.000 0.000
rail7 530 530 0 10 0 0.000 0.000
rail8 520 520 0 10 0 0.000 0.000
rail9 530 530 0 10 0 0.000 0.000
rail10 520 520 0 10 0 0.066 0.126
rail11 520 520 0 10 0 0.006 0.012
rail12 500 500 0 10 0 1.048 2.097
rail13 490 490 0 10 0 0.000 0.000
Machine report
No. of % % % % % Setup %
Name
attachcollar03 18 23.00 0.00 76.73 0.00 0.00 0.27
makeplacket05 8 37.90 0.00 59.89 0.00 0.00 2.21
makeplacket06 7 40.10 0.00 59.55 0.00 0.00 0.35
makeplacket07 8 40.19 0.00 57.78 0.00 0.00 2.03
Loadshirt 55 38.24 0.00 61.76 0.00 0.00 0.00
attachsleeve02 26 66.35 0.00 33.28 0.00 0.00 0.37
175
makeslit03 12 48.02 0.00 51.19 0.00 0.00 0.79

makeslit04 12 50.47 0.00 48.83 0.00 0.00 0.70
attachcollar01 18 22.74 0.00 76.85 0.00 0.00 0.41
bindingonneck 53 5.66 0.00 93.91 0.00 0.00 0.43
makeplacket01 8 44.43 0.00 54.41 0.00 0.00 1.16
attachsleeve01 27 66.00 0.00 33.56 0.00 0.00 0.44
bottomhem 52 31.44 0.00 67.20 0.00 0.00 1.37
sideseam01 25 28.19 0.00 70.94 0.00 0.00 0.87
tackingcuff01 49 14.52 0.00 85.06 0.00 0.00 0.42
makeslit01 12 50.37 0.00 48.87 0.00 0.00 0.76
makeslit02 11 52.87 0.00 45.47 0.00 0.00 1.66
sideseam02 25 30.27 0.00 69.12 0.00 0.00 0.62
makeplacket02 8 41.54 0.00 58.13 0.00 0.00 0.33
makeplacket03 7 44.30 0.00 54.82 0.00 0.00 0.88
makeplacket04 7 44.60 0.00 53.90 0.00 0.00 1.50
attachcollar02 18 22.69 0.00 76.87 0.00 0.00 0.44
176

Part statistics
No.
Na Assembl
me e
shirt 606 531 0 0 0 75 59.51 43.21 6
Buffer statistic
rail1 575 567 8 34 0 6.310 10.974
rail2 566 566 0 8 0 0.226 0.399
rail3 565 563 2 7 0 1.447 2.561
rail4 575 529 46 66 0 40.958 71.232
rail5 532 532 0 3 0 0.112 0.211
rail6 532 532 0 3 0 0.038 0.072
rail7 530 530 0 3 0 0.090 0.169
rail8 531 531 0 2 0 0.003 0.006
rail9 530 530 0 3 0 0.037 0.069
rail10 530 530 0 4 0 0.017 0.033
rail11 531 531 0 1 0 0.000 0.000
rail12 531 531 0 3 0 0.067 0.125
rail13 533 531 2 7 0 1.716 3.220
Machine report
No. of % % % % % Setup %
Name
Loadshirt 566 44.77 0.00 55.23 0.00 0.00 0.00
attachcollar01 265 1.62 0.00 97.65 0.00 0.00 0.73
bindingonneck 532 19.06 0.00 80.94 0.00 0.00 0.00
makeplacket01 132 12.03 0.00 86.51 0.00 0.00 1.45
attachsleeve 530 40.46 0.00 59.20 0.00 0.00 0.33
bottomhem 531 38.53 0.00 60.24 0.00 0.00 1.23
sideseam01 131 67.61 0.00 31.57 0.00 0.00 0.82
177
tackingcuff 531 19.29 0.00 79.19 0.00 0.00 1.52

makeslit01 266 2.87 0.00 94.20 0.00 0.00 2.93
makeslit02 265 2.90 0.00 93.66 0.00 0.00 3.44
sideseam02 134 68.02 0.00 31.98 0.00 0.00 0.00
sideseam03 133 68.16 0.00 31.84 0.00 0.00 0.00
sideseam04 132 68.57 0.00 31.43 0.00 0.00 0.00
makeplacket02 132 11.08 0.00 85.83 0.00 0.00 3.09
makeplacket03 133 11.59 0.00 87.19 0.00 0.00 1.22
makeplacket04 132 12.52 0.00 86.10 0.00 0.00 1.38
attachcollar02 264 1.78 0.00 97.91 0.00 0.00 0.31
178

Part statistics
No.
Na Assembl
me e
shirt 603 539 0 0 0 64 67.32 49.13 6
Buffer statistic
rail1 572 572 0 26 0 2.791 4.879
rail2 572 572 0 5 0 0.096 0.167
rail3 572 572 0 5 0 0.279 0.487
rail4 585 535 50 64 10 46.727 79.876
rail5 538 538 0 3 0 0.128 0.238
rail6 538 538 0 3 0 0.038 0.071
rail7 536 536 0 2 0 0.038 0.072
rail8 537 537 0 2 0 0.006 0.011
rail9 536 536 0 3 0 0.073 0.137
rail10 536 536 0 4 0 0.016 0.029
rail11 536 536 0 1 0 0.000 0.000
rail12 537 537 0 3 0 0.055 0.102
rail13 539 539 0 7 0 0.985 1.827
Machine report
No. of % % % % % Setup %
Name
Loadshirt 572 44.23 0.00 55.77 0.00 0.00 0.00
attachcollar01 267 0.00 0.00 99.20 0.00 0.00 0.80
Bindingonneck 538 18.20 0.00 81.80 0.00 0.00 0.00
makeplacket01 134 11.54 0.00 87.57 0.00 0.00 0.90
attachsleeve 536 39.36 0.00 59.94 0.00 0.00 0.71
bottomhem 536 37.81 0.00 61.08 0.00 0.00 1.11
sideseam01 133 67.27 0.00 31.79 0.00 0.00 0.94
179
tackingcuff 537 18.79 0.00 80.34 0.00 0.00 0.87

makeslit01 271 2.66 0.00 95.46 0.00 0.00 1.88
makeslit02 268 2.62 0.00 94.56 0.00 0.00 2.82
sideseam02 135 67.89 0.00 32.11 0.00 0.00 0.00
sideseam03 135 67.79 0.00 32.21 0.00 0.00 0.00
sideseam04 133 67.92 0.00 32.08 0.00 0.00 0.00
makeplacket02 134 11.46 0.00 87.32 0.00 0.00 1.22
makeplacket03 133 11.23 0.00 87.41 0.00 0.00 1.36
makeplacket04 134 11.87 0.00 87.75 0.00 0.00 0.38
attachcollar02 268 0.00 0.00 99.17 0.00 0.00 0.83
180

Part statistics
No.
Na Assembl
me e
shirt 580 540 0 0 0 40 44.26 33.58 6
Buffer statistic
rail1 549 535 14 26 0 8.962 16.325
rail2 534 534 0 5 0 0.093 0.175
rail3 533 533 0 4 0 0.297 0.557
rail4 545 535 10 41 6 16.149 29.631
rail5 538 538 0 3 0 0.122 0.226
rail6 538 538 0 3 0 0.045 0.083
rail7 536 536 0 3 0 0.062 0.115
rail8 537 537 0 3 0 0.006 0.011
rail9 537 537 0 4 0 0.049 0.091
rail10 537 537 0 4 0 0.023 0.043
rail11 537 537 0 1 0 0.000 0.000
rail12 538 538 0 3 0 0.078 0.145
rail13 540 540 0 8 0 1.062 1.966
Machine report
No. of % % % % % Setup %
Name
Loadshirt 534 47.88 0.00 52.12 0.00 0.00 0.00
attachcollar01 269 0.00 0.00 99.23 0.00 0.00 0.77
bindingonneck 538 18.17 0.00 81.83 0.00 0.00 0.00
makeplacket01 134 11.44 0.00 87.55 0.00 0.00 1.01
attachsleeve 537 39.56 0.00 60.01 0.00 0.00 0.42
bottomhem 537 37.74 0.00 61.09 0.00 0.00 1.17
sideseam01 133 67.41 0.00 31.81 0.00 0.00 0.79
181
tackingcuff 538 18.91 0.00 80.73 0.00 0.00 0.35

makeslit01 270 1.46 0.00 95.67 0.00 0.00 2.87
makeslit02 270 1.26 0.00 96.31 0.00 0.00 2.44
sideseam02 136 67.62 0.00 32.38 0.00 0.00 0.00
sideseam03 134 67.80 0.00 32.20 0.00 0.00 0.00
sideseam04 134 67.96 0.00 32.04 0.00 0.00 0.00
makeplacket02 134 11.35 0.00 87.48 0.00 0.00 1.17
makeplacket03 135 11.07 0.00 88.05 0.00 0.00 0.88
makeplacket04 132 11.90 0.00 86.56 0.00 0.00 1.54
attachcollar02 266 0.00 0.00 98.71 0.00 0.00 1.29
182

Part statistics
No.
Na Assembl
me e
shirt 639 613 0 0 0 26 31.57 21.74 6
Buffer statistic
rail1 622 622 0 30 0 3.559 5.721
rail2 622 622 0 5 0 0.231 0.371
rail3 622 620 2 15 0 2.162 3.476
rail4 619 619 0 1 0 0.000 0.001
rail5 615 615 0 2 0 0.013 0.021
rail6 615 614 1 3 0 0.606 0.986
rail7 612 612 0 3 0 0.023 0.038
rail8 612 612 0 5 0 0.252 0.412
rail9 612 612 0 1 0 0.002 0.003
rail10 613 613 0 7 0 0.401 0.655
rail11 613 613 0 1 0 0.000 0.000
rail12 613 613 0 1 0 0.001 0.002
rail13 613 613 0 1 0 0.005 0.008
Machine report
No. of % % % % % Setup %
Name
attachcollar03 154 34.10 0.00 65.90 0.00 0.00 0.00
attachcollar04 153 34.31 0.00 65.32 0.00 0.00 0.37
bindingonneck02 306 44.24 0.00 53.59 0.00 0.00 2.17
makeplacket05 101 21.20 0.00 75.65 0.00 0.00 3.15
makeplacket06 103 21.68 0.00 77.87 0.00 0.00 0.45
Loadshirt 622 30.21 0.00 69.79 0.00 0.00 0.00
attachcollar01 154 34.03 0.00 65.54 0.00 0.00 0.43
183
bindingonneck01 309 44.39 0.00 54.11 0.00 0.00 1.51

makeplacket01 102 21.78 0.00 76.66 0.00 0.00 1.56
attachsleeve 612 20.41 0.00 78.08 0.00 0.00 1.51
bottomhem 613 18.83 0.00 79.92 0.00 0.00 1.24
sideseam01 205 43.35 0.00 56.34 0.00 0.00 0.32
tackingcuff01 307 46.83 0.00 53.17 0.00 0.00 0.00
makeslit01 153 36.38 0.00 62.23 0.00 0.00 1.39
makeslit02 151 35.64 0.00 61.45 0.00 0.00 2.91
sideseam02 205 43.35 0.00 56.29 0.00 0.00 0.36
sideseam03 203 43.35 0.00 55.83 0.00 0.00 0.82
tackingcuff02 306 46.82 0.00 52.77 0.00 0.00 0.41
makeplacket02 104 21.24 0.00 78.28 0.00 0.00 0.48
makeplacket03 100 23.60 0.00 75.58 0.00 0.00 0.81
makeplacket04 102 22.42 0.00 76.02 0.00 0.00 1.56
attachcollar02 154 34.47 0.00 65.53 0.00 0.00 0.00
makeslit03 155 36.28 0.00 63.23 0.00 0.00 0.50
makeslit04 154 36.32 0.00 62.84 0.00 0.00 0.84
184

Part statistics
No.
Na Assembl
me e
shirt 691 675 0 0 0 16 35.46 22.58 6
Buffer statistic
rail1 674 674 0 28 0 3.552 5.270
rail2 674 674 0 2 0 0.130 0.193
rail3 674 672 2 11 0 2.544 3.775
rail4 671 671 0 1 0 0.001 0.002
rail5 667 667 0 2 0 0.005 0.008
rail6 667 667 0 3 0 0.119 0.178
rail7 666 666 0 3 0 0.018 0.027
rail8 665 665 0 11 0 0.710 1.068
rail9 665 665 0 2 0 0.005 0.007
rail10 668 668 0 7 0 0.665 0.995
rail11 669 669 0 1 0 0.001 0.001
rail12 671 671 0 1 0 0.002 0.003
rail13 672 672 0 1 0 0.004 0.006
Machine report
No. of % % % % % Setup %
Name
attachcollar03 168 28.35 0.00 71.65 0.00 0.00 0.00
attachcollar04 166 28.77 0.00 70.80 0.00 0.00 0.43
bindingonneck02 331 40.85 0.00 58.02 0.00 0.00 1.13
makeplacket05 111 15.88 0.00 82.89 0.00 0.00 1.24
makeplacket06 113 14.80 0.00 84.91 0.00 0.00 0.29
Loadshirt 674 24.41 0.00 75.59 0.00 0.00 0.00
attachcollar01 166 28.64 0.00 70.83 0.00 0.00 0.53
185
bindingonneck01 336 40.35 0.00 58.96 0.00 0.00 0.69

makeplacket01 112 14.84 0.00 83.76 0.00 0.00 1.40
Attachsleeve 665 12.99 0.00 85.18 0.00 0.00 1.82
Bottomhem 669 11.44 0.00 87.31 0.00 0.00 1.25
sideseam01 224 37.45 0.00 61.73 0.00 0.00 0.82
tackingcuff01 336 41.75 0.00 57.90 0.00 0.00 0.35
makeslit01 168 30.03 0.00 68.56 0.00 0.00 1.41
makeslit02 168 29.55 0.00 68.16 0.00 0.00 2.29
sideseam02 226 37.76 0.00 61.84 0.00 0.00 0.39
sideseam03 221 37.55 0.00 60.50 0.00 0.00 1.95
tackingcuff02 336 41.95 0.00 57.60 0.00 0.00 0.44
makeplacket02 109 15.46 0.00 81.92 0.00 0.00 2.62
makeplacket03 111 15.86 0.00 83.69 0.00 0.00 0.46
makeplacket04 110 15.24 0.00 82.63 0.00 0.00 2.13
attachcollar02 167 28.51 0.00 71.12 0.00 0.00 0.37
makeslit03 169 30.51 0.00 68.64 0.00 0.00 0.85
makeslit04 170 29.85 0.00 69.21 0.00 0.00 0.94
186

Part statistics
No.
Na Assembl
me e
shirt 730 677 0 0 0 53 37.39 22.54 6
Buffer statistic
rail1 713 697 16 32 0 11.905 16.696
rail2 696 695 1 3 0 0.672 0.965
rail3 694 683 11 18 0 7.282 10.492
rail4 682 682 0 1 0 0.002 0.003
rail5 679 679 0 2 0 0.008 0.012
rail6 679 678 1 4 0 0.745 1.097
rail7 676 676 0 2 0 0.021 0.031
rail8 676 675 1 9 0 1.250 1.849
rail9 675 675 0 1 0 0.004 0.006
rail10 677 677 0 7 0 0.511 0.755
rail11 677 677 0 1 0 0.001 0.002
rail12 678 678 0 2 0 0.009 0.013
rail13 677 677 0 2 0 0.049 0.072
Machine report
No. of % % % % % Setup %
Name
27.3
171 0.00 72.69 0.00 0.00 0.00
attachcollar03 1
27.1
169 0.00 72.23 0.00 0.00 0.67
attachcollar04 0
39.5
339 0.00 59.43 0.00 0.00 1.06
bindingonneck02 1
14.0
113 0.00 84.96 0.00 0.00 1.02
makeplacket05 2
14.3
112 0.00 84.35 0.00 0.00 1.35
makeplacket06 0
37.3
336 0.00 61.83 0.00 0.00 0.86
topstitchonbinding02 1
Loadshirt 696 21.9 0.00 78.01 0.00 0.00 0.00
187
9
39.2
334 0.00 59.22 0.00 0.00 1.51
topstitchonarmhole02 7
19.6
694 0.00 79.52 0.00 0.00 0.82
joinshoulderseam 6
10.7
682 0.00 87.53 0.00 0.00 1.72
topstitchonshoulder 5
27.1
169 0.00 72.41 0.00 0.00 0.43
attachcollar01 6
39.7
340 0.00 59.50 0.00 0.00 0.80
bindingonneck01 0
14.0
114 0.00 85.26 0.00 0.00 0.74
makeplacket01 0
37.5
340 0.00 62.42 0.00 0.00 0.00
topstitchonbinding01 8
11.1
675 0.00 86.59 0.00 0.00 2.29
Attachsleeve 2
39.1
342 0.00 60.83 0.00 0.00 0.00
topstitchonarmhole01 7
Bottomhem 677 9.91 0.00 88.92 0.00 0.00 1.17
37.0
228 0.00 62.63 0.00 0.00 0.33
sideseam01 5
41.2
338 0.00 58.33 0.00 0.00 0.44
tackingcuff01 2
29.2
169 0.00 68.48 0.00 0.00 2.27
makeslit01 5
29.4
170 0.00 69.00 0.00 0.00 1.52
makeslit02 8
37.2
228 0.00 62.51 0.00 0.00 0.21
sideseam02 7
36.6
222 0.00 60.91 0.00 0.00 2.40
sideseam03 9
41.1
339 0.00 58.34 0.00 0.00 0.49
tackingcuff02 7
14.0
111 0.00 83.16 0.00 0.00 2.81
makeplacket02 3
14.1
113 0.00 85.08 0.00 0.00 0.78
makeplacket03 4
14.4
113 0.00 84.53 0.00 0.00 1.04
makeplacket04 3
27.2
170 0.00 72.35 0.00 0.00 0.38
attachcollar02 7
29.2
170 0.00 69.58 0.00 0.00 1.22
makeslit03 1
29.6
168 0.00 69.08 0.00 0.00 1.30
makeslit04 2
188
189

Part statistics
No.
Na Assembl
me e
shirt 611 574 0 0 0 37 33.42 24.07 6
Buffer statistic
rail1 582 568 14 35 0 9.876 16.969
rail2 568 568 0 5 0 0.125 0.221
rail3 568 568 0 1 0 0.021 0.037
rail4 568 568 0 1 0 0.000 0.000
rail5 568 568 0 2 0 0.032 0.056
rail6 567 567 0 3 0 0.028 0.050
rail7 562 562 0 2 0 0.008 0.014
rail8 563 563 0 6 0 0.173 0.308
rail9 564 564 0 2 0 0.002 0.003
rail10 582 576 6 28 0 7.113 12.223
rail11 576 576 0 2 0 0.006 0.010
rail12 576 576 0 1 0 0.004 0.007
rail13 575 575 0 1 0 0.004 0.007
Machine report
No. of % % % % % Setup %
Name
attachcollar03 190 56.78 0.00 43.22 0.00 0.00 0.00
makeplacket05 80 39.40 0.00 59.01 0.00 0.00 1.58
makeplacket06 79 39.25 0.00 58.41 0.00 0.00 2.33
makeplacket07 81 38.61 0.00 60.04 0.00 0.00 1.35
Loadshirt 568 39.43 0.00 60.57 0.00 0.00 0.00
attachsleeve02 289 39.19 0.00 60.42 0.00 0.00 0.39
190
attachcollar01 190 57.12 0.00 42.88 0.00 0.00 0.00

Bindingonneck 567 39.36 0.00 60.64 0.00 0.00 0.00
makeplacket01 80 38.96 0.00 59.65 0.00 0.00 1.40
attachsleeve01 275 38.68 0.00 57.43 0.00 0.00 3.89
Bottomhem 576 9.08 0.00 90.40 0.00 0.00 0.52
sideseam01 287 24.34 0.00 75.21 0.00 0.00 0.45
Tackingcuff 575 27.53 0.00 72.07 0.00 0.00 0.39
makeslit01 144 27.13 0.00 71.96 0.00 0.00 0.91
makeslit02 143 27.50 0.00 70.74 0.00 0.00 1.77
sideseam02 289 24.21 0.00 75.42 0.00 0.00 0.37
makeslit03 143 27.99 0.00 70.75 0.00 0.00 1.26
makeplacket02 81 39.57 0.00 60.09 0.00 0.00 0.34
makeplacket03 81 39.56 0.00 59.95 0.00 0.00 0.49
makeplacket04 80 39.48 0.00 59.36 0.00 0.00 1.16
attachcollar02 188 56.85 0.00 42.74 0.00 0.00 0.41
makeslit04 144 27.59 0.00 70.73 0.00 0.00 1.69
191

Part statistics
No.
Na Assembl
me e
shirt 589 554 0 0 0 35 27.78 20.75 6
Buffer statistic
rail1 560 559 1 27 0 3.048 5.443
rail2 559 559 0 5 0 0.135 0.241
rail3 559 559 0 1 0 0.015 0.026
rail4 559 559 0 1 0 0.000 0.000
rail5 559 559 0 2 0 0.023 0.042
rail6 558 558 0 4 0 0.027 0.048
rail7 551 550 1 2 0 0.509 0.924
rail8 548 548 0 3 0 0.057 0.103
rail9 549 549 0 2 0 0.004 0.007
rail10 565 558 7 21 0 6.453 11.421
rail11 558 558 0 2 0 0.003 0.005
rail12 557 557 0 3 0 0.008 0.014
rail13 556 556 0 1 0 0.002 0.004
Machine report
No. of % % % % % Setup %
Name
attachcollar03 188 57.37 0.00 42.63 0.00 0.00 0.00
makeplacket05 81 38.76 0.00 60.11 0.00 0.00 1.13
makeplacket06 79 39.44 0.00 58.88 0.00 0.00 1.68
makeplacket07 79 40.23 0.00 58.77 0.00 0.00 1.00
Loadshirt 559 40.29 0.00 59.71 0.00 0.00 0.00
attachsleeve02 277 41.82 0.00 57.80 0.00 0.00 0.38
192
attachcollar01 187 57.71 0.00 42.29 0.00 0.00 0.00

bindingonneck 558 40.31 0.00 59.69 0.00 0.00 0.00
makeplacket01 78 41.37 0.00 58.25 0.00 0.00 0.38
attachsleeve01 272 41.75 0.00 56.78 0.00 0.00 1.47
bottomhem 558 12.45 0.00 87.28 0.00 0.00 0.27
sideseam01 278 26.84 0.00 72.65 0.00 0.00 0.51
tackingcuff 556 29.80 0.00 69.84 0.00 0.00 0.36
makeslit01 139 30.28 0.00 69.00 0.00 0.00 0.72
makeslit02 138 31.35 0.00 67.53 0.00 0.00 1.12
sideseam02 279 26.41 0.00 73.16 0.00 0.00 0.43
makeslit03 138 30.79 0.00 68.66 0.00 0.00 0.55
makeplacket02 79 41.22 0.00 58.40 0.00 0.00 0.39
makeplacket03 78 41.79 0.00 57.80 0.00 0.00 0.41
makeplacket04 77 41.81 0.00 57.40 0.00 0.00 0.79
attachcollar02 184 57.29 0.00 41.83 0.00 0.00 0.88
makeslit04 139 30.53 0.00 68.76 0.00 0.00 0.71
193

Part statistics
No.
Na Assembl
me e
shirt 661 618 0 0 0 43 37.46 24.94 6
Buffer statistic
rail1 632 613 19 36 0 12.626 19.978
rail2 613 613 0 4 0 0.062 0.101
rail3 613 613 0 1 0 0.023 0.037
rail4 614 614 0 1 0 0.000 0.000
rail5 616 616 0 2 0 0.044 0.071
rail6 616 616 0 3 0 0.096 0.156
rail7 616 616 0 2 0 0.015 0.024
rail8 617 617 0 4 0 0.098 0.159
rail9 618 618 0 2 0 0.003 0.005
rail10 636 620 16 30 0 13.235 20.809
rail11 620 620 0 2 0 0.003 0.005
rail12 619 619 0 3 0 0.011 0.017
rail13 619 619 0 3 0 0.009 0.015
Machine report
No. of % % % % % Setup %
Name
attachcollar03 206 53.10 0.00 46.90 0.00 0.00 0.00
makeplacket05 89 32.55 0.00 65.42 0.00 0.00 2.04
makeplacket06 88 33.37 0.00 65.11 0.00 0.00 1.52
makeplacket07 88 33.77 0.00 65.07 0.00 0.00 1.16
Loadshirt 613 34.57 0.00 65.43 0.00 0.00 0.00
attachsleeve02 310 34.13 0.00 65.00 0.00 0.00 0.86
194
attachcollar01 206 53.48 0.00 46.52 0.00 0.00 0.00

Bindingonneck 616 34.13 0.00 65.87 0.00 0.00 0.00
makeplacket01 88 33.72 0.00 64.97 0.00 0.00 1.31
attachsleeve01 308 34.53 0.00 64.28 0.00 0.00 1.20
Bottomhem 620 2.10 0.00 97.59 0.00 0.00 0.31
sideseam01 309 18.48 0.00 81.14 0.00 0.00 0.38
Tackingcuff 619 22.23 0.00 77.42 0.00 0.00 0.35
makeslit01 156 22.47 0.00 77.04 0.00 0.00 0.49
makeslit02 154 21.97 0.00 76.45 0.00 0.00 1.58
sideseam02 310 18.41 0.00 81.18 0.00 0.00 0.40
makeslit03 154 22.06 0.00 76.65 0.00 0.00 1.29
makeplacket02 88 34.46 0.00 65.11 0.00 0.00 0.42
makeplacket03 88 34.53 0.00 65.09 0.00 0.00 0.38
makeplacket04 87 34.24 0.00 64.16 0.00 0.00 1.60
attachcollar02 204 53.24 0.00 46.35 0.00 0.00 0.41
makeslit04 154 22.65 0.00 76.14 0.00 0.00 1.21
195
Appendix E:
F-Table
Appendix F: F Table
F.0 F-Table
196
197

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University of Mauritius

Submitted as a partial fulfillment for the degree of

B.Eng. (Hons) Manufacturing Engineering

Name: RADHA Yashvan

Student ID: 0711623

Programme of Studies: BEng (Hons) Manufacturing Engineering

Module Code/Name: MECH 4000Y

Name of Supervisor(s): Dr. DK Hurreeram

(v) Notwithstanding the supervision provided to me by the University of Mauritius, I warrant

Signature: Y.R Date: 30. March 2012

Chapter 2: Literature Review

Chapter 5: Data Collection

Chapter 6: Model Construction

Chapter 8: Conclusion and Further Works

ANOM - Analysis of Mean

Figure 2.1 Production system ........................................................................................... 5

Table 4.1 Operation Breakdown ..................................................................................... 29

I would like to thank my supervisor, Mr HURREERAM D.K. for having being

I would also thanks Mr. RAMASAWMY H. for his lectures on WITNESS

I am also grateful to the University of Mauritius Library for having provided me

1.1 Export Processing Zone

1.2 Company profile

1.3 Problem statement

The main problems identified at the company were:

1.4 Objectives of the project

1. To study the actual production system.

2. To identify the modules of the software not being use.

1.5 Overview of chapters

Chapter 3 – Enterprise Resource Planning (ERP) software. This chapter discusses

Figure 2.1 Production system

There are 3 main types of production systems:

2.1.1 Job Shop Production

2.1.2 Batch Production

Batch production usually involves producing products or semi-finished products in a bit

2.1.3 Mass Production

In the manufacturing sector, productivity is defined as the ratio of what is produced to

2.1.4.1 Factors affecting productivity

The factors affecting productivity can be classified into 2 main categories:

Some of the internal hard factors are listed below.

 Product – variations in the product specification will lead to changes in the

 Technology – lack of up-to-date technologies will tend to lower the productivity.

Some of the internal soft factors are listed below.

Some of the external soft factors are listed below.

Some management techniques for improving productivity are

 Travel chart, proper plant layout, good production planning.

 Statistical process control (SPC) to reduce scraps on finished products.

2.1.4.2 Type of productivity

Productivity can be expressed in many ways such as partial-factor productivity, single-

Partial-factor productivity (PFP) measures productivity with respect to a specific

Single-factor productivity (SFP) measures ratio of a specific output to a single input.

Multi-factor productivity (MFP) measures ratio of output to a set of key resources.

(H. Noori, R. Radford, 1995)

2.2 Work study

Figure 2.2 Work study

2.2.1 The basic procedure of work study

There are 8 basic steps in conducting a work study.

2.2.2 Work measurement

However, this project will deal with only time study.

2.2.3 Time study

2.2.3.1 Main steps in making a time study

The main steps in making a time study are as follows.

Choosing the job to be studied

The Time study equipments are: