Productivity Improvement Through Line Balancing and Layout On Shirt

Internship report at garment evolution (2014)
PRODUCTIVITY IMPROVEMENT THROUGH LINE

BALANCING AND LAYOUT ON SHIRT
PREPARED BY: TEGENE NEGASH
ID NO. 1824/03
MENTORS NAME: G/HIWOT ASFHA
SUBMMITION DATE: July 2014
Declaration
Bahir Dar University (EITEX) Page i Pre. By Tegene Negash 4th year GED
I declared that this internship report is submitted by me. I assure that the report contains
actual data and project I assigned to work on the intern ship stay. The content of the report
are my own and has not been submitted to any other university or institute.
Date ___________________________________________
Signature_______________________________________
Signature_______________________________________
Mentor Ins. G/Hiwot Asfha
Student TegeneNegash
Bahir Dar University (EITEX) Page ii Pre. By Tegene Negash 4th year GED
Table of Content
Declaration.............................................................................................................................................i
Acknowledgement................................................................................................................................5
Executive Summary...............................................................................................................................6
CHAPTER ONE...................................................................................................................................7
HISTORICAL BACKGROUND OF THE COMPANY.......................................................................7
1.1 Introduction...........................................................................................................................7
1.1.1Missionof the Company........................................................................................................7
1.1.2 Visions of the Company........................................................................................................7
1.2Organizational Chart....................................................................................................................8
1.3Material Flow Process of Garment Evolution Factory...............................................................10
Design/Sketch.............................................................................................................................10
Pattern Marking..........................................................................................................................11
Sample Making............................................................................................................................11
Production Pattern......................................................................................................................11
Grading........................................................................................................................................11
Marker Making............................................................................................................................11
Fabric Spreading..........................................................................................................................11
Cutting.........................................................................................................................................11
Bundling......................................................................................................................................12
Sewing.........................................................................................................................................12
Inspection....................................................................................................................................12
Ironing.........................................................................................................................................12
Packing........................................................................................................................................12
Ware House.................................................................................................................................13
1.4 Machineries/Infrastructure.......................................................................................................13
1.5 Product Variety in Garment Evolution Factory..........................................................................14
1.6 DEPARTEMENT DETAIL..............................................................................................................15
1.6.1 Material Storage Section....................................................................................................15

1.6.2 Finished Material Store (Ware House)...............................................................................16
Receivingof Material...................................................................................................................16
1.6.3 Main Problemin Store........................................................................................................16
1.6.4 Recommendation of the Section in the Company..............................................................17
Store............................................................................................................................................17
1.7 Cutting Room.............................................................................................................................17
1.7.1CuttingDepartment Floor....................................................................................................17
1.7.2 Capacity of Cutting Section.................................................................................................17
1.7.3Main Problemin the Cutting Room......................................................................................18
1.7.4Recommendation................................................................................................................18
1.8Production Room.......................................................................................................................18
1.8.1 Sewing Section...................................................................................................................18
1.8.2 Quality Control...................................................................................................................19
1.8.3 Material Handling System..................................................................................................19
1.8.4Capacityof Sewing Room.....................................................................................................19
1.8.5 Probleminthe Production Room.........................................................................................19
1.8.6Recommendation................................................................................................................20
1.9Strengthofthe Company.............................................................................................................20
1.10Weaknessofthe Company........................................................................................................20
CHAPTER 2..........................................................................................................................................21
PROJECT TITLE.....................................................................................................................................21
PRODUCTIVITYIMPROVEMENT THROUGH LINE BALANCING AND LAYOUT ON SHIRT........................21
Abstract...............................................................................................................................................21
2.1 Introduction..............................................................................................................................21
2.2Statementofthe Problem...........................................................................................................21
2.3 Objective...................................................................................................................................22
2.3.1General Objective................................................................................................................22
2.3.2 Specific Objective...............................................................................................................22
2.4 Scope of the Study....................................................................................................................22
2.5Limitationofthe Project..............................................................................................................22
2.6 Significance of the Project.........................................................................................................22

2.7Literature Review.......................................................................................................................23
2.8 Methodology.............................................................................................................................24
2.8.2 Secondary Data..................................................................................................................24
2.8.3Data Analysesand Calculations............................................................................................24
Before Balancingthe Lines...........................................................................................................24
2.8.4 Operation Break Down Before Changing Line Layout.........................................................28
2.8.5 Line Layout before Changing..............................................................................................30
After Balancingthe Line...............................................................................................................31
2.8.6 Operation Break Down After Changing the Line Layout.....................................................34
2.9 Equipment and Material...........................................................................................................36
2.1o Reccomendation ....................................................................................................................37
2.11 Conclusions.............................................................................................................................38
CHAPTER 3..........................................................................................................................................39
3. BENEFITS FROM INTERNESHIP EXPERIENCE....................................................................................39
3.1 Internship Experience................................................................................................................39
3.2 Benefits I Gained From Internships...........................................................................................39
3.3 Practical Skill..............................................................................................................................39
3.4 Theoretical Knowledge.............................................................................................................39
3.5 Problem Solving........................................................................................................................40
3.6 Team Playing Skill....................................................................................................................40
3.7 Leader Ship Skill........................................................................................................................40
3.8 Work Ethics Issues and Industrial Psychology...........................................................................40
3.9 Internship Communication Skill.................................................................................................41
References..........................................................................................................................................41
List of tables
Table 1.1 organizational structure of the company…………………………………………………………….9
Table 1.2 machineries and infrastructure…………………………………………………………………………..13
Table 2.1 time study sheet before balancing the line…………………………………………………………25
Table 2.2 time study sheet after balancing the line…………………………………………………………….31
List of figures
Figure 1.1 different product variety…………………………………………………………………………………..15
Figure 2.1 operation break down before changing the layout………………………………29
Figure 2.2 line layout before changing………………………………………………………30
Figure 2.3 operation break down after changing the layout…………………………………35
Figure 2.4 new layout………………………………………………………………………..36
List of abbreviation
 Sl.no-serial number
 GEF-Garment Evolution Factory
 SNLS-Single Needle Lock Stitch
 DNLS-Double Needle Lock Stitch
 OL-Over Lock
 Pcs-pieces
 SAM-Standard Allowance Minute
 Min-minute
 PLC-private limited company
Acknowledgement
I would like to thank Sisay for this time and advice during the cause of this project. I would
also like to thank Meseret for their patience and support throughout the process. I would also
thank my adviser G/Hiwot advice during the project. I would like to thank my parents and
family for providing me with the best of opportunities and having faith in my abilities.
Finally, I wish to thank all my friends who have made my stay away from home a happy
experience.
Executive Summary
This final report covers my internship practice which I have been working in garment
evolution factory from March, 2014 up toJune 2014. For the past three months. This report
has different section and also discusses about this departments. The report covers three
chapters, chapter one discusses about the historical background of the company, customers,
products, location, mission, vision. Organizational structure and also discusses about main
departments of this company. Chapter two discusses about project works on productivity
improvement through line balancing and line layout in garment evolution factory. In this title
discusses about objective of the project, statement of the problem, scope of the project,
significance of the project, limitation on the project, methodology, result and discussion and
finally conclude this project. Chapter three discusses about internship experience.
CHAPTER ONE
HISTORICAL BACKGROUND OF THE COMPANY
1.1 Introduction
Garment Evolution is one of the private industries available in Ethiopia. It is found in Addis
Ababa around Gorge area. Garment evolution is established in 19/2/1997 in Ethiopian
calendar. That means it established before nine years. The initial capital of this company is
around 3.4 million Ethiopian birr.
1.1.1Missionof the Company
Garment Evolution is the industries that producemany types of product. These products are
shared into their own shopping center. These companies are imports and they have some
exports. Therefore the missions of this company are:
 To increase customer satisfaction

 To produce good quality of products for customer
 To produce timely fashionable product
 To satisfy need of market
 To produce variety of product
1.1.2 Visions of the Company
This company is the companies that are in the stage of developing. In company different
types of products are produced. And also these companies are used by manually. It is not
have computerized system. Therefore, these visions of this company are:
 To use the computerized method

 To compute the international market
 To became overall leading garment factory
 To apply modern technology
 Export to foreign market
 To produce raw material by own factory
1.2Organizational Chart
Organization chart is the indication of how to information flow from head of administrative
to operators.
Owner
Factory manager
Marketing Assistant manager Finance
Production manager
Line super visor
Operators
Table 1.1 organization chart

Sl.no Position Responsibility

1 Owner  Raw material searching
 Design selection
 Design on financial issues
 Foreign market searching
2 Factory manager
 Decide on employee based problems
 To monitor daily production rate
 Guest reception try to banner number of operator to
production capacity with discuss to production
manager
3 Assistant  Transfer order from customer/owner into production
manager manager
 Take daily attendance of employee
 To approve order to finished product
 To monitor warehouse
4 Finance  Weekly calculate general output and input of product
 Employee salary payment
 Record every information
5 Marketing  Market searching

 Audit outlets/shop
6 Production  Sample making
manager  Take decision about quality requirement
 In production process
 Keep required design
 Decide the balance of operator to production capacity
 Organize cutting and sewing department
 Decide on the of production
7 Super visors  Some extent quality checking
 Bundle transfer from operator from operator

 Monitoring operator
8 Operators  Sew the garment
1.3Material Flow Processof Garment Evolution Factory

Sample
Order Design/s Pattern Production
making
receiving ketch making pattern
Bundling/s Cutting Spreading Marker Grading/

orting making manual
Ware Shopping
Ironing Packing
Sewing Inspection house center
Design/Sketch
In the garment manufacturing the first step is designing the pattern. In this factory when the
order is received first prepare the designing/sketching. The designers also draw working
drawings along with the sketch.
Pattern Marking
Hard paper copy of each component of the garment of exact dimensions of each component
is called pattern. This pattern having seam allowances, pleats, darts and etc. in the GEF
pattern can be done by manually. It is not using computerized method.
Sample Making
In this factory there is no having sampling section. But using the sample garment we produce
different pattern.
Production Pattern
The production pattern is one which will be used for huge production of garments. It includes
style number, style name, size, grain line, etc.
Grading
The purpose of grading is to create patterns in different standard sizes. Pattern sizes can be
XXL, XL, L, M, S and 8,10,12,14. In the GEF grading is not applicable.
Marker Making
Marker is a thin paper which contains all the components for different sizes for particular
styles of garments. In this factory mostly use either way marker making. It is not knowledge
about these marker modes. But using experience to use these marker modes.
Fabric Spreading
To spread the fabrics on table properly for cutting.
Cutting
To cut fabric according to marker dimensions.
Bundling
Sort out the fabric according to size and for each size make in individual bundles. After cut
the entire fabric lay, all the garments components in stack form is sorted out as per size and
color. To avoid mistake in sorting to use code number on each component.
Sewing
To assemble a full garment. It is the most important section in this industry. Sewing section
of different types is arranged as a vertical line to assemble the garments. Sequence of types
of sewing machine arrangement depends on sequence of assembling operations.
Inspection
Should be approved as initial sample. Each and every garment after sewing passes through
the line inspection table/point, where the garments are thoroughly and carefully checked to
detect/find any defect if present in the garment. For example, the defect may be variation of
measurement, sewing defect, fabric defects and etc. if the defect is possible to overcome,
then the garment is sent to the respective person for correction. If the defect is not correction
able, then the garment is separated as wastage.
Ironing
After passing through the inspection table, each garment is normally ironed/pressed to
remove unwanted crease and to improve the smoothness, so that the garments looks nice to
the customer. Folding of the garment is also done here for poly packing of the garments as
per required dimensions.
Packing
After ironing the garments are poly packed, dozen-wise, color wise, size ratio wise, bundled
and packed in the plastic.
Ware House
After packing the garment, the packed garment is come to the warehouses. After this all
process the garments are share to their own shopping center.
1.4 Machineries/Infrastructure
Table 1.2 machineries/infrastructure
Sl.no Department Types of No. of Brand Remar

machine/infrastructu machine/infrastructu name k
re re
1 Cutting Straight knife 2 Eastman

Band knife 1
Binder/ribs machine 1
Spreading table 2 12×2.5
6×2.5
2 Inspection area Inspected table 3
3 Sewing section Shelf 3
SNLS 34 Juki 1-with

work aid
DNLS 2 Juki
Over lock 19 15-juki 1-with
4- work aid
pegasus
Cover stitch 24 Kansai 6-binder
1-work
aid
Button hole machine 2 Juki
Button attach 2 Juki
machine
Belt loop machine 1 Kansai
Binder/ribs making 4
machine
Bar tack machine 1 Juki
Feed of the arm 2 Juki
drilling 1
Embroidery machine 1
4 Final Inspected table 4
inspection area
5 Finishing/press Ironing machine 8
ing area
6 Packing area Packing table 3
7 Knitting Knitting machine 4
section
1.5 Product Varietyin Garment Evolution Factory

In the garment evolution over 200 types of garments are produced. In this factory there are
four lines. In the line one over 150 types of garments are produced. In the line two different
types of t-shirts are produced. In the line three different types of trousers are produced. In the
line four mostly the shirt product is produced. From this four lines line one are many types of
fabric are produced per day. The following pictures are show different products in garment
evolution factory.
Figure 1.1 product varieties.
1.6 Department detail

1.6.1 Material Storage Section
In this store floor there are available different types of woven and knitted fabric. And also
found non-woven material and other accessories. There are four main stores in the factory..
1.6.2 Finished Material Store (Ware House)
There are three warehouses in this factory. Those ware houses are:
 Adults product store

 Children product store
 School uniform products
The finished products are prepared in this store for the shopping center. In this factory the
warehouses are used.
Receivingof Material
The factory is manufacturing in cut make trim for import market. Materials are received from
foreign country and customer import.
Foreign country;
 India
Local customer;
 Alameda
 Adama textile factory
 Ayka Addis
1.6.3 Main Problemin Store
 There is no inspection of fabric rolls and accessories during receiving and

unloading of materials.
 The arrangement of the fabric
 Different fabric rolls are stored together without separation of fabric type or color.
 There is no specific place for particular fabric or customer they only stored
materials on open space gotten during unloading.
 Fabric rolls and accessories are stored together.
 There is no material handling systems for transportation they just use labor force
for transportation and arrangement of materials and less for storage.
 There is high dust accommodation fabric rolls and accessories
 There is no ventilation systems
 There is no compute for store keepers
1.6.4 Recommendation of the Section in the Company

Store
To increase productivity, there should be material handling systems for transportation,

loading and unloading purpose.
1.7 Cutting Room
In the GEF there are two cutting section/cutting table. This cutting section is used for woven
fabric and knitted fabric. The cutting floor is combined unit for designing, sampling,
spreading, cutting, ticketing and bundling
1.7.1CuttingDepartment Floor
Cutting is the most important department of garment evolution the productivity and quality
of the garment. Mostly depend on this department since it is the main supplier for the sewing
room. Cutting room is available in G+1 in this factory. It is the second section next to the raw
material store. In this two cutting section different types of product are cuts.
1.7.2 Capacity of Cutting Section
In the GEFper/day different types of fabric are cuts. In cutting section the capacity of cutting
department is (1100-1400) pieces per day.
1.7.3Main Problemin the Cutting Room
 There is no inspection for fabric roll

 Edge alignment when the fabric is spreading
 There is no enough temporary table in the cutting room
 No marker efficient
 In correct placement of wastage
 No handling equipment
1.7.4Recommendation in the section
Air conditioning, ventilation and window in the overall company should have to be
installed to increase the productivity of the company
Improve welfare facilities and worker motivation
Leaning, edging and end loss should be minimized by applying pin tables
Cleaning should have to before finished before spreading cutting is begin
1.8Production Room
In the production room, sewing room, finishing and packaging section are available.
1.8.1 Sewing Section

In the sewing room there are found four lines. Each for line is produce different types of
products. These products are different in types, styles and colors. In the sewing line operators
are sewing different components. For example: one operator can sew one component. Quality
control is performed at the end of the sewing line.
1.8.2 Quality Control
Quality control is done through the end line checkers. In the line the product is checked by
the supervisor (line supervisor). Each supervisor are checked the product randomly. But if
this garment can have error, it is back to the rework. At the station before moving to the next
operation in order to prevent damage at the source. End line checkers are responsible to
inspect the final garment for approval. Each line has their own end line checkers (quality
inspected table). When the problems happen the line it’s done by the line supervisors. When
there is a problem between operator and line supervisor it is come to the production manager
and this problem are solved by the production manager.
1.8.3 Material Handling System
In the GEF the material handling system that applied in the production area are mainly for
storage of cut pieces and to hold the bundles in the line when transfer from operator to
operator. And also the tables for sorting finished garment before transfer to packing room. In
this factory there are four lines. Each line is having racking that used for fabric stored. In
racking the cut pieces fabric are stored. In the sewing room different tables are available for
different purposes. Such as quality checkers table, ironing table, packing table, temporary
thread table and etc. quality checking tables that are placed after the trimming fabric is for
checking the quality of the garment produced in that line. After this there is ironing table for
pressing the garment. There are also tables packing at the station in order to hold garments to
be pack.
1.8.4CapacityofSewing Room
In the sewing room different types of fabric are produced. In this sewing room up to 5500
pieces are produced per week. That means to 916 garments are sewed.
1.8.5 Probleminthe Production Room
 There is no ventilation system in the GEF

 There is no independent finishing room
 There is no independent the sampling room
 Before starting the job, machine is not cleaned
 Operators are not maintain their machines simple maintenance like threading,
cleaning and oiling
 Shade variation of the garment, absenteeism, in correct pattern cutting, in line
sewing damage, operator skill and communication with super visors, super visors
problems.
 Line layout
 There is no efficient shelf available
 The table/rack size is not equal
1.8.6Recommendationin the section
GEF should have train supervisors, quality checkers, and operators to minimize
rework, to increase productivity to meets its customer due date
To create new layout
To cleaned the machine before starting the job
To prepare efficient shelf
1.9Strengthofthe Company
The strength of this GEF is that produced different types of fabric. In this industry fabric is
produced started from small/inside pant up to trouser are produced. This is used for
minimizing wastage and also used for competitiveness in national market.
1.10Weaknessofthe Company
Some weakness of garment evolution industry is:
Lack of technical person

Lack of proper promotional program
The work can be done by experience, which means there are not educated people
by this field.
CHAPTER 2
PROJECT TITLE
PRODUCTIVITYIMPROVEMENT THROUGH LINE

BALANCING AND LAYOUT ON SHIRT
Abstract
Line balancing means balancing the production line. Line balancing is to know how
tasks are to be assigned to workstations, so that the predetermined goal is achieved
minimization of the number of work stations and maximization of the production rate
are the most common goals. Poor layout design is determine as a major problem
contribution in small and medium industry. These particular problems thus affect the
productivity and the line efficiency as well. Throughout the study, the aim is to
proposed new layout to the related company to increase their productivity.
2.1 Introduction
This project is done on productivity improvement through line balancing and line layout in
GEF plc.in sewing room department. Most of garment industry is affected by line balancing
and line layout. This project discusses more on how to create new layout in GEF on shirt
style.
2.2Statementofthe Problem
Poor line balancing and line layout affects the productivity and line efficiency. The skill of
operator is not equal, the number of operator in that line is not equal, and absenteeism
problem. The product variety is also affected on productivity improvement. Thus we have to
give more attention to the sewing room especially on shirt line.
2.3 Objective
2.3.1General Objective
 To improve productivity
 To improve line layout
2.3.2 Specific Objective
 Regular material flow

 Utilize labor efficiently
 Utilize space efficiently
 Minimizing work station
 Maximum output at the desired time
2.4 Scopeofthe Study

This project is done on GEF that found in Addis Ababa Ethiopia. The project focuses only on
productivity improvement through line balancing and line layout in GEF. It is done specially on shirt
line.
2.5Limitationofthe Project
While doing the project there are some limitations. Those are lack of information from
related person/supervisors, and there is no written document about the line balancing and line
layout in this company.
2.6Significanceofthe Project
The significance of the project is that if all the principles of the project are applied correctly
in garment evolution factory. The following results arebeing shown;
 improve productivity by using line balancing

 create new line layout
 reduce fatigue
 reduce production time
 increase line efficiency
 Utilize space efficiently
2.7Literature Review
Line layout means placing of machines and center table (trolley with wheel) as per style
requirement. The main purpose of choosing a better layout is to reduce transportation time in
the line as much as possible. A stable/constant line is not a good idea if you produce multiple
products in a same line. A straight assembly line with center table at left side is good for a
product that has no preparatory work and individual operation SAM is nearby the pitch time.
Line balancing is defined as the process to minimize the imbalance between machines or
personnel while meeting a required output from line assembly. Line balancing is a technique
to solve problems occurred in assembly line. Is a technique to minimize imbalance between
workers and workloads in order to achieve required run rate. This can be done by equalizing
the amount of work in each station and assign the smallest number of workers in the
particular workstations. Here the job is divided into small portion called job element. The
aim is to maintain production at equal rate. Line balancing is leveling the work load across
all processes in a cell or value stream to remove bottle neck and excess capacity results in
waiting and absorption of fixed costs. It is the allocation of sewing machine, according to
style and design of the garments we have to produce. It is done to increasing productivity.
Importance of line balancing is:
 Line balancing helps to know about new machine required for new style
 It becomes easier to distribute particular job to each operator
 It becomes possible to deliver goods at right time at the agreed quality for list cost.
 Good line balancing increase the rate of production

 Line balancing helps to compare the required machinery with the existing one and
compare balance
 It also helps in the determination of labor requirement
 Good balancing reduces production time
2.8Methodology
Data can be collected in two methods. Primary and Secondary data2.8.1 Primary Data
The information can be gain by asking the related person, that means the supervisor and
production manager. And also to use by observing the data to examine:
 Interview
 Observation
2.8.2 Secondary Data
I record data that have been stored in the sewing section to analyze depending upon the
references, internet access and document of the company.
EQUATIONS;
Standard time=basic time × allowances (%)
Target = total man power per line× total working minutes÷ SAM ×100
Labor productivity = total number of output per day per line÷ number of worker
worked
Machine productivity = total number of output per day per line ÷number of machine
used
Line efficiency = total output per day per line × SAM ÷total number of man power per
line × total working minutes×100
2.8.3Data Analysesand Calculations

Before Balancingthe Lines
Time study sheet is attached showing the different types of machines used, number of
operators and helpers, basic and standard pitch time and capacity per hour.
Total output per day= 227

Total man power per line = 25
Working time = 470min
SAM =33.4
Target/hour = 29
Labor productivity = 9.16
Machine productivity = 12.6
Line efficiency =63.5%
Observation before balancing the line has been reflected as labor and machine productivity is
9.16 and 12.6 respectively, and line efficiency is 63.5%.
Table 2.1Time study sheet showing total operator and helper with standard pitch time and
capacity per hour
Sl.n Process Oper Help Machin Basic Allowa Standar Capacity

o Name ator er e type time nces d /hour
Time
1 Preparatio 1 Ironing 1.14 20% 1.3 46
n of cuff machine
and collar
with
interlinin
g
2 Preparatio 2 SNLS 1.28 20% 1.53 39
n off cuff
stitching
3 Cuff top 1 SNLS 0.7 20% 0.84 71
stitch
4 Stitch 1 SNLS 1.7 20% 2.04 30

collar
band
5 Attach 1 SNLS 1.24 20% 1.48 41
collar
band with
collar
stand
6 Front 1 Ironing 1.19 20% 1.428 42
placket Machin
preparatio e
n
7 Placket 1 SNLS 0.87 20% 1.04 57
attaching
8 Collar 1 1.39 20% 1.67 72
and cuff
folding
n of Machin
pocket e
folding
and
ironing
n of cuff machine
and collar
folding
ironing
11 Yoke 1 SNLS 0.85 20% 1.02 59
attachmen
t
12 Sleeve 1 SNLS 0.71 20% 0.85 70
placket
attaching
13 Pocket 1 SNLS 1.07 20% 1.28 47
attach
with front
panel
14 Shoulder 1 SNLS 1.615 20% 1.938 31
attaching
15 Sleeve 1 OL 1.23 20% 1.47 41
and side
seam
attaching
16 Cuff 2 SNLS 2.58 20% 3.09 20
attaching
with body
17 Collar 2 SNLS 2.38 20% 2.85 21
attach
with body
18 Bottom 1 SNLS 1.29 20% 1.548 39
hemming
19 Trimmer 2 scissor 2.465 20% 2.95 21
20 Button 1 Button 1.24 20% 1.48 41

hole hole
attach
21 Button 1 Button 1.25 20% 1.5 40
attach attach
TOTAL 17 6 33.4
2.8.4 Operation Break Down Before Changing Line Layout

Figure 2.1 operation break down of shirt before changing the layout.
2.8.5 Line Layoutbefore Changing

Ironing table × X X X X X X X X
used for fusing
1 2
Cuff Cuff Cuff Button
X X X X X Botto X X X
stitching stitchin top attach
m
g stitch hem
ming

Col Collar Yo Fr Po S. Shou Side Cuff Cuff Coll Colla Bu
lar band ke on ck pla lder and attac atta ar r tto
ba with att t et cke attac sleev h ch atta atta n
nd stand ac pl t h e ch ch hol
h ac e
X
1-quality
Cuff topinspected tablewe produce 71 pieces, but preparation of collar band is produce 30 pieces per
stitch per hour
hour. Totable
2-Ironing balance thisfor
used two operation,
preparation Free space -
Figure 2.2 line layout before changing
60min= 71pcs
?= 60pcs
60min × 60pcs ÷ 71= 50.7min
60min – 50.7min = 9.3 min
1 pcs = 0.84min
? = 9.3min
9.3min × 1pcs ÷ 0.84min = 11pieces
Therefore the operator on the cuff is produce 60 pieces per hour and we can also sew 11
pieces of collar band. Because the operator on the collar band is sew only 30 pieces per hour.
Shoulder attachment is produce 31 pieces per hour. But, yoke attaching is produce 59 pieces
per hour. Therefore to balance this two operation,
60min = 59 pieces
? = 40 pieces
60min × 40 pieces ÷ 59 pieces = 40.6min
60min – 40.6min = 19.4min
1pieces = 1.938min
? = 19.4min
1pieces × 19.4min ÷ 1.938min = 10pieces
Therefore, the operator on the yoke is share 10 pieces from shoulder.
After Balancingthe Line
Table 2.2Proposed capacity per hour for each process showing proposed man power
Sl.no Process SAM Capacity/hou Actual Proposed

name r man man
Power power
1 Preparation 1.3 46 1 1
of collar
and cuff
with
interlining
of pocket,
cuff and
collar
folding
ironing
of placket
with
interlining
4 Placket 1.04 57 1 1
attaching
5 Pocket 1.28 48 1 1
attach with
left panel
6 Yoke 1.02 59 1 1
attachment
7 Shoulder 1.938 29 1 1
attach
8 Attach 0.85 70 1 1
sleeve
placket
9 Sleeve and 1.47 41 1 1
side seam
of cuff
stitching
11 Cuff top 0.84 71 1 1
stitch
12 Cuff 3.09 20 2 2
attaching
with sleeve
13 Bottom run 1.548 39 1 1
stitch
14 Collar band 2.04 30 1 1

preparation
15 Attach 1.48 41 1 1
collar band
with collar
stand
16 Attach 2.85 21 2 2
collar with
body
17 Trimming 2.958 20 2 2
Button hole 1.48 41 1 1
18 attachment
11111 Button 1.54 39 1 1
1 attach
TOTAL 33.4 25 23
Target/hour =33.4min = 1pieces
60min =?
60min × 1pieces ÷ 33.4min = 1.7pieces
One operator per hour can produce 1.7 pieces
Target/hour = 23×1.7 = 39pieces
Total output/day = 39pieces × 470min ÷60min = 305pieces
Total man power per line = 23
Working time = 470min
SAM = 33.4min
Labor productivity = 305÷23= 13.2
Machine productivity = 305÷17= 17.9

Line efficiency = (305×33.4)÷(470×23)×100= 94.2%
2.8.6 Operation Break Down After Changing the Line Layout

Figure 2.3 operation break down of shirt after changing the layout
2.8.7New Machine layout
X X X X X X Ironing table used Ironing table for using

for fusing preparation
1
Front
X X X X Po Slee Cu Cuff Colla Collar Butto Button
plac cke ve ff top r band + n hole attach
ket t plac sti stitc band collar
ket tc h stand
h
X X X X Yoke Shou Side Botto Cuff Cuff Colla Collar X

attac lder and m attac attac r attach
h attac sleev attach h h atta
h e ch
1-quality inspection table
-rack/table
x
-free space
Figure 2.4 new line layout
2.9 Equipmentand Material

 Stop watch
 Short note
 Pen
 Ruler
 paper
2.10 Recommendation
The factory should use tools that can be able to eliminate barriers that are exists as bottle necks
.to overcome those problems the factory can be invest on core solutions .this core solutions are
listed below.
 Using cad systems for accurate and precise patterns

 By hiring skilled operators
 By improving good work station and line layout
 By cared out pre- production systems: design and sampling
 By establishing planed and organized maintenance
 There is no sequencing and scheduling
 Give training fore line super visors and quality checkers
 Air conditioning, ventilation and window in the overall company should have to be
installed to increase the productivity of the company
 Improve welfare facilities and worker motivation
 Leaning, edging and end loss should be minimized by applying pin tables
 Cleaning should care out before starting the job.
 Installing good ventilation system
2.11Conclusions
Good line balancing and line layout are very important to improve productivity. And also
plays a vital role on the side of customer satisfaction, increase production, reduce fatigue,
reduce transportation, reduce material handling and etc. Before improving line balancing and
changing line layout output per day is 227 Pisces.But after the improvement of line balancing
and proposed new layoutoutput per day reaches up to 305 pieces are produced
Generally I conclude that better line balancing and proposing good line layout are very
crucial for one garment factory in different aspects: they are important for the establishment
of smooth material flow, reduction of non-productive times and reductions of material
handling processes.
CHAPTER 3
3. BENEFITS FROM INTERNESHIP EXPERIENCE
3.1 Internship Experience

When I am to do the internship we get different experience. We can develop my professional
interest, and valuable work experience. When I am finding a feel that manufacturing
company is good and to apply the knowledge I have learned in the class room to the practical
way.
3.2Benefits I Gained FromInternships

Internship helps to me to get experience in my field of study. During internship we to know
more about my field. The benefits of internship is
 Interpersonal communication skill

 Entrepreneurship skill
 Practical skill
 Solving problem in industrial
 Team playing skill
3.3Practical Skill
During internship program benefited me to have practical skill. Example, how to spread the
fabric, how to cut the fabric by using different machine in garment industry is performed. I
have learned this theoretically and I experienced this practically in internship program.
3.4Theoretical Knowledge
After completed may internship program I am able to upgrade my theoretical knowledge.

When I was learned in the class it will be a theory. But after I had completed this internship
program. I have checked that those I have learned in theory are real and are found in the
practical like sewing room.
3.5Problem Solving
After completed this internship program makes me to identify the problems and how to solve
this problem if it is happened. My internship gave the opportunities to apply some problem
solving skill. Learned in the class room to real world activity within the industry.
3.6Team Playing Skill

During internship I enable me to develop my team playing skill.
3.7Leader Ship Skill

Doing an internship made me to build my confidence and knowledge on leader ship skill.
3.8Work Ethics Issuesand Industrial Psychology

An internship made me to have a strong willing to work. With strong willing to work ethic I
am always committed to the work and will stay until the task is complete. The internship
made me to avoid personal issues on work time and to keep my positive attitude and I
remember that I have smaller tasks to handle prior to my large, more important ones. I also
develop the following things after my internship program,
 Punctuality and accountability to a given task

 Build motivation and work ethics
 Transparency in working once duty etc.
Internship enables me to act as advisers, professionals, provide recommendations for how to

resolve conflicts, increase worker productivity, and improve employee morale among other
thing
3.9Internship Communication Skill

At the end of internship program I am able to identify how employee behaviors and attitudes
can be improved through hiring practices, training programs, and feedback and management
systems physiologists also help organizations.
References
Shuang, L.X. wang and M.lixin. 1997. Optimization of assembly line based on work
studyCooklin, G. 1991. Introduction to clothing manufacturing
Glock, R.E and kunz, G.I. 1995. Apparel manufacturing sewn product analysis
Kursun S.2009. Simulation of production line balancing in apparel manufacturing

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Internship report at garment evolution (2014)

PRODUCTIVITY IMPROVEMENT THROUGH LINE

MENTORS NAME: G/HIWOT ASFHA

SUBMMITION DATE: July 2014

Mentor Ins. G/Hiwot Asfha

1.6.1 Material Storage Section....................................................................................................15

2.6 Significance of the Project.........................................................................................................22

Table 1.1 organizational structure of the company…………………………………………………………….9

Table 1.2 machineries and infrastructure…………………………………………………………………………..13

Table 2.1 time study sheet before balancing the line…………………………………………………………25

Table 2.2 time study sheet after balancing the line…………………………………………………………….31

Figure 1.1 different product variety…………………………………………………………………………………..15

Figure 2.1 operation break down before changing the layout………………………………29

Figure 2.2 line layout before changing………………………………………………………30

Figure 2.3 operation break down after changing the layout…………………………………35

Figure 2.4 new layout………………………………………………………………………..36

HISTORICAL BACKGROUND OF THE COMPANY

1.1.1Missionof the Company

 To increase customer satisfaction

1.1.2 Visions of the Company

 To use the computerized method

Marketing Assistant manager Finance

Line super visor

Table 1.1 organization chart

Sl.no Position Responsibility

5 Marketing  Market searching

 Bundle transfer from operator from operator

1.3Material Flow Processof Garment Evolution Factory

Bundling/s Cutting Spreading Marker Grading/

To spread the fabrics on table properly for cutting.

To cut fabric according to marker dimensions.

Sl.no Department Types of No. of Brand Remar

1 Cutting Straight knife 2 Eastman

SNLS 34 Juki 1-with

1.5 Product Varietyin Garment Evolution Factory

Figure 1.1 product varieties.

1.6 Department detail

1.6.2 Finished Material Store (Ware House)

 Adults product store

1.6.3 Main Problemin Store

 There is no inspection of fabric rolls and accessories during receiving and

1.6.4 Recommendation of the Section in the Company

To increase productivity, there should be material handling systems for transportation,

1.7 Cutting Room

1.7.2 Capacity of Cutting Section

1.7.3Main Problemin the Cutting Room

 There is no inspection for fabric roll

1.7.4Recommendation in the section

1.8.1 Sewing Section

1.8.2 Quality Control

1.8.3 Material Handling System

1.8.5 Probleminthe Production Room

 There is no ventilation system in the GEF

1.8.6Recommendationin the section

Some weakness of garment evolution industry is:

Lack of technical person

PRODUCTIVITYIMPROVEMENT THROUGH LINE

2.3.2 Specific Objective

 Regular material flow

2.4 Scopeofthe Study

 improve productivity by using line balancing

Importance of line balancing is: