3idel Time

Internship project @jay jay textile plc
BAHIR DAR UNIVERSITY
ETHIOPIAN INSTITUTE OF TEXTILE AND FASHION

TECHNOLOGY
HOSTING COMPANY: - JAY JAY TEXTILE PLC.
PROJECT TITLE: - INVESTIGATION OF IDLE TIME IN

SEWING SECTION
BY: ENDALE BAYEW
ID: BDU0904101UR
ACADAMIC ADIVISOR: -MR. SOLOMON TILAHUN
SUBMITED TO:-INDUSTRY LINKAGE OFFICE
18 Feb, 2021
BAHIR DAR, ETHIOPIA

DECLARATION
I am Endale Bayew, a fourth year garment engineer student of Bahir Dar university
in Ethiopian institute of textile and fashion technology taking an internship for about
three months at jay jay textile plc. and I want to certify that this is my original work
complied according to the internship report writing guideline given by the Institute-
Industry Linkage office of the Institute
As a student my work is not copy paste, and I certify that this work is only concerned
in my knowledge.
Solomon Tilahun ___________ ___________
Name of academic advisor Signature Date
Endale Bayew __________ ___________
Name of the student Signature Date
i
ACKNOWLEDGEMENT
Before and above all I would like to thanks “GOD” for making me healthy and give
strength to finish this project. Secondly I just want to thank may academic adviser Mr.
Solomon.
Last but not least, I would like to thanks my friends for their support and suggestion
to this project work
ii
EXECUTIVE SUMMARY
Internship is a certified way to gain relevant knowledge, skill and experience while
establishing important connection in the field. In our internship in Jay Jay textile plc.
For the specified period of time, we got the required experience and knowledge and in
this report I have tried to list the overall aspects of the internship experience
In the first part of the project, it provides information about the hosting company’s
brief history and overall organizational structure. Also in this chapter I will try to
present their customers, and then comes to mention the raw material sourcing regions
and also the working procedure of each department.
In the second part the project work, it describes mainly the particular project I have
executed in the company. It starts by describing the title, objective and significance of
the study. Then after it continues to tell the data collection, presentation and analysis
methods to accomplish the project work. Also this part contains recommendation and
solution. .
iii
Table of content
DECLARATION ............................................................................................................ i
ACKNOWLEDGEMENT .............................................................................................ii
EXECUTIVE SUMMARY ..........................................................................................iii
LIST OF FIGURE........................................................................................................vii
LIST OF ACRONYMS ..............................................................................................viii
1. Introduction ........................................................................................................... - 1 -
1.1 Mission of the company ............................................................................. - 2 -

1.2. Vision the company.................................................................................... - 2 -
1.3. Value of the company ................................................................................ - 2 -
1.4. Raw materials and its suppliers .................................................................. - 2 -
1.5. Material Flow Process of Garment Factory .................................................... 5
1.6. Department Detail ........................................................................................... 7
1.6.1. Fabric Store .............................................................................................. 7
1.6.2. Accessories Room .................................................................................... 8
1.6.3. Sample making....................................................................................... 10
1.6.4. Spreading ............................................................................................... 10
1.6.5. Cutting Department ................................................................................ 11
1.6.6. Embroidery and printing department ..................................................... 13
1.6.7. Production line ....................................................................................... 14
1.6.8. Packaging ............................................................................................... 18
1.6.9. AQL (Acceptable Quality Level) process.............................................. 18
1.6.10. FGS process (Finished Goods Store) ................................................. 19
1.7. Organizational Structure ............................................................................... 20
1.8. Main product of the company ....................................................................... 23
1.9. Customer of the company ............................................................................. 24
CHAPTR TWO............................................................................................................ 25
2. INVESTIGATION OF IDLE TIME IN SEWING SECTION ............................. 25
2.1 Introduction ................................................................................................... 25

2.2. Problem statement ......................................................................................... 26
2.3. Objectives ...................................................................................................... 27
2.3.1. General objectives .................................................................................. 27
iv
2.3.2. Specific objectives ................................................................................. 27

2.4. Scope of the project ....................................................................................... 27
2.5. Challenges to do this project ......................................................................... 27
2.6. Significance of the project............................................................................. 28
2.7. Literature review ........................................................................................... 28
2.8. Methodology ................................................................................................. 33
2.8.1. Data collection ....................................................................................... 33
2.8.2. Primary Data Collection ........................................................................ 33
2.8.3. Interview ................................................................................................ 34
2.8.4. Observation ............................................................................................ 34
2.8.5. Secondary Data Collection .................................................................... 34
2.9. Data presentation and analysis ...................................................................... 34
2.9.1. Data presentation ................................................................................... 34
2.9.2. Data analysis .......................................................................................... 39
2.10. Result and discussion................................................................................. 44
2.11. Conclusion and Recommendation ............................................................. 44
2.11.1. Conclusion.......................................................................................... 44
2.11.2. Recommendation ................................................................................ 45
3. OVERALL BENEFITES GAINED FROM INTERNSHIP ................................ 46
3.1. Internship experience .................................................................................... 46

3.2. Benefit of internships .................................................................................... 46
1. Practical skill ............................................................................................................ 46
2. Problem solving skill ............................................................................................... 47
3. Personal communication skill and approach with others ......................................... 47
4. Work ethics and industry psychology ...................................................................... 48
5. Team work skill ....................................................................................................... 48
6. Being familiar for Entrepreneur-ship skill ............................................................... 48
REFERENCE ............................................................................................................... 49
v
LIST OF TABLE
Table 1. Raw material and its supplier .................................................................................. - 3 -
Table 2. Daily production presentation .................................................................................. 35
Table 3. Daily recorded idle time by different reasons .......................................................... 37
Table 4. Daily recorded problems in sewing section sewing machine .................................... 39
vi
LIST OF FIGURE
Figure 1 Company profile ......................................................................................... - 1 -
Figure 2 Material flow chart ......................................................................................... 5
Figure 3 Fabric store ..................................................................................................... 7
Figure 4 Fabric inspection machine .............................................................................. 8
Figure 5 accessory store ................................................................................................ 8
Figure 6 Sample making flow chart ............................................................................. 10
Figure 7 Spreading table ............................................................................................. 10
Figure 8 cutting room................................................................................................... 11
Figure 9 Straight knife ................................................................................................. 12
Figure 10 End cutter .................................................................................................... 12
Figure 11 Binding cutter .............................................................................................. 12
Figure 12 Printing machine ......................................................................................... 13
Figure 13 Embroidery machine ................................................................................... 13
Figure 14 Sewing room ............................................................................................... 14
Figure 15 Production process flow chart .................................................................... 15
Figure 16 Flat lock machine ........................................................................................ 16
Figure 17 over lock machine ....................................................................................... 16
Figure 18 Single needle lock stich ............................................................................... 17
Figure 19 Snap fastener ............................................................................................... 17
Figure 20 Ironing machine .......................................................................................... 17
Figure 21 Metal detector machine ............................................................................... 18
Figure 22 Organizational structure flow chart ........................................................... 20
Figure 23 product of the company ............................................................................... 23
Figure 24 Methodology flow chart .............................................................................. 33
Figure 25 T-shirt graphic sample ................................................................................ 35
Figure 26 Idle time existence indicator chart .............................................................. 38
Figure 27 Data analysis graph .................................................................................... 43
Figure 28 Personal involvement in the company ........................................................ 47
vii
LIST OF ACRONYMS
HR ------------------------------------------- Human resource
SAH ------------------------------------- Standard available minute
M/c ------------------------------------------ -Machine
Plc. ------------------------------------------ Private limited company
FGS ----------------------------------------- Finished goods store
M -------------------------------------------- Month
NB ------------------------------------------- New born
TPDM --------------------------------------- Technical product development manager
IE ---------------------------------------------- Industrial engineer
GCI --------------------------------------------Gerber children’s wear
H&M ------------------------------------------Hennes and muritz
TCP -------------------------------------------- The clothes place
AQL ------------------------------------------- Acceptable quality level
SAM ------------------------------------------- Standard allowed minute
viii
CHAPTER ONE
COMPANY BACK GROUNED
1. Introduction
Figure 1 Company profile
Jay Jay textile plc was establishing in Ethiopia in October 18/10/2013 by Indian
investor with an authorized capital of birr 40 million owned by Sri Kumar
balasuprayam. The area of the factory is 2700 square meter. The Company has gained
an investment license from the government (EIP-IP/022668/06) for producing
children wear. The main products of the company are children’s garment. The
company planting its mill in India, Srilanka, Bangladesh, and Ethiopia and exporting
its products for GCI, TCP, Carter’s, H&M and garn buyers.
Initially the total power of the company was 350 and the work force is relatively 90%
young female with basic knowledge skill is to write and read, to operate and maintain
the installed machine and equipment. The company starts its production process by
giving training in one training room (block 9) and the training takes maximum 21
days and minimum 16 days. Since the workers were finished their training program,
they will directly transfer to the production line.
-1- Bahir Dar university

The current numbers of workers totally reached 7545 from these workers 55 are
foreign experts & 95% are young girls whereas 5% are men. From 95% of young girls
92% are operators on 75 production line but the remaining percent young girls and
3% of men are staff workers, in shifts daily work of 8 hours.
1.1 Mission of the company

In Jay Jay textile Plc. to be the best benchmark for the baby wears manufacturing
industry. Therefore, the missions of this company are:
 The most desired workplace for employers

 The most reliable baby wears manufacture in quality and delivery.
 Among the top 3 prefer suppliers for all our buyers key strategies goals
 Achieve 100% on time delivery/customer satisfaction
 Most reliable baby wear manufacturer for the EU &USA markets
 Innovator of leaner systems by continually eliminating waste.
1.2.Vision the company

 To be most trusted baby wear manufacturer in the world
 The vision of Jay Jay textiles plc. Is to be the best baby wear manufacturer in
the world.
1.3. Value of the company

To their employers: to provide the best work environment training and opportunity for
self-development where they can reach their maximum potential
To their customers: to be truthful and transparent in all their dealings and provide
products that consistently meets with their costumer expectations
To their suppliers: to be fair in all transactions and pay dues on time for products and
services received
To their environment: to actively contribute to protect their environment by reducing

the impact crated by their process
1.4.Raw materials and its suppliers

The company purchases its raw materials mainly from abroad with some of the
accessory are from domestic companies such as labels and tags. All fabric types are
from foreign companies only most commonly from India and Srilanka.
Table 1. Raw material and its supplier
Types of raw materials Suppliers
Organic and in organic fabric Srilanka and India
Button Thailand
Hanger India
Wrap band India
Thread cone Dubai
Size sticker India
Clear round India
Header card India
RFID sticker Hong Kong
Embroidery thread India
Poly bag India
Zipper India
Care labels Be connected
Heat seal Dubai
Company quality fabric inspection system

The company uses 4-point system for fabric inspection. Faults are scored with penalty
point of 1, 2, 3&4 according to the size and significance.
3” or less = 1 point
>3” but not >6” = 2 point
>6” but not>9” = 3 point
>9” = 4 point
Amount to Inspect: Inspect at least 10%of the total rolls in the shipment.

Selection of rolls: Select at least one roll of each color, if more than one roll per color
must be inspected then select the number of additional per color received.
In case quality was not approved for 10%inspection control will precede
for100%quantity and reported to managerial.

1.5.Material Flow Process of Garment Factory
Marker
Order Sample Productio Grading/c making
receiving making n pattern omputeriz
ed
Sewing Printing/ Sorting/

Cutting Spreading
embroider bundling
y
Inspection Ironing Packaging Warehouse Dispatch
Figure 2 Material flow chart
order receiving: the company takes orders from the customer by specification sheet of
that particular garment so it goes to sample making process to approve if they meet the
customer specifications or not.
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 NB, 3M, 6M, 12M, 18M, etc.
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.
𝒂𝒓𝒆𝒂 𝒐𝒇 𝒎𝒂𝒓𝒌𝒆𝒓 𝒖𝒔𝒆𝒅 𝒇𝒐𝒓 𝒈𝒂𝒓𝒎𝒆𝒏𝒕𝒔
Marker efficiency(%) = * 100
𝒕𝒐𝒕𝒂𝒍 𝒎𝒂𝒓𝒌𝒆𝒓 𝒂𝒓𝒆𝒂
Fabric Spreading: To spread the fabrics on table properly for cutting.
Cutting: To cut fabric according to marker dimensions.
5 Bahir Dar university

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.

1.6.Department Detail
1.6.1. Fabric Store
Figure 3 Fabric store
Fabric store process
Receiving fabric roll: fabrics are supplied in roll package. Once these rolls of fabric are
delivered the store in-charge receives the incoming consignment.
In-house Inventory: Once these rolls are received, the store in-charge matches the
packing list of the fabric consignment with the original quantity of the fabric rolls (i.e.
fabric width, fabric length). He also keeps the all the record in a log book. This inventory
maybe done alone by the store in-charge or with the presence of a representative of the
fabric supplier.
Cutting for inspection: At the time of inventory a piece of fabric is cut form every roll.
The piece is of full width of the fabric and of a length depending on buyer (i.e. for H&M
22 inch of length, for GCI 12 inch of length). These cut piece is send for inspection tests
like shrinkage, blanket making for shade segregation.
Storing: Is arranging the received materials according to their item number which is
found on the sticker of each fabric roll. Rolls which has the same item number are stored
under the same shelf

Issuing: Is a process of sending fabrics to cutting department, by using the lay plan.
NB: - Lay plan is a standard document that used to take a fabric from store .it is prepared
by cutting department by using the packing list. According to the lay plan the store
manager will approve whether the fabric is taken or no
Fabric inspection
Figure 4 Fabric inspection machine
It automatically checks the quality of the fabric by Large viewing glass with two way
lighting system facilities for easy viewing and inspection when the fabric pass throug
1.6.2. Accessories Room
Figure 5 accessory store

Accessory rom process
Receiving: accessories are supplied in cartons. Once these cartoons of accessories are
delivered the store in-charge receives the incoming consignment.
In-house Inventory: once the cartons of accessories are received the store in-charge
matches the packing list of the accessories consignment with the original quantity of the
accessories.
Accessories inspection: the qualities of the received accessories are checked according
to the po’s trim card
Issuing: Is a process of sending accessories to different lines by using the accessories

issue note.
NB: Accessory issue note is a standard document which has lists of accessories that are
used for making one garment and the number of accessories for one job number. It is
prepared by the store manager according to the po’s trim card. It is used to approve
whether those accessories are taken or not from store.

1.6.3. Sample making

The major activities of sample department:-in this operation class they make samples for
reduces errors and body fitted garments or products in the order they takes different sizes.
Order receiving with the specification
Level of the required sample pattern
Receive the required fabric type from the store for the
sample
Prepare a sample for customer specification based Back

to
Sample approved
sample not
Coasting by sales approved
depart
Finally prepare
production pattern
Figure 6 Sample making flow chart
1.6.4. Spreading
Figure 7 Spreading table

Spreading process:
The company uses manual spreading method hold the end of the fabric and spread the
required length in the table cut the fabric at the end of alignment -make perfect alignment
both end and edge of the layers should be equal continue the above process until the layer
amount is accomplished cut out defect fabric when over appear.
1.6.5. Cutting Department
Figure 8 cutting room
Cutting is one the most important department for ultimate of the productivity and quality
of the finished garment and it is the main and essential supplier of sewing room.
Cutting process
Pattern is not making in jay jay Ethiopian textile plc which is prepared in siri lanka and
mailed to the jay jay Ethiopian textile plc. Merchandisers after download the mailed
pattern pattern grading, marker planning and fabric consumption are done in TPD room
after finished those jobs the file sent to cutting room. In cutting room the the pattern is
drawn on paper by plotter machine. And the cutting manger also takes the roll from
fabric store by the approval of store assistant manager based on planning department
issue note. Spread the fabric based on the required plies, marker length and width on the
cutting table. after completed spread the fabric and then spread the the marker paper on
the above the spread fabric and the cut out the pieces of pattern.

Machines Available In Cutting Department
Straight knife cutter: - for the purpose of cutting the spread fabric which we want.
End cutter: - these one is used for the cutting fabric after the required length of lay the
fabric from the total fabric roll.
Binder cutting machine: Is a type of the cutting machine which used to cut the binding
fabric.
Figure 9 Straight knife
Figure 10 End cutter
Figure 11 Binding cutter

1.6.6. Embroidery and printing department
Figure 13 Embroidery machine . Figure 12 Printing machine
Embroidery and printing are two processes that occur only if directly specified by the
customer; therefore, these processes are commonly subcontracted to off-site facilities.
Customers may request embroidery to put logos or other embellishments on garments.
The Company has 2 printing machines with 26 standard set's made from India. It
produces 3000 pieces per day.
Jay Jay textile plc.Have 6 set of Baroda 20 heads embroidery machine with 9 color thread
capability. This embroidery machine is made in Japan, which is connected to computer
software to run the machine based on buyers design. The name of software called Wilcox
Embroidery. It produces 120 pieces at a time within five minutes.
This department is also found in the ground floor, receives garment bundle from cutting
room. They can make different type of embroidery design according to customer
specification& the design is come from Germen.
Available machines: - Thread Winder Machine
- Electronic Multi head Automatic Embroidery Mac

1.6.7. Production line
Figure 14 Sewing room

Sewing line is one of the main and critical departments of changing a cutter fabric piece
in to 3 dimensional garments which needs to be fit and balance the required person. In
these line the operators receive a cut bundle fabric through the lines supervisors and
repeatedly sew the required product and the end of the lines there is a quality assurance is
performing to ensure that the produced garment will reworked or mended at a designated
room.
Production System
In ‘Modular production system’s sewing operators work as a team. Neither they sew
complete garment nor do they sew only single operation. Multi skilled operators form a
group and each of the team members do multiple operations. In modular system,
operators help each other to finish the garment quickly and team is fully responsible for
quality and production. In modular, always team performance is measured instead of
individual operator performance. This system is very successful where quick response is
needed.
Production process
Merchandisers risk prepared analysis meeting with TPD, quality, IE and all managers
Pre-production meeting (after one week of risk analysis meeting)
IE department make layout for sample
Allocate the operators for each operation
Making make up sample for the operators
Fabric input and accessory to the line
Checking quality and matching quantity of accessory and fabric input
IE department check the capacity operators and give forecast for lines
Preparing finished goods
Sending to FGS
Figure 15 Production process flow chart
Machine Availability in Sewing Section

Flat lock (cover stitch)
Figure 16 Flat lock machine
Is a machine that operates finishing the raw edge by Heming and by attaching the binding
fabric? It has 4 threads, 2 for needle and2 for looping. it has a flat bed. The operation that
are done by flat lock machine are sleeve hem, waist hem, neck binding, bottom binding
and leg hem.
Over lock
Figure 17 over lock machine
Is a kind of machine that sews over the edge of one or two pieces of cloth? It has four
threads, two for needle and two for looping. It has flat bed. The operation that are done
by over lock in the factory are side seam attach, elastic attach and sleeve attach.
Single needle lock stitch

Figure 18 Single needle lock stich

.
As the name indicates the machine has only one needle and has two threads, the first one
is for needle which on the upper side coming from cone and second one for bobbin thread
which is in the underside of the machine. It has a flat bed. The stitches can be adjusted by
the pad which is found at the top of the machine. Most of the single needle machine
found in the company is adjusted only for the tacking purpose.
Snap fastener machine
It attaches the snaps (eye let and socket) to the shoulder placket and to the bottom of the
garment.
Figure 19 Snap fastener
Finishing
in Jay Jay Textile plc.is done only ironing to give the garments a pleasant look.
Figure 20 Ironing machine
.
…..
1.6.8. Packaging
Packaging In the last steps of making a product retail-ready, garments are folded, tagged,
sized, and packaged according to customer specifications. Also, garments may be placed
in protective plastic bags, either manually or using an automated system, but in these
company the process is done by manually to ensure that the material stays clean and
pressed during shipping. Lastly, garments are placed in cardboard boxes and shipped to
client distribution centers to eventually be sold in retail stores. Most garments are packed
in plastic bags, either at the end of production or when they enter the finished goods
store.
1.6.9. AQL (Acceptable Quality Level) process
Figure 21 Metal detector machine
Before accepting the finished goods, the buyers (H&M, TCP, GCI&garan)
do inspection of goods. It is so much important step because buyers are so much concern
about product quality.
In this department the checker only checks the sample. There are criteria for the rejection
and passing of a garment. The criteria are listed on the standard document.be proceed
with the damage free cartons from FGS storage area. If any carton is damaged due to
transporting or storing, it shall be segregated to separate area. It is the responsibility of
FGS packers to re pack the packs to cartoon with the same carton measurement and then
it is loaded to the vehicle.
All finished garment to passed finished goods store (FGS) must be detected free from any
metal pieces.

1.6.10.FGS process (Finished Goods Store)

When the FGS received the pieces the pack quality in issue note must match with actual
received pack.
Baler packing: It should match with the corresponding PO’S trim card. If it is not match
with the PO’S, the baler packer should inform to the FGS coordination and repack by
other.
Carton packing: Baler /packs shall be loaded to the carton box as per the carton packing
and loading check list.
The shipments shall be processed only after goods passing to the final inspection. If
failed due to packing errors, it shall be informed to AQL auditor & production supervisor
by FGS executive.
Loading: During shipment it shall be proceed with the damage free cartons from FGS
storage area. If any carton is damaged due to transporting or storing, it shall be
segregated to separate area. It is the responsibility of FGS packers to re pack the packs to
cartoon with the same carton measurement and then it is loaded to the vehicle.
All finished garment to passed finished goods store (FGS) must be detected free from any
metal pieces.

1.7.Organizational Structure
General
Manager
Deputy
General
Operational
manager
Maintenanc FGS IE QA Deputy Productio TPD

e manager executive manager Manager HR n manager Manager
Manager
Manager of Manager Planning Manager IT

Embroidery and account manager merchandi manager
printing ser
Figure 22 Organizational structure flow chart
The Responsibilities of Functional Areas
1. Responsibilities of Deputy Manager HR (Human Resource)
 Preparing short term and long term plan of HR and submitted to General Manager
(Operational Manager) for approval.
 Studying the need of different departments for human resource
 Selecting workers through identifying their capabilities based on their identity

card, Birth certificate and Exam (for direct workers).

 Providing awareness for workers about The way how to inform their grievance,
Safety procedures, Leave procedures, Termination and resignation procedure.
2. Maintenance Manager Responsibility
 Maintaining machine break down to zero level through the following mechanism
Preventive, Corrective and Detective.
 Proper maintenance of Building and machine and machine inventory
 Managing machine spare part and energy
3. Manager Planning Responsibility
 Insuring maximum utilization of sewing capacity in the factory for delivery of

orders as required by the buyer
 Developing and implementing systems procedure to improve the effectiveness of

planning process
 Producing regular reports and statistics on a daily, weekly and monthly basis.
4. FGS Executive Responsibilities
 Receiving packs and cartons
 Checking pack quantity in issue note whether it is matched with actual while
receiving the packs.
 Forwarding the non-conformation report to quality manager through FGS

manager for decision making whether to accept or return the incoming cartons.
5. Production Manager Responsibilities
5.1Production Responsibility
 Conforming accessories from the store and Checking out customer order
 Checking out requisition form of material Accessories, fabrics and trims

 Issuing the shortage quantity of FGS and Ordering TPD manager for preparing
samples.
5.2Man Power Responsibility
 Providing training system for production line workers
 Motivating workers by giving awards for their better performance.
 Allocating man power in each production line and balancing workers through
rotation systems.
6. Managers Account
 Plans, organizes, directs and controls the activities of finance department by

insuring the proper accounting, finance and budgetary control system
 Manage and facilitate external and internal audit process
 Handling finance related correspondence of the company
7. Executive IE Responsibilities
 Data management, analyzing performance identifying problems and developing

recommendations that support improve and develop the process and system in a
cost effective manner.
 Planned the feeding plan
 Follow up all the machines, layout, thread are in house before one particular style
start in production
8. Manager Quality
 Receiving and checking all the sample garment quality, appearance and
measurements.
 Completing the packing method as per the buyer requirement and submit to the
merchandizing

 Sending garments to Lab testing in each size to check (shrinkage/GSM/pull

test/hand feel).
9. Manager Merchandizing Responsibilities
 Costing of the garment with buyer
 Receiving order from buyers with different details
 Controlling out the sampling process
 Getting sample approval from buyers.
 Negotiate with raw materials and accessory suppliers regarding with the price
10. Technical Product Development Manager (TPDM)
 Provide effective leader ship
 Take a proactive and strategic role agreed between job holder and manager
1.8.Main product of the company
Figure 23 product of the company
The main products of Jay Jay Textile TCP, GCI, H&M and Carter's baby wear with
different sizes such as:
New Born,0-3 months ,3-6 m New Born,0-3 months ,3-6 months ,6-9 months,912 months
12-18 months ,18-24 months 36 months ,48 months And different size T-shirts from XS
toXL.

1.9.Customer of the company

The company exports its product to the following buyers.
 GCI (Gerber children's wear)

 TCP (The children's wear)
 Garanimals
 H&M

CHAPTR TWO
2. INVESTIGATION OF IDLE TIME IN SEWING
SECTION
2.1 Introduction
Now a days Garment industry is a major contributor to the economies of many
countries, and also it has a long history in human beings’ life. Due to this long life of
manufacturing time it has its own working process, rule or policy, and challenges.in the
manufacturing process of garment industry sewing section is the back bone because two
dimensional clothes or fabric converts in to three dimensional cloths in this section and it
is more labor intensive from the other garment manufacturing process like, cutting,
pattern making, finishing, sample making, and others manufacturing process
departments. and also productivity of most garment manufacturing company deepened on
the manufacturing capacity of sewing section.so to improve productivity of garment
manufacturing company, sewing section manufacturing ability should be improved. Due
to this principle to improve productivity of sewing section identifying challenges which
are faced during manufacturing process is essential. Because identifying problem is one
part of setting improvement solution. In so many sewing section challenges idle time is
the main challenges and more influential more than other challenges, let u see some
challenges
 Operator absenteeism; with the operator shortage, operator absenteeism increases

labor problem in sewing floor
 Frequent change in production planning; this is often happened in factories that
production team loads a style to line and certainly get instruction to stop the style
and load one urgent style. This breaks the production momentum and reduces
line performance.
 Insufficient information; factories conduct pre-production meeting and weekly

meeting. Even after meeting, complete and correct information is not passed to
the production team. Due to delivery schedule, bulk production is stated without
complete approval.

 Long line setting time; due to poor preparation prior to line setting, line setting
time increase.
 Idle time; this challenge is more influential and commonly happen in garment
industry, which is the unproductive time of either the machines or the employees
that is call Idle time is also known as Waiting time, down time, or allowed
time.in many manufacturing company idle time can be categorized in to two.
Those are normal idle and abnormal idle time.
 Normal idle time; is the unavoidable loss of valuable labor hours in the company
is known as Normal idle time. It includes, Time lost when a worker walks down
from the factory gate to the place of his work, Time lost when the worker has to
walk from one department to another, Time lost during authorized lunch and tea
break, Time lost during setting of tools, machines or implements, Time lost when
the labor sits idle to overcome fatigue, Time lost when one shift is completed and
the next starts, Some of the idle time can be controlled but cannot be stopped
altogether.
 Abnormal idle time; the abnormal idle time is one in which the wasted time can
be avoided by taking precautionary methods. These are; Power failure, Lack of
work, Lack of important tools, Breakdown of machinery, Lock-out, Strikes,
Materials not available, Bottlenecks during production, Hazards like flood and
fire, Excessive automation, Too much of the time spent on rectifying the defect
and, Stoppage of work because of bad management policy.
2.2.Problem statement
To improve productivity of garment manufacturing company sewing section, identifying
challenges which are faced during production process in sewing section is the first task to
propose possible and effective solution. In many garment companies sewing section the
most problematic such as unproductive operator, working condition, planning technique,
communication between line supervisor, and co –worker, lack of understanding between
departments, etc. Those problems are stumbling block in productivity so to improve
productivity minimizing or eliminating those above listed if it can possible mandatory, by
applying diffident controlling technique as the nature of the challenges. While Jay jay

textile plc. Also the most known children wear manufacturing company, across the
world, and it confront in so many factors which affect productivity of the company like
the other garment manufacturing company. Those problems are; sewing section daily,
production target is not well achieved and also there is WIP in so many production line
which indicates there is existence of non-productive time these non-productive time
happened by so many causes like, cutting delay, printing delay, maintenance mechanic
waiting and corrective maintenance to the machine during production process is going
on, and operator carelessness etc.in addition to this the operator also cannot have skill of
maintain even simple maintenance activities (total productive maintenance skill), like,
cleaning, adjusting, needle, bobbin and lopper threads, replacing needle while needle is
broken, and adjusting sewing guides.so this project address those problems which is
explained above by investigation of idle time in sewing section and propose possible
solution by identifying critical cusses to the worker not be productive.
2.3.Objectives
2.3.1. General objectives
The general objective of this project is investigate idle time of the company and propose
solution.
2.3.2. Specific objectives

 To study the existence of idle time in sewing section
 Identify the root cause how idle time is existing in sewing section
 Propose possible solution to control idle time in sewing section
2.4. Scope of the project

This project is done on jay jay textile PLC which is found in Addis Ababa Ethiopia. It
focuses investigate idle time in sewing section and propose solution after identified
occurrence percentage of idle time.
2.5. Challenges to do this project

While doing the project there are some limitations. Those are lack of information from
related person, lack of internet access to write and search important information for the

project, want of personal computer to do as the perfect time and disturbance of corona
virus and political condition of the country.
2.6. Significance of the project

Significance of this project is that the Indies of the project is well implemented in
jay jay textile plc. The following results will be shown.
 WIP will be eliminated

 The skill of the operator will be improved
 Maintenance mechanic’s work load also minimized because the main aim of the
study is give well organized simple maintenance activities so which is will be
minimize mechanics work load.
 The productivity of the company will be boosted and then the company become
profitable.
 Finally, if the sewing section idle time will be investigate and its cause will be
identify the companies sewing section working flow become smooth.
2.7. Literature review

Idle time is the time that company pays to employees or workers, but they
cannot complete any works due to other reasons beyond their control. It is the time when
employees have nothing to do during the working hour, they are not able to do the work
because of various reasons. For example, there are two workers in the restaurant, the chef
and waiter. There is an idle time when the waiter waits for the chef to cook food. It is
similar to Machine idle time which is the time that machines do not break, but they are
not being used. There are two kinds of idle times: -
 Normal Idle time

 Abnormal Idle times
Normal idle time happens due to normal business operation, which is not under the
control of management, staff, or company. It is the idle times within manufacturing
cycles, such as worker have to wait for a period of regular maintenance. It can be the idle
time during working hours due to worker personal breaks such as tea or toilet break. They

are normally happening in the production process, which cannot avoid, but we have to
ensure that they are within a manageable level.
Abnormal idle time; Abnormal Idle Time is that time the wastage of which can be
avoided if adequate precautions are taken like, Breakdown of machinery, Power failure,
Non-availability of materials, Strikes and lockout, Fire, Flood and other hazards,
Bottlenecks in production, Stoppage of work as a result of bad policy decisions by the
management, Excessive time taken to rectify the defects, Excessive automation,
Identify and reduce idle time is very important for business, especially the manufacturer
because it is very coasty. We still pay for employees even they do not involve in any
productive activities. Depreciation yet charges even those machines do not use. Huge
unutilized time shows that the company has underutilized its resources. The longer it
takes, the more expensive the company needs to spend on its production cost. When
employees are not engaged in productive activities it can have serious implications for
employers. According to a 2018 study from the Harvard Business School, 78.1% of
workers find themselves on a weekly basis with involuntary idle time, which costs
employers an estimated $100 billion per year.to identify the idle time calculating idle
time is essential (Monica Torres feb 1,2018). Idle time formula will help us to calculate
the percentage which idle occurs compare to a total working hour. In other words, it is the
time which company waist due to unutilized time.
To calculate idle time, we simply deduct the actual working hour from the total standard
hour, the difference is idle time. It shows the number of hours which company spends
without getting anything.
We can calculate idle time per employee, by the departments, or a whole company.
Management should calculate idle time by department or processing stage which easies to
find causes and solutions. Mathematically we can express. Like this: -
Idle time ratio=idle hour/total working hour×100%
Idle time = Total time spent by a worker – Actual time spent by a

worker on the production

Idle time is typically caused or started by factors outside of the person or

machine’s control. When it starts growing beyond that time, it’s typically caused by
simple human ignorance or laziness. It’s the manager’s responsibility to deal with idle
time in proactive ways that take into account both the short and the long term. Other
causes of idle time include:
1 Administrative causes
The administrative causes occur because of reasons like,
Poor planning
Not discharging skilled workforce during depressions
Hiring skilled workers anticipating future growths
2. Production-related causes
The production-related cause of idle time is one where the worker has to wait and sit idle
for reasons like
Breakdown of machinery,Waiting for raw materials,Waiting for machinery,Inadequate

power facility,Due to previous operations,Unutilized workforce,Delayed instructions
3. Economic causes –
The economic causes are the ones that happen because of a lack of demand for that
product. The idle time cost is not treated as a part of the cost of production instead is
written off by debiting the profit and loss account. The cost of idle time that has resulted
because of the following reasons :-Fall in demand because of lock-out or strike, General
recession in the economy, The need for a seasonal product is no more as it is off-season
And Cyclical fluctuations because of which the demand for the product has minimization.
(agrawal, 18 feb 2021)
most of the above causes are happen in jay jay textile PLC.specially simple machine
break dowm like thread tension adjustment, cleaning problem, needle replacing when
needle is broken,sewing guied adjusting,overall understanding of machin.etc... is main
cuses of the companies sewing section idle time which means maintenace idle time .this
project also focuse how to solve it.

Developing idle time control theqnique is mandayory to eliminate perentage of idle

time which occers because of the above causes .when i have seen previous reasrch
works and rcomendation in diffrent countries garment companies are focused theortical
solutions based on difference circumstances let as see some recomendations .
" Involvement from employees on workflow design :Employees should involve in

workflow design because they are doing it every day. There are some techniques that
they know more than managements. We can assign employees representatives in each
assembly line to share their experience in the workflow design. In case of unexpected idle
time exist, employees in that station are the first one need to be discussed. They know the
reason and be able to share more appropriate and practical solutions.
Analyzing work station:Managers have to ensure that every work stations can produce a
similar level of output so that there will be no bottleneck which will cause idle time. On
the other hand, some work stations may have too many resources (machines or workers),
so that they do not work at their maximum level. So they should allocate some resources
to other stations. However, the company may face other forms of downtime, each
assembly line should document them in a proper file. So that management will solve
them base on the actual situation.
Decrease Transit time:The material supposes to move from one station to another
without any interruption. We should record the time spend from moving material from
one location to another. Any movement which takes longer than usual must be double-
checked to find out the root cause. The location of each assembly line should place next
to each other based on workflow; the movement area should be free from the obstacles.
Proper production planning and flexibility:Management needs to have an appropriate

plan which can increase utilization to the maximum level. However, the actual situation
will happen differently, so we have to flexible to respond to those changes. We may
provide overtime for a short time to allow bottleneck station to catch up with others and
reduce other stations’ idle time. Other solutions, such as increased working shifts may be
useful as well.

High-quality material :The Purchasing department has to ensure that materials’

qualities are within acceptable standards. If we consider buying cheap and low-quality
material, it may require long time processing and finished goods quality. In the end, we
will incur more cost on direct labor (both processing time and idle time of next station),
and customers return.
Repair and maintenance machines : If machines are frequently breakdown, we should

prepare an inspection of machines’ condition and capacity. If machines’ capacity is too
low, we need to consider conducting a full repair (overhaul). The broken spare parts need
to replace to improve their condition. The inspection and repair must perform outside
working hours to prevent any additional idle time. Even machines are in good condition;
technical teams need to be on-site and be ready for unexpected broken and reduce
downtime to the minimum level (brodsky, 2017).While this study is focuse identify
occurence percentage of sewing section idle time and propose thecnical solutions ,which
is traing simple maintenabce activities to the operator .becuse a recent report from The
National Center on the Educational Quality of the Workforce concluded that "a 10%
increase in education level resulted in an 8.6% improvement in productivity across all
industry types (Root D. , june 21 2016; franklin b. , 1893).Benjamin Franklin said also
“An investment in education always pays the highest returns (franklin b. , 1893)so those
studies and statments indicates traing or improving skil of worker is the best way to
control or reduce idle time .if idle time is reduced productivity is boost if productivity
also bostesd the compnies become profitable.

2.8.Methodology
Literature review
problem identification
Data collection primary data and secondary data
Data analysis
propose possible solution
Result and Discussion
Conclusion and recommendation
…. Figure 24 Methodology flow chart
2.8.1. Data collection

While carrying out the project, multiple data collection techniques were used in order to
have more reliable outcomes Likewise, different data sources can support each other and
bring strong and exciting results According to type of the data that collected, these
techniques can be classified under two main categories; primary and secondary.
2.8.2. Primary Data Collection

The aim of primary data collection in this study is to build ground work for the analysis.
For this purpose, several techniques such as interview, observation, and recordings have
been used and will be described in following section

2.8.3. Interview
The design of the interviews was based on the project objectives. During this study I have
done oral interview (informal interview) with sewing operators, maintenance mechanic of
the company, and also different responsible person.
In JAY JAY textiles PLC, when asking or interviewing the sewing operator they tell that;
we are idle for waiting the maintenance mechanic when some problem is happening on
sewing machine during on the production process. And some other problems like
maintenance mechanic waiting (i.e. printing and cutting delay).and we have not skill skill
about how to maintain the sewing machine. And maintenance mechanic say that the
operators have no knowledge about maintenance of sewing machine due to this case
every maintenance activity done by ours.
2.8.4. Observation
In this project direct observation is used to assess that more of the time operators
are idle during some machine problem is happened during production process, as
I have seen most problem is cleaning problem tensioning, handling of clothes,
bobbin thread adjusting, bobbin case adjustment, etc... so due to this case WIP
will occur.
2.8.5. Secondary Data Collection
 Internet access: collect some data from internet around may project title.
 Different reference books and exercise books related to idle time.
 Company document
 Academic book
 Published document
2.9.Data presentation and analysis
2.9.1. Data presentation
In this project we have collected day wise idle time in randomly selected sample lines
and I have going to collect data in different circumstance which means daily forecast,
daily achieved product, SMV of the product which is done in the selected sample line,
and waiting of maintenance mechanic when some problem is happening in sewing
machine during the operation is going on, collected waiting time for printing and cutting

delay is happen in selected sewing line. And am going to identify which cause is
frequently happening. And then I have to done data analysis after this I have going to
propose technical solution to control this idle time.
 Selected sample line –garan style product

 Garment-boys T-shirt-graphic
 Buyer- Garan
Figure 25 T-shirt graphic sample
Table 2. Daily production presentation
Day SMV No of Forecast achievement SAH Achieved Idle hour

carder SAH
23/11/2020 3.55 16 1350 1186 80 70 10
24/11/2020 3.55 16 1320 820 78 49 29
26/11/2020 3.55 16 1485 1050 88 62 26
27/11/2020 3.55 16 1485 976 88 58 30
28/11/2020 3.55 15 1350 900 80 53 27
30/11/2020 3.55 15 1200 792 71 47 24
01/12/2020 3.55 15 1200 912 71 54 17
02/12/2020 3.55 16 1485 0 88 0 88
03/12/2020 3.55 16 1530 1518 91 90 1
04/12/2020 3.55 16 1360 1304 80 77 3

05/12/2020 3.55 16 1360 1260 80 75 5
07/12/2020 3.55 16 1360 1298 80 77 3
08/12/2020 3.55 16 1360 1180 80 70 10
09/12/2020 3.55 15 1200 1150 71 68 3
10/12/2020 3.55 16 1360 1228 80 73 7
Total 53.2 236 20405 15574 1206 923 283
To identify the existence of idle time in this section we have to calculate idle time
percentage ad then find out what is the cause.
Idle time=standard available hour - achieved available hour or
Idle time = Total time spent by a worker – Actual time spent by a worker on the
production
1206-923=283
Idle time percentage=SAH-achieved SAH/SAH
1206-923/1206*100=23.46%
These data indicate 23.46% from total available working hour are abnormal idle in so
many cause. let us identify the causes.as I observed and collected different data from jay
jay textile PLC sewing section main causes of idle time in sewing section are;
 Cutting delay
 Printing delay
 Maintenance mechanic waiting time when machine is break
down during the production process is going on.
 Giving corrective maintenance when the machine is break
down

Identification the cause of idle time in sewing section
Table 3. Daily recorded idle time by different reasons

Day No of Printing delay in Cutting delay in Waiting time Operating
carder hour hour for time in hour
maintenance
in hour
23/11/2020 16 0 0 9 2
24/11/2020 16 0 0 8.7 3
26/11/2020 16 1.5 0.5 7.9 3.6
27/11/2020 16 0 0 10.25 4.15
28/11/2020 15 0 0 9.6 5
30/11/2020 15 0 0 8.44 2.23
01/12/2020 15 0 0 9.04 1.605
02/12/2020 16 0 88 0 0
03/12/2020 16 0 0 10.3 3.768
04/12/2020 16 0 0 6.39 3.8
05/12/2020 16 0 0 7.14 2.7
07/12/2020 16 1 0 8.5 2.04
08/12/2020 16 1.05 0 7.4 2.5
09/12/2020 15 0 0 5.9 1.93
10/12/2020 16 0 0 7.056 2.16
Total 236 3.55 88.5 115.616 40.483
Based on the above data can calculate each idle time percentage and identify the problem
which is frequently happen. Let us see

 %of idle time because of printing= total printing delay in

hour/total standard available hour*100
% of idle time because of printing= 3.55/1206*100=0.3%
 %of idle time because of cutting delay= total cutting delay

hour/SAH*100
%of idle time because of cutting =88.5/1206*100=7.3%
 %0f idle time because of waiting for maintenance =total

waiting time for maintenance/SAH*100
%0f idle time because of waiting for maintenance =115.616/1206*100=9.58%
 %of idle time because of operating machine during machine

problem is happen=total maintain time /SAH*100
%of idle time because of operating machine during machine problem is

happen=40.483/1206*100=3.35
1%
13% because of waiting
maintenance mechanic time
because of cutting delay
14% 41%
because of correcting
because of other causes
because of printig delay
31%
Figure 26 Idle time existence indicator chart

2.9.2. Data analysis

Based on the above data in a single production line 29.99 and 10.38 minute are idle per
day for the reason of waiting maintenance mechanic and giving corrective maintenance to
sewing machine when problem is happened during production process respectively.
Which indicates waiting machine mechanic and machine problem is the Maine causes of
idle time happing in jay jay textile plc. Sewing section relative to the cutting and printing
delay time. Because sewing machine problem is daily happing problem while cutting and
printing delay is sometimes occurrences.so waiting sewing machine mechanic and
corrective maintenance time is a cause of influenced production idle time occurrence. so
to propose solution for minimize idle time I have to identify what is the problem is
happing in sewing machine.as I observed in each production day most machine problem
is simple and can be done by operators or line leader but which is done by maintenance
mechanic. Let us see below those problems which are happened randomly selected
sewing line for 15 days.
Table 4. Daily recorded problems in sewing section sewing machine
S Days Machine type Problem happened Action taken Frequen

no by mechanic cy of
problem
1 23/1 Over lock ,flat Upper loppers thread Adjust 5

1/20 lock tension, needle thread thread
20 tension. (loose and thigh) tension
Single needle Losses bobbin case Tighten it 1
Over lock Pressure foot loses Adjust 1

pressure foot

Over lock Cleaning problem Clean 2
2 24/1 Flat lock Tensioning lopper thread Checking 2

1/20 ,and needle thread threading
20 and adjust
Over lock Losing and tightens of Adjust 3

lopper and needle thread
3 26/1 over lock, flat Tensioning problem Adjust 5

1/20 lock and single (bobbin ,needle, upper
2 needle and lower thread)
Bar tag Bobbin case losing Tighten 1
4 27/1 Over lock and Tensioning problem Adjust 3

1/20 flat lock (lopper and needle thread)
20
Flat lock Needle broken Replacing 1
Cleaning problem Clean 1
5 28/1 Over lock Change of Sound Advice the 1

1/20 worker
20
Over lock and Tension of threads Adjust 4
flat lock
6 30/1 Over lock and Tension of threads Adjust 3

1/20 single needle
20
7 01/1 Flat lock Cleaning problem Clean 2

2/20
Over lock Handling problem Advice 1
20
Over lock and Tensioning problem Adjust 4
flat lock

8 02/1 Over lock, flat Tension problem Adjust 5

2/20 lock and SNLS
20
Over lock Broken needle Replace 1
Over lock and Cleaning problem Clean 2

flat lock
9 03/1 Bar tag, over Tensioning problem Adjust 6

2/20 lock ,flat lock
20
Over lock Pressure foot loss Adjust 1
10 04/1 SNLS Control panel setting Set 1

2/20 problem operation
20 order
Over lock , flat Tensioning problem Adjust 6

lock and SNLS
Flat lock Cleaning problem Clean 1

2/20 flat lock
20
SNLS Bobbin case problem Adjust 1
bobbin case
Over lock and Needle broken Replace 2

flat lock
12 07/1 Flat lock sleeve hem gage problem Adjust gage 1

2/20
Over lock, flat Tensioning problem Adjust 5
20
lock and bar
tag
Over lock Cleaning and threading Clean and 2

problem check

threading

2/20 flat lock
20
SNLS Bobbin and pressure foot Adjust 1
Flat lock Needle broken Replace 2
14 09/1 Over lock and Cleaning problem Clean 3

2/20 flat lock
20
Over lock, Tensioning problem Adjust 3
SNLS and flat
lock
15 10/1 Over lock Broken needle Replace 1

2/20
Flat lock and Tensioning problem Adjust 4
20
over lock
Single needle Bobbin case problem and Adjust 3

winding problem
Those problems which are recorded in the above are simple and can be done by the
operator or line leader by giving simple maintenance training. So if the company could
implement this idea main sewing section idle time will become eliminate which caused
by maintenance mechanic waiting. Let us see the difference after train the operator and
before train the operator about simple maintenance activities.
If the operator or line leader can do simple maintenance activities the above presented
data will become.

Data analysis
%of idie time in different cuase 12.00% 9.58%
10.00%
7.30%
8.00%
6.00%
2.93% 3.35%
4.00%
2.00% 0.30% 0%
0.00%
printing delay other causes mainting time cutting delay waiting time
cuases of idle time occurence
befor implementing this project if impliment this project
Figure 27 Data analysis graph
If the companies train the operators or line leader about simple maintenance activities
waiting maintenance mechanic time will become zero.so out of 23.46% of company’s
abnormal idle time 9.58% will be eliminate. Which means if the company could
implement this project will save 29.9 minute per day in a single line, for increases its
production. Let us see how this project can boost production.
To produce one T- shirt graphic =3.55 minute
?pcs =in 29.99 minute
Saved product=1pcs*29.99minute/? Pcs *3.55minute
? Pcs= 29.99/3.55=8.44 pcs.
Approximately could save 8 pcs per day in a single garan style production line which
SMV is 3.55minute. Which means 8pcs *3.98$ =31.98$ can save per line in one day for
graphic T-shirt only.

2.10. Result and discussion

Currently in jay jay textile plc. The operators are not trained about simple maintenance
activities and idle time was not studied. Due to this case the production was not produced
at expected level by means of idle time. And theses abnormal idle was occurred by in
different cases which is identified in this project. Specially maintenance mechanic
waiting time is the main cause and frequently occurred in day today production activities
and the work load of sewing machine mechanic also high before done this project, after
this project is done those problems will be solved and the current companies’ production
level will be change at maximum confidence level. Because the root cause of production
bottle neck has been identified and proposed effective technical solution to create smooth
and productive sewing section by minimization and identification of idle time and its
percentage if the company implemented.
2.11. Conclusion and Recommendation

2.11.1.Conclusion
To solve the problems which are happen in jay jay textile plc. Sewing section like WIP
in the production line, the gap between daily forecast and daily achievement, and other
production bottleneck, investigating productive and non-productive time is mandatory.
This project also discovers firstly identify the existence of idle time in the companies
sewing section after identifying the existence find out the root cause and then propose
effective solution to achieve daily forecast. Based on the problem identification part of
this project waiting maintenance mechanic time is the main frequently occurrence things
in day today production process activities, and it is influential causes on the day problem
in production process more and more than the other cause of non- productive time
occurrence like , cutting, printing, giving corrective maintenance and other causes.so the
main effective solution to control this causes is identifying the type of problem which is
happen in the production line during production process.so based on this principle most
problems are simple and done by either the operators or line leaders those are cleaning,
adjusting needle, bobbin, and lopper threads, handling of clothes during sew the clothes,
changing needle while needle is broken and understand of the machine etc.. After
identifying those problems give reliable solutions.so this project propose to jay jay textile

plc. Industrial engineering manager giving training to sewing operators and line leaders
about simple and common maintenance activities is the best way to control idle time
which occurs because of waiting maintenance mechanic. Because improving skill of the
worker is more and more effective to boost production and productivity.
2.11.2.Recommendation
My recommendation for jay jay textile plc to control sewing section idle time and save
production time is listed bellow
 I recommend to the company reducing idle time to achieve daily production

forecast by implementing this project.
 Minimize work load of the maintenance mechanic by giving common and
simple maintenance activities to the new trained operators.
 Train the senior sewing operators or line leaders by using either break time or
free time as the schedule or comfort time of the company and trainer.
 After train the sewing operators or line leaders finally checkup the skill of
operators about maintenance.
 Study productive and none productive time of the sewing section of the
company and give either daily or weekly improvements or solutions.
 Checkup daily forecast achievement if the forecast is achieved the production
process is well, if not achieved identify the root cause and record it.

CHAPTER THREE
3. OVERALL BENEFITES GAINED FROM INTERNSHIP

3.1.Internship experience
When I am to do an internship, I believe by doing an internship I can learn new skill,
develop my professional interest, and valuable work experience. My first task was
finding an organization which has some applications which are related with my
study/department
3.2. Benefit of internships
Internship helps me to get experience in my field of study. I was not sure what I wanted
to do when I graduated. So I thought some real life experience would help me solidify my
future endeavor. Doing internship help me to know more about my field. It also gives me
an in depth analysis of what it really like to work best field of study.
The benefit of internship which I acquired during my internship includes the following.
 Practical skill
 Upgrade theoretical knowledge by practical practicing
 Industry problem solving skill
 Interpersonal communication skill
 Work ethics and industrial psychology
 Team work skill
 Entrepreneurship skill
1. Practical skill
During the time of internship I take beginners practice and I also work as a supervisor for
production line. I also developed theoretical knowledge into practical.
Upgrade theoretical knowledge by practical practice
When I was in the class and when I have completed this internship program I have
checked that those I have learned in theory are real and they are found in the practical
world. It gives me an opportunity to apply the fundamentals learned in the classroom to
real world issues.

Figure 28 Personal involvement in the company
2. Problem solving skill

Completing this internship program makes me to identify the industrial problems and
then how to solve them; this internship gave me the opportunity to apply some industrial
problem solving skill learned with in the classroom to real world activity within the
industry. It gives me an in-depth analysis of the industrial problems really and how to
solve them.
3. Personal communication skill and approach with others

I have developed my personal communication skill until at the end of my internship
program. I developed both oral and communication skill. I got an experience on how to
approach to people who works in the company. I also developed how to communicate
with people in the factory using written communication method. They also helping me by
asking about different questions about general garment industry and this motivates me
what ever in the company.

4. Work ethics and industry psychology

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
 Build motivation and work ethics

 Punctuality and accountability to a given task
 Transparency in working once duty
 Respecting and friendship building with co-workers.
 Strong working relations with operators in the company
Internship enables me to act as advisers, professionals, provide recommendations for how
to resolve conflicts, increase productivity, and improve employee morale, among other
things.
5. Team work skill

Doing internship enables me to develop my team playing skill. It enables me working
with my colleagues who have substantial experience within this garment factory. I
develop my understanding on my contribution to the company as a member the group on
the entire objective to be succeeded. My internship was a great way to meet people in my
field of study. It allows me to meet people who help me land a job later on and give me
the contacts in the factory.
6. Being familiar for Entrepreneur-ship skill

Entrepreneurs are a people who are able to develop new business & affect the overall
condition of the global economy. When I was in Jay Jay textile plc. Garment factory I
saw a lot of business opportunity that can create wealth. In my 4 month internship
industrial visiting I saw a lot of points that can be corrected with simple and easy
technical support, so I am proposing that after graduation I want to organizing myself and
my friends by giving technical supporting. I hope we can make good business and
support industries in market computation and improving their performances.

REFERENCE
agrawal, m. (18 feb 2021). study notes on idle time. www.yourartilelibrary.com.
brodsky, a. (2017). the prevalence and work pacing consequences of idle time at work..
franklin, b. (1893). woolever.
Root, D. (june 21 2016). training and development.


3idel Time

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3idel Time

Uploaded by

Copyright:

Available Formats

Internship project @jay jay textile plc

BAHIR DAR UNIVERSITY

ETHIOPIAN INSTITUTE OF TEXTILE AND FASHION

HOSTING COMPANY: - JAY JAY TEXTILE PLC.

PROJECT TITLE: - INVESTIGATION OF IDLE TIME IN

BY: ENDALE BAYEW

ACADAMIC ADIVISOR: -MR. SOLOMON TILAHUN

SUBMITED TO:-INDUSTRY LINKAGE OFFICE

BAHIR DAR, ETHIOPIA

Solomon Tilahun ___________ ___________

Name of academic advisor Signature Date

Endale Bayew __________ ___________

Name of the student Signature Date

EXECUTIVE SUMMARY ..........................................................................................iii

LIST OF ACRONYMS ..............................................................................................viii

1.1 Mission of the company ............................................................................. - 2 -

2. INVESTIGATION OF IDLE TIME IN SEWING SECTION ............................. 25

2.1 Introduction ................................................................................................... 25

2.3.2. Specific objectives ................................................................................. 27

3.1. Internship experience .................................................................................... 46

2. Problem solving skill ............................................................................................... 47

3. Personal communication skill and approach with others ......................................... 47

4. Work ethics and industry psychology ...................................................................... 48

5. Team work skill ....................................................................................................... 48

6. Being familiar for Entrepreneur-ship skill ............................................................... 48

Table 1. Raw material and its supplier .................................................................................. - 3 -

Table 2. Daily production presentation .................................................................................. 35

Table 3. Daily recorded idle time by different reasons .......................................................... 37

Table 4. Daily recorded problems in sewing section sewing machine .................................... 39

SAH ------------------------------------- Standard available minute

M/c ------------------------------------------ -Machine

Plc. ------------------------------------------ Private limited company

FGS ----------------------------------------- Finished goods store

NB ------------------------------------------- New born

TPDM --------------------------------------- Technical product development manager

IE ---------------------------------------------- Industrial engineer

GCI --------------------------------------------Gerber children’s wear

H&M ------------------------------------------Hennes and muritz

TCP -------------------------------------------- The clothes place

AQL ------------------------------------------- Acceptable quality level

SAM ------------------------------------------- Standard allowed minute

Figure 1 Company profile

-1- Bahir Dar university

1.1 Mission of the company

 The most desired workplace for employers

1.2.Vision the company

1.3. Value of the company

To their environment: to actively contribute to protect their environment by reducing

1.4.Raw materials and its suppliers

-2- Bahir Dar university

Table 1. Raw material and its supplier

Types of raw materials Suppliers

Organic and in organic fabric Srilanka and India

Wrap band India

Thread cone Dubai

Size sticker India

Clear round India

Header card India

RFID sticker Hong Kong

Embroidery thread India

Poly bag India

Care labels Be connected

Heat seal Dubai

Company quality fabric inspection system

Solomon Tilahun _ _

Endale Bayew _