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BGMEA-SEIP TRAINING INSTITUTE
 Module 3: Operation Analysis
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Operation Breakdown
 WHAT IS OPERATION
BREAKDOWN ?
Operation breakdown is the basic and fundamental,
sequential elements of various processes which starts
from the parts to make up the whole.

Each process being the sum of methods and

techniques employed to accomplished the said activity.

Each process being the result of a scientific or engineered

approach in an effort to bridge the gap between input and output
with the objective of a shortened process time possible without
disregard for the required specifications.
 WHY DO WE NEED TO MAKE OPERATION
BREAKDOWN ?

To provide as a sole basis of determining the following:

1) Target Output per operation

2) Target Output of making up the part and the whole
3) Skill required and Manpower Distribution
4) Type of machines required
5) Type of attachment required
6) Process Line Balancing
7) As basis for capacity Planning
8) As basis for production planning and scheduling
9) As basis for product costing
10) To be able to rationalize the shapes(patterns) of parts in
relation to the processes involved while finalizing the
operation breakdown.
INFORMATION REQUIRED BEFORE
MAKING OF AN OPERATION
BREAKDOWN
 NECESSARY FIELDS OF OPERATION
BREAKDOWN AND THEIR EXPLANATIONS.

Sequence Number : In order to give an operation a unique identity

and easy accessibility where ever required. Shows the sequence
number of an operation in software and, it is used in layout software to
call the data of a particular operation.
 Continued …

 Parts = This field is for describing heading of garment part and it is also
helpful for sectionalizing the production lines.

SHIRT
•Collar, Cuff, Sleeve, Pocket
Example •Back, Front, Assembly
for
Garment

PANT
•Belt Loop, Waist Band
Parts
•Back, Front, Assembly

 Parts SMV = This field is for showing the total SMV for a part of a garment,
which can be used in separately defining the total output and productivity.
 Continued …

Operation Description : This field is to

describe operations in a simple and
standard terminology

Attachment: This field is for describing

Attachment used for deskilling the
operation
WHAT IS SKILL ?

A skill is a learned talent or acquired

capacity to perform and achieve a given
task with a predetermined results.
WHAT IS SKILL
MATRIX?

A classification of skill level based on the

know-how and ability to achieve various
predetermined tasks.
 Continued …

Operator Skill: This field is for describing skill required for the
operation and factory must also have skill matrix grading system
for implementing O.B skill matrix.

•Best Efficiency •Good Efficiency

•Multi Skill •Average Multi
•Best Attitude
A B Skill
•Best •Good Attitude
Attendance Grad Grad •Good
e e Attendance
•Helpers Job D C
•Marking
•Pressing Grad Grad •Average Efficiency

•Good Attitude e e •Having Single Skill

•Good Attitude
•Average •Average Attendance
Attendance
 Continue….

 Machine Description = This field is for describing machine type required for
operation and also for describing which kind of manual work is required
3 for the
operation.

 S.M.V (Standard Minute Value) = This field is for giving standard minute
value for the operation and this data is also used for calculation in other various
field of operation breakdown. ( ** This topic will be taught in time Study Section)
 Continued …

 Operator Allocation Number : This field is for giving operator allocation

number going further this will be useful for making sewing line layout by
user.
 This column is used to allocate actual number of operator to a
particular operation.
 This column is also used for combining operation
 Operator allocation is done through the figures of “Operator
Required” & “Hours Required” given in next two columns.
 This would further help to make sewing line layout.
 Continued …

 Operator Required: This field is for showing number of operators

required for achieving planned daily output & it is also useful data for
line balancing and the operations which do not need any operator or
machine balancing the text will appear in green colour & operations
which need balancing will show in red colour.

Formula For Operator Required:

((Planned Daily Output/(Attended Minutes / Operation S.M.V)) /
Planned Efficiency))
= ((394 / (480 / .41)) / 75%) = 0.45 Opr. Req. ( Example – 1 )
= ((394 / (480 / .61)) / 75%) = 0.67 Opr. Req. ( Example – 2 )
= ((394 / (480 / .51)) / 75%) = 0.56 Opr. Req. ( Example – 3 )
 Continued …

 Plan Target = This field is for showing hourly target for the
operation at the planned efficiency level given by user.

Formula For Planned Target = (60 Minute / Operation S.M.V) /

Planned Efficiency)

= ((60 / .41) * 75%)= 110 Pcs. Per Hour ( Example – 1 )

= ((60 / .61) * 75%)= 74 Pcs. Per Hour ( Example – 2 )

= ((60 / .51) * 75%)= 88 Pcs. Per Hour ( Example – 3 )

 Continued …

 Hours Required = This field is for showing how many hours input
is required for achieving planned daily output & it is also useful data for
line balancing and the operation which does not need any operator or
machine balancing the text will appear in green colour & operation
which need balancing will show in red colour.
Formula For Hours Required = (Plan Daily Target/ Planned
Individual Target)

= (394 / 110 )= 3.58 Hour. Req. ( Example – 1 )

= (394 / 74 )= 5.32 Hour. Req. ( Example – 2 )

= (394 / 88 )= 4.48 Hour. Req. ( Example – 3 )

 CONTINUED …

Target at 100% Efficiency = This field is for showing

hourly target for the operation at the hundred percent
efficiency level.

Formula For Target at 100% Efficiency = (60 Minute /

Operation S.M.V)
= (60 / .41) = 146 Pcs. Per Hour (Ex.1 )
= (60 / .61) = 98 Pcs. Per Hour (Ex. 2 )
= (60 / .51) = 118 Pcs. Per Hour ( Ex.3)
Line Balancing
 WHAT IS LINE BALANCING ?
Line Balancing is levelling the workload across all
processes in a cell or value stream to remove bottlenecks
and excess capacity.

One of the simple technique to asses the line balance is

capacity study & pitch diagram.

Diagrammatic view of the capacity of various operations

 A CONVENTIONAL SEWING LINE
1 2 3 4 5

70 sec. 80 sec 60 sec 40 sec 60 sec

How
• Question 1: Who is the fastest operator?
• Question 2: Who is he slowest operator? ?
• Question 3: What is the hourly line output?
 REASONS FOR IMBALANCE LINE
• Irregular distribution of work
• Less monitoring
• To Fail to identify the skill operator for said operation
• Changing the skill ness of the operators
• No motivational activities for operators
• Quality fault
• Less effective decision making
• Input gap
• Machine problem or no supply
• Avoiding attitude to implement the proposed method
or system
 WHAT IS BOTTLENECK?

• Bottleneck is a low production area in which

the flow of production is reduced.
• In bottle neck point the output is low with
compare to previous and next operation.
 BOTTLENECK ELIMINATION
TECHNIQUES
Methods improvement:
by improving the way the operator is handling the
material and doing the operation.

Better operator allocation:

We could check if any ‘A’ grade operator is
allocated on a high capacity operation, and
whether the bottleneck operator is only ‘B’ grade. If
this be the case both the operators could be
swapped to get more productivity out of
bottleneck.

Machine speed or calibrations:

Could check , whether they are set right.
 BOTTLENECK ELIMINATION
TECHNIQUES
Workplace Improvements:
This could be relating to ergonomic issues like light, fan, seat adjustment,
etc.

Work Aids & Specialized Machine:

Guide, Folder, attachment, Jigs etc. Using computerized UBTs and other
specialized machines.

Work Breakdown:
Investigate whether it is possible to further divide the process.
 BOTTLENECK ELIMINATION
TECHNIQUES
Work Sharing:
Giving some part of the work (or some of the pieces) of bottleneck operation to
which has potentially higher capacity than required
for line output. Care should be taken that the operator with which work is
shared has
• Same machine as that of bottleneck
• Right skill required for the bottleneck operation.

Quality Problems:
Could look if there is any Quality issue in previous process
due to which the operator is not receiving proper input to
work on, thus decreasing its productivity.
 BOTTLENECK ELIMINATION
TECHNIQUES
Work Overtime:
Bottleneck operations could be made
to work overtime to make enough of
WIP.

Adding additional
manpower/machine:
In case we find the potential
capacity per hour too less than the
target output of the line.
Predetermined Motion Time System (PMTS)
OR
Predetermined Time Standards (PTS)
 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance

A Predetermined Time Standard (PTS) is a work

measurement technique whereby…times are
established for basic human motions.
 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance
MTM 1
Published in 1948 MTM1 contained 350 motion codes
Each code hasMOTION
2
REACH
CODE
variables,
R
distance and difficulty
GRASP G
Each code has an
RELEASE associated
RL Time
MOVE M
POSITION P
Times are shown in TMU’s (Time Measurement Units)
DISENGAGE D
TURN T

MTM1 established the TMU standard for PTS systems

 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance

The Derivation of TMU Values

 MTM 1 established 100,000 TMU = 1 Hour

 Giving 1667 TMU = 1 Minute

 27.8 or 28 TMU = 1
Second
 This is true for Non Incentive “Day Rate”
working conditions

 MTM 100
 MTM Low Task
 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance

The Derivation of TMU Values

 At higher Performance 120,000 TMU = 1 Hour

 Giving 2000 TMU = 1 Minute

 33.33 TMU = 1 Second

 This is true for Incentive working conditions

 MTM 120
 MTM High Task
 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance
MTM 2
Published in 1965 it contained 39 motion codes
GET & PUT codes have 2 variables, distance and
difficulty
Each code has an associated time
Developed from the statistical integrity of MTM1
Times are shown in TMU’s (Time Measurement Units)
 Productivity Improvement
Predetermined
Time‐Cost Time Standards
Benchmarking
Quality & Compliance

MTM1 MTM2
Reach
GET (G) Motion
Grasp

Move
Locate PUT (P) Motion
Release
 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance

Are any grasping motions Decision Model

required NO GA
GET (G) Motion
YES

GA = Easy GET
Is it enough to close hand or GB
fingers in one motion
YES GB = Medium GET
NO

GC = Difficult GET

GC
 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance

Is it a continuously smooth Decision Model

motion YES PA
PUT (P) Motion
NO

PA = Easy PUT
Are there obvious correction PB
motions
NO PB = Medium PUT
YES

PC = Difficult PUT

PC
 Productivity Improvement
Predetermined Time Standards
Time‐Cost Benchmarking
Quality & Compliance

MTM 2 Example Data Card

C O D E

GA GB GC PA PB PC

TMU
5 (< = 5 cm) 3 7 14 3 10 21

15 (< = 15 cm) 6 10 19 6 15 26

30 (< = 30 cm) 9 14 23 11 19 30

45 (< = 45 cm) 13 18 27 15 24 36

80 (< = 80 cm) 17 23 32 20 30 41
 Productivity Improvement
Predetermined Time Standards (PTS)
Time‐Cost Benchmarking
Quality & Compliance
MTM Core Data
Created in 1970 By the UK MTM Association & GSD
Flexible & Multilevel

Core Data was developed 1970 and has 1440 codes

Facilitated the Building of Industry Specific PTS

 GSD –General Sewing Data

GSD is a technique for Methods Analysis and the setting of Time

Standards for the Sewn Products Industries.

Share Your Knowledge

If you are interested share your IE & Planning or Textile related knowledge or articles &
any method or process development video or any kind of information.
If you are interested, you can send article at textilelibrary.diu@gmail.com or
ie4garments@gmail.com
N.B: You have to attach your name, Profession & profile picture with file.
 GSD –General Sewing Data
GSD was developed using MTM Core Data, to provide a consistent,
accurate and easy to understand, easy to communicate methods
analysis and time standards determination technique. It was designed
specifically for the Sewn Products Industries, and was researched and
developed within these industries.

GSD is transferable between locations and it recognizes that variable

work places, production flow systems and batch sizes affect output.

The final system consists of 36 codes of data in 7 categories with

simple retrieval codes for ease of application and understanding. Each
item of data has a constant TMU value. There is also a system of
Sewing Code Derivation within the system and sewing formulae to
facilitate the calculation of machine time.
 GSD –General Sewing Data

GSD consists of 25 codes at the First Level (General) which is

supplemented by 11 codes at the Second Level (Get & Put).

Share Your Knowledge

If you are interested share your IE & Planning or Textile related knowledge or articles & any
method or process development video or any kind of information.
If you are interested, you can send article at textilelibrary.diu@gmail.com or
ie4garments@gmail.com
N.B: You have to attach your name, Profession & profile picture with file.
 GSD –General Sewing Data
.
ACTIVITY BASE CODE
FIRST LEVEL CATEGORIES
1. Obtaining and Matching Parts
2. Aligning and Adjusting Parts
3. Forming Shapes
4. Trimming and Tool Use
5. Asiding Parts
6. Handling Machine

SECOND LEVEL CATEGORIES (Get and Put actions)

7.Get and Put
SEWING
8. Sewing
 GSD –General Sewing Data

Obtaining and Matching part

1. MG2T
2. MG2S
3. MAP
4. MAP1
5. MAP2

Aligning & adjusting

AM2P
AJPT
ARPN
APSH
 GSD –General Sewing Data

Folding & Forming Shape

1. FFLD
2. FCRS
3. FUNF

Scissoring
1. T CUT
2. T CAT
3. TBLD
4. TDCH

Asiding
1.APSH
2. AS1H
3.AS2H
 GSD –General Sewing Data

Holding Machine
1. MS1A
2. MS1B
3. MS1C
4. MHDW
5. MBTB
6. MBTE
GET & PUT part
1. GP1E
2. GP1H
3. GP2H
4. GPCO
5. GPOH
6. GPAG
 GSD –General Sewing Data

GET & PUT part

1. PPAL
2. PPOH
3. PPST
4. PPL1
5. PPL2

Sewing
THANK YOU