ABSTRACT

Apparel industry basically, the production industry has vastly growing economy in the world
trade, Production describes the making of the garment which mainly consists of man, machines
etc. to work on, for the smooth functioning any production industry it is very important to have
a standard in which they are working upon. And for the buyer’s satisfaction it is necessary to
deliver in the desired time. The productivity in garment sector depends on many factors. Time
and motion study is very important factor that control the productivity of garment sector. In
garment sector to make the shipment in exact time it is very necessary set a target for sewing
section. The total productivity per day working time 8 hours how much the machine actually
worked depends upon the needle working time of the particular machine. This paper
represents the importance of calculation of actual needle time for a particular operation during
the working hours. And the way to replace the manpower with machine
1. INTRODUCTION
The production of clothes, which was considered to be an art in the prehistoric period, has
undergone several technological changes. The technological innovations have helped apparel
manufacturers, brand merchandisers and retailers to shift towards a new global reality where
customer choice and service are not just the priorities; but have the potential to create a
difference between the success and failure in a highly competitive market. Today, in the global
apparel trade, the retailers and brand merchandisers are playing a dominant role, and the
apparel industries continue to change faster than ever. The retail sector is becoming
increasingly concentrated, and the largest international retailers are becoming more powerful
through mergers and acquisitions. To become successful in the highly competitive market, it is
essential to understand each and every aspect of the apparel business. This introductory
chapter describes the global scenario of clothing production, major challenges and ways to face
the challenges and the future trends in apparel production.
Problem Identification
Time calculation generally the actual needle time is very difficult for the particular line or
machine. To identify and get the actual production time is important as the production at the
end of the day particularly depends upon the time the needle work.
PROBLEM DEFINATION
To identify correctly the needle working time of a particular sewing in the line through
Automation for a particular sewing operator.
2. LITERATURE REVIEW
As we know that the time study is very important for, the objective of a time study is to develop
and check production standards. An operation is studied by time analysts while a style is in
production. Time studies are an appropriate method of work measurement for high-volume
operations with a high degree of repetitiveness. They are frequently used to establish
production standards for operations performed in a progressive bundle system. SAM
(STANDRARD MINUTE VALUE) Defines the Standard Allowed Minute in short it is a Time
allowed to do a particular task. Mostly it is measured in Minutes or Second. It is used to
measure work content of a garment and then work content for individual operation. The pieces
or the output/day depends upon the total time the operator works in machine for the
particular operation in single day.
PRIMARY DATA COLLECTION
Collection of primary data through the video analysis for a particular line is being done. Video
was recorded for the working time of the particular operation done by the operator in that
machine Per hour.

NEEDLE DOWNTIME
30.00

20.00

10.00

0.00
E H SE T . D
O S AT C T/
S
RI HT PK AND INS EA
T
CU OPE
N NG
CL P T K IG
C K B R D A KI
K C R A W T H
TH TO N P BA SIDE H B ST SE 5 AN NER LE M
OU KT. COI T/S AI P
M P T C W A M
O O OR HO
E T IN PA T O SE . L /B C ON
E T
CK CO ON BEL SI
D AT W UTT
PO TT. T / S LA B
H A .
A TC A TT
P

AVG

DATA ANALYSIS
According to the graph shown above we can clearly see the operation done by the operator Y-
axis and the needle time(actual) taken to complete the particular operation.
According, to the graph the actual needle time (needle running is shown) per operation of
the line, we can clearly see that, the operation attach W/B to piece has more needle downtime
as compared to another.
ASSEMBLY SECTION
Particular line has 3 sub section front, back (preparatory), assembly section the critical
analysis of needle time (needle downtime) is recorded and the results are further being shown.
 AVG.
30
25
20
15
10
5
0
.
M AM SE OK RT OP OP RS HT F T F T NG NG CK LE UT CE EN NG NG CK
S EA S E CLO K Y .PA LO LO F T RIG LE LE MI MI TA HO D C PIE OP MI AKI TA
R
IN IN M AC PKT LT LT T O B /B RN EM EM A ON AN TO ER EM M AR
E W ON S EA T. B /S .BE . B E AIS W/ E W TU M H M H B TT OP B R N M H OLE B
S /S E AT T TT TT W S E OS /S O O BU LO T. W CO TO N H
T ID T
S E AM A A TO CLO CL /B OTT OTT T . AT / B O T T O
E
S / B W B B AT W B UT
D B
SI T . W
AT

DATA ANALYSIS
According to the graph shown above it shows the average needle downtime for the particular
operation of the operator.

3. SYSTEM ARCHITECTURE

CONNECTED
TO
OPERATION SEWING MACHINE SENSOR ………………
NEEDLE TIME
DATA (RPM)

NEEDLE START ARDUINO MICROCONTROLLER

TIME CALCULATION IDE SOFTWERE

DATA FROM IDE

SOFTWERRE

EXCEL OR SPREADSHEET NODEMCU WIFI MODEULE

NEEDLE TIME DISPLAY

CLOUD BASED DATA

NODE RED /
THINGSPEAK
COMPARISION BETWEEN LINES

TIME GRAPH
ATT. WAIST SIZE LABEL

FRONT CROTCH JOINT

T/S ON ZIP

BELT LOOP MAKING

ATT.SIDE PKT

CLOSE STITCH AT C.PKT

CLOSE FRONT PKT. BAG

ATT.EXT.TO WAIST

ATT. STRIP TO BELT SECTION

ATT.FRONT PKT./TAK.

F/B FLY OVERLOCK

0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00
remaining hrs not worked(HRS) hrs

The following graph shows the needle time not worked and worked time as per the operation.
Methodology
The above graph shows the primary data collected through video analysis of the selected
operation in the line. The video analysis was taken from second week after joining the
company,
What is the need of the project?
The time calculation is very important for the proper functioning of apparel industry the total
lead time,

 The total production depends upon the needle time of a particular line or machine time.
 Insist correctly the actual operator working time for a particular operation.
 Sewing machine working is totally depends upon the needle working it also includes
material handling time.
What benefits are about this project?
Key benefits to the industry are as follows: -

 Difference between total pieces made/day to the actual time attended by the operator.
 Helps I.E department to find the reasons for the delay in the lead time.
 Helps to clearly identify the skill of the operator as the other methods can also solve it.
 The non-productive time attended by the operator to the concerned supervisor for
better training programs.
 Helps to set SOP (STANDARD OPERATION PROCEDURE) for the particular line sewing
operation.
 Helps to set the rate (piece rate) or fixed rate working operator judge on their time
attended.