Improvement of Productivity of a Sewing Line

by Using Line Balancing Technique.

Prepared By
Sheikh Firoz Ahmed
EBTX-160200965
 
MD. Farhad Hossain
EBTX-160301321
 
Md. Mehedi hasin
EBTX-160301337
 
 Supervised by
 MD. Shafiqul Islam Chowdhury
Lecturer
Department of Textile Engineering
Northern University Bangladesh
 Acknowledgement
 
At first our gratefulness goes to almighty Allah to give us strength and ability to complete
the project and this report. You have made our life more beautiful. May your name be
exalted, honored and glorified.
 
We should like to express our heartiest gratitude to Prof. Dr. Engr. Md. Humaun kabir
Pro Vice-chancellor & Dean (Faculty of Science and Engineering) and Asst prof, Lefayet
Sultan Lipol, head, Department of Textile Engineering Northern University Bangladesh
for their kind help to complete our project effectively and successfully.
 
Md. Shafiqul Islam Chowdhury, Lecturer, Department of textile Engineering our
supervisor, to whom we extremely indebted for this tremendous support and guidance
throughout our training period. Being working with him we have earned valuable
knowledge.
 
 Abstract
This project is “Improvement of productivity of a sewing line by using line balancing technique.
“We discussed the paper comparing the productivity before and after applying the Industrial
engineering technique. By using method, time, capacity and production study, it is possible to
improve productivity while reducing wastage. To find out the (standard minute value) S.M.V,
process wise capacity has been calculated, in addition to that we have calculated the target,
capacity, manpower, line graph, labor productivity and line efficiency. we have compared the line
graph after balancing the line, labor productivity and line efficiency. Finally proposed production
layout has been modeled and ensures a better productivity. In this paper we discussed some
procedure about Time, Capacity, and Production study. Also discussed about operation
breakdown and others tools and techniques which consist of different experimental discussion,
experimental result & discussion.
 Introduction

The garment manufacturing and exporting industry is facing heavy

challenges due to various factors including global competition, production
costs increase, less productivity/efficiency, labor attrition, etc. the basic fact
that our country has immense strength in human resources itself is the
motivating aspect to feel for such an analysis. Our analysis arrives at a view
that we need better focus and Concentration in identifying the real issues,
taking corrective actions suiting to the specific industrial center or unit,
empowering the workers, supervisors, Executives and managers by
enhancing their knowledge and ability, analyzing orders effectively and
decide whether it is viable for the factory, etc. There is a lot of internal
correction and openness to knowledge/technology approach that needs to be
built into the minds of the facility owners and managers and so also down
the line. The facilities have to upgrade as system run, rather than people run.
 Literature Review

1.SMV:
SMV means standard minute value. It is a numerical value which is represented the Standard time of a
process or operation in a standard environment for standard worker To convert cycle time to normal or basic
time we have to multiply it with operator Performance.

2. Objectives of SMV:
To determine line balancing
To increase the productivity of the company
To make proper distribution of SMV
To make better utilization of man, machine & materials

3.Bi-hourly production board:

The bi-hourly production report where the production details of each and every section noted for every 1
hours. This is vital information to conduct bi-hourly meeting with all the department staffs to ensure the line
in balance. This report has the loading details and WIP details to make the balancing decision.

4.Stop-watch measurements:
 When using a stopwatch some points are to be noted on mind to exactly make the best use of the
equipment and perfectly measure the time or SMV
5.Line layout:
Layout means to distribute/allocate elements (Sequentially) to the individual operator in the line by
considering total worker, worker experience, total machine, types of machine & mainly the estimated
SMV of allocated/distributed elements in a broken down garments. A good layout is that physical
arrangements which permits the product to be produced with minimum unit cost in the shortest time.

6. Operator motivation:
Operators will is the most crucial part in productivity improvement. If they are motivated, they will put
enough efforts on the work. Employee motivation generally depends on various factors like work
culture, HR policies, bonus on extra effort or achieving target. In garment manufacturing operator’s
motivation come through extra money. Operator motivation can be improve by sharing certain
percentage of you profit made from operators extra effort.

7. Time Study:
time study standardizes the time taken by average worker to perform these opera­tions. It can also be
defined in the following words “work measurement” is the application of techniques designed to
establish the time for a qualified worker to carry out a specified job at a definite level of performance

8. Cycle Time:
The total time from the beginning to the end of your process, as defined by you and your customer.
Cycle time includes process time, during which a unit is acted upon to bring it closer to an output, and
delay time, during which a unit of work is spent waiting to take the next action. In a nutshell, cycle time
is the total elapsed time to move a unit of work from the beginning to the end of a physical process
9. Method study:
The main purpose of method study is to eliminate the unnecessary operations and to achieve the best
method of performing the operation. “Method study is the systematic recording and critical
examination or existing and proposed ways or doing work as a means or developing and applying
easier and more effective methods and reducing cost. "Method study scope lies in improving work
methods through process and operation analysis

10. Bottleneck in production line:

The lowest output point in production line is called bottleneck. The bottleneck area is where supply
gathered and production goes under capacity. In the chain working systems the supply of an operator
is the feeding of next operator. So, the minimum supply from bottleneck point will be the feeding
of next operator as well as the production will not be more than the output of bottleneck point

Figure: Bottleneck in production line

11. Hourly operator capacity check:
Employ work study personnel (if you don’t have) and start checking operator capacity hourly or bi-
hourly. Compare actual operator’s hourly production with their capacity. If production is less then
question them why? It helps in two ways – first, when operators’ capacity is checked at regular
interval they will be under pressure. Secondly, work study personnel start thinking on methods how
cycle time can be reduced. Using the capacity data, you can move ahead in balancing.

12. Operation Sequence:

Some of the production departments work without a properly planned or written operation
sequence. This is a critical step in garment production and a mistake ornegligence at this stage can
result into huge losses later in terms of operator time, work content and quality.

13. Operator Monitoring :

Most of the companies do not have the means to establish their performance against standard, so
they have no idea where they stand. There are no proper measurements so their efficiency levels
are at best a guess, it is impossible to understand how they will be able to continue to compete
unless they have proper controls in place, and have established productivity improvement programs
to move forward in the future
13. Workplace Engineering: 
The management wants to fit as many machines in the factory as possible, reducing the scope for
methods improvement. The space between machines is insufficient in many cases. A good
workplace layout will eliminate unnecessary motions and fatigue resulting in substantial increase
in the efficiency of the operator. Just look at the picture alongside and think how efficiently
someone will be able to work 8 hours a day sitting in that posture.

Figure: work place engineering

14.Motion Study:
 Motion study is a technique of analyzing the body motions employed in doing a task in order to
eliminate or reduce ineffective movements and facilitates effective movements. By using motion
study and the principles of motion economy the task is redesigned to be more effective and less
time consuming.

15. The Goals of Motion Study:

 Capacity Improvement
 Planning/scheduling
 Safety

16.Classification of body movement:

Operators use their body for different operations, and spend their maximum time. The
motion time is long but sewing time is short. So, body movement is classified by 5
divisions. They are as below-
 
Knuckle: only finger is used for this movement.
Wrist: using hand and finger.
Elbow: For arms, hand and finger.
Shoulder: Upper arm, forearm hand and finger.
runk: For so upper arm, for arm hand and finger.
 Materials and Methods
1.Material used:
i) Single jersey
ii) Pattern paper
iii) Measuring tape
iv)Scissor
v) Pencil
vi)Eraser
vii)Curve ruler

2. T-shirt material:

Figure: Long sleeves T-shirt

3.sewing Process Flow-Chart Of a Long Sleeve T-shirt:
Neck and bottom rib make tack
Cuff and bottom rib make tack  
Neck rib sewing

 Cuff rib sewing

Bottom rib Sewing

Raglan sleeve join B.K part

Raglan sleeve t/s

Raglan sleeve front part

Raglan sleeve t/s

Neck join
Neck top stitch

Label join

Side seam close

Bottom rib join

Cuff Rib join

Bottom rib top stitch

Cuff rib top stitch

Final Output
4.Calculation Method of Standard Minute Value (SMV)
SAM or SMV ={ Basic Time + (Basic Time × Allowance)}
= 0.27 + (0.27 × 10%)
= 0.27 + 0.027
= 0.297minute
So, SMV value for that operation is 0.351 minute.

5.Line Balancing Improvement:

A production line is said to be in balance when every worker’s task takes the same amount of time.
In our working time we used some expert worker and used update machine. But before improvement
we get low production. After improvement in the same work done by some expert worker and used
some update machine whose efficiency are good get good out production.
6.Operation Bulletin of a Long Sleeve T-shirt before Improvement:

Figure : Operation Bulletin of a Long Sleeve T-shirt before Improvement

7.Line Feeding of a Long sleeve T-shirt before Improvement:

Remove Helper/Operator
Helper
Operator

Figure: Line Feeding of a Long sleeve T-shirt before Improvement

8.Operation Bulletin of a Long Sleeve T-shirt After Improvement:

Figure: Operation Bulletin of a Long Sleeve T-shirt after Improvement

9. Line Feeding of a Long sleeve T-shirt after Improvement:

Helper

Operator

Figure: Line Feeding of a Long sleeve T-shirt after Improvement :

Results and Discussion
5. Table comparison between before and after improvement method of T-shirt with diagram:
6. Results and Discussion:

The SMV includes additional allowances for Rest and Relaxation, Machine Delay and
anticipated Contingencies. We get SMV of a long t-shirt 11.18 minute. After line balancing
here we say that qualified worker working at standard performance to finished sewing of a
designer T-shirt on time 10.51 minute.
 
In figure it can be seen that the line of actual capacity is below the graph chart and it is
before the balancing. In after the line balancing and revised line capacity. The output per
hour is increased from 141 to 146 that mean an increase in quantity of 5 pieces of garments
per hour. If it is calculated in the mean of SMV it states that total 56 working minute is saved
in hand due to the work sharing line balancing method.
 
In the end but not last on sewing floor line balancing should be maintained according to
sewing machine sequence. Proper line balancing in a sewing floor can be found with the help
of work study and SMV calculation. This line balancing process can be change according to
garment style and design.
 Conclusion
Industrial engineering is an important and essential part of any Garments Industry. We learn
all the implementations and techniques of the processes which we have studied theoretically.
It gives us an opportunity to compare the theoretical knowledge with practical facts and thus
develop our knowledge and skills. This project also gives us an opportunity to enlarge our
knowledge of textile administration, production planning, procurement system, production
process, and machineries and teach us to adjust with the industrial life.

The End