Balancing Exercises

Exercise I
• The second team of Phil's Section (N to Z) will make most of a
child's dress, work content 17.40 standard minutes, at a
required rate of 21 per hour.
• Predicted line utilisation 80%
• Predicted line attendance 90%
• Predicted operative performance 80%
• Required output sm hour _ ?
• Operatives required _ ?
• Floaters required _ ?
• Line operatives required _ ?
• Expected output garments/minute _ ?
ANSWERS

For any operation the performance to select ('expected performance')

is the work content in sm's X 0.438 X 100 BSI.
 Operation breakdown for style 7300
TABLE - 1

No. Machine Operation Work Content

ex. Known
1Lockstitch Mitre point of belt, aft. buckle and    
loop, and top stitch. 0.6
2Lockstitch Turn hem of insertion and art. to
front neck. 1.2
3Lockstitch Join side of collar and turn out. Hem
sleeves. 1.4
4Lockstitch ZZ Att. lace to collar 0.9
5Lockstitch ZZ Att. lace to front neck. 0.7
6Lockstitch ZZ Att. lace to sleeve. 0.4
7Lockstitch 2N Top stitch sleeves at cuff (pre O/L). 0.7
8Lockstitch Att. belt loops to front yoke. 0.6
9Overlock Join shoulders. 0.5
10Lockstitch Att. collar plus tab and turn backs. 1.4
 Operation breakdown for style 7300
No. Machine Operation Work Content
ex. Known
11Overlock Neaten collar. 0.6
12Lockstitch Join centre back seam of yoke and att.
zip. 1.8
13Lockstitch Att. front skirt to yoke. 0.7
14Lockstitch Join centre back seam of skirt and att.
to yoke. 1.0
15Overlock Neaten back and front yoke: join. 0.6
16Overlock Att. sleeves out flat. 1.0
17Overlock Join sleeves and side seams. 1.2
18Lockstitch 2N Top stitch collar to neck edge. 0.8
19Lockstitch 2N Top stitch 2 sleeves. 0.6
20Blindstitch Close hem. 0.7
  Total     17.4

ZZ Lockstitch—Zig Zag Machine.

2N Lockstitch—Two Needle Lockstitch.
 QUESTIONS
• (1) Calculate the missing figures.
• (2) Produce a theoretical operations balance.
• (3) From the skills inventory, decide upon
section initial manning.
• (4) Prepare an initial balance.
• (5) Comment upon the figures obtained.
 Additional information
(1) Skills inventory for Phil's Section - Nan to
Zelda (see Table 2).
(2) Operation breakdown (see Table 1).
(3) Operations may be grouped out of sequence.
The work boxes go to and from a central
storage rack between operations.
Theoretical operation balance for style
7300
Theoretical operation balance for style
7300
Theoretical operation balance for style
7300
 SKILLS
INVERNTORY
TABLE – 2
Skills Inventory for Phil's
Section N to Z
INITIAL MANNING
INITIAL BALANCE
INITIAL BALANCE
COMMENTS ON INITIAL BALANCE

30.5
 COMMENTS ON INITIAL BALANCE
(2) There is a major imbalance at operations (3, 13 and
14) of —5.8 gmts/hr. This can be made up (since it is
a plain lockstitch operation) by the floater.
(3) Terry and Vera, both potentially 100 BSI performers
have not been used.
(4) Ran is not on her best operation. The balance
would have been improved if the two garments
(2800 and 7300) had been made on one line,
choosing the operatives from all of Phil's section.
Exercise 2
 Information
• Information is supplied for a trouser section,
on straight line work (see Table 3).
• The system is 'progressive', which means that
work cannot be backtracked. The work in
process between workstations is 220
garments. It must be maintained.
• Target output (expected output) is 220
garments/hour.
 Initial manning
'Serge on fly and buckette' A, B and C
'Fob' (not on this style) Nil
'Hang pockets' D, E, F, G and H
'Close pockets' I, J, K and L
'Tack' M and N
'Pass' (8 am to 12 noon) O and P
(1 pm to 5 pm) Q, R and S
(1) Calculate the imbalance of the proposed
manning.
(2) Comment on it.
(3) Suggest internal movements to correct the
balance.
 Points to note
• Try to keep learners on one job all day.
• The greatest efficiency comes from putting
operatives on the jobs that they know best and
not from merely keeping people busy.
• The output of operatives should always be
checked after the first hour, to see if it is as
expected.
• The effects of absenteeism and utilisation do not
affect the calculation.
Skills inventry
Skills inventry
Skills inventry
Description Operators Output diff
Serge on fly and buckette A, B & C 220 0

Hang pocket D, E, F, G & H 260 +40

Close pocket I, J, K & L 240 +20
Tack M&N 210 -10
Pass from 8 am to 12 noon O&P 160 -60

1 pm to 5 pm 240 +20
Q, R & S
Target 220