IE BASIC

TRAINING
PROGRAM
Conducted by I.E. Department
What is work study ???

It’s a Management Tool to

Investigate all Factors which
are affecting to the
productivity.

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2
 Why We Need Work Study
1. Improving the Productivity.

2. Minimizing the Cost.

3. Improving the Efficiency.

4. Developing the People.

5. Making Standards. (Activities & manning)

 Classification of Work Study
Work Study

Work Measurement. Methods Study.

Motion study
Time study

Manually PMTS
(GSD)
 General Sewing Cycle
Handling Time
Stitching Time

Gamini Wijekoon
 What Is Productivity
Productivity is the parameter of measuring the use Of
Resources in an Organization.

The other way, it’s The Ratio of Out put & In put.

Productivity = Out Put

In Put

It’s the main Factor to be measured in the Organization.

 How can we improve the Productivity…?
We can do it basically in 3 ways….

 Increase the Out put while decreasing the In put.

 Increase the Out put keeping the In put in a certain level.

 Increase the Out put up to a higher percentage while increasing

the In put to a lower percentage.
 What is the SMV ???

Time taken by a standard operator to complete

any given operation/s with pre-defined
conditions.

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Why we need to go for
the ‘SMV’

o To set Targets process wise.

o And set Targets line wise.

o To define the right CM. (Cut & make price)

 The Standards for SMV.
 Operator rating (speed) should be 100%.

 Need to use appropriate machine for selected operation.

 Working environment should be standard level. (Work area,

Lighting &, temperature , sound, etc…)

 Work place need to be arranged according to the define work

method .

 Operator should be good health and physical condition.

 Calculation Of SMV
• SMV = BT + ALLOWANCES
• Direct Basic Time can be generated by GSD or any PMTS
versions.
In Stop watch Time study
• BT = OT X OR
SR =100

BT- BASIC TIME

OT- OBSERVED TIME
OR- OBSERVED RATING
SR- STANDARD RATING
 How to calculate SMV
 Obtain cycle times(10) by observing a particular operation considering the Rating
factor.
 Work-out basic time using observe time & observe rating.
 BT = OT X OR
100
 When add allowances (relaxation & contingency allowances) to basic time, the SMV
can be generated.

 Ex- Working out the SMV of Attach placket of Polo shirt.

 Operation Observations Avr

 Attach Cy/T .28 .26 .27 .28 .26 .27 .26 .28 .26 .26 0.268
placket
Rating 80 100 90 80 100 80 95 80 95 90 89

Basic Time (BT) = .268 X 89

100
= .238
• Bundle handling time - 0 .025

When added bundle handling time = 0.238 +0.025

= 0 .263

Adding allowance,

Consider the operation carry out in an environment with specific conditions and use SNL
lock stitch machine. An allowance of 18% is added in such a situation.

when add allowances = 0.263 +18%

• SMV = 0 .31

Operation 100% SMV target = 60 minutes

SMV

= 60
0.31
•
100% SMV target = 194 pcs
 Line Target of a Style.

This is the Target of a particular style using limited man power

in limited time period.

Required factors to calculate the Target’

1). SMV of the Style – Item.

2). Available man power/ Given man power.

3). Working time. (in minutes)

 How to calculate the
• Ex -;
o
Target ???
Style/ Item - Polo shirt
o SMV - 12.52
o Given man power - 36 m/o + 10 hel (46)
o Working time - 10 hours ( 10 X 60 = 600 mts)

100 % Tgt = Manpower X Working minutes

SMV

100 % eff. Tgt = 46 X (1 x 60)

12.52
= 2760
12.52
= 220 pcs If 70 % eff = 220 X 0.7
= 154pcs
 Process Target Calculation
• Target = 60 minutes (1 hour)
SMV

Ex;

Operation - Sleeve attach

SMV - 0.56 mts.

100% hourly Target - 60 mts. (1 hour)

0.56

- 107 pcs

80% hourly Target - 107 X 0.8 = 86 pcs.

 SAH CALCULATION
• PLAN TARGET= 46*60/SMV*PLAN EFF
• ACH TARGET= TOTAL PRODUCTION

• PLAN SAH= SMV*PLAN TARGET/60

• ACH SAH=SMV*ACH TARGET/60
 What is SAH…….?

 SAH= Standard Achieve Hour

SAH= SMV X Production / 60

 Ex;
Product - Tee Shirt
Minute value(SMV) - 12.50
Production - 1200 pcs

produce minutes - SMV X Production /60

- 12.50 X 1200 / 60
- 250 Hour
 What Is Capacity?
Calculation Of Capacity
• Capacity is the capability of a Manpower. It means how much
production can give by A Manpower.

• Capacity= 60/ Basic Time.

• Basic Time= Avg Min+Allowance 5%
• EX-
o Slv Attach Process Avg min of 10 pcs
• .50 .48 .52 .55 .55 .50 .52 .50 .52 .54 = .518 min+5% = .54 Minutes
• So, Capacity = 60/.54 = 111 Pcs
 Why We Need Capacity?
• To know the Capability(How much production A M/P Can
give)
• To Achieve line Plan Target.
• For Line Balancing (To Solve Bottleneck Process).
What is the Efficiency…?
Efficiency is the “SPEED”.

Efficiency = SMV X Out Put X %

Man power X Working minutes.
 Efficiency Calculation
 Required Factors to calculate the Efficiency..

- SMV of the style.

- Production(Line out put) 0f the style.

- Used Directs (Man power) to produce above production.

- Worked minutes (working hours X 6o mts).

 Calculation
o Example-
• SMV of the style - 12.52
• Hourly production - 1700 pcs
• Used directs(man power) - 36 + 10 = 46
• Worked minutes - 1 hour (60 mts)

• Efficiency = SMV X Production X %

Man power X Working time

= 12.52 X 1700 X 100

46 X 10 X 60
= 2128400
2760
= 77 %
 What is Line
balance ?

Line Balance = Pitch time (average time) * 100%

Bottle neck process time

Line Balance = 50sec * 100% = 62.5%

80sec
 Exercise 1:- A,B,C,D,E
Game
 1st Operator
A B C D E
 2nd Operator
A B C D E
 3rd Operator
A B C D E
 4th Operator
A B C D E
 2nd Operator
A B C D E
Exercise 1:- A,B,C,D,E
Game
1st Operator = A, B
2nd Operator = C,D,E,A,B,C,D,E
3rd Operator = A,B,C
4th Operator = D,E,A,B,C,D,E,
5th Operator = A,B,C,D,E
 Exercise 2:-
A B C
NO . 1
D E
A B C
NO . 2
D E
A B C. 3
NO D E
A B C
NO . 4
D E
A B C
NO . 5
D E

NO- NO- NO- NO-4 NO-

1 2 3 5
 Exercise 2:-
1st Operator = A,B,C,D,E
2nd Operator = A,B,C,D,E
3rd Operator = A,B,C,D,E
4th Operator = A,B,C,D,E

5th Operator = A,B,C,D,E

 LEARNING CURVE
CRITERIA
Types of Learning SMV Range
Curve
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

L-1 Below 4.99 20% 30% 40% 60% 65% 65% 70% 70% 70% 75% 75% 75% 75% 75% 75% 75% 75% 75% 75% 80%
Over 5.00-
L-2 Below 12.00 20% 30% 40% 60% 60% 65% 65% 70% 70% 70% 75% 75% 75% 75% 75% 75% 75% 75% 75% 80%
Over 12.01 -
L-3 Below 18.00 20% 30% 40% 50% 60% 60% 65% 65% 70% 70% 70% 70% 70% 75% 75% 75% 75% 75% 75% 80%
L-4 Over 18.01 10% 20% 30% 40% 50% 60% 60% 60% 65% 65% 65% 65% 65% 65% 70% 70% 70% 70% 70% 75%
                                     
SMV less than two minutes, within the range then
Current to Similar below learning curve will be
applied.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Current to
Similar 30% 50% 60% 65% 65% 70% 70% 70% 75% 75% 75% 75% 80% 80% 80% 80% 80% 80% 80% 80
 QCO & THROUGHPUT
TIME
• QCO= QUICK CHANGE OVER. TIME BETWEEN OLD
STYLE LAST OUTPUT & NEW STYLE 1ST OUTPUT.

• THROUGHPUT= TIME TO COMPLETE LAYOUT.

 Off Standard Calculation
• Off Standard: Lost Minute*Idle M/P

Man Machine Materials Method

TTL. OFF
TOTAL HURS
STND OFF
Late M/C B/D OFF LOST
UNIT Needle POWER CUTS PRINTING EMB Compresso TECH QUALITY ACD.TO STANDAR
/other DELAY R/M DELAY STND DUE TO
Lost Time OFF DELAY DELAY DELAY r Problem DELAY DELAY EFF D%
Issues HRS IN EFF%
LEVEL.

G1 96 390 407 363 8 150 420 9 58 0 0 1901 25655 1036 2%

G2 195 1044 529 472 0 0 0 0 0 0 13 2253 26760 1125 2%
G3 0 953 512 199 0 77 50 0 26 0 0 1816 28074 849 2%
G4 191 618 329 105 501 0 135 0 0 19 0 1898 24917 971 0%
G5 25 287 82 18 17 0 138 0 17 0 0 584 25486 277 0%
A1 68 326 125 0 542 764 32 100 12 31 558 2557 37451 1374 2%
A2 99 127 119 0 73 297 156 0 10 50 432 1364 34685 743 1%
F1 0 1870 82 202 0 156 3013 0 0 0 0 5322 39776 2696 3%
F2A 408 748 473 587 0 0 6 0 0 820 0 3041 16601 1657 4%
F2B 415 1526 441 593 0 0 9 0 13 805 0 3801 15412 2121 5%
F3 55 117 105 0 28 400 291 24 82 0 57 1159 43036 568 1%
F4 1082 1037 391 681 0 1430 0 0 87 0 1576 6283 44933 3139 3%
F5 12 135 130 1920 25 0 0 0 11 0 320 2552 27123 1534 2%
C1 21 965 232 765 0 0 299 0 0 0 1155 3437 18349 2132 4%
C2 105 1599 106 656 0 0 0 0 0 0 1603 4070 17451 2643 5%
I1 79 159 153 141 0 40 0 0 0 0 46 618 28754 368 1%
I2 1890 2830 830 0 0 0 0 0 0 0 0 5550 39736 2640 3%
I3 0 290 228 190 213 0 0 0 0 0 0 921 51463 357 0%
IDR-4 337 314 259 21 33 112 0 0 0 0 30 1106 47364 483 1%
IDR-5 140 201 82 57 0 0 0 0 0 0 0 481 8447 374 1%
KDS Total 5216 15534 5615 6971 1439 3426 4548 133 317 1726 5791 48233 601473 25354 2%
LINE FEEDING PLAN
Feeding Plan UNIT #   LINE #  

BUYER #   STYLE #   ITEM :   DATE :  

FEEDING END
FEEDING START TIME   TIME   TTL TIME TAKEN  

PLAN ACTUAL REMARK

WST # PROCESS M/C ST.TIME F.TIME TTL MTS ST.TIME F.TIME TTL MTS S
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
 KDS APPARELS LTD.
OB
IE Department
OPERATIONS ANALISES SHEET
Buyer H&M Machine SMV   9.32
Item SHORT Manual SMV   2.05
Style No. GLAMPING Total SMV   11.37
Total SMV. 11.37 Target/Hr. 100%   243
Total Manpower 46 Target/Hr. 80%   194

Component Operation Type of Basic SMV Target Target THI Act. Op No of No of Attachments
    M/c Time 100% 80%   Load M/C Help  
1 FRONT Sew Front Rise 4TOL 14.856 0.2476 242 194 1.0 1 1    
2   Attach Upper Pocket Bag At Body SNLS 27.27 0.4545 132 106 1.8 2 2    
3   BackStitch at Pocket Bag. SNLS 12.996 0.2166 277 222 0.9 1 1    
4   Mark Lower Pocket Bag HEL 7.638 0.1273 471 377 0.5     0.5
BALANCE
5   Match Pocket & Body HEL 5.814 0.0969 619 495 0.4     0.5
6   Close Pocket Bag 4TOL 26.256 0.4376 137 110 1.8 2 2    
7   Tack Lower Pocket Bag At Body SNLS 22.434 0.3739 160 128 1.5 1 2    
8   Tack Pocket Bag at Waist Position SNLS 19.842 0.3307 181 145 1.3 1 1    
9   Tack At O/L Stitch End - SNLS 13.344 0.2224 270 216 0.9 1 1    
10 BACK Sew Back Rise 4TOL 15.15 0.2525 238 190 1.0 1 1    
11 ASSEMBLE Match Back and front HEL 6.192 0.1032 581 465 0.4     1  
12   Sew Inseam 4TOL 14.34 0.2390 251 201 1.0 1 1    
Bartack at Inseam - Only 1 BTK at inseam motion without bundle handling
13 13+38
  time(Only balancing process) BTK 3.036 0.0506 1186 949 0.2 0.5 1  
14   Sew Bottom Hem 3TFL 33.162 0.5527 109 87 2.2 2 2    
15   Cut excess at Bottom. HEL 12.276 0.2046 293 235 0.8     1  
16   Measure And Cut Waist Elastic HEL 5.88 0.0980 612 490 0.4     0.5
17   Elastic tack SNLS 9.084 0.1514 396 317 0.6 1 1   BALANCE
18   Mark Waist Elastic. HEL 5.79 0.0965 622 497 0.4     0.5
19   Tack at Bottom Hem SNLS 18.558 0.3093 194 155 1.3 1 1    
20   Sew Side Seam 4TOL 20.754 0.3459 173 139 1.4 1.5 2   20+24
21   1/4 Tack at side seam SNLS 15.414 0.2569 234 187 1.0 1 1    
22   Make Waist Band Ring SNLS 15.054 0.2509 239 191 1.0 1 1    
23   Mark Waist Band for Attach & Tack. HEL 13.38 0.2230 269 215 0.9     1  
24   Attach Waist Band At Body 4TOL 38.166 0.6361 94 75 2.6 2.5 3   20+24
25   Top Stitch At Waist Band 3TFL 16.428 0.2738 219 175 1.1 1 1    
26   Back/Edge Stitch at waist band SNLS 36.126 0.6021 100 80 2.4 2 2    
27   Fold & Tack Waist Elastic SNLS 42.426 0.7071 85 68 2.9 3 3    
28   Close Waist Band T/C 42.36 0.7060 85 68 2.9 3 3    
29   Remove Tack at Waist Band HEL 15.918 0.2653 226 181 1.1     1  
30   Mark Waist Band For Eylet HEL 15.27 0.2545 236 189 1.0     1  
31   Eyelet Punch EYPN 8.682 0.1447 415 332 0.6 0.5 1    
32   Eyelet Attach EYAT 13.584 0.2264 265 212 0.9 0.5 1    
33   Make Care Label SNLS 11.79 0.1965 305 244 0.8 1 1    
34   Tack Care Label SNLS 20.964 0.3494 172 137 1.4 2 2    
35   Attach Main Label at Waist & size label at waist SNLS 18 0.3000 200 160 1.2 1 1    
36   Fold & Tack Drawcord Mouth SNLS 17.424 0.2904 207 165 1.2 1 1    
37   Insert drawcord HEL 35.094 0.5849 103 82 2.4     2  
38   Bartack At Waist band BTK 11.712 0.1952 307 246 0.8 0.5 1   13+38
                         
  682 11.37 287 230 46.0 37.0 41.0 9.0

No of Target
ACT OP. Bottleneck
MACHINERY REQUIREMENT Basic Time SMV THI M/c NO OF Hel 80%
Load M/C Trgt/hr
   
SNLS 300.73 5.01 20.3 20.0 21.0 0.0 168
4TOL 129.52 2.16 8.7 9.0 10.0 0.0 151
3TFL 49.59 0.83 3.3 3.0 3.0 0.0 131
BTK 14.75 0.25 1.0 1.0 2.0 0.0 597
68
EYAT 13.58 0.23 0.9 0.5 1.0 0.0 212
EYPN 8.68 0.14 0.6 0.5 1.0 0.0 332
T/C 42.36 0.71 2.9 3.0 3.0 0.0 68
HEL 123.25 2.05 8.3 0.0 0.0 9.0 323
Total 682.46 11.37 46.0 37.0 41.0 9.0
 FOLD AND ATTACH NECK
41 TOP STITCH AT SLEEVE CUFF 118 67 42 136
33 206 0.51 40TAPE 206 0.44 136
TOP STITCH AT BOTTOM RIB -70
  154     #DIV/0!  
35CM 206 0.39   - 206 -
           
  - 206 -   - 206 -
  M/c Sl.1 3T F/L   Mins utilized 185   M/c Sl.1 SNLS   Mins utilized 91
  M/c Sl.2           M/c Sl.2        
  Attach: 0           Attach:          
OPTR   OPTR
   
Skill       NAME   Skill     NAME  
     
TOP STITCH AT BOTTOM RIB -70
39 154 154 40 TOP STITCH AT SLEEVE CUFF 118
35CM 206 0.39 33 206 0.51 118
  #DIV/0!     #DIV/0!  
  - 206 -   - 206 -
           
  - 206 -   - 206 -
  M/c Sl.1 3T F/L   Mins utilized 80   M/c Sl.1 3T F/L   Mins utilized 105
  M/c Sl.2           M/c Sl.2        
  Attach: 0           Attach:          
OPTR OPTR
   
Skill       NAME   Skill       NAME  
           
37
32
ATTACH SLEEVE CUFF 206 0.48
125 66 38
34
ATTACH BOTTOM RIB-70 CM 206 0.43 140
140

  ATTACH BOTTOM RIB-70 CM 140     #DIV/0!  

34 206 0.43   - 206 -
           
  - 206 -   - 206 -
  M/c Sl.1 4T O/L   Mins utilized 187   M/c Sl.1 4T O/L   Mins utilized 89
  M/c Sl.2 4T O/L         M/c Sl.2        
  Attach: 0           Attach:          
OPTR OPTR
   
Skill       NAME   Skill       NAME  
           
35 CLOSE BOTTOM RIB-70 CM 176 176 36 ATTACH SLEEVE CUFF 125
14 206 0.34 32 206 0.48 125
  #DIV/0!     #DIV/0!  
  - 206 -   - 206 -
           
  - 206 -   - 206 -
  M/c Sl.1 SNLS   Mins utilized 70   M/c Sl.1 4T O/L   Mins utilized 99
  M/c Sl.2           M/c Sl.2        
  Attach: 0           Attach:          
OPTR OPTR
   
Skill       NAME   Skill       NAME  
•THANK YOU