Application Of Workstudy

RESEARCH TITLE : APPLICATION OF WORK STUDY CONCEPTS IN APPAREL MANUFACTURING RESEARCH ASSOCIATES IQBAL AHMED – BS in Industrial Engineering NIRANJAN K. H – BS in Industrial Engineering Dr. Ambedkar Institute of Technology Bangalore University BALAJI B JAGANNATH Head Of Industrial Engineering Bombay Rayon Fashion Limited CONDUCTED AT BOMBAY RAYON FASHIONS LIMITED(UNIT-1) BANGALORE

OBJECTIVE OF THE PROJECT WORK ,[object Object]

ROLE OF INDUSTRIAL ENGINEERING DEPARTMENT IN APPAREL INDUSTRY. ,[object Object],[object Object],[object Object]

ABOUT THE COMPANY-BRFL: is one of the leading garment manufacturer in India, currently operating with 7 units in Bangalore.

GARMENT MANUFACTURING – BLOCK DIAGRAM Fabric from stores Cutting section Sewing section Finishing section Finished garment to warehouse

TOPICS COVERED DURING THE PROJECT WORK ,[object Object],[object Object]

PLANT LAYOUT & WORKSTATION DESIGN

CUTTING SECTION – EXISTING LAYOUT

CUTTING SECTION – PROPOSED LAYOUT

CALCULATION – CUTTING SECTION ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

COMPARISION B/W EXISTING & PROPOSED CUTTING SECTION LAYOUT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

FINISHING SECTION – EXISTING LAYOUT

FINISHING SECTION – PROPOSED LAYOUT

FINISHED SECTION: EXISTING LAYOUT V/S PROPOSED LAYOUT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

WORKSTATION DESIGN ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

WORKSTATION AT SEWING BATCH- EXISTING

WORKSTATION- Proposed/Implemented

COMPARISION OF EXISTING Vs PROPOSED 57 cm 18 minutes With out disturbing Barrier does not exists 63 cm 20 minutes Disturbing the operator Restricted by the barrier to a limit ,[object Object],[object Object],[object Object],[object Object],Proposed work station Existing work station Description

COMPARISION OF EXISTING Vs PROPOSED Calculation % Efficiency = 3168 – 2884 × 100 = 9 % 3168 20 operations 18mins 3.33*20 = 66 garments/hr 66*8 = 528 garments/day 528*6 = 3168 garments/day 20 operations 20mins 3*20 = 60 garments/hr 60*8 = 480 garments/day 480*6= 2884 garments/day No. of operations /batch To manufacture 1 garment Hourly production per batch Daily production per batch Daily production from sewing section Proposed Existing Description

IMPORTANCE OF WORK STUDY ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

IMPLEMENTING WORK STUDY CHARTS IN APPAREL MANUFACTURING ,[object Object]

WORK STUDY- DEFINITION ,[object Object]

METHOD STUDY WORK MEASUREMENT HIGHER PRODUCTIVITY WORK STUDY

PROCESS CHART SYMBOLS ,[object Object],[object Object],[object Object],[object Object],[object Object]

OUT LINE PROCESS CHART: ,[object Object],[object Object],[object Object],[object Object],[object Object]

Out line process chart: for apparel manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 18

FLOW PROCESS CHART ,[object Object],[object Object],[object Object],[object Object]

MAN TYPE – FLOW PROCESS CHART ,[object Object]

Flow Process Chart – Man type Feeding helper in Sewing Section. Click to Download File Flow Process Chart – Man Type Present Click to Download File Flow Process Chart – Man Type Proposed Improvement 4.08(8%) 51.5 55.58 Time (Min) 98 (41%) 136 235 Distance (Mtrs) 2 2 - - 1 13 10 - 2 1 15 12 - 2 - Operation Transport Delay Inspection Storage Savings Proposed Present Activity SUMMARY Subject Charted : Feeding Helper in Sewing Section Activity: Feeding of all parts and trims to assembly line Location: Sewing Section – Unit – 1 - BRFL Charted by: IQBAL & NIRANJAN Approved by: Date:5-03-07

MATERIAL TYPE – FLOW PROCESS CHART ,[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],Click to Download File Flow Process Chart – Material Type Present Click to Download File Flow Process Chart – Material Type Proposed Improvement 1.9(35%) 3.4 5.3 Time (Mins) 94 (35%) 171 265 Distance (Mtrs) - - - - - 16 21 2 - 3 16 21 2 - 3 Operation Transport Delay Inspection Storage Savings Proposed Present Activity SUMMARY Subject Charted: Stitched Garment in Finishing section Activity: Buttoning, Inline Trimming, Pressing, Inspection & Dispatch Location: Finishing Section – Unit – 1 – BRFL Charted by: IQBAL & NIRANJAN Approved by: Date:05-03-07

EQUIPMENT TYPE – FLOW PROCESS CHART ,[object Object],[object Object],[object Object],[object Object]

TWO- HANDED PROCESS CHART ,[object Object]

MULTIPLE ACTIVITY CHART ,[object Object]

MAN-MACHINE CHART FOR PLACKET TRIM & JOINT OPERATION Existing condition: The operations, placket trim and placket joint were carried on by 2 different operators at different places for a single batch. Proposed condition: A single operator to perform both the operations on two machines placed front & back of the operator , providing with a rotating chair.

MAN-MACHINE CHART FOR PLACKET TRIM & JOINT OPERATION 0 3 4 5 Idle Placket trim operation on m/c 1 Working 6 7 Working Placket joint operation on m/c 2 Idle 7.5 (placket joint machine) (trimming machine) (mins) Machine 2 Operator 1 Machine 1 Time Date: 06/04/2007 Approved by: Charted by: Iqbal and Niranjan Charted on: Placket trim & Placket joint operations for a bundle of 10 pieces MAN MACHINE CHART : 2 M/C 1 OPERATOR

NUMBER OF OPERATORS WORKING ON SINGLE MACHINE

CONCLUSION ,[object Object],[object Object]

Application Of Workstudy

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