Optimization of productivity of garments

7/29/2019 Optimization of productivity of garments

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Of a basic shirt, polo shirt & trouser

Project Supervisor: Farzana Rahman


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With the growing international competition the apparel factoriesof Bangladesh must be in the path of continuous improvement.This improvement also needs to be measured continually tounderstand how much improvement has taken place. Productivitydata is the essential indicator of the improvement rate and thelevel of performance of the factory.

Though the importance of productivity is huge, data onproductivity is rarely available. Apparel factories of our countrysometimes feel that collection of productivity data, its

measurement and generation of reports is simply extra paperwork. As a result they seldom have time for such paper work.Again, apparel factories have misconceptions about productivityand they lack knowledge of the true dimension of the benefit theycan derive from productivity measurement.


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To measure productivity.

To identify the methods of efficient utilization of inputs(manhours, machine hours etc) in producing outputs(basic shirt, poloshirt &trouser).

To trace the technical changes in production such as advances indesign & quality of machines and products.

To find out reasons of changes in efficiency such as highefficiency and low efficiency.

To identify cost saving techniques in production by productivity

measurement , to minimize cost and maximize production. To find out the factors of productivity loss such as annual labor

turnover, absenteeism, repairs, rejects etc.


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Optimization of productivity consists of threemajor steps:

Measuring the productivity

Finding ways to improve productivity

Identifying the reasons for low productivity


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Productivity is a ratio to measure how well anorganization (or individual, industry, country) convertsinput resources (labor, materials, machines etc.) into

goods and services.

This is usually expressed as,Productivity = Output / Input

=Doing Things Right + Doing the Right Things

(Efficiency) (Effectiveness )

So , Productivity = Doing the Right Things Right


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Measurement is the first step that leads to control and eventuallyto improvement.

If you cant measure something, you cant understand it.

If you cant understand it, you cant control it.

It you cant control it, you cant improve it.

James Harrington


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Productivity measurement is done-

To monitor performance

To reveal problem area

To appraise how well resources are utilized

To improve productivity situation.


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Industry Level

Industry Segment Level

Firm/Plant Level

Plant-A Plant-BPlant-C

Departments

Pre-Cutting Cutting Sewing Post Sewing

Spreading Cutting Bundling

Fusing

Production Line/Floor

Group/Sections

Operations

Operator/Machine/Helper

-Inspection

-Ironing-Laundry-Packaging


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i) Factor productivity / Single Factor Productivity

(SFP)

ii) Multi Factor Productivity (MFP)

iii) Total Factor Productivity (TFP)


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Single Factor Productivity (SFP) is defined as the ratio of ameasure of output quantity to the quantity of a single inputused.

Output/Labor: Labor Productivity is units of output perlabor hour;

Output/ Machine: Machine Productivity is units ofoutput per machine hour;

Output/ Capital: Capital Productivity is units of out putper taka input


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Problem: 12 workers manufacture 480 pcs of T-shirt in 8hours shift. SMV of a T-shirt is 5 minutes. What is the laborProductivity?

Solve: Productivity=Output/Input=Minutes produced/ Total available minutes

=(OUTPUT QUANTITY * SMV *100%) / (NO. OF

WORKER * WORKING MINUTES)= (480 * 5 *100 %) / (12 * 480)=41.7 %

(Ans)


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TECHNIQUES OF WORK MEASUREMENT

Time study

Work Sampling

PMTS (Predetermined Motion-Time System) etc.

PMTS is also known as MTM (Methods TimeMeasurement)


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Normal Time (NT) or Basic Time = (Average Cycle Time) x (RatingFactor)

Standard Minute Value (SMV) = (NT) + (NT x Al %)

=( NT) + (NT x AF)

SMV = NT (1+ AF)

SMV = Normal Time x (1+ AF)

SMV = Average Cycle Time x RF x (1+ AF


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Rating is a technique used to assess the speed andeffectiveness of an operator.

Following Considerations may take into account

Speed of movement

Effort

Effectiveness etc.

Rating is the measure of speed with which an operator works.Speed heremeans the effective speed of operator.

Performance(Rating)=Predetermined Time/Actual TimeR = P / A


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Allowance is basically some additional time for needs (drink water, Cleaning fatigue and delays).

Allowance can be given as a percent of work time .

Allowance are the interruptions that occur during the working day.

Personal Allowance: drink water, going to wash room and Cleanup after operations.

Fatigue Allowance: Standing with a load, walking with a load,lifting a load, anxiety, monotony, temperature, sound, illumination,

Delay Allowance: Machinery is kept in repair, tool breakage, minorAdjustment.


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Operation

CycleTimeT1(min)

CycleTimeT2(min)

CycleTimeT3(min)

CycleTimeT4(min)

CycleTimeT5(min)

AverageCycleTime

Shoulder Join .45 .43 .40 .41 .43 .42

Sleeve Join .36 .39 .37 .39 .36 .37

Side Seam .60 .58 .61 .51 .60 .59

Body Hem .42 .44 .43 .41 .44 .43


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Operation Average Cycle

TimeRating Factor Basic Time or

Normal Time

Shoulder Join .42 .90 .378

Sleeve Join .37 .80 .296

Side Seam .59 .1.10 .649

Body Hem .43 .1 .43


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Standard Minute Value (SMV) = NT + Al % of NT

= NT (1+Al %)

Shoulder Join, SMV= .378 (1+20%) = .4536 min

Side Seam, SMV = .649 (1+ 20%) = .7788 min


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- defined as the ratio of a measure of outputquantity to a measure of the quantity of abundle of inputs often intended to approximate

total input.Output

Multi Factor Productivity = ----------------------------

(Labor + Capital) Input


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defined as the ratio of a measure of total outputquantity to a measure of the quantity of total input.

OutputTotal Productivity = --------------------------------------

(Labor +Capital +Material +Energy +Others )Input

Thus, total productivity measure reflects the jointimpact of all the


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General Techniques of ProductivityImprovement:

1. Motivation of Workforce

2. Education, Training &Development 3. Maintenance of Machines

4. Line Balancing

5. Scheduling 6. Modifying Machines

7.Automation


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8. Layout Planning

9. Improving Employee Morale

10. Using Work Aids

11. Reducing Absenteeism

12. Reducing Employee Turnover

13. Job Satisfaction

14. Organizational Culture 15. Quality Control

16. Infra-Structural Facility


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17. Organizational Culture

18. Wages Policies

19. Waste Reduction


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Areas Of Application Approx. increase in productivity(%)

Computer Pattern Grading 150

Die Cutting 270

Laser Cutting 190

Continuous fusing process 60

Programmable sewing machines 5-100

Folders 20-100

Needle Positioners 10-20


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Factors influencing productivity can beclassified into two categories:

a. Controllable or internal factors and

b. Non-controllable or external factors.


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a. Controllable or Internal factors:

Product Factor

Plant and Equipment

Technology

Material and Energy

Human Factors Work Methods

Management Style


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b. Non-controllable or External Factors :

Social Changes: Education, Cultural values,

and Attitudes Natural Resources :Manpower, Land, and

Raw Materials

Government and Infrastructure: GovernmentPolicies,

Programs and Fiscal Policies etc.


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EMPLOYEE : ATTITUDES & ABILITIES

MANAGEMENT : PLANNING & COMPETENCY

FACILITIES : PLANT & EQUIPMENT

TECHNOLOGY : PROCESS & PRODUCTS

GOVERNMENT : REGULATIONS & SUPPORT

ENVIRONMENT : MATERIAL, ENERGY, CLIMATE


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Line Imbalance

Annual Labor Turn-over

Absenteeism of Workers

Repair of machines , Reject of products

Unmeasured work


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Due to the reasons of productivity loss, productivity ofan apparel factory can be lost up to 57% -

(Source : Introduction to Clothing Production Management A

J Chutter)Reason Productivity Loss (%)

Line Imbalance 6

Annual Labor Turn-over 20

Absenteeism of Workers 8

Repair of Machines 6

Reject of Products 2

Unmeasured Work 15


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Thank You

Documents

Optimization of productivity of garments