time study (1).docx

8/10/2019 time study (1).docx

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M

TIME STUDY

LINE # 10


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BEFORE IMPROVEMENT TIME STUDY


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S.No Operations

Operator

Name

c1

(sec)

c2

(sec)

c3

(sec)

c4

(sec)

c5

(sec)

Average

time

(sec)

Operation

Average

(sec)

1

Cuff

Hemming Sadhna 16 18 20.7 19.4 16.5 18.12 18.12

2 Cuff Making Meena 24.4 25.7 24.4 26.1 25.6 25.24 25.24

3 Collar Profile Sushma 22.2 24.2 21.1 16.5 18.1 20.42 20.42

4

Collar/

Collar Band

Margin

Cutting Sangita 5.3 7.2 18.5 11.3 9.12 10.28 10.28

5

Collar

Turning Jayalakshmi 6.12 6 5.3 7.1 5.5 6.00 6.00

6 Cuff Turning Hemlata 17.4 16 16.9 18.7 17.4 17.28 17.28

7

Front Placket

Strip joining Jyoti 11.7 10.6 11.9 9.8 11.7 11.14 11.14

8

Collar Band

Marking Tara 31.5 30.5 38 33.6 32.4 33.20 33.20

9

Cuff

trimming and

ironing Anita 29.5 34.1 33.3 27.4 28.4 30.54 30.54

10

Collar

ironing Raju 20.3 18.9 25 20.4 23.8 21.68 21.68

11

Collar

Topstitch Kusum 29.3 27.6 27.6 25.6 28.5 27.72 27.72

12

Collar

Marking and

Trimming Laxmi 9.4 6.2 9.5 7 11.7 8.76 8.76

13

Collar Band

Attachment Poonam 41.7 35.4 32.6 33.6 30 34.66 34.66

14

Collar Peak

Making Renu 15.3 15.4 16.3 15.1 15.1 15.44 15.44

15 Wash Care Brahmwati 6.7 6.1 6 17.1 18.2 10.82 10.82


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Label

Attachment

16

Main Label

Attachment Deepali 29.2 33 23.6 23.3 26.1 27.04 27.04

17

Back Pleat

making Reena 22.9 18.9 18.4 15.9 16.5 18.52 18.52

18

Front Dart,

pocket

marking Soni 23.4 23.5 21.1 19.1 22 21.82 21.82

19

Front Placket

Attachment Dinesh 69.4 59.8 78.9 49.2 57.8 63.0255.39

20

Front Placket

Attachment Pushpender 45.5 40.4 38.5 57.6 56.8 47.76

21

Back yoke

Attachment Mohini 22.2 24.1 27.1 25.4 23.8 24.52 24.76

22

Back Yoke

Topstitch Halima 16.9 18.2 26.7 16.4 20.6 19.76 19.76

23

Front Placket

Topstitch Jancy 25.5 33.5 28.4 26.7 25.4 27.90 27.90

24

Placket

Temporary

Stitch Babli 11.3 16.1 12.2 11.3 11 12.38 12.38

25

Placket

Temple

Making Mukesh 51.4 64.1 42.6 59.5 48.4 53.20

46.23

26

Placket

Temple

Making Sunita 44.4 40.3 36.8 36.9 37.9 39.26

27

Front Dart

Making Anita 25.7 27.7 26.1 29.7 27.8 27.40 27.40

28

Pocket

Hemming Parvati

11.0

1

12.1

2 11.6 12.9 13.3 12.19 12.19

29 Pocket Seema 28.4 30.9 29.1 34.3 30.4 30.63 30.63


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Fusing 5

30

Pocket

Ironing Sunil 19.3 19.4 19 19.2 19.1 19.20 19.20

31

Pocket

Attachment Anu 46.4 48.3 55.9 59.5 59.1 53.84 49.75

32 42.1 38.7 52.5 52.5 42.5 45.66

33

Shoulder

attachment Vibha 26.2 23.2 26.8 30.2 24.6 26.20 26.20

34

Shoulder

Topstitch Reeta 20 19.9 21.9 24.6 21 21.48 21.48

35

Collar

Attachment Ramvati 12.9 9.8 8.9 10.5 12 10.82 10.82

36

Back Neck

Temporary

stitch Gudiya 23.7 27.3 23.7 24.2 20.9 23.96 23.96

37

Sleeve

placket

attachment Ram kumar 1.72 1.73 1.71 1.72 1.73 1.72 1.72

38

Cuff

Matching

Bhumi

kumari 21.4 23.3 24.7 26.1 21.2 23.34 23.34

39

Sleeve

Temple

Making Anju 31.8 34.9 26.4 44.2 28 33.0632.79

40

Sleeve

Temple

Making Mamta 29.4 34.7 29.1 31.2 38.2 32.52

41

Sleeve

Attachment Bala 49.3 32.6 34.4 31.7 35.4 36.6842.05

42

Sleeve

Attachment Ashok 51.6 50.6 46.5 46.1 42.3 47.42

43

Armhole

Attachment Poonam 69.6 47 62.8

37.4

4 36.6 50.69 57.56

44 Armhole Surender 59.8 70.2 60 60 72.2 64.44


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Attachment

45 Checking Manju 21.9 22.2 27 19.4 24.2 22.94 22.94

46

Side Seam

Attachment Saroj 48.3 86.5 65.3 56.1 62.7 63.7871.24

47

Side Seam

Attachment Pooja 90.2 71.8 69.1 83.3 79.1 78.70

48

Sleeve Pleat

Making Maya 20.4 24 21.5 21.2 19.2 21.26 21.26

49 Bottom hem Lalpari 40.2 40.3 56.2 41.9 48.2 45.36 24.36

50

Collar

Finishing Premlata 46.6 39.7 41.8 39.9

41.4

8 41.90 41.90

51

Cuff

Attachment Urmila 67.7 77.2 60.3 64.3 48.5 63.60 63.60

52

Cuff

Topstitch Babita 21.9 29.8 22.1 23.9 23.6 24.26 24.26


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CALCULATIONS (CAPACITY, EFFICIENCY, AND PITCH TIME)

S.No Operations

Operation

Average

(sec)

Allowance

(15%)

Operation

SAM Efficiency

Capacity

per hour

Pitch

Time

Upper

Limit

Lower

Limit

1

Cuff

Hemming 18.12 2.72 0.35 0.54 173

0.42 0.47 0.37

2 Cuff Making 25.24 3.79 0.48 0.76 124

3

Collar

Profile 20.42 3.06 0.39 0.61 153

4

Collar

Margin

Cutting 10.28 1.54 0.20 0.31 305

5

Collar

Turning 6 0.90 0.12 0.18 522

6 Cuff turning 17.28 2.59 0.33 0.52 181

7

Placket Strip

joining 11.14 1.67 0.21 0.33 281

8

Collar Band

Marking 33.2 4.98 0.64 0.99 94

9

Cuff

Trimming

and Ironing 30.54 4.58 0.59 0.91 103

10

Collar

Ironing 21.68 3.25 0.42 0.65 144

11

Collar

Topstitch 27.72 4.16 0.53 0.83 113

12

Collar

Marking and

trimming 8.76 1.31 0.17 0.26 357

13

Collar Band

Attachment 34.66 5.20 0.66 1.04 90


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14

Collar Peak

Making 15.44 2.32 0.30 0.46 203

15

Wash Care

Label

Attachment 10.82 1.62 0.21 0.32 289

16

Main label

Attachment 27.04 4.06 0.52 0.81 116

17

Back Pleat

Making 18.52 2.78 0.35 0.55 169

18

Front Dart,

Pocket

Marking 21.82 3.27 0.42 0.65 143

19

Placket

Attachment 55.39 8.31 1.06 1.66 57

20

Back Yoke

Topstitch 24.76 3.71 0.47 0.74 126

21

Back yoke

Attachment 19.76 2.96 0.38 0.59 158

22

Placket

Attachment 27.9 4.19 0.53 0.84 112

23

Placket

Topstitch 24.76 3.71 0.47 0.74 126

24

Placket

Temporary

Stitch 12.36 1.85 0.24 0.37 253

25

Placket

Temple

Making 46.23 6.93 0.89 1.38 68

26

Front Dart

Making 27.4 4.11 0.53 0.82 114

27

Pocket

Hemming 12.19 1.83 0.23 0.37 257


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28

Pocket

Fusing 30.63 4.59 0.59 0.92 102

29

Pocket

Ironing 19.2 2.88 0.37 0.58 163

30

Pocket

Attachment 49.75 7.46 0.95 1.49 63

31

Shoulder

Attachment 26.2 3.93 0.50 0.78 119

32

Shoulder

Topstitch 21.48 3.22 0.41 0.64 146

33CollarAttachment 10.82 1.62 0.21 0.32 289

34

Back Neck

Temporary

Stitch 23.96 3.59 0.46 0.72 131

35

Sleeve

placket

Attachment 3.44 0.52 0.07 0.10 910

36

Cuff

matching 23.34 3.50 0.45 0.70 134

37

Sleeve

Temple

Making 32.79 4.92 0.63 0.98 95

38

Sleeve

Attachment 42.05 6.31 0.81 1.26 74

39

Armhole

Topstitch 57.56 8.63 1.10 1.72 54

40 Checking 22.94 3.44 0.44 0.69 136

41

Side Seam

Attachment 71.24 10.69 1.37 2.13 44

42

Sleeve Pleat

Making 21.26 3.19 0.41 0.64 147


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43

Bottom

Hemming 24.36 3.65 0.47 0.73 129

44

Collar

Finishing 41.9 6.29 0.80 1.25 75

45

Cuff

Attachment 63.6 9.54 1.22 1.90 49

46

Cuff

Attachment 24.26 3.64 0.46 0.73 129

TOTAL SAM CALCULATED= 23.39 min


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Pitch Diagram

Time


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TIME STUDY AFTER IMPLEMENTATION OF OUR METHODS


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Time Study

S.No. OperationsOperatorName

c1(sec)

c2(sec)

c3(sec)

c4(sec)

c5(sec)

averagetime(sec)

OperationAverage

(sec)

1CuffHemming Sadhna 16 18 20.7 19.4 16.5 18.12 18.12

2 Cuff Making Meena 24.4 25.7 24.4 26.1 25.6 25.24 25.24

3 Collar Profile Sushma 22.2 24.2 21.1 16.5 18.1 20.42 20.42

4CollarTurning

Jayalakshmi 6.12 6 5.3 7.1 5.5 6.00 6.00

5 Cuff Turning Hemlata 17.4 16 16.9 18.7 17.4 17.28 17.28

6

FrontPlacket Stripjoining jyoti 11.7 10.6 11.9 9.8 11.7 11.14 11.14

7Collar Bandmarking Tara 31.5 30.5 38 33.6 32.4 33.20 33.20

8

Cufftrimming

and ironing Anita 29.5 34.1 33.3 27.4 28.4 30.54 30.54

9Collarironing Raju 20.3 18.9 25 20.4 23.8 21.68 21.68

10CollarTopstitch Kusum 29.3 27.6 27.6 25.6 28.5 27.72 27.72

11

CollarMarking andtrimming Laxmi 9.4 6.2 9.5 7 11.7 8.76 8.76

12

Collar band

attachment Poonam 41.7 35.4 32.6 33.6 30 34.66 34.66

13Collar PeakMaking Renu 15.3 15.4 16.3 15.1 15.1 15.44 15.44

14

Wash careand mainlabelattachment Brahmwati 29.7

30.67

29.22 29.8 30.5 29.98 30.40

15Back pleatmaking Reena 22.9 18.9 18.4 15.9 16.5 18.52 18.52

16 Front dart, Soni 23.4 23.5 21.1 19.1 22 21.82 21.82


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pocketmarking

17 FrontPlacketattachment

Dinesh 59.4 49.8 68.9 39.2 47.8 53.0245.39

18

Pushpende

r 35.5 30.4 28.5 47.6 46.8 37.76

19Back yokeAttachment Mohini 22.2 24.1 27.1 25.4 23.8 24.52 24.76

20Back YokeTopstitch Halima 16.9 18.2 26.7 16.4 20.6 19.76 19.76

21PlacketTopstitch Jancy 25.5 33.5 28.4 26.7 25.4 27.90 27.90

22

PlacketTemporary

Stitch Babli 11.3 16.1 12.2 11.3 11 12.38 12.38

23

PlackettempleMaking Mukesh 51.4 64.1 42.6 59.5 48.4 53.20

46.23

24

PlackettempleMaking Sunita 44.4 40.3 36.8 36.9 37.9 39.26

25Front dartmaking Anita 25.7 27.7 26.1 29.7 27.8 27.40 27.40

26Pockethemming Parvati

11.01

12.12 11.6 12.9 13.3 12.19 12.19

27PocketFusing Seema 28.4 30.9 29.1

34.35 30.4 30.63 30.63

28PocketIroning Sunil 19.3 19.4 19 19.2 19.1 19.20 19.20

29PocketAttachment Anu 36.4 38.3 45.9 49.5 39.1 41.84

38.75

30PocketAttachment 32.1 28.7 42.5 42.5 32.5 35.66

31Shoulderattachment Vibha 26.2 23.2 26.8 30.2 24.6 26.20 26.20

32ShoulderTopstitch Reeta 20 19.9 21.9 24.6 21 21.48 21.48

33Collarattachment Ramvati 12.9 9.8 8.9 10.5 12 10.82 10.82

34

Back necktemporaryStitch Gudiya 23.7 27.3 23.7 24.2 20.9 23.96 23.96

35

Sleeveplacketattachment Ram kumar 1.72 1.73 1.71 1.72 1.73 1.72 1.72

36 Cuff Bhumi 21.4 23.3 24.7 26.1 21.2 23.34 23.34


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matching kumari

37

SleeveTempleMaking Anju 31.8 34.9 26.4 44.2 28 33.06

32.79

38

SleeveTempleMaking Mamta 29.4 34.7 29.1 31.2 38.2 32.52

39Sleeveattachment Bala 49.3 32.6 34.4 31.7 35.4 36.68

42.05

40Sleeveattachment Ashok 51.6 50.6 46.5 46.1 42.3 47.42

41ArmholeTopstitch Poonam 59.6 37 42.8

17.44 26.6 36.69

45.56

42ArmholeTopstitch Surender 49.8 60.2 50 50 62.2 54.44

43 Checking Manju 21.9 22.2 27 19.4 24.2 22.94 22.94

44Side seamAttachment Saroj 38.3 66.5 55.3 46.1 52.7 51.78

58.24

45Side seamAttachment Pooja 70.2 61.8 59.1 63.3 69.1 64.70

46Sleeve pleatmaking Maya 20.4 24 21.5 21.2 19.2 21.26 21.26

47Bottomhemming Lalpari 40.2 40.3 56.2 41.9 48.2 45.36 24.36

48 Collarfinishing Premlata 46.6 39.7 41.8 39.9 41.48 41.90 41.90

49Cuffattachment Urmila 57.7 67.2 50.3 54.3 38.5 53.60 53.60

50CuffTopstitch Babita 21.9 29.8 22.1 23.9 23.6 24.26 24.26


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Calculations (Sam,Capacity, Efficiency and Pitch time)

S.No Operations

Operation

average

(sec)

Allowance

(15%)

Operation

SAM Efficiency

Capacity

per hour

Pitch

Time

Upper

Limit

Lower

Limit

1

Cuff

Hemming 18.12 2.72 0.35 0.54 173

0.39 0.44 0.34

2

Cuff

Making 25.24 3.79 0.48 0.76 124

3

Collar

Profile 20.42 3.06 0.39 0.61 153

5

Collar

turning 6 0.90 0.12 0.18 522

6Cuffturning 17.28 2.59 0.33 0.52 181

7

Strip join

Joining 11.14 1.67 0.21 0.33 281

8

Collar

band

marking 33.2 4.98 0.64 0.99 94

9

Cuff

trimming

and ironing 30.54 4.58 0.59 0.91 103

10Collarironing 21.68 3.25 0.42 0.65 144

11

Collar

Topstitch 27.72 4.16 0.53 0.83 113

12

Collar

marking

and

trimming 8.76 1.31 0.17 0.26 357

13

Collar

band

Attachment 34.66 5.20 0.66 1.04 90

14

Collar peak

Making 15.44 2.32 0.30 0.46 203

15

Wash care

and main

label

attachment 2.98 0.45 0.06 0.09 1050

17

Back pleat

making 18.52 2.78 0.35 0.55 169


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18

Front dart,

pocket

marking 21.82 3.27 0.42 0.65 143

19

Placket

attachment 45.39 6.81 0.87 1.36 69

20back yokeTopstitch 24.76 3.71 0.47 0.74 126

21

Back yoke

attachment 19.76 2.96 0.38 0.59 158

22

Placket

Attachment 45.39 6.81 0.87 1.36 69

23

Placket

Topstitch 24.76 3.71 0.47 0.74 126

24

Placket

TemporaryStitch 12.36 1.85 0.24 0.37 253

25

Placket

temple

Making 46.23 6.93 0.89 1.38 68

26

Front dart

making 27.4 4.11 0.53 0.82 114

27

Pocket

hemming 12.19 1.83 0.23 0.37 257

28

Pocket

fusing 30.63 4.59 0.59 0.92 102

29

Pocket

Ironing 19.2 2.88 0.37 0.58 163

30

Pocket

attachment 38.75 5.81 0.74 1.16 81

31

Shoulder

attachment 26.2 3.93 0.50 0.78 119

32

Shoulder

Topstitch 21.48 3.22 0.41 0.64 146

33

Collar

attachment 10.82 1.62 0.21 0.32 289

34

Back Neck

Temporary

Stitch 23.96 3.59 0.46 0.72 131

35

Sleeve

placket

attachment 3.44 0.52 0.07 0.10 910

36

Cuff

matching 23.34 3.50 0.45 0.70 134

37

Sleeve

templemaking 32.79 4.92 0.63 0.98 95


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38

Armhole

attachment 42.05 6.31 0.81 1.26 74

39

Armhole

Topstitch 45.56 6.83 0.87 1.36 69

40 Checking 22.94 3.44 0.44 0.69 136

41

Side seam

Attachment 58.24 8.74 1.12 1.74 54

42

Sleeve

pleat

making 21.26 3.19 0.41 0.64 147

43

Bottom

hemming 24.36 3.65 0.47 0.73 129

44

Collar

finishing 41.9 6.29 0.80 1.25 75

45 Cuffattachment 53.6 8.04 1.03 1.61 58

46

Cuff

Topstitch 24.26 3.64 0.46 0.73 129

TOTAL SAM Obtained 21.78


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Pitch Diagram


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RESULTS:

1. 5 bottleneck operations have been improved by adding containers and following

proper bundle system.

a. PLACKET ATTACH AND FINISH:

SAM of the operation before improvement: 1.06 min

SAM of the operation after implementation: 0.63 min

b. POCKET ATTACH



c. SIDE SEAM ATTACHMENT



d. ARMHOLE TOP STITCH



e. CUFF ATTACH




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2. Clubbing of 2 operations: Main label Attach and Wash Care label

attach.

Wash Care Label

Attach

cycle 1 18.2

cycle 2 17.14

cycle 3 17.92

cycle 4 16.5

cycle 5 19.2

average

cycle time17.79

Let the number of labels to be attached be 750.

Therefore, the time taken in attaching these labels= (750*17.79) sec= 13342.5 sec=

222.375 min= 3.70 hours.

Main Label Attach

cycle 1 29.2

cycle 2 33.04

cycle 3 23.6

cycle 4 23.3

cycle 5 26.1

average

cycle time

(sec) 27.04

Time taken to attach 750 labels= (750*27.04) sec = 20280 sec= 338 min= 5.63 hours.

Total time taken by both the labels= 9.33 hours

Total time taken to attach both labels separately to one garment= 44.83 sec


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In order to club these two operations we need to make back pleat first and attach back

yoke to it. And after that we can club these two operations where both Main label and

Wash Care label at one machine by the same operator.

operation mane: wash care label attach

+ main label attach (as predicted)

cycle time 1 30.04

cycle time 2 31. 67

cycle time 1 29.22

cycle time 4 29.1

cycle time 5 31.6

Average cycle time (sec) 29.99

Time taken to attach labels to 750 pieces= (750*29.99) sec = 22492.5 sec = 374.875 min =

6.24 hours

Time saved per day= (9.33-6.24) hours = 3.09 hours

Time saved on one garment= (44.83-29.99) sec = 14.84 sec = 1.05% of SAM.


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3. Margin cutting of collar band and collar should be eliminated.

collar/ collar

band trimming

collar band

attach

The two operations should be eliminated because either the marking or the initial cutting of

the collar band and collar should be done carefully. Moreover the collar assembly which is

done on SNLS Edge Cutter machine can also trims these edges. Therefore, these operations

could be clubbed and hence time can be the saved. The amount of time that could be saved

has been calculated as follows:

Let the number of pieces produced per day = 750

Time taken for collar band

trimming

cycle 1 9.57

cycle 2 8.1

cycle 3 8.38

cycle 4 7.57

cycle 5 8.12

average 8.34


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Time taken to trim collar band for 750 pieces= (750*8.34) = 6255 sec = 104.25 min=

1.72 hours.

Similarly, for trimming 750 collar pieces in a separate edge cutter machine time taken=

750*7.58 seconds = 5685 seconds = 94.75 minutes = 1.57 hours.

time taken for collar

trimming

cycle 1 8.23

cycle 2 7.9

cycle 3 6.3

cycle 4 8.4

cycle 5 7.1

average 7.586

Therefore, by eliminating these two operations, a total of (1.72 + 1.57) hours could be

saved each day = 3.29 hours.

Also by eliminating these two operations 15.92 seconds can be reduced out of SAM of the

garment Style # 979B being manufactured for Target which = 1.13% of SAM.

4. After all the improvements:

We have managed to reduce :

SAM from 23.39 min to 21.59

Pitch Time from 0.42 min to 0.39 min

Documents

time study (1).docx