Implementation of industrial engineering techniques for improving productivity and its impact in controlling labour cost in garment industry
Saranya D V, Chandru S, Mohana Preethi A
Department of Fashion Technology, Bannari Amman Institute of Technology, Erode, India.
Abstract
Every garment industry demands in improving productivity in an effective way. Lead Time, rework, abseentism, lack of line balancing, lack of process standardization are few reasons which results in low productivity and increased Labour cost. This work involving industrial engineering technique(s) such as Time study, Work study, two handed Process chart and Line balancing enhances the production process. In this study, observations are made in the exiting method and a new method (two handed process chart) has been proposed which influenced in increased productivity and reduced labour cost.
Key words: Productivity, Industrial Engineering Techniques, Labour Cost, two handed process chart.
 |
| A Garments Industry Sewing Line |
1. Introduction
It is essential to find out the factors that affects the productivity. It plays a vital role in identifying the issues influencing productivity. The evaluation of productivity can be done based on relationships between input and output of industry. Modern Engineering is worried about the plan, improvement and establishment of coordinated arrangement of men, materials and hardware. To manage the ongoing issues and difficulties, enterprises need to improve creation effectiveness and efficiency; diminish lead time, guaranteeing appropriate quality necessities. Failure mode and effects analysis (FMEA) technique is one of the effective tools which can help for prevention, identification, control and elimination of possible errors occurred in Apparel industry(7). Time study is the solid tool used for balancing the sewing line as well as solving the bottlenecks in apparel industry. To improve the current circumstance in the apparel industry, this time study can be utilized which in turn upgrade in the sewing area accomplished. For example, SMV, labour, bottle neck, limit feasible, generation/hr, execution rating, balance %.
The objective of this work is to 1.Study the existing methods that are followed in the apparel industry 2.Identify the reasons for low productivity in the apparel unit 3. To identify the suitable industrial engineering techniques to increase productivity.
2. Materials
The material(s) selected for this work is woven shirt (cotton/Polyester). The other requirements include stop watch, a study board, and Time study forms.
3. Methods
This study is predicated on the first information that was collected through the interview schedule form. Time-and-motion study taken by victimization stop watch that covers the foremost a part of the project, so as to record the time for specific job for nominative conditions. The following flow chart shows the methodology followed for the execution of the process.
3.1 ANALYZING THE CAUSES FOR LOW PRODUCTIVITY IN APPAREL INDUSTRY
The causes for low productivity are
1. Improper Machine layout and space utilization.
2. Inadequate material handling.
3. Ineffective method of sewing operations.
4. Improper inventory control system.
5. Lacking in technological upgradation.
3.2 SELECTION OF APPAREL UNIT AND ITS STUDY ON THE EXISTING METHODS FOLLOWED FOR PRODUCTION.
NAME OF THE FIRM : Kads Resources Garments
COMPANY’S POLICY : Quality products, Zero error
BUSINESS TYPE : Manufacturer & Exporter
The below given detail provides the flow process that was followed for the production execution in the existing method.
Collar Preparation
↓
Pocket Preparation
↓
Flap Preparation
↓
Sleeve Preparation
↓
Front Yoke Preparation
↓
Back yoke Preparation
↓
Placket Preparation
↓
Front Yoke attachment
↓
Back yoke Preparation
↓
Shoulder seam
↓
Pocket attachment
↓
Flap Preparation
↓
Collar attachment
↓
Sleeve attachment
↓
Side seam
↓
Tape attachment care
↓
Label attachment size
↓
Label attachment
↓
Bottom hem
No. Of operations in existing method: 19
3.3 ANALYSING THE PROBLEMS OBSERVED DURING THE STUDY
To understand the existing method followed in the factory, it is important to gather the information relating to quantity of labors, number of machines, man power utilization and factory layout. During the study, problems in the sewing department has been observed and listed.
1. Absenteeism
2. Poor workmanship
3. Ineffective usage of material and space
4. Poor supervision
5. No training
3.4 IDENTIFICATION OF IE TECHNIQUES FOR IMPROVING THE PRODUCTIVITY
IE techniques may be enforced in each and every department associated with the execution of the order. However importance was given in sewing department.
Based on the observation in the existing method, two handed process chart has been chosen to execute the new method.
4. RESULTS AND DISCUSSION
The symbols used for the execution of production is given below
4.1.1 I) TYPE OF OPERATION: FRONT YOKE
II)
II)
4.1.3
I) TYPE OF OPERATION: PLACKET PREPARATION
II)
4.1.4
I) TYPE OF OPERATION: SHOULDER ATTACHMENT
4.1.5.
I) TYPE OF OPERATION: SLEEVE ATTACHMENT
II)
4.1.6
I) TYPE OF OPERATION: COLLAR ATTACHMENT
II)
4.1.7. I ) TYPE OF OPERATION : SIDE SEAM FINISHING
II)
4.1.8
I) TYPE OF OPERATION: LABEL ATTACHMENT
4.1.9
I) TYPE OF OPERATION: BOTTOM HEM
II)
4.1.10.
I) TYPE OF OPERATION: POCKET ATTACHMENT
II)
4.2 IMPACT OF INDUSTRIAL ENGINEERING TECHNIQUES IN REDUCED LABOUR COST
The proposed method has reduced the number of operations which is shown below
Collar preparation Pocket
↓
Flap preparation
↓
Front and back yoke preparation
↓
Placket preparation
↓
Pocket and back yoke preparation
↓
Shoulder seam pocket
↓
Flap attachment collar
↓
Sleeve attachment
↓
Side seam
↓
Care,size level and tape attachment
↓
Bottom Hem
No of operation in the proposed method: 13
The number of operation reduced = 6. It is obvious that when the numbers of operations are reduced, it influences the wages to be paid to the labors.
5. CONCLUSION
By the implementation of two handed process chart, the effective utilization of both left and right hand of the operators to carry out the sewing operations were done. The movementsof the hand are recorded and the best methods of carrying out the operations were identified. This helps in job simplification and results in decrease in operating time. Based on the existing method, the successive process of minimum time requirement for operations are combined, which is carried out in the same Line. So those no of operations areconsiderably reduced from 19 to 13. Hence there must be an increase in productivity. By reducing the number of operations labour cost also reduced which is most wanted by every Manufacturer.
ACKNOWLEDGEMENT
The authors wish to thank KADS RESOURCES GARMENTS, TIRUPUR for giving us the opportunity to perform this research work.
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