Work study is an analytical study under industrial engineering that plays a vital role to reduce garment manufacturing costs and increasing productivity with minimum resources. Method study and time study are two branches of work-study. This article is about work-study that would help you.
Work-study
Work study is a higher technological science that works for systematic examination of methods of carrying out activities such as to improve the effective uses of resources & to set up standards of performances for activities carrying out. Work-study is the investigation of the work done in an organization by means of a consistent system, in order to attain the best possible use of men, machines, and materials at presently available conditions. Garments factories paid a big amount to this department as this department works to increase productivity. It is the analysis of the operations required to produce a style. It is also important to ergonomics decisions, job design, and workstation development. An effective work-study requires both work measurement and method analysis.
Tools and Techniques used in Garment Industry:
· Work study.
· Line layout.
· Line balancing.
· Material management/information System (MIS).
· Quality management system (QMS).
· Scheduling.
Tasks of work-study
· Operation Break-down
· Line layout
· Time study
· Line balancing
· SMV for target production
· Efficiency
· Daily production report
· Weekly, Monthly & Yearly production report
· Loss study
· Cause study
Influences of work-study:
By using work-study techniques in an industry can influence the following factors.
· Lower the costs
· Productivity ratios
· Manufacturing profitability
· Eliminations of unnecessary work
· Set equitable workloads
· Determine performance standers
· Determine methods for checking achievement
Method Study:
A method study is an investigating technique used to determine the best way of doing a job. It determines the most effective means of executing each process. It also engaged in solving problems concurred with methods.
Method study use a basic pattern that is SREDDIM S=select the task to study
R=record the facts from observation E= examine critically D=develop the best method
D=define a new method which is most economic I=Install it as an std practice M=maintain by regular routine checks
Work-study flow chart:
Receive order list
↓
Receive sample
↓
Do process breakdown
↓
Provide SMV to marketing & planner
↓
Making a paper layout
↓
Average pp Meeting
↓
Follow up m/c layout
↓
Do time study & line graph
↓
Help rebalance the line & finalize SMV online by time study
↓
Do efficiency & other reports
Application of Method Study:
· Designing work station to increase efficiency
· Develop layout
· Improve material flow
· Planning the best rate of movement of people
· Develop a system of various functions
Work measurement:
Work measurement is used to determine the required time to complete one operation & the amount of work that can be performed by one operator at a specific time. It provides a fair way of estimating the time to do a job by a skillful operator with plentiful work supply & proper equipment
Methods of Work Measurement:
· Time study
· Experience of personnel
· Predetermines Motion / Time System [PMTS]
· Standard data
· Operator reporting
· Work sampling
Time study:
Time study is the study of each of the step of an operational procedure and time consumed by them for the purpose to increase the efficiency of wears.
The calculation process of time study:
· First we have to record the names of the operation, m/c used workers information in the time study chart.
· Then using the stopwatch we have to take the required time to complete the 10 cycles as the Operation.
· Then we have to add a 30% allowance of this time.
· At last, using SMV average time we have to enclose on the time study chart.
Calculation of Sewing Line Efficiency:
Line efficiency = (Total production *SMV*100) / (No of operator *Working hour *60) Formula of Operation
Capacity graph:
· Capacity/hr = (60/Capacity total avg. time)x total manpower.
· Capacity achievable = capacity/hr x balance%
· Performance = (SMV/ capacity total time) x 100
· Balance = Basic pitch time / bottleneck time
· Improve% = 1- (production per hr/ capacity per hr)
· BPT = Capacity total avg time/ total use worker
· UCL = BPT x 120%
· LCL = BPT x 80%
Work study Formula
· Target/hr = Total worker x (60/ SMV) x 73%
· Efficiency = (Earn hr/ available hr) x 100
· Earn hr = (Total production x SMV)/60
· Available hr = Total worker x total working hr
· Performance = Earn hr/ (available hr- total off hr) x 100
· Target achieve efficiency =(total prod – total target) x 100
· Variance = (total prod – total target) / total target x 100
· Basic time = (Observed time x rating)/ standard rating
· Standard minute value = Basic time + Allowance time
Job responsibilities of Work study Department
Work-study job in Garments industry:
Nowadays most garments industries have a work-study department or assigned employees for work study related works.
1. Assistant manager- Work study
2. Work study officer
3. Senir officer- Work study
4. Executive- Work study