JOB ROTATION

AFTER THE OPERATORS ARE TRAINED FOR MULTI SKILL, THEY SHOULD BE ASSIGNED DIFFERENT KIND OF JOB AT DIFFERENT INTERVALS.THIS IS KNOWN AS JOB ROTATION .THIS WILL ELIMINATE RESISTANCE TO CHANGE. THERE ARE LOT OF ADVANTAGES IN FOLLOWING THE PRINCIPLE OF JOB ROTATION AND FEW ARE MENTIONED HERE. IT WILL REMOVE MONOTONY IN THE JOB,SINCE REPETITION IS AVOIDED BY CHANGE OF JOB.OPERATORS WILL BE MOTIVATED AND THEY CAN PERFORM WELL. RESISTANCE TO CHANGE OF JOB WILL BE ELIMINATED FROM THE MINDS OF OPERATORS AND THEY WILL BE READY TO DO DIFFERENT KIND OF JOB AS AND WHEN REQUIRED. THIS CULTURE TO BE BROUGHT IN TO THE ORGANISATION .

MULTISKILL
GENERALY OPERATORS ARE PUT TO ONE TYPE OF JOB AND THEY WILL BE ALLOWED TO CONTINUE TO DO THE SAME TYPE OF JOB. WITH THE RESULT ,THEY WILL EXPRESS THEIR INABILITY AND MAY NOT PERFROM WELL. THIS SITUATION CAN BE AVOIDED BY A SYSTEMATIC TRAINING IN THE BEGINNING ITSELF FOR DIFFERENT KIND OF JOBS. BY THIS WAY THE OPERATORS GET CONFIDENCE AND CAN PERFORM ALL OTHER TYPE OF JOBS WITH EASE. THE MANAGER / SUPERVISOR CONCERNED,TO TAKE STOCK OF SKILL INVENTORY OF OPERATORS UNDER HIM AND DESIGN A SUITABLE TRAINING PROGRAMME TO TRAIN THEM FOR DIFFERENT KINDS OF JOB. EACH OPERATOR SHOULD BE IN A POSITION TO HANDLE ATLEAST 4 TO 6 JOBS AT ANY TIME.

Multi Skill Chart

THIS CHART GIVES INFORMATION ABOUT THE CAPACITY OF INDIVIDUAL OPERATOR.HERE WE TRY TO RECORD WHAT ARE THE DIFFERENT OPERATIONS EACH OPERATOR CAN DO AND AT WHAT EFFICIENCY. THIS IS VERY USEFUL INCASE OF CHANGE OF OPERATORS DUE TO ABSENTEEISM OR RESIGNATION.

S. N o

Description of Operation Shirt Collar sub-assy.

TimeSeconds

Kala

Mala

Vimal a

Meena Uma

Guna

1 2 3 4

Collar Marking
Collar Run Stitch Collar Turning Collar Pointed

17
57 12 38 75% 90%

90%
70% 75% 85% 90%

75%

85%
75%

90%

85% 75%

PITCH DIAGRAM
THIS DIAGRAM IS VERY MUCH USEFUL IN BALANCING THE SEWING LINE. HERE THE SEQUENCE OF OPERATIONS OF EACH PRODUCT IS RECORDED. FOR EACH OPERTION, THE ACTUAL TIME TAKEN BY THE OPERATOR FOR THAT JOB IS NOTED DOWN.WE PLOT THE PITCH DIAGRAM. OPERATIONS ARE MARKED ON ONE AXIS AND THE TIMINGS ON OTHER AXIS.FIND ALL THE OPERATIONS WHERE THE TIMING IS HIGH AND THIS IS TAKEN AS BOTTLE NECK STATIONS OR CONTROL STATION, DE-BOTTLENECK THESE BY , 1. 2. 3. ADDING ADDITIONAL STATIONS COMBINE WITH OPERATION IMPROVE THE METHOD OF WORK.

PITCH DIAGRAM
Opera tion/ Statio n Operation Description Trouser Assembly: Timesec

1
2 3 4 5 6 7 8 9 10

Front & Back Number set & feed - H Side top stich s/n machine Sew side and inseam Clip panels, set w/b, mark for w/b -H Open Side seam Top stitch pocket bag Attach Loops Attach w/b lining to w/b Attach w/b to body

28
53.4 47.8 24.6 45.3 49.9 29.9 35.8 43.3 53.9

UCL

BPT
LCL

w/b extension-bottom & top close

FORMULAS
B.P.T(BASIC PITCH TIME) = NET TOTAL PROCESSING TIME / NUMBER

OF WORKERS S.P.T ( SANDARD PITCH TIME) = BPT X ( 1+ ALLOWANCE ). (say 20 % allowance). TOTAL PROCESSING TIME = NET TOTAL PROCESSING TIME X (1 + ALLOWANCE RATE ) TARGET WORK FLOW = DAILY WORK HRS / SPT =DAILY WORK HOURS X NO OF WORKERS / TOTAL PROCESSING TIME. DAILY WORK FLOW (BOTTLENECK WORK FLOW ) = DAILY WORK HOURS / BOTTLENECK PROCESSING TIME. = TARGET WORK FLOW X ORGANISATION EFFICIENCY. ORGANISATION EFFICIENCY ( PROCESS FORMATION - LINE BALANCING ). = B.P.T / BOTTLENECK PROCESSING TIME (NET) U.C.L = B.P.T / 0.85 ( TARGET ORGANISATION EFFICIENCY ) L.C.L = ( 2 * B.P.T ) U.C.L