PROJECT :1 PRODUCTION IMPROVEMENT OF SHIRT SEWING LINE

(MOTION STUDY) & REMOVAL OF BOTTLE NECKS

OBJECTIVE OF THE PROJECT

Primary objective : To do a Motion study to Eliminate unproductive operations performed by
the operators and to train them for the same. And to eliminate the bottle necks.

Secondary objective : To increase their efficiency and hence, the production. Proper
line balancing and work in progress.

SCOPE OF THE PROJECT

The scope of this project is very large as this is the only possible way to increase the efficiency
of line and as to balance the line is such a proper way so that the line requires minimum WIP.

LITERATURE
The operation of Shirt line is categorized into five sections; collar section, sleeve section, front
and back end line and the assembly line. The collar section is completely independent, where
as the sleeve section has dependent operations like attaching the cuff. Front and back are
independent too, coming together in the assembly line.

Parts Of the Shirt

Front panel- 2
Placket-2
Back panel- 1
Yoke – 2
Collar- 2
Collar stand-2
Sleeve-2

Opeartion Breakdown
Collar Section
Run stitch collar
Trim collar
Top stitch Collar
Hem neckband
Insert collar in NB
Trim neckband @ bottom
Sleeve Section (Half Sleeve)
Hem sleeve
Front Section
Hem left front placket
Hem right front placket

Back Section

Sew back darts

Attach label @ basket yoke

Join yoke

Top stitch Yoke

Assembly Section
Join shoulder
Top stitch shoulder

Stay stitch neck

Attach collar

Close Collar

Set sleeve to armhole

Topstitch armhole

Tack side seam label

Trim @ armhole

Join Sideseam

Hem bottom

Sleeve tack

METHODOLOGY 1
To remove bottle necks and increase the productivity.

STEPS TAKEN -

1. To find out problem

2. To check the efficiency of the operators
3. To analyze the bottle necks.
 4. To do re allocation as needed.

**Put those 3 excel sheets, their allocation, our 1st

solution and then our final solution**
OUTCOME
Total output increased per day (8 hours) from 750 pcs to 1050 pcs.
This is done by re allocation of a few operators.
Thus increasing the monthly capacity by 350 * 25 = 8750 pcs

METHODOLOGY 2

To find out problem in shirt sewing line (excess of un-productive motions).

To remove unproductive motion
To achieve the given
target Work sampling

FOLLOWING PROBLEM FOUND -

More waiting time for loading - at times workers had to search for the garment panels
More style change - due to frequent change in style workers need to adjust for every
style resulting in start-up losses & learning curve.
More number of unproductive motions performed - all the motions produced by the
workers are not productive motions.
WIP is less (not constant) - the WIP between two workers are not constant.
Operator sitting idle - few of the times the workers are found idle
Empty machines - few of the times the machine was idle.
Line Balancing - if two operations are merged, it will save time.

STEPS TAKEN -

1. To find out problem

2. To do method study
3. To do loss time study
4. Work sampling
5. Motivate them to work efficiently
6. Suggest training of operators (to perform productive motions and eliminate un
productive motions)

PROBLEM ANALYSIS THROUGH TIME & MOTION STUDY

 SAM for the current style in line -12 is 23 minutes.

**Put the excel sheet with comments that I made**

OUTCOME

Total time which can be saved in construction of one shirt = 29.5

seconds. Total working hours of line - 12 = 8 hours
Line - 12 Consists of 2 Rows of Machines = 29 * 2 = 58 ≈ 60
Machines Total Machines in Line - 12 = 60 Machines.

Total Throughput time for Line - 12 in a hour = 60 * 60 = 3600

min. Production/hour in line - 12 = 132 pcs
Total Time which can be saved in line - 12 per Hour = 132*29 = 3806 Sec. =63.4 Mins.

Total Throughput time for Line - 12 in a Day (8 Hours) = 60 * 60 * 8 = 28800

min. Production/Day in line - 12 = 1050 pcs
Total Time which can be saved in line - 12 per day = 1050*29.5 = 30975 Sec. = 516.2
Mins. which is equal to 8.6 Hrs.

Total Throughput time time can be saved in a line - 12 per day (8 hours) = 516.2 Mins.

Total Production/Day = 1050 Pcs.

 We know that the Total SAM of the Current garment is 23 Mins.

So, Total Extra Garments can be made with that Saved time = 516.2/23 = 22.44 ≈
22 Gmts.

So, 22 Extra garments can be made with this saved time in a day (8 hours).

Our New Capacity of 1 line will be 1072 Garments per day.

And, There are 3 lines currently running in the Production floor = 1072 * 3 = 3216
Garments.

So, The New Capacity of the Production floor raised from 3150 Pcs to 3216 Pcs per day.
 
Monthly Capacity

On a Month (25 working days) the previously Capacity of Production floor = 3150 * 25 =
78750 Gmts.

And, The New Capacity of production floor in a month = 3216 * 25 = 80400 Gmts.

The Capacity of Production Floor is increased by 1650 Gmts/Style in a

month.
 
 Yearly Capacity
On a Year, the previously Capacity of Production floor = 78750 * 12 = 9,45,000 Gmts.

And, The New Capacity of production floor in a Year = 80400 * 12 = 9,64,800 Gmts.

Difference in yearly Capacity = 9,64,800 - 9,45,000 = 19,800 Gmts

The Capacity of Production Floor is increased by 19,800 Gmts in a Year.