SET –B

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

(Common Examination Board)
(End Term Exam-Session Jan-June, 2017)
Subject: Apparel Production Planning and Control, B FTech – VI
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Hours: 03 hours Max. Marks: 100
Non-Programmable Calculator MAY BE ALLOWED.
Part – A
Q. 1 – State True or False. 15 x 1 Mark = 15 Marks
a. Floaters can be allocated to any specific operation in any line plan.
b. Bigger the bundle size, higher the throughput time.
c. Mass production, borne out of the assembly line concept, is flexible enough to introduce
substantial variety in to products.
d. Unit Production System is the most widely used production system for apparel manufacturing.
e. Flexible flow system is not appropriate for short-run production and frequent style
changes, as these do not require rearrangement of the workstations.
f. The much talked about just in time production system can work only if there is an
external support from Suppliers.
g. Productivity always increases if the production increases.
h. Waiting for work is an example of On Standard Time.
i. Skill Matrix helps with Multi skilling plans.
j. Assembly line in mass production is basically an example of a process layout.
k. Assembly line production system is most suited for sample making.
l. Direct Labour Productivity is equal to Machine Productivity.
m. The sequence of operations adopted for any product has no effect on the time and cost of
production.
n. Production lead time is independent of throughput time.
o. The difference between Potential Capacity and Committed Capacity for a certain period
of time is referred as Available Capacity.

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Q. 2 - Fill in the Blanks 15 x 1 Mark = 15 Marks
a. Make through production system caters to _______ order quantity and __________style
changes. (1+1)
b. Poor operator utilisation is an important reason for lost __________ in garment mass
manufacturing.
c. __________________________determines the sequence of assembly, a list of the steps
in the production process.
d. Higher number of style variations increase _____________loss.
e. GSD stands for _____________________.
f. The slowest operation in a line is known as _______________.
g. _________________________ consists of list of the operator in a factory, which shows
their expected performance for a particular operation/s.
h. Throughput time ____________ with increase of WIP.
i. _______________________is the process of estimating the future sales volume, the rate
of sales and the rate of delivery.
j. SAM = (Observed time X ___________ ) + Allowances
k. ___________ is the deviation of operation timings from pitch time, better the balancing
efficiency that can be achieved.
l. In process chart , inspection is indicated by symbol ____________
m. Poor operator utilisation is an important reason for lost ______________ in garment
mass manufacturing.
n. Floaters are primarily used to handle ______________in the garment mass
manufacturing.

Part – B

Q. 3 –Answer any6 (Max. 150 words). 6x 5 Mark = 30 Marks

a. Discuss Throughput time and Lead time. (2.5 + 2.5)
b. Discuss minimum 4 measures of productivity of a plant.

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 c. What are the Steps for production analysis of a garment in mass manufacturing environment?
d. Discuss and differentiate production and productivity with example.(1.5 +1.5 + 2)

e. Define plant capacity. What are the factors which affect the capacity of the unit? Explain
with examples? (2 + 3)
f. Discuss Process Layout
g. Explain about the factors determining control procedure in production control.
h. Discuss the need of line balancing in mass manufacturing of garments with suitable
examples?
Part – C

Q. 4 - Answer any 2 (Max. 500 words). 2 x 10 Mark = 20 Marks

i. Discuss the role and responsibilities of a supervisor in an apparel manufacturing factory.
ii. Discuss process flow diagram. What are independent operation and dependent
operations? Draw a complete process flow diagram of any garment. (1.5 + 1.5 + 7)
iii. Explain the three phases of change over time.

Part – D

Q. 5 The operation breakdown and other details are given below. Using them, answer the
questions.
S. No Operation Name SMV Workstation
1 Collar profile setting & run stitch 0.66 SNLS-UBT
2 Collar edge cut 0.32 SNLS-EC
3 Collar turn & crease 0.38 Turning MC
4 Collar top stitch 0.35 SNLS-UBT
5 Collar band hem 0.22 SNLS-UBT
6 Collar peak run stitch 0.65 SNLS-EC
7 Collar peak trim, turn & crease 0.67 Iron Table
8 Collar bottom edge cut & center notch 0.32 SNLS-EC
9 Back yoke attach (3 ply) 0.58 SNLS-UBT
10 Main label attach mark & attach with size label 0.60 SNLS-UBT
insert
11 Back yoke edge stitch 0.45 SNLS-UBT

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 12 B/H placket attach 0.50 DNCS
13 Button placket hem 0.44 SNLS-UBT
14 Pocket hem 0.22 SNLS-UBT
15 Pocket crease 0.55 Iron Table
16 Pocket attach mark & set 0.48 Table
17 Pocket attach 0.74 SNLS-UBT
18 Front & Back set 0.35 Table
19 Shoulder attach 0.55 SNLS-UBT
20 Shoulder turn & edge stitch 0.60 SNLS-UBT
21 Collar set 0.32 Table
22 Collar attach 0.64 SNLS-UBT
23 Collar finish 0.65 SNLS-UBT
24 Sleeve set 0.35 Table
25 Sleeve attach 0.67 SNLS-UBT
26 A/H topstitch 0.64 SNLS-UBT
27 W/C label ready 0.33 SNLS-UBT
28 S/S attach (W/C label insert also) 0.78 Twin Needle FOA
29 Sleeve hem 0.80 SNLS-UBT
30 Bottom hem 0.65 SNLS-UBT
Predicted absenteeism…………………………………………………………………………. 7%
Predicted operator utilization……………………………………………………………….. 85%
Predicted average ‘piecework’ performance on standards ………………….. 90 BSI
No. of hours per shift …………………………………………………………………………….. 8 hours
No. of shifts per day ………………………………………………………………………………. 1
1. Calculate the Total SAM of the garment……………………………………... (2 Marks)
2. If the style is set in a line of 25 workstations what is the pitch time?(3 Marks)
3. If an assembly line of 25 sewing operators and 2 helpers produces 370 shirts per shift,
calculate the labour productivity …………………………………. (5 marks)
4. If the targeted production per shift (8 Hrs.) is 500 shirts, calculate the number of
operators required to achieve the target ………………...…………..….… (10 Marks)

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