Every garment industry demands improvement in improving productivity in an effective way. Lead Time, rework, absenteeism, lack of line balancing, and lack of process standardization are a few reasons that result in low productivity and increased Labor cost. This work involves industrial engineering techniques (s) such as Time study, Work study, two-handed Process chart and Line balancing enhance the production process. In this study, observations are made in the existing method and a new method (two-handed process chart) has been proposed which influenced in increased productivity and reduced labor cost. This article is about the Implementation of industrial engineering techniques for improving productivity and their impact on controlling labour cost in the garment industry.
Implementation of industrial engineering techniques for improving productivity and their impact on controlling labour cost in the garment industry
It is essential to find out the factors that affect productivity. It plays a vital role in identifying the issues influencing productivity. The evaluation of increasing productivity can be done based on the relationships between the input and output of the industry. Modern Engineering is worried about the planning, improvement, and establishment of ca oordinated 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 that can help for the prevention, identification, control and elimination of possible errors occurred in Apparel industry(7). Time study is a 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 upgrades 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 suitable industrial engineering techniques to increase productivity.
Materials
The material(s) selected for this work are a woven shirt (cotton/Polyester). The other requirements include stop watch, a study board, and Time study forms.
Methods
This study is predicated on the first information that was collected through the interview schedule form. Time-and-motion study taken by a 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.
Analyzing the causes for low productivity in the apparel industry.
⬇️
Selection of the apparel unit and its study on the existing methods followed for production.
⬇️
Analyzing the problems observed during the study
⬇️
Identification of IE techniques for improving productivity
Analyzing the Causes for Low Productivity in the Apparel Industry
The causes for low productivity are:
- Improper machine layout and space utilization.
- Inadequate material handling.
- Ineffective method of sewing operations.
- Improper inventory control system.
- Lacking in technological upgradation.
Selection of the apparel unit and its study on the existing methods followed for production.
- Name of the firm: KAD’s Resources Garments
- company’s policy: quality products, zero error
- Business type: manufacturer & exporter
The following 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 the existing method: 19
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 the quantity of laborers, the number of machines, manpower utilization, and factory layout. During the study, problems in the sewing department have been observed and listed.
- Absenteeism
- Poor workmanship
- Ineffective usage of material and space
- Poor supervision
- No training
Identification of IE techniques for improving productivity
IE formula and techniques may be enforced in each and every department associated with the execution of the order. However, importance was given in the sewing department. Based on the observation in the existing method, a two-handed process chart has been chosen to execute the new method.
Results and discussion
The symbols used for the execution of production are given below:
○ – Operation
➡ – Transport
D – Delay
▽ – Holds
Type of operation: front yoke– (2)
| Step | EXISTING Process | Step | PROPOSED Process |
|---|---|---|---|
| A | Picking bodice | A | Picking bodice and yoke |
| B | Picking yoke for one side | B | Positioning |
| C | Positioning | C | Stitching |
| D | Sewing | D | Disposing |
| E | Disposing | E | Picking bodice and yoke |
| F | Picking bodice | F | Positioning |
| G | Picking yoke for other side | G | Sewing |
| H | Positioning | H | Disposing |
| I | Sewing | ||
| J | Disposing |
Table: Operations Reduction
| Method | Existing | Proposed | Remarks | ||
|---|---|---|---|---|---|
| LH | RH | LH | RH | ❖ Both hands are used simultaneously for picking and transporting. ❖ Idle time of the left hand is considerably reduced. | |
| Operation | 2 | 6 | 4 | 4 | |
| Transport | 4 | 4 | 4 | 4 | |
| Delay | 4 | 0 | 0 | 0 | |
| Holds | 0 | 0 | 0 | 0 | |
| Total | 10 | 10 | 8 | 8 |
Type of operation: back yoke
| Step | EXISTING Process | Step | PROPOSED Process |
|---|---|---|---|
| A | Picking bodice | A | Picking bodice and yoke |
| B | Picking yoke | B | Positioning |
| C | Positioning | C | Stitching |
| D | Sewing | D | Disposing |
| E | Disposing |
II) Operations Reduction
| Method | Existing | Proposed | Remarks | ||
|---|---|---|---|---|---|
| LH | RH | LH | RH | ||
| Operation | 1 | 3 | 2 | 2 | |
| Transport | 2 | 2 | 2 | 2 | |
| Delay | 2 | 0 | 0 | 0 | |
| Holds | 0 | 0 | 0 | 0 | |
| Total | 5 | 5 | 4 | 4 |
Type of operation: placket preparation
| EXISTING | PROPOSED | ||
| A | Picking bodice | A | Picking bodice and placket |
| B | Picking placket for one side | B | Positioning |
| C | Positioning | C | Stitching |
| D | Sewing | D | Disposing |
| E | Disposing | E | Picking bodice and placket |
| F | Picking bodice | F | Positioning |
| G | Picking placket for other side | G | Sewing |
| H | Positioning | H | Disposing |
| I | Sewing | ||
| J | Disposing | ||
Operations Reduction Table
| Method | Existing | Proposed | Remarks | ||
| LH | RH | LH | RH | ||
| Operation | 2 | 6 | 4 | 4 | – Both the hands are used simultaneously for picking and transporting |
| Transport | 4 | 4 | 4 | 4 | – Idle time of left hand is considerably reduced |
| Delay | 4 | 0 | 0 | 0 | |
| Holds | 0 | 0 | 0 | 0 | |
| Total | 10 | 10 | 8 | 8 | |
Type of operation: shoulder attachment
| EXISTING | PROPOSED | ||
| A | Picking front | A | Picking front and back |
| B | Picking back | B | Positioning |
| C | Positioning | C | Folding |
| D | Folding | D | Stitching |
| E | Stitching | E | Trimming |
| F | Trimming | F | Top stitching |
| G | Top stitching | G | Disposing |
| H | Disposing | ||
Operations Reduction Table
| Method | Existing | Proposed | Remarks | ||
| LH | RH | LH | RH | ||
| Operation | 4 | 6 | 5 | 5 | ✓ Both the hands are used simultaneously for picking and transporting |
| Transport | 2 | 2 | 2 | 2 | ✓ Idle time of left hand is considerably reduced |
| Delay | 2 | 0 | 0 | 0 | |
| Holds | 0 | 0 | 0 | 0 | |
| Total | 8 | 8 | 7 | 7 |
Type of operation: sleeve attachment
Task Comparison Table
| EXISTING | PROPOSED | ||
| A | Picking bodice | A | Picking bodice and collar |
| B | Positioning | B | Positioning |
| C | Picking collar | C | Sewing |
| D | Positioning | D | Turning |
| E | Sewing | E | Topstitching |
| F | Turning | F | Disposing |
| G | Topstitching | ||
| H | Disposing |
Operations Reduction Table
| Method | Existing (LH) | Existing (RH) | Proposed (LH) | Proposed (RH) | Remarks |
| Operation | 3 | 7 | 4 | 6 | Both hands work simultaneously |
| Transport | 3 | 3 | 2 | 2 | Idle time for the left hand is significantly reduced |
| Delay | 2 | 0 | 1 | 0 | Minimal adjustment delay |
| Holds | 0 | 0 | 0 | 0 | |
| Total | 8 | 10 | 7 | 8 |
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.
Conclusion
Implementation of industrial engineering techniques for improving productivity and their impact on controlling labour cost in the garment industry is playing a role here. By the implementation of a two-handed process chart, the effective utilization of both the left and right hands of the operators to carry out the sewing operations was achieved. The movements of the hand are recorded, and the best methods of carrying out the operations were identified. This helps in job simplification and results in a decrease in operating time. Based on the existing method, the successive process of minimum time requirement for operations is combined, which is carried out on the same Line.
So the number of operations is considerably reduced from 19 to 13. Hence, there must be an increase in productivity. By reducing the number of operations, the labour cost also reduces, which is most wanted by every Manufacturer. That’s all on the Implementation of industrial engineering techniques for improving productivity and their impact on controlling labour cost in the garment industry.