Faculty of Engineering

Department of TextileEngineering

REPORT ON
“Study on Industrial Engineering in Knit
Garments Production”
Course Title: Project (Thesis)
Course Code: TE 4214

Submitted By
Foujia Alam Esha ID: 161-23-4552
Shabihatul Zannat Misha ID: 161-23-4658

Supervised By
Md. Abdullah Al Mamun
Assistant Professor

This Report Presented in Partial Fulfillment of the Requirements for the Degree
of Bachelor of Science in Textile Engineering.

Advance in Apparel Manufacturing Technology

Fall, 2019

©Daffodil International University

 Declaration

We attest that this report is totally our own work, except where we have given fully
documented references to the work of others and that the materials contained in this report
have not previously been submitted for assessment in any formal course of study. If we do
anything, which is going to breach the first declaration, the examiner/supervisor has the right
to cancel our report at any point of time.

……………………..

Name: Foujia Alam Esha

ID:161-23-4552

……………………..

Name: Shabihatul Zannat Misha

ID:161-23-4658

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 Faculty of Engineering
Department of Textile Engineering

Approval Sheet
This research entitled “Study on Industrial Engineering in ‘Knit garments production’ at
Daffodil International University, Fall, 2019’’ prepared and submitted by Foujia Alam
Esha(ID:161-23-4552) &Shabihatul Zannat Misha(ID:161-23-4658)in partial fulfillment
of the requirement for the degree of BACHELOR OF SCIENCE IN TEXTILE
ENGINEERING has been examined and hereby recommended for approval and acceptance.

Md. Abdullah Al Mamun

Assistant Professor
Supervisor

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 Acknowledgement

At first we would like to express our deep appreciation to Allah for providing the opportunity
to complete our Thesis “Study on Industrial Engineering in Knit garments production.”

Then, our special thanks go to Md. Abdullah Al Mamun, Assistant

Professor,DepartmentoftextileEngineering,DaffodilIntentionalUniversityforhisencourageme
ntand valuablesuggestions.

We would like to thanks the management of the “FAKHRUDDIN TEXTILE MILLS

LTD.”for giving us the opportunity to perform the thesis successfully.

We are indebted to Mr. Razzak Hossain Manager of IE Department of FAKHRUDDIN

TEXTILE MILLS LTD. forhisvaluableteaching,advising,supervisingandtrainingduringour
industrial attachment. We hope his valuable information regarding to production process will
help us a lot for our futurecarrier.

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 Dedication

At first we want to dedicate our thesis reports to almighty Allah.

Then we dedicate this report to our Parents who give us chance to study in Textile
Engineering and support us all time.

We have also dedicate this report to Md. Abdullah Al Mamun, Assistant Professor of Daffodil
International University who helped us a lot to complete our industrial training report.

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 Abstract

This project is on “Study on Industrial Engineering in knit garments production”.

Traditionally operated garment industries are confronting issues like low productivity,
low efficiency, longer production lead time, high remake, modify, and rejection, poor
line
balancing,lowflexibilityofstylechangeoveretc.Theseproblemswereaddressedinthisstud
y by the using of Industrial Engineering. This paper introduces the various concepts
utilizing method,
wastage. Work study took to record the actual individual capacity of each operator.
We have recorded the actual cycle time to each operation for each and every operator
and helper to discover the ideal number of worker, type of machines, and individual
capacity. To find out the standard minute value (SMV) = 5.239, in additional to that
we have calculated the target (100%) per day= 2288pcs,cycletime=.23 sec,
efficiency= 48%,manpower= 22,capacity= 1832pcs.In this paper we discussed about
ladies T-shirt measurement sheet, layout plan, and the operation breakdown, SMV
calculation for each operation, Target calculation for each operation, cycle time,
efficiency, process wise capacity has been calculated, and others tools and techniques
which consist of different experimental details, experimental result and discussion.

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 Contents
List of FIGURES....................................................................................................... 9
1. Introduction ........................................................................................................... 1
1.1 IndustrialEngineering: .................................................................................. 1
1.2 Aim of the report: ......................................................................................... 1
1.3 Background of IndustrialEngineering: ......................................................... 2
Literature Review ...................................................................................................... 3
2.1 Previous Work Study: .................................................................................. 4
2.2IndustrialEngineering: ................................................................................... 4
2.3ObjectivesofIndustrial Engineering: .............................................................. 4
2.4Role of Industrial Engineer: .......................................................................... 5
2.5IE Department Working Procedure:............................................................... 5
2.5.1 For Pre-Production of Development Step: .............................................. 5
2.5.2. For Pre-Production of Confirm Step: ............................................... 6
2.5.3For Production Step:............................................................................ 6
2.6Working Field of IE: ....................................................................................... 7
Figure 2.1: Working Field of IE................................................................................. 7
2.7Obligations of an Industrial Engineer: ........................................................... 8
2.7.1 Primary obligations: ............................................................................... 8
2.7.2 Secondary obligations: ........................................................................... 8
2.8Target of an Industrial Engineer .................................................................... 8
2.9Applications of IndustrialEngineering: .........................................................10
2.10Merchandising .....................................................................................10
2.12Fundamental tools: .....................................................................................12
2.13ProductionPlanning: ...................................................................................12
2.14Quality: .............................................................................................................13
2.15 Some Important Definition: .......................................................................13
2.16Different types of study: ............................................................................15
2.16.1 Time Study: ........................................................................................15
2.16.2 Method Study: ....................................................................................15
2.16.3 Motion Study: .....................................................................................16
2.17Standard Minute Value (SMV): ..........................................................................16
2.18Calculation ofSMV: .....................................................................................17

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 2.19UsefulFormulasforIndustrialEngineers: ......................................................18
2.20WhyIndustrialEngineeringisNeedinApparelIndustry? .................................19
3. Methodology ........................................................................................................20
3.1 Datacollection: ............................................................................................21
3.2 Productinformation: ....................................................................................21
3.3 ProductSketch: ............................................................................................22

Fig 3.1: Ladies t-shirt (front & back part) ..................................................22

3.4Measurement sheet: ..................................................................................23
3.5 Operation Breakdown sheet from factory: ...................................................24
3.6Operation Breakdown sheet from our ...........................................................25
3.7Operation Breakdown: .................................................................................26
3.7.1Operation BreakdownProcedure: ...........................................................26
3.9 Line balancing table: ...................................................................................27
3.10 Production, Productivity & Non-Productivity: ...........................................28
3.10.1 Production: .........................................................................................28
3.10.2Productivity: ........................................................................................28
3.10.3 Non- Productivity: ..............................................................................28
3.11 Production Study Sheet for a specific operation of a t-shirt with loss time: 29
Table 3.4: Production study with loss time ........................................................29
3.12 Production Study sheet for a specific operation with loss time in word: .....30
3.13Calculation: ................................................................................................30
3.14Calculation process of each operation of a garment: ...................................31
3.15 Calculation Process of per line: .................................................................31
3.16Bellow analysis is subjected to following assumptions: ..............................32
3.17EfficiencyCalculation: ..................................................................................33
4. Result and discussion............................................................................................34
4.1. Operation breakdown .................................................................................35
4.1.1. Result: .................................................................................................35
4.1.2. Discussion: ..........................................................................................35
4.2. Manpower: .................................................................................................35
4.2.1. Result: .................................................................................................35
4.2.2. Discussion: ..........................................................................................35
4.3. Required Machine: .....................................................................................35

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 4.3.1. Result: .................................................................................................35
4.3.2 Machine Types: ....................................................................................36
4.4. Time Study: ...............................................................................................36
4.4.1. Result: .................................................................................................36
4.4.2 Discussion:.............................................................................................36
4.5 Line target:..................................................................................................37
4.5.1 Result: ...................................................................................................37
4.5.2 Discussion:.............................................................................................37
4.6Production capacity: .....................................................................................37
4.6.1 Result: ...................................................................................................37
5. CONCLUSION......................................................................................................38
5.1 CONCLUSION: ...........................................................................................39

List of Figures:

2.1 Working field of IE ……………………………………………………………...07

3.1 Sketch of ladies t-shirt……………………………………………………………21

List of Table:
3.1 Measurement sheet……………………………………………………………….22
3.2 Operation breakdown sheet………………………………………………………23
3.3 Operation breakdown sheet from our own experiment…………………………..24
3.4 Line balancing sheet……………………………………………………………...26
3.5 Production study with loss time………………………………………………….28
3.6 production study with loss time in word…………………………………………29

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1. Introduction
Since the beginning of civilization, human beings by their nature, have been involved in
continuous improvements and have had an unending thirst to raise living standards and
improve the quality of life everyday! Industrial Engineering has played a vital role in
achieving these objectives. Apparel Manufacturing has improved significantly from Industrial
Engineering techniques. Engineering makes things helpful to man. Industrial engineering is
the engineering in where applied to all factors, including the human factor, engaged with the
product and allocation of goods and supplies.

1.1 Industrial Engineering:

We choose this topic because Industrial Engineering is an important part of garments
producing. IE is a branch of engineering which is utilized to reduce waste of time, product
cost, materials, machine time, working-hours, and different resources that are adding value.
As like many other manufacturing industry, IE is now broadly used in textile and RMG
sector. Textile and RMG sector have to face heavy Challenges because of different factors,
including their global competition, product price increase, low productivity, labor corrosion
and many more. For surviving in those difficulties work study sense and formulas are utilized
in RMG sector.

1.2 Aim of the report:

Productivity is more important to a factory for profit, but for some un planning work.
Productivity being reduce for proper planning, Its very much needed to use properly of every
machine, operator, time& others equipment. So, for this purpose IE department works always
& try to maintain any waste of those following things. They try to use those properly & also
try to reduce cost & save time. Industrial Engineering are a department which are totally
connected with factory profit, without this department factory profit will not increase
anymore. So, for this reason we select this IE department as our thesis topic. Here we try to
show the whole IE department work & also try to show how they work for increase factory
profit with properly use of all following things within as possible as less time & also with as
possible as low cost.

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1.3Background of Industrial Engineering:
IE became a significant factor during the Industrial Revolution in Europe during the mid-
eighteenth century, and one of the first Industries to apply its principles was the Textile
Industry. Frederick Taylor is named as father of scientific management and industrial
engineering. But before Frederick Taylor, Adam Smith gave concept of Division of Labor
through his book The Wealth of Nations. Also James Watt, Bolting Mathew and Robinson
obtained a place in the history of Industrial Engineering because of their work related with
improvements in the performance of machines and industries.

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 Literature Review

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 2.1 Previous Work Study:

At first we collect a previous thesis report from library of our senior, Then we found some similarity with us
because they also choose IE as a thesis topic like us. Then we study their report & collect some data from
then, Which collected data are given below:

Data Collection:

Buyer: VORO MODA

Item: VMGAVA LS ROLL NECK DRESS
Fabric: S/J
GSM: 160
Order no: 10222085
Quantity: 2416
Color: Tortoise shell
S.M.V: 6.84
Line Target: 1297/ day
Efficiency: 51%

In this thesis report we also show that data about order & also try to given operation breakdown sheet
with result like basic time, S.M.V, target, efficiency etc. And we also try to give operation break down
sheet, different IE related term & also with their result.

2.2IndustrialEngineering:
A branch of engineering dealing with the design, development, and implement of integrate
system of humans, machines, and information resources to provide products and services.
Industrial engineering encompasses specialized knowledge and skills in the physical, social,
engineering, and management sciences, computer system, and information technologies,
manufacturing processes, operation researches, production and automation. The major
activities of Industrial engineering stem from manufacturing industries and include work
methods analysis and improvement.

Industrial engineering (IE) = Production ↑ cost↓ proper use of all elements↑ efficiency↑ profit↑

2.3Objectives of Industrial Engineering:

 Improving process and method of working to increase factories overall performance
and standardized garment manufacturing processes.
 Monitoring production floor and having better control over the production floor.

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  Contribute to the success of companies throw effective problem solving.

2.4Role of Industrial Engineer:

• Safety

• Line Balancing

• Quality- operation control

• Training- how to train new employees

• Operator output- maintain high output and improves abilities of those with low output

• Loss control- minimize off- standard loss

• Waste control- in materials supplies and machinery

• Standard conditions- in the workplace, in sewing method, in the machines

2.5IE Department Working Procedure:

2.5.1 For Pre-Production of Development Step:

Merchandisers receive tack pack from buyer.

↓
Buyer co-ordinate (merchandiser)
↓
IE section
↓
Pre-sampling meeting comments (style analysis)
↓
Pattern section
↓
Pattern check according to style analysis
↓
Sample section
↓
Attachments and folder direction from IE section

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2.5.2. For Pre-Production of Confirm Step:

Pre-sampling meeting comments check with the sample

↓
Simplifying the operation
↓
Costing productivity
↓
Confirmed style machine requirement/ Style evaluation report
↓
Operation bulletin making & SMV calculating
↓
SMV & learning curve entry to 1st react for planning

2.5.3For Production Step:

Collect the next style details

↓
Sample collect & folder attachment
↓
Process break down collect
↓
Primary layout & line fitting
↓
Method study
↓
After five days make the Time study for line balance
↓
After eight days target set according to five day analysis
↓
Final report

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2.6 Working Field of IE:

Figure 2.1: Working Field of IE

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2.7Obligations of an Industrial Engineer:

2.7.1 Primary obligations:

• Provide safety

• Plan and balance production lines

• Develop employees

• Control quality

• Follow up on low output employees

• Material utilization

• Discipline

2.7.2 Secondary obligations:

• Bundle handling and movements

• Adjustments to machines

• Distributes supplies

• Handle parts that need to reprocessing

• Samples

• Maintenance

2.8Target of an Industrial Engineer

• How to increase efficiency

• How to improve out going quality

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 • How to prepare for routine problems or problems that might arise

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2.9Applications of Industrial Engineering:
The parts and duties of the Industrial Engineering office are not simply restricted to timing
administrators and making task notices as it is just a piece of the activity. The I.E work can
contribute essentially to change in working and efficiency of all the bureaus of clothing
fabricating. Give us a chance to examine few of the exercises of different areas of clothing
producing which can be related with mechanical designing.

2.10Merchandising

In merchandising Department the Industrial engineer can work closely in following:

Product Analysis-
 Determine the optimum method of construction to achieve required finished product
Quality.
 Install the operation sequence.

 Specify the equipment system and work aim to beused.

When IE department contact with the Merchandising department they also think about following
parameters:

 Target

 Efficiency

 Output ( per day)

 Capacity

 Total no of workplaces

 Total standardtime

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It can be extended to include-

 Hourly/ period targets for each operation

 Man power Requirements

 Equipment Requirements

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2.12Fundamental tools:
When they need to complete a operation they have to use many fundamental tools for different functions, as
like-

 Engineering Methods
 Planning Line
 Planning Capacity
 Measurement Performance
 Manpower Planning etc.

2.13ProductionPlanning:
Production planning is an essential prerequisite to production control. It involves
management decisions on the resources that the firm will require for its manufacturing
operations and selection of these resources to produce the desired goods at the appropriate
time and at the least cost. Production planning is defined as, “the technique of foreseeing or
picturing ahead, every step in a long series of separate operations, each step to be taken in the
right place, of the right degree and at the right time, and each operation to be done at
maximum efficiency.“Production planning provide a line for effective, balanced flow of
product, incorporating line and individual (operation) productivity standards. The end product
of production planning efforts is the formulation of production plans. The plans are
formulated in light of specified future period. The plans are to be implemented in the light of
the estimated cost and agreed policies.

 Plant limit can be ascertained by I.E department with the goal that arranging can book
arrange according to the accessible limit.
 I.Ecanaidbetterarrangingbyaidinginbetterstyledesignationtovariousunitsorlines.
 I.E can figure a proficiency/execution develop for a specific style in light of the work
content or past execution. This can advise the arranging department that a specific line
willtakehowlongtodeliveraparticularamountofastyle.Thiswillhelpthearranging
department to design the accessibility of assets and material ahead oftime.

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 2.14Quality:
Quality is an advantage, which might be offered to the potential client of an item. There are two
parts of value, which add to a definitive nature of the item. Nature of configuration is the
primary viewpoint, which relies upon the kind of materials utilized, specs determined by the
purchaser, technique for creation, information of the outline and expertise level of the
individual. How much this quality is accomplished underway that is the nature of conformance
is the second viewpoint.

2.15 Some Important Definition:

SMV:

SMV is a standard minute value to produce a complete garments.

SMV = basic time + (basic time * allowance)

Cycle Time:
The actual time taking by a worker at working pace to complete an operation from pick to
dispose.

Observed time:

In industrial engineering, the standard time is the time required by an average skilled operator,
working at a normal place, to perform a specified task using a prescribed method.

Basic time:

Basic time of a job is determined by multiplying rating factor to the observed time (cycle
time) & then divided by 100. Basic time is also expressed as Normal time.

Allowance time:
It is the time permitted to an worker for non performing assignment, for example, going to
research center, rest, evolving needle, taking guideline of boss and so on.

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Relaxation allowance:

It is the time permitted to the worker to take care of individual need.

Standard time:
It is the time required by operator to complete a garment had she/he worked at 100% rating with
allowance time.

Bottleneck:
Bottleneck means the extra time from one operator to next operator. One operator complete his
work; now he/she passes the product to the next operator, the time of passing is called
bottleneck. Bottleneck make for-
1. Improper arrangement
2. Wrong working method
3. Less skill operator
4. Unhealthy operator
5. Poor m/c capacity
6. If material not ok etc.

Rating:

Rating is a speed of work, which given from a operators work. Standard rating is 100%.

Capacity:

Capacity means the production of a operator or line per hr.

Capacity 2 types- 1. Line capacity.

2. Process capacity

Line Capacity:

Line capacity per hour.

Process Capacity:

Per operator production per hour.

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WIP:

Work in Process, a garments body are waiting for sewing one operator to another operator. WIP are 2 types-

1. Process WIP: It occurs in specific process.

2. Line WIP: Settled body in every process.

Line Balancing:

Setting all m/c & worker properly for achieve target at specific line. Line balancing is necessary for-

1. To get easily output.

2. To get worker better performance.
3. To ensure proper use of time & manpower also m/c.
4. To get higher productivity.

2.16Different types of study:

2.16.1 Time Study:

Time study is a work of measurement technique to get a observation time & observation rating of a worker.

Use of Time Study-

• To record the observation time of a worker.
• To record the observation rating of a worker.

2.16.2 Method Study:

Method study is a systematic recording & critical examination to reduce cost of a product, which is
going to set up developing& applying easier & more effective.

Use of Method Study:

• For better design of plant equipment & building.
• Improve layout of factory & office.
• Higher standard of safety & health.
• To improve the flow & work.
• To get the better quality.
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 • Effective material handling.
• To improve the proper utilization for resources.
• To get maximum output.
• To improve administration.
• Waste reduction.

2.16.3 Motion Study:

Motion study is a technique of analyzing of body motion of a worker & reduce the ineffective body
movement & facilitates effective movement.

Use of Motion Study:

• To improve the operators work.
• To give better safety of a worker.

2.17Standard Minute Value (SMV):

SMV is One of the tasks done by the IE department is to calculate the time taken to make a
specific garment. This is usually called a SAM (Standard Allowed Minute), although some
factories call this the Standard Minute Value (SMV).

Standard Allowed Minute or Standard Minute Value (SAM or SMV) is an important factor
in garments manufacturing industry. Production rate can be calculated by usingit.

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2.18Calculation of SMV:

SMV = basic time + (basic time * allowance)

Basic time = observed time * rating/100
Observed time = total cycle time
If time for sewing a side seam of a ladies t-shirt is 20, 20, 18, 22 and 20
seconds Observed time = (20+20+18+22+20)/5 = 20
If workers rating is 0.80
Basic Time = Observed Time* Rating
SMV= Basic Time + (Basic Time*Allowance)

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2.19Useful Formulas for Industrial Engineers:

Formula 1:
Basic Time = Rating * Observation Time / 100

Formula 2:
S.M.V = Basic Time * (Basic times allowance)

Formula 3:

Daily Line Target = (Man power* working hr* 60)/Garment SMV.

Formula 4:

Individual operator target = (Man power* working hr* 60)/Operation SMV.

Formula 5:

Line Efficiency% = (produced minute) / (Spent minute)

Produced minute = Production *SMV

Spent minute = Man power* working hr

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2.20Why Industrial Engineering is Need in Apparel Industry?

Industrial way of garment production needs a thorough preparation of production because in

the same time, it is necessary to combine a few factors: people, time, machines and place of
production, organization and material in a coordinated and rational system. Technological
system of garment production must enable expected quality of product, necessary scope of
production, delivery of ready-made garments in the expected time, maximum use of capacity
with minimum expenses. An Industrial Engineer can perform several activities to fulfill their
task, processes and Procedures of manufacturing or service activities can be examined
through Process Analysis. Industrial engineers can use Work Study comprehending Method
Study and Time Study. The mentioned activities are also called operations Management.
Furthermore can Industrial Engineering involve inventory management to make a
manufacturing process more feasible and efficient. Industrial Engineers used to increase
efficiencies and cost-effectiveness of operations by the products strategies like High-volume
production, long-runs and minimal variations.

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 3. Methodology

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3.1 Data collection:

We have collected our experiment data from sewing section, of a knit garments factory; where Industrial
Engineering department are working for better production. We also collect data from line where we work
with the line supervisor and with the operator directly.

And we have also collected information from IE manager of this knit garments factory.

3.2 Product information:

Buyer: M&S

Item: Ladies t-shirt

Style: 3040

Total no of machine: 21

Total no of operation: 15

Total no of operator:

25Total SMV: 5.239

Target: 2288pcs

Capacity: 1832pcs

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3.3 Product Sketch:

Fig 3.1: Ladies t-shirt (front & back part)

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3.4Measurement sheet:

Parts name: TOL (+,-) S * M L XL

Shoulders width 0.2 10 0.3 0.3 0.3
Front width 0.5 33.5 1 1 1
½ Chest circumference 1 44 2 2 2
Waist height from HPS 0.7 38 1.5 1.5 1.5
½ Waist circumference 1 37.5 2 2 2
½ Bottom circumference 1 46 2 2 2
Full length at front 1 61.5 2 2 2
Front neck drop 0.3 10.5 0.5 0 0.5
Armhole 0.4 18 0.6 0.6 0.6
½ Sleeves opening 0.3 14.5 0.5 0.5 0.5
Sleeves length 0.3 13.5 0.5 0.5 0.5
Width across shoulders at back 0.5 36.5 1 1 1
Back width 0.5 34.5 1 1 1

Table 3.1: Measurement sheet

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3.5 Operation Breakdown sheet from factory:

Table 3.2: Operation Breakdown sheet

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 3.6Operation Breakdown sheet from our
own experiment:
Process no. Operation M/C name Basic time S.M.V Target
1 Care label 4T OL 7.455 sec 0.143 sec 280pcs
make
2 Moon 4T OL 3.75 sec 0.071 sec 280pcs
servicing
3 Sleeve hem 3T FL 7.48 sec 0.14 sec 428pcs
4 Moon join Auto 25.631 sec 0.491 sec 122pcs
5 1st shoulder 4T OL 10.84 sec 0.207 sec 289pcs
join
6 Main label Auto 10.26 sec 0.196 sec 306pcs
attach
7 Neck binding 3T FL 12.03 sec 0.23 sec 260pcs
8 Back tape DNLS 8.11 sec 0.155 sec 387pcs
join
9 Back tape Auto 11.44 sec 0.219 sec 273pcs
end stitch
open, cut
10 Back tape Auto 13.14 sec 13.14 sec 239pcs
tuck
11 2nd shoulder 4T OL 8.46 sec 0.162 sec 370pcs
join
12 Sleeve join 4T OL 13.65 sec 0.26 sec 230pcs
13 Side seam 4T OL 35.87 sec 0.68 sec 88pcs
with label
14 Bottom hem 3T FL 15.52 sec 0.297 sec 202pcs
15 Loop join Auto 25.84 sec 0.49 sec 122pcs.
then tuck
16 Neck, sleeve Auto 13.77 sec 0.26 sec 75pcs
& bottom
tuck
17 Sleeve tuck Auto 13.77 sec 0.26 sec 75pcs

18 Bottom tuck Auto 13.77 sec 0.26 sec 75pcs

Table 3.3: Operation Breakdown sheet own experiment

N.B (Here, we can see 18 operations but in their factory operation breakdown sheet they given
19 operation but we saw there they don’t follow this sheet properly; some operation they work
as combined. This table given to follow only our own experiment, that’s why 18 operations are
exit)

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Full name of machine:
4TOL- 4 thread over lock
3TFL- 3 thread flat lock
DNLS- Double needle lock stitch.

3.7Operation Breakdown:

3.7.1Operation Breakdown Procedure:

Industrial Engineering team, Production team leader, technician and Lean project officer
must sit together to make break down. Technician breaks the garments in to parts a gathered
the parts one after another by operation/process Then work study section and production
section leader fix up the SMV of those operation by preceding this technique when all
process completed need to summarize all process SMV and the total will be called as
respective garments SMV.

3.8 Line Balancing:

Line balance means the better parceling of the necessary tasks between the worker, which
reduces waiting time.

For line balancing we have to focus some data & information, those are given below:

1. Number of Operation

2. Operation name

3. Operation S.M.V

In that following operation breakdown sheet we can see that there is 15 operation but 25
operator. Because, in that 15 operation they used 25 workers for line balancing.
For example-We saw there for moon joint S.M.V was 0.491 &for 1st shoulder join
S.M.V was 0.20. That’s why for moon joint 2 operators works there for balance

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 theirwork with the next operation 1 st shoulder join. So, for that reason they got better
production & also save their time easily.

3.9 Line balancing table:

Number of Operation: Operation name: Machine name:

01 Care label make+ Moon joint 4TOL
02 Sleeve hem 3TFL
Sleeve hem
03 Moon attach Auto
Moon attach
Moon attach
04 1st shoulder joint 4TOL
05 Main label attach Auto
06 Neck binding 3TFL
Neck binding
07 Back tape join DNL
08 Back tape end stitch open & cut Auto
09 Back top tack Auto
10 2nd shoulder join 4TOL
11 Sleeve join 4TOL
Sleeve join
12 Side seam 4TOL
Side seam
Side seam
13 Bottom hem 3TFL
Bottom hem
14 Loop join then tack Auto
Loop join then tack
15 Neck+ Sleeve+ Bottom tack Auto
Neck+ Sleeve+ Bottom

Table 3.4: Line Balancing

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 3.10 Production, Productivity & Non-Productivity:
3.10.1 Production:

After sewing all garments are known as product, which fulfill their requirement or not doesn’t matter. All
are called their product.

3.10.2Productivity:
After sewing which garments are fulfill all the requirement only those garments are known as
productivity. In productivity there 1st objective is fulfill their all requirement & these product
have to pass their QC board.

3.10.3 Non- Productivity:

After sewing which garments are not fulfill all the requirement only those garments are known as
non-productivity. In non- productivity there 1 st objective is breaktheir at least one requirement &
these product have not pass their QC board.

If those non-productivity products are possible to rectify then those will be product after rectify but if any
rectify is not possible there then those product are permanently convert into non-productivity.

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3.11 Production Study Sheet for a specific operation of a t-shirt with loss time:

Table 3.5: Production study with loss time

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 3.12 Production Study sheet for a specific operation with loss time in word
as example for understand:
Buyer: M&S
Item: T-shirt
Operation name: Piping joint
Line: 08
Checked by: Esha

Cycle time: Lose time area: Lose time:

10.95sec Machine breakdown 17.81sec
15.55sec 16.25sec
15.46sec 11.31sec
12.74sec 32.29sec
11.92sec Re-work 27.64sec
13.11sec 17.17sec
6.90sec 15.11sec
11.91sec 25.05sec
13.34sec 20.16sec
22.23sec 25.82sec
12.10sec Bundle change 22.80sec
13.69sec 35.08sec
11.32sec 32.99sec
10.24sec 21.49sec
15.09sec 23.63sec
20.32sec 17.19sec
13.4sec 30.21sec
13.4sec 14.49sec
12.0sec 18.84sec
11.1sec Piping change 1 min 51sec
11.45sec 2 min 10sec

Table 3.6: Production study with loss time in word

When we prepared this production study sheet in that time we took 172cycle times. For 172 cycle time we
got those types to loss time. But here in word we show 21cycle time as example for understand.

3.13Calculation:

Target Hourly = 60/ S.M.V

Hourly Line Target=60 * No. of Worker / Total S.M.V

Line Daily Target= 60 * No. of worker * Working hr / Total S.M.V

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3.14Calculation process of each operation of a garment:

Here, given a specific operation calculation for example:

Sleeve hem:

Basic Time = Rating * Observation / 100

=90* 8.318 / 100
= 7.48 sec

S.M.V = Basic Time + (Basic Time Allowance)

= 7.48 + (7.48* 15/100)
= 8.602/60
=0.14

Target = Manpower * working hr * 60 / S.M.V

= 1*1 *60 / 0.14
= 428 PCS

3.15 Calculation Process of per line:

Total line S.M.V = 5.293 (Calculate individual operator S.M.V then calculate the average)
Total Man Power = 25
Line Target Per hr. = Total man power * Total working hr * 60 / Total S.M.V
=25 * 1* 60 /5.239
= 286pcs
100% Line Target per day = 25 * 8 * 60 / 5.239
= 2290pcs
Produced minute = Production * S.M.V
=1832 * 5.239
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 =9597.848
Spent minute = Man power * Working hr
=25 * 8
=200
So, Efficiency%= Produced minute / Spent minute
= 48 %

3.16Bellow analysis is subjected to following assumptions:

1. No. Of workers (Operator and Helper)

25
2. Efficiency
48%
3. No Of Working Hours
8
4. Total garments S.M.V
5.239

Day Line Target = 2290pcs

Target Per Hour = 286pcs

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 3.17EfficiencyCalculation:

Here,
Work hour =8
SMV = 5.239
Manpower = 25
Output = 1820pcs.

Line Efficiency % = production per day * S.M.V / Manpower * W/H * 60

= 0.7998 * 100

= 80%

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 4. Result and discussion

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 4.1. Operation breakdown
4.1.1. Result:
In this thesis we collect all kind of data for our experiment. In the floor our working
line number was 7(A). And there was 15 operations.
4.1.2. Discussion:
Here the product is long ladies t-shirt and it is a normal process that’s why operation
breakdown is not more high. In the other product like pant, trouser, joggers, ladies
tang-top etc. here operation breakdown is higher than long ladies t-shirt, because
those are critical process.

4.2. Manpower:
4.2.1. Result:
Manpower is 25 with helper and in this line input was 2288 pieces per day (8 hours)
and output was 1832 pieces per day (8 hours).

4.2.2. Discussion:
There are some unskilled operator and helper, that’s why line efficiency was decrease
and they did not complete their target. And there also some machinery problems are
exist that’s the others reason for not achieve their target properly.

4.3. Required Machine:

4.3.1. Result:
Total number of machine = 21

From line balancing we have seen that they used 21 machines

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 4.3.2 Machine Types:

Name Of Machine Number of Machine

Auto 12
Double needle lock stitch 1
Flat lock (3 thread) 4
Over lock (4 thread) 6

Table 4.1: Types of Machine

4.4. Time Study:

4.4.1. Result:
By using stopwatch we took cycle time then calculated its average. After adding
rating we got basic time. Then with basic we add allowance (15%) then we got 5.239
SMV.

Then we calculated Total line target = 286 pcs/hr & Total line target = 2288 pcs/day(
for 100% target) &
1832 pcs for 80% target.

And we also calculated the line efficiency = 48%

4.4.2 Discussion:
The SMV of long ladies t-shirt is 5.293 that mean the lines take 5.293
minutes to complete a full garment.

Their target 286 pcs per hr &2288 pcs per day. But they achieve almost
80% target which was 1832 pcs per day.

Their productivity was 97% & non-productivity was 1% and rectify

product was 2% per day.

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 4.5 Line target:
4.5.1 Result:
By considering 80% target and SMV= 5.239the line target was almost
230pieces per hour and 1832 pieces per day.

4.5.2 Discussion:
From the line we collect data, here line efficiency as 48% then we
calculated target in actual line efficiency and we got the target very low
than their productivity. But we saw the production was 1832 pieces per
day.

4.6Production capacity:
4.6.1 Result:
Production capacity per day 1832 pieces (8 hour duty without lunch).
Here working hour is 8 but when shipment date is knocking the door
and the shipment target are not completed they extend 2 hours overtime
and then working hours will 10.

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 5. CONCLUSION

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5.1 CONCLUSION:
Industrial engineering is now most important and essential part of any apparel industry. By
doing this experiment we learn many procedure and important thing about Industrial
engineering. We found many problems in Industrial engineering, by doing this experiment we
also know how to solve problems and how to arrange all the work of Industrial Engineering.
Before IE there was many problems in garment industry such as production capacity, daily
line target capacity, layout, delivery problem. After this experiment we find out this
calculation, the standard minute value (SMV) = 5.239, in additional to that we have
calculated the target= 2288pcs, efficiency = 48%, man power = 25, capacity = 1832. After IE
and planning there is implementation in line balancing, daily line target, production capacity
increase. Additionally gives us a chance to extend our insight into material organization,
generation arranging, acquisition framework, creation process, and apparatuses and
encourage us to modify with the modern life.

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