Line Balancing In Garments Industry

Prepared By : Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh

Total Textile Process at a Glance

Introduction Line and work cell balancing is an effective tool to improve the throughput of assembly lines and work cells while reducing manpower requirements and costs. Assembly Line Balancing or simply Line Balancing (LB) is the problem of assigning operations to workstations along an assembly line, in such a way that the assignment be optimal in some sense. LB has been an optimization problem of significant industrial importance: the efficiency difference between an optimal and a sub-optimal assignment can yield economies (or waste) reaching millions of dollars per year. LB is a classic Operations Research (OR) optimization problem, having been tackled by OR over several decades. Many algorithms have been proposed for the problem. Yet despite the practical importance of the problem, and the OR efforts that have been made to tackle it, little commercially available software is available to help industry in optimizing their lines.

LINE BALANCING (Process Organization) The Line Balancing is “to design a smooth production flow by allotting processes to workers so as to allow each worker to complete the allotted workload within an even time” It is a system where we meet the production expectations and we can find the same amount of work in process in every operation at any point in the day.

Reasons to have balance the production line (1)Keeping inventory costs low results in higher net income. (2) Keeping normal inventory levels lets the operator work all day long giving him/her the opportunity to earn more money by increasing his/her efficiency. (3)Keeping the line balanced let’s the supervisors improve other areas because they can use their time better. (4) Balanced production keeps prices low which turns into repeat sales. (5) Balanced production means better production planning.

Balancing Method Method The most basic methods are the Time Study, Bottle Neck Process Theory and Data Collection and Analysis.

How do we start balancing the production line? Well we can start by determining how many operators for each operation are needed for a determined level of production. After this we need to determine how much WIP we need to anticipate production problems. Recommended WIP is 1-hour inventory level for each operation. A good range would be from 30 min to 120 min inventory level.

There are 3 rules for balancing (1) Have at least ½ hour of WIP for each operation (2) Solve problems before they become any larger (3) Meet production goals by keeping every operator working at their maximum capacity

Time Study What is time study? Time study is a work measurement technique for recording the time of performing a certain specific job or its element carried out under specific condition and for analyzing the data so as to obtain the time necessary for an operator to carry out at a defined rate of performance

Time Study Time study is a method of direct observation. A trained observer watches the job and records data as the job is being performed over a number of cycles. Time study equipment the stop watch in general, two types of watch are used for time study. Fly back Continuous These watches may be used any of the following time scales Seconds Decimal minutes Decimal hours

SMV SMV – time that is allowed to perform the job satisfactory. SMV = Basic time + Allowances Standard Minute Value SMV = B.T + Allowances

Basic Time The basic time for the operation is found by applying concept of rating to relate the observed to that of a standard place of working. Calculated as follows: Basic time = observed time * observed rating 100 (BT = Observed time * Observed Rating= A constant) 100

Example.. Rating 50 75 100 125 Observed time1.2 0.8 0.6 0.5 Basic Time 1.2*50 0.8*75 0.6*100 0.5*125 100 100 100 100 = 0.6 0.6 0.6 0.6

SMV calculation Element description Element description Obser Obser rating rating Obser. Obser. time time Basic Basic Time Time Freq. Freq. Basic Basic Time/Gmt Time/Gmt 95 95 0.32 0.32 0.304 0.304 1/30 1/30 0.010 0.010 Get bundle and sort parts Get bundle and sort parts 105 105 0.11 0.11 0.116 0.116 1/1 1/1 0.116 0.116 Match pocket flap to lining Match pocket flap to lining 100 100 0.48 0.48 0.480 0.480 1/1 1/1 0.480 0.480 Sew round flap Sew round flap 58 58 0.35 0.35 0.298 0.298 1/1 1/1 0.298 0.298 Trim threads and turn out Trim threads and turn out flap flap 90 90 0.56 0.56 0.504 0.504 1/1 1/1 0.504 0.504 Top stitch flap Top stitch flap 110 110 0.23 0.23 0.253 0.253 1/30 1/30 0.008 0.008 Close bundle and place Close bundle and place aside aside 1.416 1.416 Total Total

Total basic time/garment (brought forward) 1.416 Add machine attention allowances 7% 7% of (0.480 + 0.504) = 0.07 x 0.984 = 0.069 0.069 Basic time + MAA (1.416 + 0.069) 1.485 Add personal needs and relaxation allowances 14% 14% of 1.485 = 0.14 x 1.485 = 0.208 0.028 Standard minute Value (SMV) = Basic time + all allowances = 1.485 + 0.208 = 1.693 (SMV)

Production Planning Load and capacity Planning Successful planning requires knowledge of two variables to determine the time required to manufacture a contract. Load – How much work we are putting on a section Capacity – How much work a section is capable of completing In an ideal situation >> Load = Capacity

Load and capacity LOAD – Contract size x Work content Capacity – The amount of work the factory or section is capable of doing.

The scheduling rule Balance load and capacity Arrange the programmed of work so that the load can be achieved Use common units – standard minutes

Balancing & Capacity Load Capacity Uncertainty about the number of garments to be sold Demand? Uncertainty about the number of operators and performance Speculation? Total numbers Prediction? Attendance hours Uncertainty about work content Absenteeism Performance Standard minute value Learning curve Uncertainty about the equipment Measured Estimated Availability Reliability

Pitch Time Reference value for synchronization in the division of labor is called Pitch Time (PT). Pitch Time provides average time allotted to each worker.

Bottleneck Process: The time at which the longest time is required is called “bottleneck Process” The state of line organization should be evaluated as “Organization Efficiency” Using the pitch time and Bottleneck Process Time. Pitch Time Organization Efficiency (%) = ________________________ x 100 Bottleneck Process Time 100 = ______ X 100 140 = 71.4 % (For the aforementioned case study)

Pitch Diagram in the form of Column Graph 1st bottleneck Process 2nd bottleneck Process Loss in balance Loss in balance (Seconds) 160 140 120 1 4 0 100 Work Allotment Time 115 110 80 Work Allotment Time 85 1 0 5 95 60 70 80 40 20 A B C D E F G H Name of worker (in the order of processes) Pitch Diagram (bar graph)

How to reduce the number of bottleneck processes (1) Investigate the relation between the bottleneck process and its previous and subsequent processes to correct the line organization. (2) Investigate whether it is possible to further divide the process. (3) Conduct the motion study for work improvement. (4) Make improvements to equipment, jig and tools. (5) Mechanize the manual work. (6) Change the positions of workers. (7) Investigate the modification to the machining specifications. (8) Make it a rule to lend the worker in charge of the bottleneck process a helping hand

Control limit (seconds) 160 Bottleneck Process 140 140 140 140 140 140 140 Upper Limit 120 115 115 115 115 115 115 Work Allotment Time 110 110 110 110 105 105 105 105 105 105 100 80 Lower Limit 95 95 95 95 140 140 140 140 140 85 80 60 70 70 40 20 A B C D E F G H Name of worker (In order of processes)

Control limit Pitch Time Upper Limit = _________________________ X 100 Target organization efficiency = 0.85 = 117.6 Seconds Lower Limit = 2 x Pitch Time – Upper Limit = 2 x 100 – 117.6 =82.4 Seconds

Data Collection One Composite Mills Ltd. Capacity check sheet U-1 (Line: 2) Style no: 29694 Target: 180pcs/ hour Buyer: Collin’s Order quantity: 18694 Description: T-Shirt Type: Basic

27-03-2013 Operator Name & ID M/C SL Operation Name Actual output per hour 138 212 200 225 212 120 157 189 124 68 72 116 113 65 68 72 116 129 106 116 113 103 200 300 Process time (3pcs) 22,24,21 16,13,14 16,14,16 14,12,12 15,13,14 26,23,25 18,20,18 16,15,17 24,25,24 44,46,43 42,40,43 28,26,23 26,29,27 48,44,45 44,42,45 41,42,44 27,25,26 23,24,22 28,30,27 24,25,23 25,28,28 30,28,29 14,16,15 10,11,10 Avg. time with 20% allowance 26 17 18 16 17 30 23 19 29 53 50 31 32 55 53 50 31 28 34 31 32 35 18 12 type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Roman Tuni Johura Mukul Sajida Taslima Arif Rekha Alal Hasina Shapla Helena Afsana Laboni Ashiq Parvin Mukta Alpona Khaleda Hameed Sayeed Hasan Julhash Sanjida 17371 19021 20568 20918 3357 2199 19799 20954 3011 850 19930 18332 20922 20145 19659 3360 2124 19564 20878 7495 20871 20414 19927 20011 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M

One Composite Mills Ltd. Capacity check sheet U-1 (Line: 3) Style no: 29694 Target: 180pcs/ hour Buyer: Collin’s Order quantity: 18694 Description: T-shirt Date: 27-03-20013 Type: Basic

27-03-20013 Operator Name & ID M/C SL Operation Name Actual output per hour 131 180 192 206 180 120 131 169 137 58 68 103 107 55 56 56 102 120 102 115 93 96 180 280 Process time (3pcs) 21,21,23 14,16,17 13,14,17 13,14,15 15,17,17 23,24,25 20,21,26 17,17,16 25,20,19 50,51,49 43,40,44 30,27,28 24,29,29 53,54,48 50,53,49 51,51,52 28,28,29 24,24,25 28,29,26 23,24,29 30,33,31 29,30,30 17,17,15 11,9,10 Avg. time with 20% allowance 26 19 18 17 19 29 26 20 25 60 50 34 32 62 61 61 34 29 34 30 37 36 19 12 type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Kajoil Rehena Reema Sima Any Salma Rina Bulbuli Laboni Amena Asadul Anwara Johir Reena Nupur Khadija Mannan Nargis Tara Rabea Rajib Rojina Ripon Lota 19865 20617 20306 20827 20640 22037 20616 22038 19044 20145 20839 5037 20928 19509 19486 9384 20698 18289 22060 19874 21013 3361 20998 19871 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M

28-03-2013 Operator Name & ID SL Operation Name M/C type Actual output per hour Process time (3pcs) Avg. time Avg. time with 20% allowance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Kajoil Rehena Reema Sima Any Salma Rina Bulbuli Laboni Amena Asadul Anwara Johir Reena Nupur Khadija Mannan Nargis Tara Rabea Rajib Rojina Ripon Lota 19865 20617 20306 20827 20640 22037 20616 22038 19044 20145 20839 5037 20928 19509 19486 9384 20698 18289 22060 19874 21013 3361 20998 19871 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M 151 206 221 192 192 124 151 180 124 60 69 99 115 58 65 55 102 115 102 131 81 107 180 320 18,20,20 14,15,13 12,13,13 13,15,17 15,15,14 24,23,23 18,20,19 16,15,16 22,22,25 49,50,46 39,40,44 31,28,27 24,25,25 50,48,49 45,45,47 53,55,55 31,26,28 24,25,25 27,27,29 21,24,21 35,38,31 27,27,28 15,15,17 10,8,10 23 17 16 18 18 28 23 19 28 58 49 35 30 59 55 65 34 30 34 26 42 32 19 11

29-03-2013 SL Operation Name Operator Name & ID M/C type Actual output per hour Process time (3pcs) Avg. time Avg. time with 20% allowance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Kajoil Rehena Reema Sima Any Salma Rina Bulbuli Laboni Amena Asadul Anwara Johir Reena Nupur Khadija Mannan Nargis Tara Rabea Rajib Rojina Ripon Lota 19865 20617 20306 20827 20640 22037 20616 22038 19044 20145 20839 5037 20928 19509 19486 9384 20698 18289 22060 19874 21013 3361 20998 19871 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M 137 192 221 221 206 131 151 192 137 60 68 107 110 58 56 55 99 115 107 124 93 99 160 320 19,20,24 17,13,15 12,14,14 13,13,12 15,14,13 22,21,24 19,20,19 17,15,14 23,20,19 47,47,48 40,42,43 28,28,26 27,25,25 46,51,50 49,52,53 50,53,54 29,30,27 23,27,25 28,26,26 22,24,23 30,31,31 28,29,29 16,18,19 9,10,9 25 18 16 16 17 26 23 18 25 55 50 32 31 59 61 62 35 30 32 28 37 35 22 11

One Composite Mills Ltd. Capacity check sheet U-1 (Line: 4) Style no: 29694 Target: 180pcs/ hour Order quantity: 18694 Shirt Date: 27-03-20013 Buyer: Collin’s Description: T- Type: Basic

27-03-2013 Operator Name & ID SL Operation Name M/C type Actual output per hour Process time (3pcs) Avg. time Avg. time with 20% allowance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Kohinur Soriful Moli Popi Sadia Sahara Helena Kobir Aklima Asha Motin Rojina Helena Rahima Sopna Najmul Panna Rojina Rina Samad Manik Sahid Joynal Moyna 9497 18066 20524 13051 19905 18461 21050 21093 20118 1545 12080 20659 20952 20416 9898 20173 7207 19031 20535 21075 5183 20658 19341 21057 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M 110 180 164 192 180 125 164 164 96 62 70 115 131 58 66 58 125 115 99 137 76 82 180 240 29,26,23 15,19,18 20,17,18 14,13,17 16,15,19 25,21,23 16,20,17 20,16,17 31,29,30 53,42,46 38,42,43 23,25,28 23,20,23 53,48,50 42,46,44 48,52,50 20,27,23 23,25,27 31,26,29 23,20,20 37,38,40 36,33,35 14,19,15 11,11,13 31 20 22 18 20 28 22 22 36 55 49 30 26 60 53 60 28 30 35 25 46 42 19 14

28-03-2013 SL Operation Name Operator Name & ID M/C type Actual output per hour Process time (3pcs) Avg. time Avg. time with 20% allowance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Kohinur Soriful Moli Popi Sadia Sahara Helena Kobir Aklima Asha Motin Rojina Helena Rahima Sopna Najmul Panna Rojina Rina Samad Manik Sahid Joynal Moyna 9497 18066 20524 13051 19905 18461 21050 21093 20118 1545 12080 20659 20952 20416 9898 20173 7207 19031 20535 21075 5183 20658 19341 21057 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M 125 192 180 222 192 115 164 180 120 66 74 102 131 55 66 58 125 115 160 144 90 93 180 320 26,20,23 16,14,16 19,17,16 11,15,13 16,14,17 23,25,26 19,17,20 17,15,19 28,23,22 46,41,45 38,40,40 29,27,28 21,23,22 52,50,55 43,42,47 50,48,52 23,25,21 26,21,27 29,31,30 19,17,24 34,28,33 33,29,31 15,17,15 9,8,10 28 18 20 16 18 30 22 20 29 53 47 34 26 62 53 60 28 30 36 24 38 37 19 11

Data Analysis Capacity check sheet U-1 (Line: 2)

28-03-2013 SL Operation Name Operator Name & ID M/C type Actual output per hour Process time (3pcs) Avg. time with 20% allowance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Roman Tuni Johura Mukul Sajida Taslima Arif Rekha Alal Hasina Shapla Helena Afsana Laboni Ashiq Parvin Mukta Alpona Khaleda Hameed Sayeed Hasan Julhash Sanjida 17371 19021 20568 20918 3357 2199 19799 20954 3011 850 19930 18332 20922 20145 19659 3360 2124 19564 20878 7495 20871 20414 19927 20011 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M 144 200 180 257 200 129 138 189 144 67 73 120 116 62 69 68 120 129 113 129 113 100 200 257 21,22,20 14,16,14 17,15,18 11,14,12 15,14,16 24,23,21 21,24,22 18,15,16 20,22,21 44,44,46 41,42,40 27,24,25 26,27,26 47,48,50 44,42,43 46,44,42 27,23,26 22,25,23 30,25,25 24,22,23 28,26,27 30,29,30 16,14,16 11,12,12 25 18 20 14 18 28 26 19 25 54 49 30 31 58 52 53 30 28 32 28 32 36 18 14

29-03-2013 Operator Name & ID SL Operation Name M/C type Actual output per hour Process time (3pcs) Avg. time with 20% allowance 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Roman Tuni Johura Mukul Sajida Taslima Arif Rekha Alal Hasina Shapla Helena Afsana Laboni Ashiq Parvin Mukta Alpona Khaleda Hameed Sayeed Hasan Julhash Sanjida 17371 19021 20568 20918 3357 2199 19799 20954 3011 850 19930 18332 20922 20145 19659 3360 2124 19564 20878 7495 20871 20414 19927 20011 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M 129 200 200 225 225 133 144 200 144 67 73 124 116 64 67 65 116 124 106 124 100 100 189 277 21,23,24 13,14,17 15,13,18 12,13,13 14,12,13 25,20,22 19,23,21 17,14,15 23,21,20 45,42,47 41,43,40 27,23,22 28,24,26 47,49,45 43,46,45 44,46,47 28,27,24 25,22,24 29,26,28 24,23,24 27,33,29 29,31,29 17,15,15 10,12,10 28 18 18 16 16 27 25 18 25 54 49 29 31 56 54 55 31 29 34 29 36 36 19 13

Capacity check sheet U-1 Capacity check sheet U-1 (Line: 3) (Line: 3)

27-03-2013 Operator Name & ID M/C SL Operation Name Actual output per hour 131 180 192 206 180 120 131 180 137 58 68 103 107 55 56 56 102 120 102 115 93 96 180 280 Process time (3pcs) 21,21,23 14,16,17 13,14,17 13,14,15 15,17,17 23,24,25 20,21,26 17,17,16 25,20,19 50,51,49 43,40,44 30,27,28 24,29,29 53,54,48 50,53,49 51,51,52 28,28,29 24,24,25 28,29,26 23,24,29 30,33,31 29,30,30 17,17,15 11,9,10 Avg. time with 20% allowance 26 19 18 17 19 29 26 20 25 60 50 34 32 62 61 61 34 29 34 30 37 36 19 12 type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Shoulder join-1 Shoulder join-2 Neck rib folding & servicing Neck rib edge joint Neck joint Piping shoulder to shoulder-1 Piping shoulder to shoulder-2 Piping top stitch shoulder to shoulder-1 Piping top stitch shoulder to shoulder-2 Sleeve joint-1 Sleeve joint-2 Arm hole position zigzag top stitch-1 Arm hole position zigzag top stitch-2 Side seam-1 Side seam-2 Side seam-3 Side seam position zigzag top stitch-1 Side seam position zigzag top stitch-2 Arm hole point position tack(2T)-1 Arm hole point position tack(2T)-2 Sleeve hem-1 Sleeve hem-2 Body hem Label make Kajoil Rehena Reema Sima Any Salma Rina Bulbuli Laboni Amena Asadul Anwara Johir Reena Nupur Khadija Mannan Nargis Tara Rabea Rajib Rojina Ripon Lota 19865 20617 20306 20827 20640 22037 20616 22038 19044 20145 20839 5037 20928 19509 19486 9384 20698 18289 22060 19874 21013 3361 20998 19871 O/L O/L O/L P/M O/L F/L F/L F/L F/L O/L O/L F/L F/L O/L O/L O/L F/L F/L P/M P/M F/L F/L F/L P/M

Capacity check sheet U-1 Capacity check sheet U-1 (Line: 4) (Line: 4)

Line Balancing In Garments Industry