World University of Bangladesh

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cOMPARATIVE STUDY AMONG INDUSTRIAL PRODUCTION PROCESS OF DIFFERENT GARMENTS Supervisor Engr. Elias Khalil Lecturer & Co-ordinator, Department OF Textile Engineering Submitted By: Md. Rakibul Islam ID NO: WUB-08/12/12/364 Khan Mahibur Rahman ID NO: WUB-08/12/15/419 Md. Al-Amin ID NO: WUB-08/11/15/421

Introduction In a garment industry there are several items of garments can be produce. For different types of garments different time required to produce. SAM and SMV is one of them which calculate out the mean time for produce a complete garment. Here the study going to about the time variation for producing different kind of garments item.

Aim and Objective Production study is used to calculate the actual production of a worker per hours. To calculate the actual production we have to see the total working minute in hour without lost time. To know target of a worker. To evaluate the finishing time of an item or product. Production study helps for planning to maintain the layout and line balancing of machine and product. For use as the basis for determining the unit cost of manufacture and the wage rate. For use the basis for introducing a production control system.

Materials Stop watch Time Study Format Pen Paper Calculator Camera Measurement Tape Scissor

Data Table for Various Garments Items Sl. No. Item Number of Processes Number of Type of Machines Used No of M/C Used Number of Manpower Needed Standard Allowed Time.(SAM)Min. Sewing Thread Consumption (m/dz) Cost/Pc 1 T-Shirt 17 8 13 19 6.48 106.71 $ 6.20 2 Denim Pant 47 10 40 57 23.00 295.56 $ 9.52 3 Jacket (Dual Hood with Fur across Hood) 84 78 107 66.54 603.4 $ 18.63 4 Shirt (5 Pocket) 48 12 42 52 19.53 306.52 $ 8.15 5 Cargo Pant 73 66 44.6 201.36 $ 9.25 6 Army Jacket 97 86 57.18 589.23 $ 16.82 7 Short Pant 53 46 50 20.09 95.45 $ 3.15 Kids Pant 37 32 17.95 76.32 $ 6.59 9 Double Pocket Shirt 54 11 38 20.00 256.5 $ 7.69 Girls Denim Pant 64 26.40 285.36 $ 12.38

Production Summary of a T-Shirt Sl. No. Operation Average Cycle time(sec) Estimated SMV 01. SMV for Number matching front to back part 15 0.24 02. SMV for Shoulder joining 17 0.27 03. SMV for Neck make 16 0.26 04. SMV for Neck joint 19 0.30 05. SMV for Neck piping 18 0.29 06. SMV for Round neck edge tack 20 0.32 07. SMV for Back tap top stitch 38 0.60 08. SMV for Main label attaching 09. SMV for Sleeve hem 10. SMV for Sleeve match 11. SMV for Sleeve joining 12. SMV for Side joining 51 0.80 13. SMV for Care label joining 13 14. SMV for Body turning 15. SMV for Side top stitch 16. SMV for Neck top stitch 22 0.35 17. SMV for Bottom hem Total SMV 6.48

Production Summary of a T-Shirt

Comparison Between a T-shirt and a Stylish 5 Pocket Shirt In comparing between T-shirt and a Stylish 5 pocket Shirt we see that there is a huge difference in SAM (T-shirt-6.48 and 5 Pocket shirt- 19.53). But in case of costing there is only $1.95 difference. In this case our concerned industry will give the production priority to T-Shirt. Where requires less time more production and more profit.

Production Summary of a Denim Pant

Production Summary of a Girls Denim Pant

Comparison Between a Denim Pant and a Girls Denim Pant In comparing between Denim Pant and a Girls Denim Pant we see there are small difference in SAM (Denim Pant-23 and Girls Denim Pant-26.40) and cost ($ 2.8 difference). But Girls denim pant requires more processes and manpower. Also it has critical type of laser treatment for allover design. In this case the company should give priority to denim pant. But for a special purpose that to attract buyer for collect more orders, the company will give priority to Girls Denim Pant which is a fancy style.

Production Summary of a Hoody Jacket

Production Summary of a Army Jacket Machine SAM Manpo wer S/N 31.2 52 D/N 1.9 3 Angular(D/N) 0.0 C/S 0.3 K/S S/N (E/C) 5.8 11 3 O/L 0.6 1 5 O/L 6.9 12 PUNCH S/B 0.4 Velcro BTK 0.9 Operators 48.1 81 Helper 6.2 IRON 2.9 5 9.1 16 Operators + Helpers 57.18 97 Operators Target @100% Eff @ 10Hours 1011 Operators Target @80% Eff @ 10 Hours 809 Operators Target @70% Eff @ 10 Hours 708 Expected Pcs/Machine 8.74 Expected Pcs/Man(Operators + Helpers) @ 65% Eff 7.29

Comparison Between a Denim Pant and a Girls Denim Pant In comparing between Dual Hood Jacket and Army Jacket we see a small difference in SAM (Jacket with dual hood-66.54 and Army Jacket-57.18). Also costing difference is small ($1.81 difference). But there are big difference in no of processes are used where Dual Hood Jacket requires more manpower and machine. So the planning department of the company give more priority to the Army Jacket.

Production Summary of a Cargo Pant Machine SAM Manpower S/N 23.1 47 F/L 0.4 1 3 O/L 3.0 6 5 O/L 2.1 4 BTK 2.0 3 K/S FOA 1.1 2 S/B CHAIN ST. 0.5 APW 0.3 N/H Vi-be Operators 37.5 75 Helper 4.2 8 IRON Operators+Helpers 44.6 89 Operators Target @ 100% Eff @ 10 hours 1202   Operators Target @ 75% Eff @ 10 hours 901 Operators Target @ 65% Eff @ 10 hours 781 Expected Pcs/Machine 12 Expected Pcs/Man(Operators + Helpers) @ 75% Eff 10

Production Summary of a Short Pant   Machine SAM Manpower S/N 9.1 24 S/N (E/C) 1.2 3 D/N 1.5 4 3 O/L 5 O/L 1.0 F.O.A A.P.W 0.4 1 K/S 0.3 BTK 0.7 2 F/L Belcro Att: 0.6 B/H 0.2 B/A Operators 18.0 50 HELPER 3.0 7 IRON 0.0 Operators + Helpers 20.90 57 Operators Target @ 100% Eff/ 10 Hours 1671 Operators Target @ 75% Eff /10 Hours 1253 Expected Pcs/Machine @ 100% Eff 25 Expected Pcs/Man(Operators + Helpers) @ 75% Eff 19

Comparison Between a Cargo Pant and a Short Pant In comparing between Cargo Pant and Short Pant we see cargo pant requires more SAM, more cost, more manpower and processes than a short pant. In this case the factory should give more priority to short pant. But the Cargo Pant give more profit than a short pant and it increases the efficiency of worker. Also this item requires a long lead time which keeps the whole production process busy for a long time.

Conclusion This research is based on some effective layout model of different garments items where to use balancing process using short cut method. During the research it is seen thread trimming is being done manually using helper which is non-value added unnecessary operation can be removed by setting auto trimmer along with machine or by using auto machine. The study shows that this balanced layout model has brought a better synchronization among man machine and materials increasing the efficiency and productivity.

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