!" #$"%""%"% "&' $"$ ( $ ) *"%&$$$+ ,-,. / #$ * & "% 0 " ) *+ "% 1&$0 " "% 2 #" 0 # balanced0 ++"% "% $ * + !"#" $% * # * + ) " $ # 0 " $ # ( * " # + 3 (0 * *" #240 " #"+ $% Line 1 Line 2 Total Date Daily Prod. Cumm Prod. Daily Prod. Cumm Prod. Daily Prod. &' ()*+,& -+ / + &* + *' * * + &0 0 +' *0. ,0. + &1 00. ,' , 10. * * 2 0' , &*0. () -&0 / , 2' , &20. . . , 3' , *.0. & & 0 1' , *,0. + , 3 4' , *10. +0. 30. 30. &.' &0. + +0. && 0 &&' (),+*5 -00 / , &0 , &*' & & ()65,0 -,0 / & &+' *0. +0. * * ,0. &,' 0 10. *0. ,0. 30. &0' 0 &+0. , 10. 4 &2' 0 &10. , &*0. 4 &3' 0 *+0. , &20. 4 &1' 0 *10. , *.0. 4 &4' 0 ++0. , *,0. 4 *.' 0 +10. , *10. 4 *&' 0 ,+0. , +*0. 4 **' 0 ,10. , +20. 4 *+' &0. 0 , ,.0. 00. Daily Prod.7'/8/ Cumm Prod97#:8;/8<=8 "#'>#' "? • !==/8@A=;?:;=8:=/<= ;:9 • (:BA9 • !C::<:/A:=/9 • !::/8:9 • !:D(8:9 • !:D(A89 • !C::/=8:9 • -:<=(:9 • /89 5673 • " &" * "$ *+ • 7 &" $+ • &* "$$ $" 0"($#8 $ 9:## ""% #%+ 9%&$"0 9""%$& $$ ;"%<$ 9%"" 9# =>?@ A-3 • ?(=/A?A:=E<A9 • ?:?/8F?=/9 • ?:/?;((=8:=(E<9 • $?(=</89 • ?(=/:/=E:=A==C8(:/?9 • =/=:8<?E:9 • $?(/88:9 • G<<??//?(9 • /?(/8::/8=(E9 • <=G=/9 -B+ -,.CD7 4A> ,,?-,.CD7+ -E+ -,.CF7 4A> ,,?-,.CD7+ -4+ -,.CD7 4A> ,,?-,.CD7+ ,-,. -4+ -,.CD7 4A> ,,?-,.CD7+ -4+ -,.GD7 4A> ,,?-,.CD7+ -4+ -,.CD7 4A> ,,?-,.CD7+ -4+ -,.CF7 4A> ,,?-,.CD7+ -4+ -,.GD7 4A> ,,?-,.CD7+ A -B+ -,.CD7 4A> ,,?-,.CD7+ -C+ -,.GD7 4A> ,,?-,.CD7+ -4+ -,.CD7 4A> ,,?-,.CD7+ -E+ -,.CF7 4A> ,,?-,.CD7+ -F+ -,.GD7 4A> ,,?-,.CD7+ [...].. .LINE BALANCING AND PRODUCTION there are 3 rules for balancing • • • have at least ½ hour of wip for each operation Solve problems before they become any larger Meet production goals by keeping every operator working at their maximum capacity LINE BALANCING TOOLS Production sheets Daily production report The inventory levels by operation Production boards Stop watch Calculator Line balancing. .. compare the cost-benefits while work content is higher use high performers of putting additional machine into the line Improve workstation layout and improve methods Do extra work at bottleneck operations Reduce cycle time using work aids and attachments STEPS TO A BALANCED LINE All in all… From Imbalanced line TO BALANCED LINE STEPS TO A BALANCED LINE Limitations of Line Balancing • Production lines were... Inevitable changes lead to production lines being out of balance • Rebalancing causes disruptions to production Sl No Operation List SAM 1 Pinning to profile 0.234 2 Run stitch collar 0.219 3 Trim collar 0.285 4 Clip and turn collar 0.223 5 Crease collar 0.381 6 Top stitch collar 7 Run stitch (R/s) collar band 0.291 8 Crease collar band 0.317 9 Insert collar in neck band 0.799 10 Turn and crease collar 0.452... TO A BALANCED LINE STEPS TO A BALANCED LINE Step 3: Target setting With the above step 1 & 2 data set your target output per hour from one line Generally it is calculated using following formula (Target per hour= Total no of operators X 60 /garment SAM) Check current hourly operator production report Draw a straight line with target output data on the line graph. STEPS TO A BALANCED LINE Step 4 Identification... trunk short, and develop operation breakdown and confirm possible bottleneck STEPS TO A BALANCED LINE step4 Elimination of bottlenecks from the line Methods of eliminating bottlenecks from the line Club operations where possible Give the operator another operation with less Shuffle operators Operations that have low work content use low performer work content considering machine type and sewing thread... Current hourly operator production report is analyzed Current hourly operator production report is analyzed • • D C C Target per hour = Total no of operators X 60 /garment SAM Target per hour = Total no of operators X 60 /garment SAM • • B B With the capacity data set target output per hour from one line • • + OPERATION STANDARD ALLOWED MINUTES OF EACH Step 2 Operational breakdown and setting the Target... report The inventory levels by operation Production boards Stop watch Calculator Line balancing in BALANCED LINE STEPS TO A apparel manufacturing Step 1 Calculation Of The Labor Requirements and Capacity study The Requirement Of Worker Depends Upon The Probable Efficiency Of The Line Selected And Percentage Of Time They Work List down all operations with operator name as per operation sequence Check... “Bottleneck Process” * The state of line organization should be evaluated as “Organization Efficiency” * Pitch Time provides average time allotted to each worker * Using the pitch time and Bottleneck Process Time Bottleneck process 160 Work Allotment Time 140 140 140 120 105 115 100 80 80 60 40 20 0 A B C D E F Name of worker (In order of processes) G H H a n e s STEPS TO A BALANCED LINE Step 4 Identification... Trim cuff 0.36 16 Turn cuff 0.527 17 Crease cuff bottom 0.566 18 Attach placket to sleeve 0.795 19 Lock and make diamond 1.026 20 Sew pleats (4 no.) 0.389 21 Hem right front 0.494 22 Attach front placket 0.603 23 Crease pocket 0.542 24 Hem pocket mouth 25 Attach pocket to front 26 Attach brand label and tack loop 0.589 27 Crease patch pieces 0.236 28 Attach patch piece 0.333 29 Sew pleats 0.278 30 Attach... seam 1.036 39 Attach & close cuff 0.696 40 Top stitch cuff 0.524 41 Hem bottom Total SAM 0.42 0.28 0.861 0.64 1.01 0.947 22.322 Product: Full Sleeve Men’s Formal Shirt Brand: Arrow From given table draw a line diagram as well balance the line THANKS . =>?@ A - 3 • ?(=/A?A:=E<A9 • ?:?/8F?=/9 • ?:/?;((=8:=(E<9 • $?(=</89 • ?(=/:/=E:=A==C8(:/?9 • =/=:8<?E:9 • $?(/88:9 • G<<??//?(9 • /?(/8::/8=(E9 • <=G=/9 - B+ - ,.CD7 4A> ,,? - ,.CD7+ - E+ - ,.CF7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ , - ,. - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - 4+ - ,.GD7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - 4+ - ,.CF7 4A> ,,? - ,.CD7+ - 4+ - ,.GD7 4A> ,,? - ,.CD7+ A - B+ - ,.CD7 4A> ,,? - ,.CD7+ - C+ - ,.GD7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - E+ - ,.CF7 4A> ,,? - ,.CD7+ - F+ - ,.GD7 4A> ,,? - ,.CD7+ B. =>?@ A - 3 • ?(=/A?A:=E<A9 • ?:?/8F?=/9 • ?:/?;((=8:=(E<9 • $?(=</89 • ?(=/:/=E:=A==C8(:/?9 • =/=:8<?E:9 • $?(/88:9 • G<<??//?(9 • /?(/8::/8=(E9 • <=G=/9 - B+ - ,.CD7 4A> ,,? - ,.CD7+ - E+ - ,.CF7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ , - ,. - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - 4+ - ,.GD7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - 4+ - ,.CF7 4A> ,,? - ,.CD7+ - 4+ - ,.GD7 4A> ,,? - ,.CD7+ A - B+ - ,.CD7 4A> ,,? - ,.CD7+ - C+ - ,.GD7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - E+ - ,.CF7 4A> ,,? - ,.CD7+ - F+ - ,.GD7 4A> ,,? - ,.CD7+ B. =>?@ A - 3 • ?(=/A?A:=E<A9 • ?:?/8F?=/9 • ?:/?;((=8:=(E<9 • $?(=</89 • ?(=/:/=E:=A==C8(:/?9 • =/=:8<?E:9 • $?(/88:9 • G<<??//?(9 • /?(/8::/8=(E9 • <=G=/9 - B+ - ,.CD7 4A> ,,? - ,.CD7+ - E+ - ,.CF7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ , - ,. - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - 4+ - ,.GD7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - 4+ - ,.CF7 4A> ,,? - ,.CD7+ - 4+ - ,.GD7 4A> ,,? - ,.CD7+ A - B+ - ,.CD7 4A> ,,? - ,.CD7+ - C+ - ,.GD7 4A> ,,? - ,.CD7+ - 4+ - ,.CD7 4A> ,,? - ,.CD7+ - E+ - ,.CF7 4A> ,,? - ,.CD7+ - F+ - ,.GD7 4A> ,,? - ,.CD7+ B